hEnergy Meters

Energy meters are the most important part of the electrical system. The revenue of the utilities is dependent on the accuracy of energy meters. The Government of India has decided to install meters in all the consumers premises. In view of this, it is very important to check the quality and reliability of energy meters so that their performance is satisfactory and bill electricity accurately. Earlier electromechanical meters having accuracy of class 1.0 and 2.0 were used and with the advancement of technology, static energy meters having accuracy class 1.0, 0.5 and 0.2 are available in the market. ERDA has complete type test facilities for testing energy meters as per Indian and International Standards. ERDA can also calibrate 0.05 class reference energy meters using a 0.02 class reference energy meter.

Fully automatic test bench upto 120A with a reference energy meter of class 0.01 IS:13010, IEC:62052-11, IEC:62053-11 IS:13779, IEC:62052-11, IEC:62053-21 IS:14697 IEC:62052-11, IEC:62053-22 IEC:62053:23 CBIP Publication No. 304 & 88

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AC Induction Watt-hour Meters, Class 0.5, 1&2 AC Static Watt-hour Meters Class 1&2 AC Static CT operated Electrical Energy Meters (Trivector meters) AC Static Watt-hour meters Class 0.5 & 0.2 for active energy AC static meters for reactive energy class 2&3 Manual on standardization

The tests for insulation, accuracy, electrical, EMI / EMC, mechanical (as per customers requirement and climatic requirement, electrical and thermal properties are performed as per IS:13010 and IS:13779. Endurance, impulse, climatic, vibration, shock, harmonic and ingress rotection testing ensures the reliability of the energy meter. ERDA has a reference standard meter of class 0.02 and a fully automatic test bench with a reference meter of class 0.02. EMI/EMC Test Facility ERDA has test facilities mainly for static electrical energy meters (1 and 3). This laboratory provides testing and certification facilities under the head Tests for Electromagnetic Interference and Compatibility. The tests are carried out according to CBIP Technical Report No. 88, IS:13779, IS:14697

and IEC-62052-11. The facility provides following tests: 1 2 3 4 5 Test of immunity to Electrostatic Discharge Test of immunity to Electromagnetic HF fields Fast transient burst test Radio Interference measurement Immunity to conducted disturbances induced by frequency field IEC:61000-4-2 IEC:61000-4-3 IEC:61000-4-3 CISPR-14, CISPR-22, CISPR-11 IEC:61000-4-6

The facility is useful for energy meter manufacturers and users. Testing of Components The following components of energy meters can also be tested as per relevant standards. 1 2 3 4 5 6 7 8 9 Winding wires enamelled copper wires Electromagnetic core (CRNGO) Frame die cast aluminium Pinions leaded brass/Synthetic materials Counter frame brass sheet Counter frame - Al sheet Terminals plated brass Gaskets synthetic rubber Plastics IS:13730, IS:13778-1-6 IS:648, IS:649, IEC:60404-2, ASTM:A343, A717, A718 IS:617 IS:4253-1-2, IS:2221 IS:410 IS:2657 Sup. by 1608-1995 IS:410, 3168 IS:4253 IS:4253, 2221, 882

Calibration Calibration of reference standards upto class 0.02 is undertaken at ERDA. ERDA carries out calibration of 0.05 class meters at site also.

Infrastructure Some of the related test facilities include: Fully automatic test bench upto 120A with a reference energy meter of class 0.01 Solid-state substandard energy meter calibrator class 0.02, 3 phase static phantom source upto 100 Amps, stability 0.05%. Fully automatic test bench upto 120 A with a reference energy meter of class 0.02 Temperature rise test bench Life test bench Short time overcurrent test facility Test facilities for Influence quantities Glow wire test apparatus Vibration test apparatus Shock test apparatus IP 51 facility Cold cabinet (-40oC) Ovens Humidity chamber Impulse test facility Non-flammability test apparatus Harmonic test facility EMI/EMC Test facility Recognition ERDAs facility for Energy Meter is accredited by NABL, Govt. of India and BIS for its marking scheme. Electrical Inspectorate of Gujarat and other Electricity Boards have recognized the facilities. Services ERDA also provides technical services like condition monitoring, failure analysis, RLA, third party inspection, developmental testing and Technical Information Services. Consultancy for carrying out improvement in the design and quality of energy meters. Development of test equipments like impulse generators, voltage dips and interruptions setup, short time overcurrent setup, 3rd and 5th harmonic generators surge testing generators and so on R&D Projects Study of the effects of harmonics, voltage variation and frequency variation on the performance of energy meters.

Evaluation of Batches ERDA carries out evaluation of the batch of energy meters for electricity boards tender samples and grades them according to their quality.

Transformers
Transformers are important component of power systems, and are expected to find increased demand with thrust on infrastructure development. Instrument Transformers (CTs and PTs) have wide application in metering and protecting power systems. Indigenously manufactured distribution transformers have a wide range of ratings. At ERDA transformers from 5 kVA to 2000 kVA (at ERDA) and upto 200 MVA/220 kV (at site) can be tested. Transformers are an important part of ERDAs testing facilities and R&D activities.

Test Facilities The establishment offers facilities for testing of raw materials, components, transformer and also its condition monitoring. Products 1 2 3 4 5 6 7 Distribution Transformer Power Transformer Current Transformer Potential Transformer Inductive Voltage Transformer Continuously variable voltage auto transformers Dry type transformer Reactor ANSI-C-57, IS:2026, IS:1180 IS:2026, IEC:60076 IS:2705, IEC:60044-1 IS:3156, IEC:60044-2 IS:5142, IEC: 60989-1 ANSI/IEEE C 57.12.91, IS: 11171 IS: 5553-1990

Components 1 2 3 4 5 Transformer Paper covered copper conductors Paper covered Al. Conductors High voltage bushings Insulators IS:3024, IEC:60404-2 IS:7404, IEC:60488 IS:6162, IS:1363 IS:2099, IEC: 60137 IS:731, IEC: 383

High voltage isolators upto 245 kV

IS:9921, IEC:60129

Condition Monitoring Capacitance and tan measurement - Transformers - Bushings On-line Partial Discharge measurements by Acoustic Emission Dissolved Gas Analysis Transformer Oil - New Oil - Old Oil Furan Content Degree of Polymerisation of paper

ANSI-C-57, IS:2099

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IEEE:C57-127-2000 IS:10573, IS:9434 IS: 335 IS:12463 IS: 1866 IEC:61198 IEC:60450

Field Studies Related to transformers, ERDA offers following field studies and measurements:

Condition monitoring by capacitance and Tan Delta measurements Measurement of no load and load loss at site Harmonic measurements of magnetizing current Partial Discharge measurement Failure Analysis Error Measurement DIRANA / DOMINO USS (For paper moisture determination) Frequency Response Analysis Third party testing using calibrated instruments Calibration of CTs and PTs Testing of CTs and PTs Noise level measurement Online condition monitoring by acoustic emission method

Infrastructure The major facilities include:

Routine and type testing facilities for Transformer upto 2000 kVA/33 kV Lightning impulse voltage test facility upto 1600 kV, 80 kJ for Transformers upto 100 MVA, 220 kV Wideband partial discharge bridge and Balance Detector, Biddle, USA with Faraday Cage Condition monitoring by capacitance and loss angle measurement by Automatic C & tan test set (Tettex, Switzerland & Doble, USA) Short Circuit tests on Distribution transformer 11 kV, 1600 kVA and upto 22 kV or 33 kV and 500 kVA Short circuit tests on LT switchgear upto 50 kA, 1 sec. and 40 kA, 3 sec. at 525 V / 250V. Type test facilities for potential transformers upto class 0.2, 66 kV Type test facilities for current transformer upto class 0.1, 4500 A. Automatic microprocessor based error measuring test sets Measurement of harmonics (ZEWS ZIMMER, Japan). Loss measurement by using 0.1 class CTs & PTs and digital power meter of : Yokogawa make Dissolved Gas Analysis (Netel, Agiland) Furan Analysis on HPLC (Shimadzu, Japan) Epstein test frame for core loss measurement Hysterisis graph plotter Franklin Insulation Tester Acoustic emission test set for online P.D measurement

Calibration Calibration of CTs and PTs of class 0.2 for various ranges is also undertaken at site and at ERDA laboratory at Vadodara. R&D Activities Areas of work related to transformers include:

Development of prototype hydrogen gas sensor

Impulse breakdown studies on transformer oil Residual life assessment of transformer Heat transfer studies on radiators Acoustic emission detection technique for discharge detection and location Accelerated ageing tests on distribution transformers to assess the insulation life

Transformer Oil
Liquid dielectrics form an important part of insulating systems in electrical equipment. One of its important uses is in transformers, where mineral oil is used. It acts as an insulating and heat transfer medium. It is also an arc-quenching medium for power and distribution electrical equipment like switchgears, transformers and capacitors. ERDAs facilities include a complete setup for testing and condition monitoring of transformer oil. All activities from sample collection to analysis and consultancy are covered here. Testing & Analytical Services The condition of transformer oil has to be well monitored through routine testing & DGA. The tests covered in the national standards fall into the categories of evaluation, quality, reliability studies and life expectancy of transformer. The following Indian Standards are currently followed for routine tests: 1 2 New Oil Oil in Service IS:335, IS: 12463 IS:1866

Special Tests

PNA Analysis Gas content analysis Viscosity index test Aromatic content determination Dissolved Gas Analysis Furan measurement DP measurement Gassing tendency of insulating oil Compatibility of solid insulating materials with oil

Technical Services

Third party inspection Witness testing Certification Consultancy

Testing & Analytical Services Sampling of oil from transformer

Infrastructure

Gas Chromatograph with Toepler pump Oxidation stability test set up FT-IR spectrophotometer Resistivity and tan delta bridge Liquid Chromatograph Rotating Bomb

R&D activities Developmental work has always gone hand in hand with testing activities at ERDA. Some projects undertaken include the following:

Evaluation of super absorbent for transformer oil reconditioning Field trial of Thermosyphon in Power Transformers in GEB grid Development of demonstration model of transformer oil reconditioning plant for rural areas. Residual life assessment of power transformer by laboratory simulated studies Development of prototype Thermosyphon for Power Transformer

High Voltage Impulse Testing

A wide range of electrical equipment, apparatus and components are used in transmission and distribution network of electrical power. Equipment like transformers, reactors, instrument transformers, bushings, insulators, lightning arresters and isolators of different ratings are manufactured in India. ERDA has equipped itself to undertake high voltage impulse testing on such equipment (rating upto 400 kV) as per Indian and International standards. Infrastructure

AT MAKARPURA Impulse Voltage Generator 1200 kVp (60 kJ) 800 kVp (40 kJ) 1200 kVp 800 kVp 300 kVp 600 kVrms 1200 kVp 0.1, 0.5, 1.0 12 Bit Nicolet with software PD / RIV Measuring Instrument 500 mm sphere gap

AT SAVLI 1600 kVp (80 kJ)

Impulse Voltage Divider H. V. A. C. Transformer Multiple Chopping Gap Low Resistance Non Inductive Shunts Digital Impulse Analyzer System PD/RIV Measurements Sphere gaps

1600 kVp 700 kV 1600 kVp 0.1, 0.5, 1.0 14 Bit MIAS High Volt PD / RIV Measuring Instrument 750 mm sphere gap

Infrastructure facilities for bringing large trailer loaded apparatus to the testing lab, arrangement for lifting and mounting of bushings, conservator tank and provision for installing oil filtration facility also exist. Equipment that can be tested includes: 1 2 Power Transformer Current Transformer IS:2026 IEC:60076-3 IEEE:C-57.98 IS: 2705

IEEE:C.57.13-1993 IEC:60044-1 3 Voltage Transformers (including CVT) IS:3156 IEEE:C.57.13-1993 IEC:60044-2 IS:2099 IEC:60137 IS:731 IEC:60383 IS:9921 IEC:60129 IEC:62271-100 IEC:62271-100 IS:13118 IS:3070 IEC: 60099-4 IS: 7098 IS:1554-2 IEC:60502 IS:5553 IEC: 60289 IS:335 IS:1866 IEC:60897 IS:13925 IEC:60688-I IEC-60353

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High Voltage Bushings Insulator upto 400 kV (Tension & Suspension) High Voltage isolators upto 400 kV HV Switchboard HV Outdoor breakers upto 400 kV Lightning arresters and ZnO blocks

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High voltage cables

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Reactors

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Transformer oil Capacitors (HT) Rotating machine stator coils for impulse, switching surge and steep front wave Line Trap

ERDA provides facilities for type, developmental and certification testing of these equipment and also calibration of impulse voltage & AC, DC voltage at site.

TESTS

HV Lightning Impulse test HV Switching Impulse test HV Dry / Wet Power frequency test Capacitance and Tan delta measurement Partial discharge measurement Insulation Resistance / Polarization index Losses and Temperature rise tests RIV, Corona measurement HV Calibration, CT/PT Calibration Measurement of Earthing system Voltage Distribution Test on String Insulators Recovery Voltage / Acoustic emission tests RLA / Condition Monitoring at site HV AC/DC & Impulse Calibration at site Calibration of Impulse test system at site

R&D Activities Studies in the area of impact of high voltage on equipment and their components are undertaken. These include

Power system grounding Online condition monitoring of lightning arresters Failure analysis of transformer during impulse test On line condition monitoring of insulators

Ongoing work includes

Study the Effect of corona ring on polymer insulators Studies on polymer insulators Design of earthing grid for power stations Accelerated aging test on metal oxide blocks

Aging studies on polymeric housing lightning arresters

The HV impulse testing, Short Circuit testing facility, along with the insulating materials testing facilities at ERDA provide a complete set of facilities for testing some of the important electrical equipment.

Switchgear & Controlgear

A wide range of electrical equipment such as Power transformers, Current transformers & Cables are used in transmission and distribution network of electrical power. The Control and protection equipment like switchgear and controlgear are important components of power distribution systems. The conformance of these products to standards / specifications is crucial for the reliability and safety of electrical equipment. ERDA has complete facilities for testing and evaluation of products likes Power transformers, CTs, Cables, ACBs, HRC fuses, MCBs, MCCBs, RCCBs, Contactors, Starters, Switchfuse units and cables, LT Panels, Switchboards, Distribution boards etc. ERDA is one of Indias premier Testing Laboratories accredited by Intertek (ASTA), UK for Type tests and certification of various electrical products. The products covered under this accreditation are listed below. ERDA Switchgear test laboratory is also accredited by National Accreditation Board for Testing and Calibration Laboratories (NABL), Govt. of India and recognized by Bureau of Indian Standards (BIS). ERDA has recently established temperature-rise test facilities up to 20kA, Time-current characteristics up to 40kA, Electrical endurance test up to 2.5kA at 690V, Mechanical endurance test for HT Circuit Breaker up to 145kV, 24kV Impulse Generator, and Feeder load unit (3 nos.). ERDA has one of the largest IP 40 ton test facilities in Asia The facilities are also utilised for testing as per UL and CSA standards for export of electrical products conforming to the requirements of these standards. ERDA has also established an Online Short Circuit Testing Laboratory for 120 kA, 575 V at Savli and 50 kA, 500V at Makarpura. Test facilities for the following products have been covered under ASTA BEAB accreditation. Sl. 1 2 3 4 5 6 7 Product Switchgear and Controlgear Assemblies LV Switchgear and Controlgear Assemblies Busways LV Switchgear and Controlgear Assemblies Distribution boards Circuit breakers (ACBs/MCCBs) Switches/ Disconnectors/SFU/ SDF Contactors and Motor Starters Electromechanical control circuit devices Standard IEC: 61439-1&2 IEC: 60439-2 IEC: 60439-3 IEC 60947-2 IEC:60947-3 IEC:60947-4-I IEC 60947-5-1

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Terminal Blocks Low Voltage fuses MCBs RCCBs RCBOs Power transformers (upto 33 kV, 4000 kVA - 11 kV, 1600 kVA) Instrument Current transformers (upto 3500 A) Power cables (upto 36 kV) PVC cables General requirement (upto 36 kV) Rubber insulated cables General requirements

IEC 60947-7-1 IEC 60269-1 IEC 60269-2 IEC: 60898-1 IEC:61008-1 IEC 61009-1 IEC 60076-1 IEC 60076-2 IEC 60076-11 IEC 60044-1 IEC 60502-2 IEC 60227-1,2,3,5 IEC 60245-1,2,3,5

Facilities recognized for CE Marking and EMI / EMC testing Sl. 1 2 3 4 5 Type of Test Electrostatic discharge immunity test Radiated radio frequency electromagnetic field immunity test Electrical fast transient / burst immunity test Surge immunity test Conducted radio frequency immunity test Standard IEC:61000-4-2 IEC-61000-4-3 IEC:61000-4-4 IEC:61000-4-5 IEC:61000-4-6 EN-55022 CISPR-22 CISPR-14 CISPR-11

Radio interference / Disturbance measurement

Infrastructure The test facilities include:

Short circuit making & breaking capacities 120 kA, 575V and & 50 kA, 500 V for LV Switchgerar

Short time withstand current test 120 kA for 1 second or 70 kA for 3 second at Savli and 50 kA for 1 Sec, at Makarpura 20kA & 10kA, 10V stabilized High Current source for temperature rise test Time current characteristics up to 40kA, 40V 170 Channels computerized temperature scanner Electrical endurance and Making & Breaking setup, 4 kA at 415V, - 1 No. 2 kA at 690V, - 1 No. 1 kA at 415V, - 3 Nos. 200A at 415V 2 Nos. 24kV, 1.2/50s Impulse generator Impulse Test 1600 kV, 80KJ High Voltage one minute power frequency test dry & wet 750kV Ring wave cum current surge generator Current surge - 3000A, 8/20 sec Ring wave - 250A,0.5 sec 100 kHz Computerized Single phase & Three Phase Relay testing kit Feeder load unit 3Nos.( Each of 8 ways outgoing feeder) Environment chamber: - 40C to +180C Cold chamber : - 65C Size: 950 mm x 1000 mm x 950 mm.

Size : 580mm x 550x 1120 mm

Mechanical endurance test set up for HT circuit breaker up to 145 kV IP test ( Degree of Protection ): 40 Tonne Size: 6.8 Mtr x 5.8 Mtr. x 5.0 Mtr.

WITNESS TESTS ERDA can witness tests on HV circuit breakers for mechanical endurance, temperature rise test, dielectric tests at manufacturers premises. ERDA can also witness tests on transformers at manufacturer premises.

Motors Manufacturing process in cement, fertilizer, steels textile, paper and agricultural industry etc.,runs on rotating electrical machines. Approximately 50% of the electrical energy used in India is by industries, 40% by agriculture and the balance for residential and other requirements. It is however noteworthy that irrespective of whether the electrical energy is utilized in households, transport or industry rotating electrical machines play a very important role. The most widely used rotating electrical machine is the induction motor, well known for its simple and robust construction, rugged operation and low cost. The modern drive system, used in several process industries, comprise of motors and power electronic controllers with wide range of operating speeds and torques. Considering the above, it is necessary to evaluate the performance and verify the design of each variety of motors through type testing as per relevant Indian and International standards. Testing Facilities The following products can be tested at ERDA.

1. 2.

Three phase induction motor - upto 30 hp Lift motors - upto 30 hp Three phase induction motor for agricultural purpose - upto 30 hp Energy efficient induction motor - upto 30 hp

IS:325 IEC:60034-1 IS:8151

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IS:7538 IS:12615 IEEMA 19

4. 5. 6. 7. 8.

Single phase AC and universal Motors IS: 996 upto 5 hp Submersible motors- upto 60 hp Increased safety motors DC motors - upto 5 hp Small single phase motors for agriculural purposes upt 30 hp IS:9283 IS:6381 IS:4722 IEC:60034-1 IS:14582

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Eddy current drives AC generators used with IC engines - upto 20 kVA Degree of Protec-tion (IP) on rotating electrical machines

As per clients requirements IS:13364-Pt.1 IS:4691 IEC:60034-5

On Site Test Facilities

Current signature analysis Motor circuit analysis Acoustic analysis Online partial discharge measurement Vibration analysis HP rating evaluation Load cycle measurement of motor Transient measurement of HT motors and alternators Harmonic measurement at motor installations Capacitance and Tan delta measurement of HT motors/alternators Failure investigation of single and three phase Induction motors Starting current measurement of motor Residual life assessment of motors

Infrastructure

Digital precision grade Power Meters (basic accuracy :0.1%) Torque transducers Eddy current Drive 1 HP, 7.5 HP, 15 HP and 30 HP Speed Torque characteristics of Motors Vibration & Noise measurement of Rotating Electric Machines Test setup for FHP Motor Digital storage Oscilloscope Load Cell Proximity sensor for speed measurement

Short circuit testing of terminal boxes 120 kA for 1 sec. Digital Tachometer IP Chamber-40 tons; Size 5.8x6.8x4.5 m Sound level Meter

Additional Test facilities ERDA also has complete type test facilities for testing of various types of pumps such as Centrifugal pumps, Submersible pumps, Self priming pumps, Jet pumps, Monosets as per relevant Indian Standards. ERDA also has type test facilities for testing of flameproof enclosures as per IS 2148 except for flame proofness and explosion proof test. ERDA has complete type test facilities for testing of IC engines as per relevant Indian standards. R&D Activities Developmental work on related topics include:

Development of 3 phase Hysteresis motor Study of grid abnormality on Wind Turbine driven Induction Generator performance Comparative study of indigenous and imported Energy Efficient motors Design of Energy efficient Submersible motor Online condition monitoring on Induction motor through stator current Design verification of Induction motors through computer software Development of motor current signature analysis instrumentation for online condition monitoring of motors