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TEST GUIDE INSTRUCTION

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Contents
CHAPTER

PAGE

1.

Generalities

2.

General Site test procedures

2.1
2.2
2.3
2.4
2.5
2.6

Introduction
Contact resistance test
Bus bar contact resistance test
DC HI POT for Power cable
AC withstand for Switchgear
Grounding system

5
6
6
8
10
12

2.6.1 Earthing circuit test


2.6.2 Step voltage measurement
2.6.3 Touch voltage measurement

12
13
14

2.7 Insulation resistance test


2.8 Power circuit breaker Timing test
2.9 Power transformer test
2.10 Power circuit breaker
2.11 Voltage transformer
2.12 Current transformer
2.13 Lightning arresters
2.14 Disconnecting switch
2.15 Battery and battery charger
2.16 AC & DC Boards
2.17 6.6KV Switchgear
2.18 Power and control cable
2.19 Bus work
2.20 Insulator and bushing
2.21 Steel structure
2.22 Out door lighting and miscellaneous
2.23 Energizing

17
18
19
26
27
29
32
32
33
37
37
37
37
38
38
38
38
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2.24 Protective relay

0/1

1. GENERALALITIES
1.1 PURPOSE
This document describe all requirements and recommendations for site inspection and
testing of electrical equipment supplied by SCHNEIDER (THAILAND)
1.2 INSTALLATION
Prior to installation and after unpacking, cleaning, storing, handling, preliminary
positioning, the following details are to be checked :
-Verified the material are conformed with final approved drawing and specification
-Physical quality of materials
-Their identity and conformity with drawing
-Mounting instructions
-Accordance with civil works
For the whole installation period check that :
-All completed works meet the technical specification and the rules of art.
-Personal safety is observed.
After installation verify :
-Tightening
-Absence of foreign bodies
-Cleanliness of electrical and mechanical part
-Presence of grease on the various mechanisms
-State of protective coatings
1.3 TEST & SETTINGS
Tests and settings must be carried out in order to check that the materials are installed,
connected and adjusted in compliance with the documents.
-Equipment setting
:
Each manufacturer documentation. &
installation details dwg.
-Function, interlocking and alarm
:
Logic diagram & Schematic diagram dwg.
-Relay settings
:
Relay setting and relay co-ordination sheet.
1.3.1 Pre-commissioning tests
Tests are performed prior commissioning and energizing (AC WITHSTAND TEST).
All individual tests and functional tests must be carried out during this checking step.
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The installation shall be in conformity with the documents and ready to be energized.
1.3.2 Commissioning checks
Tests are performed prior AC WITHSTAND TEST.
Final checking is done with customer and customers representative in order to prepare
and ensure the first energization.
Purpose : to improve or guarantee the followings:
-Correct status of equipments shown on L/R control boards.
-Correct interlocking and diagram functions.
-Protections stability
-Correct readings on metering parts.
-Correct currents & voltages values flowing into protective relays including final
settings.
-Correct functionalities of tripping/inter tripping function.
1.3.3

AC WITHSTAND TEST

Tests are performed during the first energization of substation.


Jointly with our customer and customers representative the procedure of
energization shall be defined prior energizing. This procedure shall be followed
during this test.
AC/DC boards and battery/charger shall be checked in order to guarantee the good
supply of equipment. An insulation measurement is generally requested before and
after energizing.
Voltages, currents, powers & phase rotations shall be checked for all loops going to
protective/control/metering parts.
1.4

SCOPE OF SUPPLIES
Our services are limited to equipment supplied by ourselves and installed in the
various substations, MV switchgear and low votage switchboards and cabinets.
Our supplies include :
-Equipment test and adjustments
-Checking of wiring, HV, MV, LV control and earthing connections
-Function tests and automations
-Checking of conformity with diagrams and documents
-Technical assistance for equipment operation and energizing
Are excluded in particular :
-Materials not supplied by ourselves

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2. SITE TEST PROCEDURES


2.1 INTRODUCTION
Before proceeding to the energization of an electrical installation it is necessary to
Check that :
-the HV, LV equipment are complied with final approved drawing and specification;
-all control and electrical locking circuits are well done (analysis of documents).
-all the routine test data and result available.
Ensure that :
-cables and wiring have been checked during erection or at the end of erection.
CODES AND STANDARDS
The tests will be done under the specifications of the applicable standards of IEC or
equivalent (ANSI, MEA, PEA & EGAT ).

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2.2 CONTACT RESISTANCE MEASUREMENT


1. Purpose
To verified the contact resistance of circuit breaker are complied to the manufacturing
standard.
2. Scope
This procedure shall apply voltage test for DC. Current injection main caontact of circuit
breaker
3. Reference and standard
Manufacturing standard.
4. Equipment
Micro Ohm Meter
A measurement use the DC Volt -Amp method with the current 100 Adc. The contact
resistance measurement is performed as follows :
- Close CB and connect the measurement circuit ( Fig. B )
- Feed current 100 ADC. Through the main circuit .
- Measure the voltage across a main contact .
- Calculation of resistance
Contact resistance

Measure voltage
100ADC

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Normally contact resistance value is in micro-Ohm

Curr
ent

Main
Micro ohm meter

Volt
age
circui
t

Fig.B Contact resistance testing.

2.3 BUSBAR CONTACT RESISTANCE TEST


5. Purpose
To check and make sure that the joint strength tightening of bus bars.
6. Scope
This procedure shall apply voltage test for DC. Current injection to bus bar.
7. Reference and standard
8. Equipment
Micro Ohm Meter
Voltage lead
Current lead

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9. General
9.1 Personnel with adequate technical capability should be available to do the testing
make observation and evaluate the results.
9.2 Micro Ohmmeter tester used for testing shall be calibrated.
10. Procedure of bus bar contact resistance.
10.1
Connect test lead to bus bar as shown in fig. 8.
10.2
Inject 100 ADC to joint by increasing the current until reach 100 ADC
10.3
After item 6.2 then press the pushbutton wait for 3 second the test value in
micro-ohm will be shown at display.
10.4
Record the test values and complete for one joint.
Bus bar

Voltage Lead

Current Lead

Micro Ohm Meter

2.4 DC HI - POT FOR POWER CABLE


1. Purpose
To check that the DC. leakage current of power cable limit after finished installation .
2. Scope
This procedure shall apply for DC. high voltage test.
3. Reference and standard
Test results of DC. Leakage current should be not exceed the recommendation form the
manufacturer .
4. Equipment
DC. HI-POT Tester
Insulation resistance tester
Discharge stick
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5. General
5.1 Personnel with adequate technician capability should be available to do the testing,
make observation and evaluate the result .
5.2 The DC. HI-POT tester and the Insulation resistance tester used for testing shall be
calibrated .
6. Procedure of DC.HI-POT power cable test .
6.1 Measure insulation resistance of power cable ( A-G, B-G, C-G ) before HI-POT test
for 1minute.
6.2 Using DC. HI-POT test set by injection DC. High voltage to power cable as detail:
- Testing DC. voltage ( 60% of rate ) per phase for 15 minutes.
6.3 Rerecord the DC. Current leakage current ( mA). ) per phase to the field test report .
6.4 Decrease DC. High voltage until zero volt then discharge power cable by discharge
stick for safety .
6.5 Test the other phase according to procedure 6-2
6.6 Measure the insulation resistance once again immediately after the DC. HI-POT test
are finished ( same as procedure 6-1 )
6.7 Complete a field inspection test report for every test carried out.
6.8 The test criteria shall be as per the manufacturer specification data accepted by the
client.
High voltage
Phase A
Phase B
DC Hi-Pot
Tester

Phase C

Control
unit

6.9 Formula for test


Voltage inject

U0V L L
3

2 . 4 2 . 5 %Test

Note:
2.4
= Constant value for alternating current convert to direct current.
2.5
= 250% of voltage test.
%Test = %voltage inject used for old cable (60%), 50% for maintenance cable.

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2.5 AC WITHSTAND TEST FOR MV SWITCHGEAR


1. Purpose
To ensure that all HV. Circuit including circuit breaker, current transformer, voltage
transformer, busbar and insulator are able to withstand the relevant test voltage for one
minute.
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2. Scope
This procedure shall apply AC high voltage at MV switchgear
3. Reference and standard
The switchgear and control gear shall be consider to have passed the test if no disruptive
discharge occurs
4. Equipment
AC. High voltage Tester
Discharge stick
5. General
5.1 Personnel with adequate technician capability should be available to do the testing,
make observation and evaluate the result.
5.2 The DC. HI-POT tester and the Insulation resistance tester used for testing shall be
calibrated .
6. Procedure of Test
6.2 The Insulation Resistance shall be carried out before Hi-pot

Test
6.3 All auxiliary circuit must be isolate
6.4 Using AC. HI-POT test set by injection DC. High voltage to MV switchgear Bus bar
(as detail) and all circuit Breaker shall be open
- Testing. voltage per phase for 1 minutes.
6.1 Record the. Current leakage ( mA). ) per phase to the field test report .
6.2 Decrease AC. High voltage until zero volt then discharge the test object by discharge
stick for safety .
6.3 Test the other phase according to procedure 6.2 to 6.4
6.4 Close 6.6kV Circuit Breaker and be sure that all Feeder cable are removed and all
earthing switches are opened. Repeat the test as per procedure 6.2 to 6.5
6.5 Measure the insulation resistance once again immediately after finished HI-POT Test

6.6kV Switchgear
6.6kV Bus bar

A
B
C

x
\
Control
unit

\
\

x
x
ES

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AC Hi-Pot
Tester

CB
Other Feeder

6.6kV Bus bar

A
B
C
AC Hi-Pot
Tester

Control
unit

xCB

Other Feeder

x
ES

6.6kV Switchgear with


Circuit Breaker Close.

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2.6 GROUNDING SYSTEM


2.6.1 Earthing circuit measurement
1. Purpose
To confirm the earthing resistance of substation grounding and the value shall be less
than 1 ohm.
2. Scope
Measure the substation earthing circuit with the existing earth at 5 time of substation
wide.
3. Reference and standard
The test method are base on our substation Grounding system design / calculation note
and IEEE 80-1986 standard by Fall- of - Potential method.
4. Equipment
-Earthing tester

5. Notice.
1. Check test equipment and geological area for test.
2. The weather should be dry or no rain.
6. Test Procedure
1. Set test equipment at substation ground grid.
2. Jump C1 to P1 on test equipment to ground grid.
3. Connect test lead to C2 on test equipment, to pitch it on earth at 100 meter
or 5 time of substation wide.
4. Connect test lead to P2 on test equipment, to pitch it on earth at 20 meter,
measure and record the earth resistance (R1).
5. Measure and record the earth resistance at 40 meter ( R2), 60 meter ( R3)
6. Calculate using the following formula.
R R2
PT
3
EC
R 2 R1
PT
7. Find the value of
from table in Megger DET 5/2 manual page 41
EC

to 45 ( Chart for use with Slope method )


8. Measure and record the true resistance of ground system at calculated
distance.

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20m
40m
60m
Ground grid
100m
C1

P1

P2

C2

Display
3Pole

4Pole

Fig.1 Procedure of ground system test (slope method)

2.6.2 Step Voltage Measurement


1. Purpose
To confirm the Step Voltage Value at site that shall not higher than the Design Value.
2. Scope
- The actual step voltage at maximum fault current can not be perform cause of limited on
current source.
- This procedure shall apply the AC current 50-100A to Grounding Grid and Earth. across
the test point. Then transfer step voltage at 50-100A to maximum fault level by multiply
factor.
3. Reference and standard
The test method are base on our substation Grounding system design / calculation note
and IEEE 80-1986 standard.
4. Equipment
- Multi Ratio Transformer 220/380V : 220/../1000V, 100A Secondary current
- AC clamp on 0-1000A
- Multi meter
- Test Rod
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5. Test procedures
5.1 Connect the Transformer to grounding Grid and Earth at outside substation Grid
across the test Rod
5.2 Inject AC Voltage and keep/adjust current to Ground Grid and Earth 100A by select
Transformer Tap
5.3 Measurement and record the voltage on the test rod by multi meter
5.4 Measurement and record the Injected current by clamp-on 0-100A

380V AC
Source

Volt meter

1m

6. Formula for Test


Step voltage at 40kA

Transformer

Test Rod

Crush Rack

Ground Grid

V step (at Injected Current) x 40kA


Injected Current (A)

2.6.3 Touch voltage Measurement


Perform the same method of step voltage measurement except the test connection
380V AC
Source
Volt meter

Transformer

Test Rod

Crush Rock

Ground Grid

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Note. The result from this method can be directly compare to the grounding system
calculation note. The step and touch voltage as measurement by this method and from the
grounding system calculation note are voltage across soil under the crash rock.
* Step voltage and Touch Voltage measurement for GIS.
Perform the same method o step and touch voltage measurement except the test
connection
380V AC
Source
Test TR

Clamp on 0-1000A

GIS
Concrete Floor
Crush Rack
Mutimeter

Ground Grid

Earth

Test connection for step voltage

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380V AC
Source
Test TR

Clamp on 0-1000A

GIS
Concrete Floor
Crush Rack
Mutimeter

Ground Grid

Earth

Test Connection for Touch Voltage Metal to Concrete Floor

380V AC
Source
Clamp on 0-1000A

Mutimeter

Test TR
GIS

GIS
Concrete Floor

Reference: Rod

Crush Rack

Ground Grid

Earth

Test Connection for Touch Voltage, Metal to metal

Page 17 of 39

2.7 INSULATION RESISTANCE MEASUREMENT


The insulation resistance test for the SF6 Gas circuit breaker is performed as follow :
- Use 500, 2500 or 5000 Vdc. Insulation resistance meter for the insulation
resistance test.
- Measurement insulation resistance ( Phase to Ground and Phase to Phase ) by
connect the measurement circuit ( Fig. A1, A2 ). A circuit breaker shall be close
for the test.

Main

circui
t

Fig. A1 Phase to Ground measurement.

Main

Page 18 of 39

Fig. A2 Phase to Phase measurement


2.8 POWER CIRCUIT BREAKER TIMING TEST
The Timing measurement is an on - off time interval measurement of circuit breaker. A
Breaker Analyzer is used for this purpose. Timing test for operating mechanism .
inspection is performed as follows :
1. Connect measurement circuit diagrams. (Fig. C)
2. Provide control voltage supply to Timing tester ( 1 ). Confirm that voltage
level is corrected
3. Confirm that short circuit condition cannot occur in closing and tripping
circuit.
4. Turn operate button ( 2 ) clock-wise to operate close-open the CB.
5. Turn measure button ( 3 ) clock-wise to operate and analyzing .

Analyzing
supply

1
Display
Test report
print out

control

voltage

To close circuit

Channel

To open circuit
2

Page 19 of 39

Fig. C.

2.9 POWER TRANSFORMER


After the transformer has been properly installed and is in operation under
the condition, for which it was designed, it must receive periodic test and
inspections.
Important: Always de-energized and has been removed power cables, all tools or
other objects used from the transformer. The transformer tank must be grounded
permanently by connecting a ground cable to the ground system.
Item test:
1. Insulation resistance test ( Polarization index ) PI
2. DC. Winding resistance test.
3. Vector group or phase relation test.
Procedure of test.
1. Insulation resistance test ( Polarization index ) PI
1.1 Before insulation resistance test the transformer must be short-circuit all
three phase together on HV & LV. bushing .
1.2 Connect test lead to the bushing at need to test
Test connection
1.2.1 HV. To LV. + GND.
1.2.2 LV. To HV. +GND.
1.2.3 HV. To LV.
Apply 2500 voltage test for 1.2.1, 1.2.3 and 1000 voltage test for 1.2.2
for ten minute and record the test values every 1 minute for calculate Polarization
index as note.
Note:

Polarizati on Index ( PI )

PI above 2.00

Insulation resistance at 10 minutes


Insulation resistance at1minute

GOOD
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PI 1.25 to 2.00
PI 1.00 to 1.25
PI less than 1.00

=
=
=

FAIR
BAD
DANGEROUS

Example: HV to LV+GND

A
a

Power transformer
c
b

C
n

Fig. 1 Insulation resistance measurement


2. DC. Winding resistance test.
2.1 When energizing a test winding the normal primary and secondary winding
should be open-circuited. There should be a continuity check of all
windings and all tap positions, measure the winding resistance and compare
to the factory test values.
2.2 Preparation all accessories used for test. Connect test lead to the bushing
and set tap position.
2.3 Injection directed current from battery to the bushing conductor. And
measurement voltage values when current Volt
values
constantly. Record
meter
voltage and current measured. See fig. Below. Or apply by the test set for
winding resistance of transformer

A
C
B
Power transformer
a
b
c
n

Battery
Amp meter

Page 21 of 39

Fig. 2 Winding resistance test


3. Vector group or phase relation test.
The vector group or phase relation between the high voltage and low voltage
terminals is represented by pharos diagram. When voltage measured.
Procedure of vector group or phase relation test.
3.1 The angular displacement and phase sequence is verified by connecting the
reference vector component together ( connected H1 to X1 ) and excite the
unit at a three phase voltage, and taking measurement between the various
pairs of the terminals
3.2 Measure and record voltage values.
Example:
Vector group Dyn1

H1-H2
H2-H3
H3-H1
H3-H2

385.5
383.5
386.3
321.9

Measured voltage of each terminal


H1-X1
78.1
H2-X2
H1-X3
77.9
H2-X3
H2-X1
38.4
H3-X1
H3-X3
321.6

320.0
391.4
386.1

H1
X1
X2

X3
Fig. 3 Vector group Dyn11
H3

H2

Note: If the measured value satisfies the follow relationship the polarity and phase
relations are good
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Judgement criterion H3-X3 = H1-X1 = H2-X2 < H3-X2


4. Turn ratio test.
This procedure is represented by transformer ratio meter model TR800. The
TR800 is a portable instrument designed for the accurate ratio measurement of
transformers and devices with AC ratio metric divides associated with then.
4.1 Preparation for use.
Insure that the apparatus to be tested is cleared and de-energized prior to test.
It is highly recommended that the user familiarize him self with the controls.
4.1.1 Connect high side leads (H markings on alligator clips) to H input
panel controls. Connect low side leads (X marking an alligator clip) to
X input panel controls.
4.1.2 Determining in-phase X and H vectors.
Example
For this diagram, one must determine two lines, which are parallel to
each other. For example, H2 H1 will ratio against X2-X0. Vector
group Dyn11 represents this example.
X1

X1

H1
X2

X2

X3

H3

H2

X3

Fig.4 Vector group


4.1.3 Set H selector to H2-H1. Set X selector to X2-X0
4.1.4 Set the instrument controls as follows.
Detector Phasing switch:
Ratio

Detector sensitivity:
Midway

Phase multiplier switch:


0.1

Phase deviation dial:


0

Ratio multiple switch:


1 (example)

Ratio switch:
8-0-0 (example)

Percent deviation dial:


0

X Selector switch:
X2-X0

H Selector switch:
H2-H1

Polarity switch:
Normal

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Test voltage selector:


12V.
Excitation range switch:
10.

4.1.5 Turn instrument ON


4.1.6 Null Detector needle should be balance with detector phasing with
on Ratio and Phase

Example
If ratio dial records 8.00, multiples is 1 and deviation dial read +1.5,
then
Ratio

100 1 . 5
1000
1001 . 5
8 . 00
1000

1 8 . 00

8 . 012

Note: If ratio deviation dial is used for balancing, determine ratio by factor
1000 D
1000

to obtain exact value.

5. Phase angle balance.


The phase deviation dial reads directly in centi-radiaus regardless of ratio, as
long as proper multiplier (0.1 or 1.0) is applied. In normal testing, phase
deviation should be minimal. Excessive dial reading from normal should be
investigated because they indicate possible shorted turns, presence of circulating
current paths, or other errors. One centi-radian is equal to 34.37 minutes.
H1

X1
A

H2

X2
B

H3

X3
C

c
X0

TR800

Page 24 of 39

Fig. 5 Connection of a three-phase transformer

PROCEDURE OF FIELD TESTING


OIL DIELECTRIC STRENGTH TEST
This procedure is represented by Oil dielectric strength tester. The maximum 60
kV. Output allows test to be performed on oil from a wide variety of electric
installations including transformer. The operation of the test set is extremely simple
and the results are displayed.
Preparing the oil test vessel.
1. Optional vessels are available for testing to national specification. (See table
and accessories) Some specifications require stirring of the oil sample as
different test electrode shapes.
2. The suitable ramp rate for test to be performed should be selected using the
key.
3. The start key will then turn on the high voltage.
4. The HV. indicator will light to show the output voltage is on. The voltage
will then increase at the selected ramp. Rate and the corresponding value
will be shown on the display.
Oil Testing Specifications
Test
Specification

Electrode
Shape

Electrode
Gap

Initial
Stand Time

Rate of rise
of voltage

Stir time

Stand Time

Number of
Test

Average
Start
Test no.

Page 25 of 39

AS1767
ASTM D877
ASTM D1816
BS148
BS5730a
BS5874
CEI344
IEC156
IP295
IJIS C2101
KSC2101
NFC27-131
NFC27-221
ROCT6581
SABS555
STAS286
UNE21
VDE0370

A,B
C
A
A,B
A,B
A,B
A
A,B
A,B
B
B
A,B
A,B
A,B
A,B
A,B
A,B
A,B

2,5 mm
2,5 mm
1 or 2 mm
2,5 mm

3 min.
2 min. 20 s.
3 min.
3 min.

2,5 mm
2,5 mm
2,5 mm
2,5 mm
2,5 mm
2,5 mm
2,5 mm
2,5 mm
2,5 mm
2,5 mm
2,5 mm
2,5 mm
2,5 mm

3 min.
3 min.
3 min.
3 min.
3 min.
3 min.
3 min.
3 min.
3 min.
3 min.
3 min.
10 min.
3 min.

2 kV/s
3 kV/s
0,5 kV/s
2 kV/s
2 kV/s
2 kV/s
2 kV/s
2 kV/s
2 kV/s
3 kV/s
3 kV/s
2 kV/s
2 kV/s
2 kV/s
2 kV/s
2 kV/s
2 kV/s
2 kV/s

1 min.
Continuous
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.

1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.
1 min.

6
1
5
1
5
1
6
1
Withstand (Proof) Test
6
1
6
1
6
1
6
1
5x2
2
5x2
2
1x3
1
6
2
6
1
6
1
6
2
6
2
6
1

Electrode Shape
A
36 mm mushroom
B
12.7 mm (0,5in.) spherical
C
25,4 mm (1 in.) cylindrical

Fig.1 Oil dielectric strength tester

2.10 POWER CIRCUIT BREAKER


1. General construction and Final check before commissioning

Page 26 of 39

-Check packing &physical condition before erection


-Insulation part
-Structure grounding and earthing continuity
-Wiring and cable termination
-Check level and polarity of auxiliary power supply
-Check SF6 gas compartment pressure before erection
-Check tightening of bolt/nut
-Concrete grouting of CBs structures shall be completed
-The Commissioning checklist must be used to check and fill up to ensure that all
activities required for efficient operation have been performed.
2. Checks to be carried out before start-up
-Before starting up the circuit breaker, the tests given in the table below must be
carried out after powering the control cabinet with the auxiliary voltages
specified in the diagrams, in order to check for the absence of malfunctions
might have been caused during transport and assembly.
3. Test and commissioning item
POS.
3.1
3.2

3.3
3.4
3.6
3.7
3.8

TEST
-SF6 gas pressure control
-Compressor and pumping
time after a C-O cycle.
-Check the correct cut-in of
the density meter contacts
during the O-t-CO-t-CO
cycle and cut-in of the low
gas pressure locks
-Check alarms and locks for
minimum gas differential
(functional check of the
circuits)
-Anti pumping test
-Operating times during
opening and closing and CO
cycle.
-Functional tests
-Remote/Local operation
-Measurement of main circuit
resistance
-Check CB counter operation
-heater and lighting

INSTRUMENTS
-Hose with reference pressure
gauge(fig 10)
-SF6 gas bottle
-Hose with reference pressure
gauge(fig10)
-Special fitting(fig. 14)
-Multimeter

-Recording
-Multimeter
-Multimeter
-Micro-ohmmeter

4. Procedure
4.1 Checking the compressor stop pressure and pumping time after a C-O cycle
Page 27 of 39

In order to check the compressor stop pressure, carry out following operations:
- perform an opening and closing operation and wait for the compressors to
stop;
- using the hose(fig.10) with reference gauge (pos.5 fig.10), check that the
pressure in the extinction unit at 20C corresponds to the value given in Table
15/A or 15/C;
- perform a CO cycle, starting from the pole open position and the compressor
stop pressure;
- record each compressor operating time until it stops this will be indicated by
the switching of the XP relay. This period is usually less than limits indicated
in table 1.
4.2 Checking the correct cut-in sequence of the density meter contacts during the O-tCO-t-CO cycle and cut-in of the low gas pressure locks
Perform the check on all the poles separately, proceeding as follows:
- Disconnect the connectors of the two poles not being tested.
- Perform a closing operation, wait for the compressor to stop and disconnect it
using the corresponding link fuses F.
- Wait a few minutes for the stabilization of the SF6 gas pressures.
- Perform the O-t-CO cycle ;
-No locks should occur, if a lock occurs, please contact manufacturer;
-Perform further closing and opening operations until locks CH(closing lock)
and AP(opening lock) appear. Usually one C-O sequence is sufficient. In case
the AP lock does not appear, execute a further closing operation, as indicated
in par.7.2.
- Connect the pressure reducer with the hose (fig.10) to a bottle of SF6 gas.
- Fit the reference gauge (pos.5 fig. 10) to the hose (fig.10).
- Turn the pressure regulator knob(pos. B fig.10) until the low pressure
gauge(pos. E fig. 10)indicates the filling pressure.
- Expel the air from the hose by opening the taps of the bottle(pos. C fig.10) and
reducer (pos.A fig. 10) for a few seconds.
- Keeping the taps partially open, contact the hose (pos.3 fig.10) to the valve
(pos.1 fig.10).
- Immediately close the taps (pos. A and C fig. 10) of the gas bottle;
- Start the SF6 gas compressor by closing the link fuses F relative to the pole
being tested;
- Check that the cut-in sequence of the density meter contacts corresponds to
the sequence give below.
Contact
Contact function
Setting at 20C
63/3,63/4
Low gas contact for opening
inhibit
63/2
Low gas contact for closing
inhibit
63/1
Compressor stop
0.64Mpa
Note : Tolerance threshold 0.01Mpa
- Disconnect the hose from the valve(pos. 1 fig. 10) and close the valve with
their cap and nut.
- Valve tightness is assured by cap (pos.2 fig. 11), the gaskets have been filled
and are intact (pos. 6 and fig. 11) and by nut (pos.1 fig.11).
4.3 Checking the operating time during opening and closing of the C-O cycle
Page 28 of 39

Perform all the checks below, ensuring that the values recorded remain within the
limits indicate
Check and record the operating times for the cycles run.
The reference valves for the operations run at nominal power supply are;
Description
Time close
Time open
Time gap remain in
closed position
during CO cycle
Pole discrepancy
Pole discrepancy

Max. value(ms)
61 +3-2
31 +/-2

At sequence
C
O

37 +/-5

CO

5
3

C
O

4.4 Test of resistance of main circuit by 100A DC current injection


4.5 Check and record resistance of the main contacts, shall be less than 38micro .and
test the Insulation resistance test (5,000V-1Min.)
4.6 Function Test
Verify that the systems electrical circuits correspond to the operating diagrams, in
particular checking the following:
-CB Closing/Opening auxiliary contact measurement
-Operation counter
-SF6 Gas low level 1st and 2nd stage auxiliary contact measurement
-Interlocking function test (opening and closing inhibit)

Page 29 of 39

2.11 VOLTAGE TRANSFORMER


Checking Item

References (name plate)


Earthing of S2 LV wiring terminal
Earthing of P2 HV wiring terminal
Polarity
Ratio
HV and LV wiring insulation
Phase Sequence

Test Procedure
1) Polarity

milli volt meter

1.1)
1.2)

P1

S1
LV

HV

P2

S2

SW1

+
-

9V

Connect milli-volt meter to HV terminal and Battery with switch to LV


Terminal of PT as per the connection diagram.
Close and open the switch SW1 and observe the milli-volt meter direction will
indicate.
- A positive deviation at closing.
- Negative deviation at the opening.

2) Checking of the ratio


P1

S1

AC Volt meter

~ 500V
P2

S2

2.1) Connect AC supply voltage about 500 Volts and connect standard voltmeter as per the
test connection
2.2) Inject Voltage 500VAC on primary side and measure at secondary side, The ratio
is given by U1/U2.
3) Measure of wiring Insulation
3.1 disconnection of the earth from S2 of secondary side.
3.2 Connect the Insulation resistance Tester as per the test connection as following
- Between HV and LV winding (Test voltage 2500Vdc)
- Between LV winding and Earth (Test Voltage 500 1000 Vdc.)
Page 30 of 39

- Between HV and Earth (Test Voltage 5000 Vdc.)


The measured values must be upper than 100 Mega-ohms.
Note. Check of S2 earthing, after tests, connect the earth and check the interconnections of the
S2 terminal S of VT.
4) Measure of the secondary winding resistance
4.1) Measure the secondary winding resistance by a low resistance measurement
equipment or
4.2) by Voltage drop method.
P1

S1

P1

S2

P2

DC Soure

P2

- Connect as per test connection


- Inject voltage on secondary side until meet 20 mA. current, then record the voltage
drop at the winding
The winding resistance given by
R=

Vdc
Idc

5) Checking of Phase rotation

Page 31 of 39

5.1) Connect as per test connection


5.2) See direction on phase rotation meter
5.3) check the secondary voltage with volt meter

2.12 CURRENT TRANSFORMER


Checking Item

References (name plate)


Earthing of terminal S2 of the LV wiring
Polarity
Ratio
LV wiring insulation
Excitation test
SF6 Gas pressure check (Shall be 4 MPa relative at 20 C

Test Procedure
1) Polarity
9Vdc.

Milli Volt Meter


1.1)
1.2)

Connect as per test connection


On and of switch SW1 and see direction of milli- volt meter shall be
- A positive variation at the closing
- A negative variation at the opening

2) Ratio test
Standard clamp on meter
Supply

AC current Souce
Primary Injection
P1

P2

AC Amp.
Meter

Page 32 of 39
Relay / Metering

2.1) Connect the current source, AC Amp meter and AC clamp on as per test
connecting
2.2) Primary injection current at in (if possible and record I inject at I secondary
- The ratio is given by the value of I inject (Primary) per
I secondary
- Compare the calculated ratio with the manufacture's name plate of CT.
3) Measure the Insulation resistance
3.1) disconnect the CT earthing
3.2) Connect the Insulation resistance tester as per the test connection as following
- between HV and LV wining (Test voltage 2500 Vdc.
- between LV winding and earth (Test voltage 500-1000 Vdc.)
- between HV and earth (Test voltage 5000 Vdc.)
The value must be upper then 1 mega-ohm.
4) Measure of the secondary winding resistance
4.1) Measured the resistance of winding by a low resistance measurement equipment
(what store bring set)
or 4.2) by voltage drop method (see test procedure of voltage transformer)
5) Magnetization Curve (for protection core only)
P1

P2
A
V

Relay / Metering
5.1) Connect Amp meter, voltmeter, step up transformer and variable transformer as per
the test connection
5.2) adjust the variable transformer step by step and record voltage and current from
voltmeter and amp meter, increase the voltage until meet the knee point (saturate
voltage and current still increase) Then compare with the factory test report
Note : be sure that the HV circuit Breaker is opened and earthing is opened
- The knee point voltage is characterized by the value which increase by 50% of the
magnetization current when the voltage applied at the secondary of the CT is increased by
10% (all other winding being open)
Page 33 of 39

- The excitation current will be drawn until the point corresponding to an increase by
100% of the current when the voltage increase by 10%

Precautions
-

At the end of the tests, it is absolutely necessary to reduce gradually the voltage before the
interruption of the feeding voltage, because and abrupt variation of the flax could produce
a sufficient voltage to damage the insulation of the secondary winding
Some CT's magnetization curve require high voltage (about 2000V); ensure that safety
rules are followed and safety tools available

Calculation of VK
The minimum knee point voltage Vk and maximum current Ie are calculated as follows;
Vk

2 If (Rs + Rp)

Ie

Is Ir
n

Where :
If
=
Is
=
Ir
=
Rs
=
Rp
=
n
=
n
=
n
=
n
=

equivalent secondary pilot current of maximum fault current


effective fault setting expressed in secondary Amps
relay setting current
CT secondary winding resistance
Maximum loop lead resistance between CT's and relay
number of CT groups forming
2 : for Transformer differential protection
3 : for restricted earth fault protection on delta winding
4 : for restricted earth fault protection on star winding

2.13 LIGHTNING ARRESTERS

Checking Item

Visual Inspection
Name plate ; according to drawing
Running of surge counter
Insulation measurement
Voltage withstand test

Test Procedure
1) Surge counter
1.1) Charge the capacitor (spec.voltage > 500V) with dc. voltage 500V by 1
minute.
2) Insulation resistance
2.1) remove the earth connection on Lightning Arresters
2.2) Apply the insulation tester 5000Vdc at phase to earth connection for 10 min.
Page 34 of 39

2.14 DISCONNECTING SWITCH


1. General construction
-check connector bolt/nut tightening
-Support structure/mechanical part bolt/nut tightening
-Porcelain condition
-Check lubricant/grease on moving part and contact part
-Check earthing connection
-Check wiring and cabling
-Check alignment and clearance
-Check heater and aux. Power supply polarity and level
2. Insulation resistance test (5,000 Vdc.)
3. Contact resistance test (The minimum test current shall be 100A)
4. Operation test
-Mechanical closing and opening
-Electrical closing and opening (local and remote)
-Penetration of connecting blades
-Dead point crossing of opening and closing
-Closing and opening interlock function test
-Closing and opening signal and status check

2.15 BATTERY (Lead Acid Maintenance free) AND BATTERY CHARGER


1. Purpose
To check capacity of battery and battery charger at full rated of charge and discharge
mode
2. Reference and standard
The test shall perform as per the manufacturer specification
3. Equipment
- Bank of Resister 20A, 120Vdc with adjustable Heater load cell 1 A/Step
-DC Clamp-on 0 100A
-DC Volt meter
-Hydrometer
-Thermomiter
4. Battery field Test
The technical data and instruction are included in maintenance and handling instruction of
PANASONIC manufacture(Model LC-X 12100P).
4.1 Checking
- Visual / Characteristics inspection
- Cleanliness of the battery
Page 35 of 39

- Tightening and correct connections (polarity) of the cells


- Voltage per cell
- No leak on cells
4.2 Testing
Specially charge/discharge voltage, current measurement refer to PANASONIC
manufacture's documentation.
Charge
Being filled with electrolyte the battery has to be charged to complete it capacity this
charge shall be I-U characteristic and the rising battery charging voltage is limited to a
value of 2.22 2.26 Volts per cell. The maximum charging current must be restricted
to a maximum of 1.5 x I5 and upon reaching the above final voltage, the charger must
switch from boost charge mode to float charge mode
Charging Time
1) Initial charge, where batteries are supplied for 15 Hrs. at rated charging current I5
(20A).
2) Recovery charge after complete discharge test the charging time for recovery
charge to bring back the capacity is calculated by the following formula;
t(h)

1.4 x rated capacity (Ah)


mean charging current (A)

1.4 x 100 Ah
20A

7 Hrs.

Test Procedure
First charge (on batteries at already has initial charged from manufacture)
1) Connect the battery charger to battery set
2) Select switch at battery charger to boost charge mode and adjust timer of boost
charge to 7 Hrs.
3) Turn on the battery circuit breaker, the current limit of charger shall be limited at I 5
(20A).
4) Record the volt/cell, charging current every 1 Hrs.
5) always check the temperature must be less than 35C during charge. If temperature
reaches 35C, charging must be stopped and resumed when electrolyte temperature
is 35C.
6) after 5 Hrs if the charging current become lower than 5A and the voltage/cell of
battery meet 2.22 to 2.26 v/cell that mean the batteries set are fully charged, then
select the switch to float charge for deep charging
Discharge Test (5 Hrs final voltage 1.80V/cell)
1) The batteries set must be fully charged and will be kept in float charge condition
during one day before start discharge test.
2) Connect the resister bank to batteries set
3) On the circuit breaker of the resister bank until meet 18A discharge current (see
battery specification) and always keep constant on this current by control the
resister cells.
4) Record discharged current, volt/cell every 1/2 Hrs. until meet 5 Hrs.
5) always check the temperature as same as first charge
Page 36 of 39

6) Discharge time for battery PANASONIC Model LC-X 12100P is 5 hrs and the
final voltage shall not less than 1.8 V. (see battery specification)
Recovery charge
1) Reconnect the Battery set to Battery Charger
2) Perform the test as same as first charge except the charging time of boost charge
shall be extended to 7 Hrs.
5. Battery Charger Field Test
The Technical data and instruction are included in operation manual of Battery Charger
5.1) Checkings
- Visual inspection, accessibility of charger
- Absence of vibration
- Conformity of equipments
- Tightening of equipments
- Insulation value regarding to earth
- Incoming and out going voltage
-Alarm and Safety device
5.2) Field Test and Setting
1) Setting the boost and Float charge voltage as per the battery characteristic
2) Setting the limit current (20A) of charger as per battery specification
3) Setting the load output voltage alarm and shutdown as per the system requirement
5.3) Test Procedure
5.3.1) Capacity test at full rated current
1) Disable the current limit setting.
2) Connect the load blank to battery charger at load terminal.
3) Adjust the load blank until meet he maximum current of charger (see name
plate and charger specification).
4) Measure and record the output voltage by DC Voltage and ripple voltage by
AC voltmeter.
5) The ripple shall be less than 5% and voltage drop shall be +/- 1%
5.3.2) Input voltage variation test
1) Connect 3 380Vac variable source to battery charger input terminal
2) Adjust the input voltage between 10%
3) Measure and record the output voltage by dc voltmeter
5.3.3) Operation test
1) Connect battery set and power supply to battery charger
2) Select switch to float charge mode
3) Measure the voltage at battery terminal and load terminal
4) Select switch to boost charge mode
5) Measure the voltage at battery terminal and load terminal
6) The charger output shall be adjusted the voltage to float and boost charge
voltage setting.
7) Connect load bank to charger at load out put terminal
8) Switch on the load cell until meet the maximum of charger rated (see
battery charger specification)
9) Switched off the AC supply of Battery Charger
10) The load current shall be received from battery set by uninteruption at full
rated current
Page 37 of 39

5.3.4) Current limit test


1) Connect load blank to Battery Charger at Battery terminal
2) Switched on load cell of load blank until meet the current limit setting, the
alarm LED will indicate "Current Limit" alarm.
3) Switched one more load cell, the charger current shall be stilled limit at the
current limit setting

AC Power supply

Battery
Charger
To Battery

To Load
dc clamp on

Load Blank

Test connection for capacity test


2.16 AC & DC BOARD
1. General construction
-Check wiring continuity, cabling
-Check cable, wiring and equipment marking
-Check circuit breaker operation and characteristic
-Check bus bar sizing and tightening of bolt/nut
-Check earthing connection
2. Insulation resistance test (500 Vdc.)
3. Metering apparatus accuracy test
2.17

MV. SWITCHGEAR
1. General construction
-Check panel level, alignment, base and wall fixing
-Check bus bar sizing and tightening of bolt/nut
-Check earthing connection
-Wiring and cabling check
-Check damage on all porcelain
2. Operation and function test
-Check rack in and rack out position
-Check closing of shutter
Page 38 of 39

-Electrical closing and opening with local and remote operation


-Mechanical closing and opening operation
-Electrical, mechanical and key interlock test
-Anti pumping test
-Check position indicator, semaphore and lamp indicator
-Check alarm and status contact
3 .Contact resistance test on CB, DS, ES and bus bar connection(The minimum
test current shall be 100A)
4. Circuit breaker closing and opening timing measurement
5. Insulation resistance test (5,000 Vdc.)
6. High voltage DC test
7.Characteristic test for current transformer, voltage transformer, protective
relay and metering/apparatus
2.18

LV. POWER AND CONTROL CABLE


1. General construction
2. Insulation resistance test (500 VDC 1min.)
3. Check continuity, shield ground, and cable termination

2.19

BUS WORK AND OVER HEAD CONDUCTOR


1.
2.
3.
4.
5.
6.
7.
8.

2.20

General construction
Check phasing
Crack or scratch on conductor and wire check
Sag and tension check
Grounding connection check
Check all welded, compression, bolt joint, and bolt/nut tightening
Contact resistance test (The minimum test current shall be 100A)
Insulation resistance test ( 5,000 Vdc.)
INSULATOR AND BUSHING

1.
2.
3.
4.
5.
2.21

General construction
Check for cracks or damage
Check all fitting & bolt/nut tightening
Cleanliness check
Insulation resistance test ( 5,000 Vdc.)
STEEL STRUCTURE

1.
2.
3.
4.
5.

General construction
Check galvanize coating / painting
Check Bolt/nut tightening
Check alignment/arrangement
Check earthing connection

2.22

OUTDOOR LIGHTING
1.General construction
-Correct number and location of fixtures
-Support/ Junction box fixing and galvanize coating check
Page 39 of 39

-Check cable and Wiring


2. Function/ operation test
3. Flood light aiming check

2.23

ENERGIZING
After completion of all equipment individual testing and checkout the switchyard
equipment and bus conductors shall be energized by PEAs 115kV for 10 minutes
before loading the transformer or de-energizing the system.
1. General requirement before energize the substation
-Examine all insulator unit, bus work and fitting for cracked or defective parts
-Examine all disconnecting switches for general construction, alignment,
clearance, break distance, interlocking, pad lock key and re-check for closing
and opening operation.
-Examine all contacts for fit and alignment
-Examine operating mechanisms for each of operation lubrication and proper
travel.
-Check phase and ground clearances on all bus work and on live part of
equipment to the steel structures.
-Check all power circuit breaker for correct operation
-Check equipments and structures grounding connection
-Repeat the insulation resistance on bus work and HV. Equipment to confirm that
no any part contact between phase and earth, the disconnecting switch and
circuit breaker shall be close for test. The test result shall be higher than
1,000Meg-ohm.
-record all equipment operating counter.
2. First energizing
-The voltage level for energizing test shall be 115 kV. but not over 123kV.
-The switching procedure shall be performed in accordance with SEHVTs
substation energizing procedure and PEAs regulation, this document would
issue and submit to customer before first energizing.
-During the test the following shall be recorded or checked :
-The indicating value of meters mounted on control and relay panel shall be
record on the test record sheets.
-The current and voltage magnitude and phasing shall be check at the relay
test terminal to confirm the phase rotation and protective relaying.
-The transformer on load tap change must correspondence the setting value
-Check and record the transformer oil temp and winding temp
-Check audible noise on the main equipment.

Page 40 of 39

-Power transformer shall be energized at no load condition for at least 6 hrs. to


confirm the transformer operation

Page 41 of 39