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AES - MV WORK INSTRUCTION

SUBJECT:- MV Switchgear / Controlgear Inspection & Test Procedure (IEC) SCO PREPARED ON : 12-10-2011
of 01PAGE 09

REVISED ON: 19-02-2012 REF No: MV:16:00:1001:01

Purpose & Scope


Routine inspection and testing procedure for different MV Switchgear / Controlgear as per IEC 62271-200 and IEC 62271-1 standards.

Contents
This procedure undergoes the following stages: 1. Design and Visual Checks 2. Mechanical Operation Tests 3. Insulation Resistance Test 4. Dielectric Test on the Main Circuit 5. Dielectric Test on Control and Auxiliary Circuits 6. Functional Tests 7. Measurement of the Resistance of the Main Circuit 8. Test of Measuring and Protection Circuits 9. Final Check and Preparation for Packing

1.0 Design and Visual Checks


(Acc. to IEC 62271-200 Sec. 7.5 and sec 7.2.1)

Purpose
The switchgear / controlgear shall be checked to verify its compliance with the purchase specification.

Preliminary Conditions
The switchgear / controlgear shall be completely assembled.

Documents Required
Single Line Diagram Layout Drawing Schematic Diagrams BOM List

Procedure
1. Check correctness of apparatus fastening. 2. Check correctness of wires marking as per the drawings. 3. Check correctness of name plates, labels and mimic diagrams as per the drawings. 4. Check proper earthing of movable parts.

DEPT:- MV

PREPARED BY: RA

APPROVED BY: MK

AES - MV WORK INSTRUCTION


SUBJECT:- MV Switchgear / Controlgear Inspection & Test Procedure (IEC) PREPARED ON : 12-10-2011
of 02PAGE 09

REVISED ON: 19-02-2012 REF No: MV:16:00:1001:01

5. Check correctness of LV apparatus accommodation as per the drawing. 6. Check basic and diagonal dimensions of the cubicles after assembly. 7. Check proper earthing of apparatus wherever required. 8. Check the presence of all constructional parts of each panel. 9. Check that no damages in the apparatus occurred during assembly. 10. Check that the type and ratio of each current and voltage transformer are according to the single line diagram. 11. Check that the type of each circuit breaker is according to the specification. 12. Check bus bar markers / torque. 13. Check quality of painting finish.

2.0 Mechanical Operation Test


(Acc. to IEC. 62271-200 Sec. 7.102)

Purpose
Operation tests are made to ensure that the switching devices and removable parts comply with the prescribed operating conditions and that the mechanical interlocks work properly.

Preliminary Conditions
Switchgear / controlgear completely assembled.

Procedure
1. Check the correctness of door closing. 2. Check proper operation of shutters. 3. Check the interlock to insert or isolate the CB when closed. 4. Check that the mechanical interlock prevents the CB contacts from closing when the truck is positioned between service and test positions. 5. Check that the circuit breaker cannot be inserted into service position when the earthing switch is closed. 6. Check that the earthing switch cannot be closed when the circuit breaker is in service position. 7. Check that the opening of the door is prevented during the racking in and out of the circuit breaker or when it is racked in and closed. 8. Check that the circuit breaker cannot be inserted into service position when the secondary contacts plug has not been fitted. 9. Check the impossibility to disconnect the secondary contacts plug of the circuit breaker when the circuit breaker is in service position. 10. Check the interchangeability of circuit breakers that have the same rated current and the interlock for interchangeability of circuit breakers different in rated current. 11. Check the functionality of the key interlocks, if provided and the difference in code. DEPT:- MV PREPARED BY: RA APPROVED BY: MK

AES - MV WORK INSTRUCTION


SUBJECT:- MV Switchgear / Controlgear Inspection & Test Procedure (IEC) PREPARED ON : 12-10-2011
of 03PAGE 09

REVISED ON: 19-02-2012 REF No: MV:16:00:1001:01

12. Check the signaling of the mechanical indicators. 13. During these tests which are performed without voltage on or current in the main circuits, it shall be verified, in particular, The switching devices open and close correctly within the specified limits of the supply voltage and pressure of their operating devices. Each switching device and each removable part shall be tested 5 operations or attempts in each direction.

3.0 Insulation Resistance Test


Measure the insulation resistance of electrical equipment phase to phase and phase to ground for one minute, before and after dielectric (HV) test. Test voltage and minimum acceptable values as per table 1
Table 1 Insulation Resistance Tests Electrical Apparatus and Systems Maximum Rating of Equipment in Volts 100 - 250 251 - 600 601 - 5000 Over 5000 Minimum Test Voltage, dc 500 1000 2500 5000 Recommended Minimum Insulation Resistance in Mega Ohms 1 2 1000 2000

Over potential tests should not proceed unless insulation resistance levels are equal to or above the listed minimum values.

Figure 1: Connection scheme of insulation test for control and aux. circuits

DEPT:- MV

PREPARED BY: RA

APPROVED BY: MK

AES - MV WORK INSTRUCTION


SUBJECT:- MV Switchgear / Controlgear Inspection & Test Procedure (IEC) PREPARED ON : 12-10-2011
of 04PAGE 09

REVISED ON: 19-02-2012 REF No: MV:16:00:1001:01

4.0 Dielectric Test on the Main Circuit


(Acc. to IEC 62271-200 Sec. 7.1)

Purpose
Power frequency withstand tests is performed on switchgear / controlgear assemblies to demonstrate the ability of the insulation system to withstand rated voltages in accordance with the below table.

Preliminary Conditions
Equipment installed and connected. Switchgear / controlgear is cleaned of dust, dirt, moisture, etc. Temporary disconnection of electronic devices. Control power transformers and potential transformers drawn out. Current transformers shall have the secondary windings short-circuited and grounded. All the circuit breakers are inserted in service position and closed. All earth switch is open and any temporary earthing removed.

Procedure
Carrying out the main circuit power frequency voltage insulation test between each phase in succession and the earthed one. All the circuit breakers are inserted in service position and closed. At 60Hz and for 60 sec, voltages will be applied according the below table: Rated insulation Applied Voltage Voltage (kV) (kV) 7.2 20 12 28 17.5 38 24 50 36 70 For the second time testing should be with a value of 80% from the original.

Acceptance Criteria
The test is considered successful if neither flashovers nor perforations occur during each test.

Figure 2: Connection scheme of power frequency test for main circuits

DEPT:- MV

PREPARED BY: RA

APPROVED BY: MK

AES - MV WORK INSTRUCTION


SUBJECT:- MV Switchgear / Controlgear Inspection & Test Procedure (IEC) PREPARED ON : 12-10-2011
of 05PAGE 09

REVISED ON: 19-02-2012 REF No: MV:16:00:1001:01

5.0 Dielectric Tests on Control and Aux. Circuits


(Acc. to IEC 62271-200 Sec. 7.2.4)

Purpose
Dielectric test is performed to verify if the insulation of control and auxiliary circuit is satisfactory and to permit the control and auxiliary circuit to be energized.

Preliminary conditions
Equipment installed and connected. Switchgear / controlgear is cleaned of dust, dirt, moisture, etc. Temporary disconnection of electronic devices.

Procedure
Auxiliary and control circuits of switchgear / controlgear shall be subjected to short duration power frequency voltage withstand tests. Each test shall be performed: a) between the auxiliary and control circuits connected together as a whole and the frame of the switching device; b) If practicable, between each part of the auxiliary and control circuits, which in normal use may be insulated from the other parts, and the other parts connected together and to the frame. The test voltage shall be 1 kV with duration of 1 s.

Acceptance Criteria
The auxiliary and control circuits of switchgear / controlgear shall be considered to have passed the tests if no disruptive discharge occurs during each test.

Figure 3: Connection scheme of power frequency test for control and aux. circuits

DEPT:- MV

PREPARED BY: RA

APPROVED BY: MK

AES - MV WORK INSTRUCTION


SUBJECT:- MV Switchgear / Controlgear Inspection & Test Procedure (IEC) PREPARED ON : 12-10-2011
of 06PAGE 09

REVISED ON: 19-02-2012 REF No: MV:16:00:1001:01

6.0 Functional Tests


(Acc. to IEC 62271-200 Sec. 7.2.2)

Purpose
A functional test of all low-voltage circuits shall be made to verify the proper functioning of auxiliary and control circuits in conjunction with the other parts of the switchgear / controlgear.

Preliminary Conditions
Switchgear / controlgear completely assembled. Interconnection between panels finished. Auxiliary circuit supplies available.

Procedure
The test procedures depend on the nature and the complexity of the low-voltage circuits of the device. 1. Check the correctness of the control wiring by either or both of the following: a) Actual electrical operation of the component control devices b) Individual circuit continuity checks by electrical circuit testers 2. Check the function of the circuit breaker position aux. contacts (test / service). 3. Check the function of the circuit breaker status aux. contacts (open / closed). 4. Check the function of the earth switch status aux. contacts (open / closed). 5. Check the function of the protection relays BI / BO contacts. 6. Check the function of the control and Aux relays operation and aux. contacts (open / closed). 7. Check the operation limits of releases A shunt closing release shall operate correctly between 85% and 110% of the rated supply voltage. A shunt opening release shall operate correctly between 70% in the case of d.c. or 85 % in the case of a.c. and 110% of the rated supply voltage 8. Check the correct function of the circuits to be connected to the SCADA (if applicable). 9. Following the SWGR functional schemes and the protection relays circuits, verify the panels and switchgear function. Checking: Electrical interlocks, electrical sequences, functional and control indicators, etc.

DEPT:- MV

PREPARED BY: RA

APPROVED BY: MK

AES - MV WORK INSTRUCTION


SUBJECT:- MV Switchgear / Controlgear Inspection & Test Procedure (IEC) PREPARED ON : 12-10-2011
of 07PAGE 09

REVISED ON: 19-02-2012 REF No: MV:16:00:1001:01

7.0 Measurement of the Resistance of the Main Circuit


(Acc. to IEC 62271-200 clause 7.3)

Purpose
Measuring resistance of main circuit test is performed to verify if good contact of primary movable parts, primary fixed parts and verification of tighten.

Preliminary Conditions
Equipment installed and connected. Switchgear / controlgear is cleaned of dust, dirt, moisture, etc. All bolts tighten (torque wrench method).

Procedure
Measuring the resistance of the main circuit and earthing circuits, to verify the contacts correctness for movable parts, this is done by applying a current of 50A up to the rated current on each phase in succession. All the CBs should be inserted in service position and closed.

Acceptance Criteria
The measured resistance shall not exceed 1,2 x Ru where Ru is equal to the resistance measured before the temperature-rise test.

Figure 4: Proper connection of contact resistance test

DEPT:- MV

PREPARED BY: RA

APPROVED BY: MK

AES - MV WORK INSTRUCTION


SUBJECT:- MV Switchgear / Controlgear Inspection & Test Procedure (IEC) PREPARED ON : 12-10-2011
of 08PAGE 09

REVISED ON: 19-02-2012 REF No: MV:16:00:1001:01

8.0 Test of Measuring and Protection Circuits Purpose


This test defines the correct connection and specification of instrument transformer and functioning of protection relays and measuring devices.

Preliminary Conditions
Switchgear / controlgear completely assembled. Instrument transformer finished connection and terminals block adjusted. Auxiliary circuit supplies available.

Procedure
8.1 Current Circuits According to the CT ratio inject to the primary side a suitable single/three phase current and measure on the secondary side. Verify the correct ammeter, protection relay reading, current transducers function and other related circuits if applicable. According to specifications of current protection functions, carry out the secondary injection to the protection relays to verify the correct operation of protection circuits.

Figure 5: Connection scheme of primary current injection test

8.2 Voltage Circuits According to the VT ratio apply to the primary side a suitable single / three phase voltage and measure on the secondary side. Verify the correct voltmeter, protection relay reading, voltage transducers function and other related circuits if applicable According to specifications of voltage protection functions carry out the secondary injection to the protection relays to verify the correct operation of protection circuits.

DEPT:- MV

PREPARED BY: RA

APPROVED BY: MK

AES - MV WORK INSTRUCTION


SUBJECT:- MV Switchgear / Controlgear Inspection & Test Procedure (IEC) PREPARED ON : 12-10-2011
of 09PAGE 09

REVISED ON: 19-02-2012 REF No: MV:16:00:1001:01

Figure 6: Connection scheme of primary voltage injection test

Figure 7: Connection scheme of secondary injection test

9.0 Final Check and Preparation for Packing Purpose


This check is to ensure that the panel is ready for packing.

Preliminary Conditions
Switchgear / controlgear completely assembled.

Procedure
1. Eliminate all bridges and external circuits used during electrical testing procedures. 2. Check the switchgear / controlgear cleaning 3. Check all circuit breakers and voltage transformers fixed and in test position 4. Check all hinged doors and covers are closing 5. Collect all the drawings used during testing for "as manufactured" update

DEPT:- MV

PREPARED BY: RA

APPROVED BY: MK