GOPA-INTEC

Middle East

WELLCOME

Testing and
Commissioning of MV/LV
Cables and 11KV
Package Unit
Substations - Session 1

Date: 28.04.2016

PREPARATION FOR THE TESTING

The electrical testing shall be performed using
calibrated test equipments
All materials and relevant documentation to
testing works shall be checked by the
responsible personnel.
All necessary schematic drawings
Data sheets
Mehod of statement of tests
and test formats to be available at the test area.

Page 2

Procedure for Partial discharge test of

MVcable FAT
The test voltage shall be applied
between conductor and the
metallic shield / Cu.tape
The Partial Discharge test Voltage
gradually raised to 2Uo and
then reduced to 1.73Uo. Obtain
a steady discharge value at
1.73Uo and then voltage reduce
to zero.
PD Measurement : 3 pC Max.
Page 3

Procedure for Insulation Resistance

test (MV Cable) FAT/SAT
Measurement shall be between conductor and the
cores & metallic shields.
The core shall be connecting ' + ' lead wire and all
other are to be ' - ' terminal. This test will show up
any deficiencies in the insulation,
Insulation Resistance measurement shall be done at
5KV DC for 1min. Insulation resistance measure
between R to (Y+B+E), Y to (B+R+E), B to (R+Y+E)
Min Requirements : 1 Giga Ohms/km

Page 4

Procedure for HV test

Cable FAT

I Date I Name

The test Voltage shall be applied

between conductor and
metallic screen. The voltage
shall be 3.5xUo and duration is
5min. 11kV Test V = 6.35x3.5 =
23kV for 5 minutes , 22kV Test
V = 45kV and 33kV cable, Test
V = 67kV for 5 minutes
When AC voltage is used the rule
of thumb is 2 x nameplate
voltage + 1000.
HV Test Result : No breakdown
shall occur
age 5

Procedure for AC Voltages test

(LV Cable) FAT
The test Voltage shall be applied between conductor
and other conductors & metallic shield. The
voltage shall be 3.5xUo and duration is 5min. If LV
cable is 1KV Test V = 1x3.5 = 3.5KV

Should withstand at 3.5KV AC for 5 min. 1KV Cable

Page 6

HV Test VLF ( Very Low Frequency

voltage) MV Cable SAT
The applied frequency will be 0.1 Hz AC wave shape
is sinusoidal and capacitance doesnt change with
frequency.
Isolate the cable to be test, connect the high voltage
output lead of the VLF to the conductor and
ground the shield.
Apply the test voltage for the required duration
15Min. The IEEE/EPRI/CEA and other world
engineering bodies recommended test level for
solid dielectric cable is up to three times (3Uo) line
to ground voltage for 15 + minutes.
Page 7
Eg..For 11KV cable 3Uo=11000/1.732=3*6351=19KV

Page 8

Capacitance measurement on MV
cables FAT/SAT
Capacitance measurement shall made with a
calibrated LCR meter at a frequency of 1 kHz.
The measurement shall be done between each
core against copper screen. The measured
value shall be converted to micro Farad/km.
The measurement shall be made at ambient
temperature

Page 9

Procedure for Conductor, Screen &

Armour resistance test of Cable FAT/SAT
Resistance shall be measured by micro ohm meter.
Cable length and ambient temperature shall be
correctly entered in the measuring unit. When
start, the digital display of equipment will be the
Resistance per km at 20C in Ohm Conductor
resistance test shall be made at ambient
temperature.

Page 10

HV DC Test on outersheath for 22

& 33KV Cables FAT/SAT
This test is applicable when outersheath having
graphite or Semicon coating or any other
Coating must be remove (aprox 10cm)
DC High voltage (25KV dc for 1 min)
shall be applied between the
graphite/Semicon and Armour layer
and test equipment must be earthed properly.
Voltages are depends on thickness
(8 * nominal thickness)
Maximum test Voltage limited to 25KV dc.
Requirements : No breakdown shall occur at
Page 11
25KVdc for 1 minute.

Phase Identification Test of 3 core

Cable SAT
To identify the phase of the cable, apply 1kV / 5kV
DC voltage between the conductor and armor with
the help of 5 kV Insulation Tester.
Ensure that other two phases are earthed during the
test except the phase under test.
Instruct the operator at the other end to earth the
same phase under test
Once the phase is earthed the Insulation resistance
will become zero.
Hence it is confirmed as one phase, say Red.
Repeat the above steps for other 2 phases, Yellow &
Blue
Page 12

Procedure for Hot set test for

XLPE insulation FAT
Sampling: Make dum-bell samples
from the shaved piece of insulation
to 0.8~2.0 mm thick. .
Procedure: The test pieces shall be suspended in
the oven and weight (20N/cm (2039.432G))
attached to the bottom .
After 10 min in the oven at the temperature
(2003C), the distance between the two
marker lines(L) shall be measured.
Elongation under load = ( L - 20 ) / 20 100 (%)
L : Distance between the two marker lines under
Page 13
load

Procedure for Hot set test for

XLPE insulation FAT
Load shall be removed from the test piece, and the
test piece left to recover for 5 min at 200 3C
The test pieces shall then be removed from the
oven and allowed to cool slowly to ambient
temperature, after which the distance between
the two marker lines shall be measured and the
percentage elongation calculated.
Permanent elongation after cooling = ( Li - 20 ) / 20
100 (%) Li : Distance between the two marker
lines after cooling.
Requirements : Elongation under load : Max. 175%
Permanent Elongation after cooling : Max. 15% Page 14

Color Stability\ test on

Outersheath of Cable FAT
Sampling:-The color test shall be done on
Outersheath (except black color). Cut a strip of
outersheath sample from a completed cable.
Sheath sample. The sample size shall be approx
4~6mm width and 120mm long.
Procedure :
Sheath sample
Half portion of this sample shall be
immersed in saturated Sodium Sulphide
solution. After 4hours take out
the sample from the solution and check any
discoloration.
The test shall be carried out at ambient temperature.
Requirements - There shall not be any significant
change in color
Page 15

Color Stability FAT test on LV XLPE

Insulation of the Cable (ADDC Spec)
Sampling:-The color test shall be done on LV XLPE
Insulation (except black color). Cut a strip of
Insulation piece from a completed cable. The
sample size shall be approx 4~6mm width land
120mm long.
Procedure :
LV XLPE Insulation sample
Half portion of this sample shall be immersed
in saturated Sodium Sulphide solution . After
4hours take out the sample from the solution and
check any discoloration.
The test shall be carried out at ambient temperature.
Requirements - There shall not be any significant
change in color
Page 16

Measurement of Overall diameter

of the Cable FAT
Sampling: A piece of cable taken from one
end of the length after having discarded , if
necessary, any portion which have suffered
damage.
Procedure: Cable overall diameter shall be
measured at few places.
The measurement shall be done by diameter
tape or digital vernier caliper

Page 17

Procedure for Measurement of

thickness of (Cable) FAT
Thickness of insulation shall be measured at 6
points by profile projector or
Automatic measuring equipment

Thickness of bedding sheath shall be measured at

6 points by digital vernier caliper.
Thickness of outer-covering shall be measured at 6
points by digital vernier caliper
Page 18

Conductor / Armour wire

examination of Cable FAT
Diameter of conductor: Out side
diameter of conductor shall be
measured at 3 points by caliper and
average value shall be calculated.
Diameter of armour wire: Diameter of
armour wire shall be measured on
10% of total armour wires.

Thickness of Tape armour: Thickness of GS Tape

shall be measured at few places and take the
average. Measurement shall be taken away from tape
edges, done with micrometer
Requirements :Page 19

TRM Earth Resistance Testing SAT

As per earthing design, transformer neutral earthing
must be separate (not connected with body
earthing) Use earth resistance tester to measure
PU body earth and Transformer Neutral earth
value
Accepting Reading below 1 ohm
3Point/Fall of Potential method

TRM Visual & Function Check SAT

Carry out a visual inspection of the switchgear for
any non-conformances.
Operation of the TRM is checked during the
functional test in accordance to the approved and
as manufactured drawings,
Check operation of close/open for all switches
mechanical interlocks (ON & Earth position)
All mechanical indication & Check SF6 pressure.

Page 21

Padlocking to prevent operation

Firmly lift the operating handle up

from the 'ON' to the 'OFF

Earth CB/T-Off from 'ISOLATE'

position Insert operating handle

Remove padlock for operation

Operate CB/T-Off from 'ON' to OFF

Insert the operating handle

Isolate T-Off from 'OFF' position Firmly lift the operating handle up
Insert the operating handle
from the 'SERVICE' to the'ISOLATE'

now show 'Isolated'and

'Earth Selected' as shown

pull operating handle down

Remove Earth from T-Off lift Operate CB/T-Off from 'ISOLATE'
from 'OFF &RESET' to 'ON up 'ON' to the 'OFF& RESET' to 'ON' Insert the operating handle

Page 22

pull operating handle down

'ISOLATE' to'SERVICE'

Close CB to SERVICE Insert

the operating handle

Switch Operation Padlocking Switch from 'MAIN ON' to 'OFF'

to prevent operation
Slide Selector' to 'Main Switch'

pull operating handle down from

'OFF & RESET' to 'ON'

Locate operating handle

]to 'Ring Switch'.

Rotate the operating handle

from 'MAIN ON' to the 'OFF'

'OFF' to 'MAIN ON Rotate handle

Test connections can be made onto
Switch from 'OFF' to 'EARTH ON Open cable test access cover , bushings marked phase L1, L2,L3).
'OFF' to the 'MAIN ON'
Rotate handle 'OFF' to 'EARTH ON' pulling access knob

Page 23

Contact /Circuit Resistance test

FAT/SAT
Measure circuit resistance using micro-ohm meter.
Ring to Tee should be 265 micro ohms (max)
Ring to Ring should be 260 micro ohms (max)
Ring to Earth should be 500 micro ohms (max)
T-Off to Earth should be
1200 micro ohms (max)

Page 24

Auxiliary wiring Power frequency

test in FAT 2KV and in SAT 1KV FAT/SAT
Remove the Earth link Where units are not fitted
with, ensure all earths are removed from the unit.
If relays are fitted remove it before the test.
Attach black lead to the unit at any point where a
bolted connection is present (nut etc.).
Using the red (positive) lead as a probe, test each of
the connections located on the terminal block in

the Marshalling box for approx 2 seconds.

Page 25

Auxiliary wiring Power frequency

test in FAT 2KV and in SAT 1KV FAT/SAT
Any indication of continuity should be investigated
and rectified.
SAT is conducted at 1kV in accordance with
international standards. unit is tested at 2kV
during the manufacturing
It is recommended that sensitive electronic devices,
motors and actuators, be detached from the unit
prior to testing 1kV testing across auxiliary
indication wiring and contacts across EFIs/FPIs
SAT Test voltage must not exceed 1kV.
Page 26

Auxiliary wiring Power frequency

test in FAT 2KV and in SAT 1KV.

Other Wiring Checks

Using a continuity tester the following features are to be
checked for full functionality in accordance with the
customer requirement:
Auxiliary switches All wiring is to be checked at the
relevant marshalling box location.
Micro switches All micro switches fitted for indication
and for operation of actuators and other aux
equipment must be checked to confirm full operation
and indication.
Pressure switch(if fitted) Confirm correct operation of
related pressure switch
Other indication circuits All other wiring forming part of
an indication circuit or aux control circuit is to be
tested
Page 27

FPI CT Wiring Tests and

Protection CT Wiring Tests
CT insulation resistance: Remove the earth link.
Measure the insulation resistance to earth of the CTs
using a 1kV insulation resistance tester. The
insulation resistance should be greater than
100Mohms.
Replace the CT wiring earth link on completion of
the test.
CT loop continuity: Measure the continuity of the
L1 CT and the CT wiring from the CT wiring
terminal block. The resistance should be in the
region of 0.1-1.5 depending on the components
in the circuit being measured.
Repeat for L2 and L3. Reconnect CTs to the relay.
Page 28

Relay Secondary Injection Test

Procedure: FAT/SAT
Test to be carried out after applying final relay
setting.
The following test to be conducted for a Over
current Earth fault Relay.
Pickup test :
Inject the current above than the setting value
and note down the Relay Pickup Value
Pickup current should be in the range of 100 %
- 110 % from setting value.
I Date I Name

Presentation Title

Page 29

Relay Secondary Injection Test

Procedure: SAT
High set element checking:
Set the desired High Set value.
Inject the current and measure the pickup
value of instantaneous element.
Apply 2 times of pick up value and note done
the tripping time.
This should be in the range of 50 milli-seconds
if tripping time setting zero.

I Date I Name

Presentation Title

Page 30

Secondary Injection Tests

Carry out the overcurrent test at 2x and 5x setting as follows:
Close the circuit-breaker.
Connect the injection test set across L1/L2 phase CTs.
Connect the timing circuit across a pair of auxiliary contacts for
the circuit breaker open position.
Apply the appropriate 2x setting secondary injection current
calculated above and measure the trip time.
Connect the injection test set across L2/L3 phase CTs, reset the
relay and close the circuit breaker.
Apply the appropriate 2x setting secondary injection current
calculated above and measure the trip time.
Connect the injection test set across L3/L1 phase CTs, reset the
relay and close the circuit breaker.
Apply the appropriate 2x setting secondary injection current
calculated above and measure the trip time.
Repeat the test using 5x setting secondary injection current.
Page 31

Secondary Injection Tests

If instantaneous overcurrent settings are being
used carry out the following tests:
Reset the relay and close the circuit-breaker.
Connect the injection test set across L1/L2 phase
CT.
Connect the timing circuit across a pair of
auxiliary contacts for the circuit breaker open
position.
Apply the instantaneous overcurrent setting
secondary injection current calculated above
and measure the trip time.
Reset the relay and close the circuit breaker.
Repeat the test for L2/L3 and L3/L1 phase CTs.
Page 32

Secondary Injection Tests

Carry out the earth fault test at 2x and 5x setting as follows:
Reset the relay and close the circuit-breaker.
Connect the injection test set between L1 phase CT and earth.
Connect the timing circuit across a pair of auxiliary contacts for
the circuit breaker open position.
Apply the appropriate 2x setting secondary injection current
calculated above and measure the trip time.
Connect the injection test set between L2 phase CT/earth, reset the
relay and close the circuit breaker.
Apply the appropriate 2x setting secondary injection current
calculated above and measure the trip time.
Connect the injection test set between L3 phase CT/earth, reset the
relay and close the circuit breaker.
Apply the appropriate 2x setting secondary injection current
calculated above and measure the trip time.
Repeat the test using 5x setting secondary injection current.
Page 33

Secondary Injection Tests

If instantaneous earth fault settings are being used
carry out the following tests:
Reset the relay and close the circuit-breaker.
Connect the injection test set between L1 phase CT
and earth.
Connect the timing circuit across a pair of auxiliary
contacts for the circuit breaker open position.
Apply the instantaneous earth fault setting secondary
injection current calculated above and measure the
trip time.
Reset the relay and close the circuit breaker.
Repeat the test for L2 phase CT/earth and L3 phase
CT/earth.
Page 34

Primary Injection Test

Apply the overcurrent and earth fault test settings as
specified on the test form to the relay.
Carry out the overcurrent pickup test as follows:
Close ring switch 1, open ring switch 2 and close the
circuit-breaker.
Connect a shorting-link across L1, L2 and L3 on the
circuit-breaker.
Connect injection test set between L1 and L2 on ring
switch 1.
Slowly increase the primary injection current from zero
until the relay picks up.
Record the value of current at which the relay picks up.
Reset the relay and, if necessary, close the circuit breaker.
Repeat the test with the test set connected between L2 and
L3 on ring switch 1.
Remove the shorting-link from the circuit-breaker. Page 35

Primary Injection Test

Carry out the earth fault pickup test as follows:

Close ring switch 1, open ring switch 2 and close

the circuit-breaker.
Connect the injection test set between L1 on ring
switch 1 and L1 on the circuit-breaker.
Slowly increase the primary injection current
from zero until the relay picks up.
Record the value of current at which the relay
picks up.
Reset the relay and, if necessary, close the circuit
breaker.
Repeat the test for L2 and L3.
Page 36

TRM Insulation Resistance Test

before and after HV test SAT
IR Test to be done Before and after HV Test
By applying 5KV DC for 1 min between each BB and
earth to measure insulation resistance Value.
Observe the reading and record in the test
format between R to (Y+B+E), Y to (B+R+E), B to (R+Y+E)
Measure the insulation resistance
to earth of each of the three
terminals in turn, with the
other two earthed.
The readings should not be
less than 100 megohms
Page 37

HV/Power Frequency withstand

FAT/SAT
For 11/12 kV - Apply 28 kV AC
at power frequency for
1 min.(For SAT 80% between
R to (Y+B+E), Y to (B+R+E),
B to (R+Y+E) and after any
routine HV test Voltage will
be 60% of 28KV )
A
B
C

Test RH Ring
Switch
1
Closed/On
2
Closed/On

LH Ring
Switch

Selector
Switch

a
b
c

Circuit Breaker

Selector
on

eart
h

LHS Ring
Switch

RHS Ring
Switch

on
off

CB Switch

on
off
earth

earth

Apply Test
Voltage to:

A
B
C

Earth

Closed/On Closed/On

Closed/On

A,C

Frame, b

Closed/On Closed/On

Closed/On

Frame, a, c

Closed/On

Closed/On Closed/On

Open/Off

Open/Off

Open/Off

Closed/On A,B,C,A,B,C

Closed/On

A,B,C

a, b, c
a, b, c

Shunt Trip Coil and Emergency Trip

(if fitted) SAT
Locate the shunt trip coil terminals in the
marshalling box.
If the unit is fitted with a DC shunt coil then tests
should be done at 70% & 110% rated voltage.
If the unit has an AC coil fitted, then testing should
be done at 85% & 110% of rated voltage. Close the
circuit-breaker.
Using an appropriate test set apply rated voltage to
the shunt trip coil and circuit-breaker should trip.
Check that the emergency trip button correctly trips
the circuit-breaker.
Page 39

Earth Fault Indicator test

Earth fault test to be checked as per relevant

procedures for suitable type of EFI.

Page 40

Line Indicator VPIS & NEON

Indication test (if fitted) FAT/SAT
Line Voltage 6.9 kV AC (apply between Phase to
earth) - Check for neon lamps lit.

Page 41

TOOLS AND EQUIPMENTS TO BE

USED FOR TESTING:
1. Insulation Resistance Tester Megger S1 1052/2
2. Secondary Injection SVERKER 760
3. High Voltage Tester PFT
4. Primary Injection Programma 600AT
5. Earth Resistance tester CHAUVIN ARNOUX C.A 6470
6. Transformer Ohm Meter CHAUVIN ARNOUX C.A 6240
7. Transformer Ratio Tester PATTR-03
8. Digital Multi meter FLUK 179
9. VLF Frequency Instrument
10. Discharge Rod
11. High Voltage gloves
12. Necessary additional tools & tackles as per the
Page 42
Requirement

To be continued for the next Session-2

Testing and Commissioning of MV/LV Cables and
11KV Package Unit Substations (FAT/SAT) Session 2

I Date I Name

Presentation Title

Page 43

GOPA-INTEC
Middle East

THANK YOU!