TESTING OF SWITCHGEAR

SWITCH GEAR
Circuit Breaker
Busbars and associated Insulators.
Isolators/ Disconnectors
Instrument Transformers
Protective Relays and auxiliary circuits

SWITCHGEAR TESTING

Developmental Test
Type Test
Routine Test
Factory Inspection Test
Pre-Commissioning Test

Developemental Test

Carried out on components,sub-assemblies

and complete switchgear during and after
the development of switchgear.

Related with R&Ds and manufacturing

processes.

Not covered under any reference standard.

Type Test
These tests are carried out for the purpose
of proving characteristics of switchgear and
control gear, their operating devices and
auxiliary equipment.
The type tests are carried out on a
maximum of four test specimen unless
otherwise specified in the relevant IEC
standards.

Type Test

Lightning Impulse Test

Switching Impulse Test
Power Frequency Over Voltage Withstand Test
Partial Discharge Test
Artificial Pollution Test
Temperature Rise Test
Resistance Measurement of the Main Circuit.
Short Time Withstand Current Test, Peak Withstand
Current Test
Making Current and Breaking Current Test
Mechanical Endurance Test

Lightning Impulse Test

The insulation of switchgear should be so

designed that it can withstand the occasional
Lightning surges of high peak value, sharp rate of
rise and short duration.
The lightning impulse voltage withstand level of
the switchgear is proved by conducting this test.
The test is performed with voltages of both
positive and negative polarity with respect to
earth using the standard Lightning Impulse
1.2/50s waveform (Fig 1).

Lightning Impulse Test

Rated Voltage (KVrms)

Rated Lightning Impulse Test

Voltage (KVpeak)

3.6

40

7.2

60

12.0

75

36.0

170

145.0

650

245.0

1050

Brief test procedure

The standard test involves the application of 15 nos. of test
voltages(1.2/50microsec lightning impulse wave surge to
simulate lightning stroke condition) between each phase and
earth in turn with CB closed & other phases earthed. In
addition, test voltages are also applied across each set of open
CB contacts. The overall test is considered to be satisfactory if
not more than 2 flashovers occur during any series of 15 tests
provided that these discharges only occur in self-restoring
insulation (i.e. air, oil or SF6 gas). A breakdown of solid
insulation normally results in an inability to recover and
constitutes a test failure.

BASIC CIRCUIT FOR IMPULSE

GENERATOR

Switching Impulse Test

The purpose of this test is to verify the
ability of the insulation of switchgear to
withstand the occasional high frequency
Switching surges occurred during opening
& closing of unloaded EHV AC lines,
switching of small inductive or capacitive
loads etc.
This test is necessary for switchgear of
rating 300 KV and above.

The switching surges are simulated in test

laboratories by a representative 250/2500 s
switching impulse wave obtained from an
impulse generator.
The test procedure of switching impulse is
same as that of Lightning Impulse Test.

Power Frequency Over voltage

Withstand Test
The purpose of this test is to verify the
ability of the insulation of switchgear to
withstand the temporary power frequency
over votages for a specified short duration.
These over voltages of 50Hz waveform are
produced by sudden load-throw-off, faults,
resonance, and poor voltage regulations by
OLTC of transformers etc.

Test procedure
Main Circuit

The switchgear is subjected to the withstand level

of the power frequency high voltage for 1 min.
(with respect to earth and between poles)
The result will be satisfactory if no failure occur.
The withstand voltage levels for different ratings
of breakers are given below.

Rated Voltage (KVr.m.s)

Rated Power Frequency

Test Voltage (KVrms)

3.6

10

7.2

20

12.0

28

36.0

70

145.0

275

245.0

530

On Auxiliary & Control Circuits

Auxiliary and control circuits of switchgear shall be

subjected to power frequency voltage withstand test
in accordance with IEC 61180-1.
The test is performed between the auxiliary and
control circuits connected together as a whole and the
frame of the switching device.
The test voltage is 2 KV with duration of 1 min.
The auxiliary and control circuits of switchgear are
considered to have passed the tests if no disruptive
discharge occurs during test.

Partial Discharge Test

The primary reason of this test is to check the

healthiness of insulation of switchgear .
Main cause of PD is the formation of localised void in
the insulation.
The applied power frequency voltage is raised to a prestress value which is identical to the power frequency
withstand voltage test and maintained at that value for 1
min. Partial discharge occurring during this period is
disregarded. Then the voltage is decreased to a specific
value defined in the table below depending upon the
configuration of equipment and system neutral for
partial discharge measurement.

The maximum permissible

partial discharge level shall

not exceed 5 pC.
However some equipment in

sw. gear like Voltage

Transformer have an
acceptable level of PD greater
than 5 pC.
Any sub-assembly

containing such components

shall be considered acceptable
if the discharge level does not
exceed 10 pc, but in that case
these will be tested for PD
separately.

Artificial Pollution Test

These tests are intended to provide information on the behaviour of

external insulations under conditions representative of pollution in
service.

No artificial pollution tests are necessary when the creepage distances

of the insulators comply with the relationship given below :
It = a x If x Ur x KD
Where, It = minimum nomianl creepage distance in mm
a = application factor
If = minimum nominal specific creepage distance (mm/kV)
Ur = Rated voltage of switchgear in KV
KD= Correction factor due to diameter

Temperature Rise Test

Temperature rise test is performed

to prove that temperature rise
comply to limits specified in
standards and to derive thermal
characteristic of the transformer.

Temperature Rise Test

The test is done with the normal rated

sinusoidal current with the three poles
connected in series. Temperature rise test is
carried out over a period of time sufficient
for the temperature rise to reach a constant
value.When the steady temperature is
reached the maximum temperature rise of
each part should be less than the
permissible limits as per IS.

Resistance measurement
of Main Circuit
Measurement of resistance of Main Circuit
is made for comparison between Sw. Gear
type tested for temperature rise and sw.
gears of the same type.
The resistance is measured before and after
temperature rise test and the readings in
these two conditions should not differ by
more than 20%.

The resistance is measured by Millivolt

Drop Test Method.
The DC current should be more than 50A
and less than rated current of circuit
breaker.
The resistance should be measured at
ambient air temperature.

Resistance measurement
of Auxilliary Circuit

These test is intended to verify the contact performance

under extremely low voltage condition due to the
reason that on auxilliary contact materials, oxidation
may occur which results in an increased contact
resistance or even no conduction at very low voltage.
One sample of each type of auxilliary contacts is
inserted into a resistive load circuit through which
flows a current of 10 mA when energised by a source
having an open circuit voltage of 6 V DC with a
relative tolerence of 0-15% and the resistance is
measured according to IEC 60512-2.

Rated Short Time Withstand

Current Test

Defn :The r.m.s value of the current which

the switchgear can carry in the closed
position during a specified short time.

Routine Test

Tightness test
Measurement of resistance of main
circuit of each pole
Power frequency voltage withstand test
on main circuit and auxiliary circuits
Mechanical operating test
Design and visual checks
Tests on auxiliary and control circuits

Tightness Test

The purpose of tightness tests is to demonstrate

that the absolute leakage rate does not exceed the
specified value of the permissible leakage rate.

The test shall be performed at normal ambient air

temperature with the assembly filled at the
pressure (or density) corresponding to
manufacturers test practice.

Mechanical operating test

Mechanical operational tests are
following points:
(a) at specified max. supply
applicable)
1.
five closing operations
2.
five opening operations
(b) at specified min. supply
applicable)
1.
five closing operations
2.
five opening operations
(c) at specified rated supply
applicable)
1.
five closing operations
2.
five opening operations

performed on switchgear at the

voltages and gas pressure(if

voltages and gas pressure(if

voltages and gas pressure(if

Design and Visual Check

The switchgear and control gear shall be
checked to verify its compliance with the
purchase specification.

Tests on Auxiliary and Control Circuits

The tests includes :
(i) Inspection of auxiliary and control circuits
The nature of the materials, the quality of assembly, the
finish etc. shall be checked. The components for auxiliary
circuits inside enclosures shall be checked for proper
mounting.
.

(ii) Functional tests

This test is necessary to verify proper functioning of
auxiliary and control circuits in conjunction with other
parts of switchgear. Operational tests on closing circuits
should be done satisfactorily within the range of 85%110% of normal rated voltage. Operational tests on
Tripping circuits should be done satisfactorily within the
range of 70%-110% of normal rated voltage.
Measurement of operating times of the switchgear
(Closing, Tripping and close-open operation time) is also
done in functional tests

Factory Inspection Test by Client

During inspection at the manufacturing
works, sample tests are witnessed by client .
The normal routine tests are conducted on
sample switchgear. Additionally, client may
ask for other tests also as per their
requirement or they can ask for repeat test
on same switchgear

Pre Commissioning Test

High voltage withstand test (HVAC)

Resistance measurement test
Measurement of insulation resistance of
the auxiliary and control circuit
Current Transformers ( all tests ).
Voltage Transformers ( all tests ).

Current Transformer Test

IR measurement.
Ratio Checking.
Winding resistance measurement.
Polarity Test .
Magnetizing Characteristic Tests.

Insulation Resistance
Measurement
Insulation resistance of the CT secondary is
measured with the help of 1000V
Megger (Insulation Tester) with respect to
Earth & in between different cores.

Ratio Checking
The usual method is to apply test current to
the primary winding of CT close to rated
primary current and measure the
magnitudes of primary and secondary
currents with a low value of secondary
burden.

Ratio Check
(Connection Diagram)

Winding Resistance
Measurement

Secondary winding resistance of a CT is

measured as per the circuit diagram given
below.

Polarity Testing
If at any instant, current is entering the
primary from P1 the current should leave
secondary from terminal marked S1. A set
up shown in the figure tests wheather the
polarity markings with respect to the
secondary are correct or not. (P1 should
correspond to S1)

Polarity Test

Magnetizing Characteristic Test

Magnetizing current is measured for several secondary

emfs. This is accomplished by applying appropriate
voltage to the secondary winding, and measuring the
current taken by secondary winding under test.
During the test the primary and other windings are
kept open circuited.
The RMS value of the sinusoidal voltage of rated
frequency applied to the secondary winding which,
when increased by 10%, causes the secondary
magnetizing current to increase by 50% is called Knee
Point Voltage (Vk).

Magnetizing Characteristic Tests

Voltage Transformers
Measurement of IR
Ratio Test
Polarity Test
Measurement of secondary winding resistance
Measurement of primary winding resistance
Magnetizing Characteristics & Over Voltage
Withstand Test

Insulation Resistance
Measurement
Measurement is done with a 1000V Megger to
ascertain the insulation resistance of primary
winding w.r.t earth isolating the intentional
earthing, insulation resistance of secondary
windings w.r.t earth and insulation resistance in
between primary and secondary winding.

Ratio Test

The ratio of VT is checked by applying variable

AC voltage to the secondary winding and
measuring its voltage reflection in the primary.

Ratio Test
(Back to Back connection of two VTs)

Polarity Test

Measurement of secondary
Winding Resistance

Measurement of primary
Winding Resistance

Magnetizing Characteristics &

Over Voltage Withstand Test

Magnetizing characteristic gives a clear picture of

amount of magnetizing current drawn by secondary
core and the secondary e.m.f up to which the core
exhibits its magnetic properties.
The varying voltage is applied in the secondary of
VT keeping the primary winding open and is raised
upto 120% of the normal rated voltage (i.e. 120% of
63.5 V) to ascertain that VT can withstand this
overvoltage without any failure.
The magnetizing current drawn by the VT secondary
core is also noted for different applied voltages.

Magnetizing Characteristics &

Over Voltage Withstand Test

Questions ?

Thank You.