174

POWE CABLES TESTS

(a) LV Power cables
Following tests should be performed after laying and before termination as per IEC60227-2:-
1. Continuity test.
2. Phasing test.
3. Insulation Resistance test.
4. AC High voltage test.
(1)- Continuity test
Purpose

To check any damage to conductor during laying.

To verify the continuity of cable conductor from terminal to terminal.
Test Equipment
Multi meter with connection leads
Preparation

 Short and ground all the cable cores/phases at one side or if armor cable than short all the cable
cores with sheath at one side.

 Select the multi meter on continuity.

Procedure

 Check the continuity between phasing / cores.

 Similarly change the Multi meter lead to Y,B and N phase and check continuity.
(2)- Phasing test
Purpose

To verify the correct phase marking.

This test usually done on Power supply cables.
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Test Equipment
Multi meter with connection leads.
Preparation

 Ground one side of cable phase i.e Red.

 Connect common terminal of multi meter with ground.
 Select the multi meter on continuity.

Procedure

 Check the continuity of red phase usually buzzer sound.

 Similarly connect Y,B and neutral one by one with cable sheath or ground and measure the
continuity with multi meter at other end.
(3)- Insulation resistance test
Purpose

To check any major insulation failure during pulling of cable.

Test Equipment
Megger with connection leads
Preparation

Phase to ground or core to ground

 Connect the all phases cores & sheath of cable at one side with ground except core under test.
 Connect Megger L (+Ve) terminal with other end of same phase under test.
 Connect Megger L (-Ve) terminal with ground.
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Phase to phase or core to core

 Connect Megger L (+Ve) terminal with R-phase at one end of cable.
 Connect Megger L (-Ve) terminal with Y-phase at same end of cable.
 Leave other ends of cable open and clear from ground.

Procedure

Phase to ground or core to ground

 Inject 1kV for 01 minute and measure R-phase or core to ground IR value.
 Similarly measure IR value of Y,B and N phase by changing multi meter connection.
Phase to phase or core to core
 Inject 1kV for 01 minute and measure IR value between R-Y phases/core to core.
 Similarly measure IR value between R- B,R-N,Y-B,Y-N and B-N phases by changing multi meter
connection.
(4)-AC High voltage test
Purpose

To check the dielectric strength of cable insulation.

Test Equipment
AC High voltage set with connection leads
Preparation
Phase to ground or core to ground
 Connect the all phases cores & sheath of cable at one side with ground except core under test.
 Connect AC HI POT tester Output terminal red with other end of same phase under test.
 Connect AC HI POT tester output other terminal black with ground.
 Ground the testing set.
 Give AC supply to testing set.
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Phase to phase or core to core

 Connect AC HI POT tester Output terminal red with other R-phase and terminal black with Y-phase at
one end of cable leaving the other ends of cores isolated and clear from ground.
 Ground the testing set, sheath and phases not under test.
 Give AC supply to testing set.

Procedure

Phase to ground or core to ground

 Inject 2kV for 01 minute and measure R-phase or core to ground leakage current value.
 Similarly measure leakage current value of Y,B and N phase to ground by changing HI POT tester
connection.
Phase to phase or core to core
 Inject 2kV for 01 minute and measure leakage current value between R-Y phases/core to core.
 Similarly measure leakage current value between R- B,R-N,Y-B,Y-N and B-N phases by changing HI
POT tester connection.
Sample test record
IR value at 1kV DC Leakage current value at 2kV AC
Cable number Continuty Phasing
Phase to ground Phase to phase Phase to ground Phase to phase
R-ground=550MΩ R-Y= >1GΩ R-ground= 0.01mA R-Y= 0.02mA
Y-ground=590MΩ R-B= >1GΩ Y-ground= 0.02mA R-B= 0.02mA
B-ground=650MΩ R-N= >1GΩ B-ground= 0.01mA R-N= 0.02mA
P101 N-ground=750MΩ Y-B= >1GΩ OK OK N-ground= 0.03mA Y-B= 0.02mA
.. Y-N= >1GΩ .. Y-N= 0.02mA
.. N-B= >1GΩ .. N-B= 0.02mA
..

Acceptable criteria
o IR value must be >100MΩ.
o AC Hi pot test no break down or tripping of set.

(b) LV control cables

 Control cable tests are same as power cable testing except there will be no AC HI POT test of control
cables.
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(c) MV XLPE cables

Following test should be performed before energizing medium voltage cables 11kV to 34kV as per IEC
60502:-
1. Sheath Armor continuity test.
2. Sheath insulation resistance test.
3. Main conductor phasing and continuity test.
4. Main conductor insulation resistance and capacitance test.
5. Hi POT test
(1) Sheath Armor continuity test.
Purpose

To check damage of outer XLPE insulation.

To find any breakdown of cable sheath.
Test Equipment
Multi meter with connection leads or megger.
Preparation

 Connect the cable sheath at one end to ground.

 Connect the other end of cable sheath with megger or multi meter.
 Connect the common terminal of multi meter with ground or L (-ve) terminal of megger with ground.
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Procedure

 Select the multi meter on continuity and measure the continuity buzzer sound will also come if
sheath continuity OK.
 If testing with megger due to long length of cable inject 1kV and measure insulation resistance which
must be zero.
(2) Sheath insulation resistance test.
Purpose

To check damage of outer XLPE insulation.

Test Equipment
Megger with connection leads.
Preparation

 This test is done from sheath to ground at 1kV.

 Connect the main conductor of cable with ground.
 Isolate the sheath from ground at one end.
 Connect the other end of sheath with megger L (+ve) terminal.
 Connect the L (-ve) of megger with ground.
 Check that megger battery is in charged position otherwise give ac supply to megger.

Procedure

 Switch ON the megger and inject 1kV for 01 minute sheath to ground.
 Note the reading of IR and correct at 20°C.
Acceptable criteria
o IR value must be >10MΩ.
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Sample test record

IR value at 1kV DC
Cable size Phase Continuity Remarks
sheath to ground
R 2.28GΩ OK
185 sq-mm Ambient
Y 16.3GΩ OK
Single Temp.=25°C
B 2.96GΩ OK

(3) Main conductor phasing and continuity test.

Purpose

To verify the continuity of cable conductor from terminal to terminal.

To verify the correct phase marking.
Test Equipment
Multi meter with connection leads or megger.
Preparation

 Connect the R-phase cable conductor at one end to ground.

 Connect the other end of R-phase cable conductor with megger or multi meter.
 Connect the common terminal of multi meter with ground or L (-ve) terminal of megger with ground.

Procedure

 Select the multi meter on continuity and measure the continuity buzzer sound will also come if
sheath continuity OK.
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 If testing with megger due to long length of cable inject 1kV and measure insulation resistance which
must be zero.
 Similarly measure the continuity and phasing of Y and B phases.
Sample test record

Cable size Phase Phasing Continuity Remarks

R OK OK
185 sq-mm
Y OK OK
Single
B OK OK

(4) Main conductor insulation resistance test.

Purpose

To check any major insulation failure.

Test Equipment
Megger with connection leads
Preparation
 This test should be done conductor to ground at 5kV before and after HI POT test.
 Isolate the cable from both sides.
 Connect the cable sheath at one side with ground.
 Connect Megger L (+Ve) terminal with main conductor at one side.
 Leave the other side cable conductor open and clear from ground.
 Connect Megger L (-Ve) terminal with ground.
 Charge the battery of megger or give AC supply to megger.
Procedure

 Switch ON the megger and inject 5kV for 01 minute main conductor to ground.
 Note the reading of IR and correct at 20°C.
 After HI POT test again perform IR test of same cable.
 Similarly measure the IR value of other phases.
Note
o If cable is three core than insulation test between phases R-Y,Y-B and Y-R should be also performed.
Acceptable criteria
IR value must be >10MΩ
Sample test record
IR value @5kV IR value @5kV
Cable size Phase Remarks
before HV test after HV test
R-ground 162GΩ 118GΩ
185 sq-mm Ambient
Y-ground 140GΩ 131GΩ
Single Temp.25°C
B-ground 168GΩ 121GΩ
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(5) Hi POT Test

(A) AC High voltage test
Purpose

To check the dielectric strength of cable insulation.

Test Equipment
AC High voltage set with connection leads, AC supply
Preparation
 The HV test voltage can be calculated by the formula = 3xU0/√3.
 13.8kV cable test voltage = 3x13.8 / 1.732 =23.90 or 24kV for one hour.
 Connect cable main conductor one side with HV output of test reactor keeping other side clear form
other cables and ground.
 Connect the reactor with HV set control unit by manufacturer provided data cable.
 Connect the set control unit 2nd output to reactor ground point and with station ground.
 Connect the cable sheath and cables not under test with station ground.
 Select the leakage current measuring range to suitable range.
 Barricade all test area with red warning tape.
 Give AC supply to testing set.

Procedure

 Switch ON the power button of testing set control unit.

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 Inject slowly voltage by rotating the set dial and observe the injected voltage, leakage current on the
meters provided on set until 24kV voltage.
 Test duration is 01 hour. After every 10 minutes note the reading of leakage current.
 After completing the test discharge the cable /testing reactor with the ground rod provided by
manufacturer.
 Similarly perform HV test on other phase’s cables.
Acceptable criteria
o No break down should occur.
Sample test record
Leakage current after every 10 minutes
Resonant
Cable size Phase Remarks
frequency 10 20 30 40 50 60

R-ground 0.1Hz 6mA 6mA 6mA 6mA 6mA 6mA OK

185 sq-mm
Y-ground 0.1Hz 6mA 6mA 6mA 6mA 6mA 6mA OK
Single
B-ground 0.1Hz 6mA 6mA 6mA 6mA 6mA 6mA OK

(B) DC High voltage test

Purpose
To find the insulation resistance of electrical components ( bus bars, trolleys, cables )
Test Equipment
DC High voltage set with connection leads, AC supply
HV TEST WITH 80KV SET
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Preparation

 Connect the operation unit, high voltage unit and equipment to be tested as in diagram given
below

 Ground and short the conductor which is not to be tested.

 Ground the ground terminal of high voltage unit and operation ground with station ground.
 Join the high voltage terminal of high voltage unit to test object.
 Connect the ground and discharge rod to the ground terminal of test object and hold it for
ready.
 Connect the five pin connecting cable of operation unit to high voltage unit terminal.
 Connect the operation unit to the mains.
 The blue cable connecting high voltage unit and tested object should be un insulated overhead
cable.
Procedure

 Select the largest range for current measuring i.e. 10mA.

 In case of cable set the load selector switch to C and in case of substation component to R.
 Turned ON the mains switch white lamp lights up .
 Green lamp also lights up if the equipment is properly grounded.
 Press the HV (Black) ON button the HV off button lights up indicating that HV voltage are
switched ON.
 Slowly turn the adjuster anticlockwise up to prescribed test voltage.
 Note the leakage current of the test object by adjusting the current selector switch from range
0.1mA ,1mA , 10mA.
 Now turn back adjuster clockwise to bring the test voltage to zero.
 Press the power off button HV On lamp lights up.
 Turned off the power switch.
 Discharge the induced voltage with discharge rod.
 Measurement should be made three times during testing.
 The test time should be at least 15 min. and max.30min.
 Discharge the HV unit discharge rod.
Acceptable criteria
o If the leakage current is exceeded the over current trip will disconnect the set from mains, it
shows test object is defective.
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(d) HV & EHV XLPE cables

Following test should be performed before energizing high voltage and extra high voltage cables as
per IEC 62067 & 60840:-
1. Main conductor continuity and phasing test.
2. Main conductor insulation resistance and capacitance test.
3. Main conductor DC resistance measurement test.
4. Outer jacket/Sheath integrity test.
5. Link box ground resistance measurement test.
6. Link box contact resistance measurement test.
7. Surge voltage limiter (SVL) insulation resistance test.
8. Zero and positive sequence Impedance test.
9. Cross bonding verification test.
10. AC High voltage test.
Preparation

 Cable must be disconnected from all external connections.

 If HV cable is connected with GIS than connection should be made through GIS ground switch or
cable sealing ends/ termination connection boxes.
 If the cable is connected to outdoor type sealing ends than connection should be made through
sealing ends. Sealing ends connection to other equipment should be removed.
 If the cable is connected to transformer than cable connection to transformer Air/oil/SF6 bushings
must be disconnected.
 The above preparation before starting cable testing except HV test.
(1) Main conductor continuity and phasing test.

Procedure

 The test equipment, preparation and procedure of phasing and continuity test of HV/EHV cables is
same as MV cables already explain above.
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(2) Main conductor insulation resistance and capacitance test.

 The test equipment, preparation and procedure of main conductor insulation resistance test of
HV/EHV cables is same as MV cables already written above.
 Megger insulation resistance also gives the capacitance value at the end of insulation test which can be
also noted along with IR value.
(3) Main conductor DC resistance measurement test.
Purpose

To check the conductivity of conductor,

Test Equipment
DC resistance measurement set with connection leads, AC supply
Procedure

 Short all the three phases of cables at on end.

 Note the Ambient temperature with multi meter or thermometer.
 Connect the resistance measuring set between phases R-Y.
 Measure the resistance between two phases.
 Correct the reading at 20°C.
 Similarly measure the resistance between phases Y-B and B-Y.
 Compare the measured resistance value with manufacturer provided data.
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Note:- connection leads resistance must be subtracted from conductor resistance.

Sample test record
Cable size / Measured Measured Resistanc calculated Resistanc calculated
Phase Ambient temp
length resistance resistance/KM at 20°C at 20°C/KM

2000 sq-mm R-Y 0.00185 Ω 0.01 24°C 0.0018 0.01

Single/179 Y-B 0.00195 Ω 0.011 24°C 0.0019 0.01
meters 0.0019 Ω 0.011 24°C 0.0019 0.01
R-B

Formula for resistance at 20°C=measured resistance x 1/1+0.00393(t-20)=0.00185x 1/ 1+0.00393(24-20)=0.0018Ω

(4) Outer jacket/Sheath integrity test.

Purpose

To check the over condition of sheath and XLPE insulation,

To check the dielectric strength of cable outer protective jacket.
This test is done by injecting 10kV DC in sheath to ground.
Test Equipment
Megger 10kV or DC Hi pot test with leads, AC supply
Procedure

 First perform megger test at 5kV from sheath to ground.

 Disconnect the sheath phase to be tested from link box bus bars at both ends.
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 First perform insulation resistance test phase to ground at 5kV than connect the same sheath to HV
output of DC HI Pot test set.
 Connect the other point of dc hi pot set with ground.
 Leave the other end of sheath open and clear from ground/main conductor.
 Ground the main conductor/sheaths not under test.
 Set the leakage current range to higher setting i.e mA.
 Give AC supply to dc Hi pot test.
 Inject 10kV DC voltage in cable sheath and see the leakage current dial reading in mA if no deflection
of needle set the current range to µA.
 Note the measured leakage current in µA.
 Perform again megger insulation test of sheath.
 Similarly perform insulation resistance and DC HI Pot test of Y,B phase sheaths.
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Sample test record

IR value @5kV IR value @5kV
Cable size Sheath Phase Remarks
before HV test after HV test
R 5.05GΩ 11GΩ
2000 sq-mm Ambient
Y 3.57GΩ 18.4GΩ
Single Temp.24°C
B 9.15GΩ 6.31GΩ

Cable size Phase Test Voltage Leakage current Remarks

R-ground 1.5µA
2000 sq-mm 10kV @01
Y-ground 1.2µA Ambient temp.24°C
Single minute
B-ground 1.0µA

(5) Link box ground resistance measurement test.

Purpose

To verify the continuity of link box ground path.

This test is performed by fall of potential method.
Test Equipment
Ground resistance tester with leads.
Preparation

 Disconnect the ground connection cable of link box / sheath ground bus bar.
 Clean the outer surface of conductor for good continuity.
 Connect the ground conductor under test to set E( Exc) terminal with green cable this cable must be
as short as possible as its resistance will be included in final earth resistance value.
 Connect set H(EC) red cable with E3 (current) rod and insert the rod in soil up to maximum available
length of red cable.
 Connect set S(ET) blue cable with E2 (voltage) rod and insert the rod in soil up to maximum available
length of blue cable.
 Select the FUNCTION selector switch of set to position R.
 Select the highest measuring range 20kΩ with RANGE selector switch.
 Check the testing set battery in charge position.
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Procedure

 Press the start push button of testing set.

 If R measurement screen does not showing any reading adjust the RANGE to any lower suitable
value.
 If there is alarm beep stop testing and check rods wiring or battery of testing set.
 If number 1 appears on the screen it means measured value is greater than selected value than
immediately increase the range of RANGE selection switch.
 If the measured value is greater than acceptable limit than clean the contact surface otherwise check
the connection of equipment with ground mesh after digging the soil.
Acceptable criteria
o Earth resistance should not be greater than 1Ω.
Sample test record

Link Box Link Box serial no. Earth resistance

LB:1 LS 294 0.15Ω

LB:2 LS 295 0.14Ω

(6) Link box contact resistance measurement test.

Purpose

To verify that all joints/connection are securely tight.

Test Equipment
Low resistance testing set Programma MOM600A or megger DLRO10 with leads.
Preparation

 Connect the testing set with any cable or other joint as given below:-
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Procedure

 The contact resistance test method is same as breaker contact resistance test.
 Inject 100A and measure contact resistance in µΩ.
 Similarly measure all joints resistance in link box.
Acceptable criteria
o Contact resistance should not be less than 20µΩ.
Sample test record

Contact face Resistance inµ Ω Remarks

Link box top 1.7 OK

Link box bottom 9.3 OK
..
..

(7) Surge voltage limiter (SVL) insulation resistance test.

Purpose

To verify the dielectric strength of SVL.

Test Equipment
Megger testing set with leads.
Preparation

 Disconnect the one side of SVL.

 Connect the megger testing set with SVL R -phase as under:-

Procedure
 Inject 2.5kV for 01 minute and measure the IR value by adopting all other test arrangement /
procedure as discussed previously.
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 Similarly measure the IR value of Y and B phase SVL.

 Compare the measured value with the factory value.
Acceptable criteria
o Insulation resistance value must be >1000MΩ.
Sample test record

Link Box SVL phase Measured IR value Ambient temp.

R-phase 11.3GΩ
Y-phase 8.74GΩ 17.2°C
B-phase 9.04GΩ

(8) Zero and positive sequence Impedance test.

Purpose

Cable Impedance is required for relay setting calculations.

Test Equipment
AC generator with step down or welding transformer, Clamp meter, Multi meter, phase angle meter and
necessary connection leads / shorting jumper conductors.
(a) Positive sequence Impedance measurement
Preparation

 Short all three phases of cables at one end:-

1. If cables are terminated in outdoor type cable sealing end short all three phases with jumper
conductor or wire.
2. If cables are terminated into GIS than close the ground switch of GIS and remove the ground
connection of ground switch.
3. If cables are terminated into Power transformer using cable oil chamber than remove oil from
chamber and disconnect the cable link connection with transformer and short all three phases
with insulated cable.
 Make sure that all connection leads are kept away from ground.
 Make sure Cable sheaths are grounded in Link boxes and SVL are closed.
 Connect AC generator, step down or welding transformer, Clamp meter, Multi meter, phase angle
meter between R-Y phase as given under:-
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Procedure

 Inject single phase AC supply by starting generator and adjust the generator output voltage on step
down transformer to i.e 15V as high voltage will increase cable capacitance.
 Take the current, voltage and phase angle readings using clap meter, multi meter and phase angle
meter.
 Similarly measure the injected voltage, current and phase angle value by changing the connections
between Y-B and B-R phases.
 Calculate the positive sequence Impedance by using formula:-
ZRY = V / I Cos ø + V/I j Sinø Ohms → ZRY= V / I ( Cosø + j Sinø )
ZYB = V / I Cos ø + V/I j Sinø Ohms → ZYB= V / I ( Cosø + j Sinø )
ZRB = V / I Cos ø + V/I j Sinø Ohms → ZRB= V / I ( Cosø + j Sinø )
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Acceptable criteria
o Compare the measured value with cable manufacturer provided data.
Sample test record
Measured Impedance
Measured Measured R=ZCosφOh X=Zsinφ Positive sequence Impedance
Phase phase angle Cosφ Sinφ Ω/Km=Z/179 x
current(A) voltage (U0) m Ohm I Z+I=V/I ( Cosφ+j Sin φ ) ohm
(degree ) 1000

ZRY 81.6 11.1 87.53 0.043 0.999 0.1358 0.0058 0.1358+ j 0.0058 0.7586+ j 0.0324
ZYB 68.8 13.1 88.54 0.025 0.999 0.1902 0.0047 0.1902+j 0.0047 1.0625+ j 0.0262
ZBR 75.7 8.5 80 0.174 0.984 0.1105 0.0195 0.1105+j 0.0195 0.6173+ j 0.1089
Mean
75.36 10.9 .. 0.0806 0.994 0.1455 0.01 0.1455+j 0.01 0.8128+ j 0.0558
value
Impedance per pgase
ZR = (ZRY +ZBR)- ZYB / 2 0.1567 + j 0.0575 Ω/Km
ZY = (ZYB +ZRY)- ZBR / 2 0.6019+ j 0.0252Ω/Km
ZB = (ZBR +ZYB)- ZRY / 2 0.4606+ j 0.0513Ω/Km

(b) Zero sequence Impedance measurement

Preparation

 All preparation is same as positive sequence impedance test except all phases of cables will be
shorted at test end and at far end all phases will be shorted /grounded.
 Make connection as under:-

Procedure

 Take reading of Clamp meter, multi meter and phase angle meter by adopting same procedure as in
positive sequence impedance measurement.
 Calculate the zero sequence impedance by the formula:-
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Z0 = 3V0 / I (Cosø ± Sinø)

Acceptable criteria
o Compare the measured value with cable manufacturer provided data.
Sample test record
Measured
Measured Measured Zero sequence Impedance IZ0I=3U0 / I Zero sequence Impedance
phase Cosφ Sinφ Cosφ +Sinφ
current(I) voltage(V) Cosφ +j 3U0 / I Sinφ (Z0) per phase
angle(φ )
92.4A 9.0 V 57.7239° 0.534 0.8455 1.3795 0.1560 + j 0.2470 Ω 0.8715 + j 1.3798 Ω/ Km

(9) Cross bonding verification test.

Purpose

To ensure that cross bonding is suppressing the sheath current correctly.

Test Equipment
AC generator with manually controlled exciter 100A, Clamp meter, Multi meter, external dc current
source0-50V,0-5A and necessary connection leads / shorting jumper conductors.
Preparation

 Connect the Generator to all 3 phases of cables at one side and short all phases of cables at other
side.
 Deactivate the Generator AVR and connect an external dc current source i.e SEVERKER 750 to
generator exciter winding.
 Test connection as under:-

Procedure

 Start the Generator with zero excitation and close its output Breaker verify 60Hz frequency.
 Measure the output current and voltage of Generator with clamp and multi meter.
 Now inject dc current in exciter with SEVERKER 750 until 100A achieved on clamp meter.
 Measure the current of each phase and ground and voltage of each phase in all link boxes.
 Value of measured current and induced voltage must be very less.
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 Bring the generator current to zero than open the generator output MCB.
 Now reverse the sheath connection in any link box and start the generator and measure again the
current and induced voltage in same link boxes this current will be high as 4 times or more.
Acceptable criteria
o Sheath leakage current must be less than 3%.
Sample test record

Connections correct

Current Voltage
Location R Y B Ground R Y B
Link Box.1 10.15mA 10.15mA 10.15mA 10.15mA 100.95mV 86.96mV 90.35mV
Link Box.2 9.25mA 9.45mA 10.15mA 13.95mA 110.85mV 100.95mV 75.90mV
Link Box.3 8.45mA 10.15mA 10.15mA 10.15mA 95.45mV 80.95mV 95.66mV
Link Box.4 10.15mA 12.65mA 10.15mA 11.65mA 88.98mV 86.95mV 100.95mV

Connections reversed

Current Voltage
Location R Y B Ground R Y B
Link Box.1 30A 35A 30A 30A 110.99V 108.89V 105.68V
Link Box.2 50A 40A 35A 38A 115.45V 110.99V 110.99V
Link Box.3 45A 39A 30A 48A 105.66V 95.22V 85.69V
Link Box.4 45A 50A 30A 36A 108.89V 110.99V 110.99V

(10 ) AC HI POT test.

Purpose

To check the dielectric strength of cable insulation.

Test Equipment
AC High voltage testing unit usually fixed on trailer having main parts given below:-
Reactor, Exciter transformer, damping resistor, connection leads, AC Generator 500KVA.
Preparation
 The HV test voltage can be calculated by the formula = 2xU0/√3for single phase .
 115kV cable test voltage = 2x115 / 1.732 =132kV for one hour.
I. Connect cable main conductor one side with HV output of reactor using corona ring keeping
other side clear form other cables and ground.
II. If other sides of cables connected with Power transformer through oil chamber than open the
connection of cables to power transformer winding and filled the cable oil chamber with
insulated oil.
III. If other sides of cables connected with GIS than GIS line ground switch and disconnector must be
in open position and other portion of GIS not involved in test must be grounded. GIS portion
where the cables are connected SF6 gas pressure must be full.
IV. Make sure all cable link boxes are connected and tested.
V. Cables not under test must be grounded.
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VI. Any Surge Arrester within test portion must be disconnected.

VII. All area under test must be barricaded and watchmen should be deployed to stop the entrance
of unauthorized workers.
VIII. Note the Ambient temp. and humidity.
Test arrangement as under:-

Procedure

 First perform insulation test of cable before Hi POT test at 5kV.

 Inject 132kV in cable for one hour there should be no flash over or excess leakage current.
 After HV test again perform insulation test at 5KV.
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Sample test record

Ambient temp./ Humidity 25.8°C / 21% 25.3°C / 22% 22.1°C / 35% Remarks
Phase Red Yellow Blue Ok
Cable length in meter 209 x 3 m 209 x 3 m 209x 3 m Ok
Test duration 01 Hour 01 Hour 01 Hour Ok
Voltage injected 132kV 132kV 132kV Ok
Resonant frequency (Hz) 98.72 Hz 99.40 Hz 98.72 Hz Ok
Charging current 12.9 A 12.8 A 12.8 A Ok
Capacitance (nF) 151nF 150nF 149nF Ok
Insulation resistance test (beforw HV
57.5 GΩ 72.8 GΩ 70.7 GΩ
test) @5kV Ok
Insulation resistance test (After HV
57.5 GΩ 70.8 GΩ 68.7 GΩ
test) @5kV Ok

BATTERY TESTING
Following tests should be performed before putting the station battery in service as per IEC60227-2:-
(a) Battery capacity / discharge test
Purpose
To find the discharge capacity of battery.
To find that battery can Support the required load for the specified time.
To find out the condition and problem of battery at load.
This test usually taken for new battery at one time only.
Test Equipment
Load banks or inductive load, AC supply and connection leads.
Preparation

 The discharge test duration is 10 hours so divide the AH capacity of cell with 10 and put the same load
on battery bank. Let battery cell AH capacity is 1500AH than 1500/10=150A load will be put on battery
bank for 10 hours.
 Battery must not discharge 7 days before capacity test.
 Battery charger and load must be disconnected from battery bank.
 Record the voltage per cell and terminal voltage of battery.
 Select the number of load banks required for conducting test as per load bank manufacturer provided
data.
 Connect the load bank with battery as below:-
 199

 Set the load on 150A ampere and time duration 10 hours on load bank using keypad.
 Digital load banks automatically adjust load current as battery voltage decreases.
 Give AC supply to load bank.
Procedure

 Set the load current on 150A ampere on auto adjustment and time duration 10 hours on load
bank using keypad.
 Switch On the main breaker of load bank and start the testing set.
 Apply the temperature correction factor to discharge load.
 Monitor the voltage per cell and battery terminal voltage and load current after every 30 minutes.
 After 10 hours note the voltage per cell / terminal voltage and compare the testing results
with manufacturer.
 Usually discharge voltage of one cell is 1.75v and for 60 cell battery bank discharge voltage will be
60x1.75=105.0 V and if during discharge test terminal voltage reaches to this limit stop the test
and find problem i.e Weak cell, loose connection etc.
 If there is overheating stop the test.
 Most of digital set having volt, AM meter and time device included in the set.
 % age Capacity at 77°F= Ta / Tb x 100 where Ta =Actual test time, Tb=Specified test
time.
 After discharge test recharge the battery by putting the charger on AUTO charge/
boost charge.
Sample test record
Time 0 Hr 1st Hr 2nd Hr 3rd Hr 4th Hr 5th Hr 6th Hr 7th Hr 8th Hr 9th Hr 10th Hr
Terminal voltage 126 117.19 116.71 116.1 115.44 114.16 113.94 113.02 112.15 110.82 109.5
Terminal current 0 150 150 150 150 150 150 150 150 150 150
Specific gravity 1.26 1.24 1.23 1.22 1.23 1.2 1.18 1.18 1.16 1.14 1.13
Temperature 28 29 29 30 31 31 33 30 32 33 33
Cell No Voltage
1 2.1732 2.016 2.008 1.993 1.995 1.976 1.96 1.943 1.929 1.905 1.881
2 2.18 2.026 2.017 2.007 1.996 1.98 1.971 1.955 1.94 1.916 1.892
3 2.076 2.023 2.014 2.001 1.993 1.974 1.965 1.949 1.935 1.913 1.892
4 2.168 2.02 2.01 1.999 1.998 1.981 1.963 1.946 1.931 1.908 1.886
..

..

..

..

..

..

..

..

..

..

..

..
..

..

..

..

..

..

..

..

..

..

..

..

58 2.162 2.026 2.018 2.001 1.996 1.97 1.959 1.942 1.926 1.922 1.873
 200

(b) Battery Impedance test

Purpose
To find the condition of battery cells.
To measure the internal ac impedance of each cell/strap.
Test Equipment
Battery Impedance tester, AC supply and connection leads.
Preparation

 This test is conducted for battery in service.

 Battery charger should be on float charging.
 Record the cell and ambient temperature.
 Battery impedance tester having following main parts:-
o Receiver
o Current and potential probes.
o Transmitter.
 Before starting test make sure that receiver is charged and disconnected from transmitter charger.
 Connect the 7 pin connector of receiver to potential probe.
 Connect the Clamp meter with 4 pin connector of receiver.
 Power On the receiver by pressing power On button its LCD screen will display after few seconds.
Select N until CONNECT CT bar is appeared using up/down keys.

 Place the clamp meter around any strap to measure the ripple current.
 Pull the receiver trigger to save the ripple current value.
 Connect the transmitter current source leads (J2) Red to positive terminal specified portion and
Black to negative terminal.
 Give AC supply to transmitter.
Procedure

 Switch ON the Power and than current buttons of transmitter.

 Current ready lamp will light up after a while.
 Observe the screen of receiver to view the source current once its appear pull the receiver trigger to
save this value.
 Place the clamp meter over the cell interconnection strip to measure the current, receiver on +ve
terminal and potential probe over -ve terminal of cell to be tested and press down both probes as
under:-
 201

 Press the receiver trigger to measure and store the impedance and volts reading appeared on the
screen.
 To test the cell strap position the receiver probe on +ve terminal and potential probe on –ve
terminal of strap as under:-

 When reading on receiver is stable press the receiver trigger to save the reading.
 Once the 1st cell readings are saved 2nd cell test will appear on receiver screen, procedure of testing
2nd cell is same as cell 1.
 Similarly test all cells within the portion where transmitter current cables are connected.
 To save the last cell record short the receiver and potential probe together when screen display last
cell & strap test result and then press receiver trigger otherwise last cell data will be lost.
 Once the all cells in the portion are tested press receiver down key to complete the test , select Y
and to confirm press up key.
 Switch OFF the current button of transmitter to block the current and shift transmitter current leads
to other battery portion to be tested.
 202

 Test the other cells with the same procedure as described above.
 After finishing the impedance test press and hold the enter key of receiver and use up/down keys to
select and confirm power down. OFF the current button of transmitter and then switch OFF
transmitter power button. Remove all the interconnection cables.
Acceptable criteria
o The battery cell impedance must be less than 1.5mΩ and strap 0.1mΩ.
Sample test record
Impedance in Resistance in Cell Ambient
Cell No Voltage
mΩ mΩ Temperature Temperature
1 2.1732 0.95 0.321 26°C 26°C
STRAP.1 0.09 0.001
2 2.18 1 0.372 26°C 26°C
STRAP.2 0.095 0.002
3 2.076 0.88 0.331 27°C 26°C
STRAP.3 0.099 0.001
4 2.168 0.85 0.351 27°C 26°C
STRAP.4 0.095 0.002
..

..

..

..

..

..
..

..

..

..

..

..
58 2.162 0.098 0.0018 28°C 26°C
STRAP.58 0.099 0.0015

BATTERY CHARGER TESTING

Following tests should be performed before putting the battery charger in service as per IEC 60623:-
1. Function check.
2. Load test
3. Efficiency test.
4. Calibration of AM/Volt meters
(1) Function test
Purpose
To verify the function of various charger components.
Procedure

Give AC supply to charger and switch ON power button and on display unit select Test and manual
operation of charger and verify the following:-
(a) Measured values
 Go to display unit AC Input measures and note the following using up/down keys.
1. Nominal AC voltage and Frequency.
2. Float voltage (set the charger on float charging)
3. Boost voltage (set the charger on Boost charging)
4. Pre commissioning voltage (set the charger on Boost charging)
Acceptable criteria
 203

o Compare the measured values with charger name plate data or manufacturer given values.
Sample test record
AC Input DATA DC output DATA Measured Expected
Phase R Y B Float voltage 129.3V 129.3V
Nominal voltage 374.6 V 382.1 V 376.8 V Boost voltage 135.1V 135.2V
Frequency 58.3 Hz 58.9 Hz 58.3 Hz Pre commissioning voltage 150.8V 150.8V
Current 1.2A 1.3A 1.3A

(b) Alarm and indication

1. Float indication (manually put on charger float charging and check alarm/indication)
2. Boost indication (manually put on charger boost charging and check alarm/indication)
3. Pre commissioning mode (manually put on charger boost charging and checks alarm/indication).
4. Mains fault (Switch Off the charger main AC MCB or switch off the source supply and verify the
indication on LCD.
5. Charger fault (Switch Off the charger main AC MCB , source supply or DC output MCB ) and verify
the indication on LCD.
6. AC MCB open ( to verify this alarm/indication do the same procedure as in sr.4.
7. DC MCB open ( to verify this alarm/indication do the same procedure as in sr.5
8. High DC voltage (manually adjust the charger output voltage more than 150V and verify this
alarm/indication).
9. Low DC voltage.( this alarm/indication will come along mains fail indication).
Sample test record
Description Alarm indication
Float .. OK
Boost OK OK
Pre commissioning mode OK OK
Mains fault OK OK
Charger fault OK OK
High DC Voltage OK OK
Low DC Voltage OK OK
AC MCB Open/Trip OK OK
DC MCB Open/Trip OK OK
Coolin fan fault OK OK

2. Load test
Purpose
To verify that charger can take designed full load for specified time.
To identify any problem at full load.
This test is done on 25%,50%,75% and 100% load.
Test Equipment
Load banks programma or other, AC/DC clamp meter, AC supply and connection leads.
 204

Preparation

 Let we are using 03 load banks to test 450A charger.

 Connect the load banks in parallel and then to DC output MCB of charger as under:-


 Connect the charger to generator or permanent AC supply.
 Switch ON the charger AC supply MCB and than charger On switch.
 Give AC supply to load banks.
Procedure

 Adjust the load current @25% i.e 112.5A and start the load banks.
 Close the output DC MCB.
 Note the AC voltage & current, output dc voltage& current, frequency, Power factor and ripple
voltage using AC/DC clamp meter and multi meter.
 Similarly adjust the load banks on 50% (225A), 75% (337.5A) and 100% (450A) and take the same
readings as taken at 25% load.
 To take the ripple voltage by adjusting the multi meter on AC voltage measurement and take voltage
on dc output side of charger.
Acceptable criteria
o There should be no abnormal sound, excessive heating and tripping of battery charger.
Sample test record
Input AC Voltage AC Current (A)
Load in Output DC DC Current Frequency Ripple
Power factor
% Voltage (V) (A) (Hz) voltage (mV)
R-Y Y-B B-R R Y B

25% 378.8 379.4 379.4 30.1 30.2 29.8 129.6 112.5 60.01 0.8 90
50% 379.9 379.5 379.3 59.7 59.7 59.8 129.04 225 60.02 0.8 120
75% 380.4 381.4 381.4 91.03 90.03 91.04 128.96 337.5 60.03 0.8 140
100% 384.2 385.3 385.1 126.66 126.65 126.66 128.74 450 60.02 0.8 150
 205

(3) Efficiency test

Purpose
To verify the performance of charger.
Procedure

 Efficiency of charger can be calculated by taking the readings of Input current/voltage and output
current/voltage taken during battery load test.
 The efficiency of battery is calculated on 50% and 100% load.
 Efficiency of charger can be calculated by the formula
Efficiency= DC Output power/ AC input Power x 100 = VI / √3VICOSφ
Sample test record

Load in Output Output Input Input

Efficiency
% current voltage voltage (avg) Current (avg)

50% 225 129.04 379.5 59.7 92%

100% 450 128.74 371.2 126.66 89%

METERS TESTING
Following meters are used in substation to measure various electrical quantities:-
1. LV AC &DC Volt & AM meters
2. HV AC Volt & AM meters
3. Multifunction (MFM) meters
Transducers
(1) LV AC Volt & AM meters testing
Calibration test of Voltmeters
(a) Analogue AC Voltmeter
Purpose
To verify measuring accuracy of voltmeter.
This test is done on 0%,25%,50%,75% ,100%,120% of rated voltage and full scale display (FSD) of
meter.
Test Equipment
Variable voltage transformer or digital secondary injection tester SEVERKER760or Freja300, AC supply
and connection leads.
Preparation

 Disconnect the voltmeter power supply cables.

 Connect Severker 760 with the voltmeter as below:-
 206


 Set the Severker on AC output voltage.
 Give AC supply to testing set.
 207

Procedure

 Let the meter rated voltage 380V AC full scale display (FSD) is 500V AC.
 Inject 25% of rated voltage (95V) in meter by SEVERKER 760 or Freja300 and note the injected and
measure voltage values.
 Similarly inject 50% (190V), 75% (285V), 100% (380V), 120% (456V) and FSD 500V note the injected
and measured voltage.
 Calculate the %age error by formula= (Injected voltage-measured voltage / Injected voltage) x100
Acceptable criteria
Acceptable criteria depends on meter class, If the meter is class.1 than % age error must be < ±1%,if 1.5
than< ±1.5%.
Sample test record

%age of Injected voltage Measured

%Error Criteria Remarks
Volts (d) Voltage (c)

25% 95 94.5 -0.52

50% 190 190 0

75% 285 284 -0.35 % Error=[ (c-d)/d ]*100
Class 1.0=±1%
100% 380 381 0.26
120% 456 457 0.22
FSD 500 501 0.2

(b) Analogue DC Voltmeter

Procedure

 The testing procedure of dc voltmeter is same as AC voltmeter except select testing set output
voltage to dc.
 Make sure set +ve cable should be joined with +ve meter and –ve with –ve of meter.
 Test record of 150V FSD and rated voltage 120VDC is as under:-
 208

Sample test record

%age of Injected voltage Measured

%Error Criteria Remarks
Volts (d) Voltage (c)

25% 30 30 0

50% 60 60 0
75% 90 90 0 % Error=[ (c-d)/d ]*100
Class 1.0=±1%
100% 120 120 0
120% 144 145 0.69
FSD 150 152 1.33

Calibration test of AM meters

(a) Analogue AC AM meter
Purpose
To verify measuring accuracy of AM meter.
Most of AM meters are operated by CT having some ratio.
This test is done on 0%,25%,50%,75% ,100%,120% of rated secondary current.

Procedure

 This meter is operated by a CT ratio same as meter ratio.

 209

 Let the meter CT ratio is 150/5A, full scale display (FSD) is 180A.
 Inject 25% of rated secondary current 5x25%= (1.25A) in meter by SEVERKER 760 or Freja300 and
note the injected and measured current values.
 The reading on meter should be 150x25%=37.5A
 Similarly inject 50% (2.5A), 75% (3.75A), 100% (5A), 120% (6A) and note the injected and measured
current values.
 Calculate the %age error by formula= (expected current- Injected current / expected current) x100
Acceptable criteria
Acceptable criteria depends on meter class, If the meter is class.1 than % age error must be < ±1%,if 1.5
than< ±1.5%.
Sample test record

%age of Measured current Expected current

Injected current %Error Criteria Remarks
sec.current (c) (d)

25% 1.25A 37 37.5 -1.33

50% 2.5A 73.5 75 -2

% Error=[ (c-d)/d ]*100
Class 2.5=±2.5%
75% 3.75A 110.5 112.5 -1.77
100% 5A 148 150 -1.33
120% 6A 178 180 -1.11

(a) Analogue DC Ammeter

Procedure

 DC Ampere meters works on mV given by the shunt connected in series with the power circuit.
 Let the meter scale shows data class 2.5, 100A/60mV, this means if voltage drop in shunt is 60mV
than the reading on Ampere meter will be 160A.

 We will inject 25% of 60mV,60*25%=15mV than the reading on meter should be 160x25%=40A
 210

 Similarly inject 50% (30mV), 75% (45mV), 100% (60mV), and 120% (72mV) and note the injected and
measured current values.
Sample test record

%age of Measured current Expected current

Injected volts %Error Criteria Remarks
sec.mV (c) (d)

25% 15mV 39 40 -2.5

50% 30mV 79 80 -1.25 % Error=[ (c-d)/d]*100

Class 2.5=±2.5%
75% 45mV 118 120 -1.66
100% 60mV 158 160 -1.25

(2) VT operated High voltage Volt meters testing

(a) Analogue VT operated Voltmeter
Purpose
To verify measuring accuracy of voltmeter.
To verify that meter can work on specified line or bus bar voltage.
This test is done on 0%,25%,50%,75% ,100%,120% of rated voltage and full scale display (FSD) of
meter.
Test Equipment
Freja 300 as it can inject 3 phase voltage, connection cables, AC supply
Preparation

 Let the available data on voltmeter is as under:-

1. PT ratio=380kV/ √3/110/√3
From above information 380kV Phase to phase and 380/√3 =220kV phase to ground primary voltage
110V Phase to phase and 110/√3 =63.5 phase to ground secondary voltage
2. Frequency=60Hz
3. Class=1
4. Full scale display (FSD)=456kV
 Disconnect the voltmeter power supply cables.
 As this meter is tested by injecting VT secondary voltage it is also called meter secondary injection
test.
 Connect Freja 300 with the voltmeter as below:-
 Give AC supply to testing set.
 In 1st page of set the two phase voltage 64.3,64.3 and frequency 60Hz.
Procedure

 As VT secondary rated voltage written on the meter is 110V ph-ph or three phase, 25 % will be
110x25%=16.13V.
 Go to 1st page of Freja 300 and select 16.13V on each phase and then press start button of Freja 300.
 211

 Note the Ph-Ph and Ph-G voltage appeared on kV meter, it should be 380x25%=95kV Ph-Ph and
95/√3=54.5kV Ph-G or single phase.
 Similarly inject 50% (55V), 75% (82.5V), 100% (110V), 120% (132V) of rated secondary voltage and
note the injected and measured voltage values.
 Calculate the %age error by formula= (expected voltage- Injected voltage / expected voltage) x100
(b) Digital VT operated AC Voltmeter
Procedure

1. The preparation & procedure of digital meter testing is same analogue meters.
(3) Digital Power demand meter (DPDM) testing
Digital Multifunction are widely used now a days as they provide the full metering information of Current,
voltage, power factor, frequency and Power as well. These meters can also be connected to PCC trough
SCADA or SAS for remote monitoring.

These meters need only CT & VT inputs of the system.

Purpose
To verify measuring meter accuracy.
This test is done on 0%,25%,50%,75% ,100%,120% of rated voltage and full scale display (FSD) of
meter.
Test Equipment
Freja 300 as it can inject 3 phase voltage, connection cables, AC supply
Preparation

 Let the available data on DPDM is as under:-

1. Meter CT Ratio=3000/1 A.
2. Meter VT ratio=380000/ √3/110/√3.
3. Accuracy class= 0.5
 Disconnect the meter from all inputs/outputs.
 Ground the testing set.
 Give AC supply to testing set and switch On the power button.
 Connect Freja 300 with the voltmeter as below:-
 212

Procedure

 First give AC/DC 120V Auxiliary supply to meter with Freja300.

Voltage measurement test

 Go to freja300 Mode1 1st page of 7 and set voltage 25% of rated secondary voltage i.e 110*25/√3=15.8
V for each phase.
 Press the start button of Freja 300.
 Note the primary voltage between Ph-Ph and each phase-G appeared on meter display
 Similarly inject 50%, 75%, 100% and 120% of meter rated secondary voltage and note the primary
values of voltage appeared on meter.
 Calculate the %age error and compare with manufacturer provided limit.

Sample test record

Measured voltage Measured voltage
Expected Ph- %Error=(c-d)x100/d
%age of (c) (c) Expected Ph-N
Injected Ph Voltage
rated Voltage (kV)
volts (V) (kV)
sec.voltage L1-N L2-N L3-N L1-L3 L2-L3 L1-L2 (d) L1-L3 L2-L3 L1-L2 L1-N L2-N L3-N
(d)

25% 15.88 54 54 54 94 94 94 95 54.85 -0.2 -0.4 -0.2 -0.18 -0.18 -0.18

50% 31.76 110 109 110 192 191 191 190 109.7 0.4 0.2 0.2 0.06 -0.15 0.06
75% 47.63 164 165 164 287 285 286 285 164.55 -0.4 0 0.2 -0.12 0.09 -0.12
100% 63.51 219 220 219 381 380 382 380 219.4 0.2 0 0.4 -0.08 0.13 -0.08
120% 76.21 264 263 264 455 455 455 456 263.28 -0.2 -0.2 -0.2 0.02 -0.06 0.02
 213

Current measurement test

 In freja300 Mode1 1st page of 6 and set current 25% of rated secondary current i.e 1*25/ 100=0.25A for
each phase.

 Press the start button of Freja 300.

 Note the primary current value of each phase displayed on meter.
 Similarly inject 50%, 75%, 100% and 120% of meter rated secondary current and note the primary
values of current appeared on meter.
 Calculate the %age error and compare with manufacturer provided limit.

Sample test record

Actual reading Expected reading
Injected (d) (c)
%age of rated
current in %Error=(c-d)x100/c Manufacurer limit
sec.current
phase (A) A-phase B-phase C-phase A-phase B-phase C-phase

25% 0.25 749.5 748.5 749.5 750 750 750 0.0667 0.2 0.066667

50% 0.5 1498.5 1499.5 1497.5 1500 1500 1500 0.1 0.0333 0.166667
75% 0.75 2245 2248 2249 2250 2250 2250 0.2222 0.0889 0.044444 ±0. 17

100% 1 2999 2999 3000 3000 3000 3000 0.0333 0.0333 0

120% 1.2 3595 3597 3597 3600 3600 3600 0.1389 0.0833 0.083333

Active, Reactive and Apparent Power measurement test

 This test is done by injecting rated secondary voltage/current and changing the phase angle only i.e
0°,45°,90°,135°,180°,270° and 315°
 In freja300 Mode1 1st page of 6 and set current 1A and voltage 63.5V for each phase.
 Make the angle between U&I 0°.

 Press the start button of Freja 300.

 Note the all power MW,MVAR and MVA readings appeared on meter.
 Similarly change only the phase angle 45,0,135,180,270,315 and note the values of power appeared on
meter.
 214

 Find the calculated value by using formulas below:-

Active Power=√3 V I Cosø =1.732x380000x3000xCos0° / 106=1974.48MW
Reactive Power =√3 V I Sinø=1.732x380000x3000xSin0° / 106 =0MW
Apparent Power= √3 V I= 1.732x380000x3000 / 106 =1974 MVA
 Calculate the %age error on each angle and compare with manufacturer provided limit.

Sample test record

MW MVAR MVA
Injected
Injected
current in Phase angle
volta
phase (A) Calculated Measured %age Error Limit Calculated Measured %age Error Limit Calculated Measured %age Error Limit

63.5 1 0° 1972.2 1973 -0.04 0 0 0 1974 1973 0.05

63.5 1 45° 1394.54 1396 -0.1 1393 1394 -0.07 1974 1973 0.05
63.5 1 90° 0 0 0 1972.2 1974 -0.09 1974 1973 0.05
63.5 1 135° -1394.54 -1394 0.03 ±0.2% 1394.5 1390 0.32 ±0.5% 1974 1973 0.05 ±0.2%

63.5 1 180° -1972.2 -1972 0.01 0 0 0 1974 1973 0.05

63.5 1 270° 0 0 0 -1972.2 -1972 0.01 1974 1973 0.05
63.5 1 315° 1394.54 1395 -0.03 -1394.54 -1393 0.11 1974 1973 0.05

Energy measurement test

 The procedure and preparation of this test is same as power measurement test except the
current/voltage is injected for specified time.
 Adopt the same procedure as in power measurement test and injection should be made i.e for 05
minutes on each angle.
 Note the reading of MWH and MVARH after 05 minutes displayed on meter screen.
 Calculated power can be find using same power formula only multiply with time:-
Active Energy =√3 V I Cosø x time =1.732x380000x3000xCos0° / 106=1974.48MW x5/60=164.5MWH
Reactive Energy =√3 V I Sinø x time

Sample test record

MW MVARH
Injected
Injected
current in Phase angle
volta
phase (A) Calculated Measured %age Error Limit Calculated Measured %age Error Limit

63.5 1 0° 164.5 164 0.33 0 0 0

63.5 1 45° 116 115 0.86 116 116 0

63.5 1 90° 0 0 0 ±0.2% 164.5 164 0.33 ±0.5%
63.5 1 135° -116 -116 0 -116 100
63.5 1 180° -164.5 -164 0.33 0 0 0
63.5 1 270° 0 0 0 -164.5 -164 0.33

Frequency measurement test

This test is done by injecting the rated voltage in the meter and changing the frequency.

Compare the injected frequency with the measured frequency on meter.

 215

Sample test record

Injected Injected Eppected

Actual Reading % error
volta Frequency (Hz) Reading

63.5 45 45 45 0

63.5 50 50 50 0
63.5 55 55 55 0
63.5 60 60 60 0
63.5 65 65 65 0

Power factor measurement test

 This test is performed by injecting rated voltage and changing the phase angle from 0 to 180°.

Sample test record

Injected
Injected Expected
current in Phase angle Expected PF=Cos Actual Reading % Error
volta Reading
phase (A)

63.5 1 0° 1 1 1 0

63.5 1 30° 0.866 lag 0.866 lag 0.866 lag 0.69

63.5 1 60° 0.5 lag 0.5 lag 0.5 lag 0
63.5 1 90° 0 1 2 0
63.5 1 120° 0.5 lead 0.5 lead 0.5 lead 0
63.5 1 150° 0.866 lag 0.866 lag 0.866 lag 0.69

(4) Digital Energy meter testing

Purpose
To verify measuring accuracy of meter.
Test Equipment
Digital accuracy meter i.e. ZERA, Connection leads, Freja 300, AC supply, calculator, stop watch..
Preparation

 Digital energy meter are fully programmable through software usually by the manufacturer.
 Install the manufacturer provided software in computer/laptop.
 Give Auxiliary supply to energy meter and calibration meter.
 Connect the energy meter with laptop and then open meter main menu enter your system data i.e
CT/PT ratios, limits and items to be displayed in various columns of meter programme.
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 After entering your desired value in each card click OK and then save the settings.
 Enable the meter in Test mode.

 Let the available data on energy meter is as under:-

1. Meter CT Ratio=3000/1 A.
2. Meter VT ratio=380000/ √3/110/√3.
3. Accuracy class= 0.5
4. Meter M.F=1000
 Connect the energy meter, accuracy meter (ZERA) and Freja 300 as under:-

Procedure
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Voltage/current measurement test

 This test is done on rated secondary voltage and current or any other values.
 Set Freja 300 1St page of 6 voltage on each phase 63.5Vand current 1A, frequency 60Hz and then
press the button under start to start the test.
 Scroll the meter display and note the measured current/voltage values.
Sample test record
%Error=(c-d)/c x100

Injected values V-AN V-BN V-CN IA IB IC

V-AN V-BN V-CN IA IB IC Accuracy

Injected values 63.5 63.5 63.5 1 1 1

Expected values-c 219.39 219.39 219.39 2000 2000 2000 0.03191 0.0283 0.02826 0.15 0.15 0.2 ±0.2%

Measured values-d 219.32 219.328 219.328 1997 1997 1996

Minimum operating current test

 Minimum operating current test is done as per meter data i.e 10mA=10/100 or 0.1A for pulse
indication.
 Set 3 phase voltage 63.5v and current 0.1A on Freja 300 and then start the set.

 Check the meter pulse LED is glowing after specified time.

Creep test
Inject 3 phase rated secondary voltage 63.5V with zero current in the meter for 05 minutes (more than
pulse time) there should be no pulse indication.
Sample test record

Injected sec.voltage-3Ph Injection time Pulse indication

63.5V 05 minutes No Pulse indication

Frequency measurement test

 Inject rated secondary voltage 63.5V in each phase, frequency 50Hz or 60Hz with zero current in the
meter and note the measured frequency of meter.
Sample test record
Injected voltage values 63.5 63.5 63.5

Injected frequency values-c 59 60 61

±0.2%
Measured frequency values-d 58.99 59.99 60.99
%age Error 0.016 0.016 0.016
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Active/Reactive Energy measurement test

 Inject rated secondary voltage 63.4V and rated current 1A through Freja 300 and only change their
phase angle.
 Injection time for each reading may be 05 minutes or as per requirement.
 First note the meter reading MWH/MVARH (Delivered), MWH/MVARH (Received) at 0°.
 Similarly note the readings by changing the angles only 30°,45°, 60°,90°,135°,180°,270° .

Sample test record

MWH MVARH
Injected
Injected Phase
current in Time P.F P.F
volta angle Standard meter Standard meter
phase (A) Calculated Measured %age Error Limit Calculated Measured %age Error Limit
reading reading

63.5 1 0° 05 minutes 1 109.69 (Del) 109.51 109.5 0.17 0 0 0 0 0

63.5 1 30° 05 minutes 0.866 94.99 (Del) 94.98 94.97 0.02 0.5 54.84 (Del) 54.85 54.71 0.02

63.5 1 60° 05 minutes 0.5 54.84 (Del) 54.7 54.71 0.02 ±0.2% 0.866 94.99 (Del) 94.98 94.97 0.02 ±0.2%
63.5 1 90° 05 minutes 0 0 0 0 0 1 109.69 (Del) 109.68 109.5 0.17
63.5 1 180° 05 minutes -1 109.69 (Rec) 109.52 109.5 0.17 0 0 0 0 0
63.5 1 270° 05 minutes 0 0 0 0 0 -1 109.69 (Rec) 109.6 109.5 0.17

Meter Accuracy test

Meter accuracy test is one by injecting meter rated secondary voltage and at 10%, 100% rated
secondary voltage.
Sample test record

Injected Injected current Energy measurement

Phase angle
volta in each phase (A) Accuracy

63.5 0.1 0° -0.04

63.5 1 0 -0.05
63.5 0.1 90° -0.04
63.5 1 90° -0.04
63.5 0.1 180° -0.05
63.5 1 180° -0.05
63.5 0.1 270° -0.03
63.5 1 270° -0.04

Pulse test

 This test is done to count the number of pulses per KWH.

 Check the manufacturer provided data No. of pulses per KWH or MWH.
 Fix the manufacturer provided pulse counter in front of infrared pulse indicator.
 Inject rated voltage or current in meter i.e 63.4V,1A in each phase.
 Note the no. of pulses per KWH and compare with manufacturer data.
(5) Transducer testing
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(a) Current transducer testing

Purpose
To verify measuring accuracy of transducer
Test Equipment
Current injection set i.e Freja 300, Multi meter, AC supply.
Preparation

 Note the input and output current of transducer.

 Input current is usually in Ampere and output in mill ampere.
 Make connection as under:-
 This test is done same as AM meter by injecting 0,25,50,75 and 100% of input current of transducer.
Procedure

Let the input current to transducer is 1A.

Inject 25 % of 1A i.e 0.25A and measure the output current in mA.
Calculate the %age error in measured and expected value and compare with manufacturer provided
data.