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I MEHUL MORWAL of 8th SEM Electrical student hereby declare that this written submission
represents my ideas in my own words and where others’ idea or words have been included, I
have adequately cited and referenced the original sources. I also declare that I have adhered to all
principles of academic honestly and integrity and have not misrepresented or fabricated or
falsified any idea / data / fact / source in our submission. I understand that any violation of the
above will be cause for disciplinary action by the PANDIT DEENDAYAL PETROLEUM
UNIVERSITY and can also evoke penal action from the sources which have thus not been
properly cited or from whim proper permission has not been taken when needed.
____________________
(Signature)
____________________
(Name of Student)
____________________
(Roll No.)
Date:
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CERTIFICATE
This is to certify that the Report entitled ‘Testing of HT and LT panels and
equipments used in it’ is submitted by Mehul Morwal (15BEE054)
towards partial fulfilment of the requirements for the award of degree in
Bachelor of Technology in the field of Electrical Engineering of Pandit
Deendayal Petroleum University is the record of work carried out by him
under our supervision and guidance. The work submitted has in our opinion
reached a level required for being accepted for examination. The results
embodied in this project work to the best of our knowledge have not been
submitted to any other University or Institution for award of any degree or
diploma.
Sign:
Date: ___________________
(Lecturer)
Gandhinagar
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ACKNOWLEDGEMENT
It gives me great pleasure and deep satisfaction in presenting the final report towards the fulfilment
of Comprehensive Project in Gayatri Electric Projects Pvt. Ltd.
I am extremely grateful to the company for giving me this opportunity to carry out my
Comprehensive Project which plays a major role for my Bachelor’s Degree. I feel deeply honoured
in expressing my sincere thanks to my industry mentor Mr. Krunal B. Patel (Technical General
Manager, Gayatri Electric), for making the resources available at right time, providing valuable
insights and for his constant guidance, valuable suggestions and continuous encouragement which
led to the accomplishment of this Project.
I would like to express my sincere gratitude to several people with whose help and encouragement,
I have been able to complete this project successfully.
I express my gratitude to my College Guide Mrs. Leena Santosh (Lecturer, PDPU) who gave his
valuable time and assisted me in compiling this project.
I am also thankful to Dr. JG Jamnani (Head of Department of Electrical Engineering) and all the
other staff members for their immense corporation and motivation for completing out the project.
I am also very grateful to my parents for their constant and loving support. Finally, I also wish to
express a word of thanks to all my fellow colleagues and all those directly or indirectly involved in
the project for their help and cooperation.
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ABSTRACT
The aim of the project was to go through the testing procedure for circuit breakers, relay, current
transformer, potential transformer, cables and busbars and then perform the final testing of the panel
before dispatching.
The testing of protection equipment schemes presents a number of problems. This is because the
main function of protection equipment is solely concerned with operation under system fault
conditions, and cannot readily be tested under normal system operating conditions. This situation is
aggravated by the increasing complexity of protection schemes and use of relays containing
software. So, after solving each problem stages by going through various attempts and several
results I tried to get the required results for each test.
The testing of protection equipment may be divided into four stages: type tests, routine factory
production tests,commissioning tests, periodic maintenance tests out of which the tests which are
performed at the industry level i.e. by routine factory tests are discussed in this report in detail.
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LIST OF CONTENT
CH 1: TESTING OF CIRCUIT BREAKER 8
1.1 Type test on circuit breaker 8
1.2 Routine tests on circuit breaker 11
CH 2: TESTING OF RELAYS 15
2.1 Electrical production type Tests on Relay 15
2.2 Electromagnetic compatibility test on relay 17
2.3 Product safety type test on relay 22
2.4 Environmental type test 23
CH 3: TESTING OF CURRENT AND POTENTIAL TRANSFORMER 26
3.1 Testing of Potential Transformer 26
3.1.1 Insulation resistance test 26
3.1.2 Polarity Test 28
3.1.3 Ratio Test 29
3.1.4 Partial Discharge Test 30
3.2 Testing of Current transformer 31
3.2.1 Insulation Resistance Test 31
3.2.2 CT Polarity Test 31
3.2.3 CT Ratio Test 33
3.2.4 Excitation Test 35
3.2.5 Burden Test 37
CH 4: TESTING OF BUSBARS AND POWER CABLES 40
4.1 Testing of Busbars 40
4.1.1 Temperature rise test 40
4.1.2 Rated short time and momentary current test 40
4.1.3 High voltage test 40
4.1.3.1 Power frequency voltage test 40
4.1.3.2 Impulse voltage test 41
4.1.4 Vibration test 42
4.2 Testing of Cables 42
4.2.1 Acceptance Tests at Works 42
4.2.2 Tests on Pressurised Cables 46
Conclusion 49
References 50
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LIST OF FIGURES
Page 6
LIST OF TABLES
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CH 1: TESTING OF CIRCUIT BREAKER
Type tests are organised with the aim of proving the abilities and making sure the rated
characteristic of the circuit breaker are exact. Such tests are conducted in the specially built testing
laboratory.
i. The circuit breaker must be smoothly operated at maximum as well as minimum allowable
auxiliary and control circuit supply voltage. Closing and tripping operation should be performed
at least 5 times for specified maximum allowable control circuit supply voltage as well as
specified minimum allowable control circuit supply voltage.
ii. The closing and opening operation of circuit breaker are also to be checked for rated supply
voltage of control circuit.
iii. 110% of control voltage is taken as maximum limit for closing and opening operation of circuit
breaker.
iv. 85% of control voltage is taken as minimum limit for closing operation of circuit breaker and
70% of control voltage is taken as minimum limit for opening or tripping operation of circuit
breaker.
v. During maximum and minimum control voltage operation it would be found that operating
times are less and more respectively than that in rated control voltage but all the times should be
within specified times limits.
vi. If it is applicable, such as in the case of pneumatic circuit breakers, the breaker should also be
operated at least 5 times in specified maximum allowable operating pressure, in specified
minimum allowable operating pressure and in specified rated operating pressure.
vii. A circuit breaker is also intended for rapid auto reclosing; at least 5 open close operating cycles
should be checked against specification given on the rating plate.
viii.The actual time interval between open and close operations should be tallied with the time
interval given in the operating cycle specification.
ix. When the circuit breakers are shipped as separate units and reassembled at site, the
manufacturer should participate in commissioning test to give confirmation about compatibility
of such separate units and components when assembled as a complete circuit breaker.
x. For all required operation sequences, the test should be conducted and all closing and opening
operating times along with intervals between two conjugative operations are recorded.
xi. Where applicable, the measurements of fluid compression (pressure difference) during circuit
breaker operation are also recorded.
xii. No load operating cycle can be performed on the circuit breaker to draw the no-load travel
curve. The curve should be within the prescribed envelope of the reference mechanical travel
characteristics.
The parameters should be measured and recorded during operation test of circuit breaker, are
given below:
When sub assemblies of circuit breaker are fitted together at site, the mechanical travel
characteristics of the breaker should confirm the correctness at the end of the commissioning test
on site. If this is done on-site, the manufacturer should prescribe the exact procedure of doing that
otherwise the result may be different and the comparison of the instantaneous contact stroke may
be impossible to achieve. The mechanical travel characteristics of circuit breaker contacts are
produced by using travel transducer or similar device connected to the circuit breaker contacts
mechanism.
In addition to this, each connection in the control and auxiliary circuit in the circuit breaker should
be checked. It should also be checked whether control and/or auxiliary switches correctly indicate
the open and close position of circuit breaker. All auxiliary equipments should also be operated
correctly and smoothly for specified maximum and minimum allowable control voltage supply.
b. Thermal Test
Thermal tests are carried out to check the thermal behaviour of the circuit breakers. The breaker
under test deal with the steady-state temperature rises due to the flow of its rated current through
its pole in a rated condition. The temperature rise for rated current should not exceed 40° for
current less than 800A normal current and 50° for normal value of current 800A and above.
c. Dielectric Test
These tests are performed to check power frequency and impulse voltage withstand
capacity. Power frequency tests are kept on a new circuit breaker; the test voltage
changes with a circuit breaker rated voltage.
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The test voltage with a frequency between 15-100Hz is applied as follows:
(1) between poles with circuit breaker closed
(2) between pole and earth with circuit breaker open, and
(3) across terminals with circuit breaker open.
In impulse tests impulse voltage of specified magnitude is applied to the breaker. For outdoor
circuit dry and wet tests are conducted.
d. Short-Circuit Test
Circuit breakers are subjected to sudden short-circuits in short-circuit test laboratories, and
oscillograms are taken to know the behaviour of the circuit breakers at the time of switching in,
during contact breaking and after the arc extinction.
i. In order to test the circuit breakers at different voltages and at different short circuit currents,
short circuit laboratories are provided.
ii. The schematic layout of a short circuit testing laboratory is given in Figure 2. It consists of a
short circuit generator in association with a master circuit breaker, resistors, reactors and
measuring devices.
iii. A make switch initiates the short circuit and the master circuit breaker isolates the test device
from the source at the end of a predetermined time set on a test sequence controller. Also, the
master circuit breaker can be tripped if the test device fails to operate properly. Short circuit
generators with induction motors as prime movers are also available.
The oscillograms are studied with particular reference to the making and breaking currents, both
symmetrical and asymmetrical re-striking voltages, and switchgear is sometimes tested at rated
conditions.
• Making test : The sequence will be C-t-C where the operating sequence will be O- t-CO-- CO
at 100% rated current
• Breaking tests : The sequence will be O-t-O-t-O where the operating sequence will be O-t-
CO-t– CO at 100% breaking current
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e. Short time current test
i. Test 1 : This test duty is in O-t- OC sequence in three phase circuit having symmetrical and
peak currents not less than 100% of its rated value along with fuses connected.
ii. Test 2: This test duty is in O-t- OC sequence in three phase circuit value along with fuses
connected current is passed for producing max. arc energy within the fuse links to demonstrate
the switch gear is capable of withstanding the max. Energy.
iii. Test 3: This test comprises of one O-operation on an outer pole and repeated on other outer pole
with fuse links fitted in all poles in a single phase circuit rated short circuit breaking current to
verify that the complete switch gear is capable of withstanding the cutoff currents of fuse links.
Routine tests are done as per references of standards of Indian Engineering Service and Indian
Standards. These tests are performed on the manufacturers’ premises. Routine tests confirm the
proper functioning of the circuit breaker. The routine tests confirm the proper functioning of the
circuit breaker. Routine testing doesn’t necessarily include complex gear in order to ensure that a
circuit breaker is functional. Some guidelines and recommendations for these tests include routine
maintenance and verifying that that circuit breaker performance is in line with manufacture’s
calibration curves. It is crucial that these tests are performed under stable conditions at suitable
temperature so that there are no variations in the data. Some of the tests are listed below.
The power system may experience different temporary power over voltage conditions may be due
to sudden cut of load from the system, wrong operation of online tap changer, insufficient shunt
compensation in the system, etc. Power frequency over voltage withstand test of circuit breaker is
performed to verify sufficiency of insulation strength of the main circuit to withstand this kind of
abnormal over voltage conditions of the system. The circuit breaker should also be designed to be
capable of withstanding over voltages due to lightning and switching impulses. A circuit breaker
like other costly engineering equipment, are designed for safely facing all kind of abnormal
situations, but at the same time, the designers cannot sacrifice economical aspects.
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To verify the capability of withstanding all kinds of over voltages conditions without sacrificing the
economical aspects of manufacturing, a circuit breaker has to go through and pass different
dielectric tests. But only power frequency over voltage withstand test comes under the category of
routine test of circuit breakers.
Power frequency
high voltage
i. Here normally top of all poles of all circuit breakers of same voltage rating to be tested, are connected
together preferably by copper conductor.
ii. This connection then is earthed properly.
iii. Similarly base of all circuit breakers under test is to be properly connected to earth.
iv. The bottom of all poles of all circuit breakers under test, are connected together preferably by copper
conductor.
v. This connection then is connected to the phase terminal of single phase high voltage cascaded
transformer. High voltage transformer used here is a cascaded auto transformer where input voltage can
be varied from zero to several hundred volts and corresponding secondary voltage would be zero to
several hundred kilo volts.
vi. During test the voltage is applied at the button terminal of breakers by high voltage cascaded
transformer, and varied from 0 to specified value slowly and gently then stay there for 60 second and
then slowly decreased to zero.
vii. During test the leakage current to the ground to be measured and the leakage current should not cross the
specified maximum allowed limit.
viii. Any failure of insulation during test indicates the insufficiency of insulation used in breaker.
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b. Impulse withstand test
This tests is especially important whenever changing from one polarity to the opposite to remove
and reverse the charge that builds up on the floating shield during the testing at one polarity. Any
disruptive discharges that occur in the preliminary trials at less that rated voltage are not counted in
the statistics for pass/fail determination at the rated impulse voltage.
Normal wear and tear of contacts within the CB emerges after extended usage. An easy method to
identify traces of weakening within the circuit breaker is to quantify the resistance across every pole
of the breaker. Indications of abnormal conditions within the CB such as erosion and contamination
of contacts are evident if there are excessive millivolt drops across the breaker. The contact
resistance test is important in finding out if or not a circuit breaker is still apt for functioning.
i. The resistance of main circuit is measured from DC voltage drop across the circuit.
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ii. In this test, direct current is injected to the circuit and corresponding voltage drop is measured
and from this resistance of the circuit is measured.
iii. The injected current would be from 100 A to maximum rated current of the circuit breaker.
iv. The maximum measured value can be 1.2 times the value obtained at the temperature rise test.
Overload tripping components of CB’s can be tested by inputting 300% of the breaker rating into
each pole of the circuit breaker to determine that it will open automatically. The motive of this is to
make sure that the circuit breaker will operate or not. Refer to NETA standards for trip times that
are acceptable for the overload tripping test. When trying to find out tripping characteristics, it is
advisable to consult with manufacturer’s manuals.
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CH 2: TESTING OF RELAYS
2.1 Electrical production type Tests on Relay
The standards that cover most aspects of relay performance are IEC 60255 and ANSI C37.90.
However compliance may also involve consideration of the requirements of IEC 61000, 60068 and
60529, while products intended for use in the EEC also have to comply with the requirements of
Directives 89/336/EEC and 73/23/EEC.
a. Functional test
The functional tests consist of applying the appropriate inputs to the relay under test and measuring
the performance to determine if it meets the specification. They are usually carried out under
controlled environmental conditions. The testing may be extensive, even where only a simple relay
function is being tested.
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b. Rating test
Rating type tests are conducted to ensure that components are used within their specified ratings
and that there are no fire or electric shock hazards under a normal load or fault condition of the
power system. This is in addition to checking that the product complies with its technical
specification. The following are amongst the rating type tests conducted on protection relays, the
specified parameters are normally to IEC 60255-6.
The thermal withstand of VT’s, CT’s and output contact circuits is determined to ensure compliance
with the specified continuous and short-term overload conditions. In addition to functional
verification, the pass criterion is that there is no detrimental effect on the relay assembly, or circuit
components, when the product is subjected to overload conditions that may be expected in service.
Thermal withstand is assessed over a time period of 1s for CT’s and 10s for VT’s.
The burdens of the auxiliary supply, optically isolated inputs, VT’s and CT’s are measured to check
that the product complies with its specification. The burden of products with a high number of
input/output circuits is application specific i.e. it increases according to the number of optically
isolated input and output contact ports which are energised under normal power system load
conditions. It is usually envisaged that not more than 50% of such ports will be energised in any
application.
The insulation resistance test is carried out according to IEC 60255-5, i.e. 500V d.c. ±10%, for a
minimum of 5 seconds. This is carried out between all circuits and case earth, between all
independent circuits and across normally open contacts. The acceptance criterion for a product in
new condition is a minimum of 100MΩ. After a damp heat test the pass criterion is a minimum of
10MΩ.
f. Relay Input
Relay inputs are tested over the specified ranges. Inputs include those for auxiliary voltage, VT, CT,
frequency, optically isolated digital inputs and communication circuits.
Protection relay output contacts are type tested to ensure that they comply with the product
specification. Particular withstand and endurance type tests have to be carried out using d.c., since
the normal supply is via a station battery.
Page 16
h. Auxiliary supplies
Digital and numerical protection relays normally require an auxiliary supply to provide power to the
on-board microprocessor circuitry and the interfacing opto-isolated input circuits and output relays.
The auxiliary supply can be either a.c. or d.c., supplied from a number of sources or safe supplies -
i.e. batteries, UPS’, generators, etc., all of which may be subject to voltage dips, short interruptions
and voltage variations. Relays are designed to ensure that operation is maintained and no damage
occurs during a disturbance of the auxiliary supply.
Tests are carried out for both a.c. and d.c. auxiliary supplies and include mains variation both above
and below the nominal rating, supply interruptions derived by open circuit and short circuit, supply
dips as a percentage of the nominal supply, repetitive starts. The duration of the interruptions and
supply dips range from 2ms to 60s intervals. A short supply interruption or dip up to 20ms, possibly
longer, should not cause any malfunction of the relay. Malfunctions include the operation of output
relays and watchdog contacts, the reset of microprocessors, alarm or trip indication, acceptance of
corrupted data over the communication link and the corruption of stored data or settings. For a
longer supply interruption, or dip in excess of 20ms, the relay self recovers without the loss of any
function, data, settings or corruption of data. No operator intervention is required to restore
operation after an interruption or dip in the supply. Many relays have a specification that exceeds
this requirement, tolerating dips of up to 50ms without operation being affected.
In addition to the above, the relay is subjected to a number of repetitive starts or a sequence of
supply interruptions. Again the relay is tested to ensure that no damage or data corruption has
occurred during the repetitive tests.
Specific tests carried out on d.c. auxiliary supplies include reverse polarity, a.c. waveform
superimposed on the d.c. supply and the effect of a rising and decaying auxiliary voltage. All tests
are carried out at various levels of loading of the relay auxiliary supply.
There are numerous tests that are carried out to determine the ability of relays to withstand the
electrical environment in which they are installed. The substation environment is a very severe
environment in terms of the electrical and electromagnetic interference that can arise. There are
many sources of interference within a substation, some originating internally, others being
conducted along the overhead lines or cables into the substation from external disturbances. The
most common sources are:
a. switching operations
b. system faults
c. lightning strikes
d. conductor flashover
e. telecommunication operations e.g. mobile phones
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A whole suite of tests are performed to simulate these types of interference, and they fall under the
broad umbrella of what is known as EMC, or Electromagnetic Compatibility tests.
This is a test to determine the maximum length of time that the relay can withstand an interruption
in the auxiliary supply without de-energising, e.g. switching off, and that when this time is exceeded
and it does transiently switch off, that no maloperation occurs.
The test is specified in IEC 60255-11 and comprises a interruptions of 2, 5, 10, 20, 50, 100 and
200ms. For interruptions lasting up to and including 20ms, the relay must not de-energise of
maloperate, while for longer interruptions it must not maloperate.
The relay is powered from a battery supply, and both short circuit and open circuit interruptions are
carried out. Each interruption is applied 10 times, and for auxiliary power supplies with a large
operating range, the tests are performed at minimum, maximum, and other voltages across this
range, to ensure compliance over the complete range.
This test (IEC 60255-11) determines that the relay is able to operate correctly with a superimposed
a.c. voltage on the d.c. supply. This is caused by the station battery being charged by the battery
charger, and the relevant waveform is shown in Figure 5. It consists of a 12% peak-to-peak ripple
superimposed on the d.c. supply voltage.
Page 18
c. High frequency disturbance test
The High Frequency Disturbance Test simulates high voltage transients that result from power
system faults and plant switching operations. It consists of a 1MHz decaying sinusoidal waveform,
as shown in Figure 6. The interference is applied across each independent circuit (differential mode)
and between each independent circuit and earth (common mode) via an external coupling and
switching network. The product is energised in both normal (quiescent) and tripped modes for this
test, and must not maloperate when the interference is applied for a 2 second duration.
The Surge Immunity Test simulates interference caused by major power system disturbances such
as capacitor bank switching and lightning strikes on overhead lines within 5km of the substation.
The test waveform has an open circuit voltage of 4kV for common mode surges and 2kV for
differential mode surges. The test waveshape consists on open circuit of a 1.2/50ms rise/fall time
and a short circuit current of 8/20ms rise/fall time. The generator is capable of providing a short
circuit test current of up to 2kA, making this test potentially destructive. The surges are applied
sequentially under software control via dedicated coupling networks in both differential and
common modes with the product energised in its normal (quiescent) state. The product shall not
maloperate during the test, shall still operate within specification after the test sequence and shall
not incur any permanent damage.
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e. Power frequency interference test
This test simulates the type of interference that is caused when there is a power system fault and
very high levels of fault current flow in the primary conductors or the earth grid. This causes 50 or
60Hz interference to be induced onto control and communications circuits.
There is no international standard for this test, but one used by some Utilities is:
a. 500V r.m.s., common mode
b. 250V r.m.s., differential mode
applied to circuits for which power system inputs are not connected.
Tests are carried out on each circuit, with the relay in the following modes of operation:
1. current and voltage applied at 90% of setting, (relay not tripped)
2. current and voltage applied at 110% of setting, (relay tripped)
3. main protection and communications functions are tested to determine the effect of the
interference
The relay shall not maloperate during the test, and shall still perform its main functions within the
claimed tolerance.
In this case the discharge is only ever applied to the front panel of the relay, with the cover both on
and off. Two types of discharges are applied, air discharge and contact discharge. Air discharges are
used on surfaces that are normally insulators, and contact discharges are used on surfaces that are
normally conducting. IEC 60255-22-2 is the relevant standard this test, for which the test
parameters are:
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Figure 7: ESD discharge waveform
These tests simulate the magnetic field that would be experienced by a device located within close
proximity of the power system. Testing is carried out by subjecting the relay to a magnetic field
generated by two induction coils. The relay is rotated such that in each axis it is subjected to the full
magnetic field strength. IEC 61000- 4-6 is the relevant standard, using a signal level of Level 5:
300A/m continuous and 1000A/m short duration.The test arrangement is shown in Figure 8.
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To pass the steady-state test, the relay shall not maloperate, and shall still perform its main functions
within the claimed tolerance. During the application of the short duration test, the main protection
function shall be exercised and verified that the operating characteristics of the relay are unaffected.
These tests simulate the magnetic field that would be experienced by a device located within close
proximity of the power system during a transient fault condition. According to IEC 61000-4-9, the
generator for the induction coils shall produce a 6.4/16µs waveshape with test level 5, 100A/m with
the equipment configured as for the steady state magnetic field test. The relay shall not maloperate,
and shall still perform its main functions within the claimed tolerance during the test.
These tests simulate the magnetic field that would be experienced by a device located within close
proximity of the power system during a transient fault condition. IEC 61000-4-10 specifies that the
generator for the coil shall produce an oscillatory waveshape with a frequency of 0.1MHz and
1MHz, to give a signal level in accordance with Level 5 of 100A/m, and the equipment shall be
configured as in Figure 8.
A number of tests are carried out to demonstrate that the product is safe when used for its intended
application. The essential requirements are that the relay is safe and will not cause an electric shock
or fire hazard under normal conditions and in the presence of a single fault. A number of specific
tests to prove this may be carried out, as follows.
Dielectric Voltage Withstand testing is carried out as a routine test i.e. on every unit prior to
despatch. The purpose of this test is to ensure that the product build is as intended by design. This is
done by verifying the clearance in air, thus ensuring that the product is safe to operate under normal
use conditions. The following tests are conducted unless otherwise specified in the product
documentation:
1. 2.0kV r.m.s., 50/60Hz for 1 minute between all terminals and case earth and also between
independent circuits, in accordance with IEC 60255-5. Some communication circuits are excluded
from this test, or have modified test requirements e.g. those using D-type connectors open contacts
intended for connection to tripping circuits, in accordance with ANSI/IEEE C37.90
3. 1.0kV r.m.s., 50/60Hz for 1 minute across the normally open contacts of watchdog or changeover
output relays, in accordance with IEC 60255-5
Page 22
The routine dielectric voltage withstand test time may be shorter than for the 1 minute type test
time, to allow a reasonable production throughput, e.g. for a minimum of 1 second at 110% of the
voltage specified for 1 minute.
Class 1 products that rely on a protective earth connection for safety are subjected to an earth
bonding impedance (EBI) type test. This ensures that the earth path between the protective earth
connection and any accessible earthed part is sufficiently low to avoid damage in the event of a
single fault occurring. The test is conducted using a test voltage of 12V maximum and a test current
of twice the recommended maximum protective fuse rating. After 1 minute with the current flowing
in the circuit under test, the EBI shall not exceed 0.1Ω.
1. Temperature Test
Temperature tests are performed to ensure that a product can withstand extremes in temperatures,
both hot and cold, during transit, storage and operating conditions. Storage and transit conditions
are defined as a temperature range of –25°C to +70°C and operating as –25°C to +55°C.
Dry heat withstand tests are performed at 70°C for 96 hours with the relay de-energised. Cold
withstand tests are performed at –40°C for 96 hours with the relay de- energised. Operating range
tests are carried out with the product energised, checking all main functions operate within
tolerance over the specified working temperature range –25°C to +55°C.
Page 23
2. Humidity Test
The humidity test is performed to ensure that the product will withstand and operate correctly when
subjected to 93% relative humidity at a constant temperature of 40°C for 56 days. Tests are
performed to ensure that the product functions correctly within specification after 21 and 56 days.
After the test, visual inspections are made for any signs of unacceptable corrosion and mould
growth.
3. Mechanical Tests
Mechanical tests simulate a number of different mechanical conditions that the product may have to
endure during its lifetime. These fall into two categories
Tests in the first category are concerned with the response to vibration, shock and seismic
disturbance. The tests are designed to simulate normal in-service conditions for the product, for
example earthquakes. These tests are performed in all three axes, with the product energised in its
normal (quiescent) state. During the test, all output contacts are continually monitored for change
using contact follower circuits. Vibration levels of 1gn, over a 10Hz-150Hz frequency sweep are
used. Seismic tests use excitation in a single axis, using a test frequency of 35Hz and peak
displacements of 7.5mm and 3.5mm in the x and y axes respectively below the crossover frequency
and peak accelerations of 2.0gn and 1.0gn in these axes above the crossover frequency.
Page 24
The second category consists of vibration endurance, shock withstand and bump tests. They are
designed to simulate the longer-term affects of shock and vibration that could occur during
transportation. These tests are performed with the product de-energised. After these tests, the
product must still operate within its specification and show no signs of permanent mechanical
damage. The waveform for the shock/bump test is shown in Figure 10.
Page 25
CH 3: TESTING OF CURRENT AND POTENTIAL TRANSFORMER
3.1 Testing of Potential Transformer
3. Connect the megohm meter to one terminal of the H side of the PT and the negative to one
side of the X side and to ground.
4. Increase the voltage slowly to the test voltage and wait for one minute. Monitor the
insulation resistance during the test to ensure that reading is not linear and does not increase
exponentially as the test voltage increases. Either condition could indicate insulation failure,
poor insulation, and/or improper test connections.
6. Use the insulation resistance compensation Table 1 to determine the equivalent insulation
resistance at 20degree celsius.
7. Check NETA ATS-99 Table to ensure the 20degree celsius equivalent resistance is not
lower than the specified value or compare results to previous test results. Ensure previous
results have been converted to equivalent 20degree celsius resistances.
8. Repeat steps 1 to 7 exchanging primary and secondary connections to include all the
following test for 2 and 3 winding PTs. Use Figure 1 diagrams to help you visualise the
connections.
• 2 Winding:
i. H-X&G
ii. X-H&G
• 3 Winding:
i. H-X&G (Guard Y)
Page 26
iii. X-H&G (Guard Y)
v. X-Y&G (Guard H)
Page 27
3.1.2 Polarity Test
Polarity test on each transformer to verify the polarity marks or H1-X1 relationship as
applicable. We describe the two polarity test methods available using the most basic equipment.
a. To test polarity using DC voltage, a lantern battery and a voltmeter with an analog scale is
required. Use the following steps for DC polarity testing as shown in Figure 2.
1. Connect the positive of the voltmeter to the marked terminal of the high voltage side of the
PT and the negative lead to the non-marked.
2. Calculate the expected voltage using the battery voltage and the PT ratio. (Battery voltage *
PT ratio) if the expected voltage exceeds the battery rating; switch the battery to the primary
side of the PT and voltmeter to the secondary side. Re-calculate the expected voltage and set
the voltmeter scale accordingly. (Battery Voltage / PT ratio)
3. Connect the negative terminal of the battery to the non-polarity of the PT winding under test.
Momentarily touch or connect the battery positive terminal to the polarity terminal of the PT
winding under test.
4. Closely watch the needle or analog scale of the voltmeter. It should jump in the positive
direction. This happens in a fraction of a second and the meter must be monitored very
closely. If the voltmeter kicks in the positive direction the polarity marks are correct and if it
kicks in the negative direction then the polarity marks are incorrect.
b. To test polarity using ac voltage; a variac and voltmeter are required. Use the following steps
to test for PT polarity using the AC method as shown in Figure 3.
3. Connect a voltmeter (VM2) from the polarity mark of the H side to the non-polarity mark of
the X side.
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4. Connect the non-polarity mark of the H side winding to the polarity mark of the X side
winding.
5. Increase the voltage to a known value. Calculate the expected value. ([VM1/PT ratio]+
[VM1]) if VM2 displays the expected result, the PT polarity markings are correct. If VM2 is
less than the expected result, the test connection or the PT polarity markings are incorrect.
(Note: VM1 and VM2 can be 1 voltmeter switching between positions if the test voltage
remains stable.)
3. Increase the voltage to the test voltage.(Typically an easy multiple of the PT ratio e.g. 35:1V
PT ratio=35V) Calculate the expected secondary voltage. (Test voltage / PT Ratio)
5. After the ratio tests have been completed, ensure that the connection is left as specified.
Note: Never energise the secondary winding and measure the primary winding as
dangerous voltages could be created.
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3.1.4 Partial Discharge Test
1. Detect the presence of any partial discharge in the insulators in the transformer this could
turn into a complete breakdown.
2. Verify that the transformer doesn’t exhibit partial discharge greater than specified magnitude.
3. Determine the voltage amplitude at which partial discharges of a specified low magnitude
commence with increasing and crease with decreasing voltage.
4. To determine the magnitude of the specified discharge quantity at a specified voltage.
5. Detect the presence of any partial discharge in the cooling oil transformer this is difficult to
detect except by conducting that test
Steps:
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Figure 14: Setup for partial discharge test
2. Primary to Earth : Connect the Test kit Red Lead to the Primary lead of the CT and Black
Lead to the Earth. If CT is on the Ground, the Black lead of the Test kit, be connected to the
Body of the CT. Start the Megger, with 5 KV Test Voltage and note down the Value.
3. Primary to Secondary: Connect the Red Lead of the Meggar to the CT Primary Stud and
connect the Black Lead to the CT Secondary. In case of a Connected CT, remove the
Secondary connections from the CT MK, and connect the Black Lead of the Meggar to the
each Secondary Core. Run the Test with 5 KV Test Voltage
4. Secondary to Earth: Red Lead of the Megger connected to each CT Core Secondary and
Black Lead is kept common to Earth. Run the Test with 1 KV Test Voltage.
5. Secondary to Secondary (Core to Core): Test Leads are connected between Secondary Wires
of two Cores. Test is carried out at 1 KV Voltage.
This is the tried and true method for testing CT polarity, used before electricity was discovered
by some accounts. For this test you need a 6 or 9 V lantern battery, a DC voltmeter or ammeter
(preferably analog), and test leads.
This method is a quick and easy test for polarity but there is a very small possibility that it may
saturate the CT. Always perform an excitation and/or saturation test after performing this test.
1. Connect the positive of the voltmeter to the marked terminal of the high voltage side of the
CT and the negative lead to the non-marked as shown in “Figure 4: CT DC polarity Test
Connections”
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(a) If the CT is enclosed within a breaker, close the breaker and connect your voltmeter across
the breaker poles. Review the CT drawing carefully, note the CT polarity, and Meter polarity.
(b) If the CT is enclosed within a generator, connect your voltmeter across the generator
windings. Review the CT drawing carefully and note the CT polarity and Meter polarity.
(c) If the star point is not accessible, connect the Voltmeter across 2 generator leads and short
the remaining generator lead to one of the generator leads under test.
(d) If the CT is enclosed within a transformer, connect your voltmeter across the transformer
bushings associated with the CT and short the remaining bushings to the non-polarity
bushing under test. Review the CT drawing carefully and note the CT polarity and Meter
polarity
1. Calculate the expected voltage using the battery voltage and the CT ratio. (Battery voltage /
CT ratio.)
2. Connect the negative terminal of the battery to the non-polarity of the CT winding under test.
Momentarily touch or connect the battery positive terminal to the polarity terminal of the CT
winding under test.
3. Closely watch the needle or analog scale of the voltmeter. It should jump in the positive
direction. This happens in a fraction of a second and the meter must be monitored very
closely. If the voltmeter kicks in the positive direction the polarity marks are correct and if it
kicks in the negative direction, the polarity marks are incorrect.
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3.2.3 CT Ratio Test
Perform a ratio-verification test using the voltage or current method in accordance with ANSI
C57.13.1 (IEEE Guide for Field Testing of Relaying Current Transformers).
The CT ratio test determines the CT accuracy and the results should be compared to the accuracy
class. The easiest and most accurate ratio test method for CT ratio is the voltage method for most
applications and is the method we will discuss here.
It may seem strange to use voltage to test a CT ratio, but basic transformer theory applies to all
transformers, including CTs. One of the first transformer fundamentals is that the transformer
ratio applies inversely to current and voltage.
A 400:5 CT will convert 400 primary amps to 5 secondary amps and convert 80 secondary volts
to 1 primary volt. We apply this principle to CT testing because it is easier to locate, carry, and
apply an 80V voltage source instead of a 400A current supply. The voltage method is also more
accurate because you can measure the test and resultant values directly instead of applying CT’s
1. Connect a voltage source (Variac) and voltmeter (VM1) across the CT secondary.
3. Apply a voltage to the CT secondary and measure the Secondary(VM1) and Primary
voltages (VM2) simultaneously. Calculate the ratio between the two voltages.(VM1 / VM2)
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Figure 17: Muti ratio CT AC ratio test connections
4. This voltage should match the CT ratio. (Pri / Sec). You can repeat the procedure above for
each tap of a multi-tap CT, but I prefer to treat the CT taps as I would an auto-transformer. I
apply a voltage across the maximum ratio tap and measure all remaining taps to a common
point as shown in “Figure 6 – Multi Ratio CT AC Ratio CT Test Connections.”
You can prove all tap combinations using the information recorded from this test.
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3.2.4 Excitation Test
Perform an excitation test on transformers used for relaying applications in accordance with
ANSI C57.13.1. (IEEE Guide for Field Testing of Relaying Current Transformers).
During normal operation, the CT operates as a nearly perfect machine with very small energy
losses necessary for CT operation. The magnetic theory involved in transformer operation is too
complex to address in this article but the magnetic circuit can be compared to a normal electrical
circuit (The primary winding “Generator”, iron core “transmission line”, and secondary winding
“load”.) During normal CT operation the Hi side winding (generator) supplies energy through
the iron core (transmission line) to the low side winding (load) with small losses in the
transmission line.
When a CT is “saturated”, the magnetic path inside the CT operates like a short circuit on the
transmission line. Almost all of the energy supplied by the primary winding is shunted way from
the secondary winding and is used create a magnetic field inside the CT. Saturated CT’s can be
very dangerous when used to supply protective relays as the CT’s may operate normally at low
current levels and not operate at all during fault currents.
The excitation test is used to prove that CT is not saturated and the CT will operate correctly at
the rated burden. It is important to remember when comparing test results to the burden rating
that the burden rating is a minimum value and the CT could actually have a higher rating. This
happens often in transformer bushing applications.
A saturation test is performed by applying an AC voltage to the CT secondary and increasing the
voltage in steps until the CT is in saturation. The test voltage is slowly decreased to zero to de-
magnetize the CT. The test results are plotted on a logarithmic graph and evaluated based on the
transition period between normal operation and saturation. This transition is called\the “knee” of
the curve and is directly related to the voltage burden rating of the CT.
3. Connect the test equipment as per “Excitation Test connection” to the first CT scheduled for
test.
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4. Slowly increase the voltage until saturation (We will use 1000 mA but saturation could be
higher or lower depending on CT construction). Watch the current and note the voltage
where the current increase begins to increase dramatically. Note the voltage where the
current reaches 1000 mA.
6. Determine your test voltages using 4 equal steps to the 1st noted voltage and in 6 equal steps
between the 1st noted voltage and the 2nd noted voltage at 1.0A.
7. Repeat the test using the voltage steps determined above and record the mA at each step.
NEVER decrease the voltage until the maximum test voltage is reached. You must either
skip the voltage step or re-start the test from 0 V if the voltage must be decreased to record
a result.
8. Slowly decrease the voltage to zero volts. If the voltage is turned off for any reason before
the test is complete, the CT may remain saturated. To de-saturate the CT, increase the
voltage to 1000mA and slowly decrease the voltage to zero.
9. Graph the results on a logarithmic graph and compare to manufacturers supplied results. See
“Excitation Test Results” to help evaluate the results.
10. Manufacturer’s results are often typical for a class of CT and each CT may not have been
tested. Because every CT has different operating characteristics, the results may not be
exactly the same. Look for similarities and glaringly obvious differences when evaluating the
results.
11. If manufacturer’s results are not available, the “knee” of the curve must be higher than the
rated burden voltage.
12. Repeat the test using the same test voltages for all CT’s of the same rating. Start from the
beginning for CT’s with another rating.
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Figure 20: CT excitation test graph
(i) Not energised with shorting devices installed if used for metering or protection.
This method is time consuming, but only requires a voltage source, a resistance, and a voltmeter.
The test consists of applying 5A through the secondary circuit with a known ground reference
at the source and measuring the voltage at every point of the circuit to ground.
Measuring the voltage drop at the source combined with ohms law will give us the burden
impedance. Analysing the voltage drop patterns throughout the circuit confirms the wiring is
correct.
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After all CT testing and secondary circuit wiring is complete, follow the following steps to
perform a secondary loop test via the voltage drop method.
1. Remove the CT secondary shorting devices and remove the ground from the circuit. Every CT
circuit should be grounded at ONE point only and have its own path to ground as per IEEE
standard C57.13.2. Many manufacturers incorrectly chain all CT grounds together contrary to
this standard.
2. Connect an AC source(A 120 V source and light bulbs in parallel or series can be substituted
for the AC source) between the CT secondary feeder (as close to the CT as possible) and ground
and slowly increase the voltage or current dial. No current should flow. If current flows, there is
second ground somewhere in the circuit that must be permanently removed.
3. Connect a temporary ground between the neutral of the test source and the CT star point.
Increase the source voltage until 5 amperes flows in the circuit. If no current flows, the ground is
incorrectly applied or the circuit is incomplete. Investigate possible sources of open circuit.
4. Measure the voltage between the first CT circuit terminal and ground. Multiply this number
with the measured current to obtain the VA burden. Divide the voltage by the current to
determine the burden in Ohms. Check the CT rating to ensure the burden is less than nameplate
value.
5. Measure the voltage between ground and every CT wiring connection. The voltage should
drop incrementally as you work through the circuit. Any rise in voltage should be immediately
investigated. The most common problems found are:
• Assuming what the terminal point should be instead of using drawing references.
7. After all the testing has been completed, the voltages consistently drop throughout the circuit,
and the measurements between phases are consistent; turn the AC source off and remove all test
leads. Reconnect the CT ground and check with an ohmmeter after it is installed. Record the
circuit burdens on your test sheet.
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CH 4: TESTING OF BUSBARS AND POWER CABLES
4.1 Testing of Busbars
Here, one of the 3 bus section in shorted to form a star point. The other end is connected to a
low voltage, high current testing transformer. The current is adjusted to rated current of busbar
by adjusting taps of transformer. Current balance is obtained by putting iron rings on busbar
carrying higher current than other 2 phases. Measurement of current is done by wound air-core
CT.
The rated short circuit current i.e 25 times normal rated current is passed through busbar for 1
second. One phase should have peak current of 2-5 times rated rms short circuit current during
1st peak. This is called momentary short circuit current
This test verifies the strength of insulators and conductors to withstand temperature rise and
mechanical forces during short circuit.
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Figure 23: Breakdown in insulators
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4.1.4 Vibration test
Carried on typical bus section to prove the suitability for installation in earthquake prone areas.
For rigid bus testing, the bus section is installed on vibration table. Vibrations are imparted to the
table in vertical - horizontal X axis - horizontal Y axis sequence. The amplitude of deflections
and stress at different points are recorded and response of busbar is recorded for a wide
frequency range. For a flexible ACSR bus, the hardware is subjected to a special test rig.
(a) Voltage test: The applied voltage must be of approximately sinusoidal shape and of any
frequency between 25 and 100 Hz. It must be increased gradually to the full value and maintain
continuously for 15 minutes between conductors and between each conductors and sheath. The required
values of the test voltages are tabulated in the specification and, as one illustration of the magnitude relative
to the normal voltages, the figures for the 11 kV cables for earthed system are given in the table.
where (i) Between conductors, (ii) Between any conductor and sheath
It will be seen that a voltage test is made before and after a bending test. In this the cable has to
be bent around a cylinder of specified diameter to make one complete turn: it is then unwound
and the process repeated in the opposite direction . The cycle of process has to be carried out
three times.
It is a non-destructive and integral procedure that serves to evaluate the condition of an entire
cable route. With the dielectric dissipation factor tan δ, the relation of effective power to reactive
power of the cable is measured. The measurement provides clear information on the condition of
the cable insulation and its ageing condition.
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With the dissipation factor measurement you will discover
▪ areas in the insulation of XLPE cables that are damaged by water (water trees) which lead to
electrical trees and represent the natural cause of a cable fault;
The tan δ measurement is effected through multiple voltage steps that are provided in our
devices. With aged cables, a characteristic increase in dissipation factor can be seen with
increasing measurement voltage. A classification of the cables is possible, which proves highly
valuable when planning the maintenance measures.
1. The cable on which tan delta test or dissipation factor test to be conducted, is first isolated from
the system.
2. A very low-frequency test voltage is applied across the equipment whose insulation to be tested.
First, the normal voltage is applied. If the value of tan delta appears good enough, the applied
voltage is raised to 1.5 to 2 times of normal voltage, of the equipment.
3. The tan delta controller unit takes measurement of tan delta values.
4. A loss angle analyzer is connected with tan delta measuring unit to compare the tan delta values
at normal voltage and higher voltages and analyze the results.
The leading cause of partial discharge in cable systems is field workmanship. As opposed to sterile
factories with tight quality control measures, field installation of cables is difficult. Cables are
spliced and terminated under adverse conditions, including weather, access, visibility, and
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cleanliness. Repairs are often made in the rain, in middle of the night, and in a hole with bad
lighting and severe time pressures.
Testing types are:
1. Offline PD testing: Offline partial discharge testing uses a similar setup to tan delta testing in
that the cable should be disconnected from external equipment and connected to a high-quality,
low-discharge voltage source. Additional precautions must be made because any discharge in the
test equipment or setup will render the results meaningless. Below is a typical offline PD test setup.
While the goal is to measure the PD current pulse, it is not measured directly; rather, it is inferred
from the voltage drop when the discharge occurs. For this reason, a known pulse generator is
typically required to calibrate the system by relating a measured voltage drop to a Pico-Coulomb
amount. Test procedures and general evaluation guidelines are given in the relevant IEEE 400 series
standards.
2. Online PD testing: Online partial discharge testing makes use of the power system voltage and
only requires a monitoring circuit. While it is possible to attach a monitoring circuit to the
conductor, it is also possible to connect to the ground strap of the conductor since the discharge
must travel down it to ground. This ground connection is preferable due to its increased safety and
the fact that the connection will not adversely affect the electric field at the conductor. By
connecting via a high-frequency current transformer (HFCT), a direct measurement can be made,
eliminating the need for a calibrator (Figure 4). Tests can be done in a few minutes, as a periodic
survey or as continuous monitoring.
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Figure 27: Typical Online PD Test Connections
Murray Loop Bridge is a bridge circuit used for locating faults in underground or underwater
cables.
It has been used for more than 100 years. This method can be used for both low and high resistance
fault in circumstances-
1. Fault in one or two cores
2. When three cores are faulty, provided that an adjacent cable is used for measurement.
3. When three cores are faulted if the contact resistance differs from each other by a factor more
than 500.
4. When contact resistance does not exceed 500ohms, if working with low voltage bridge and 1.5
Mega ohm if working with a high voltage bridge.
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Murray loop test is the most common and accurate method for fault localization. In this test, the
principle of Wheatstone bridge is used to locate the ground fault. In ground fault, one or more
cables are earthed. if the fault current is more than 10 mA when battery voltage is 100V, the fault
resistance may be of the order of 10KΩ . A high gain dc amplifier can be used for high sensitivity.
Working: The faulty core is looped with sound core of the same cross sectional area and a slide wire
or resistance box with 02 sets of coils are connected across the open end of the loop. A
Galvanometer is also joined across the open end of the loop and a dc hand operated generator
supplies the current for the test. Balance is obtained by adjusting the slide or resistance. The fault
position is given by the formula:
d = a/(a+b)
Figure 28: Murray test setup
Type approval tests, are stipulated for each design of cable and accessory. These tests are carried out
on the maximum and the minimum conductor sizes for each design and voltage rating, and if
successful, no further type tests are required, except in the case of changes in the design. The
dielectric thermal resistance test included in the schedule is applied only to the minimum conductor
sizes.
The tests are as follows:
(a) Loading cycle test: A test loop, comprising the cable and each type of accessory to be
subjected to 20 load cycles to a minimum conductor temperature 5 degree C in excess of the
design value, with the cable energised to 1.5 times the working voltage. The cable to be tested at
a stipulated minimum internal pressure.
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(b) Thermal stability test (132 kV cables only): After test (a), the cable to be energised to 1.5
times working voltage and the loading current adjusted to give a maximum temperature 5 degree
C in excess of the design value. The current to be maintained at this value for a period of 6 hours,
with other test conditions unaltered, to prove that the cable is thermally stable. For 275 kV
cables, 1.33 times the working voltage is proposed.
(c) Impulse test: A test loop, comprising cable and each type of accessory to be subjected to 10
positive and 10 negative impulses at test voltage. [Ex: Working voltage 132 kV, Impulse test
voltage 640 kV, Peak working voltage ratio during impulse test 6.0]
(d) Cold power-factor/voltage test: The power factor of a 100 m length of cable to be measured
at 0.5, 1.0, 1.5 and 2 times the working voltage with the cable at the stipulated minimum internal
pressure. The values not to exceed the makers' guaranteed values.
(e) Mechanical Test of metallic reinforcement: A sample of cable to withstand twice the
maximum specified internal pressure for a period of seven days.
(f) Binding test: The cable to be subjected to three binding cycles round a drum of diameter 20
times the diameter of the pressure retaining sheath. The sample then to withstand the routine
voltage test carried out on all production lengths of cable.
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CH 5: TESTS ON COMPLETE HT AND LT PANEL
5.1 Continuity test: This test is performed with help of multimeter. It helps to check the open
circuit or loose connections in the wiring of panel.
5.2 Primary Injection test: This test is done only for HT panel. Here we inject 25% of rated
primary current between one phase and earth with all connected burden. Measure secondary
current at all points of CT circuits. It shall be done for other phases.
When one CT is having several cores used for different purposes. The cores can be identified
during primary injection test by shorting the one of the core at CT terminal itself and check there
is no current only at relevant load. The same can be verified for other cores.
Inject 25% of rated primary current between phase to phase with all connected burden. Measure
secondary current at all points of CT circuits. It shall be done for other phases.
5.3 HV test: Power frequency voltage withstand test and impulse voltage test is performed. 28KV
rms test voltage for 1 min without flashover or puncture of insulator. The voltage is applied between
each phase conductor and earth, with other phase conductor and enclosures earthed. Similarly it
carried out for other phases.
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5.4 Insulation resistance test: It is performed both before and after 28 KV high voltage test to
authorise the insulation strength of the insulating materials used in the panel. It is performed using
megger at busbars. The insulation resistance should be above 1 tera-ohm to pass the test.
Conclusion
During the complete project, I went through the testing procedures for circuit breaker, current
transformers, potential transformers, relays, busbars and power cables with required precaution and
safety measures to ensure that they are fit to be used in HT and LT panels and then final testing of
complete panel before dispatch.
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References
1. Protective Relays Application Guide, 3rd edition. AREVA Transmission and Distribution,
Protection and Control, 1987.
2. https://www.electrical4u.com/routine-test-of-circuit-breakers/
3. http://www.cired.net/publications/cired1999/papers/1/1_23.pdf
4. https://uk.megger.com/applications/circuit-breakers/recommended-circuit-breaker-tests
5. https://bralpowerassociate.blogspot.com/2013/11/underground-cable-fault.html
6. https://www.top-ee.com/partial-discharge-test-of-transformer/
7. http://ljs.academicdirect.org/A19/001_012.pdf
8. http://www.baou.edu.in/assets/downloads/e_tender_etc_work_21.pdf
9. https://electrical-engineering-portal.com/secondary-injection-tests
10. https://electrical-engineering-portal.com/testing-commissioning-current-transformer#38
11. https://smcint.com/panel-test/
12. https://specialties.bayt.com/en/specialties/q/303712/what-are-the-types-of-testing-methods-for-
a-lv-panel/
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