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Inspection and Test Procedures
Inspection and Test Procedures
Inspection and Testing should be done with the utmost regard for safety not only of
the testing and inspection personnel but of the tested materials and equipment.
In the minimum, safety shall follow the guidelines of the following references:
1. Occupation Safety and Health Act
2. Applicable Local Ordinance
3. Owners safety practice if available
I TESTING:
All tests shall be performed with the apparatus under test de-energized except in
cases where the test requires otherwise.
The testing shall be witnessed by the Owners Safety Representative.
All test equipment shall be in good mechanical and electrical condition.
All test equipment must be properly calibrated within the rated accuracy.
All accuracy test made on the calibrating and test instruments must be directly
traceable to the applicable Philippine Testing Agency or National Institute of
Standards and Technology (NIST)
Instruments shall be calibrated in accordance with the following frequency schedule.
a. Field Instruments: Analog, 6months max; Digital, 12 months max
b. Laboratory instruments : 12 months
c. Leased equipment: 12 months where accuracy is guaranteed by Lessor.
Dated Calibration labels must be visible on all test equipment.
Calibrating records and result of the calibration on the test instrument must be kept
up to date.
Test Report
The test report shall include the following:
1. Summary of project.
2. Description of equipment tested.
3. Description of test.
4. Test data.
5. Analysis and recommendations.
Test data records shall include the following minimum requirements:
1. Identification of the testing organization.
2. Equipment identification (brand, model, serial nos., etc.)
3. Humidity, temperature, and other atmospheric conditions that may
affect the results of the tests/calibrations.
4. Date of inspections, tests, maintenance, and/or calibrations.
5. Identification/signature of the testing technician.
6. Indication of inspections, tests, maintenance, and/or calibrations to
be performed and recorded.
7. Indication of expected results when calibrations are to be performed.
8. Indication of as-found and as-left results.
9. Sufficient spaces to allow all results and comments to be indicated.
The testing firm shall furnish a duly signed copy/ies of the complete report
to the owner/representative.
II Inspection and Test Procedures:
Switchgear and Switchboard Assemblies:
A. Visual and Mechanical inspection:
1. Compare equipment nameplate data with drawings and specifications.
2. Inspect physical and mechanical condition.
3. Verify appropriate anchorage, required area clearances, physical damage,
and correct alignment.
4. Inspect all doors, panels, and sections for corrosion, dents,
scratches, fit, and missing hardware.
5. Verify that fuse and/or circuit breaker sizes and types correspond to
drawings and coordination study as well as to the circuit breakers
address for microprocessor-communication packages.
6. Inspect all bolted electrical connections for high resistance using one
Transformers
Liquid-Filled
A. Visual and Mechanical Inspection
1.
2.
3.
4.
5.
6.
C Test Values
1. Compare bolted connection resistance to values of similar connections.
2. Bolt-torque levels should be in accordance with Table 1 unless otherwise
specified by the manufacturer.
3. Microhm or millivolt drop values shall not exceed the high levels of the
normal range as indicated in the manufacturers published data. If
manufacturers data is not available, investigate any values which deviate from
similar connections by more than 50 percent of the lowest value.
4. Minimum insulation-resistance values should not be less than 50 megohms.
5. Investigate deviations between adjacent phases.
Medium-Voltage, 69 kV Maximum
Metal-Enclosed Busways
A
B Electrical Tests
1. Measure insulation resistance of each busway, phase-to-phase and phase-toground for one minute, in accordance with Table 2.
2. Perform an overpotential test on each busway, phase-to-ground with phases
not under test grounded, in accordance with manufacturers published data.
If manufacturer has no recommendation for this test, it shall be in
accordance with Table 9. Where no dc test value is shown in Table 9, ac
value shall be used. The test voltage shall be applied for one minute.
3. Perform contact-resistance test on each connection point of noninsulated
busway. On insulated busway, measure resistance of assembled busway
sections and compare values with adjacent phases.
4. Perform phasing test on each busway tie section energized by separate
sources. Tests must be performed from their permanent sources.
C Test Values
Switches
Low Voltage Air Switches
A Visual and Mechanical Inspection
1. Compare equipment nameplate data with drawings and specifications.
2. Inspect physical and mechanical condition.
3. Confirm correct application of manufacturers recommended lubricants.
4. Verify appropriate anchorage and required area clearances.
5. Verify appropriate equipment grounding.
6. Verify correct blade alignment, blade penetration, travel stops, and
mechanical operation.
7. Verify that fuse sizes and types are in accordance with drawings and shortcircuit and coordination studies.
8. Verify that each fuse holder has adequate mechanical support.
9. Inspect all bolted electrical connections for high resistance using one of the
following methods:
B Electrical Tests
1. Perform insulation-resistance tests on each pole, phase-to-phase and phaseto-ground with switch closed and across each open pole for one minute. Test
voltage shall be in accordance with manufacturers published data or Table
2.
2. Measure contact-resistance across each switchblade and fuse holder.
3. Measure fuse resistance.
4. Perform resistance measurements through all bolted connections with lowresistance ohmmeter, if applicable.
5. Verify heater operation (if applicable).
C Test Values
1. Compare bolted connection resistance to values of similar connections.
2. Bolt-torque levels should be in accordance with Table 1 unless otherwise
specified by manufacturer.
3. Microhm or millivolt drop values shall not exceed the high levels of the
normal range asindicated in the manufacturers published data.If
manufacturers data is not available, investigate any values which deviate
from similar connections by more than 50 percent of the lowest value.
4. Minimum insulation resistance shall be in accordance with manufacturers
published data or Table 2.
5. Investigate any contact resistance values which deviate from adjacent poles
or similar switches by more than 25 percent.
6. Investigate fuse-resistancevalues that deviate from each other by more than
15 percent.
Medium-Voltage, Metal-Enclosed Air Switches
A Visual and Mechanical Inspection
1. Compare equipment nameplate data with drawings and specifications.
2. Inspect physical and mechanical condition.
3. Confirm correct application of manufacturers recommended lubricants.
3. Microhm or millivolt drop values shall not exceed the high levels of the normal
range asindicated in the manufacturers published data.If manufacturers data is not
available, investigate any values which deviate from similar connections by more
than 50 percent of the lowest value.
4. Insulation resistance values shall be in accordance with manufacturers data or
Table 2.
5. The insulation shall withstand the over potential test voltage applied.
6. Contact resistance shall be determined in microhms. Investigate any value
exceeding 500 microhms or any values which deviate from adjacent poles or similar
switches by more than 25 percent.
published data. Do not exceed maximum voltage stipulated for this test. Provide
adequate barriers and protection against x-radiation during this test. Do not perform
this test unless the contact displacement of each interrupter is within manufacturers
tolerance. (Be aware that some dc high-potential test sets are half-wave rectified
and may produce peak voltages in excess of the switch manufacturers
recommended maximum.)
6. Remove a sample of insulating liquid, if applicable, in accordance with ASTM D923. Sample shall be tested in accordance with the referenced standard.
1. Dielectric breakdown voltage: ASTM D-877
2. Color: ASTM D-1500
3. Visual condition: ASTM D-1524
7. Perform insulation-resistance tests on all control wiring at 1000 volts dc. For
units with solid-state components, follow manufacturers recommendations.
8. Perform an overpotential test in accordance with manufacturers published data.
C. Test Values
1. Compare bolted connection resistances to values of similar connections.
2. Bolt-torque levels should be in accordance with Table 1 unless otherwise
specified by manufacturer.
3. Microhm or millivolt drop values shall not exceed the high levels of the normal
range as indicated in the manufacturers published data. If manufacturers data
is not available, investigate any values which deviate from adjacent poles or
similar switches by more than 50 percent of the lowest value.
4. Contact displacement shall be in accordance with factory recorded data marked
on the nameplate of each vacuumswitch or bottle.
5. The vacuum bottles shall withstand the overpotential voltage applied.
6. Control wiring insulation resistance should be a minimum of two megohms.
7. The insulation shall withstand the overpotential test voltage applied.
8. Insulating liquid test results shall be in accordance with Table 7.
Insulated Case/Molded Case Low-Voltage Circuit Breakers
A Visual and Mechanical Inspection
1.
2.
3.
4.
5.
the values shown in Table 10.7. Circuit breakers exceeding specified trip time at
300 percent of pickup shall be tagged defective.
7. Instantaneous pickup values of molded-case circuit breakers shall be within the
tolerances shown in Table 10.8.
Low Voltage Circuit Breakers
A
1.
2.
3.
4.
C Test Values
1. Compare bolted connection resistance to values of similar connections.
2. Bolt-torque levels should be in accordance with Table 1 unless otherwise
specified by manufacturer.
3. Microhm or millivolt drop values shall not exceed the high levels of the normal
range as indicated in the manufacturers published data.If manufacturers data
is not available, investigate any values which deviate from similar connections
by more than 50 percent of the lowest value.
4. Circuit breaker insulation resistance should be in accordance with Table 2.
5. Central wiring insulation resistance should be a minimum of two megohms.
6. Trip characteristics of breakers shall fall within manufacturers published timecurrent tolerance bands.
Vacuum Medium-Voltage Circuit Breakers
A
1.
2.
3.
4.
5.
or Table 1.
8. Perform timing tests.
9. Record as-found and as-left operation counter readings.
B Electrical Tests
1. Perform a contact-resistance test.
*2. Perform minimum pickup voltage tests on trip and close coils.
3. Verify trip, close, trip-free, and antipump function.
4. Trip circuit breaker by operation of each protective device.
5. Perform resistance measurements through all bolted connections with lowresistance ohmmeter, if applicable.
6. Perform insulation-resistance tests pole-to-pole, poleto-ground, and across open
poles at 2500 volts minimum
7. Perform vacuum bottle integrity (overpotential) test across each vacuum bottle
with the breaker in the open position in strict accordance with manufacturers
instructions.
C Test Values
1. Compare bolted connection resistance to values of similar connections.
2. Bolt-torque levels should be in accordance with Table 1 unless otherwise
specified by manufacturer.
3. Microhm or millivolt drop values shall not exceed the high levels of the normal
range asindicated in the manufacturers published data.If manufacturers data is
not available, investigate any values which deviate from similar connections by
more than 50 percent of the lowest value.
4. Circuit breaker insulation resistance should be in accordance with Table 2.
5. Contact displacement shall be in accordance with factory recorded data marked
on the nameplate of each vacuum breaker or bottle.
6. The interrupter shall withstand the over potential voltage applied.
7. Compare circuit breaker timing values to manufacturers published data.
8. Control wiring insulation resistance should be a minimum of two megohms.
9. Dissipation-factor/power-factor test results shall be compared to manufacturers
published data. In the absence of manufacturers published data the comparison
shall be made to similar breakers.
10. Dissipation-factor/power-factor and capacitance test results should be within
ten percent of nameplate rating for bushings.
11. The insulation shall withstand the over potential test voltage applied.
SF6 MV Circuit Breakers (cont.)
A Visual and Mechanical Inspection
1.
2.
3.
4.
5.
is not available, investigate any values which deviate from similar connections
by more than 50 percent of the lowest value.
4. Compare time-travel data with manufacturers published data.
5. Control wiring insulation resistance should be a minimum of two megohms.
6. Circuit breaker insulation resistance should be in accordance with Table 2.
7. Dissipation-factor/power-factor test results shall be compared to manufacturers
published data. In the absence of manufacturers published data, the
comparison shall be made to similar breakers.
8. Dissipation-factor/power-factor and capacitance test results should be within ten
percent of nameplate rating for bushings.
9. The insulation shall withstand the overpotential test voltage applied.
10. Minimum pickup for trip and close coils shall conform to manufacturers
published data.
High Voltage Oil Circuit Breakers
A Visual and Mechanical Inspection
1. Compare equipment nameplate data with drawings and specifications.
2. Inspect physical and mechanical condition.
3. Confirm correct application of manufacturers recommended lubricants.
4. Inspect anchorage, alignment, and grounding.
5. Verify that breather vents are clear.
6. Perform all mechanical operation and contact alignment tests on both the circuit
breaker and its operating mechanism.
7. If performing internal inspection:
1. Remove oil. Lower tanks or remove manhole covers as necessary.
Inspect bottom of tank for broken parts and debris.
2. Inspect lift rod and toggle assemblies, contacts, interrupters,
bumpers,dashpots, bushing current transformers, tank liners, and
gaskets.
3. Slow-close breaker and check for binding, friction, contact alignment,
penetration, and overtravel. Check that all phases make contact
simultaneously.
4. Refill tank(s) with filtered oil to correct levels.
8. Inspect all bolted electrical connections for high resistance using one of the
following methods:
a. Use of low-resistance ohmmeter.
b. Verify tightness of accessible bolted electrical connections by calibrated
torque-wrench method in accordance with manufacturers published data
or Table 1.
9. Test alarms and lockouts for pneumatic and/or hydraulic operators as
recommended by the manufacturer.
*4. Perform insulation-resistance tests on all control wiring at 1000 volts dc. For
units with solid-state components, follow manufacturers recommendations.
*5. Perform dissipation-factor/power-factor tests on breaker and bushings.
*6. Perform overpotential test in accordance with manufacturers instructions.
*7. Perform minimum pick-up voltage test on trip and close coils.
8. Verify trip, close, trip-free, and antipump functions.
9. Trip circuit breaker by operation of each protective device.
C Test Values.
1. Compare bolted connection resistance to values of similar connections.
2. Bolt-torque levels should be in accordance with Table 1 unless otherwise
specified by manufacturer.
3. Microhm or millivolt drop values shall not exceed the high levels of the normal
range as indicated in the manufacturers published data.If manufacturers data
is not available, investigate any values which deviate from similar connections
by more than 50 percent of the lowest value.
4. Compare time-travel data with manufacturers published data.
5. Control wiring insulation resistance should be a minimum of two megohms.
6. Circuit breaker insulation resistance should be in accordance with Table 2.
7. Dissipation-factor/power-factor test results shall be compared to manufacturers
published data. In the absence of manufacturers published data, the
comparison shall be made to similar breakers.
8. Dissipation-factor/power-factor and capacitance test results should be within ten
percent of nameplate rating for bushings.
9. The insulation shall withstand the overpotential test voltage applied
10. Minimum pickup for trip and close coils shall conform to manufacturers
published data.
16.
17.
18.
19.
20.
21.
22.
23.
24.
c. Determine slope.
d. Determine harmonic restraint.
e. Determine instantaneous pickup.
*f. Plot operating characteristics for each restraint.
3. Control Verification
Verify that each of the relay contacts performs its intended function in the control
scheme including breaker trip tests, close inhibit tests, 86 lockout tests, and alarm
functions.
4. System Tests
After the equipment isinitially energized, measure magnitude and phase angle of all
inputs and compare to expected values.
5. Test Values
1. Use manufacturers recommended tolerances when other tolerances
are not specified.
2. When critical test points are specified, the relay shall be calibrated to
those points even though other test points may be out of tolerance.
Instrument Transformers
A
1.
2.
3.
4.
5.
6.
7.
8.
3.
4.
5.
6.
7.
ground at 1000 volts dc. For units with solid-state components, follow
manufacturers recommendations.
Perform a polarity test of each current transformer.
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).
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).
Measure current circuit burdens at transformer terminals and determine the total
burden.
When applicable, perform insulation-resistance and dielectric withstand tests on
the primary winding with secondary grounded. Test voltages shall be in
accordance with Tables 10.13 and 10.9 respectively.
E Test Values
1. Compare bolted connection resistance to values of similar connections.
2. Bolt-torque levels should be in accordance with Table 1 unless otherwise
specified by manufacturer.
3. Microhm or millivolt drop values shall not exceed the high levels of the normal
Tables:
Table 1 >> Table 10.12
Table 2 >> Table 10.1