Acceptability of Disconnect Switches

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Assessing the Acceptability of Disconnect Switches
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcoís employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written
permission of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Electrical For additional information on this subject, contact

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Engineering Encyclopedia Electrical
CONTENTS PAGES
VERIFYING THAT THE TYPE, CONSTRUCTION, OPERATIONAL

CHARACTERISTICS, AND RATINGS OF DISCONNECT SWITCHES
ARE CORRECT FOR THE APPLICATION ............................................................ 1
Types of Disconnect Switches ............................................................................. 1
Non-Loadbreak.............................................................................................. 5
Loadbreak ..................................................................................................... 6
Single Operation ............................................................................................ 7
Gang-Operated .............................................................................................. 8
Motor-Operated............................................................................................. 8
Low Voltage Disconnect Switches....................................................................... 8
Construction and Operational Characteristics ................................................. 9
Ratings .........................................................................................................10
Applications..................................................................................................12
Medium Voltage Disconnect Switches ................................................................13
Types............................................................................................................13
Construction and Operational Characteristics ................................................14
Ratings .........................................................................................................17
Applications..................................................................................................17
High Voltage Disconnect Switches .....................................................................17
Types............................................................................................................17
Construction and Operational Characteristics ................................................18
Applications..................................................................................................20
VERIFYING CORRECT CONDITION AND OPERATION OF
DISCONNECT SWITCHES....................................................................................21
Visual Inspections...............................................................................................21
Alignment .....................................................................................................22
Contacts .......................................................................................................22
Mechanism/Linkage ......................................................................................23
Three-Phase Contact Blades Make and Break Together ................................23
Physical Damage...........................................................................................24
Lubrication ...................................................................................................24
Cleanliness....................................................................................................25
Suitability .....................................................................................................26
Mechanical Inspections and Tests .......................................................................26
Open/Close Operation...................................................................................26

Arcing Horns Function..................................................................................27

Bolt Torque ..................................................................................................28
Contact Wipe................................................................................................29
Mechanical Locking of Contact Blades .........................................................29
Key Interlock System Operation ...................................................................30
Electrical Tests ...................................................................................................30
Contact Resistance........................................................................................31
Insulation Resistance.....................................................................................31
Oil Dielectric ................................................................................................32
High Potential (High Voltage Class)..............................................................33
Functional Operation Test...................................................................................34
Thermographic Survey (System Energized and Loaded) .....................................35
Review of Testing and Inspection Results ...........................................................37
WORK AID 1: RESOURCES USED TO VERIFY THAT THE TYPE,
CONSTRUCTION, OPERATIONAL CHARACTERISTICS, AND
RATING OF DISCONNECT SWITCHES ARE CORRECT FOR THE
APPLICATION .......................................................................................................39
Work Aid 1A: Guidelines, Requirements, and Ratings that are Used in
the Application and Selection of Loadbreak Switches .........................................39
Work Aid 1B: Disconnect Switch Applications Checklist....................................43
WORK AID 2: RESOURCES USED TO VERIFY THE CORRECT
CONDITION AND OPERATION OF DISCONNECT SWITCHES........................44
Work Aid 2A: Saudi Aramco Pre-Commissioning Form, P-001,
Switches; High and Medium Voltage Air, Oil, and SF6 .......................................44
Work Aid 2B: Information, Formulas, and Tables for Use in Evaluating
the Results of Insulation Resistance (Megger) Tests............................................47
Work Aid 2C: Information, Formulas, and Tables for Use in Evaluating
the Results of Connection Resistance Checks......................................................48
Work Aid 2D: AC or DC Hi Pot Tests................................................................49
Work Aid 2E: Information, Formulas, and Tables for Use in Evaluating
the Results of Hi-Pot Tests .................................................................................50
GLOSSARY ............................................................................................................51

VERIFYING THAT THE TYPE, CONSTRUCTION, OPERATIONAL

CHARACTERISTICS, AND RATINGS OF DISCONNECT SWITCHES ARE CORRECT
FOR THE APPLICATION
Disconnect switches have several different applications and can be used to serve many purposes.
Disconnect switches can be used to alter circuit arrangements and to provide electrical isolation
for equipment that has to be removed from service for maintenance. Standard disconnect
switches are designed to be opened and closed when no current flow is present. With certain
modifications, disconnect switches can also be used to isolate circuits under load. Disconnect
switches that have the capability to interrupt load current are called loadbreak switches. Special
application switches are also available that can intentionally ground circuits, provide power from
standby systems, or serve as a temporary circuit breaker replacement. Special application
switches are not covered in this Module. This Module contains information on the Saudi Aramco
requirements for disconnect switches.
To ensure that disconnect switches that are chosen for a particular installation provide the proper
operation, protection, and maintenance capabilities, the disconnect switches are verified to ensure
that they comply with Saudi Aramco and industry standards and practices. The minimum
mandatory requirements for the design and construction of disconnect switches are provided in
Work Aid 1. This section will describe the following topics that are pertinent to the verification
of disconnect switches in Saudi Aramco applications:
• Types of Disconnect Switches

• Non-Loadbreak
• Loadbreak
• Single Operation
• Gang-Operated
• Motor-Operated
Types of Disconnect Switches
Circuit breakers are used in electric power transmission and distribution systems to switch circuits
that carry normal, overload, or fault current. Because circuit breakers are required to interrupt
overload and fault currents, most circuit breakers require sophisticated arc-suppression devices,
protective relaying equipment, and interlocks to function safely and properly. While the purpose
of a circuit breaker is to provide protection and control of an electrical system, the purpose of a
disconnect switch is to alter the circuit arrangements and to provide electrical isolation for
equipment that has to be removed from the electrical system for maintenance evolutions.
Disconnect switches are almost always used in series with a circuit breaker or fuses, both of which
can safely interrupt short-circuit fault currents.
Saudi Aramco DeskTop Standards 1

A good example of the relationship between a disconnect and a circuit breaker is shown in Figure
1. Figure 1 shows a standard distribution bus that is fed by one generator. Each feeder has a
circuit breaker and a disconnect switch. This type of bus configuration should only be used where
interruptions to load service are unimportant because outages must exist to all feeders
simultaneously when the feeder bus, the generator breaker, or the generator is out of service for
any reason. The circuit breaker provides protection against short circuits on the feeder and
enables the feeder to be removed from service while it is carrying load, if necessary. With the
breaker open, the disconnect switch serves as additional backup protection for personnel during
maintenance or repair work on the feeder. The disconnect switch also enables the feeder breaker
to be isolated from the bus for inspection and maintenance on the breaker. Disconnect switches
are frequently arranged so that when the disconnect switch blades are opened, they are connected
to a grounded clip to prevent maintenance personnel from exposure to dangerous voltage
potentials.
Disconnect Use on Example Feeder Bus

Figure 1

Disconnect switches are used extensively in substations. Although disconnect switches are simple
and relatively inexpensive, they have a high degree of reliability and require very little
maintenance. Medium and high voltage disconnect switches are normally installed so that
extensive outages are usually necessary to gain access to them.
Disconnect switches are simply large-scale knife switches, disconnect switches must meet certain
design considerations to function properly. Specific manufacturers and models may use different
designs and techniques, but the function and operation of all disconnect switches are basically
similar. Important disconnect switch design considerations are as follows:
• Some means must be provided to ensure that a proper blade-to-jaw contact is

made when the switch is closed. The blade is the movable portion of the
disconnect switch, and the jaw is the stationary part of the switch that makes
contact and secures the blade in place. Proper blade-to-jaw contact can be
accomplished by having the jaw spring-loaded to maintain contact pressure.
• The end of the blade that pivots must be capable of carrying current through the
pivot point. In older disconnect switches, copper braids were used to bridge the
current across the pivot point. In newer disconnect switches, the current is carried
through the pivot point. Another design is to have the blade pivot at the center
and make electrical connection at two jaws on either end of the blade.
• The disconnect switch must maintain its adjustment throughout its specific
maintenance cycle.
• The switch should be within the capability of maintenance or operations personnel

to operate it. For larger disconnect switches, “helper” springs are used to assist
the operator.

Figure 2 shows a side view of five typical disconnect switch configurations. In Figure 2, the
disconnect switch pivot (hinge) points are represented by dots, and the switch jaws are
represented by parallel lines. The insulation support stacks are shown as triangles. Switch A is a
vertical disconnect switch with three insulation stacks. The movable blade pivots up along the
vertical plane approximately 90o from the horizontal (i.e., pointing to the top of the page). Switch
B is a horizontal double-break disconnect switch with three insulation stacks. The movable blade
pivots in the middle and rotates along the horizontal plane. Switch C is a side disconnect switch.
The movable blade pivots at one end and rotates along the horizontal plane. Switch D is a center-
make disconnect switch with two movable blades. Each movable blade pivots at the end and
rotates along the horizontal plane. The two movable blades rotate in opposing directions, and the
switch circuit connection is made in the center. Switch E is a hook disconnect switch that
operates in a similar manner to the vertical switch (Switch A). The difference between Switch E
and Switch A is that Switch E has a hook operator. The hook disconnect switch will be described
later in this Module.
Typical Disconnect Switch Configurations

Figure 2

In general, disconnect switches that use horizontal blade movement require fewer insulation
stacks as structural supports. Fewer insulation stacks can mean a less expensive disconnect
switch; however, the horizontal blade movement requires a greater spacing between adjacent
conductors. In three-phase system disconnect switch installations, greater spacing between
conductors may not be practical.
The two basic types of disconnect switches are those that are opened and closed only when there
is no current through them (non-loadbreak), and those disconnect switches that are designed to
interrupt some limited capacity of load current (loadbreak). Once the interrupting capability of a
disconnect switch is known, the switch can be further categorized by the type of operating
mechanism that it uses. For a single-phase ac or dc circuit, a single operation-type disconnect
switch is used. For three-phase systems, a group- or gang-operation-type mechanism is used.
The gang-operated mechanism provides simultaneous operation of all three phases. For higher
voltage systems, or for systems in which the switch is difficult for personnel to operate, a motor-
operation-type mechanism is used.
Non-Loadbreak
Disconnect switches are used with almost every type of major circuit or piece of electrical
equipment as a safety measure to ensure that the line or equipment cannot be accidentally
energized during the performance of maintenance. Disconnect switches can also be used to
sectionalize circuits when it is necessary to locate a faulted section of the circuit. Disconnect
switches are connected in series on both sides of a piece of electrical equipment (e.g., a circuit
breaker) or at some point or points in an electric supply line. The non-loadbreak disconnect
switch should never be opened unless the associated circuit breaker is opened. For example, a
non-loadbreak disconnect switch can be used in a motor controller to isolate the controller for
maintenance periods. The non-loadbreak disconnect switch provides a second physical break in
the circuit to prevent personnel or equipment damage in the event that the motor controller circuit
breaker is accidentally closed.
In the power industry, non-loadbreak disconnect switches are usually referred to as simply
“disconnects.” Non-loadbreak disconnect switches are not designed to be opened while the
circuit in which they are connected is energized. While non-loadbreak disconnect switches are
also not designed to close on an energized circuit, they may, under emergency circumstances and
with special care, be closed while a circuit is energized.

A special type of non-loadbreak disconnect switch exists. This special type of non-loadbreak
disconnect switch is called an air-break switch, and it is designed to break transformer
magnetizing current but not any load current. These air-break switches use arcing horns to direct
the arc that is formed when the switch opens and when magnetizing current is present. The arc
horn is designed to localize all arcing during opening and closing operations at the arc horn or
switch auxiliary contacts, if present.
Loadbreak
Loadbreak switches are disconnect switches that are designed to interrupt a specified amount of
load current in an electric system. Loadbreak (load interrupting) switches must not be used
except with the prior written approval of the Manager, Aramco Power Distribution Department.
Although loadbreak switches are not normally required to interrupt fault current, they must be
capable of the following:
• Breaking currents that are equal to the continuous current rating of the switch at
the rated system voltage and load.
• Interrupting small inductive or capacitive currents for applications in which the

switch is used to disconnect unloaded transformers, cables, or overhead lines.
• Performing a closing operation onto a terminal short circuit.
Air loadbreak switches are essentially simple disconnect switches with additional arc-suppression
devices. In addition to arcing horns, air loadbreak switches use some form of arc chute or arc box
to rapidly extinguish the arc that is produced by load current. Some loadbreak switches use oil as
the arc-interrupting medium, and other forms of arc-interruption (such as gas or vacuum) are
being developed and used for high voltage loadbreak switches. Oil loadbreak switches are widely
used for switching load currents in high voltage systems. Oil loadbreak switches are dependable
and convenient; however, the initial cost and lifetime maintenance requirements make them more
expensive than air loadbreak switches. Installation of oil switches is not allowed by Saudi
Aramco standards.

Single Operation
A single operation disconnect switch is a large “knife switch” that consists of a hinged blade with
contact clips that are mounted on porcelain insulators. Locking devices or latches are sometimes
provided to prevent the disconnect blade from being opened accidentally or from being blown
open during heavy short-circuit conditions. Single operation disconnects are usually operated
locally by a single actuating device. In most cases, the single actuating device is a hook stick.
The hook stick is a hook that is mounted at the end of an insulated stick or pole. A disconnect
switch that uses a hook stick operation has a circlet or eye that is mounted on the switch. The
operator inserts the end of a hook stick into the circlet or eye to operate the disconnect switch.
Single operation-type loadbreak switches are used in single-phase electric power distribution and
control systems. Because a non-loadbreak disconnect switch is designed to physically disconnect
equipment after all the current has been interrupted by other means, single operation-type non-
loadbreak disconnect switches can also be used in three-phase systems. When single operation
disconnect switches are used, the number of operations that are required to reposition the device
is equal to the number of poles. For example, if single operation-type loadbreak switches are
installed in three-phase systems, three separate operations would be required to open the entire
three-phase circuit.
The single operation-type disconnect switch can also be used as a special application grounding
switch. Grounding switches are used to place an intentional ground on a circuit or system to
remove hazardous voltage potentials during maintenance operations. Some power systems
employ a special class of ground switch that is called a high-speed ground switch. A high-speed
ground switch is used to place an intentional ground fault on a circuit or a system to cause the
rapid operation of protective relays. Because each phase of a three-phase system is connected
through either a delta- or a wye-wound transformer configuration in electric power systems, a
single operation high-speed ground switch can be used.

Gang-Operated
Gang-operation-type disconnect switches are used in multipole units when it is desirable to have
all of the switch blades operate simultaneously. If each phase of a disconnect switch that is
installed in a three-phase system does not operate simultaneously, momentary single-phasing of
equipment could result. A gang-operated loadbreak switch is used in three-phase systems to
prevent the rotating equipment from becoming single-phased. The operation of all of the poles in
a gang-operated, multiple-pole switching device is performed by one operating mechanism. The
control by a single operating mechanism is in contrast to single pole operation in which the
number of operations that is required to reposition (open) the circuit is equal to the number of
poles in the circuit.
Motor-Operated
For single operation disconnect switches, or in low voltage systems in which the physical size of
the switch would allow for manual operation, disconnect switches are typically operated manually
via a hook switch stick. For higher voltage systems, or for systems in which the switch is difficult
for personnel to operate, a motor-operation-type mechanism is used. A disconnect switch that is
motor-operated uses links and couplings to translate the rotation of the motor to the gang-
operated, multiple-pole disconnect switch operating mechanism. The motor operating mechanism
should be supplied with a manual handcrank for disconnect switch operation during maintenance
evolutions. The manual handcrank is also used in the event of a motor failure.
Low Voltage Disconnect Switches
Low voltage disconnect switches are used in electrical distribution systems that have a maximum
ac rms voltage of 600 volts. Common low voltages in Saudi Aramco electrical power distribution
systems are 480/277 V, 208/120 V, and 240/120 V. Low voltage disconnect switches either
consist of enclosed individual units that are installed adjacent to the equipment that they control,
or they are combined in a centrally located enclosure or structure. The four basic components of
a disconnect switch are as follows:
• Insulation
• Connections
• Mechanical linkage
• Contacts

Construction and Operational Characteristics
Figure 3 shows a typical single operation, non-loadbreak, low voltage disconnect switch. In
Figure 3, the mounting insulator functions as part of the structural support for the disconnect
switch and provides insulation between the live parts and ground. The mounting insulators
usually consist of porcelain or an epoxy-based insulating material. The connections function to
attach the conductor to the disconnect switch and to provide structural strength to support the
conductor. The example disconnect switch uses bolted compression terminations to make the
connections between the conductors and the disconnect switch. The mechanical linkage functions
to operate the disconnect switch and to provide a current path when the disconnect switch is
closed. In Figure 3, the movable operating blade pivots at the blade pivot point and makes a
connection with the stationary contacts when the disconnect switch is closed. The contacts
function to provide an electrical connection with the movable operating blade at the proper
pressure. The ring for hook-stick operation pivots at the locking pivot point to allow operating
personnel to open the disconnect switch. The locking assembly (jaw) is spring loaded to ensure
that the disconnect switch stays closed.
Typical Single Operation, Non-Loadbreak, Low Voltage Disconnect Switch

Figure 3

Low voltage loadbreak switches are not generally used for fault-making duties. If low-voltage
loadbreak switches are to be used for fault-making duties, they should be of the fused disconnect
type. If disconnect switches are used, and if short-circuit protection is required, the fuses should
be installed in the same enclosure.
The operational characteristics of a non-loadbreak, low voltage disconnect switch are very
straightforward. When the circuit has been verified to be deenergized, the operator opens the
disconnect switch by lifting the disconnect switch hook with the hook end of the hook stick. The
act of lifting the ring causes the ring assembly to rotate about the lock pivot point (against the
spring-load) and unlock the operating blade. The operator continues to lift the ring until the
operating blade is 90o from its closed position. To close the non-loadbreak, low voltage
disconnect switch, the operator verifies that the circuit is deenergized and pulls the operating
blade down to the closed position with the hook stick and the ring. When the disconnect switch is
being closed, the locking assembly will move the locking jaw out of the way of the stationary
contacts. When the switch is in the closed position, the locking assembly will also lock the
operating blade in place.
The operational characteristics of a loadbreak (or air-break) low voltage disconnect switch is
similar to the non-loadbreak disconnect switch; however, the operator must ensure that the
existing system current does not exceed the ratings of the switch prior to any switch operations.
Ratings
All disconnect switches that are used in Saudi Aramco power systems must have a nameplate that
is clearly visible on the disconnect switch. If the disconnect switch is contained in an enclosure
(e.g., switchgear), the nameplate must be clearly visible on the front of the enclosure. The
nameplate should contain manufacturer-type information. The information that describes the type
of disconnect switch should consist of the manufacturer’s name, the type designation, and the
serial number. The frequency, the voltage, and the current ratings of the disconnect switch should
also be provided on the nameplate. Electric power distribution systems are designed to operate at
a specific rated frequency. Saudi Aramco electrical distribution systems are designed to operate
at a rated frequency of 60 Hz.

The voltage ratings of a disconnect switch are the rated voltage and the rated maximum voltage.
The rated voltage of a disconnect switch is the highest nominal system voltage on which the
switch is intended to be applied. The nominal system voltage refers to the general voltage class
designation. Typical Saudi Aramco voltage classes are 208 V, 480 V, 4.16 kV, 13.8 kV, 34.5
kV, and 69 kV. Disconnect switches that are used in Saudi Aramco applications will have a rated
voltage that corresponds to one of the voltage classes. The rated maximum voltage is the highest
rms voltage for which the disconnect switch is designed, and it is the upper limit for operation.
Saudi Aramco electric systems are allowed a voltage variance of plus five percent. The rated
maximum voltage of a disconnect switch must be higher than the allowable voltage variance of the
electric system.
The rated withstand voltage is the voltage that the disconnect switch must be able to withstand
without flashover or other electric failure. The rated withstand voltage is a measure of the
maximum insulation levels of the disconnect switch. The two rated insulation levels for
disconnect switches are the impulse withstand voltage and the low frequency withstand voltage.
To test a disconnect switch to determine whether the dielectric strength (insulation level) is
adequate to protect against damage from lightning and other surges, the disconnect switch is
impulse tested. The basic impulse insulation level (BIL) is the reference impulse level, expressed
in full wave kilovolts, that the disconnect switch can withstand without a flashover. The BIL is
based on a test that uses a 1.2 x 50 microsecond wave that is intended to simulate a lightning
stroke. The wave goes from zero to a crest voltage in 1.2 microseconds, and the wave reaches a
magnitude that is half of the value of the crest voltage in 50 microseconds. In the tests, both
positive and negative impulse voltages are applied to the disconnect switch without damage or
flashover. The wave crest value is equal to the rated full wave impulse withstand voltage of the
disconnect switch.
A low-frequency withstand voltage test is also performed on disconnect switches. The low-
frequency withstand voltage test determines the ability of a disconnect switch to withstand a low-
frequency voltage for a period of time without flashover. The insulation withstand levels for the
corresponding rated maximum voltages are provided in Work Aid 1.
Disconnect switches are designed for and should be marked with the rated continuous current that
the disconnect switch is capable of carrying without damage to the switch. The rated continuous
current at 60 Hz is the amount of current that can be continuously carried by the disconnect
switch without exceeding the allowable temperature rise. Rated continuous current values for
disconnect switches are provided in Work Aid 1.

The rated short-time current of a disconnect switch is the maximum direct current, or rms total
current, including the transient direct-current component, that the disconnect switch is required to
successfully carry for a specified short-time interval. Disconnect switches have two rated short-
time currents: the rated momentary current and the rated three-second current. The rated
momentary current of a disconnect switch is the rms total current, including the transient direct-
current component, that the switch must be required to carry for at least one cycle. The rated
three-second current of a disconnect switch is the rms total current, which includes the direct
current component, if present, that the switch must be required to carry for three seconds.
Loadbreak switches are required to have an additional load current interrupting rating. The load
current interrupting rating of a loadbreak switch is the highest rms current (in amperes) between
unity and 0.8 power factor (lagging) that the loadbreak switch must be required to interrupt at the
rated voltage and frequency for the expected operating life of the switch.
Applications
Low voltage disconnect switches that are used in Saudi Aramco installations have a variety of
applications that depend on the system requirements and the voltage class of the installation. In
general, low voltage disconnect switches are used in conjunction with low voltage circuit breakers
and motor control centers to provide system and component isolation for maintenance purposes.
Low voltage disconnect switches are also used to isolate circuit breaker and switchgear control
power circuits.
In the application of disconnect switches, the electrical characteristics of the circuit in which the
switch is installed is the most important factor. Electrically, the main application concern of
disconnect switches is that the current ratings of the disconnect switches are sufficiently high
enough to accommodate the maximum system load. Loadbreak switches must also have a
sufficient load current interrupting rating to interrupt the maximum system load without damage
to the disconnect switch or any connected equipment. The physical application of the disconnect
switch is a secondary concern.

Medium Voltage Disconnect Switches
A medium voltage Saudi Aramco electrical distribution system is an electric system that has an
rms ac voltage that is above 600 volts but that is not more than 15 000 volts. Common medium
voltages in Saudi Aramco electrical power systems are 2.4 kV, 4.16 kV, and 13.8 kV. Because
medium voltage systems at Saudi Aramco installations are used to distribute power to process and
support equipment at process facilities, medium voltage systems are not generally deenergized.
Because medium voltage systems are not generally deenergized, the majority of medium voltage
disconnect switches are loadbreak switches; however, non-loadbreak disconnect switches are used
in some cases.
Types
There are several types of disconnect switches that are suitable for use at medium voltages in
Saudi Aramco installations. Each type of switch is best suited for a particular application. The
following types of switch constructions are available:
• Frame-mounted loadbreak switch (oil-immersed)

• Pad-mount switches (oil, SF6, vacuum)
• Metal-enclosed interrupter switchgear (air)
Frame-Mounted, Oil-Immersed-Type Loadbreak Switch - The frame-mounted, oil-immersed

type loadbreak switch is the most prevalent type of disconnect switch that is used by Saudi
Aramco for industrial applications; however, the oil switches are currently being replaced with
SF6 switches. 16-SAMSS-510 should be referenced for specification requirements. Construction
requirements for frame-mounted, oil-immersed-type loadbreak switches are provided in Work Aid
1.
Pad-Mount Disconnect Switches - Pad-mount disconnect switches are available in switchgear

construction that incorporates the following types of switches:
• Oil switches that are immersed in oil-filled sealed tanks.
• Vacuum switches that are immersed in oil- or SF6-filled sealed tanks.
• SF6 switches that are immersed in SF6-filled sealed tanks.
• Air switches that are installed in air-insulated enclosures.

The function of pad-mounted disconnect switches is to provide a wide array of medium voltage
outdoor disconnect capabilities. Construction requirements for pad-mounted disconnect switches
are provided in Work Aid 1.
Metal-Enclosed Interrupter Switchgear - Metal-enclosed interrupter switchgear is built

standard with air-break interrupter switches and bare air-insulated buses. The function of metal-
enclosed interrupter switchgear is to provide a suitable indoor and outdoor mechanism to switch
commercial and industrial distribution system loads and power transformers. 16-SAMSS-501
should be referenced for specification requirements. Construction requirements for metal-
enclosed interrupter switchgear are provided in Work Aid 1.
Figure 4 shows a typical, single pole, medium voltage disconnect switch. The disconnect switch
that is shown in Figure 4 is a vertical break, outdoor air switch that is designed for operation by
either a manual or a motor operating mechanism. The spring assembly and the hinge tie function
together to position the main blade. The upper crank arm, the expansion link assembly, and the
lower bearing assembly function together to rotate the main blade about its axis to lock and
unlock the main blade contact assembly. The stationary arc horn and the movable arc horn
function to dissipate the arc that is produced when the switch is operated. The three insulation
stacks function to provide structural support and insulation to ground.
The operational characteristics of the example medium voltage air disconnect switch are similar to
the operational characteristics of a low voltage disconnect switch; however the example medium
voltage switch has some extra features (e.g., arc suppression equipment and an additional
insulation stack). To open the disconnect switch, the operating mechanism rotates the left-most
insulation stack of the disconnect switch that is shown in Figure 4. As the left-most insulation
stack rotates, the upper crank arm and the expansion link assembly act to rotate the main blade
about its axis. As the main blade rotates, the movable contact surfaces also rotate, and they
disengage from the contact assembly. As the left-most insulation stack continues to rotate, the
upper crank arm and the expansion link assembly lift the main blade into the open position with
the assistance of the spring assembly.

Typical, Single Pole, Medium Voltage Disconnect Switch

Figure 4

Figure 5 shows a close-up view of a typical, single pole, medium voltage disconnect switch
contact assembly. In Figure 5, the main blade is shown in a partially open position. The contacts
in the contact assembly are spring-loaded so that when the disconnect switch is closed, and when
the main blade’s movable contact surfaces are horizontal, the main blade is locked in place. As
the disconnect switch opens, the movable arc horn and the stationary arc horn control and
dissipate any arc that is formed.
Close-Up View of a Disconnect Switch Contact Assembly

Figure 5

Ratings
The requirements for nameplate rating data on medium voltage disconnect switches are in
accordance with ANSI C37.32-1990. Specific values for medium voltage disconnect switch
ratings are provided in Work Aid 1.
Applications
The applications for medium voltage disconnect switches are similar to the applications for low
voltage disconnect switches; however, the majority of medium voltage disconnect switches will be
of the loadbreak-type. Loadbreak switches have several applications in Saudi Aramco distribution
systems. Circuit breakers can be used in place of loadbreak switches but at a higher cost.
Loadbreak switches are often combined with fuse assemblies to provide greater system transient
protection. Loadbreak switches are used in Saudi Aramco distribution systems for the following
applications:
• Load interruption
• Loop sectionalizing (parallel switching)
• Transformer switching
High Voltage Disconnect Switches
A Saudi Aramco high voltage system is an electric system that has an rms ac voltage that is above
15 kV but that is not more than 230 kV. High voltage disconnect switches in Saudi Aramco
installations are rated up through 38 kV.
Types
The types of disconnect switches that are suitable for use at high voltages in Saudi Aramco
installations are the same as those disconnect switches that are suitable for use at medium
voltages. Each type of switch is best suited for a particular application. The following types of
switch constructions are available in ratings up through 38 kV:
• Frame-mounted loadbreak switch (oil-immersed)

• Pad-mount switches (oil, SF6, vacuum)
• Metal-enclosed interrupter switchgear (air)
The function of each of the types of high voltage disconnect switches is the same as the medium
voltage disconnect switches. For nominal system voltages that are above 34.5 kV, custom-
engineered equipment is required for enclosed switchgear applications.

Figure 6 shows a typical, high voltage disconnect switch. The disconnect switch that is shown in
Figure 6 is a three-pole, vertical, motor-operated, loadbreak disconnect switch. The function of
the movable operating blade is to make contact with the contact assembly and to provide a path
for system current. The function of the arc extinction chamber is to suppress and dissipate any
arc that forms when the loadbreak switch is opened. The operating bar and the spring assembly
function together to control the movement of the movable operating blade, the arcing pin, the
arcing pin cantilever, and the blade operating link for each of the disconnect switch phases. The
function of the terminals is to provide a connection point between the line and the load side of the
disconnect switch and the rest of the electrical system. The mounting insulators function to
provide structural support and insulation to ground.
Three-Pole, Vertical, Motor-Operated, Loadbreak Disconnect Switch

Figure 6

The operational characteristics of the example high voltage air disconnect switch are similar to the
operational characteristics of a medium voltage disconnect switch; however the example high
voltage switch has some extra features (e.g., an arc extinction chamber). To open the disconnect
switch, the operating mechanism, with the assistance of the spring assembly, rotates the operating
bar about its axis. As the operating bar rotates, each blade operating link acts to open its
respective movable operating blades. As the contacts in the main contact assemblies part, the arc
extinction chamber suppresses and dissipates any arc that is formed.
Figure 7 shows a cut-away operational view of a typical arc extinction chamber. Part A of Figure
7 shows that as the arcing pin moves away from the stationary arcing contact during a disconnect
switch opening operation, an arc is formed. Part B of Figure 7 shows that when the arcing pin
slides from between the plates, the plates are forced against the arc. As the arcing pin clears the
opening, the gas that is created in the arcing process is forced through the opening into the
expansion chamber and the arc is extinguished.
Cut-Away View of a Typical Arc Extinction Chamber

Figure 7

Applications
Applications for 34.5 kV disconnect switch systems are similar to medium voltage applications.
Figure 8 shows an example application of loadbreak switches in a high voltage system. In Figure
8, loadbreak switches are used to sectionalize loads between two alternative feeders in a loop
network. The “X” sectionalizing loadbreak switches provide operational and load division
switching. It is normal to operate such a system with one end open in which case a fault will be
cleared by the operation of one of the “Y” breakers. The faulty section can then be isolated and
the supply can be restored to the rest of the system.
Key interlocks (Kirk-Key) may be used on manually operated schemes to prevent inadvertent
paralleling of the two different supply feeders (e.g., the preferred and emergency supply). For
both the “X” and “Y” switches, one set of keys is available for each set. Because only one key is
provided for each set, only one of the two switches in each set can be closed at any one time.
Example Application of High Voltage Disconnect Switches - Load Sectionalizing

Figure 8

VERIFYING CORRECT CONDITION AND OPERATION OF DISCONNECT

SWITCHES
The verification of the correct condition and operation of disconnect switches will ensure that the
disconnect switches will properly perform their disconnect function in the circuit in which they are
placed. The following reviews, inspections, and tests are performed on Saudi Aramco disconnect
switches to assess their condition and operation:
• Visual Inspections
• Mechanical Inspections and Tests
• Electrical Tests
• Functional Operation Test
• Thermographic Survey (System Energized and Loaded)
• Review of Testing and Inspection Results
Visual Inspections
Visual inspections are used to assess the physical condition of disconnect switches. A visual
inspection is a pass/fail verification about a particular aspect of the physical condition or the
operation of disconnect switches. The Saudi Aramco Pre-Commissioning Form, P-001, Switches;
High and Medium Voltage Air, Oil, and SF-6, contains guidance on the items that should be
checked during a visual inspection of disconnect switches. Because the criteria that are
established to determine the acceptability of the visual inspections can be subjective, the visual
inspections should be performed by an experienced Electrical Engineer. The following visual
inspections are used to assess the condition of disconnect switches in Saudi Aramco systems:
• Alignment
• Contacts
• Mechanism/Linkage
• Three-Phase Contact Blades Make and Break Together
• Physical Damage
• Lubrication
• Cleanliness
• Suitability

Alignment
The purpose of the alignment inspection is to ensure that the disconnect switch will properly pass
current when it is connected to the rest of the electrical system and that no improper connections
are present. Improper alignment can cause uneven equipment heating and wear. Proper
alignment of the live disconnect parts (e.g., disconnect switch jaws, blades, and connectors) will
ensure a proper electrical connection and will minimize adverse heating effects. Due to the
construction of disconnect switches, most of the parts are visible to inspection personnel, and the
proper disconnect switch alignment, connections, and clearances will be evident.
The alignment visual inspection should be performed during the normal maintenance cycle of
switchgear and disconnect switches as determined by Saudi Aramco procedures and practices.
Technical data to evaluate the results of the alignment inspection can be found in the switchgear
and disconnect switch manufacturer’s technical manuals.
Contacts
When the disconnect switch is connected to the electrical system and is closed, the contacts
provide a current path through the disconnect switch. The contacts must also withstand current
levels that occur when loadbreak switches are opened under load. Damage can occur at the
contacts as a result of the mechanical stress from closing operations and the electrical arc that
forms during contact opening operations. The purpose of the visual inspection of the contacts is
to ensure that they provide a low resistance current path and that the contacts of loadbreak
disconnect switches can safely interrupt load current.
Small burn and pock marks can develop on the surface of the contacts over the operating life of a
disconnect switch. Such marks will not interfere with the operation of the contacts, but the
contacts will need to be replaced when they erode over time to some wear point that is defined by
the manufacturer. For loadbreak disconnect switches that have arc extinction chambers (e.g., air,
oil, or vacuum), a contact wear indicator is checked.
The visual inspection of the disconnect switch contacts should be performed during the normal
switchgear or disconnect switch maintenance cycle as determined by Saudi Aramco procedures
and practices. The most stringent of the applicable maintenance cycles is the cycle that should be
applied. Technical data to evaluate the results of the contact visual inspection can be found in the
switchgear or disconnect switch manufacturer’s technical manual.

Mechanism/Linkage
The mechanism/linkage assembly of disconnect switches performs the actual movement of the
disconnect switch contacts when the switch opens or closes. The purpose of the
mechanism/linkage inspection is to ensure that the mechanism/linkage can move freely. Free
movement of the mechanism/linkage will ensure that the disconnect switch can be properly
operated by the operator (or operating mechanism). The inspector should visually determine that
no obstructions exist that will restrict or impede the proper operation of the mechanism/linkage.
The mechanism/linkage visual inspection should be performed during the normal maintenance
cycle of switchgear and disconnect switches as determined by Saudi Aramco procedures and
practices. The most stringent of the applicable maintenance cycles is the cycle that should be
applied. Technical data to evaluate the results of the mechanism/linkage visual inspection can be
found in the switchgear and disconnect switch manufacturer’s technical manuals.
Three-Phase Contact Blades Make and Break Together
When three-phase disconnect switches operate, the contacts must open and close as a group.
Additionally, the arcing contacts (and the arc horn, if used) must make and break in sequence with
the main movable blade contacts during disconnect switch operations. The proper contact make
and break should be observed during the open/close operation test. Proper contact make and
break consists of both the physical contact operation and the sequence of the contact operation.
The three-phase contact blades’ make and break visual inspection should be performed during the
normal maintenance cycle of the disconnect switches as determined by Saudi Aramco procedures
applied. Technical data to evaluate the results of the three-phase contact blades make and break
visual inspection can be found in the disconnect switch manufacturer’s technical manual.

Physical Damage
Physical damage of disconnect switches can prevent the proper operation of protective equipment
(e.g., arc horn failure), or it can lead to dangerous system grounds or shorts. Because of the
magnitude of the electric energy that passes through disconnect switches and the installed
interrupting devices, and because of the large forces that are required to open and close
disconnect switches, any physical damage to disconnect switches can propagate and will often
require major equipment replacement. The most obvious and common forms of physical damage
are cracks, dents, and missing or broken pieces. The disconnect switch blades should be checked
for warps, distortions, or bent structural framework.
The purpose of the physical damage inspection is to identify whether corrective maintenance or
equipment replacement is necessary due to physical damage. The physical damage inspection of
the disconnect switch must include any and all equipment that is contained or attached to the
disconnect switch. Disconnect switches and the installed equipment that show any form of
physical damage, no matter how small, should be determined to have failed the physical damage
inspection.
The physical damage visual inspection should be performed during the normal maintenance cycle
of switchgear and disconnect switches as determined by Saudi Aramco procedures and industry
applied. Technical data to evaluate the results of the physical damage visual inspection can be
found in the switchgear and disconnect switch manufacturer’s technical manuals.
Lubrication
The lubrication visual inspection should be performed in conjunction with the mechanism/linkage
visual inspection. The purpose of the lubrication visual inspection is to ensure that all moving
parts, bearing points, and sliding mechanisms of the disconnect switch are properly lubricated and
free of rust.
Before the application of new lubrication can take place, hardened grease, dirt, and rust should be
removed from the surfaces that require lubrication. A cloth that is dampened with kerosene
should be used to remove the hardened grease and dirt. Care must be taken to ensure that the
cloth does not deposit fibers on the moving parts. The deposit of cloth fibers on moving parts can
cause subsequent improper mechanism operation. After the proper preparation of the moving
parts, a thin layer of lubrication should be applied. Excess lubrication should be wiped off with a
clean cloth.

The lubrication visual inspection should be performed during the normal maintenance cycle of
switchgear and disconnect switches as determined by Saudi Aramco procedures and industry
standards. The most stringent of the applicable maintenance cycles is the cycle that should be
applied. Lubrication of the disconnect switches is acceptable if it allows free range of motion of
the disconnect parts and if the lubrication is not hard. Technical data to evaluate the results of the
lubrication visual inspection can be found in the switchgear and disconnect switch manufacturer’s
technical manuals.
Cleanliness
The purpose of the cleanliness visual inspection is to ensure the proper operation of the
disconnect switch over the maximum operating life. The accumulation of dirt over a period of
time in a disconnect switch will impede the proper operation of the disconnect switch and the
installed protective equipment, and the accumulation of dirt will reduce the dielectric strength of
the insulation stacks and mountings.
To maintain the proper operation of the disconnect switch, the accumulation of heavy amounts of
dust should be cleaned away from the disconnect switch during maintenance cycles. Inspections
should be performed both before and after cleaning or dust removal is conducted. For disconnect
switches that are installed in switchgear or enclosures, telltale signs can be left in dust that can
reveal otherwise hidden adverse conditions. For example, moisture droplets can leave small
craters in dust. Dust can also mask adverse conditions. For example, a carbon track that exists
on a bus support may be completely hidden under a layer of dust.
The cleanliness visual inspection should be performed during the normal maintenance cycle of
switchgear and disconnect switches as determined by Saudi Aramco procedures and industry
applied. Disconnect switches that are installed in extremely dirty, dusty, or humid areas may have
to be cleaned more often than once during the normal maintenance cycle. Dirt or dust should be
cleaned away when, in the opinion of the person who performs the maintenance, the dirt or dust
would impede the disconnect switch operation.

Suitability
The purpose of the suitability visual inspection is to determine whether the disconnect switch is
appropriate for the application in which it is placed. To determine the suitability of a disconnect
switch, a visual inspection of the nameplate information on the disconnect switch should be
performed and compared to the known information about the electrical system in which the
disconnect switch is placed. If the disconnect switch nameplate information does not match the
ratings of the electrical system, the disconnect switch should be replaced.
Although the suitability inspection of the disconnect switch is usually performed during
commissioning, it should also be performed during the normal maintenance cycle of the
disconnect switch as determined by Saudi Aramco procedures and industry standards. Periodic
visual inspections should be performed to ensure that changes that may have been made to the
system have not exceeded the ratings of the disconnect switch. The most stringent of the
applicable maintenance cycles is the cycle that should be applied. Technical data to evaluate the
results of the suitability visual inspection can be found in Saudi Aramco and industry standards as
well as the disconnect switch manufacturer’s technical manual.
Mechanical Inspections and Tests
Mechanical inspections and tests are used to assess the ability of a disconnect switch to physically
perform the mechanical movements that are necessary to make or to break an electric circuit. The
mechanical inspections and tests also assess the safety functions (e.g., key interlock) of the
disconnect switch. The mechanical inspections and tests that are performed on disconnect
switches that are installed in Saudi Aramco systems are as follows:
• Open/Close Operation
• Arcing Horns Function
• Bolt Torque
• Contact Wipe
• Mechanical Locking of Contact Blades
• Key Interlock System Operation
Open/Close Operation
Some disconnect switches in Saudi Aramco electrical systems can go from maintenance cycle to
maintenance cycle without a single operation. A disconnect switch must always be in a condition
to operate, no matter how infrequently the disconnect switch has been used. The purpose of the
open/close operation test is to ensure that the disconnect switch opens and closes properly.

To perform the open/close operation test, the disconnect switch is cycled from the fully open
position to the fully closed position and back to the fully open position. During the closing and
opening operations, the mechanical condition of all of the connected devices (e.g., arc horns and
position indicators) are checked for proper operation. For disconnect switches with interruption
chambers in which the contacts are not visible, the manufacturer’s technical manual should
contain information on the minimum moving contact travel distances.
The open/close operation test should be performed during the normal maintenance cycle of a
disconnect switch as determined by Saudi Aramco procedures and practices. The most stringent
of the applicable maintenance cycles is the cycle that should be applied. Technical data to
evaluate the results of the open/close operation test can be found in the disconnect switch
manufacturer’s technical manual.
Arcing Horns Function
Disconnect switches can contain arc horns, arc chutes, arcing tips, arcing boxes, or a combination
of all of these arc-suppression devices. The arc horns direct developed arcs away from the
disconnect switch contact assembly, which prevents damage to any connected or adjacent
equipment. The purpose of the visual inspection of the arc horns (and other arc-suppression
devices) is to ensure that the arc horns can safely suppress the arc that forms when the disconnect
switch opens. The arc horns (or arcing tips) should be adjusted so that the arcing devices close
before the main disconnect contacts close and open after the main disconnect contacts open.
During the visual inspection, the arc horns (or arcing tips) should be inspected for pitting or
scoring that could prevent the arc horn from properly directing the developed arc.
If the disconnect switch uses an arc chute or an arc extinguishing chamber, the chute or chamber
should be inspected for burn marks, scale, and cracks. Burn marks change the consistency of the
surface of an arc chute. If burn marks are present on an arc chute, the arc chute should be
replaced. Scale is the accumulation of foreign material in the arc chutes that can impede the
ability of the arc chutes to extinguish an arc. Scale should not be removed from the surface of the
arc chutes, so the inspector must determine whether the scale will impede the ability of the arc
chute to extinguish an arc. If the inspector determines that the scale will impede the ability of the
arc chute to extinguish an arc, the arc chute is replaced. Cracks form in the arc chutes during the
normal operation of a switch. The inspector must determine whether the cracks will interfere with
the ability of the arc chute to extinguish an arc, and he should replace the arc chute accordingly.

Oil-immersed switches are also used for medium and high voltage loadbreak switch applications.
Oil-immersed medium and high voltage loadbreak switches are commonly used by Saudi Aramco
for industrial applications. Oil-immersed switches are only suitable for outdoor use. For high
making and breaking capacity, the oil-immersed switch should incorporate either a spring toggle
mechanism or some form of arc control. The preferred type of switch construction has spring
toggle mechanisms that are enclosed inside the tank. Regular inspection and maintenance of oil-
immersed switches are necessary to remove accumulated sludge and to test the quality of the oil.
The visual inspection of the arc suppression device (e.g., the arc horn) should be performed
during the normal maintenance cycle of a disconnect switch as determined by Saudi Aramco
procedures and practices. The most stringent of the applicable maintenance cycles is the cycle
that should be applied. Technical data to evaluate the results of the arc suppression device visual
inspection can be found in the disconnect switch manufacturer’s technical manual.
Bolt Torque
The terminations of most low voltage and medium voltage disconnect switches use bolted
connections. Disconnect switch supports and movable blades use bolted metal segments. For a
given disconnect switch installation, many connecting bolts must be installed. Each bolt has a
torque specification that should be met for the installation. During the evaluation of the
disconnect switch installation, the Electrical Engineer should spot test the torque on the
connecting bolts.
When the spot test of the connecting bolts is performed, the Electrical Engineer should check that
all bolted connections have the correct hardware (e.g., washers and nuts) installed. The purpose
of a bolt torque inspection is to ensure that enough force is present to hold the bolts in place
during all required operations. To determine the amount of force that exists at a bolt, a torque
wrench is applied to the bolt in the direction that will tighten the bolt, and the amount of torque is
read.
The bolt torque inspection should be performed during the normal maintenance cycle of
disconnect switches as determined by Saudi Aramco procedures and industry practices. The most
stringent of the applicable maintenance cycles is the cycle that should be applied. Technical data
to evaluate the results of the bolt torque inspection can be found in the Saudi Aramco Pre-
Commissioning Form, P-000, Testing Guidelines, as well as the disconnect switch manufacturer’s
technical manual. Bolt torque values are provided in Work Aid 2.

Contact Wipe
The purpose of the mechanical inspection of the contact wipe is to ensure that the correct contact
wipe is present at the disconnect switch contacts. The contact wipe should be observed and
measured during the open/close operation test of disconnect switches. The contact wipe is the
distance that the stationary contacts move as the disconnect switch main contact blade moves
from the open to the closed position. The various disconnect switch main contact assembly
designs all require that specific pressures be kept on the movable blade contacts to ensure proper
electrical contact. The contact pressure is usually a function of the travel distance of the
stationary contacts after the tips touch during a closing operation.
The contact wipe inspection should be performed during the normal maintenance cycle of a
disconnect switch as determined by Saudi Aramco procedures and practices. The most stringent
of the applicable maintenance cycles is the cycle that should be applied. Technical data to
evaluate the results of the contact wipe inspection measurements can be found in the disconnect
switch manufacturer’s technical manual.
Mechanical Locking of Contact Blades
If the disconnect switches are provided with a locking feature, a mechanical inspection and test
should be performed on the mechanical locking jaws of disconnect switches. The purpose of the
mechanical inspection and test of the mechanical locking feature of a disconnect switch blade is to
ensure that the blade contact locks into place when the switch is closed and to test that the
locking feature releases the blade when the switch is opened. The inspection and test of the
mechanical locking feature is performed by cycling the switch and by observing the proper
operation of the locking feature. For gang-operated disconnect switches, the inspection and test
personnel should also determine that each phase makes connection and that the locking jaws lock
simultaneously.
The mechanical inspection and test should be performed on the mechanical locking feature during
the normal maintenance cycle of a disconnect switch as determined by Saudi Aramco procedures
applied. Technical data to evaluate the results of the mechanical locking feature inspection and
test can be found in the disconnect switch manufacturer’s technical manual.

Key Interlock System Operation
Disconnect switches are usually associated with a circuit breaker or switchgear installation. When
a disconnect switch is in series with or associated with a circuit breaker, an interlock should be
used to prevent the opening of the disconnect switch with the breaker closed. The interlock can
take the form of mechanical linkages, electrical relaying systems, or key interlocks. Key
interlocks are an inexpensive way to prevent the inadvertent operation of disconnect switches.
Disconnect switches that use key interlocks may be in parallel, or they may be associated with
parallel power sources. Because a disconnect switch with a key interlock can only be operated
when the key is inserted, and because only one key is provided, both disconnect switches cannot
be operated at the same time. If both disconnect switches cannot be operated simultaneously, the
inadvertent paralleling of power sources is physically impossible. The removal of the key can
render both disconnect switches inoperable during troubleshooting or maintenance evolutions.
The purpose of the mechanical operation inspection is to ensure that the key interlock system will
function properly. The basic method that is used to perform this inspection is to attempt to
operate both disconnect switches at the same time. Extreme caution must be exercised when this
test is performed. The entire system should be deenergized prior to the test to prevent serious
injury to personnel or damage to equipment in the event that the interlock does not function
properly. The results of the key interlock system mechanical operation inspection are satisfactory
if the interlock system is visually observed to properly operate.
Electrical Tests
Electrical tests are performed to check the ability of disconnect switches to operate for a
reasonable future period of time under all operating conditions and loads. Acceptance or
installation tests will usually detect shipping or installation damage and gross defects or errors in
workmanship in disconnect switch construction. Maintenance tests are performed at periodic
intervals during the operating life of a disconnect switch. The following electrical tests are
performed on Saudi Aramco disconnect switches:
• Contact Resistance
• Insulation Resistance
• Oil Dielectric
• High Potential (High Voltage Class)

Contact Resistance
The purpose of the contact resistance test of the disconnect switch is to identify contacts that are
defective or detrimental to the operation of the disconnect switch. The contact resistance test
may also identify loose connections in a disconnect switch. With the system deenergized and
isolated, the leads of a digital, low-resistance ohmmeter should be placed across the line and load
sides of the disconnect switch blade, and measurements should be taken across the contacts of
each phase. A digital, low-resistance ohmmeter can deliver enough power to the disconnect
switch to make accurate readings that have more validity than those readings that can be obtained
through the use of an ordinary multimeter. The contact resistance is recorded on a test data sheet
and attached to the Saudi Aramco Pre-Commissioning Form, P-001, Switches; High and Medium
Voltage Air, Oil, and SF-6.
Increased contact resistance may be caused by contacts that do not make proper contact or by
pitting on the surface of the contacts. The contact resistance values that are recorded should be
consistent with the manufacturer’s recommended values. Generally, values of contact resistance
in excess of 150 micro-ohms and deviations of more than +/- 20% between adjacent poles or
similar switches should be investigated. Technical data to evaluate the results of the contact
resistance test can be found in the disconnect switch manufacturer’s technical manual.
Insulation Resistance
The purpose of the insulation resistance test is to directly measure the insulation resistance of the
disconnect switch through use of a megger. In the insulation resistance test, the megger is used to
set up an electromagnetic field, and the field that is created is used to produce leakage currents
that will flow through the insulation between each phase and ground or from phase to phase. The
amount of leakage current flow that is detected by the megger results in a megger meter readout
of insulation resistance (in megohms).

To conduct the insulation resistance test, the megger is connected between two of the blades of
an open disconnect switch, and the megger is operated. Megohmmeter test voltages vary for low,
medium, and high voltage systems. Manufacturer’s technical manuals should be consulted for the
proper megohmmeter test value. In general, the values of insulation resistance should be less than
the manufacturer’s minimum or less than the rated voltage of the system + 1 kV in megohms.
Insulation resistance evaluation information is provided in Work Aid 2. Similar megger readings
are taken between each remaining phase pair combination on both sides of the open contacts of
the disconnect switch. The megger is then connected between each disconnect switch blade and
ground, and the megger is operated. Similar megger readings are taken between each remaining
phase and ground combination on both sides of the open contacts of the disconnect switch. The
insulation resistance values are recorded on a test data sheet or in the Saudi Aramco Pre-
Commissioning Form, P-001, Switches; High and Medium Voltage Air, Oil, and SF-6.
Acceptable insulation resistance values should be determined through use of the disconnect switch
manufacturer’s technical manual. The insulation resistance test should only be performed during
the commissioning of disconnect switches and during the first few maintenance cycles. After a
few maintenance cycles, the ac hi pot test is used to determine the integrity of the insulation of the
disconnect switch.
Oil Dielectric
Oil is used in some disconnect switch installations as the arc quenching medium. The oil that is
used as an arc quenching medium must have the ability to insulate the disconnect contacts, to
quench the arc, and to dissipate the heat that is formed when the arc is developed. Because of the
importance of the oil in the operation of disconnect switches that use oil, certain tests should be
performed on the oil upon initial installation and during periodic maintenance periods.
The purpose of the electrical tests and inspections that are performed on insulating oil is to ensure
that the insulating oil has the correct dielectric properties to perform the arc interruption and that
no impurities are present in the oil. A large array of testing is performed on oil prior to shipment
and upon receipt; however, these tests generally fall into two categories: electrical tests of the
oil’s dielectric properties and tests for the presence of impurities. The electrical tests of the oil’s
dielectric properties test the dielectric breakdown voltage and the power factor of the disconnect
switch oil. Tests for the presence of impurities, such as moisture and gas, are performed because
the presence of impurities in oil has a negative impact on the dielectric properties of the oil. The
approved methods that are used to perform each of the tests are provided by the American
Society of Testing and Materials (ASTM). ANSI C57.106 - 1991 contains the ASTM test
reference information and the technical data that are necessary to evaluate the results of the oil
dielectric inspection and tests.

High Potential (High Voltage Class)
Both ac and dc high potential tests can be performed on medium and high voltage switches and
switchgear. The purpose of the ac high potential (hi pot) test is to evaluate the condition of the
high voltage class disconnect switch insulation. Insulation that is in good condition will have
sufficient dielectric strength to withstand voltage surges that are caused by switching or transient
line surges. The ac hi pot test is used during the maintenance cycles of the disconnect switch to
verify the proper condition of the disconnect switch insulation. The ac hi pot test is a go/no-go
test and will not identify insulation that is gradually deteriorating.
In general, the ac hi pot test can be performed on the same test points as the insulation resistance
test; however, the frequency with which the ac hi pot test is performed differs from the insulation
resistance test. The ac hi pot test is performed through the use of an ac hi pot test set. The leads
of the test set are applied to the same test points as the leads in the insulation resistance test. The
manufacturer’s technical manual must be consulted to determine the appropriate test voltage for
the test. Once the appropriate test voltage has been determined, the test voltage should be
applied to the disconnect switch to test the insulation for a period of one minute. The ac hi pot
test set measures the amount of current that leaks through the insulation of the disconnect switch.
When the leakage current reaches a predetermined amount, an overcurrent relay inside the test set
is actuated, and a light is lit on the test set that indicates insulation failure. Sparks or arcs around
the test leads also indicate insulation failure. If any of these test conditions occur, the disconnect
switch needs to be replaced.
The purpose of the dc overpotential (hi-pot) test is to identify internal faults in or damage to the
electrical insulation. The dc hi-pot test should be performed prior to the initial energization of a
high voltage disconnect switch and after the megohmmeter test. The dc hi-pot testing technique
involves the measurement of increased dc voltage that is applied to the system under test. The
value of the leakage current is tracked as the test voltage is increased through several steps and
becomes a criterion of the condition of the insulation.
Electrical test reference information for the ac and dc hi-pot tests is provided in the Saudi Aramco
Pre-Commissioning Form, P-000, Testing Guide Lines. The electrical test reference information
provides the recommended test procedure and test voltages for the various equipment voltage
ratings. During the test, the leakage current is plotted against time at the end of each timing
interval.

The ac or dc hi-pot test information is recorded on a test data sheet or in the Saudi Aramco Pre-
Commissioning Form, P-001, Switches; High and Medium Voltage Air, Oil, and SF-6. Ac and dc
hi-pot test evaluation information is provided in Work Aid 2. The Electrical Engineer should
evaluate the ac and dc hi-pot test leakage current test data to ensure that the test data meet the
minimum requirements for a successful test. A polarization index value of two or greater, or ac
or dc hi-pot test data curves that indicate a steady increase in leakage current over the duration of
the test should be investigated by the Electrical Engineer who performs the test data evaluation.
Functional Operation Test
The functional operation test of a disconnect switch ensures that all of the installed parts, such as
linkages and jaws, are able to work in conjunction with each other so that the disconnect switch
and the installed equipment can provide electrical system protection and operation. Most of the
tests that have been performed thus far have been tests that ensure the performance of the
individual parts of the disconnect switch. The functional operation test will ensure that the parts
will work together so that the disconnect switch will operate correctly when it is installed in an
electrical system.
To perform the functional operation test, the complete disconnect switch is installed and tested.
Because there may be several ways to operate a disconnect switch (e.g., manually by hand or with
an operating motor), each mode of operation must be tested to ensure that it properly functions.
The functional operation test must also include the proper operation of all interlocks that are
associated with the disconnect switch. The functional operational test information is recorded on
a test data sheet or in the Saudi Aramco Pre-Commissioning Form, P-001, Switches; High and
Medium Voltage Air, Oil, and SF-6. During the functional operation test, the inspector should
visually assess that all of the contacts of the disconnect switch have opened as far as possible
without grinding, scraping, or motion restrictions.
With the disconnect switches installed in the system, source feed compatibility checks are
performed on switchgear and the associated disconnect switches through application of the full
system voltage onto the switchgear. With the voltage applied, voltage phasing, synchronizing,
device rotation, protective relay calibration, and other source feed compatibility checks are
performed in conjunction with any circuit breakers that are associated with the disconnect
switches. Parallel or alternate power source feed operations are also performed to ensure the
total operation of the major components of the power distribution system.

A complete system functional test is performed on switchgear and the associated disconnect
switches and circuit breakers to ensure that the entire electric power system functions in
accordance with the system design. During the complete system functional test, the equipment is
allowed to assume a fully loaded condition for a period of time that is adequate to obtain the
maximum system temperature. After the loaded time period, the equipment temperatures are
monitored. Particular attention should be paid to wiring and terminal connections during the
complete system functional test.
Thermographic Survey (System Energized and Loaded)
A thermographic survey is essentially a “Temperature Picture” of operating equipment through

use of infrared photography. Thermographic surveys are usually performed on installed and
operating equipment that passes current and produces heat, such as high disconnect switches,
circuit breakers, or power cables. The thermographic survey is used to assess unusual amounts of
heat production. Once an instance of increased heat production is identified, the system is
investigated to determine the cause of the heat increase.
To properly perform a thermographic survey, the disconnect switch should be fully reinstalled into
its compartment and connected to the main power circuit. The disconnect switch should be
closed, and the circuit should be operated at full load to allow the disconnect switch to heat up to
its normal operating temperature. Once the disconnect switch is at its normal operating
temperature, a thermographic survey is performed.
Figure 9 is an example of a thermographic survey that is used to evaluate terminations. The

thermographic survey shows three power cables that are connected to a transformer through use
of elbow terminations.
The far-right elbow termination in Figure 9 is hotter than the other two terminations. The lighter
color of the far-right termination indicates that the far-right termination is hotter than the other
two. In black-and-white thermography, lighter colors indicate the presence of more heat, and
darker colors indicate that less heat is present. While Saudi Aramco does not currently have the
capability to perform color thermography, it may be an option in the future. When color
thermography is performed, the level of heat is represented by the order of the colors in the
rainbow; purple is the coolest, and red is the hottest. Some color thermography systems use
white as the hottest color in the color scheme.

When a source of excess heat is identified, the cause of the excess heat should be identified. The
cause of the excess heat in Figure 9 could be one of the following:
• A poor elbow termination.

• A defective transformer bushing.
• An unbalanced load that causes an increase in the load current through one phase.
Once the cause of the excess heat has been determined, an appropriate course of action can be
taken.
Example of Thermographic Survey

Figure 9

Review of Testing and Inspection Results
Once the installation and inspection data have been recorded and assembled, a methodical and
consistent program of periodic data collection and evaluation should be established. As each new
maintenance item, test, splice, system addition, or system reconfiguration occurs, new inspections
and data records will be required and should be added to the existing data on file.
The proper evaluation of inspection and testing data can maximize the operating time of
disconnect switch installations through a determination of trends towards failure. Failure
prediction can drastically reduce equipment down-time; if a failure is predicted, operational
changes can be made, maintenance can be performed, or failing disconnect switch equipment can
be replaced in a controlled manner. If a problem is corrected before it causes damage or
equipment malfunction, operating costs will be lower because equipment malfunctions can cause
associated (or nearby) equipment damage, disruption of service, or activation of emergency repair
crews.
The process to determine the acceptability of disconnect switches is to verify that all the tests and
inspections have been performed properly and to verify that the test results are within the
specifications that are designated by the applicable standards and technical manuals. If all of the
disconnect switch testing and inspection results are satisfactory, the disconnect switch is placed in
service. If all of the disconnect switch testing and inspection results are not satisfactory, the
process that is required to place the disconnect switch in service is more involved.
Because of the different inspection items that are associated with disconnect switches, several
courses of action are available for disconnect switches that have failed a visual inspection. The
course of action depends on the part of the disconnect switch that failed the visual inspection.
Some disconnect switch parts (e.g., insulation support stacks) can be corrected through the
replacement of the parts that failed the visual inspection. Visual alignment, mechanism/linkage,
lubrication, or cleanliness inspection failures can usually be corrected through maintenance
procedures. A visual physical damage and suitability inspection failure will probably require the
replacement of the entire incorrect or damaged part. For mechanical test and inspection failures,
different courses of action may be required. For example, a bolt torque test failure can be
corrected through adjustment of the bolts with a torque wrench.

Because an electrical inspection or test failure can be caused by a construction error, equipment
age, or operational misuse, some kind of troubleshooting or maintenance activity should be
performed on the disconnect switch when an electrical inspection or test is failed. Some electrical
inspection or test failures are not repairable and require the replacement of the failed equipment.
A failure in any one of the many tests that are performed on a disconnect switch during initial
installation or a maintenance cycle, no matter how insignificant the test may seem, is sufficient
cause to not allow the disconnect switch to be placed in service. The inspector must be able to
determine the appropriate action to take to place the disconnect switch back into service.

WORK AID 1: RESOURCES USED TO VERIFY THAT THE TYPE,

CONSTRUCTION, OPERATIONAL CHARACTERISTICS, AND
RATING OF DISCONNECT SWITCHES ARE CORRECT FOR THE
APPLICATION
The information that is presented in the checklists and information tables has been assembled
from SAES-P-116, SADP-P-116, SADP-P-610, ANSI C37, and associated industry standards.
Work Aid 1A: Guidelines, Requirements, and Ratings that are Used in the Application
and Selection of Loadbreak Switches
Figure 12 shows a table of Saudi Aramco guidelines for the application and selection of loadbreak
switches.
Guidelines for the Application and Selection of Loadbreak Switches

Figure 12

Guidelines for the Application and Selection of Loadbreak Switches

Figure 12 (Cont’d)

Figure 13 shows the construction requirements for medium voltage disconnect switch types.
Construction Requirements for Medium Voltage Disconnect Switch Types

Figure 13

For consistency, rated insulation levels and fault-make ratings that are applicable to air switches
(as defined in ANSI C37.32) must be used for loadbreak switches. Figure 14 shows the preferred
ratings for high- and medium-voltage loadbreak switches that are used by Saudi Aramco.
1 Short-time current ratings include a momentary and a three-second current rating that is
based on test conditions that are described in section 5 of ANSI/IEEE C37.34. Divide the
momentary rating by 1.6 to obtain the three-second current rating. When a higher
momentary current rating than is shown is required, use a switch that has the next higher
continuous current rating.
Loadbreak Switch Preferred Ratings (From C37.32-1990)

Figure 14

Work Aid 1B: Disconnect Switch Applications Checklist
Disconnect switch rating information can be found on the equipment nameplate or in the
manufacturer’s technical manual. The following is a checklist that is used to verify that the type,
the rating, and the operational characteristics of disconnect switches are correct for the
application based on Saudi Aramco and industry standards:
• Verify that the disconnect switch meets the Saudi Aramco requirements that are
shown in Figures 12 and 13.
• Verify that the disconnect switch matches the information that is provided in the
latest single line diagram (e.g., name of manufacturer, catalog or serial number).
• Verify that the disconnect switch frequency rating is correct for the application.
• Verify that the disconnect switch voltage ratings are correct for the application.
• Verify that the disconnect switch current ratings are correct for the application.
• Verify that the disconnect switch operational characteristics are suitable for the
electrical loads that are supplied by the disconnect switch and that any cautions or
warnings are listed on the nameplate.
• Verify that any key interlocks that are necessary are present and that the interlocks
function properly.

WORK AID 2: RESOURCES USED TO VERIFY THE CORRECT CONDITION AND

OPERATION OF DISCONNECT SWITCHES
This Work Aid is designed to assist the Participants in performing Exercise 2. The information
that is presented has been assembled from 16-SAMSS-510, SAES-P-116, SADP-P-116, SADP-P-
610, ANSI C37, and associated industry standards.
Work Aid 2A: Saudi Aramco Pre-Commissioning Form, P-001, Switches; High and
Medium Voltage Air, Oil, and SF6
Figure 15 shows a Saudi Aramco Pre-Commissioning Form, P-001, Switches; High and Medium
Voltage Air, Oil, and SF-6. P-001 contains a checklist and data tables for visual, mechanical, and
electrical inspections, as well as mechanical and electrical tests of switches.

Saudi Aramco Pre-Commissioning Form, P-001, Switches; High and Medium Voltage Air,
Oil, and SF-6
Figure 15

Saudi Aramco Pre-Commissioning Form, P-001, Switches; High and Medium Voltage Air,
Oil, and SF-6
Figure 15 (Cont’d)

Work Aid 2B: Information, Formulas, and Tables for Use in Evaluating the Results of
Insulation Resistance (Megger) Tests
The results of all commissioning megger tests that are performed must be documented on the
appropriate Saudi Aramco pre-commissioning form.
The following are the types of megger tests that can be conducted:
• Short time or spot reading

• Time resistance
• Dielectric absorption ratio
When the dielectric absorption ratio megger test is performed, the polarization index can be
determined through use of the following equation:
Figure 16 shows the recommended megger test voltages for various equipment voltage ratings.
Equipment Voltage Rating Recommended Megger Test Voltage
100 - 250 500

251 - 600 1000
601 - 2500 2500
5000 + 5000
Recommended Megger Test Voltages

Figure 16

Work Aid 2C: Information, Formulas, and Tables for Use in Evaluating the Results of
Connection Resistance Checks
The resistance check on the bus duct connections is conducted through measurement of the
circuit continuity across the bus connection with the proper meter. A ductor or micro-ohmmeter
is used to conduct the resistance checks; the measured values at each bus duct connection should
be less than 150 micro-ohms with deviations of less than 20% from adjacent phases.
Figure 17 provides bolt torque values for bus connections.
Bolt Torque Values

Figure 17
Figure 18 provides insulation conditions for 60/30 second ratio results and for 10/1 minute ratio
results.
Dielectric Absorption Ratio Chart

Figure 18

Work Aid 2D: AC or DC Hi Pot Tests
The ac and dc hi pot tests are high potential voltage tests that are conducted phase to ground and
phase to phase. The tests are conducted from both the line side and the load side of the open
disconnect switch contacts. The ac and dc hi pot test voltages must be in accordance with the
manufacturer’s recommended values. When the manufacturer’s recommended values are not
available, the maximum voltage values in Figure 19 should be used.
Equipment Rated kV Test Voltage kV

AC DC
2.5 5.0 9.0

5 9.35 16.0
15 26.0 44.0
25 43.0 73.0
35 60 102.0
Table of Hi Pot Test Values

Figure 19
For the dc hi pot test, apply an initial voltage step of about one-third of the recommended
maximum voltage and maintain the initial voltage for ten minutes. After the initial ten-minute test,
the dc test voltage is increased in ten uniform steps up to the maximum recommended dc value.
Each step should held be for one minute.
For the ac hi pot test, increase the test voltage at a rate of 1 kV per second until the maximum
recommended test voltage is reached. Field test voltages are determined by the following: AC
test volts = 0.85 x (2.0 x rated voltage + 1 kV).

Work Aid 2E: Information, Formulas, and Tables for Use in Evaluating the Results of
Hi-Pot Tests
During the performance of hi-pot testing, the test should be stopped if one of the following
situations occurs:
• The duration of the test has expired.

• A rapid rise in leakage current occurs.
• The polarization index < 1.
The following are the characteristics of a satisfactory hi-pot test:
• The leakage current decreases over time.

• The polarization index > 2.
• The leakage current increases on a straight line as voltage is increased. No “knee”
is noticeable in the leakage current curve.
An example of hi-pot test data is shown in Figure 20. Figure 20 shows both good and bad
insulation test data.
Figure 20

GLOSSARY
BIL The basic impulse insulation level (BIL) is the reference impulse
level, expressed in full wave kilovolts, that the equipment can
withstand without a flashover.
dielectric The ratio of two timed insulation resistance readings (such as a 60-
second
absorption ratio reading that is divided by a 30-second reading).
grounding switch A grounding switch is a mechanical switching device by means of

which a circuit or piece of apparatus may be electrically connected
to ground for maintenance and safety reasons.
group operation A group operation is the operation of all poles of a multiple- pole
switching
(ganged operation) device by one operating mechanism. Group operation is in contrast
to single pole operation where the number of operations required to
reposition the device is equal to the number of poles.
load current The highest rms current (in amperes) between unity and 0.8 power
factor
interrupting rating (lagging) that a loadbreak switch must be required to interrupt at
the rated voltage and frequency for the expected operating life of
the switch.
maximum direct The rms total current, which includes the transient direct-current
component.
current
nominal system The nominal system voltage refers to the general equipment voltage
class
voltage designation.
polarization index The ratio is a ten-minute insulation resistance reading divided by a

one-minute insulation resistance reading.
rated continuous The amount of current that can be continuously carried by the
equipment
current at 60 Hz without exceeding the equipment allowable temperature rise.
rated maximum The highest rms voltage for which the equipment is designed, and it
is the

voltage upper limit for operation.
rated momentary The rms total current that the equipment must be required to carry
for at least
current one cycle.
rated short-time The maximum direct current that the equipment is required to carry
successfully
current for a specified short-time interval.
rated three-second The rms total current, which includes the direct current component,
if present,
current that the equipment must be required to carry for three seconds.
rated voltage The highest nominal system voltage on which the equipment is
intended to be applied.
rated withstand The voltage that the equipment must be able to withstand without
flashover
voltage or other electric failure.

Acceptability of Disconnect Switches

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Acceptability of Disconnect Switches

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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Assessing the Acceptability of Disconnect Switches

Chapter : Electrical For additional information on this subject, contact

VERIFYING THAT THE TYPE, CONSTRUCTION, OPERATIONAL

Saudi Aramco DeskTop Standards

Arcing Horns Function..................................................................................27

Saudi Aramco DeskTop Standards

VERIFYING THAT THE TYPE, CONSTRUCTION, OPERATIONAL

• Types of Disconnect Switches

Types of Disconnect Switches

Saudi Aramco DeskTop Standards 1

Disconnect Use on Example Feeder Bus

Saudi Aramco DeskTop Standards 2

• Some means must be provided to ensure that a proper blade-to-jaw contact is

• The switch should be within the capability of maintenance or operations personnel

Saudi Aramco DeskTop Standards 3

Typical Disconnect Switch Configurations

Saudi Aramco DeskTop Standards 4

Saudi Aramco DeskTop Standards 5

• Interrupting small inductive or capacitive currents for applications in which the

• Performing a closing operation onto a terminal short circuit.

Saudi Aramco DeskTop Standards 6

Saudi Aramco DeskTop Standards 7

Low Voltage Disconnect Switches

Saudi Aramco DeskTop Standards 8

Construction and Operational Characteristics

Typical Single Operation, Non-Loadbreak, Low Voltage Disconnect Switch

Saudi Aramco DeskTop Standards 9

Saudi Aramco DeskTop Standards 10

Saudi Aramco DeskTop Standards 11

Saudi Aramco DeskTop Standards 12

Medium Voltage Disconnect Switches

• Frame-mounted loadbreak switch (oil-immersed)

Frame-Mounted, Oil-Immersed-Type Loadbreak Switch - The frame-mounted, oil-immersed

Pad-Mount Disconnect Switches - Pad-mount disconnect switches are available in switchgear

• Oil switches that are immersed in oil-filled sealed tanks.

• Vacuum switches that are immersed in oil- or SF6-filled sealed tanks.

• SF6 switches that are immersed in SF6-filled sealed tanks.

• Air switches that are installed in air-insulated enclosures.

Saudi Aramco DeskTop Standards 13

Metal-Enclosed Interrupter Switchgear - Metal-enclosed interrupter switchgear is built

Construction and Operational Characteristics

Saudi Aramco DeskTop Standards 14

Typical, Single Pole, Medium Voltage Disconnect Switch

Saudi Aramco DeskTop Standards 15

Close-Up View of a Disconnect Switch Contact Assembly

Saudi Aramco DeskTop Standards 16

High Voltage Disconnect Switches

• Frame-mounted loadbreak switch (oil-immersed)

Saudi Aramco DeskTop Standards 17

Construction and Operational Characteristics

Three-Pole, Vertical, Motor-Operated, Loadbreak Disconnect Switch

Saudi Aramco DeskTop Standards 18

Cut-Away View of a Typical Arc Extinction Chamber

Saudi Aramco DeskTop Standards 19

Example Application of High Voltage Disconnect Switches - Load Sectionalizing

Saudi Aramco DeskTop Standards 20

VERIFYING CORRECT CONDITION AND OPERATION OF DISCONNECT

Saudi Aramco DeskTop Standards 21

Saudi Aramco DeskTop Standards 22

Three-Phase Contact Blades Make and Break Together

Saudi Aramco DeskTop Standards 23

Saudi Aramco DeskTop Standards 24