CHAPTER 19

TESTS
GENERAL
• Tests of substation equipment are required to fulfill at least the following functions:
• a. To prove the integrity of a piece of equipment at the time of acceptance
• b. At periodic intervals, to verify the continued availability of the equipment
• c. At the time of failure of a piece of equipment, to be able to determine the specific
requirements for repair
• The types of tests to be performed for each of the above categories vary. Guidelines are
therefore included to assist in this selection. The guidelines are, of necessity, quite
general in nature and, as such, have to be tailored to meet the requirements of the
specific equipment.
• Coordinate the testing schedules with the inspections as detailed in Chapter 18. In
addition, utilize scheduled outages to the greatest extent possible as periods for testing
since certain equipment is unavailable for test unless large portions of the substation are
de-energized.
• Upon completion of tests, make provisions to follow-up with repeat tests where required
and make repairs where the need is indicated by the test results.
• In all cases, factor into the testing procedures outlined specific equipment manufacturer’s
recommendations as contained in the equipment instruction books.
Records
• Maintain a records system inspection for each site. In addition to the details contained
therein, these records should contain at least the following information:
• a. The name, date, and results of all tests performed
• b. The date when the equipment should again be tested
• c. Any requirements for follow-up or special tests required as a result of indications of
potential trouble.
Safety
• Some tests, particularly those requiring gas or oil samples, may be performed without
removing the equipment from service. The personnel performing such tests or obtaining
gas or oil samples have to observe safety regulations at all times. Special attention is
called to the minimum clearances provided in Chapter 18. Whenever possible, provide
temporary barriers to isolate the equipment being tested from adjacent energized
equipment.
• Testing equipment is usually very specialized. Restrict its use, therefore, to those
personnel who have been adequately trained. Improper use of the equipment may
expose both the user and the equipment to hazards.
• The analysis of properly obtained test data is again a specialized technique. Failure to
recognize trends while conducting a test could be injurious to the personnel, the test
equipment, and the equipment being tested. Failure to recognize trends in data obtained
at different times can result in the failure to detect potential problems in sufficient time to
permit an orderly and timely removal of equipment from service.
DETAILED REQUIREMENTS
• As indicated above, testing is performed to accomplish three distinct functions: the
acceptance of equipment, the periodic verification of its integrity, and to permit better
analyses of its failure.
Acceptance Tests
• Acceptance tests are performed after receipt and erection or installation of
equipment at a site. The results of these tests are compared with the specifications,
where applicable, evaluated, and compared with acceptable norms and factory test
data and, when found acceptable, recorded for future reference.
Periodic Tests
• Periodic tests, those used to establish the continuing quality of the equipment, are
conducted at varying intervals, depending on the type of equipment.
Tests After Failure
• Testing conducted after an equipment failure is performed to determine,
to the greatest extent possible, the location, magnitude, and cause of the
failure. Such data, when properly obtained, is used in determining
whether the equipment can be repaired in place or needs to be shipped
to a repair shop.
• Specific details for application of the test equipment are in the instruction
book for that item of test equipment. A brief reference to applicable test
equipment is also included with the description of each test. The ranges
and outputs indicated are considered appropriate for the tests and thus
should not be varied significantly.
Insulation Resistance Test
• This test is performed to verify the integrity of the insulation as is used in
all types of electrical equipment. This includes transformers, circuit
breakers, cables, motors, switches, etc.
Power Factor Test

• This test is used to measure the power factor of the insulation in all types of
electrical equipment and cable. The test has to be conducted at
temperatures above 0°C since ice is a relatively good conductor. This test
provides an indication of the quality of the insulation. Values obtained during
the acceptance tests are compared with expected ranges of values
determined from similar equipment. After the initial tests, comparison is
made between values obtained at different times so as to establish a trend
and thus anticipate potential troubles. Whenever possible, incorporate
power factor tests into the routine factory tests for equipment. The
acceptance test values may then be directly compared with the factory
values.
The GST (Grounded Specimen Test) Guard tests measures the
total current leaking to ground only. The power factor test
set ignores current flowing through the red or blue lead.
In UST (Ungrounded Specimen Test) mode, ground is considered guard since
grounded terminals are not measured. When the UST test is performed, the
only current being measured by the test set is the current flowing on the red or blue
lead. Any current flowing to a grounded terminal is bypassed directly to the AC source
return, and is eliminated from the measurement.
In the last mode of operation, the GST (Guarded Specimen Test) mode,
both leakage paths (ground lead and the red or blue lead) are measured
by the test set. The current, watts loss, and capacitance parameters of
the UST and GST Guard tests should equal the parameters in the GST
test. This gives the overall condition or power factor of the test specimen.
• Equipment Required: Test equipment, such as manufactured by the Doble
Engineering Company or Biddle Company, Inc., Hipotronics, and others, is
among that suitable for this purpose.

• Acceptable Values: Acceptable values of power factors for various items of

equipment are provided with the test equipment. Additionally, equipment
manufacturers frequently provide this data for their specific equipment. The
values for a few common items are provided for reference only, so as to
illustrate the very low magnitudes of power factors encountered.
DC High Potential Test
• This is a test of the dielectric strength of insulation. It is used to determine
the quality of the insulation in electrical equipment, particularly for items with
solid dielectrics such as porcelain, rubber, PVC, etc. It is not generally used
for on-site testing of equipment windings, with the exception of motor-
generator windings, or on oil-filled equipment.
Equipment Required: DC high potential set, similar to those manufactured by
Associated Research, Inc., Biddle Company., Hipotronics Inc., Von Inc., and
others (0 to l00 kV or higher, as required).
Typical Test Voltages
• Acceptance Tests: 80 to 85% of factory test voltage
• Periodic Tests: 60 to 65% of factory test voltage (55 to 60% of factory test
voltage with PILC cable with neoprene jacket)
Dielectric Absorption Test

• This test is again a test of the quality of the insulation. It is applicable to

transformers, regulators, and other similar devices as well as shielded high-
voltage power cable. It is not possible to provide a range of values for the
results of this test. Its primary function is to provide an indication of
deterioration prior to complete failure.

• This test is performed by charging the insulation under test with an insulation
resistance test set. The test is applied for a period sufficient to fully charge
the cable. Resistance readings are taken every 15 seconds during the first 3
minutes and at 1-minute intervals thereafter. The test shall continue until
three equal readings are obtained. This final reading shall be recorded. All
windings or other conductors (in the case of a cable) not being tested have
to be grounded. The tank (or shields) has to be grounded also.
AC Over-Potential Test
• This test is performed to verify the integrity of the insulation in low-voltage devices (600-
volt and below) and associated wiring. Observe specific manufacturers’
recommendations before applying this test to solid-state components. The test consists
of applying an ac voltage to the device for 1 minute and verifying the successful withstand
of this voltage.
Equipment Required: AC high potential set, similar to those manufactured by Biddle
Company or Hypotronics Inc. (0 to -2500V output or higher as required).
Test Voltages
• Acceptance Tests: Twice the operating voltage plus 100 volts, but no less than 1500 volts
Periodic Tests: 1.7 times the operating voltage
Contact Resistance Test
• This test is used to measure the resistance of the main contacts of a circuit breaker. A
rise in resistance is an indication of the need for maintenance or replacement of the
contacts.
Equipment Required: A digital low-resistance ohmmeter as manufactured by the Biddle
Company, or similar.
• Typical Readings: Refer to data provided by manufacturer with respect to the maximum
permissible resistance. Typical ranges, however, are as follows:
• Circuit breakers: 10 to 50 micro-ohms (medium voltage)
50 to 350 micro-ohms (high voltage)
• Reclosers: 50 to 200 micro-ohms
Winding Resistance Test
• The winding resistance in a motor, transformer, regulator, etc., is not subject to change
unless turns are open or short-circuited. An accurate measurement of the resistance at
time of acceptance will thus permit future assessment of winding faults. Periodic checks
will disclose shorted turns before further problems occur. Results have to be corrected for
temperature.
• The winding resistance test is used to find open windings, shorts to ground, wrong turn
count, wrong wire gauge, resistive connections, round wires in hand that are not
connected in a coil, some connection mistakes, the resistance balance between phases,
and in some cases shorted turns.
• Winding resistance is an important measurement because other tests and measurements
will not find some of the problems a resistance measurement will find. Some of these are
the wire gauge issues, resistive connections, and blown or disconnected magnet wires in
hand.
Insulating Oil Tests
• Perform neutralization number, interfacial tension, dielectric strength, color, and
visual examination tests as described in IEEE Std. C57.106, “Guide for Acceptance
and Maintenance of Insulating Oil in Equipment.” A comparison of the values
obtained for each test over a period of time will indicate the gradual deterioration of
the oil unless oil treatment has been performed. Sudden or accelerated changes in
the dielectric strength are not normally encountered. Should a large change occur,
perform complete inspection of the transformer rather than just instituting a treatment
program.
• A power factor test of the oil is a somewhat less accurate method of evaluating the
dielectric strength of the oil than the ASTM standard method. It is a suitable
substitute if suitable facilities for the ASTM test are not available.
Equipment Required: Two options exist with respect to the
performance of insulating oil tests. The option adopted is
generally a function of the size of the system, i.e., whether the
need for such tests is great enough to warrant the procurement
of all equipment required.

Submit an oil sample to a qualified laboratory for determination

of the neutralization number, interfacial tension, dielectric
strength, gas analysis, and color test.
Results: When the results of the insulating oil tests reach the following values,
consider performing the operation indicated:
• Neutralization number. When the number exceeds 0.35 to 0.5 for
transformers or for circuit breakers, reclaim the oil should.

• Interfacial tension. When tension is less than 18-dynes/cm, reclaim the oil.

• Dielectric strength. When the dielectric strength is less than 28 kV with a

standard gap, recondition the oil by filtering.

• Color test. When color exceeds 3.5, reclaim the oil. Visual examination. If
the oil is cloudy, dirty, or contains visible water, reclaim the oil.
Combustible Gas Analysis
• A combustible gas analysis is performed to determine the amount, if any,
of various types of combustible gases in the transformer gas cushion.
These combustible gases are produced over time by small magnitude
turn-to-turn or other internal arcing faults. Internal arcing involving the
core or other steel parts may also result in particles of carbon in
suspension. Upon detection of combustibles, repeat testing at shorter
intervals so as to ensure removal of the unit from service before major
trouble occurs.
• Equipment Required: It is generally desirable that a sample be
submitted to a laboratory for a complete analysis. This analysis will
provide details of the specific gases present.
• Results indicating 0.5 to 5.0 percent, by volume, of combustible gases
indicate the probable existence of an incipient fault. This necessitates
close observance of the unit and the need for additional tests at shorter
intervals. With percentages higher than 5 percent, it is recommended
that the unit be taken out of service for detailed internal inspection. It is
possible to examine the insulating oil itself for dissolved gases and
carbon in suspension. This should be accomplished in a laboratory.
Digital Combustible Gas Detector Meter Tester
SF6 Gas Analysis

• SF6 gas used in circuit breakers is subject to contamination as a result of the

products released during the interruption of current. This contamination
increases with the severity of the fault and with the deterioration of the
breaker contacts. Specific tests are not normally performed since the gas
should be reconditioned on a regular basis in accordance with the
manufacturer’s recommendations.
 973-SF6

The 973-SF6 is an advanced SF6 gas analyzer for the measurement of humidity,
SF6 purity and SO2 concentration in SF6 gas insulated switchgears (GIS) and
other high voltage equipment. With its internal gas containment and recovery
system, the 973-SF6 provides a high quality and environmentally safe
measurement solution within a single self-contained unit.
Equipment Required: Depending on the type of circuit breaker being tested, use one of the
following test devices:
• a. A circuit breaker operation analyzer such as one manufactured by the Cincinnati Clock
and Instrument Co. for breakers having a common operating shaft between poles such as
is the case with oil circuit breakers.
• b. A multi-channel oscillograph for air blast and most SF6 circuit breakers. This
oscillograph has to have sufficient channels so as to provide one channel for every main
contact and every resistor contact, and also for event marking such as time of
energization of the operating circuit. In all, probably a 24-channel unit is required. The
unit should have a frequency response of l50 to 5000 cycles per second.
Motion Analyzer Test
• The motion analyzer test is conducted to verify the good condition and proper adjustment
of the mechanical operating linkages of a circuit breaker.
• Equipment Required: Circuit breaker operation analyzer as manufactured by the
Cincinnati Clock and Instrument Company, M & G Instrument Company, or Barnes
Engineering Company.
CIRCUIT BREAKER ANALYZERS & TIMING TEST
EQUIPMENT
Series Overcurrent Test
• Test all reclosers and low-voltage power circuit breakers having series trip
devices periodically to verify the calibration and proper operation of the
device. Perform the test at a number of current levels so as to verify the
current versus time operating characteristics and the minimum instantaneous
trip current level, if applicable.
• Equipment Required: Test equipment similar to that manufactured by Multi
Amp Corporation, General Electric Company, EIL Laboratories, etc., is
required to provide a single-phase calibrated current source.
Turns Ratio Test
• Periodically perform a turns ratio test as an aid in detecting turn-to-turn short
circuits in power and instrument transformers. When evaluating the initial
test results, give proper consideration to manufacturing tolerances.
• Equipment Required: A turn ratio test set as manufactured by the Biddle
Company is a convenient device. The test methods outlined in ANSI
standards require less specialized equipment.
Protective Relay System Tests

• Subject all protective relays and each protective relaying scheme as a whole
to operational tests at least once per year. The test will vary depending on
the particular scheme and component relays; however, the test should in all
cases be of the type where actual abnormal operating conditions are
simulated and the proper operation of all components is checked.
• Use multi-phase current and potential sources where applicable, rather than
attempting to test multi-phase devices with single-phase sources.
• Whenever possible, use an oscillograph or other type of multi-input events
recorder for timing of the various components.
• Refer to particular instruction books for specific test values, settings, and
other pertinent data.
Meter Calibration Tests
• Test indicating instruments by comparison with a portable instrument that is connected
into the same circuit as the instrument being tested. Test switches are usually provided
for this purpose on the front of the panel.
• Energy meter testing is usually performed in the cooperative’s meter shop and thus is not
provided for at the substation site.
Equipment Required: Many test methods are employed, each of which requires different
equipment. Typically, one of the following methods is used:
• a. Portable standard loads
• b. Portable rotating standard
• c. Single-phase series tests
• d. Element balance tests
• e. When calibrating meters, the following loads should be used: 1
• 0% load at 1.0 pf.
• 100% load at 0.5 pf.
• 100% load at 1.0 pf.
Capacitance Test
• Verify the capacitance coupling capacitors, the condenser section of bushings, and other
similar capacitive devices at time of installation. Periodic measurements are usually not
made unless a specific reason is incurred.
• Equipment Required: Schering Bridge or equivalent
• Schering Bridge is an electrical circuit used for measuring the insulating properties of
electrical cables and equipment.
Pressure Test
• All high-pressure receivers and associated piping should be subjected to a pressure test
at the time of installation and any time thereafter when the system has been subjected to
repairs, extensions, alterations, etc. The pressure utilized for this test should be
approximately that operate below 100 psi. In higher pressure systems, the normal
operating pressure is usually sufficient. In either case, seal the system and monitor the
pressure over at least 8 hours (overnight is preferable). The only pressure variations
should be those caused by a change in temperature
• Equipment Required: The pressure gauge required is normally an integral part of the
system being tested. 150 percent of normal pressure in systems
Ground Grid Resistance Measurement
• As noted in Chapter 18, Inspections, the ground grid resistance should be measured
periodically to verify that significant changes have not occurred as a result of changes in
groundwater levels or other similar natural phenomena. The value obtained should be
compared with previously measured values or with design criteria values in the case of a
new installation.
• Equipment Required: Three-probe measuring device similar to Vibroground equipment as
manufactured by Associated Research, Inc. or Biddle Company.