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Medium Voltage
Switchgear Testing
Procedure | Method
Statement

This article explains about all types of testing

procedure required for medium voltage switchgear
Education
Crimson

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Medium Voltage Switchgear Testing Procedure

| Method Statement

5-1-1- Current transformer (CT)

test procedure:

a- Test objective:

– This test is considered as one of the main test, it’s

aimed to test:

Current transformer ratio.

Current transformer polarity.

Burden of current transformer.

Knee point of current transformer.

Current transformer winding resistance.

Magnetization curve of current transformer.

Megger test (insulation test).

b- Required Equipment:

Current transformer (CT) analyzer.

Megger.

c- Mechanical check and visual inspection:

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Check tightness of all connection.

Check ferrules

d- Current transformer analyzer connection:

1. CT analyzer has 4 leads, two should be connected

to primary side which contains primary side of CT
and other two should be connected to secondary
side of CT which you want to check its ratio.

2. After connecting CT analyzer through laptop and

using CT analyzer software, test can be started and
result can be printed out for CT ratio, CT polarity,
CT burden, CT knee point & CT winding resistance.

3. This result should be compared with current

transformer factory test and be sure that result
within acceptable tolerance.

4. To measure the burden: Inject 1 ampere on

secondary side of CT, and using multi-meter you
can measure voltage calculate burden by multiply
voltage and current and compare it with CT
burden.

5. To test insulation: Using megger by 1 kilo volt

injection for 1 minute, this test should be done
between primary to secondary and secondary to
secondary But for Primary to ground 5 kilo volt
injection for 1 minute.

6. See figure.1 which shows CT analyzer connection

for CT TEST.

Figure.1 CT analyzer connection

5-1-2- Voltage transformer (VT)

test procedure:

a- Test objective:

– This test also is considered as one of the main test

and its purpose is to test:

Voltage transformer ratio.

Voltage transformer polarity.

Voltage transformer winding resistance.

Megger test (insulation).

b- Required equipment:

CPC100.

Multi-meter (Fluke).

c- Mechanical checked and visual inspection:

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Check tightness of connection.

Check ferrules.

d- Voltage transformer test connection:

1. Connect two leads from CPC device to primary side

of voltage transformer and other two lead of CPC
with secondary side of VT, then press start from VT
page of CPC.

2. Using CPC with same connection but from

different page, you can measure winding
resistance.

3. To check the loop burden: inject the rated

secondary voltage and measure the current.
Burden will be the injected voltage* measured
current and then compare it with VT burden.

4. Insulation test: Using megger to test insulation by

1 kilo volt injection for 1 minute, this test should be
done between primary to secondary and secondary
to ground, But for primary to ground 5 kilo volt
injection for 1 minute.

5. See figure.2 which shows connection of VT Test.

Figure.2 show CPC100 connection to test

5-1-3- Timing test for Circuit

breaker and megger test:

a- Test objective:

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This test aimed to test the closing/opening time for

circuit breaker and to make sure that there is no pole
discrepancies between poles (red, yellow and blue)
and CB closing/opening time within acceptable range
according to factory test result.

b- Required equipment:

EGIL breaker analyzer.

B10E (used as DC supply and can resist high

burden equipment).

Megger.

High potential test kit.

c- Timing and megger test connection:

1. Connect B10 as external DC supply for closing (in

case of measurement of closing time) circuit or
opening (in case of measurement of opening time)
circuit, for switching device that should be tested.

2. Connect breaker analyzer in the circuit of opening

or closing using dry contact from device to give
command of open or close to the switching device
and take contact from this device to work as
feedback signal from the device while being closed
or opened to measure CB closing/opening time.

3. After opening or closing, the breaker analyzer will

print the result which should be compared with
factory test result to be sure that result within
acceptable range.

4. To start megger test: inject 1 KV for 1 minutes,

when breaker open inject between the same pole
(red-red, yellow-yellow and blue-blue) and when
breaker close inject between pole and ground,
between pole to pole.

d- High potential AC test:

Applying high potential AC voltage when the

breaker in service position line to line and line to
ground (see number 5-1-4 point C).

5-1-4- High potential and contact

resistance test for bus bar with
circuit breaker:

a- Test objective:

1.

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For contact Resistance, this test is aimed to

measure the resistance of bus bar and for circuit
breaker after being installed in the site to avoid
high resistance which may be results from welding
or installing in the site.

2. For high potential this test is aimed to measure

and test the withstand of the insulations and
isolators against the high voltage without break
down.

b- Required equipment:

Micro-ohm meter Contact resistance device.

High potential test kit.

c- High potential AC test:

1. Insulation test by megger to test insulation by 5

kilo volt injection for 1 minute 3 phases line to line
and line to ground.

2. Applying high potential AC voltage on the bus bar

line to line and line to ground and the CB in service
position, protection relays are energized and the
VTs are racked out.

3. Applying high potential AC (higher voltage level

than first applying time) voltage on the bus bar line
to line and line to ground and the CB in test
position, protection relays are energized and the
VTs are
racked out.

4. Take the record of passing current in mille

Amperes from the high potential test kit.

5. Insulation test by megger to test insulation by 5

kilo volt injection for 1 minute 3 phases line to line
and line to ground.

6. Compare the insulation test results to gathers

before and after high potential test.

d- Contact resistance test connection

1. Contact resistance device has 4 leads, two for

current and others for voltage, it depend on
current injection on bus bar or circuit breaker then
sense the voltage and calculate resistance by divide
voltage on current (ohm’s law)

2. Check the BB torqueing of all bolted and confirm

the torque value as per factory inspection.

3. Connect current leads between the device which

you want to measure its resistance, connect voltage
leads on the same terminals of current then adjust
100A injection then hold your hand on contact
resistance pushbutton, after few second the result
will be displayed.

4. See figure.3 which shows connection of Contact

Resistance Test.

Figure.3 shows contact resistance equipment connection

5-1-5- High potential test for

circuit breaker:

a- Test objective:

1. This test aimed to test if bus bar will withstand its

withstand voltage after being installed in the site or
it will breakdown and to check the vacuum bottle
integrity, also to measure leakage current and
insulation between CB and ground.

b- Testing equipment required:

1. AC HI-voltage injection machine (100KV, 60HZ).

2. Earthing Rod or Ground Discharge stick (coming

with high pot tester)

3. Megger 5KV DC Supply.

c- Mechanical and visual inspection:

1. All safety rules should be taken into consideration.

2. breaker cleaning and house keeping.

3. Check all shipping devices removed.

4. Inspect ground to switchgear ground bus.

5. Ensure the adequate clearance (distance) between

circuit test ends and to other Ground object and
other phases (not under the test) and also with
other electrical equipment’s to prevent flash over.

d- Test connection and test procedure

1. Test VCB withstand voltage: VCB should be close ,

inject voltage as per FAT value.

NOTE: When we conduct HIPOT Test for

one phase, other remaining phases
should be connected to Ground.

Use Ground discharge stick with high

tension Electrical for discharge the
voltage from the system after each High
potential Test.

2. Test CB withstand voltage: VCB should be open ,

inject voltage as per FAT value.

3. Measure insulation after high voltage test with CBs

close and open status then inject 5 KV for 1 minute
then record the value and compare it with the value
before high voltage test.

NOTE:
Use Ground discharge stick with high tension
Electrical for discharge the voltage from the system
after each High potential Test.

5-1-6- Miniature Circuit Breaker

(MCB):

a- Test objective:

This test aimed to test the trip time characteristic of

MCB if it’s within limits or no and check MCB
auxiliary contact if it is available.

b- Required equipment:

Sverker (used as current source).

Multi-meter.

c- Mechanical checked and visual inspection:

Check tightness for all wires.

Check ferrules.

Check for physical damage or defect.

d- Test connection and procedure:

1. Connect sverker (which used as current source)

direct to MCB, check MCB type and its rated
current value.

2. Inject from sverker twice of its rated current and

measure the trip time in which MCB will be
tripped, compare the measured trip time with its
acceptable limit from MCB manual depending on
its type.

3. Auxiliary contact should be checked in both

condition of MCB (open/close) and check that
auxiliary contact change its status from being open
to close or vise, depending on its nature Normally
open or
Normally close.

5-1-7- Auxiliary relay test:

a- Test objective:

This test aimed to test relay’s output contact, pick-up

and drop off voltage, operating and resetting time.

b- Required equipment:

Sverker (used as Voltage source and used its

voltmeter).

Multi-meter [used as Ammeter].

Miniature Circuit Breaker 2Pole (MCB).

c- Mechanical check and visual inspection:

1. Check tightness for all wires.

2. Check ferrules.

3. Check for physical damage or defect.

d- Test connection:

I. Check output contact:

Our Auxiliary relay has several points, 2 used for Coil,

before injecting any voltage on Auxiliary relay’s Coil,
check contacts at its normal condition which mean
Normally Open (NO) contact is being opened and
Normally Closed (NC) contact is being closed, Inject
the desired control voltage of Aux. coil (which is
normally 125 volt DC), at which Aux. relay will pick up
that’s mean its contact will change its position i.e NO
contact will be closed and NC contact will be opened.

II. Pick-up and drop off current and

voltage:

1. Pick up voltage can be measured using voltmeter

when the coil voltage is increased gradually from 0
volt, the Aux. relay will operate (i.e Contacts
change its normal status No will be closed and vice
versa) at a certain voltage. This voltage is called
pick-up voltage, Record the reading of voltmeter
and Ammeter which is pick-up voltage and current.

2. Drop-off voltage can be measured using voltmeter

when the coil voltage on an operate relay is
decreased gradually, the relay will release (i.e its
contact will return to its normal status) at a certain
voltage. This voltage is called drop-off voltage,
Record the reading of Ammeter which is drop-off
current.

iii Operating and resetting time:

Adjust voltage source at the coil operation voltage of

Aux. relay (in our case 125 v DC), To get operating
time, adjust sverker at (on+time location) and
switched MCB ON, To get resetting time, readjust
voltage source at 125 volt DC and switch MCB OFF.

IV. Burden test:

1. Adjust voltage source (sverker) at 125 volt DC,

select on position and make MCB ON.

2. Record reading of Ammeter.

3. Calculate burden by multiplying coil operated

voltage and reading of Ammeter.

5-1-8- Ammeter and voltmeter

test: