FAT Procedure For SWITCHGEAR & CB

This document presents the Factory Acceptance Test (FAT)

Procedures for ABB designed SWITCHGEAR & CIRCUIT
BREAKER

Document identity: PPMV-CLQ Q047 SWITCHGEAR FAT_Procedure

Revision: 00

Approved by Checked by Prepared by YR WK Total Pages

Subhash
P.P.Thanki Jalindar Shinde 2010 29 18
Ruikar

Doc No:
P.P.Thanki Jalindar Shinde M R Kulkarni PPMV-CLQ
Q047SWITCHGEAR_FAT_Procedure

Page 1 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
 FAT Procedure For SWITCHGEAR & CB

Table of Contents:

1. About this Document ......................................................................................................... 3

1.1 General .................................................................................................................... 3
1.2 Scope....................................................................................................................... 3
1.3 Intended Audience ................................................................................................... 3
1.4 Structure of document .............................................................................................. 3

2. General Introduction and Pre-requisites ............................................................................ 4

2.1 Required Documents................................................................................................ 4
2.2 Test Equipment ........................................................................................................ 4

3. Equipment description tests ............................................................................................... 5

3.1 Desighn & visual Checks.......................................................................................... 5
3.2 Wiring Checks .......................................................................................................... 5
3.3 Functional tests ........................................................................................................ 6
3.4 Mechanical operation test ........................................................................................ 6
3.5 Power frequency withstand test on the main circuit .................................................. 7
3.6 Power frequency withstand test on control & auxiliary circuit. ................................... 7

4. Routine Teat Certificate..................................................................................................... 8

5. Circuit Breaker Testing…………………………………………………………………………

Page 2 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
 FAT Procedure For SWITCHGEAR & CB

Part A : Switchgear

1. About this Document

1.1 General

This document describes the Test procedure for the Factory Acceptance of
SWITCHGEAR.The test procedure followed in the document will be used for testing
of SWITCHGEAR & Circuit Breaker at Factory.

1.2 Scope

The information provided in the document shall be valid for all the SWITCHGEAR &
Circuit Breaker being provided by M/s ABB Limited, Nasik.

The document contains instructions / guidelines / tests for the complete testing of
SWITCHGEAR

1.3 Intended Audience

The document is intended for personnel participating in the preparation,

accomplishment or evaluation of the tests.

1.4 Structure of document

Chapter 1: General description about this document

Chapter 2: Details out the purpose and pre-requisites required to carry out the tests
Chapter 3: Equipment description tests
Chapter 4: Routine Test Certificate

Page 3 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
FAT Procedure For SWITCHGEAR & CB

2. General Introduction and Pre-requisites

Introduction to the documents / equipments required for the testing is briefed in this
section.
Required Documents

Following are the documents are required to conduct the test.

1. Schematic Drawings
2. Apparatus Allocation Chart
3. List of labels
4. Front G.A.& Foundation
5. Metering G.A.
6. Cross Section G.A
7. IEC 62271-200
8. IEC 62271-100
9. IEC 60694

2.1 Test Equipment

Below mentioned the list of equipments required for conducting proper testing and
ABB will ensure the availability of the same during the test processes.

1. A.C.High voltage Test set

2. Insulation Tester.- 5Kv
3. Digital Multimeter.
4. Secondary voltage & current injection test kit for Functional test
5. paint Thickness meter

Page 4 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
 FAT Procedure For SWITCHGEAR & CB

3. Equipment description tests

3.1 Design & visual Checks

Description of the test to be conducted:

a ) Verification of items as per BOM.

b ) Check the availability of all Equipment/Items as per the General
Arrangement Diagram.
c ) Visual check of painted surface according to order document.
d ) Earthing provision for the panel.
e) Verification of circuit digramas including wiring checks
f) Dimension check
Objective of the test: To ensure the availability of all switchgear as per the
documents/customer specifications.

Expected Result: All the Hardware are mounted and wired in the panel as per the
GA & Schematic drawings.

Test Result:

[ ] Found ok [ ] not ok.

3.2 Wiring Checks

Description of the test to be conducted:

a) Check all the Input / Output wiring are as per the schematic.
b) Check all the MCB’s are mounted and wired properly.
c) All wiring shall be of Copper conductors.
d) Wire bunching shall be checked for proper routing.

Objective of the test: To ensure that the wiring has been done as per drawings.

Expected Result: All the wiring in the panel is as per schematic drawings.

Test Result:
[ ] Found ok [ ] not ok

Page 5 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
 FAT Procedure For SWITCHGEAR & CB

3.3 Functional Tests

Testing procedure: The tests are conducted by simulation as detailed below. Do the
functional tests on the mounted apparatus.

Description of the test to be conducted:

a) Give the secondary rated current to metering ckt. & check meter shows
reading / deflection .
b) Give secondary rated current to protection relay & check operation.

Objective of the test: To ensure that all apparatus working properly.

Expected Result: All mounted apparatus function properly.

Test Result:

[ ] Found ok [ ] not ok

3.4 Mechanical Operation Test.

Description of the test to be conducted:

Move Move Circuit Breaker

a) Test to service position …..5 times
b) Service to Test position …..5 times
c) Verify interlock requirement.
d) Close –Open operation of C.B.

Objective of the test: To ensure smooth operation of C.B.s.

Expected Result: All Mechanical interlocks work properly.

Test Result:
[ ] Found ok [ ] not ok

3.5 Power frequency voltage withstand test on the main circuit.

Description of the test to be conducted:

Apply High Voltage for one minute with breaker in service & close position as per
following configuration

Page 6 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
FAT Procedure For SWITCHGEAR & CB

a) Phase R to high voltage ,Y & B shorted and earthed.

b) Phase Y to high voltage ,R & B shorted and earthed.
c) Phase B to high voltage ,R & Y shorted and earthed.
d) For all above test CT secondary shall be shorted & PT ckt is disconnected.

Objective of the test: To ensure that the main circuit insulation healthiness.

Expected Result: No flash over or puncture of insulation.

Test Result:

[ ] Withstood [ ] not withstood

3.6 Power frequency voltage withstand test on control & auxiliary

circuit.

Description of the test to be conducted:

a) Apply 2 kV for 60 second on all the wire terminals and base frame
connected to the earth.

Objective of the test: To ensure insulation of wires Healthiness.

Expected Result: No puncture of wire insulation
Test Result:

[ ] Withstood [ ] not withsto

Page 7 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
 FAT Procedure For SWITCHGEAR & CB

4. Routine Test Certificate for Switchgear

ROUTINE TEST CERTIFICATE FOR SWITCHGEAR

CUSTOMER :.

PROJECT :

OUR REF. No. : 11KV. SWITCHGEAR

EQUIPMENT PANEL No. DRAWING No.

Apparatus Allocation Chart YN1V 300011 –
Schematic Drawings YN1V 300013 –
List of Labels YN1V 400014 –
Front G.A. & Foundation YN1V 300015 –
Metering G. A. YN1V 400017 –
Cross Sectional G. A. YN1V 300031 –

TESTS (AS PER IEC 62271-200 & IEC60694) REMARKS

A Design & Visual checks. Found ok
B Wiring checks. Found ok

C Functional tests. Found ok

D Mechanical operation test. Found ok
E Power frequency voltage withstand test at _ kV for one Withstood
minute on the main circuit.
F Power frequency voltage withstand test 2kV for 60 second Withstood
on control & auxiliary circuit.
C. T. RATIO – 1 C. T. Sr. No.
C.T. RATIO – 2 C. T. Sr. No.
C. T. RATIO – 3 C. T. Sr. No.
P. T. RATIO – 1 P. T. Sr. No.

TEST DATE: Quality Control & Testing

FORM NO-Q09 ABB, NASHIK

Page 8 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
 FAT Procedure For SWITCHGEAR & CB

Part B : Circuit Breaker

5.0 General Introduction and Pre-requisites

Introduction to the documents / equipments required for the testing is briefed in

this section.
Required Documents
Following are the documents are required to conduct the test.
1. Schematic Drawings

2. Details from SAP system

3. IEC 62271-100

5.1 Test Equipment

Below mentioned the list of equipments required for conducting proper testing
and ABB will ensure the availability of the same during the test processes.
1. A.C. High voltage Test set ( 100kV AC)

2. Insulation Tester.- 5kV

3. Digital Multimeter.

4. CB Analyzer

5. AC/DC Source

6. Contact Resistance Kit (100Amps DC)

Page 9 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
 FAT Procedure For SWITCHGEAR & CB

5.2 Equipment description test

5.2.1 Measurement of resistance of main circuit

The test shall be carried out with single phase 100Amps DC kit. The breaker
will be in closed condition and 100Amps DC will be passed through one of the
phase and voltage drop will be measured between top and bottom contact of the
breaker. The kit shows reading in the micro –ohms directly.
Equipment Used For Test: -

Contact resistance measurement kit

Objective of the test:

This test is carried out to ensure the healthiness of the vacuum
interrupter contacts and correct compression of the contacts as per
specification.

Expected Result: As per guaranteed particulars.

5.2.2 Functional Test

Close & Open Timing measurement test on 100% control voltage :-

Equipment Used For Test: -

CB Analyzer. AC/DC Source and multimeter.

Procedure :-

Test the breaker for percentage control voltage operation

5 open / close operation at 100 % control voltage

5 open / close operation at 85 % control voltage

5 open / close operation at 110 % control voltage

5 open operation at 70 % control voltage

5 close / open operation at 100 % control voltage

Page 10 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
 FAT Procedure For SWITCHGEAR & CB

Connect timing leads through scope test kit to each pole at top and bottom
contact
Operate the breaker through scope test kit.
Give OC (Open 0.3sec delay close) command & analyze the graph
Record the parameters of breaker with serial no.

Objective of the test:

This test describes the functional parameters of circuit breaker.

The test machine provides both graph of electrical contact signal.

To ensure the electrical operations of the coils.

Expected Result:

As per Gauranted particulars.

5.2.3 High Voltage Test for Power circuit

This test is carried out in two conditions

Equipment Used For Test :-

High Voltage kit.

Procedure :-
1. Open condition – High voltage _ kV AC to be applied across
the contacts of the circuit breaker for One minute.

2. Close condition – High voltage of 28kV AC for One minute to

be applied on the top contact of the one of the pole & bottom
contact to be earthed with other two poles.

Objective of the test:

1. This test is done to ensure that healthiness of the vacuum

interrupter ( no loss of vacuum)

Page 11 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
 FAT Procedure For SWITCHGEAR & CB

2. To ensure the healthiness of the insulation and clearances

between the phases.

Expected Result:

Test should be withstood.

5.2.4 High Voltage Test for Auxiliary circuit

Apply 2 kV for 1 second on all the wire terminals and base frame connected to
the earth.

Objective of the test:

To ensure insulation of wires Healthiness.

Expected Result:

No puncture of wire insulation

5.2.5 Visual Inspection :-

All component should be assembled as per breaker requirement

Operating instruction sticker availability

Rating plate verification as per customer requirement

Cleanliness of circuit breaker

Page 12 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
 FAT Procedure For SWITCHGEAR & CB

ROUTINE TEST CERTIFICATE

Purchaser's Name :
Purchaser's Order No.
Our Order No.

Type of Breaker

Serial Number of Breaker

Serial Number of Interrupter R-Pole

Serial Number of Interrupter Y-Pole

Serial Number of Interrupter B-Pole

Rated Voltage kV

Insulation Level kV
Rated Current A

Breaking Capacity kA

Rated Frequency 50 Hz

Mass Kg
Rated Control Voltage for Trip Coil V DC

Rated Control Voltage for Close Coil V DC

Rated Control Voltage for Motor V AC

Additional Trip Coil

Dimension Print

Year of Manufacture 2011

R O U T I N E T E S T S A C C O R D I N G T O I E C 62271-100

MECHANICAL OPERATION
1. Satisfactory.
TESTS :
1.1 5 closing and 5 opening operations at 110% of control voltage

1.2 5 closing and 5 opening operations at 85% of control voltage

1.3 5 closing and 5 opening operations at rated control voltage

1.4 5 opening operations at 70% control voltage

1.5 5 closing - opening operations at 100% of control voltage

1.6 5 opening - 0.3 sec- closing operations at 100% control voltage

Page 13 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
 FAT Procedure For SWITCHGEAR & CB

1.7 Opening - 0.3 sec - closing operation at rated control voltage.

1.7.1 Travel and contact diagrams 1 DIV = 5mm

1.7.2 Operating Speed (m/s)

Perameter R Y B
Open

Close

1.7.3 Closing travel (mm)

R Y B
Total Travel

Opening Over Travel

Closing Over Travel

Opening Rebound

Spring Stroke

Page 14 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
 FAT Procedure For SWITCHGEAR & CB

1.7.4 Operating time (ms)

Pole R Y B

Open

Close

2. RESISTANCE OF MAIN CIRCUIT : Satisfactory

Resistance in micro Ohms measured at 100A DC.

R - Pole =
Y - Pole =
B - Pole =
3. DIELECTRICAL TESTS : Satisfactory
kV, 50Hz for
3.1 Main circuit : 28
60s

Test Voltage
Breaker Position Earth connected to
connected to
Close R and B-poles Frame and Y-pole

Close Y - pole Frame, R and B-pole

Frame and Bottom
Open Top Terminal
terminal
Open Bottom Terminal Frame and Top terminal

Auxiliary
3.2 2kV, 50Hz, for 60s (Motor disconnected)
circuits :
4. VISUAL INSPECTION : Satisfactory

Quality Control Dept.

Testing
Engineer
FORM NO Q008 ABB Limited
NASIK

Page 15 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
FAT Procedure For SWITCHGEAR & CB

TEST EQUIPMENT SET UP

CIRCUIT BREAKER ANALYZER

Page 16 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
FAT Procedure For SWITCHGEAR & CB

POWER FREQUENCY TEST BENCH

Page 17 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure
FAT Procedure For SWITCHGEAR & CB

CONTACT RESISTANCE MEASUREMENT KIT

Page 18 of 18
PPMV-CLQ Q047 SWITCHGEAR & CB FAT_Procedure