Safety-focused electrical testing guidelines

Note:
Inspection and Testing should be done with the utmost regard for safety not only of
the testing and inspection personnel but of the tested materials and equipment.
In the minimum, safety shall follow the guidelines of the following references:
1. Occupation Safety and Health Act
2. Applicable Local Ordinance
3. Owners safety practice if available
I TESTING:
All tests shall be performed with the apparatus under test de-energized except in
cases where the test requires otherwise.
The testing shall be witnessed by the Owners Safety Representative.
All test equipment shall be in good mechanical and electrical condition.
All test equipment must be properly calibrated within the rated accuracy.
All accuracy test made on the calibrating and test instruments must be directly
traceable to the applicable Philippine Testing Agency or National Institute of
Standards and Technology (NIST)
Instruments shall be calibrated in accordance with the following frequency schedule.
a. Field Instruments: Analog, 6months max; Digital, 12 months max
b. Laboratory instruments : 12 months
c. Leased equipment: 12 months where accuracy is guaranteed by Lessor.
Dated Calibration labels must be visible on all test equipment.
Calibrating records and result of the calibration on the test instrument must be kept
up to date.
Test Report
The test report shall include the following:
1. Summary of project.
2. Description of equipment tested.
3. Description of test.
4. Test data.
5. Analysis and recommendations.
Test data records shall include the following minimum requirements:
1. Identification of the testing organization.
2. Equipment identification (brand, model, serial nos., etc.)
3. Humidity, temperature, and other atmospheric conditions that may
affect the results of the tests/calibrations.
4. Date of inspections, tests, maintenance, and/or calibrations.
5. Identification/signature of the testing technician.
6. Indication of inspections, tests, maintenance, and/or calibrations to
be performed and recorded.
7. Indication of expected results when calibrations are to be performed.
8. Indication of as-found and as-left results.
9. Sufficient spaces to allow all results and comments to be indicated.
The testing firm shall furnish a duly signed copy/ies of the complete report
to the owner/representative.
II Inspection and Test Procedures:
Switchgear and Switchboard Assemblies:
A. Visual and Mechanical inspection:
1. Compare equipment nameplate data with drawings and specifications.
2. Inspect physical and mechanical condition.
3. Verify appropriate anchorage, required area clearances, physical damage,
and correct alignment.
4. Inspect all doors, panels, and sections for corrosion, dents,
scratches, fit, and missing hardware.
5. Verify that fuse and/or circuit breaker sizes and types correspond to
drawings and coordination study as well as to the circuit breakers
address for microprocessor-communication packages.
6. Inspect all bolted electrical connections for high resistance using one
of the following methods:

a. Use of low-resistance ohmmeter in accordance with Electrical Tests.
b. Verify tightness of accessible bolted electrical connections by
calibrated torque-wrench method in accordance with manufacturers
published data or Table 1.
7. Verify that current and potential transformer ratios correspond to
drawings.
8. Compare equipment nameplate data with latest one-line diagram
when available.
9. Confirm correct operation and sequencing of electrical and mechanical
interlock systems.
a. Attempt closure on locked-open devices. Attempt to open lockedclosed devices.
b. Make key exchange with devices operated in off-normal positions.
10. Thoroughly clean switchgear prior to testing.
11. Lubrication
a. Verify appropriate contact lubricant on moving current carrying parts.
b. Verify appropriate lubrication on moving and sliding surfaces.
12. Inspect insulators for evidence of physical damage or contaminated
surfaces.
13. Verify correct barrier and shutter installation and operation.
14. Exercise all active components.
15. Inspect all mechanical indicating devices for correct operation.
16. Verify that filters are in place and/or vents are clear.
17. Perform visual and mechanical inspection on all instrument
Transformers. (provide guides in visual checking. What to look for).
18. Inspect control power transformers.
a. Inspect physical damage, cracked insulation, broken leads,
tightness of connections, defective wiring, and overall general
condition.
b. Verify that primary and secondary fuse ratings or circuit breakers
match drawings.
c. Verify correct functioning of drawout disconnecting and grounding
contacts and interlocks
B. Electrical Tests
1. Perform tests on all instrument transformers.
2. Perform ground-resistance tests.
3. Perform resistance tests through all bus joints with a low-resistance
ohmmeter, if applicable.
4. Perform insulation-resistance tests on each bus section, phase-to phase and
phase-to-ground, for one minute in accordance with Table 2.

5. Perform an over potential test on each bus section, each phase to ground
with phases not under test grounded, in accordance with manufacturers
published data. If manufacturer has no recommendation for this test, it shall
be in accordance with Table 3. The test voltage shall be applied for one
minute.
6. Perform insulation-resistance tests at 1000 volts dc on all control wiring. For
units with solid-state components, follow manufacturers recommendations.
7. Perform control wiring performance test.
8. Perform current injection tests on the entire current circuit in each section of
switchgear.
a. Perform current tests by primary injection, where possible, with
magnitudes such that a minimum of 1.0 ampere flows in the
secondary circuit.
b. Where primary injection is impractical, utilize secondary injection with
a minimum current of 1.0 ampere.
c. Test current at each device.
9. Determine accuracy of all meters and calibrate watthour meters. Verify
multipliers.
10. Perform phasing check on double-ended switchgear to insure correct
bus phasing from each source.
11. Control Power Transformers
a. Perform insulation-resistance tests. Perform measurements
from winding-to-winding and each winding-to-ground. Test
voltages shall be in accordance with Table 2 unless
otherwise specified by manufacturer.
b. Perform secondary wiring integritytest. Disconnect
transformer at secondary terminals and connect secondary
wiring to correct secondary voltage. Confirm potential at all devices.
c. Verify correct secondary voltage by energizing primary
winding with system voltage. Measure secondary voltage with
the secondary wiring disconnected.
D. Verify correct function of control transfer relays located in
switchgear with multiple power sources.
12. Voltage Transformers
a. Perform insulation-resistance tests. Perform measurements
from winding-to-winding and each winding-to-ground. Test
voltages shall be in accordance with Table 2 unless
b. Perform secondary wiring integrity test. Confirm correct
potential at all devices.
c. Verify secondary voltages.
13. Verify operation of switchgear/switchboard heaters.

C. Test Values
1. Compare bus connection resistances to values of similar connections.
2. Bolt-torque levels shall be in accordance with Table 1 unless
3. Microhm or millivolt drop values shall not exceed the highlevels of
the normal range as indicated in the manufacturers published data.
If manufacturers data is not available, investigate any values which
deviate from similar bus by more than 50 percent of the lowest
value.
4. Insulation-resistance values for bus, control wiring, and control
power transformers shall be in accordance with manufacturers
published data. In the absence of manufacturers published data,
use Table 2. Values of insulation resistance less than this table or
manufacturers minimum shall be investigated. Over potential tests
should not proceed until insulation-resistance levels are raised
above minimum values.
5. The insulation shall withstand the over potential test voltage applied
Transformers
Liquid-Filled
A. Visual and Mechanical Inspection
1.
2.
3.
4.
5.
6.
Compare equipment nameplate data with drawings and specifications.

Inspect physical and mechanical condition.
Verify removal of any shipping bracing after final placement.
Inspect impact recorder prior to unloading, if applicable.
Verify settings and operation of all temperature devices, if applicable.
Verify that cooling fans and pumps operate correctly and that
fan and pump motors have correct overcurrent protection, if applicable.
7. Verify operation of all alarm, control, and trip circuits from temperature and
level Indicators, pressure relief device, and fault pressure relay, if applicable.
8. Inspect all bolted electrical connections for high resistance
using one of the following methods:
a. Use of low-resistance ohmmeter inaccordance with Electrical Tests.
9. Verify correct liquid level in all tanks and bushings.

10. Verify that positive pressure is maintained on nitrogen blanketed
transformers.
11. Perform specific inspections and mechanical tests as
recommended by manufacturer.
12. Verify correct equipment grounding.
13. Verify the presence of transformer surge arresters.
B. Electrical Tests
1. Perform resistance measurements through all bolted connections with lowresistance ohmmeter, if applicable.
2. Perform insulation-resistance tests, winding-to-winding and each winding-toground in accordance with Table 4.
3. Calculate polarization index.
4. Perform turns-ratio tests at all tap positions.
5. Test load tap-changer.
6. Perform insulation power-factor/dissipation-factor tests on windings in
accordance with test equipment manufacturers published data.
7. Perform power-factor/dissipation-factor tests or hot collar watts-loss tests on
bushings in accordance with test equipment manufacturers published data.
8. Perform excitation-current tests in accordance with test equipment
manufacturers published data.
9. Measure resistance of each high-voltage winding in each noload tap-changer
position. Measure resistance of each lowvoltage winding in each load tapchanger position, if applicable.
10. If core ground strap is accessible, measure core insulation resistance at 500
volts dc.
11. Remove a sample of insulating liquid in accordance with ASTM D-923.
Sample shall be tested for the following:
1. Dielectric breakdown voltage: ASTM D-877 and/or ASTM D-1816.
2. Acid neutralization number: ANSI/ASTM D-974.
3. Specific gravity: ANSI/ASTM D-1298.
4. Interfacial tension: ANSI/ASTM D-971 or ANSI/ASTM D-2285.
5. Color: ANSI/ASTM D-1500.
6. Visual Condition: ASTM D-1524.
7. Water in insulating liquids: ASTM D-1533. (Required on 25 kV or higher
voltages and on all silicone-filled units.)
8. Measure dissipation factor or power factor in accordance with ASTM D924.
12. Remove a sample of insulating liquid in accordance with ASTM D3613 and
perform dissolved gas analysis (DGA) in accordance with ANSI/IEEE C57.104

or ASTM D-3612.
13. Perform tests on all instrument transformers.
C. Test Values
1. Compare bolted connection resistance to values of similar connections.
2. Bolt-torque levels should be in accordance with Table 1 unless otherwise
specified by manufacturer.
3. Microhm or millivolt drop values shall not exceed the high levels of the
normal range as indicated in the manufacturers published data. If
manufacturers data is not available, investigate any values which deviate
from similar connections by more than 50 percent of the lowest value.
4. Insulation-resistance test values at one minute should not be less than the
values calculated in accordance with the formula in Table 4. Results shall
be temperature corrected in accordance with Table 5.
5. The polarization index shall be greater than 1.0 and shall be recorded for
future reference.
6. Turns-ratio test results shall not deviate more than one-half percent from
either the adjacent coils or the calculated ratio.
7. Maximum power factor of liquid-filled transformers shall be in accordance with
Representative values are indicated in Table 6.
8. Investigate bushing power factors and capacitances that vary from nameplate
values by more than ten percent. Investigate any bushing hot collar wattsloss results that exceed the test equipment manufacturers published data.
9. Typical excitation-current test data pattern for three-legged core transformer
is two similar current readings and one lower current reading.
10. Winding-resistance test results, after factoring in temperature correction,
should compare within one percent of factory obtained results except
in instances of extremely low resistance values.
11. Consult manufacturer if core insulation is less than one megohm at 500
volts dc.
12. Insulating liquid test results shall be in accordance with Table 7.
13. Evaluate results of dissolved-gas analysis in accordance with ANSI/IEEE
Standard C57.104. Use results as baseline for future tests.
Cables
Low-Voltage, 600 Volt Maximum
A Visual and Mechanical Inspection

1. Compare cable data with drawings and specifications.
2. Inspect exposed sections of cables for physical damage and correct
connection in accordance with single-line diagram.
3. Inspect all bolted electrical connections for high resistance
using one of the following methods:
a. Use of low-resistance ohmmeter.
4. Inspect compression-applied connectors for correct cable match and
indentation.
5. Verify cable color coding with applicable specifications and the National
Electrical Code.
B Electrical Tests
1. Perform insulation-resistance test on each conductor with respect to ground
and adjacent conductors. Applied potential shall be 500 volts dc for 300 volt
rated cable and 1000 volts dc for 600 volt rated cable. Test duration shall be one
minute.
3. Perform continuity test to insure correct cable connection.
C Test Values
specified by the manufacturer.
manufacturers data is not available, investigate any values which deviate from
similar connections by more than 50 percent of the lowest value.
4. Minimum insulation-resistance values should not be less than 50 megohms.
5. Investigate deviations between adjacent phases.
Medium-Voltage, 69 kV Maximum

1. Compare cable data with drawingsand specifications.
2. Inspect exposed sections of cables for physical damage.
3. Inspect all bolted electrical connections for high resistance using one of the
following methods:
4. Inspect compression-applied connectors for correct cable match and
indention.
5. Inspect for shield grounding,cable support, and termination.
6. Verify that visible cable bends meet or exceed ICEA and/or manufacturers
minimum allowable bending radius.
7. Inspect fireproofing in common cable areas, if specified.
8. If cables are terminated through window-type current transformers, make an
inspection to verify that neutral and ground conductors are correctly placed and
that shields are correctly terminated for operation of protective devices.
9. Visually inspect jacket and insulation condition.
10. Inspect for correct identification and arrangements.
B Electrical Tests
1. Perform a shield-continuity test on each power cable by ohmmeter method.
2. Perform an insulation-resistance test utilizing a megohmmeter with a voltage
output of at least 2500 volts. Individually test each conductor with all other
conductors and shields grounded. Test duration shall be one minute.
4. Perform a dc high-potential test on all cables. Adhere to all precautions
and limits as specified in the applicable NEMA/ICEA Standard for the specific
cable. Perform tests in accordance with ANSI/IEEE Standard 400. Test procedure
shall be as follows, and the results for each cable test shall be recorded as
specified herein. Test voltages shall not exceed 80 percent of cable
manufacturers factory test value or the maximum test voltage in Table 8.
a. Insure that the input voltage to the test set is regulated.
b. Current-sensing circuits in test equipment shall measure only the leakage
current associated with the cable under test and shall not include internal
leakage of the test equipment.
c. Record wet- and dry-bulb temperatures or relative humidity and
temperature.
d. Test each section of cable individually.
e. Individually test each conductor with all other conductors grounded.

Ground all shields.
f. Terminations shall be adequately corona-suppressed by guard ring, field
reduction sphere, or other suitable methods as necessary.
g. Insure that the maximum test voltage does not exceed the limits for
terminators specified in ANSI/IEEE Standard 48, IEEE 386, or
manufacturers specifications.
h. Apply a dc high-potential test in at least five equal increments until
maximum test voltage is reached. No increment shall exceed the
voltage rating of the cable. Record dc leakage current at each step after
a constant stabilization time consistent with system charging current.
i. Raise the conductor to the specified maximum test voltage and hold for
15 minutes on shielded cable and five minutes on nonshielded cable.
Record readings of leakage current at 30 seconds and one minute and
at one minute intervals thereafter.
j. Reduce the conductor test potential to zero and measure residual
voltage at discrete intervals.
k. Apply grounds for a time period adequate to drain all insulation stored
charge.
l. When new cables are spliced into existing cables, the dc high-potential
test shall be performed on the new cable prior to splicing. After test
results are approved for new cable and the splice is completed, an
insulation-resistance test and a shield-continuity test shall be performed
on the length of new and existing cable including the splice. After a
satisfactory insulation-resistance test, a dc high potential test shall be
performed on the cable utilizing a test voltage acceptable to owner and
not exceeding 60 percent of factory test value.
C Test Values
4. Shielding shall exhibit continuity. Investigate resistance values in excess of
ten ohms per 1000 feet of cable.
5. Graphic plots may be made of leakage current versus step voltage at each
increment and leakage current versus time at final test voltages.
a. The step voltage slope should be reasonably linear.
b. Capacitive and absorption current should decrease continually until

Steady state leakage is approached.
Metal-Enclosed Busways
A
Visual and Mechanical Inspection

2. Inspect busway for physical damage and correct connection in accordance
with single-line diagram.
3. Inspect for appropriate bracing, suspension, alignment, and enclosure
ground.
following methods:
b. Verify tightness of accessible bolted electrical connections by calibrated
torque-wrench method in accordance with manufacturers published data
or Table 1.
5. Confirm physical orientation inaccordance with manufacturers labels to
insure adequate cooling.
6. Examine outdoor busway for removal of weep-hole plugs, if applicable, and
the correct installation of joint shield.
B Electrical Tests
1. Measure insulation resistance of each busway, phase-to-phase and phase-toground for one minute, in accordance with Table 2.
2. Perform an overpotential test on each busway, phase-to-ground with phases
not under test grounded, in accordance with manufacturers published data.
If manufacturer has no recommendation for this test, it shall be in
accordance with Table 9. Where no dc test value is shown in Table 9, ac
value shall be used. The test voltage shall be applied for one minute.
3. Perform contact-resistance test on each connection point of noninsulated
busway. On insulated busway, measure resistance of assembled busway
sections and compare values with adjacent phases.
4. Perform phasing test on each busway tie section energized by separate
sources. Tests must be performed from their permanent sources.
C Test Values
1. Compare bolted connection resistances and bus joint resistances to values of

similar connections.
2. Bus bolt-torque levels should be in accordance with Table 1 unless
normal range as indicated in the manufacturers published data.
If manufacturers data is not available, investigate any values which
deviate from similar connections by more than 50 percent of the lowest
value.
4. Insulation-resistance test voltages and resistance values shall be in
accordance with manufacturers published data or Table 2.
Minimum resistance values are for a nominal 1000 foot busway run.
Use the following formula to convert the measured resistance value
to the 1000-foot nominal value:
R1000ft =
Measured Resistance x Length of Run / 1000
Converted values of insulation resistance lessthan those in Table 2 or

manufacturers minimum shall be investigated. Overpotential tests shall not
proceed until insulation-resistance levels are raised above minimum values.
5. The insulation shall withstand the overpotential test voltage applied.
Switches
Low Voltage Air Switches
3. Confirm correct application of manufacturers recommended lubricants.
4. Verify appropriate anchorage and required area clearances.
5. Verify appropriate equipment grounding.
6. Verify correct blade alignment, blade penetration, travel stops, and
mechanical operation.
7. Verify that fuse sizes and types are in accordance with drawings and shortcircuit and coordination studies.
8. Verify that each fuse holder has adequate mechanical support.
following methods:

or Table 1.
10. Test all interlocking systems for correct operation and sequencing.
11. Verify correct phase barrier materials and installation.
12. Inspect all indicating and control devices for correct operation.
B Electrical Tests
1. Perform insulation-resistance tests on each pole, phase-to-phase and phaseto-ground with switch closed and across each open pole for one minute. Test
voltage shall be in accordance with manufacturers published data or Table
2.
2. Measure contact-resistance across each switchblade and fuse holder.
3. Measure fuse resistance.
5. Verify heater operation (if applicable).
C Test Values
normal range asindicated in the manufacturers published data.If
4. Minimum insulation resistance shall be in accordance with manufacturers
5. Investigate any contact resistance values which deviate from adjacent poles
or similar switches by more than 25 percent.
6. Investigate fuse-resistancevalues that deviate from each other by more than
15 percent.
Medium-Voltage, Metal-Enclosed Air Switches
4. Verify appropriate anchorage and required area clearances.

5. Verify appropriate equipment grounding.
6. Verify correct blade alignment, blade penetration, travel stops, and
mechanical operation.
7. Verify that fuse sizes and types are in accordance with drawings and shortcircuit and coordination studies.
8. Verify that expulsion-limiting devices are in place on all holders having
expulsion-type elements.
9. Verify that each fuse holder has adequate mechanical support.
following methods:
or Table 1.
11. Test all interlocking systems for correct operation and sequencing.
12. Verify correct phase-barriermaterials and installation.
13. Compare switchblade clearances with industry standards.
14. Inspect all indicating and control devices for correct operation.
B Electrical Tests
1. Perform insulation-resistance tests on each pole, phase-to-phase and phaseto-ground with switch closed and across each open pole for one minute. Test
voltage shall be in accordance with manufacturers published data or Table
2.
2. Perform an overpotential test on each pole with switch closed. Testeach poleto-ground with all other poles grounded. Test voltage shall be in accordance
with manufacturers published data or Table 3.
4. Measure contact resistance across each switchblade and fuse holder.
5. Measure fuse resistance.
6. Verify heater operation (if applicable).
C Test Values
1. Compare bolted connection resistances to values of similar connections.
normal range asindicated in the manufacturers published data.If manufacturers
data is not available, investigate any values which deviate from similar
connections by more than 50 percent of the lowest value.
4. The insulation should withstand the overpotential test voltage applied.

5. Minimum insulation resistance shall be in accordance with manufacturers
6. Investigate fuse resistance values that deviate from each other by more than
15 percent.
High- and Medium-Voltage, Open Air Switches
4. Verify that grounding isin accordance with industry standards and project
specifications.
following methods:
or Table 1.
6. Perform mechanical operator tests in accordance with manufacturers published
data.
7. Verify correct operation and adjustment of motor operator limit-switches and
mechanical interlocks, if applicable.
8. Verify correct blade alignment, blade penetration, travel stops, arc interrupter
operation, and mechanical operation, if applicable.
B Electrical Tests
1. Perform insulation-resistance tests on each pole, phase-to-phase and phase-toground with switch closed and across each open pole for one minute. Test voltage
shall be in accordance with manufacturers published data or Table 2.
2. Perform an overpotential test on each pole with switch closed. Test each pole-toground with all other poles grounded. Test voltage shall be in accordance with
manufacturers published data or Table 10.
3. Perform contact-resistance test across each switchblade and fuse holder.
C Test Values
2. Bolt-torque levels should be in accordance with Table 10.12 unless otherwise
3. Microhm or millivolt drop values shall not exceed the high levels of the normal
range asindicated in the manufacturers published data.If manufacturers data is not
available, investigate any values which deviate from similar connections by more
than 50 percent of the lowest value.
4. Insulation resistance values shall be in accordance with manufacturers data or
Table 2.
5. The insulation shall withstand the over potential test voltage applied.
6. Contact resistance shall be determined in microhms. Investigate any value
exceeding 500 microhms or any values which deviate from adjacent poles or similar
switches by more than 25 percent.
Vacuum Switches: Medium-Voltage

3. Inspect anchorage, alignment, and grounding.
4. Perform all mechanical operation and contact alignment tests on both the switch
and its operating mechanism.
5. Check each fuse holder for adequate support and contact.
6. Verify that fuse sizes and types correspond to drawings.
7. Test all electrical and mechanical interlock systems for correct operation and
sequencing.
following methods:
or Table 1.
9. Verify that insulating oil level is correct, if applicable.
B Electrical Tests
1. Perform resistance measurements through all bolted electrical connections with a
low-resistance ohmmeter, if applicable.
2. Perform a contact-resistance test.
3. Verify open and close operation from control devices, if applicable.
4. Perform insulation-resistance tests pole-to-pole, pole-to-ground, and across open
poles at 2500 volts minimum.
5. Perform vacuum bottle integrity (overpotential) test across each vacuum bottle
with the switch in the open position in strict accordance with manufacturers
published data. Do not exceed maximum voltage stipulated for this test. Provide
adequate barriers and protection against x-radiation during this test. Do not perform
this test unless the contact displacement of each interrupter is within manufacturers
tolerance. (Be aware that some dc high-potential test sets are half-wave rectified
and may produce peak voltages in excess of the switch manufacturers
recommended maximum.)
6. Remove a sample of insulating liquid, if applicable, in accordance with ASTM D923. Sample shall be tested in accordance with the referenced standard.
1. Dielectric breakdown voltage: ASTM D-877
2. Color: ASTM D-1500
3. Visual condition: ASTM D-1524
7. Perform insulation-resistance tests on all control wiring at 1000 volts dc. For
8. Perform an overpotential test in accordance with manufacturers published data.
C. Test Values
range as indicated in the manufacturers published data. If manufacturers data
is not available, investigate any values which deviate from adjacent poles or
similar switches by more than 50 percent of the lowest value.
4. Contact displacement shall be in accordance with factory recorded data marked
on the nameplate of each vacuumswitch or bottle.
5. The vacuum bottles shall withstand the overpotential voltage applied.
6. Control wiring insulation resistance should be a minimum of two megohms.
8. Insulating liquid test results shall be in accordance with Table 7.
Insulated Case/Molded Case Low-Voltage Circuit Breakers
1.
2.
3.
4.
5.
Compare nameplate data with drawings and specifications.

Inspect circuit breaker for correct mounting.
Operate circuit breaker to insure smooth operation.
Inspect case for cracks or other defects.
Inspect all bolted electrical connections for high resistance using one of the
following methods:

or Table 1.
6. Inspect mechanism contacts and arc chutes in unsealed units.
B Electrical Tests
2. Perform an insulation-resistance test at 1000 volts dc from pole-to-pole and from
each pole-to-ground with breaker closed and across open contacts of each phase
*4. Perform insulation resistance tests at 1000 volts dc on all control wiring. Do not
perform the test on wiring connected to solid state components.
5. Perform adjustments for final settings in accordance with coordination study
supplied by owner.
6. Perform long-time delay time-current characteristic tests by passing 300 percent
rated primary current through each pole separately unless series testing is
required to defeat ground fault functions.
7. Determine short-time pickup and delay by primary current injection.
8. Determine ground-fault pickup and time delay by primary current injection.
9. Determine instantaneous pickup current by primary injection using run-up or
pulse method.
10. Verify correct operation of any auxiliary features such as trip and pickup
indicators, zone interlocking, electrical close and trip operation, trip-free, and
antipump function.
11. Verify the calibration of all functions of the trip unit by means of secondary
injection.
C Test Values
specified by manufacturer
range asindicated in the manufacturers published data.If manufacturers data is
not available, investigate any values which deviate from similar connections by
more than 50 percent of the lowest value.
4. Circuit breaker insulation resistance should be in accordance with Table 2.
6. Trip characteristic of breakers shall fall within manufacturers published timecurrent characteristic tolerance band, including adjustment factors. If
Manufacturers curves are not available trip times shall be equal to or less than
the values shown in Table 10.7. Circuit breakers exceeding specified trip time at
300 percent of pickup shall be tagged defective.
7. Instantaneous pickup values of molded-case circuit breakers shall be within the
tolerances shown in Table 10.8.
Low Voltage Circuit Breakers
A
1.
2.
3.
4.

Compare nameplate data with drawings and specifications.
Confirm correct application of manufacturers recommended lubricants.
Inspect anchorage, alignment, and grounding. Inspect arc chutes. Inspect
moving and stationary contacts for condition, wear, and alignment.
5. Verify that all maintenance devices are available for servicing and operating the
breaker.
6. Verify that primary and secondary contact wipe and other dimensions vital to
satisfactory operation of the breaker are correct.
7. Perform all mechanical operator and contact alignment tests on both the breaker
and its operating mechanism.
following methods:
or Table 1.
9. Verify cell fit and element alignment.
10. Verify racking mechanism.
B Electrical Tests
3. Perform an insulation-resistance test at 1000 volts dc from pole-to-pole and from
each pole-to-ground with breaker closed and across open contacts of each
phase.
*4. Perform insulation-resistance tests at 1000 volts dc on all control wiring. Do not
perform the test on wiring connected to solid state components.
5. Make adjustments for the final settings in accordance with the coordination study
supplied by owner.
6. Determine minimum pickup current by primary current injection.
7. Determine long-time delay by primary current injection.
8. Determine short-time pickup and delay by primary current injection.
9. Determine ground-fault pickup and delay by primary current injection.

10. Determine instantaneous pickup value by primary current injection.
11. Verify the calibration of all functions of the trip unit by means of secondary
injection.
12. Activate auxiliary protective devices, such as ground fault or under voltage
relays, to insure operation of shunt trip devices. Check the operation of
electrically operated breakers in their cubicles.
13. Verify correct operation of any auxiliary features such as trip and pickup
indicators, zone interlocking, electrical close and trip operation, trip-free, and
anti pump function and verify trip unit battery condition.
14. Verify operation of charging mechanism.
C Test Values
range as indicated in the manufacturers published data.If manufacturers data
is not available, investigate any values which deviate from similar connections
by more than 50 percent of the lowest value.
5. Central wiring insulation resistance should be a minimum of two megohms.
6. Trip characteristics of breakers shall fall within manufacturers published timecurrent tolerance bands.
Vacuum Medium-Voltage Circuit Breakers
A
1.
2.
3.
4.
5.

Inspect anchorage, alignment, and grounding.
Perform all mechanical operational tests on both the circuit breaker and its
operating mechanism.
6. Measure critical distances such as contact gap as recommended by
manufacturer.
following methods:
or Table 1.
8. Perform timing tests.
9. Record as-found and as-left operation counter readings.
B Electrical Tests
*2. Perform minimum pickup voltage tests on trip and close coils.
3. Verify trip, close, trip-free, and antipump function.
4. Trip circuit breaker by operation of each protective device.
6. Perform insulation-resistance tests pole-to-pole, poleto-ground, and across open
poles at 2500 volts minimum
7. Perform vacuum bottle integrity (overpotential) test across each vacuum bottle
with the breaker in the open position in strict accordance with manufacturers
instructions.
C Test Values
range asindicated in the manufacturers published data.If manufacturers data is
5. Contact displacement shall be in accordance with factory recorded data marked
on the nameplate of each vacuum breaker or bottle.
6. The interrupter shall withstand the over potential voltage applied.
7. Compare circuit breaker timing values to manufacturers published data.
9. Dissipation-factor/power-factor test results shall be compared to manufacturers
published data. In the absence of manufacturers published data the comparison
shall be made to similar breakers.
10. Dissipation-factor/power-factor and capacitance test results should be within
ten percent of nameplate rating for bushings.
11. The insulation shall withstand the over potential test voltage applied.
SF6 MV Circuit Breakers (cont.)
1.
2.
3.
4.
5.

Inspect anchorage and grounding.
Inspect and verify adjustments of mechanism in accordance with manufacturers
published data.
6. Inspect air compressor in accordance with manufacturers published data.
7. Inspect hydraulic system in accordance with manufacturers published data.
8. Test for gas leaks.
9. Verify correct operation of all air and SF6gas pressure alarms and cutouts.
10. Slow close/open breaker and check for binding.
11. Perform time-travel analysis.
12. Test SF6gas for moisture and nitrogen content.
following methods:
or Table 1.
14. Record as-found and as-left counter operations.
15. Verify operation of all heaters.
B Electrical Tests
1. Perform a contact resistance test.
3. Perform insulation-resistance tests pole-to-pole, pole-to-ground, and across
Open poles at 2500 volts minimum.
*4. Perform insulation-resistance tests on all control wiring at 1000 volts dc. For
*5. Perform dissipation-factor/power-factor tests on breaker and bushings.
*6. Perform overpotential test in accordance with manufacturers instructions.
*7. Perform minimum pick-up voltage test on trip and close coils.
8. Verify trip, close, trip-free, and antipump functions.
C Test Values.
4. Compare time-travel data with manufacturers published data.
published data. In the absence of manufacturers published data, the
comparison shall be made to similar breakers.
8. Dissipation-factor/power-factor and capacitance test results should be within ten
percent of nameplate rating for bushings.
10. Minimum pickup for trip and close coils shall conform to manufacturers
published data.
High Voltage Oil Circuit Breakers
4. Inspect anchorage, alignment, and grounding.
5. Verify that breather vents are clear.
6. Perform all mechanical operation and contact alignment tests on both the circuit
breaker and its operating mechanism.
7. If performing internal inspection:
1. Remove oil. Lower tanks or remove manhole covers as necessary.
Inspect bottom of tank for broken parts and debris.
2. Inspect lift rod and toggle assemblies, contacts, interrupters,
bumpers,dashpots, bushing current transformers, tank liners, and
gaskets.
3. Slow-close breaker and check for binding, friction, contact alignment,
penetration, and overtravel. Check that all phases make contact
simultaneously.
4. Refill tank(s) with filtered oil to correct levels.
following methods:
or Table 1.
9. Test alarms and lockouts for pneumatic and/or hydraulic operators as
recommended by the manufacturer.
10. Perform circuit breaker time-travel analysis.

11. Record as-found and as-left operation counter readings.
B Electrical Tests
2. Remove a sample of insulating liquid in accordance with ASTM D-923. Sample
shall be tested for the following:
1. Dielectric breakdown voltage: ASTM D-877
2. Color: ANSI/ASTM D-1500
*3. Power factor: ASTM D-924
*4. Interfacial tension: ANSI/ASTM D-971 or ANSI/ASTM D-2285
5. Visual condition: ASTM D-1524
4. Verify trip, close, trip-free, and antipump function.
*6. Perform insulation-resistance tests pole-to-pole, poleto-ground, and across
open poles at 15,000 volts minimum.
8. Perform power-factor tests on each pole with breaker open and each phase with
breaker closed. Determine tank loss index.
9. Perform power-factor tests on each bushing. Use conductive straps and hot collar
procedures if bushings are not equipped with a power-factor tap.
*10. Perform minimum pickup voltage tests on trip and close coils.
*11. Perform an overpotentialtest in accordance with manufacturers published
data.
C Test Values
range as indicated in the manufacturers published data.If manufacturers data is
4. Compare circuit breaker travel and velocity values to manufacturers published
data.
5. Insulating liquid test results should be in accordance with Table 7.
6. Circuit breaker insulation resistance should comply with Table 2.
8. Dissipation-factor/power-factor test results and tank loss index shall be compared
to manufacturers published data. In the absence of manufacturers published

data, the comparison shall be made to similar breakers.
published data.
SF6 HV Circuit Breakers

A
1.
2.
3.
4.
5.

Inspect anchorage and grounding.
Inspect and verify adjustments of mechanism in accordance with manufacturers
published data.
6. Inspect air compressor in accordance with manufacturers published data.
7. Inspect hydraulic system in accordance with manufacturers published data.
8. Test for gas leaks.
9. Verify correct operation of all air and SF6gas pressure alarms and cutouts.
10. Slow close/open breaker and check for binding.
11. Perform time-travel analysis.
12. Test SF6gas for moisture and nitrogen content.
following methods:
or Table 1.
14. Record as-found and as-left counter operations.
15. Check spring charging motor starts counter and compare with operations
counter, if applicable.
16. Verify operation of all heaters.
B Electrical Tests
3. Perform insulation-resistance tests pole-to-pole, poleto-ground, and across open
poles at 15,000 volts minimum.
*5. Perform dissipation-factor/power-factor tests on breaker and bushings.
*6. Perform overpotential test in accordance with manufacturers instructions.
*7. Perform minimum pick-up voltage test on trip and close coils.
8. Verify trip, close, trip-free, and antipump functions.
C Test Values.
4. Compare time-travel data with manufacturers published data.
published data. In the absence of manufacturers published data, the
comparison shall be made to similar breakers.
9. The insulation shall withstand the overpotential test voltage applied
published data.
Protective Relays (where applicable)

2. Inspect relays and cases for physical damage. Remove shipping restraint
material.
3. Tighten case connections. Inspect cover for correct gasket seal. Clean cover
glass. Inspect shorting hardware, connection paddles, and/or knife switches.
Remove any foreign material from the case. Verify target reset.
4. Inspect relay for foreign material, particularly in disk slots of the damping and
electromagnets. Verify disk clearance. Verify contact clearance and spring bias.
Inspect spiral spring convolutions. Inspect disk and contacts for freedom of
movement and correct travel. Verify tightness of mounting hardware and

connections. Burnish contacts. Inspect bearings and/or pivots.
5. Set relays in accordance with coordination study supplied by owner.
B Electrical Tests
1. Perform insulation-resistance test on each circuit-to-frame. Determine from the
manufacturers instructions the allowable procedures for this test for solid-state
and microprocessor-based relays.
2. Inspect targets and indicators.
a. Determine pickup and dropout of electromechanical targets.
b. Verify operation of all light-emitting diode indicators.
c. Set contrast for liquid-crystal display readouts.
3. Functional Operation
1. 2/62 Timing Relay
a. Determine time delay.
b. Determine instantaneous contacts.
2. 21 Distance Relay
a. Determine maximum reach.
b. Determine maximum torque angle.
c. Determine offset.
*d. Plot impedance circle.
3. 24 Volts/Hertz Relay
a. Determine pickup frequency at rated voltage.
b. Determine pickup frequency ata second voltage level.
c. Determine time delay.
4. 25 Sync Check Relay
a. Determine closing zone at rated voltage.
b. Determine maximum voltage differential that permits closing at zero
degrees.
c. Determine live line, live bus, dead line, and dead bus set points.
4. Determine time delay.
5. Verify dead bus/live line,dead line/live bus and dead bus/dead line
control functions.
5. 27 Undervoltage Relay
a. Determine dropout voltage.
b. Determine time delay.
c. Determine the time delay at a second point on the timing curve for
inverse time relays.
6. 32 Directional PowerRelay
a. Determine minimum pickup atmaximum torque angle.
b. Determine closing zone.
c. Determine maximum torque angle.
d. Determine time delay.

e. Verify the time delay at a second point on the timing curve for inverse
time relays.
*f. Plot the operating characteristic.
7. 40 Loss of Field (Impedance) Relay
a. Determine maximum reach.
b. Determine maximum torque angle.
c. Determine offset.
*d. Plot impedance circle.
8. 46 Current Balance Relay
1. Determine pickup of each unit.
2. Determine percent slope.
3. Determine time delay.
9. 46N Negative Sequence Current Relay
a. Determine negative sequence alarm level and trip.
b. Determine negative sequence minimum trip level.
c. Determine maximum time delay.
d. Verify two points on the (I2)2t curve.
10. 47 Phase Sequence or Phase Balance Voltage Relay
a. Determine positive sequence voltage to close the normally open contact.
b. Determine positive sequence voltage to open the normally closed contact
(undervoltage trip).
c. Verify negative sequence trip.
d. Determine time delay to close the normally open contact with sudden
application of 120 percent of pickup.
e. Determine time delay to close the normally closed contact upon removal
of voltage when previously set to rated systemvoltage.
11. 49R Thermal Replica Relay
a. Determine time delay at 300 percent of setting.
b. Determine a second point on the operating curve.
*c. Determine pickup.
12. 49T Temperature (RTD) Relay
a. Determine trip resistance.
b. Determine reset resistance.
13. 50 Instantaneous Overcurrent Relay
a. Determine pickup.
b. Determine dropout.
*c. Determine time delay.
14. 51 Time Overcurrent
a. Determine minimum pickup.
b. Determine time delays at two points on the time current curve.
15. 55 Power Factor Relay
16.
17.
18.
19.
20.
21.
22.
23.
24.
a. Determine tripping angle.

59 Overvoltage Relay
a. Determine overvoltage pickup.
b. Determine time delay to close the contact with sudden application of 120
percent of pickup.
60 Voltage Balance Relay
a. Determine voltage difference to close the contacts with one source at
rated voltage.
*b. Plot the operating curve for the relay.
63 Transformer Sudden Pressure Relay
a. Determine rate-of-rise or the pickup level of suddenly applied pressure in
accordance with manufacturers specifications.
b. Verify operation of the 63 FPX seal-in circuit.
c. Verify trip circuit to remote breaker.
64 Ground Detector Relay
a. Determine maximum impedance to ground causing relay pickup.
67 Directional Overcurrent Relay
a. Determine directional unit minimum pickup at maximum torque angle.
b. Determine closing zone.
*c. Determine maximum torque angle.
*d. Plot operating characteristics.
e. Determine overcurrent unit pickup.
f. Determine overcurrent unit time delay at two points on the time current
curve.
79 Reclosing Relay
a. Determine time delay for each programmed reclosing interval.
b. Verify lockout for unsuccessful reclosing.
c. Determine reset time.
*d. Determine close pulseduration.
5. Verify instantaneous overcurrent lockout.
81 Frequency Relay
a. Verify frequency set points.
c. Determine undervoltage cutoff.
85 Pilot Wire Monitor
a. Determine overcurrent pickup.
b. Determine undercurrent pickup.
c. Determine pilot wire ground pickup level.
87 Differential
a. Determine operating unit pickup.
b. Determine the operation of each restraint unit.
c. Determine slope.
d. Determine harmonic restraint.
e. Determine instantaneous pickup.
*f. Plot operating characteristics for each restraint.
3. Control Verification
Verify that each of the relay contacts performs its intended function in the control
scheme including breaker trip tests, close inhibit tests, 86 lockout tests, and alarm
functions.
4. System Tests
After the equipment isinitially energized, measure magnitude and phase angle of all
inputs and compare to expected values.
5. Test Values
1. Use manufacturers recommended tolerances when other tolerances
are not specified.
2. When critical test points are specified, the relay shall be calibrated to
those points even though other test points may be out of tolerance.
Instrument Transformers
A
1.
2.
3.
4.
5.
6.
7.
8.

Verify correct connection of transformers with system requirements.
Verify that adequate clearances exist between primary and secondary circuit
wiring.
Inspect all bolted electrical connections for high resistance using one of the
following methods:
or Table 1.
Verify that all required grounding and shorting connections provide contact.
Verify correct operation of transformer withdrawal mechanism and grounding
operation.
Verify correct primary and secondary fuse sizes for potential transformers.
B Electrical Tests - Current Transformers

2. Perform insulation-resistance tests of the current transformer and wiring-to-
3.
4.
5.
6.
7.
ground at 1000 volts dc. For units with solid-state components, follow
manufacturers recommendations.
Perform a polarity test of each current transformer.
Perform a ratio-verification test using the voltage or current method in
accordance with ANSI C57.13.1 (IEEE Guide for Field Testing of Relaying Current
Transformers).
Perform an excitation test on transformers used for relaying applications in
accordance with ANSI C57.13.1. (IEEE Guide for Field Testing of Relaying
Current Transformers).
Measure current circuit burdens at transformer terminals and determine the total
burden.
When applicable, perform insulation-resistance and dielectric withstand tests on
the primary winding with secondary grounded. Test voltages shall be in
accordance with Tables 10.13 and 10.9 respectively.
C Electrical Tests - Voltage Transformers

2. Perform insulation-resistance tests winding-to-winding and each winding-toground with test voltage in accordance with Table 4. Test voltages shall be
applied for one minute. For units with solid state components, follow
manufacturers recommendations.
3. Perform a polarity test on each transformer to verify the polarity marks or H1-X1
relationship as applicable.
4. Perform a turns ratio test on all tap positions, if applicable.
5. Measure potential circuit burdens at transformer terminals and determine the
total burden.
*6. Perform a dielectric withstand test on the primary windings with the secondary
windings connected to ground.The dielectric voltage shall be in accordance with
Table 10.9.The test voltage shall be applied for one minute.
D
1.
2.
3.
Electrical Tests - Coupling-Capacitance Voltage Transformers

Perform all tests from7.10.3 Voltage Transformers.
Measure capacitance of capacitor sections.
Measure power factor/dissipation factor in accordance with test equipment
E Test Values
range as indicated in the manufacturers published data.

If manufacturers data is not available, investigate any values which deviate
4. Insulation-resistance measurement on any instrument transformer should be not
less than that shown in Table 2.
5. Polarity results shall agree with system drawings.
6. Compare measured burdens to calculated burdens supplied by owner.
7. Ratio accuracies shall be in accordance with manufacturers published data.
9. Capacitance of capacitor sections of coupling-capacitance voltage transformers
shall be in accordance with manufacturers published data.
10. Power factor/dissipation factor shall be in accordance with test equipment
Metering
A
1.
2.
3.
4.

Verify tightness of electrical connections.
Inspect cover gasket, cover glass, condition of spiral spring, disk clearance,
contacts, and case-shorting contacts, as applicable.
5. Verify freedom of movement, end play, and alignment of rotating disk(s).
B Electrical Tests
1. Verify accuracy of meters at all cardinal points.
2. Calibrate watthour meters according to manufacturers published data.
3. Verify all instrument multipliers.
4. Verify that current transformer and voltage transformer secondary
circuits are intact.
Tables:
Table 1 >> Table 10.12


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Note:

of the following methods:

phase-to-ground, for one minute in accordance with Table 2.

13. Verify operation of switchgear/switchboard heaters.

Compare equipment nameplate data with drawings and specifications.

9. Verify correct liquid level in all tanks and bushings.

perform dissolved gas analysis (DGA) in accordance with ANSI/IEEE C57.104

A Visual and Mechanical Inspection

A Visual and Mechanical Inspection

e. Individually test each conductor with all other conductors grounded.

b. Capacitive and absorption current should decrease continually until

Visual and Mechanical Inspection

1. Compare bolted connection resistances and bus joint resistances to values of

Measured Resistance x Length of Run / 1000

Converted values of insulation resistance lessthan those in Table 2 or

a. Use of low-resistance ohmmeter.

4. Verify appropriate anchorage and required area clearances.

4. The insulation should withstand the overpotential test voltage applied.

Vacuum Switches: Medium-Voltage

Compare nameplate data with drawings and specifications.

torque-wrench method in accordance with manufacturers published data

Visual and Mechanical Inspection

9. Determine ground-fault pickup and delay by primary current injection.

Visual and Mechanical Inspection

Compare equipment nameplate data with drawings and specifications.

10. Perform circuit breaker time-travel analysis.

to manufacturers published data. In the absence of manufacturers published

SF6 HV Circuit Breakers

Visual and Mechanical Inspection

Protective Relays (where applicable)

movement and correct travel. Verify tightness of mounting hardware and

d. Determine time delay.

a. Determine tripping angle.

Visual and Mechanical Inspection

B Electrical Tests - Current Transformers

C Electrical Tests - Voltage Transformers

Electrical Tests - Coupling-Capacitance Voltage Transformers

range as indicated in the manufacturers published data.

Visual and Mechanical Inspection

Table 3 >> Table 10.2

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