Principles of MV SWG Testing 01: Visual Inspection

Principles of testing medium voltage switchgear: Part 1 Visual
inspection
Wednesday, November 15, 2017, 13:06:05

Site acceptance tests
After switchgear erection, installation, control wiring assembly on-site and before
connecting any cables from the plant, the switchgear must be admitted to the site
acceptance tests (SAT), which assures the correct operation of the switchgear
according to specification before energizing it. SATs are derived from the
International Electrotechnical Commission (IEC) standards 60694 and 62271-200.
The process for a SAT consists of seven important steps, (1) the visual inspection,
(2) the functional tests, (3) the mechanical tests, (4) the measuring devices tests, (5)
protective relays tests, (6) the dielectric tests and the (7) insulation resistance tests.
The SAT is basically the same for different switchgear configurations, but the
tested functions may vary from one switchgear configuration to another. For
example, some switchgear configurations include a synchronization check function
between the incoming cubicles to synchronize the coupling of two different power
sections, or other configurations include special protection functions for the
outcoming cubicles, so for each case the different functions should be tested.
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inspection

Before working, the commissioning engineer from the contractor or
manufacturer’s side should look at the drawings and prepare the test equipment to
be delivered on-site and estimate the manpower needed to complete the job in
due time. From the customer’s side, the switchgear must be cleaned from any
dust, the area should be made clear of obstacles and the customer should provide
the 230 VAC and 380 VAC power supplies necessary for the testing equipment.
A meeting is usually held between the consultant, contractor (or supplier) and
customer before the tests to agree upon the details of the test procedure and the
documents to be signed and the certificate forms.
On-site and after the documents have been prepared, all safety measures must be
taken, barriers should be set around the switchgear, the switchgear must be
properly earthed and only authorized personnel from the three main parties
should be allowed on-site.
Visual inspection of the switchgear
The first step is to inspect the switchgear visually by comparing the drawing with
the actual installed items. Visual inspection is important because (1) it ensures that
the switchgear has been manufactured according to the drawings and
specifications and (2) it helps in identifying some problems that might have not
been realized during the factory acceptance test (FAT). In some cases, the labelling
might be wrong or some component might be missing or one might even discover
a loose connection. In the visual inspection process one should scan his eyes
through as much details as possible, because there might be a missing label, a
missing gasket or a spot that needs to be repainted or any other detail.
To prepare for this test one needs the single line diagram (SLD), the control wiring,
a pencil and highlighter.
Examples from the field
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inspection

As mentioned above, the visual inspection can identify some serious problems,
which could save a lot of time and effort, in the following figure, the ammeters are
connected to the measuring core of a current transformer, imagine if one of the
connections is loose, what do you assume will happen when the 11 kV and the
1000 A are subject to the primary core? It simply is the textbook case of an open
current transformer circuit which can cause arcing or even explode. So, it is good
practice to give the current transformer circuits some extra attention and in this
case check that the wires are properly fixed into the ammeters.

Figure 1 A loose ammeter connection means that the current transformer has a core with an open circuit, one should look
carefully at current transformer connections to avoid serious accidents.
Sometimes the installed components are not the specified ones, so it is good
practice to take a close look at the labels of the main components at least. In the
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inspection

following figure, the installed current transformer has core ratios of 200/5 A, while
the specified ones are 300/5A.

Figure 2 Checking the labels visually before going through the test procedures is important to make sure the correct
components are installed; the tests can be a nightmare if they give unexpected results.
In some cases, the components are ordered correctly, but some functions
specified for the component are missing. This is quite common with protection
relays, because they usually have too much functions.
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inspection

Figure 3 Checking the product ID of protection relays assures that the correct relay has been ordered as specified with all the
requested functions.
In some cases, the mimic diagram on the cubicle might be incorrect, the indicating
leds might be misplaced or incorrectly labelled, or a pushbutton might be broken,
so it is good practice to check and compare with the drawings.

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inspection

Figure 4 Checking the mimic diagram, indicating lamps, push buttons flag relays and comparing with the drawings to make
sure they are placed according to specification.
The cubicle nameplates can sometimes be labelled with wrong names or
misspelled, so it’s worth checking and comparing with drawings.

Figure 5 Cubicle nameplate might be labelled with wrong name or misspelled.
In this article, we went through the process of testing medium voltage switchgear
on-site and we dedicated this first article in the series to the visual inspection test.
In the next article the functional tests shall be discussed.

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inspection

Further reading
For further reading refer to,
[1] IEC 62271-200:2011 https://webstore.iec.ch/publication/6716
[2] IEC 60694:1996 Common specifications for high-voltage switchgear and
controlgear standards, https://webstore.iec.ch/publication/17249
[3] http://www.parstasis.com/wp-content/uploads/2015/04/IEC-62271-200.pdf
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Principles of MV SWG Testing 01: Visual Inspection

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Principles of testing medium voltage switchgear: Part 1 Visual

Site acceptance tests

International Electrotechnical Commission (IEC) standards 60694 and 62271-200.

example, some switchgear configurations include a synchronization check function

sections, or other configurations include special protection functions for the

documents to be signed and the certificate forms.

should be allowed on-site.

Visual inspection of the switchgear

the switchgear has been manufactured according to the drawings and

through as much details as possible, because there might be a missing label, a

missing gasket or a spot that needs to be repainted or any other detail.

a pencil and highlighter.

Examples from the field

connected to the measuring core of a current transformer, imagine if one of the

the specified ones are 300/5A.

relays, because they usually have too much functions.

leds might be misplaced or incorrectly labelled, or a pushbutton might be broken,

so it is good practice to check and compare with the drawings.

The cubicle nameplates can sometimes be labelled with wrong names or

misspelled, so it’s worth checking and comparing with drawings.

In the next article the functional tests shall be discussed.

For further reading refer to,

[1] IEC 62271-200:2011 https://webstore.iec.ch/publication/6716

[2] IEC 60694:1996 Common specifications for high-voltage switchgear and

controlgear standards, https://webstore.iec.ch/publication/17249

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