MATERIALS TESTING AND STANDARDS DEPARTMENT

This is one of the best and most important department in B.E.S.T . All the components bought by B.E.S.T through various tenders by various companies have to be passes and tested O.K by this department to be used later on at the job sites. This department does intensive quality check-tests on the various materials such as cutouts , cables , C.T , P.T , lanterns , capacitors , transformer oil , circuit breakers , fuses , transformers , etc. A total of 75 materials are currently tested as per the strict regulations specified by the BUREAU of INDIAN STANDARDS . Due to the limited time allotted, only a few of the important materials tests were explained . These tests, there principle and actual testing procedures were demonstrated in an lucid manner .

The tests can be classified as three basic types: 1. Type tests: This test is carried out on only one sample of the whole lot. The tests once performed are accepted for upto five years. 2. Routine tests: This test is carried out on all the samples of the lot. Eg. P.T, C.T, transformers. 3. Acceptance tests: This test is tried on a few samples and based on this decision is made. Before carrying out the laboratory tests on CT and PT We take a physical inspection as follows: 1. There shall be no external physical damage 2. Polarity and terminals shall be marked. 3. Name plate should contain the following information: A) Name and year of manufacture,country of origin,etc B) Rated currents C) Rated frequency and rated voltage D) Serial no. E) Rated o/p and the corresponding accuracy class F) Highest system and knee point voltage

CURRENT TRANSFORMER IS no. : 2705(P-1 to P-4) 1.H.V Test on Primary side : Short the secondary terminals and connect to earthing terminals . Now , connect the phase probe of H.V set(0-30 kV) to primary . Increase slowly to 28 kV and maintain it for 1 minute . In case of any faults tripping occurs . 2.H.V Test on Secondary winding : Primary winding is shorted and connected to earth terminals of the C.T . Test voltage of 3 kV is applied between terminals of the secondary wdg.(connected together ) and Earth for 1 minute . No disruptive discharge shall occur if there is no fault ( else TRIPPING occurs on the H.V set 0-5 kV). 3.Accuracy test : This test is done on the Ct under test by comparing its properties with a standard CT whose is authenticated by MERC. As per the result of this test CTs are divided into different classes as follows :

4.KNEE POINT VOLTAGE : It is that value of sinusoidal voltage of rated frequency to secondary terminals of CT with all terminals open circuited, which when increased by 10 % then it causes the exciting current to increase by 50 %. The equipment used in this test are1) Voltmeter (0-240 V) 2) Ammeter (0-2 Amp) 3) 0-280 V variac 4) Connecting Wires

POTENTIAL TRANSFORMER I.S no.: 3156/1992 1.HV TEST on Primary winding : a. Unearthed Voltage Transformer : Rated voltage 11 kV 33 kV Test voltage 28 kV 70 kV

Test voltage is applied for one minute between all terminals of primary winding connected together and earth. The frame case (if any),core(is intended to be earthed) and all windings of secondary winding shall be connected together and earthed. b. Earthed Voltage Transformer : A test voltage of 3 kV rms is applied for one minute between terminals of primary winding(intended to be earthed and earth). For a proper P.T there shall be no disruptive discharge.

2.H.V Test on Secondary Winding : Using a test set of 0-5 kV , a test voltage of 3 kV is applied for 1 minute between all terminals of secondary winding connected together and earth. Again for a proper P.T there should be no disruptive discharge. 3.Ratio Test: This test is carried out in the meter testing room. 100V is applied in primary winding and voltage in secondary winding is measured. Ratio is confirmed by the corresponding primary and secondary voltages.

FUSE BASE I.S no. : 2086-1993 1.H.V Test : 2.5 kV AC is applied across it for 1 minute. And it should withstand the test. 2.Insulation resistance test : it should be min. 10 M

3.Temperature rise test : When a current of 630 A is passed for 4 hours the temperature rise should be a temperature rise of 40-50 degree celcius.

HRC FUSE (High rupturing capacity fuse) I.S no. : 13703-1993 1.Temperature rise test : Maximum rated current is passed through it for 4 hours and the temperature rise should be around 55 degree celcius. 2.Non-fusing test : 1.2 times the rated current is passed through HRC fuse and it should not blow within 3 hours . 3.Fusing test : 1.6 times the rated current is passed through the HRC fuse and it should blow within 3 hours . 4.Watt loss test : current is passed through fuses for 4

hours and the watt losses should be as follows : 23 W for 315 A 06 W for 63 A 15 W for 160 A 18 W for 200 A

TRANSFORMER OIL TEST In this test we determine the HV breakdown value of transformer oil. We use HV oil test set (0-100 kV) consisting of 1.Test cell made up of glass and is enclosed. 2.Electrodes mounted on horizontal axis and are spaced 5 mm apart. 3.Voltmeter which indicates the actual test voltage and be read even after the breakdown occurs . 4.Indicating lamp which indicates the HV transformer circuit is live . It switches off at the time of failure .

If the voltage at which breakdown occurs is more than 40 kV, then the transformer oil is tested O.K .

MCB ( Miniature circuit breaker ) I.S no. : 8828/1993 1. H.V Test : 2 kV AC is applied across the MCB for a minute and it should not trip. 2.Time Current characteristics : At 1.13 times the rated current , MCB should not open within one hour . At 1.45 times the rated current , MCB should open within an hour . At 2.55 times the rated current , MCB should open within 1 minute .

MCCB ( Molded Case Circuit Breaker ) I.S no. : 13947/1993 1.Dielectric test : 3 kV AC is applied across the MCCB for one minute and it should not trip . 2.Opening for Over-current release : a.Inverse time delay at 1.05 times the rated current , tripping should not occur within 2 hours . b.Inverse time delay at 1.3 times the rated current , tripping should occur within 2 hours . 3.Temperature rise test at rated current : The temperature should not exceed 80 degree celcius .

ELCB ( Earth Leakage Circuit Breaker) I.S no. : 12640/2000 1.Insulation resistance ( IR) test : It should be minimum 2 M . 2.H.V test : We apply 1.5 kV AC for 1 sec . 3.Verification of correct operation in case of steady state increase of residual current : ELCB should open within 50 % to 100 % of rated tripping current . 4.Verification of correct operation of closing at residual current : a.At rated tripping current ELCB should open within 300 ms . b.At 5 times the rated tripping current ELCB should open within 40 ms .