ABB

Factory Acceptance Test (FAT) procedure for

Medium voltage switchgear

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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

A) Switchgear Testing

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

2.1 Required documents ................................................................................................ 4
2.2 Test Equipment ........................................................................................................ 4

3. Equipment tests ................................................................................................................. 4

3.1 Design & visual Checks............................................................................................ 4
3.2 Wiring Checks .......................................................................................................... 5
3.3 Functional tests ........................................................................................................ 5
3.4 Mechanical operation ............................................................................................... 5
3.5 Power frequency withstand test on the main circuit .................................................. 6
3.6 Power frequency withstand test on control & auxiliary circuit. ................................... 6

4. Routine Test Certificate ..................................................................................................... 7

B) Circuit Breaker Testing

5. General Introduction and Pre-requisites.….……………………………………………………8
5.1 Required documents ................................................................................................ 8
5.2 Test Equipment ........................................................................................................ 8
6. Equipment description tests ............................................................................................... 9
6.1 Measurment of resistance of main circuit ................................................................. 9
6.2 Functional Test......................................................................................................... 9
6.3 Power frequency withstand test on the main circuit ................................................ 10
6.4 Power frequency withstand test on auxiliary circuit................................................. 10
6.5 Visual Inspection ................................................................................................... 10
7. Routine Test Certificate .................................................................................................. 11
8. Test equipment set up .................................................................................................... 13

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1. About this Document

1.1 General

This document describes the Test procedure for the Factory Acceptance of MV
Switchgear and same will be used for testing of MV Switchgear and Circuit Breaker at
Factory.

1.2 Scope

The information provided in the document shall be valid for the MV Switchgear &
Circuit Breaker being supplied by M/s ABB Limited, Nasik (India).

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

· General description about this document

· Details out the purpose and pre-requisites required to carry out the tests
· Equipment description tests
· Routine Test Certificate

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A) Switchgear Testing :

2. General Introduction and Pre-requisites

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

2.1 Required Documents

Following are the documents required to conduct the test.

1. Electrical drawings including schemes,SLD

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

2.2 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

3. Equipment tests
3.1 Design & visual Checks

Description of the test to be conducted:

a) Verification of items as per apparatus allocation chart or bill of material.

b) Check the availability of all Equipment/Items as per the GA drawings.
c) Visual check of painted surface according to drawings.
d) Earthing provision for the switchgear.
e) Dimension check

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Objective of the test: To ensure the availability of all switchgear as per the
documents/customer specifications.

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

3.2 Wiring Checks

Description of the test to be conducted:
a) Check all the wiring is 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.

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.
c) Check operation of other items as per control schemes.

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

Expected Result: All mounted apparatus functions properly.

3.4 Mechanical Operation Test

Description of the test to be conducted:

Operation of Circuit Breaker

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

Objective of the test: To ensure smooth operation of C.Bs in switchgear.

Expected Result: All Mechanical interlocks work properly.

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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
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.

3.6 Power frequency voltage withstand test on control & auxiliary

circuit.

Description of the test to be conducted:

a) Apply 2 kV for one minute 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

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4. Routine Test Certificate for Switchgear
Customer:

Our Reference No.

Panel type:
Breaker type:

Apparatus Allocation Chart YN1V300011-

Single Line Diagram YN1V300013-
Schematic Drawings YN1V300013-
List Of Labels YN1V400014-
Front G.A & Foundation YN1V300015-
Metering G.A YN1V400017-
Cross Sectional drawings YN1V300031-

TESTS (AS PER IEC 62271-200 & IEC62271-1) Comments

A. Design & visual checks Found ok
System Voltage
B. Wiring checks Found ok
C. Functional tests Found ok
KV
D. Mechanical operation test SWITCHGEA Found ok
E. Power frequency voltage withstand test at kV for One minute on the main circuit R Withstood
F. IR Test before & after HV Found ok
G.Power frequency voltage withstand test at 2KV for 60second on control circuit Withstood

CT Serial Nos Type of

PT Serial Nos Prot.
Panel Panel
CT Ratio Main Relay
No. Designation "R" PH "Y" PH "B" PH"R" PH"Y" PH"B" PH
Prot. Serial nos.

Comments: Quality Control & Testing Engineer

ABB Ltd, Nashik

PAGE : 01 / 01 Date :

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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.

5.1 Required Documents

Following are the documents are required to conduct the test.
1. Circuit breaker wiring

2. Details from SAP system (for CB rating, coils voltage etc)

3. IEC 62271-100

5.2 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)

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6 Equipment test

6.1 Measurement of resistance of main circuit

The test shall be carried out with single phase 100Amps DC kit. The breaker
will be kept 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.

Expected Result: Contact resistance within specified limits.

6.2 Functional Test

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

Equipment Used For Test: - CB Analyzer. AC/DC supply source and

multimeter.

Procedure :-

a) 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

close / open operation at 100 % control voltage

b) Connect timing leads through test kit to each pole at top and bottom
contact.
c) Operate the breaker through test kit.
d) Give open close (Open 0.3sec delay close) command & analyze the graph
e) Record the parameters with breaker details.

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Objective of the test: This test describes the functional parameters of circuit
breaker. The test machine provides graph of electrical contact signal and
ensures electrical operations of the coils.
Expected Result: Smooth operation and parameters within limits.

6.3 Power frequency voltage withstand test on the main circuit

This test is carried out in two conditions

Equipment Used For Test :- High Voltage kit.

Procedure :-
a) Open condition – High voltage _ kV AC to be applied across the contacts
of the circuit breaker for One minute.
b) Close condition – High voltage of _kV 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: This test is done to ensure that healthiness of the
vacuum interrupter (no loss of vacuum) and healthiness of the insulation and
clearances between the phases.

Expected Result : Test should be withstood.

6.4 Power frequency voltage withstand test on 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

6.5 Visual Inspection:-

a) All components should be assembled as per breaker requirement

b) Operating instruction sticker availability

c) Rating plate verification as per customer requirement

d) Cleanliness of circuit breaker

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7 Routine test certificates

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8 TEST EQUIPMENT SET UP
a) CIRCUIT BREAKER ANALYZER

b) POWER FREQUENCY TEST BENCH

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