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Record no.:
ABB M.V SWGR SITE TEST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR Cover page

UniGear
General Commissioning and testing
Procedure
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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 1 of 15

General:

The following procedure is for site inspection and testing of MV Switchgear. Switchgear
is the combination of electrical disconnect switches, relays, busbar, meter, instrument
transformers, and fuses or circuit breakers.

Reference documentation:

Equivalent Standards.

1. General data and information.

The Switchgear shall be inspected to record the ratings, serial number, etc.

2. Mechanical check and visual inspection.

- Inspect for physical, electrical, and mechanical conditions.

- Compare equipment nameplate information with latest one-line diagram, all the
installed devices with the list of apparatus and report any discrepancies.

- Inspect all doors, panels, and sections for paint, dents, scratches and missing hardware.

- Check for proper anchorage, required area clearances, physical damage, and proper
alignment.

- Verify that fuse and/or circuit breaker sizes and types correspond to drawings.

- Verify that current and potential transformer ratios correspond to drawings.

- Inspect all bus connection for high resistance. Check tightness of bolted bus joints by
using a calibrated torque wrench.

- Test all electrical and mechanical interlock systems for proper operation and
sequencing.

- Clean entire switchgear using manufacturer’ approved methods and materials.

- Clean insulators for evidence of physical damage or contaminated surfaces.

- Verify proper barrier and shutter installation and operation.

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SWITCHGEAR TEST PROCEDURE Page 1 of 15

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 2 of 15

- Verify appropriate contact lubricant on moving current carrying parts and appropriate
lubrication on moving and sliding surfaces. Inspect all mechanical indicating devices for
proper operation.

- Exercise all active components.

- Inspect all mechanical indicating device for proper operation.

3. General Electrical inspection.

- Perform tests on all instrument transformers as described later in this section.

- Perform test on busbar as described later in this section.

- Perform test on circuit breaker as described later in this section.

- Perform accuracy test of all meters and test for their calibration.

- Perform accuracy test protection and simulate fault condition tests circuits (trip tests) as
decribed later in this section.

- Perform bay level functional test of all switchgear to verify the intergrity of the relay
logic configuration and internal panel control wiring as per scheme.

- Perform secondary voltage energization test on all control power circuit and potential
circuit and check voltage levels at each measuring devices to verify the intergrity of the
VT secondary circuit.

- Perform primary current injection test on entire current circuit in each section of the
switchgear as decscribed later in this section.

- Perform test for all external cabling for continuity and correct termination from
upstream/downstream substation, transformer supervisory protections, motor’s RTD
and field stop / start. Simulate and verify signals from remote to switchgear.

- Simulate alarm, measurement, and command signals in each section of the switchgear
to/from PMS system and DCS to verify the intergrity of the communication and the
correctness of the mapping signals in the relay and PMS/DCS.
- Perform functional test on Automatic / Manual switch transfer as per specification.
- Check space heater and panel lighting

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SWITCHGEAR TEST PROCEDURE Page 2 of 15

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 3 of 15

4. Circuit breaker testing.

4.1. Test equipment:

1. Insulation resistance tester ( 5KV )

2. Micro- ohmmeter ( 100A DC )
3. CB Analyzer
4. Timer
5. High Voltage tester ( 0- 50KV AC )
6. Discharge stick
7. High voltage gloves

4.2. Mechanical check and visual inspection.

- Inspect for physical and mechanical condition.

- Check proper alignment of the breaker primary and secondary contacts.

- Check racking mechanism for alignment and smoothness of operation and proper
operation of all mechanical interlocks.

- Check tightness of bolted connections by using calibrated torque wrench.

- Check for correct breaker position and spring status indications.

- Check all wiring correctness as per approved drawings and tightness of all terminal
connections secure.

4.2. Electrical test.

Insulation resistance test.

Measure the insulation resistance between phases and between phase and earth. Also,
insulation resistance between cable and busbar side of the breaker on each phase with
the help of 5KV megger. This test is done before and after High voltage test.

CB close position
1. Connect the positive and negative cable of the megger as per below connection.
2. Apply 5KV DC voltage for 1 minute.
a.1.) L1 to L2 a.3.) L1 to Earth
a.2.) L2 to L3 a.4.) L2 to Earth
a.3.) L3 to L1 a.5.) L3 to Earth

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
SWITCHGEAR TEST PROCEDURE Page 3 of 15
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Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 4 of 15

+ +
G CB CLOSE G CB CLOSE
POSITION POSITION
- -
MEGGER MEGGER

L1 L2 L3 L1 L2 L3

CB open position BUS SIDE

a.1.) L1BUS SIDE to L1CABLE SIDE
a.2.) L2BUS SIDE to L2CABLE SIDE +
a.3.) L3BUS SIDE to L3CABLE SIDE G CB OPEN
POSITION
-
MEGGER

L1 L2 L3
CABLE SIDE

Contact resistance test.

Measure contact resistance on each breaker pole by using a micro-omhmeter.
1. Close the circuit breaker.
2. Connect the mico-ohmmeter one end of the current and voltage cables to L1 BUSBAR SIDE
and the other end cables to L1 CABLE SIDE.
3. Apply 100A DC current through the Micro-ohmmeter tester. Repeat the same for the
other phases.
BUS SIDE

C+
V+ CB CLOSE
POSITION
V-
C-

MICRO-OHMMETER
L1 L2 L3

CABLE SIDE

High voltage test.

Measure the leakage current by applying high AC voltage.

CB Open position
1. CB shall be open and the cable side grounded.
2. Connect the high voltage cable to the phasebus side to be tested and the phase cabe
side to ground. Apply the test voltage for 10 seconds as per below connection.
3. Repeat the same for the other phases.

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SWITCHGEAR TEST PROCEDURE Page 4 of 15

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:

M.V SWITCHGEAR 5 of 15
BUS SIDE

Cont CB OPEN
rol POSITION
unit

L1 L2 L3
HV INJECTOR
CABLE SIDE

c.1.) L1BUS SIDE to L1CABLE SIDE

c.2.) L2BUS SIDE to L2CABLE SIDE
c.3.) L3BUS SIDE to L3CABLE SIDE

CB Close position
1. CB shall be closed and remove the ground.
2. Connect the high voltage cable to the phase to be tested and the other two
phases to ground. Apply the test voltage for 1 minute as per below connection.
3. Repeat the same for the other phases.
BUS SIDE

CB CLOSE
Cont POSITION
rol
unit

L1 L2 L3
HV INJECTOR
CABLE SIDE

c.1.) L1 to L2 + L3 + earth
c.2.) L2 to L1 + L3 + earth
c.3.) L3 to L1 + L2 + earth

Note: After each test, discharge voltage to ground using the discharge stick.
Applied voltage = 80% of factory acceptance withstand voltage as per IEC62271-200.

CB Close / Open timing test.

Check the breaker close and open operating time as per manufacturer specification.
This is done by using a breaker analyser.
1. Short the three phases of the breaker cable side terminals and connect to ground.
2. Connect the time measurement cable to the main contacts of the breaker and to the
timing contact of the test equipment. Red to L1, yellow to L2, blue to L3, and black to
ground.

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SWITCHGEAR TEST PROCEDURE Page 5 of 15

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 6 of 15

3. Connect the auxiliary contact measurement cable to the auxiliary contacts in the
operating mechanism, and to AUX1&2 contact of test equipment.
4. Close / open the breaker through the test equipment to get the operating time.
L1 L2 L3 Red
Yellow

Blue

CB

Spring charging time and current.

Measure the CB spring charging time as per manufacturer specs. This test is done using
Timer. The motor current shall be checked by using a multimeter.

1. CB shall be open.
2. Make connection as per below figure.
3. Close the breaker for the spring charging motor to run and activate the timer.
4. Record the time and the current flowing in the motor.

Ammet
er

START

M
STOP

SPRING AUX. TIMER

CB OPEN CHARGING CONTACT
POSITION MOTOR
-

Functional test.
Check all interlocks.
1. Verify interlocks of all mechanical with breaker.
2. Verify doors are interlocked with breaker.
3. Verify earthing switches are interlocked with breaker.
4. Verify circuit breaker operation local / remote in test position.
5. Verify circuit breaker may not be inserted in closed position or if the earthing switch
is on.
6. Check alarm and indications, and auxiliary contacts for correct operation.

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SWITCHGEAR TEST PROCEDURE Page 6 of 15

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 7 of 15

5. Busbar testing.

5.1. Test equipment:

1. Insulation resistance tester ( 5KV )

2. Micro- ohmmeter ( 100A DC )
3. High Voltage tester ( 0- 50KV AC )
4. Discharge stick

5.2. Mechanical check and visual inspection.

- Inspect for physical and mechanical condition and tightness of bolts joint.

- Check busbars are supported correctly and clearance requirements of busbar between
phase to phase and phase to ground.

- Identification of correct phasing and marking of phases.

5.3. Electrical test.

Insulation resistance test.
Measure the insulation resistance between busbars and between busbars and earth with
the help of 5KV Megger. This test is done before and after High voltage test.

1. Disconnect arrester and rack out VT.

2. Connect the positive and negative cable of the megger as per below connection.
3. Apply 5KV DC voltage for 1 minute.

+ +
G BUSBAR G BUSBAR

- -
MEGGER MEGGER

L1 L2 L3 L1 L2 L3
a.1.) L1 to L2 a.3.) L1 to Earth
a.2.) L2 to L3 a.4.) L2 to Earth
a.3.) L3 to L1 a.5.) L3 to Earth

Contact resistance test.

Measure contact resistance of the busbar bar joints. This is done using a micro-ohmmeter.
1. Connect the mico-ohmmeter one end of the current and voltage cables to L1 of H1
panel and the other end cables to L1 of H2 panel.
2. Apply 100A DC current through the micro-ohmmeter tester. Repeat the same for the
other phases and for H2 to Hn panel.

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
SWITCHGEAR TEST PROCEDURE Page 7 of 15
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Description: Ref. Test Record : Sheet:

M.V SWITCHGEAR 8 of 15
H1 H2 Hn

L1

L2

L3

C+ C-
V+ V-

MICRO-OHMMETER

High voltage test.

Measure the leakage current by applying high AC voltage.

1. Disconnect all the high voltage cables that are connected to the switchgear. Ensure
that the phase conductors of the cables are kept at on adequate distance from the
bus bar to prevent any flash overs.
2. Remove all dust from insulators.
3. Disconnect the primary sides of all voltage transformer.
4. Disconnect the primary sides of all surge arresters.
5. Rack out circuit breakers.
6. Connect the high voltage cable to the phase to be tested and the other phases to
ground as per below connections.
7. Apply voltage test voltage for 1 minute. Repeat the same for other phase.

BUSBAR
Cont
rol
unit

HV INJECTOR L1 L2 L3

c.1.) L1 to L2 + L3 earth
c.2.) L2 to L1 + L3 earth
c.3.) L3 to L1 + L2 earth

Note: After each test, discharge voltage to ground using the discharge stick.
Applied voltage = 80% of factory acceptance withstand voltage as per IEC62271-200.
.

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SWITCHGEAR TEST PROCEDURE Page 8 of 15

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 9 of 15

6. Current transformer testing.

6.1. Test equipment:
1. Insulation resistance tester ( 1KV )
2. Analog Current meter
3. Multimeter
4. Clamp meter
5. Battery
6. Secondary current injector
7. Variable AC single phase voltage source
8. Primary current injector

6.2. Mechanical check and visual inspection.

- Inspect for physical and mechanical condition.
- Verify proper connection of transformers with system requirements
- Verify tightness of all bolted connections and ensure that adequate clearances exist
between primary circuits and secondary circuit wiring.
- Verify that all required grounding are securely connected and all CTs secondary circuit
are closed.

6.3. Electrical test.

Insulation resistance test.
Measure the insulation resistance between primary to secondary and secondary
winding to ground (grounding removed) and secondary core to core with the help of
1KV Megger.
1. Connect the positive and negative cable of the megger as per below connection.
2. Apply 1KV DC voltage for 1 minute.
P1 P1
1S1
+ + 1S1

G 1S2 G 1S2
`
- 2S1 - 2S1
MEGGER MEGGER
2S2 2S2
P2 P2

a.1.) R – Pri. to Sec. core1 / 2 a.3.) R – Sec. core 1 to 2

a.2.) Y – Pri. to Sec. core1 / 2 a.4.) Y – Sec. core 1 to 2
a.3.) B – Pri. to Sec. core1 / 2 a.5.) B – Sec. core 1 to 2

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SWITCHGEAR TEST PROCEDURE Page 9 of 15

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 10 of 15
P1
1S1
a.7.) R - Sec. core 1/ 2 to ground +
a.8.) Y - Sec. core 1/ 2 to ground G 1S2

a.9.) B - Sec. core 1/ 2 to ground - 2S1

MEGGER
2S2
Transformer turn ratio. P2

Measure the ratio of the primary and secondary side of CT using primary current injector
and clamp meter.
Ensure thal all terminal blocks in the secondary circuit are closed.
1. Connect the primary current injector at the primary side either phase to ground
or phase to phase and measure the current at the secondary side.
2. Read the primary and secondary current using clamp meter.
3. Compute the ratio as per reading and compare it to the nameplate ratio.
P1

1S1
Relay R
`
1S2
A
A P2 AC current
Ammeter
Ammeter Source

Winding resistance test.

Measure the resistance of the primary and secondary winding using multimeter.
1. Read the resistance of the primary and secondary side of the CT as per below.
P1

1S1
Multimeter R
`1S2

P2

Polarity test.
Verify correct polarity of the CT as per drawing.
1. Connect a battery, having a predetermined polarity, for a short period, across
the
primary side of the CT as per below connection. At the same time polarity of
current induced at the secondary side.
2. If the polarity is correct, the analog meter will deflect in a positive direction.

P1

Analog 1S1
+
curent A
1S2
meter ` _
P2
Battery

Primary current injection ( Same as turn ratio test ).

Check the wiring intergrity from primary to the measuring devices by applying
primary AC current.
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SWITCHGEAR TEST PROCEDURE Page 10 of 15

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 11 of 15

Burden test.
Measure the connected load of the CT using seconday current injector and multimeter.
1. Inject rated secondary current at CT secondary terminals with the load
connected.
2. Measure the voltage drop across the CT terminals.
3. Product of the voltage drop to the rated current of the CT is the burden.
P1

1S1
Load V Voltmeter
`
1S2

P2

Secondary
current injector

Magnitization curve.
Verify the knee voltage and current as per specification using variable AC voltage source
and multimeter.
1. The primary circuit is to be open.
2. Ensure that the primary circuit is not earthed on the both side of the current
transformer.
3. The secondary burden of the current transformer is to be isolated.
4. The measuring is commenced and terminated by increasing the voltage in secondary
of the current transformer with the knee point is clearly exceeded and thereafter by
slowly reducing it to zero.
P1

1S1
V
`1S2

A P2
Variable AC
Voltage
Source

7. Voltage transformer testing.

7.1. Test equipment:
1. Insulation resistance tester ( 1KV )
2. Multimeter
3. Analog voltage meter
4. Battery
4. Secondary voltage injection
5. High voltage injector

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SWITCHGEAR TEST PROCEDURE Page 11 of 15

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 12 of 15

7.2. Mechanical check and visual inspection.

- Inspect for physical and mechanical condition.

- Verify proper connection of transformers with system requirements.

- Verify tightness of all bolted connections and ensure that adequate clearances exist
between primary circuits and secondary circuit wiring.

- Verify that all required grounding and shorting connections provide good contact.

- Test proper operation of transformer withdrawal mechanism and grounding operation

when applicable.

- Verify proper primary and secondary fuse sizes for potential transformers

7.3. Electrical test.

Insulation resistance test.

Measure the insulation resistance between primary winding to secondary and secondary
winding to ground (grounding removed) and secondary core to core with the help of 1KV
Megger.

1. Connect the positive and negative cable of the megger as per below connection.
2. Apply 1KV DC voltage for 1 minute.
HV SIDE HV SIDE

+ +
G G

- -
MEGGER MEGGER
LV1 SIDE LV2 SIDE LV1 SIDE LV2 SIDE

a.1.) R - HV side to LV1/LV2 side a.3.) R - LV1 to LV2

a.2.) Y - HV side to LV1/LV2 side a.4.) Y - LV1 to LV2
a.3.) B - HV side to LV1/LV2 side a.5.) B - LV1 to LV2
HV SIDE
a.6.) R - LV1/LV2 side to ground +
a.7.) Y - LV1/LV2 side to ground G
a.8.) B - LV1/LV2 side to ground -
MEGGER
LV1 SIDE LV2 SIDE

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SWITCHGEAR TEST PROCEDURE Page 12 of 15

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 13 of 15

Transformer turn ratio.

Measure the ratio of the HV and LV winding using AC low voltage source and
multimeter.
1. Ensure thal all terminal blocks in the secondary circuit are closed.
2. Connect single phase AC low voltage at the HV side and measure the voltage
induced at the LV side.
3. Compare the measured ratio to the nameplate ratio.

V Multimeter

AC voltage HV side LV side

Source
Winding resistance test.
Measure the resistance of the primary and secondary winding using multimeter.
1. Read the resistance of the HV and LV side of the VT as per below.

Multimeter R R Multimeter
R

HV side LV side
Polarity test.
Verify correct polarity of the VT as per drawing.
1. Connect a battery, having a predetermined polarity, for a short period, across the
primary side of the transformer as per below connection. At the same time
polarity
of voltage induced at the LV side.
2. If the polarity is correct, the analog meter will deflect in a positive direction.
A
a
Analog
V voltage
n
N meter

Battery HV side LV side

Primary voltage injection.

Check the wiring intergrity from primary to secondary by applying High AC voltage.
1. Connect the VT in the bus by racking in.
2. Apply AC high voltage single phase to the bus up to rated voltage.
3. Read the voltage in the relay / meter.
Relay/
R Voltage
meter

HV side LV side
AC HV
Source
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SWITCHGEAR TEST PROCEDURE Page 13 of 15

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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 14 of 15

Secondary voltage injection.

Check the VT secondary wiring intergrity.

1. Disconnect voltage transformer at secondary terminal.

2. Connect secondary wiring to secondary voltage injector.
3. Check the proper voltage reading at all measuring devices.

8. Protective Relays functional test.

8.1. Test equipment:

1. Secondary current injector

2. Test plug

8.2. Mechanical check and visual inspection.

- Inspect relays for physical damage and compliance with drawings and specifications.

- Check for loose terminal and holding / locking crews.

- Check for damage coil, wiring, and indicator.

8.3. Electrical test.

Logic Configuration.
1. All input and output should be programmed by the approved scheme.
2. Schematic diagram should be verified during making of logic configuration.
3. Disturbance recorder and trip indication must be included in the configuration.
3. Upload the configuration to the relay.
4. Configuration such as control, interlocking, and protective relays must be verified.

Metering.

Phase current measurement test.

Record the phase primary CT, injected secondary current, expected current, measured
current per phase and the residual / neutral current.

Phase voltage measurement test.

Record the phase primary VT, injected secondary voltage, expected voltage line to line
and line to ground, measured voltage line-line and the line to neutral.

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SWITCHGEAR TEST PROCEDURE Page 14 of 15
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Record no.:
ABB M.V SWGR SITE EST PROCEDURE
Description: Ref. Test Record : Sheet:
M.V SWITCHGEAR 15 of 15

Protection relay.

Pick up test.
Test the pick up value on each protection as per setting and record the secondary current
/ voltage injected.

Phase / earth time overcurrent protection test.

1. Test the phase / neutral overcurrent protection through IEC/ ANSI curve requirement
such as extrememly inverse, very inverse, normal inverse, long time inverse, and
definite time.
2. Record the current setting, pick up value, injected current value, time multiplier, and
if directional setting is used, record the forward and reverse operating angle and
minimum voltage required.
3. Record the operating time in seconds on each phase and neutral.

Phase / earth instantaneous overcurrent protection test.

1. Test the phase/neutral instantaneous overcurrent protection.
2. Record the current setting, pick up value, injected current value, and if directional
setting is used, record the forward and reverse operating angle and minimum
voltage required.
3. Record the operating time in seconds on each phase and neutral.

Phase undervoltage protection test.

1. Record the normal voltage, undervoltage setting, pick up value, reset value.
2. Record the operating time in seconds.

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SWITCHGEAR TEST PROCEDURE Page 15 of 15