The document outlines the routine tests procedure for the replacement of a switchboard in a hospital. It details 8 tests to be conducted: 1) visual checks, 2) insulation testing, 3) power frequency voltage testing, 4) secondary injection testing, 5) primary injection testing, 6) functional testing of circuit breakers and fuse switches, 7) temperature rise testing of switchboards A and B over two days, and 8) contact resistance testing. Remarkably, the temperature rise tests can only be done one per day due to the time needed for preparation, cool down, and setup for the next test.
The document outlines the routine tests procedure for the replacement of a switchboard in a hospital. It details 8 tests to be conducted: 1) visual checks, 2) insulation testing, 3) power frequency voltage testing, 4) secondary injection testing, 5) primary injection testing, 6) functional testing of circuit breakers and fuse switches, 7) temperature rise testing of switchboards A and B over two days, and 8) contact resistance testing. Remarkably, the temperature rise tests can only be done one per day due to the time needed for preparation, cool down, and setup for the next test.
The document outlines the routine tests procedure for the replacement of a switchboard in a hospital. It details 8 tests to be conducted: 1) visual checks, 2) insulation testing, 3) power frequency voltage testing, 4) secondary injection testing, 5) primary injection testing, 6) functional testing of circuit breakers and fuse switches, 7) temperature rise testing of switchboards A and B over two days, and 8) contact resistance testing. Remarkably, the temperature rise tests can only be done one per day due to the time needed for preparation, cool down, and setup for the next test.
The document outlines the routine tests procedure for the replacement of a switchboard in a hospital. It details 8 tests to be conducted: 1) visual checks, 2) insulation testing, 3) power frequency voltage testing, 4) secondary injection testing, 5) primary injection testing, 6) functional testing of circuit breakers and fuse switches, 7) temperature rise testing of switchboards A and B over two days, and 8) contact resistance testing. Remarkably, the temperature rise tests can only be done one per day due to the time needed for preparation, cool down, and setup for the next test.
Replacement of Switchboard in North District Hospital
Routine Tests Procedure (Phase 2) (Rev. 0)
Proposed FAT & SAT for L.V. SWBs
Testing/ Inspection/ Check FAT SAT 1. Visual Checks -- General Construction of Type Tested Assembly (TTA) -- Main Busbars and Droppers/Risers (Day 1) -- Air Circuit Breaker (ACB)/Fuse Switches -- Instrumentation and Protection -- Incoming-outgoing Cables and Busbars -- Miscellaneous 2. Insulation test (Day 1)
3. Power Frequency Voltage Test (Dielectric test) (Day 1)
4. Secondary injection test (Day 1)
5. Primary injection test (Day 1)
6. Functional Test (Day 1) 3P4W 380V Power
a. ACB, and MCCB Supply shall be provided near to L.V. SWBs during site test 7. Temperature Rise Test for L.V. SWB “A” (Day 2*) Test Loop 800789-T03 8. Temperature Rise Test for L.V. SWB “B” (Day 3*) Test Loop 800789-T04 9. Contact Resistance Test (Ductor test)
Remark: a) For temperature rise test, we can carry out one test loop per day only; we need 1 day before the test for preparation and 1 day after the test to allow for cool down, dismantling of setup and setup for next test loop. Therefore, the above “Test Day 1, 2 & 3”are not continuous. Rickson Engineering Limited 利信機電有限公司 Replacement of Switchboard in North District Hospital Routine Tests Procedure (Phase 2) (Rev. 0)
Address: Unit C, 1/F, E Tat Factory
Building, 4 Heung Yip Road, Wong Chuk Hang, Hong Kong. ( 香港黃竹坑香葉道 4 號怡達工業大廈 1 字樓 C 座) Telephone: 2554 1213 (Factory), 3120 7500 (Office) Rickson Engineering Limited 利信機電有限公司 Replacement of Switchboard in North District Hospital Routine Tests Procedure (Phase 2) (Rev. 0)
A) General Inspection and Checking For :-
1. The conformity of dimension & layout to drawings.
2. The correctness of switchgears and fuses rating.
3. The effectiveness of mechanical actuating elements, interlocks, locks, etc.
4. The proper laying and arrangement of cables/busbars.
5. The tightness and secureness of all fixing screws, connecting bolts and nuts.
6. The prescribed degree of protection, creepage and clearance distances.
7. The completion of labels.
8. The continuity of earthing.
9. Cleanliness of equipment.
B) Insulation Test (Megger Test)
Insulation test is performed by applying a d.c. voltage of 1000V between all circuits and earth and between each circuit and measuring the insulation resistance.
The general procedure is as follows:-
1. Remove links and fuses in all tripping, control and alarm circuits.
2. All switching devices to be opened.
3. Test and record the insulation resistance between all circuits and earth and between all circuits by means of a megger.
4. Repeat step 3 for all switching devices to be closed.
This test is to be repeated after the High Voltage Test.
Remark
1. Any reading of less than 1 mega ohm at 1000V d.c. should be investigated.
2. Any measuring instrument of protective device, e.g. static relay, which may be damaged by application of such a voltage shall be disconnected at one or all terminals. Rickson Engineering Limited 利信機電有限公司 Replacement of Switchboard in North District Hospital Routine Tests Procedure (Phase 2) (Rev. 0)
C) Power Frequency Voltage Test
Power Frequency Voltage test is performed by applying a 2500V a.c. at power frequency between:-
1. all live circuits (i.e. L1.L2.L3.)
2. each live circuit and all other circuits interconnected to earth (e.g. L1 to L2+L3+N+E)
The general procedure is as follows:-
1. Remove links and fuses in all tripping, control and alarm circuits.
2. Close all the switches
3. Apply a voltage of 2500V a.c. at power frequency by means of an a.c. H.V. tester between all live circuits and between each live circuit and all other circuits interconnected to earth for 1 minute.
4. Record leakage current.
Remark The test is considered to have been passed if there is no puncture or flash-over.
D) Primary Injection Test
Primary injection test involves the passing of heavy currents through the current transformers to check:-
1. The C.T. ratio and
2. C.T. polarity
L1 L1
L2
L3 L1 Rickson Engineering Limited 利信機電有限公司 Replacement of Switchboard in North District Hospital Routine Tests Procedure (Phase 2) (Rev. 0)
The General Procedure is as follows:-
1. Place a short circuit as near as possible to the current transformers as shown in the above diagram. 2. Inject current to the primary side of L1 and L2 phases with value equals to the C.T. primary rating. 3. Measure and record the secondary output current of each transformer (both M.C.T. & P.C.T.) as well as the spill current by means of a DMM. 4. Repeat for L2-L3, L1-L3, L1-N, L2-N & L3-N phases.
Remark 1. The tolerance of the secondary current measured is ± 1% and spill current within 100mA 2. If the polarity of any P.C.T. is incorrect, the sum of the currents in the secondary windings will pass through to earth and significant spill current will be recorded.
E) Secondary Injection Test (For Alstom IDMT Relay)
Secondary injection test is employed to test the characteristic of IDMT relays by injecting current at the current transformer secondary terminals (or by use of test plug for IDMT relay) to simulate the C.T. output.
The general procedure is as follows:-
1. Record model no. & serial no. of IDMT relay.
2. Insert the test plug into the L1-phase of the IDMT O/L relay.
3. Select and set the plug & time multiplier.
4. To check the relay characteristic, inject current of 2X plug-setting to the relay, measure and record the operating time. 5. Repeat step 3 but current of 5 times and 10 times is injected (Setting can be changed to other combination). 6. Repeat for L2 & L3 phase of O/L relay and the E/F relay (if any). Rickson Engineering Limited 利信機電有限公司 Replacement of Switchboard in North District Hospital Routine Tests Procedure (Phase 2) (Rev. 0)
Remark The tolerance of the operating time (at 10 times setting) is ± 5%.
According to IEC 60255-3:1989 Clause 4.3.2(b).
Limiting Errors at Defined Values of the Characteristic Quantity
Value of the characteristics quantity are
2 5 10 multiple of the setting value (GS)
Reference limiting error (%) 2.5 x (±5%)= 1.5 x (±5%)= 1 x (±5%)=
(±12.5%) (±7.5%) (±5%)
F) Functional Test for ACB, ATS and MCCB
ACB 1. Rack in and out the ACB
2. Check and record the operation of the shutter and padlock
3. Check and record the closing mechanism of the ACB
4. Check and record the tripping mechanism of the ACB
5. Check and record the panel and castell key interlock of the ACB 6. Check and record the operation of the auxiliary switch and indicating lamp of ACB MCCB 1. Check closing and open mechanism of the MCCB
2. Check tripping mechanism of the MCCB manually.
Rickson Engineering Limited 利信機電有限公司 Replacement of Switchboard in North District Hospital Routine Tests Procedure (Phase 2) (Rev. 0)
G) Temperature Rise Measurement Test
Temperature rise measurement test is performed by injection of primary current into the L.V. Switchboard and recorded the temperature to verify the temperature rise of each incoming & outgoing terminals, panel cover, operating handle, etc. are not exceed the corresponding limit as defined in Table 6 of IEC 61439-1:2011 & BS EN 61439-1:2011.
An extract of the temperature rise limits is summarized below:-
Part of Assemblies Temperature Rise Limit (K)
Terminals for external insulated conductors 70 Busbars and conductors, plug-in contacts of Limited by: removable or withdrawable parts which - mechanical strength of conducting material connect to busbars (105K for bare busbars & conductors); Manual operating means :- - of metal 15 - of insulating material 25 Accessible external enclosures and covers :- - metal surfaces 30 - insulating surfaces 40
Test Arrangement The L.V. Switchboards under test are connected in accordance with below drawing no.:
800789-T03 (Test Loop No. 1 for LVSB (A)
800789-T04 (Test Loop No. 2 for LVSB (B) R R R R R R R R R R R R R R R R R R R R R R R R R Rickson Engineering Limited 利信機電有限公司 Replacement of Switchboard in North District Hospital Routine Tests Procedure (Phase 2) (Rev. 0)
Test Procedure 1. Connect the three phase heavy current supply transformer to the input ends of the Test Loop No. 1. Any openings will be covered by cardboards (which are poor conductor of heat) throughout the test.
2. Paste thermocouples onto various testing points according to the above drawings (e.g. busbar terminals, panel covers, operating handles, etc.). Thermocouples for measurement of ambient temperature (2 nos.) will be positioned at 1m from the switchboard ends and 1m above the floor level.
3. Inject full load test current into the switchboard. Monitor and adjust the current where necessary. (Remark: (i) in order to accelerate the heating effect, the initial current injected into the SWB/MCC may be more than the rated current in the first quarter of the test, (ii) only the test current in the last quarter of the test is material and should be kept constant within ±1%).
4. Measure & record temperature of all testing points per hour and then calculate the individual temperature rise (i.e. measured temperature – average of ambient temperature). [Remark: the temperature data under the first quarter period may not be captured.]
5. Continue the test (normally not exceeding 8 hours) until the temperature rise of every testing point does not exceed 1K/hr.
6. Repeat all the above procedures for Test Loop No. 2 & 3 [Remark: allow adequate time for busbar cooling, normally 4-6 hours, before disconnect the measuring equipment and busbar setup from Test Loop No. 1.]
Test Equipment • Voltage Regulator • Three Phase Heavy Current Supply Transformer • Fluke 52-II K type Thermometer • K Type Thermocouples • Accuenergy Acuvim CL Digital Meter Rickson Engineering Limited 利信機電有限公司 Replacement of Switchboard in North District Hospital Routine Tests Procedure (Phase 2) (Rev. 0)
H) Contact Resistance Test (Ductor Test)
1. Place the test probes (2 nos.) of the ductor tester across the L1 phase of each busbar joint/connection being measured. The position of the test probes should be as close to the joint/connection as possible in order to get accurate value. For details, see Fig.1
2. Record the resistance value (in µΩ)
3. Repeat for L2, L3 and N phases of the same joint/connection
4. Repeat the test according to attached schedule (drawing: 800689-DD-01, 02 & 03).
Remark:
1) In case a particular joint/connection is difficult to measure the contact resistance, two or
more joints in series will be measured instead provided the total measured value does not exceed the sum of individual value Rickson Engineering Limited 利信機電有限公司 Replacement of Switchboard in North District Hospital Routine Tests Procedure (Phase 2) (Rev. 0)
