Value of a type Tested Commodity

Speaker / Author: Lucas Monyai SABS Commercial (NETFA) PO Box 144, Olifantsfontein, Johannesburg, 1665, South Africa e-mail: lucas.monyai@sabs.co.za Phone: 011 238 2300 Fax: 011 238 2363 Abstract Manufacturers are today facing major challenges regarding cost cutting while at the same time striving to produce high quality, reliable and safe products. The current global state of the economy has even made matters worse than before. Manufacturers are forever looking for ways to improve the efficiency and functionality of their designs using latest technologies in materials, equipment and processes, in search of cost effective solutions. The relevant standards and specifications are under constant scrutiny for changes to keep abreast with the ever-changing applications, legislation, technology and differences of interpretation. The requirements of Occupational Health and Safety and the Environmental regulations have become compulsory and more stringent to ensure greater levels of safety. The need to ensure compliance with the requirements over and above the adequacy of the product for the designed purpose has never been greater. Therefore to have a reliable, continuous supply of energy it is very crucial that all equipment used in distribution networks needs to meet the set criteria of requirements of the relevant specification. Design and simulation techniques are being used more and more. Even so, the real tests that will verify the simulation results, construction details, correlation of the theory and practice as well as knowledge build up are a major requirement for manufactures. For example many users / utilities require a comparison of the short-circuit simulation results with actual test results before purchasing their equipment. Against this background, it is clear that switchgear be subjected to a suitable comprehensive type testing programme as outlined in the relevant specification to ensure that it will reliably perform the tasks included in its functions. It is also important that equipment is type tested by an independent test facility to give more credibility to the test results. Introduction Testing of apparatus within the electrical distribution industry has become an important issue that cannot be separated form the manufacturing and supply of electrical equipment and products. The relatively high cost of testing as well as pressure to meet budget has led to many manufacturers and suppliers of electrical equipment and products not testing. However, it is becoming ever more important that the type testing of electrical equipment and products should not be compromised. This identified increased importance for type tested equipment is resulting in steps being taken by the relevant authorities to declare some of the specifications and standards as compulsory. These compulsory specifications and standards ensure that equipment and products meet the minimum

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safety requirements as outlined in the relevant specifications and standards of manufacture and installation work. The fast pace of recurring technological advancement has also made it necessary for specifications and standards to be revised and updated on a regular basis to ensure that only good quality products and equipment that comply with the latest specifications and standards appear on the shelves. Sadly, despite all these efforts, it is still common to find that some new designs of electrical products and equipment have not been properly type tested to meet the relevant specifications and standards. More than 30 years ago, there was a demand by the power electrical distribution industry to establish a third party Test House to test items such as bushings, busbars, electric cables, transformers, switchgear and surge protection devices. The South African Bureau of Standards (SABS) responded to industrys demand by establishing NETFA (National Electrical Test Facility). Equipment selection The power industry experiences a multitude of challenges ranging from the pressure to reduce operating and capital costs to the pressure to supply power at the lowest cost to the end user. To meet these challenges, it is necessary to select appropriate equipment for the network, so as to reduce maintenance or repair costs. This crucial task goes far beyond just comparing prices and rated values of equipment. Every customer (consumer) demands power of high quality that is safe, reliable, adequate and continuous at the lowest cost. It is equally true that there are some customers and/ or consumers who are willing to pay more for a premium power supply. Engineers have the task of specifying and acquiring equipment that can meet the expectations of the customers/ consumers. Every power utility, municipality or network operator strives to keep their system risks to a bare minimum. At the same time, the network management costs have to be reduced to a minimum. The possibility of failure in the network is one thought that haunts every network operator, engineer and customer because lives may even be lost on the occurrence of the failure. To meet these demands and reduce the risks to an acceptable level, it is essential to ensure that all the network components that are specified, ordered and required, fully comply with the requirements of the relevant specification. As a result, testing of equipment is therefore the most critical tool and objective in this value chain of electricity distribution. Testing of Equipment Equipment manufacturers today face major challenges with regard to cutting costs while at the same time striving to produce high quality, reliable and safe products. The current negative state of the global economy has made matters more difficult. Manufacturers always seek ways to improve the efficiency and functionality of their designs using latest technologies in materials, equipment and processes whilst searching for cost effective solutions. The relevant standards and specifications are under constant scrutiny for changes to keep abreast with the ever-changing applications, legislation, technology and differences of interpretation. The requirements of Occupational Health and Safety as well as the Environmental regulations have become compulsory and more stringent to ensure greater levels of safety. The need to ensure compliance with the requirements over and above the adequacy of the product for the designed

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purpose has never been greater. Therefore, to have a reliable and continuous supply of energy, it is crucial that all the equipment used in distribution networks needs to meet the set criteria of requirements of the relevant specification. Design and simulation techniques are being used more and more. Even so, the real tests that will verify the simulation results, construction details, correlation of the theory and practice as well as knowledge build up are a major requirement for manufacturers. For example, many users require a comparison of the short-circuit simulation results with actual test results before purchasing their equipment. Against this background, it is clear that distribution equipment (Cables, Switchgear, Transformers, Panels, etc) needs to be subjected to a suitable comprehensive type testing programme as outlined in the relevant specification to ensure that it will reliably perform the tasks included in its functions. It is also important that equipment is type tested by an independent test facility to give more credibility to the test results. The test should be conducted on representative equipment installed in truly representative arrangements. Endorsement of Equipment End users of equipment have limited methods of verifying / ascertaining whether the equipment they are purchasing fully complies with the requirements of the appropriate specification. In addition to this, engineers also need the confirmation and confidence that the equipment they have designed is adequate for the intended purpose. Type Tests The normal set of type tests for medium voltage switchgear include tests to confirm dielectric, temperature rise, mechanical, environmental, normal current making and breaking, short circuit current making and breaking, short circuit current carrying, and short circuit withstand capabilities. o Dielectric tests: These tests include as a minimum, lightning impulse and power frequency dry withstand tests, but as appropriate may include power frequency wet, artificial pollution and partial discharge tests. Tests levels are generally based on sound insulation coordination which means that the equipment will be able to withstand over voltages likely to be encountered in practice, these being limited by surge arrestors or spark gaps where appropriate. In this country, special attention to specified levels may be necessary to ensure correct operation at working altitude. Insulation levels are normally specified at sea level - where external air insulation is involved, a reduction in withstand voltage of typically 15% may be expected at reef altitude. The high incidence of lightning strikes in certain areas may also influence required insulation levels. o Temperature rise: These tests serve to ensure the reliable long term operation of switchgear equipment at maximum ambient temperatures. They confirm that operating temperatures of all components do not reach values which would result in the degradation of contact or joint resistances (and hence possibly lead to the thermal runaway), cause damage to insulating materials or other materials used in the design / construction, or functional items such as springs and ultimately could cause a fire hazard. In this country, it is

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again important to note that due to the reduction of air density with altitude, the sea level ratings may therefore not be achieved at Reef altitude. o Mechanical and environmental: The minimum requirement is the proof of reliable mechanical (open / close) operations of the switchgear device. During the specified number of operations, under specified operating conditions, malfunction or abnormal wear should not occur. In addition, tests at low or high temperatures, high humidity and under simulated seismic conditions may be required. In this connection, the pre-dawn temperatures experienced in some parts of this country have been known to be troublesome in some designs of switchgear. Making / Breaking and Short-Circuit: These tests can be considered to fall into the following categories:o Short time and peak withstand current: These tests apply to most equipment and confirm the ability to handle the mechanical and thermal stresses associated with the passage of short circuit current through the equipment. The peak asymmetrical current creates the highest mechanical stress and in three phase equipment the disposition of asymmetry between the phases should be such that the worst case conditions apply at the commencement of the test. o Fault making: These tests generally apply to circuit breakers, switches, fuse switches, fuse contactor combinations and earth switches. Unless special methods are employed, tests should be performed at rated voltages to ensure representative pre-arcing effects. Typically throw off forces tend to prevent full closing and arc damage to contacts. It should be noted that in the case of circuit breakers positioned in close proximity to generating plant, it may be necessary to specify enhanced peak making current capability. o Fault breaking: These tests generally apply to circuit breakers, fuses, fuse switches and fuse contactor combinations. These tests should be done at rated voltages at the specified power factor with specified direct current component and with the required rate of rise of recovery voltage. It should be noted that in the case of circuit breakers positioned in close proximity to the generating plant, it may be necessary to specify greater direct current components in breaking tests than normally specified. o Load making and breaking: These tests generally apply to circuit breakers, switches, fuses, fuse switches and fuse contactor combinations. These tests should be done at rated voltages under conditions appropriate to each type of equipment. o Special breaking: These tests are for special applications and it may be necessary to specify additional breaking tests typically out of phase, capacitive, or inductive current switching tests.

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o Internal arcing: On equipment not specifically designed with safety of personnel (in the event of internal arc fault) in mind, these tests can be most sobering. The destructive effects of high power arcs are dramatically displayed. Fortunately with a well thought out approach very significant improvements can be made. It is important that tests are done either at rated voltages or at voltages sufficiently high to drive representative peak and rms currents through expected arc paths. Conclusion The majority of medium voltage switchgear equipment used or sold in South Africa is either totally locally designed or substantially adapted to meet the local requirements. In either cases, type testing is of vital importance and relevant. To ensure that the high quality; safety and reliability of equipment is achieved, the equipment must be subjected to full type testing by an accredited laboratory, third party test facility or laboratory. To complete the loop, it is also important that the report resulting from the type tests be evaluated by a technically competent person. Therefore in evaluating the report, it is important to ensure that: o The specification that the equipment is tested to is the latest, most relevant and not obsolete. o The test report covers all the elements of testing that confirm full compliance to the specification as partial tests do not imply full compliance. o In the case where partial tests are conducted, the report clearly stipulates what tests were done (on the front page of the report). o Tests are conducted and reports are traceable to the issuing accredited third party test facility or laboratory. o A report for the tests conducted to clients specifications/ requirements should be scrutinised and evaluated by a technically competent person who has in-depth knowledge of the tests or the subject. Abbreviations o o o o SABS: NETFA: ISO: IEC: South African Bureau of Standards National Electrical Test Facility International Organization for Standardization International Electrotechnical Commission

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References IEC 62271-1: 2012. High-voltage switchgear Part 1: Common Specifications. IEC 62271-200: 2004 High-voltage switchgear and controlgear Part 200: AC metal-enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 52 kV. IEC 60076-4: 2004 Power transformers Part 4 Guide to the lightning impulse and switching impulse testing Power transformers and reactors. IEC 60076-5: 2006 Power transformers Part 5 Ability to withstand short circuit. SANS 780:2009 Distribution transformers Apollo- CAHORA BASSA Enigma and Diversions by EF Raynham

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