DCCD - FLAME RETARDANT LOW SMOKE LABORATORY

DCCD Home

Electric cables are designed to carry power and communications for long
distances and can act as pathway along which fire can travel and spread. In addition
there are cable installations where large number of cables are installed vertically.
These can act as an area of significant fire hazard because of the medium of high fuel
loading represented by the insulating and sheathing materials. Fires involving these
cables may cause the loss of life as well as damage to the facilities and equipment. In
order to avoid such disasters the demand has arisen for improved flame-retardant
cables to reduce not only flame propagation but also smoke and toxic emission.

The Flame retardant low smoke cables laboratory carryout fire reaction tests on
electric cables and all polymeric materials according to various national and
International standards.

Test facilities at FRLS lab

TESTING/EQUIPMENT FACILITY :-

Some of the important test facilities are

• Cone Calorimeter
 • Toxicity chamber
• NBS Smoke Box Chamber
• 3 metre cube test chamber
• Limiting Oxygen Index apparatus
• HCl Emission apparatus
• Fire Resistance test set-up

Test using Cone calorimeter

ACCREDITATIONS : -

The facility has been accredited for Flame Retardant Low Smoke testing as per
ISO/IEC 17025 by National Accreditation Board for Testing and Calibration
Laboratories (NABL) Govt of India.

TEST FACILITIES :-

Products/Apparatus Tests Conducted

 § Electric cables
§ Cable sheath materials
§ FRP composite materials
§ Cable trays
Heat release measurements using Cone
Calorimeter
Toxicity Index test
Limiting Oxygen Index (Ignition property of
Plastics )

§ Channels Temperature Index (Temp withstand

before ignition)
§ Feeder pillar boxes

HCL (Acid gas content in plastics )

§ Energy meter covers

Zero Halogen evaluation

§ Terminal blocks

Smoke Density ( smoke evolved, and light

§ Bushings
transmission, visibility under fire)

§ Supporting insulators
Fire resistance test (Circuit integrity under
fire conditions)
§ PVC conduit pipes

Flammability Test (The property of

§ Flooring materials
propagating fire)
§ Fabrics/curtain

§ Materials used in
aerospace/navy

§ Any other plastic material

The lab will be augmented shortly for tests on Bunched cables.

FRLS TEST FACILITIES :-

Test Standard
 (HRR) Heat Release Rate, Cumulative heat ISO 5660
released, ASTM 1354
Effective heat combustion, Time to ignition,
Mass loss rate, total mass loss, Smoke
obscuration
CO/CO2 production rate
Oxygen Index Test on Polymeric materials and ASTM D 2863-1997
cable sheaths NCD 1410
IS 10810(P-58)-1988
IS 13501-1992
Temperature Index Test on Polymeric materials ASTM D 2863-1997
and cable sheaths
Halogen Acid Test on Polymeric materials and IEC 754(P-1)-1994
cable sheaths
Flammability Test on Polymeric materials and UL 94-HB/VB-1980
cable sheaths ASTM D 635-1998
IS 11731(P-1,2)-1986
IS 6746-1972
Flammability Test on cables IS 10810(P-61)-1988
UL 1581-1991
IEC 332(P-1)-1979
IS 10810(P-53)-1984
IEC 332(P-3)-1991
IS 10810(P-62)-1993
IEEE 383-1974
Smoke density test on Polymeric materials and ASTM D 2843-1999
cable sheaths
Smoke density test (3 Metre cube) on cables IEC 1034-2 1991
IS 10810 (P-63)-1993
Specific Optical density(NBS smoke box) on ASTM E-662-1983
Polymeric materials and cable sheaths NCD 1411
Fire survival Test on cables IEC 331 1970

CLIENTELE :-

Facilities are extensively used by Industrial Clients like RDSO, ICF, Tyco
Electronics, Lapp India, Reliance Engineers, Nicco Corporation, Whirlpool of India Ltd,
BIS and other utilities and manufacturers. Clients from countries like Dubai, UAE, etc.
are also widely using the test facilities

Products Wise Testing :

Protocol Test:
 Energy Meter
 Data Concentrator
 IED
 Relay
 Protocol Convertor
 RTU
(The above Equipments are tested at ITID-Bangalore)

Cable Test :
 Paper/PVC/XLPE/EPR Power cables of Voltage rating up to 220 kV
 Cable accessories, etc
(The above Equipments are tested at DCCD- Bangalore, STDS-Bhopal, and RTL-Noida)

Capacitor Test:
 HV Shunt capacitors
 HV Series capacitors
 HV Capacitors for surge
 LV Motor capacitors
 LV fan motor Capacitors
 LV Capacitors for Lighting
 LV Power capacitors of self-healing type.
 LV Shunt capacitors of non self - healing type.
(The above Equipments are tested at DCCD- Bangalore, STDS-Bhopal, and RTL-Noida)

Flame Retardant Low Smoke Test :

 Electric cables
 Cable sheath materials
 FRP composite materials
 Cable trays
  Channels
 Feeder pillar boxes
 Energy meter covers
 Terminal blocks
 Bushings
 Supporting insulators
 PVC conduit pipes
 Flooring materials
 Fabrics/curtain
 Materials used in aerospace/navy
 Any other plastic material
(The above Equipments are tested at DCCD- Bangalore)

Temperature Rise Test :

 Distribution, Transmission & Power equipment and accessories

 Diagnostics Test on,
 Power Transformer

 Generators / Large motors

 Power cables

 EHV CTs, / CVTs

 Resin Cast CTs

(The above Equipments are tested at DCCD- Bangalore)

High Power Test :

 High voltage circuit breakers

 High Voltage Switches

 High Voltage Fuses

 High Voltage Switch Boards
 Terminal Boxes
 MV Metal enclosed Switchgear
 Power Transformers
  Distribution Transformers
 Traction Transformers
 Potential Transformers
 Current Transformers
 Lightning Arresters
 Insulator Strings
 AC metal enclosed switch gear & control gear.
 AC Disconnectors & Earth switches
 Reactors
 Line traps
 Bus ducts, Bus bars, Generator Neutral Bus bar Compartment

 Power connectors, ACSR conductors

 LV Circuit Breaker
(The above Equipments are tested at HPL- Bangalore, STDS-Bhopal, and SCL-Bangalore)

Insulation / Impulse voltage Withstand Test :

 Insulator ( Disc, Pin, Solid Core, Hollow)

 Insulator Strings (all types)
 Lightning Arrestor Housing & similar Insulating Materials
 Battery Container
 Rubber Mats
 Insulating Tubes etc.
 Insulating Rod
 Isolator, Circuit Breaker
 Bus duct
 Cables
 Bushing
 AB Switch
 Panel
 P T /C V T / Coupling Capacitor/ Grading Capacitor / R.V.T.S / CT-PT Units
 Tap changer
 Voltage / Current / Power / Distribution Transformers
 Reactors
 HT Capacitors
 Thyristor Valves
(The above Equipments are tested at HV- Bangalore, STDS-Bhopal,
UHVRL-Hyderabad and RTL-Noida)
Short Circuit / High Voltage / Synthetic Test :

 Circuit Breakers (LV, HV)

 Fuses
 Switches
 Starters
 Control Switches
 MCB / RCCB Switch Fuse units
 Power Connectors
 Spacers
 Bus bars
 Bus ducts
 CT's conductors
 Transformer
 P T /C V T / Coupling /Tap Changers
 Capacitors
 Grading Capacitors
 R.V.T.S
 C.T – PT UNITS
 Series & Shunt Reactors
 Line Traps
 Damping Reactors Tuning Reactors
 Neutral Earthing Reactors
 THYRISTOR VALVES
 H.V. Circuit Breaker & Switchgear Panel with Circuit Breaker
 HT switches/ Line sectionalizer
 Isolators
 Power & Distribution transformers & Traction transformers
 HT fuses
 Surge arresters
 Reactors
 Auto-reclosures
 DC Breakers
 HT switchgear panel
  Motor terminal box
 Spacers for Bundled conductor
 HV Contactors
 LT Air circuit breakers, MCCBs for voltage not exeeding 1000V
 Circuit Breakers for Over current protection for household & similar installations
 Miniature circuit breakers (MCB)
 Low voltage fuses for voltage not exceeding 1000V
 Low voltage fuse bases for voltage not exceeding 1000V
 Air break switches, Air break disconnectors, air break switch disconnectors, fuse combinations
for voltage not exceeding 1000V
 Carrier & Bases for Rewirable type fuses
 Composite unit of air break switches for rewirable type switches for voltage not exceeding
650V, AC21, 100A
 AC Miniature circuit breaker boards 1000V
 Residual current operated circuit breaker
 Factory build assemblies of switchgear & controlgears for 1000V
 For enclosed distribution board & cutouts 1000V
 Contactors & motor starters for voltages at exceeding 1000V
 Electric power connectors above 200A

(The above Equipments are tested at HPL- Bangalore, STDS-Bhopal, and SCL-Bangalore)

Dielectric Materials Test :

 Lubricating Oil
 Transformer Oil
 Polymers etc.
(The above Tests are Conducted at DMD- Bangalore)

Materials Test :

 Coal
  Analysis of coal, ash and water for thermal power stations
 Lubrication oil and all other materials.
(The above Tests are Conducted at MTL- Bangalore)

Structural / Mechanical strength/ Vibration Test :

 Transmission line towers

 Line material
 Transmission Line Conductors upto and including 800kV rating
 Compression Clamps
 Mid Span Joints
 I&V Suspension Tension Strings upto and including 800kV rating
 Structural Steel
 Steel Wire ropes
 Electrically Operated/ Hand Operated Winches
 Chain Pulley Block upto 20 Tonnes
 Load Cell
 Line Material
 Terminal Clamp
 Structural Steel
 Connecting Links for Brake Parachute/ Nylon Purchase Tape
 Insulators & Insulator Strings of Single/ Twin/ Triple/ Quad-Tension or Suspension type upto
and including 800kV rating
 Vibration Dampers upto and including 800kV
 Spacer/ Spacer Dampers upto and including 800kV.
 Transmission Line Conductors upto and including 800kV rating
 Vibration Dampers upto and including 800kV
 Spacer/ Spacer Dampers upto and including 800kV.
 Transmission Line Conductors upto and including 800kV rating
 Conductors
(These Products are tested at MED- Bangalore)
Seismic Qualification / Vibrations Test :

 Energy Meter
 Switchgear, Control Panel
 All Equipments up to 10 Tons.
(The above Tests are Conducted at EVRC- Bangalore)

Calibration Tests :

• Digital & Analog Voltmeters

• Digital & Analog Ammeters
• Multimeters
• Digital & Analog Wattmeters
• Digital Temperature indicators
• Digital & Analog Panel meters
• Electronic Thermometers
• Data Loggers
• Strip chart recorders
• Power harmonic analysers
• Process calibrators
• Hot & Cold temperature baths
• Current Clamps
• Thermometers
• Impulse measuring system
(The above Equipments calibration tests are conducted at ID- Bangalore, STDS-Bhopal)

Test :

 Relay
 UPS (Uninterrupted Power Supply) (1 KVA - 10 KVA & above)
 Single Phase Electromechanical / kWh / Static / Electronic Energy Meters
 Three Phase Four Wire / Three Phase Three Wire Electromechanical / kWh / TVM Static /
 Electronic Energy Meters
 Single phase / Three phase Static watt-hour meters
 Electronic Trivector meters
 Static protective relays
 Smaller size UPS, SMPS, Inverters, Converters, Contactors etc
 All Electronic equipments, like Static Relays, Breakers, contactors, starters, Electronic ballast,
Medical equipments

(The above Equipments are tested at ID- Bangalore, STDS-Bhopal)

Battery Testing :

Lead acid storage Batteries, VRLA, LMLA, NICAD Batteries, Tubular Batteries

(The above Tests are Conducted at EATD-Bangalore)

Flame Proof Testing :

All flame proof electrical equipment

(The above Tests are Conducted at EATD-Bangalore)

Ingress Protection Test:

All types of electrical equipment enclosures such as-

 Outdoor distribution boards

 Relay units/Panels
 Control Cubicles for PCVCB
 Switching & Control System enclosures
 RMV panels
 HT Metering & Switching Panel
 AC Distribution Board
 EWM Enclosures
 Platform Power Supply
 LT Panel
 Disconnecting Switch Assembly
 Junction Boxes
 LV switch Board
 AD/DC Panel
 weatherproof Switch Enclosures
 Dry type Transformer enclosures
 PCC Panel,
 MCC Panel, Bus Ducts
 DOL Starters
  Integral Starter
 Control Panel
 Electricity Metering Equipment Enclosures
 Actuators
 Telecommunication Equipment Enclosures
 Antennas
 Cable Connector Assembly
 GPRS Equipment Enclosures
 Battery Charger Panels
 Medical Health Monitoring Equipment Enclosures
 Drive Mechanism Box
 Marshalling Kiosks
 Surge Monitors
 MOM's
 Belt sway Switch Enclosures
 Reactor assembly Enclosures
 Starter Motors
 Sot Starter Panels
 RAPCONS
 BAPCONS

Rotating Electrical Machinery Equipment Enclosures such as :

 Enclosures of Induction Motors

 Valve Actuators
 DC Machines
 AC Machines
 Alternators
 Generators
 Vibratory Electric Motors
 Large Motors
 Automobile Electrical Motors
 Traction Motors
 Power Tool Motors
 Pumps (motors) Etc.

Luminaries and Light Fitting Equipment Enclosures such as :

 Street light Fitting Enclosures

 Aviation Light Fitting Enclosures
 Domestic
 Industrial Light Fitting Enclosures
 Corridor/ Office Light Fitting Enclosures

 Solar Operated Light Fitting Enclosures Etc.

(The above Tests are Conducted at EATD-Bangalore, STDS-Bhopal)

Luminaries :
  Tubular fluorescent lamps with Starter
 Self Ballasted Lamps for General Lighting Service (CFL)
 Safety requirements and Performance requirements
 Lamp Ballast

(The above Tests are Conducted at EATD-Bangalore)

Fan Testing :
 Electrical Ceiling Fans and Regulator
 Electrical Table Type Fans and Regulator
 Electrical Pedestal Type Fans and Regulators
 Propeller Type AC Ventilating Fans

(The above Tests are Conducted at EATD-Bangalore)

Refrigerators :
Direct cool and frost free refrigerators up to 600 lts. capacity.

(The above Tests are Conducted at EATD-Bangalore)

Air Conditioners :
Window air conditioner and split type air conditioner up to 3 TR.

(The above

Products Wise Testing :

Protocol Test:
 Energy Meter
 Data Concentrator
 IED
 Relay
 Protocol Convertor
 RTU
(The above Equipments are tested at ITID-Bangalore)

Cable Test :
 Paper/PVC/XLPE/EPR Power cables of Voltage rating up to 220 kV
 Cable accessories, etc
(The above Equipments are tested at DCCD- Bangalore, STDS-Bhopal, and RTL-Noida)

Capacitor Test:
 HV Shunt capacitors
 HV Series capacitors
 HV Capacitors for surge
 LV Motor capacitors
 LV fan motor Capacitors
 LV Capacitors for Lighting
 LV Power capacitors of self-healing type.
 LV Shunt capacitors of non self - healing type.
(The above Equipments are tested at DCCD- Bangalore, STDS-Bhopal, and RTL-Noida)

Flame Retardant Low Smoke Test :

 Electric cables
 Cable sheath materials
 FRP composite materials
 Cable trays
 Channels
 Feeder pillar boxes
 Energy meter covers
 Terminal blocks
 Bushings
 Supporting insulators
  PVC conduit pipes
 Flooring materials
 Fabrics/curtain
 Materials used in aerospace/navy
 Any other plastic material
(The above Equipments are tested at DCCD- Bangalore)

Temperature Rise Test :

 Distribution, Transmission & Power equipment and accessories

 Diagnostics Test on,
 Power Transformer

 Generators / Large motors

 Power cables

 EHV CTs, / CVTs

 Resin Cast CTs

(The above Equipments are tested at DCCD- Bangalore)

High Power Test :

 High voltage circuit breakers

 High Voltage Switches

 High Voltage Fuses

 High Voltage Switch Boards
 Terminal Boxes
 MV Metal enclosed Switchgear
 Power Transformers
 Distribution Transformers
 Traction Transformers
 Potential Transformers
 Current Transformers
 Lightning Arresters
 Insulator Strings
  AC metal enclosed switch gear & control gear.
 AC Disconnectors & Earth switches
 Reactors
 Line traps
 Bus ducts, Bus bars, Generator Neutral Bus bar Compartment

 Power connectors, ACSR conductors

 LV Circuit Breaker
(The above Equipments are tested at HPL- Bangalore, STDS-Bhopal, and SCL-Bangalore)

Insulation / Impulse voltage Withstand Test :

 Insulator ( Disc, Pin, Solid Core, Hollow)

 Insulator Strings (all types)
 Lightning Arrestor Housing & similar Insulating Materials
 Battery Container
 Rubber Mats
 Insulating Tubes etc.
 Insulating Rod
 Isolator, Circuit Breaker
 Bus duct
 Cables
 Bushing
 AB Switch
 Panel
 P T /C V T / Coupling Capacitor/ Grading Capacitor / R.V.T.S / CT-PT Units
 Tap changer
 Voltage / Current / Power / Distribution Transformers
 Reactors
 HT Capacitors
 Thyristor Valves
(The above Equipments are tested at HV- Bangalore, STDS-Bhopal,
UHVRL-Hyderabad and RTL-Noida)

Short Circuit / High Voltage / Synthetic Test :

 Circuit Breakers (LV, HV)

 Fuses
 Switches
 Starters
 Control Switches
 MCB / RCCB Switch Fuse units
 Power Connectors
 Spacers
 Bus bars
 Bus ducts
 CT's conductors
 Transformer
 P T /C V T / Coupling /Tap Changers
 Capacitors
 Grading Capacitors
 R.V.T.S
 C.T – PT UNITS
 Series & Shunt Reactors
 Line Traps
 Damping Reactors Tuning Reactors
 Neutral Earthing Reactors
 THYRISTOR VALVES
 H.V. Circuit Breaker & Switchgear Panel with Circuit Breaker
 HT switches/ Line sectionalizer
 Isolators
 Power & Distribution transformers & Traction transformers
 HT fuses
 Surge arresters
 Reactors
 Auto-reclosures
 DC Breakers
 HT switchgear panel
 Motor terminal box
 Spacers for Bundled conductor
 HV Contactors
 LT Air circuit breakers, MCCBs for voltage not exeeding 1000V
 Circuit Breakers for Over current protection for household & similar installations
 Miniature circuit breakers (MCB)
  Low voltage fuses for voltage not exceeding 1000V
 Low voltage fuse bases for voltage not exceeding 1000V
 Air break switches, Air break disconnectors, air break switch disconnectors, fuse combinations
for voltage not exceeding 1000V
 Carrier & Bases for Rewirable type fuses
 Composite unit of air break switches for rewirable type switches for voltage not exceeding
650V, AC21, 100A
 AC Miniature circuit breaker boards 1000V
 Residual current operated circuit breaker
 Factory build assemblies of switchgear & controlgears for 1000V
 For enclosed distribution board & cutouts 1000V
 Contactors & motor starters for voltages at exceeding 1000V
 Electric power connectors above 200A

(The above Equipments are tested at HPL- Bangalore, STDS-Bhopal, and SCL-Bangalore)

Dielectric Materials Test :

 Lubricating Oil
 Transformer Oil
 Polymers etc.
(The above Tests are Conducted at DMD- Bangalore)

Materials Test :

 Coal
 Analysis of coal, ash and water for thermal power stations
 Lubrication oil and all other materials.
(The above Tests are Conducted at MTL- Bangalore)
Structural / Mechanical strength/ Vibration Test :

 Transmission line towers

 Line material
 Transmission Line Conductors upto and including 800kV rating
 Compression Clamps
 Mid Span Joints
 I&V Suspension Tension Strings upto and including 800kV rating
 Structural Steel
 Steel Wire ropes
 Electrically Operated/ Hand Operated Winches
 Chain Pulley Block upto 20 Tonnes
 Load Cell
 Line Material
 Terminal Clamp
 Structural Steel
 Connecting Links for Brake Parachute/ Nylon Purchase Tape
 Insulators & Insulator Strings of Single/ Twin/ Triple/ Quad-Tension or Suspension type upto
and including 800kV rating
 Vibration Dampers upto and including 800kV
 Spacer/ Spacer Dampers upto and including 800kV.
 Transmission Line Conductors upto and including 800kV rating
 Vibration Dampers upto and including 800kV
 Spacer/ Spacer Dampers upto and including 800kV.
 Transmission Line Conductors upto and including 800kV rating
 Conductors
(These Products are tested at MED- Bangalore)

Seismic Qualification / Vibrations Test :

 Energy Meter
 Switchgear, Control Panel
 All Equipments up to 10 Tons.
 (The above Tests are Conducted at EVRC- Bangalore)

Calibration Tests :

• Digital & Analog Voltmeters

• Digital & Analog Ammeters
• Multimeters
• Digital & Analog Wattmeters
• Digital Temperature indicators
• Digital & Analog Panel meters
• Electronic Thermometers
• Data Loggers
• Strip chart recorders
• Power harmonic analysers
• Process calibrators
• Hot & Cold temperature baths
• Current Clamps
• Thermometers
• Impulse measuring system
(The above Equipments calibration tests are conducted at ID- Bangalore, STDS-Bhopal)

Test :

 Relay
 UPS (Uninterrupted Power Supply) (1 KVA - 10 KVA & above)
 Single Phase Electromechanical / kWh / Static / Electronic Energy Meters
 Three Phase Four Wire / Three Phase Three Wire Electromechanical / kWh / TVM Static /
Electronic Energy Meters
 Single phase / Three phase Static watt-hour meters
 Electronic Trivector meters
 Static protective relays
 Smaller size UPS, SMPS, Inverters, Converters, Contactors etc
 All Electronic equipments, like Static Relays, Breakers, contactors, starters, Electronic ballast,
 Medical equipments

(The above Equipments are tested at ID- Bangalore, STDS-Bhopal)

Battery Testing :

Lead acid storage Batteries, VRLA, LMLA, NICAD Batteries, Tubular Batteries

(The above Tests are Conducted at EATD-Bangalore)

Flame Proof Testing :

All flame proof electrical equipment

(The above Tests are Conducted at EATD-Bangalore)

Ingress Protection Test:

All types of electrical equipment enclosures such as-

 Outdoor distribution boards

 Relay units/Panels
 Control Cubicles for PCVCB
 Switching & Control System enclosures
 RMV panels
 HT Metering & Switching Panel
 AC Distribution Board
 EWM Enclosures
 Platform Power Supply
 LT Panel
 Disconnecting Switch Assembly
 Junction Boxes
 LV switch Board
 AD/DC Panel
 weatherproof Switch Enclosures
 Dry type Transformer enclosures
 PCC Panel,
 MCC Panel, Bus Ducts
 DOL Starters
 Integral Starter
 Control Panel
 Electricity Metering Equipment Enclosures
 Actuators
 Telecommunication Equipment Enclosures
 Antennas
 Cable Connector Assembly
 GPRS Equipment Enclosures
  Battery Charger Panels
 Medical Health Monitoring Equipment Enclosures
 Drive Mechanism Box
 Marshalling Kiosks
 Surge Monitors
 MOM's
 Belt sway Switch Enclosures
 Reactor assembly Enclosures
 Starter Motors
 Sot Starter Panels
 RAPCONS
 BAPCONS

Rotating Electrical Machinery Equipment Enclosures such as :

 Enclosures of Induction Motors

 Valve Actuators
 DC Machines
 AC Machines
 Alternators
 Generators
 Vibratory Electric Motors
 Large Motors
 Automobile Electrical Motors
 Traction Motors
 Power Tool Motors
 Pumps (motors) Etc.

Luminaries and Light Fitting Equipment Enclosures such as :

 Street light Fitting Enclosures

 Aviation Light Fitting Enclosures
 Domestic
 Industrial Light Fitting Enclosures
 Corridor/ Office Light Fitting Enclosures

 Solar Operated Light Fitting Enclosures Etc.

(The above Tests are Conducted at EATD-Bangalore, STDS-Bhopal)

Luminaries :
 Tubular fluorescent lamps with Starter
 Self Ballasted Lamps for General Lighting Service (CFL)
 Safety requirements and Performance requirements
 Lamp Ballast
 (The above Tests are Conducted at EATD-Bangalore)

Fan Testing :
 Electrical Ceiling Fans and Regulator
 Electrical Table Type Fans and Regulator
 Electrical Pedestal Type Fans and Regulators
 Propeller Type AC Ventilating Fans

(The above Tests are Conducted at EATD-Bangalore)

Refrigerators :
Direct cool and frost free refrigerators up to 600 lts. capacity.

(The above Tests are Conducted at EATD-Bangalore)

DCCD - FLAME RETARDANT LOW SMOKE LABORATORY

 DCCD Home

Electric cables are designed to carry power and communications for long
distances and can act as pathway along which fire can travel and spread. In addition
there are cable installations where large number of cables are installed vertically.
These can act as an area of significant fire hazard because of the medium of high fuel
loading represented by the insulating and sheathing materials. Fires involving these
cables may cause the loss of life as well as damage to the facilities and equipment. In
order to avoid such disasters the demand has arisen for improved flame-retardant
cables to reduce not only flame propagation but also smoke and toxic emission.

The Flame retardant low smoke cables laboratory carryout fire reaction tests on
electric cables and all polymeric materials according to various national and
International standards.

Test facilities at FRLS lab

TESTING/EQUIPMENT FACILITY :-

Some of the important test facilities are

• Cone Calorimeter
• Toxicity chamber
 • NBS Smoke Box Chamber
• 3 metre cube test chamber
• Limiting Oxygen Index apparatus
• HCl Emission apparatus
• Fire Resistance test set-up

Test using Cone calorimeter

ACCREDITATIONS : -

The facility has been accredited for Flame Retardant Low Smoke testing as per
ISO/IEC 17025 by National Accreditation Board for Testing and Calibration
Laboratories (NABL) Govt of India.

TEST FACILITIES :-

Products/Apparatus Tests Conducted

 § Electric cables
§ Cable sheath materials
§ FRP composite materials
§ Cable trays
Heat release measurements using Cone
Calorimeter
Toxicity Index test
Limiting Oxygen Index (Ignition property of
Plastics )

§ Channels Temperature Index (Temp withstand

before ignition)
§ Feeder pillar boxes

HCL (Acid gas content in plastics )

§ Energy meter covers

Zero Halogen evaluation

§ Terminal blocks

Smoke Density ( smoke evolved, and light

§ Bushings
transmission, visibility under fire)

§ Supporting insulators
Fire resistance test (Circuit integrity under
fire conditions)
§ PVC conduit pipes

Flammability Test (The property of

§ Flooring materials
propagating fire)
§ Fabrics/curtain

§ Materials used in
aerospace/navy

§ Any other plastic material

The lab will be augmented shortly for tests on Bunched cables.

FRLS TEST FACILITIES :-

Test Standard
 (HRR) Heat Release Rate, Cumulative heat ISO 5660
released, ASTM 1354
Effective heat combustion, Time to ignition,
Mass loss rate, total mass loss, Smoke
obscuration
CO/CO2 production rate
Oxygen Index Test on Polymeric materials and ASTM D 2863-1997
cable sheaths NCD 1410
IS 10810(P-58)-1988
IS 13501-1992
Temperature Index Test on Polymeric materials ASTM D 2863-1997
and cable sheaths
Halogen Acid Test on Polymeric materials and IEC 754(P-1)-1994
cable sheaths
Flammability Test on Polymeric materials and UL 94-HB/VB-1980
cable sheaths ASTM D 635-1998
IS 11731(P-1,2)-1986
IS 6746-1972
Flammability Test on cables IS 10810(P-61)-1988
UL 1581-1991
IEC 332(P-1)-1979
IS 10810(P-53)-1984
IEC 332(P-3)-1991
IS 10810(P-62)-1993
IEEE 383-1974
Smoke density test on Polymeric materials and ASTM D 2843-1999
cable sheaths
Smoke density test (3 Metre cube) on cables IEC 1034-2 1991
IS 10810 (P-63)-1993
Specific Optical density(NBS smoke box) on ASTM E-662-1983
Polymeric materials and cable sheaths NCD 1411
Fire survival Test on cables IEC 331 1970
DCCD - HEAT RUN TEST LABORATORY
 DCCD Home

Temperature rise test upto 3200 Amps Milli volt drop & resistance tests
(wherever applicable) from 1.o micro ohms to 20 kilo Ohms can be conducted on the
following equipment, as per Indian (BIS) IEC, ANSI of ASTA standards.

Pantograph Isolator

Isolated Phase BusDuct L.T Busduct

TEMPERATURE RISE TEST ON VARIOUS PRODUCTS :-

The Laboratory has facility to carry out Temperature rise test on Distribution,
Transmission & Power equipment and accessories as per relevant National &
International Specifications.

TESTING FACILITY FOR TEMPERATURE RISE TEST :-

• Current source upto 3200 Amperes , 20 Volts, Three Phase and Neutral
• DC Source 500 Amperes, 200 Volts

• Temperature Monitoring equipment: Digital & Fiber Optics

 Upcoming Programmes

Two day workshop on ‘High Voltage

Testing & Measurement Techniques’- Sept 2-
3, 2010

Five day Training Programme on ‘Test

Facilities’- Sept 6-10, 2010

Five day residential Training Programme

on ‘Protective Relays’ - Sept 13-17, 2010

Five day training programme on 'Real

Mechanical Engineering Division Time Digital Simulation of Power Systems' -
Sept 21-25, 2010
view all programme

Central Power Research Institute (CPRI) is an autonomous society under Ministry of

Power, Government of India. Set up in 1960 by the Government of India, it functions as a
centre for applied research in electrical power engineering assisting the electrical industry in
product development, Consultancy and quality assurance. CPRI also serves as an independent
authority for testing and certification of power equipment. CPRI's governing body includes
eminent professionals from industries, utilities, prestigious academic and research institutions
and the government.

High Voltage Division :

Hom
HV Division has dimension of 50(L)*40m(W)*35m(H) and an outdoor test bay which is equipped with
cascade transformer of two units, rated 600kV,2000kVA each. Facilities are available for taking supply i
to the main laboratory for indoor tests. A 600kV,2000kVA Power frequency testing transformer is locate
indoor. Facilities for tensioning of horizontal insulator strings for conducting corona and RIV tests at
EHV/UHV test voltage are also available.
Laboratories Available :

 High Voltage Laboratory

 Impulse Current Laboratory

 Pollution Laboratory
3 MV, 150 KJ
1200kv, 2 MVA Cascade Transformer Impulse Generator

Facilities Available for Testing :

 Lightning impulse & switching impulse withstand and flashover tests both under dry and wet
conditions.
 Power frequency voltage withstand & flashover test (Dry).
 Power frequency voltage withstand & flashover test (Wet).
 Visible corona inception/ extinction test with power frequency voltage under both dry and wet
conditions.
 Radio interference voltage test under both wet and dry conditions.
 Voltage distribution test on insulator strings.
 Under oil puncture test on Disc, pin & post insulator units.
 Steep front impulse puncture test on Disc, pin, & post insulator units.
 Porosity tests on porcelain insulator fragments.
 Temperature cycle tests on Disc, pin, & post insulator upto 33kV rating (indoor).
 Dc withstand & flashover test under Dry and Wet conditions.

The tests are done as per National standards (IS) and International standards like BS, IEC
ANSI etc.
It is worth mentioning here that the impulse and power frequency test facilities are of the
state of the art type and compare well with the facilities available at other International laborato
like CESI, Italy, IREQ, Canada etc.

Further information contact us:

The Head of the Division

 High Voltage Division
Central Power Research Institute
Prof. Sir C. V. Raman Road, P.B 8066,
Bangalore, India – 560 080.
Phone : +91-80-23601917(Off.)
E-mail : hv@cpri.in, nambudiri@cpri.in

High Voltage Division - Impulse Current Lab

HV Home

The Impulse Current Laboratory has been established in 1996 as a comprehensive test facility
considering the importance of ZnO arresters which are being increasingly used by several Utilities. Its
significance lies in the fact that, it has a unique Computer-controlled Impulse Current Generator
incorporating all conceivable features in a single consolidated design and is perhaps the only one of
its kind in this part of the world. All tests on ZnO blocks as per IEC 60099-4 and IS 3070 including
accelerated ageing test and loss measurement on ZnO blocks can be carried out.

Equipment available :

Impulse Current Generator 100 kV, 150 kJ

Types of Tests :
All type tests on Zno arrester blocks upto 11 kV As per National and International
Standards
Necessity Of Testing Arrester Blocks :
Lightning arresters, often called Surge Diverters, play a vital role in protecting expensive
substation equipment from high voltage surges. These surge voltages originate from either switching
operations of substation equipment or lightning strikes. In either case these over voltages have to be
limited well below the insulation levels of the equipment. By R&D, new designs of lightning arresters
have emerged, by which, it has become possible to bring down the insulation levels of the equipment
resulting in significant savings to the power systems.

Till recently gap type arresters were in use in the power system. Even in this type, new
concepts were introduced in the design by which one to two step reduction of basic insulation level
(BIL) of 145 and 220 kV systems were possible. These arresters are being now replaced by Zinc
Oxide (ZnO) Gap-less arresters, (also known as Metal Oxide Surge Arresters). As reported in the
literature, these were first developed in Japan and came into use from 1970. The replacement of
conventional arresters by ZnO type initially started from system voltages above 145 kV class owing
to their high initial cost. But now even distribution systems use ZnO arresters due to the present
affordable cost.

Considering the importance of tests on ZnO arresters which are being increasingly used by
Powergrid, NTPC, State Electricity Boards and other power utilities. CPRI has established
comprehensive test facility for undertaking tests on Zinc Oxide arresters as per IEC-60099-4 and
other relevant standards.

All tests prescribed by International/Indian Standards (IEC 60099-4) for Metal oxide arresters
without gaps for AC systems can be undertaken. Following tests can be taken up with the newly
commissioned Computer controlled Impulse Current Generator supplied by M/s. Haefely Trench,
Switzerland with a capacity of 100 kV and 150 kJ

Residual Voltage Tests:

This test can be carried out for the following exponential waveforms:

a) Steep Current Impulse 1/<20 micro second.

Front time : 1 micro second ± 0.1 micro second.
Time to half value : <20 micro second.
Max. Current : 20 kA
Residual Voltage : Upto 40 kV

b) Lightning Current Impulse 8/20 micro second.

Front time : 8 micro second ± 1.0 micro second.
Time to half value : 20 micro second ±2.0 micro second.
Max. Current : 50 kA
 Residual Voltage : Upto 50 kV

c) Switching Current Impulse 36/90 micro second.

Front time : > 30 micro second.
Time to half value : approx 2.5 T1.
Max. Current : 2 kA
Residual Voltage : Upto 30 kV

d) High Current Impulse 4/10 micro second

Front time : 4 micro second ± 0.5 micro second.
Time to half value : 10 micro second ± 1.0 micro second.
Max. Current : 120 kA
Residual Voltage : Upto 60 kV

Long duration rectangular Current Impulses :

Transmission line class tests class I to V can be carried out as per IEC 60099-4.

Operating Duty Tests :

Operating duty tests as per IEC 60099-4 can be carried out

Power frequency voltage V/S Time curve :

As per IEC 60099-4 can be carried out.

Ageing test :
Ageing test can be carried out as per IEC 60099-4. The generator is exclusively designed as
per the specifications drawn by CPRI. This is the first generator developed by M/s.Haefely with all the
features combined in one and may be a unique generator in the world.

High Voltage Division - Impulse Current Lab

 HV Hom

The Impulse Current Laboratory has been established in 1996 as a comprehensive test facility
considering the importance of ZnO arresters which are being increasingly used by several Utilities. Its
significance lies in the fact that, it has a unique Computer-controlled Impulse Current Generator
incorporating all conceivable features in a single consolidated design and is perhaps the only one of its
kind in this part of the world. All tests on ZnO blocks as per IEC 60099-4 and IS 3070 including
accelerated ageing test and loss measurement on ZnO blocks can be carried out.

Equipment available :

High Voltage Division - Impulse Current Lab

HV Home

The Impulse Current Laboratory has been established in 1996 as a comprehensive test facility
considering the importance of ZnO arresters which are being increasingly used by several Utilities. Its
significance lies in the fact that, it has a unique Computer-controlled Impulse Current Generator
incorporating all conceivable features in a single consolidated design and is perhaps the only one of its
kind in this part of the world. All tests on ZnO blocks as per IEC 60099-4 and IS 3070 including
accelerated ageing test and loss measurement on ZnO blocks can be carried out.

Equipment available :

High Voltage Division - Pollution Laboratory

 HV Home
The Pollution Laboratory has dimensions of 12M x 12M x 12M. An array of nozzles confirming
to IEC specifications combined with a salt water pumping and air compressor provide the required
salt fog. The power supply to the chamber is from one of the outdoor 600 kV, 2,000 kVA Cascade
Transformers setup.

Pollution Test on Insulator

Equipment available :
 600 kV, 3 Amperes AC source
 100 kV, 6 Amperes AC source
 150 kV, 1 Ampere DC source
With these equipment/facilities the Pollution Laboratory can carry out tests on
insulators and insulator assemblies for systems upto and including 400 kV.

Types of Tests :
 Pollution test on insulators by salt fog/solid layer method upto 400 kV AC & 150 kV DC
 SF6 Puncture withstand test facility for DC insulators
 Thermal runaway tests on insulators
This Laboratory can undertake these tests as per National & International Standards

Necessity Of Pollution Testing:

With the ever increasing demand for electrical power, there has been a steady growth in high
voltage transmission lines required for optimum and economic transfer of large blocks of power over
long distances. As the level of transmission voltage is increased, switching and dynamic over
voltages and withstand ability of the insulator under polluted conditions are important factors which
determine the insulation level of the system. The reliability of the system mainly depends on the
environmental and weather conditions which cause flashover on polluted insulators leading to system
outages.

It is generally recognized that the main events leading to flashover of polluted insulators
under service voltage are the formation of a conductive layer on the insulator surface, leakage
current surging with associated dry band formation and partial arc development and arc propagation
along the insulator surface eventually spanning the whole insulator. The problem is more complex in
case of DC systems because of large contamination due to electrostatic forces and longer duration of
partial arc. Therefore the design of external insulation under polluted conditions is very critical and
lot of investigations are under way to arrive at safe creepage distances for systems operating in
different environments.
The pollution can be broadly classified into two types:

1. Marine pollution found in the immediate neighborhood of the sea and also at considerable
distances from coast.
2. Industrial pollution caused by dust, smoke etc
Objectives Pollution Investigation :
 Collection of pollution flashover data under natural conditions
 Suitable artificial pollution test under conditions representing natural pollution
 Design of insulation for pollution conditions.
 Pollution ageing tests and investigation of causes of failures to arrive at suitable remedies.
 Pollution performance of composite insulators

Pollution Testing And Research At High Voltage Division :

The High Voltage Division of CPRI has established a pollution chamber of size 12m x 12m x 12
m where pollution tests as per IEC BIS can be conducted on all types of external insulation for
systems upto 400kV. The power source consists of testing transformers of 600kV, 3.3Amp & a
100kV, 6Amp rating. A DC source of 150kV, 1Amp with thyristorized feed back control system.

Two methods namely salt fog and solid layer are employed to test the insulators under
pollution conditions.

In the case of salt fog method, the insulator is energised at the service voltage, which is kept
throughout the test and the insulator is continuously subjected to the salt fog whose salinity
(expressed in kg of Nacl per cubic meter of water) defines the severity of the test. The series of
successive tests, each lasting for one hour, is carried out at the same applied voltage and for various
salinities. This is carried out until highest salinity which the insulator withstands is achieved for
atleast three tests out of four. The maximum degree of salinity is termed the withstand salinity of the
test object.

In the case of solid layer method, the insulator is coated/dipped/sprayed/flowed on with a

slurry containing Kaolin and sodium chloride.

1. Wetting before and during energisation,

2. Wetting after energisation

The object of the test is to confirm whether the specified withstand layer conductivity or the
specified salt deposit density is withstood at the specified voltage. The insulator complies with this
specification if three withstand tests out of four are obtained under the condition examined.

CPRI has been conducting research exhaustively on different aspects of pollution for the last
ten years. Pollution level measurements have been carried out along the proposed route of a ± 500
kV DC transmission line of M/S. MSEB

Many research activities have been carried out in collaboration with CESI, Italy and the
following are some of the important ones.

1. Effect of pollution flashover with respect to diameter of the porcelain shell

2. Pollution performance of composite insulators
3. Ageing studies on insulator of ceramic & non-ceramic material
4. Pollution test on lightning arrester

Mathematical models for pollution flashover of insulators are widely recognized as efficient
tools, which could help in arriving at optimum insulator profiles for polluted areas. A mathematical
model of arc under dynamic conditions has been formulated which can predict the safe withstand
voltage for a given degree of pollution. Thus CPRI has the capability to study theoretically the
pollution performance of insulators.

Pollution performance of insulators under DC voltages has been studied upto a voltage of
about 140kV.

CPRI hopes that both the testing and research facilities now established will be used by
manufacturers and utilities to solve the problems connected with the design of external insulation
under normal and polluted conditions.

Impulse Current Generator 100 kV, 150 kJ

Types of Tests :
All type tests on Zno arrester blocks upto 11 kV As per National and International
Standards

Necessity Of Testing Arrester Blocks :

Lightning arresters, often called Surge Diverters, play a vital role in protecting expensive
substation equipment from high voltage surges. These surge voltages originate from either switching
operations of substation equipment or lightning strikes. In either case these over voltages have to be
limited well below the insulation levels of the equipment. By R&D, new designs of lightning arresters
have emerged, by which, it has become possible to bring down the insulation levels of the equipment
resulting in significant savings to the power systems.

Till recently gap type arresters were in use in the power system. Even in this type, new concepts
were introduced in the design by which one to two step reduction of basic insulation level (BIL) of 145
and 220 kV systems were possible. These arresters are being now replaced by Zinc Oxide (ZnO) Gap-
less arresters, (also known as Metal Oxide Surge Arresters). As reported in the literature, these were
first developed in Japan and came into use from 1970. The replacement of conventional arresters by
ZnO type initially started from system voltages above 145 kV class owing to their high initial cost. But
now even distribution systems use ZnO arresters due to the present affordable cost.
 Considering the importance of tests on ZnO arresters which are being increasingly used by
Powergrid, NTPC, State Electricity Boards and other power utilities. CPRI has established
comprehensive test facility for undertaking tests on Zinc Oxide arresters as per IEC-60099-4 and
other relevant standards.

All tests prescribed by International/Indian Standards (IEC 60099-4) for Metal oxide arresters
without gaps for AC systems can be undertaken. Following tests can be taken up with the newly
commissioned Computer controlled Impulse Current Generator supplied by M/s. Haefely Trench,
Switzerland with a capacity of 100 kV and 150 kJ

Residual Voltage Tests:

This test can be carried out for the following exponential waveforms:

a) Steep Current Impulse 1/<20 micro second.

Front time : 1 micro second ± 0.1 micro second.
Time to half value : <20 micro second.
Max. Current : 20 kA
Residual Voltage : Upto 40 kV

b) Lightning Current Impulse 8/20 micro second.

Front time : 8 micro second ± 1.0 micro second.
Time to half value : 20 micro second ±2.0 micro second.
Max. Current : 50 kA
Residual Voltage : Upto 50 kV

c) Switching Current Impulse 36/90 micro second.

Front time : > 30 micro second.
Time to half value : approx 2.5 T1.
Max. Current : 2 kA
Residual Voltage : Upto 30 kV

d) High Current Impulse 4/10 micro second

Front time : 4 micro second ± 0.5 micro second.
Time to half value : 10 micro second ± 1.0 micro second.
Max. Current : 120 kA
Residual Voltage : Upto 60 kV
Long duration rectangular Current Impulses :
Transmission line class tests class I to V can be carried out as per IEC 60099-4.

Operating Duty Tests :

Operating duty tests as per IEC 60099-4 can be carried out

Power frequency voltage V/S Time curve

HV Home
The Pollution Laboratory has dimensions of 12M x 12M x 12M. An array of
nozzles confirming to IEC specifications combined with a salt water pumping and air
compressor provide the required salt fog. The power supply to the chamber is from
one of the outdoor 600 kV, 2,000 kVA Cascade Transformers setup.

Pollution Test on Insulator

Equipment available :
 600 kV, 3 Amperes AC source
 100 kV, 6 Amperes AC source
 150 kV, 1 Ampere DC source
With these equipment/facilities the Pollution Laboratory can carry out
tests on insulators and insulator assemblies for systems upto and including
400 kV.

Types of Tests :
 Pollution test on insulators by salt fog/solid layer method upto 400 kV AC &
150 kV DC
 SF6 Puncture withstand test facility for DC insulators
 Thermal runaway tests on insulators
This Laboratory can undertake these tests as per National &
International Standards

Necessity Of Pollution Testing:

 With the ever increasing demand for electrical power, there has been a
steady growth in high voltage transmission lines required for optimum and
economic transfer of large blocks of power over long distances. As the level of
transmission voltage is increased, switching and dynamic over voltages and
withstand ability of the insulator under polluted conditions are important factors
which determine the insulation level of the system. The reliability of the system
mainly depends on the environmental and weather conditions which cause flashover
on polluted insulators leading to system outages.

It is generally recognized that the main events leading to flashover of

polluted insulators under service voltage are the formation of a conductive layer on
the insulator surface, leakage current surging with associated dry band formation
and partial arc development and arc propagation along the insulator surface
eventually spanning the whole insulator. The problem is more complex in case of DC
systems because of large contamination due to electrostatic forces and longer
duration of partial arc. Therefore the design of external insulation under polluted
conditions is very critical and lot of investigations are under way to arrive at safe
creepage distances for systems operating in different environments.

The pollution can be broadly classified into two types:

1. Marine pollution found in the immediate neighborhood of the sea and also
at considerable distances from coast.
2. Industrial pollution caused by dust, smoke etc
Objectives Pollution Investigation :
 Collection of pollution flashover data under natural conditions
 Suitable artificial pollution test under conditions representing natural
pollution
 Design of insulation for pollution conditions.
 Pollution ageing tests and investigation of causes of failures to arrive at
suitable remedies.
 Pollution performance of composite insulators

Pollution Testing And Research At High Voltage Division :

The High Voltage Division of CPRI has established a pollution chamber of size
12m x 12m x 12 m where pollution tests as per IEC BIS can be conducted on all
types of external insulation for systems upto 400kV. The power source consists of
testing transformers of 600kV, 3.3Amp & a 100kV, 6Amp rating. A DC source of
150kV, 1Amp with thyristorized feed back control system.

Two methods namely salt fog and solid layer are employed to test the
insulators under pollution conditions.

In the case of salt fog method, the insulator is energised at the service
voltage, which is kept throughout the test and the insulator is continuously
subjected to the salt fog whose salinity (expressed in kg of Nacl per cubic meter of
water) defines the severity of the test. The series of successive tests, each lasting
for one hour, is carried out at the same applied voltage and for various salinities.
This is carried out until highest salinity which the insulator withstands is achieved
for atleast three tests out of four. The maximum degree of salinity is termed the
withstand salinity of the test object.
 In the case of solid layer method, the insulator is
coated/dipped/sprayed/flowed on with a slurry containing Kaolin and sodium
chloride.

1. Wetting before and during energisation,

2. Wetting after energisation

The object of the test is to confirm whether the specified withstand layer
conductivity or the specified salt deposit density is withstood at the specified
voltage. The insulator complies with this specification if three withstand tests out of
four are obtained under the condition examined.

CPRI has been conducting research exhaustively on different aspects of

pollution for the last ten years. Pollution level measurements have been carried out
along the proposed route of a ± 500 kV DC transmission line of M/S. MSEB

Many research activities have been carried out in collaboration with CESI,
Italy and the following are some of the important ones.

1. Effect of pollution flashover with respect to diameter of the porcelain shell

2. Pollution performance of composite insulators
3. Ageing studies on insulator of ceramic & non-ceramic material
4. Pollution test on lightning arrester

Mathematical models for pollution flashover of insulators are widely

recognized as efficient tools, which could help in arriving at optimum insulator
profiles for polluted areas. A mathematical model of arc under dynamic conditions
has been formulated which can predict the safe withstand voltage for a given
degree of pollution. Thus CPRI has the capability to study theoretically the pollution
performance of insulators.
Products Wise Testing :
Protocol Test:
 Energy Meter
 Data Concentrator
 IED
 Relay
 Protocol Convertor
 RTU
(The above Equipments are tested at ITID-Bangalore)

Cable Test :
 Paper/PVC/XLPE/EPR Power cables of Voltage rating up to 220 kV
 Cable accessories, etc
(The above Equipments are tested at DCCD- Bangalore, STDS-Bhopal, and
RTL-Noida)

Capacitor Test:
 HV Shunt capacitors
  HV Series capacitors
 HV Capacitors for surge
 LV Motor capacitors
 LV fan motor Capacitors
 LV Capacitors for Lighting
 LV Power capacitors of self-healing type.
 LV Shunt capacitors of non self - healing type.
(The above Equipments are tested at DCCD- Bangalore, STDS-Bhopal, and RTL-
Noida)

Flame Retardant Low Smoke Test :

 Electric cables
 Cable sheath materials
 FRP composite materials
 Cable trays
 Channels
 Feeder pillar boxes
 Energy meter covers
 Terminal blocks
 Bushings
 Supporting insulators
 PVC conduit pipes
 Flooring materials
 Fabrics/curtain
 Materials used in aerospace/navy
 Any other plastic material
(The above Equipments are tested at DCCD- Bangalore)

Temperature Rise Test :

 Distribution, Transmission & Power equipment and accessories

 Diagnostics Test on,
 Power Transformer
  Generators / Large motors

 Power cables

 EHV CTs, / CVTs

 Resin Cast CTs

(The above Equipments are tested at DCCD- Bangalore)

High Power Test :

 High voltage circuit breakers

 High Voltage Switches

 High Voltage Fuses

 High Voltage Switch Boards
 Terminal Boxes
 MV Metal enclosed Switchgear
 Power Transformers
 Distribution Transformers
 Traction Transformers
 Potential Transformers
 Current Transformers
 Lightning Arresters
 Insulator Strings
 AC metal enclosed switch gear & control gear.
 AC Disconnectors & Earth switches
 Reactors
 Line traps
 Bus ducts, Bus bars, Generator Neutral Bus bar Compartment

 Power connectors, ACSR conductors

 LV Circuit Breaker
(The above Equipments are tested at HPL- Bangalore, STDS-Bhopal, and SCL-
Bangalore)
Insulation / Impulse voltage Withstand Test :

 Insulator ( Disc, Pin, Solid Core, Hollow)

 Insulator Strings (all types)
 Lightning Arrestor Housing & similar Insulating Materials
 Battery Container
 Rubber Mats
 Insulating Tubes etc.
 Insulating Rod
 Isolator, Circuit Breaker
 Bus duct
 Cables
 Bushing
 AB Switch
 Panel
 P T /C V T / Coupling Capacitor/ Grading Capacitor / R.V.T.S / CT-PT Units
 Tap changer
 Voltage / Current / Power / Distribution Transformers
 Reactors
 HT Capacitors
 Thyristor Valves
(The above Equipments are tested at HV- Bangalore, STDS-Bhopal,
UHVRL-Hyderabad and RTL-Noida)

Short Circuit / High Voltage / Synthetic Test :

 Circuit Breakers (LV, HV)

 Fuses
 Switches
 Starters
 Control Switches
 MCB / RCCB Switch Fuse units
 Power Connectors
 Spacers
 Bus bars
 Bus ducts
 CT's conductors
 Transformer
 P T /C V T / Coupling /Tap Changers
 Capacitors
 Grading Capacitors
 R.V.T.S
 C.T – PT UNITS
 Series & Shunt Reactors
 Line Traps
 Damping Reactors Tuning Reactors
 Neutral Earthing Reactors
 THYRISTOR VALVES
 H.V. Circuit Breaker & Switchgear Panel with Circuit Breaker
 HT switches/ Line sectionalizer
 Isolators
 Power & Distribution transformers & Traction transformers
 HT fuses
 Surge arresters
 Reactors
 Auto-reclosures
 DC Breakers
 HT switchgear panel
 Motor terminal box
 Spacers for Bundled conductor
 HV Contactors
 LT Air circuit breakers, MCCBs for voltage not exeeding 1000V
 Circuit Breakers for Over current protection for household & similar
installations
 Miniature circuit breakers (MCB)
 Low voltage fuses for voltage not exceeding 1000V
 Low voltage fuse bases for voltage not exceeding 1000V
 Air break switches, Air break disconnectors, air break switch disconnectors,
fuse combinations for voltage not exceeding 1000V
 Carrier & Bases for Rewirable type fuses
 Composite unit of air break switches for rewirable type switches for voltage
not exceeding 650V, AC21, 100A
 AC Miniature circuit breaker boards 1000V
 Residual current operated circuit breaker
  Factory build assemblies of switchgear & controlgears for 1000V
 For enclosed distribution board & cutouts 1000V
 Contactors & motor starters for voltages at exceeding 1000V
 Electric power connectors above 200A

(The above Equipments are tested at HPL- Bangalore, STDS-Bhopal, and SCL-
Bangalore)

Dielectric Materials Test :

 Lubricating Oil
 Transformer Oil
 Polymers etc.
(The above Tests are Conducted at DMD- Bangalore)

Materials Test :

 Coal
 Analysis of coal, ash and water for thermal power stations
 Lubrication oil and all other materials.
(The above Tests are Conducted at MTL- Bangalore)

Structural / Mechanical strength/ Vibration Test :

 Transmission line towers

 Line material
 Transmission Line Conductors upto and including 800kV rating
 Compression Clamps
 Mid Span Joints
 I&V Suspension Tension Strings upto and including 800kV rating
 Structural Steel
  Steel Wire ropes
 Electrically Operated/ Hand Operated Winches
 Chain Pulley Block upto 20 Tonnes
 Load Cell
 Line Material
 Terminal Clamp
 Structural Steel
 Connecting Links for Brake Parachute/ Nylon Purchase Tape
 Insulators & Insulator Strings of Single/ Twin/ Triple/ Quad-Tension or
Suspension type upto and including 800kV rating
 Vibration Dampers upto and including 800kV
 Spacer/ Spacer Dampers upto and including 800kV.
 Transmission Line Conductors upto and including 800kV rating
 Vibration Dampers upto and including 800kV
 Spacer/ Spacer Dampers upto and including 800kV.
 Transmission Line Conductors upto and including 800kV rating
 Conductors
(These Products are tested at MED- Bangalore)

Seismic Qualification / Vibrations Test :

 Energy Meter
 Switchgear, Control Panel
 All Equipments up to 10 Tons.
(The above Tests are Conducted at EVRC- Bangalore)

Calibration Tests :

• Digital & Analog Voltmeters

• Digital & Analog Ammeters
• Multimeters
• Digital & Analog Wattmeters
• Digital Temperature indicators
 • Digital & Analog Panel meters
• Electronic Thermometers
• Data Loggers
• Strip chart recorders
• Power harmonic analysers
• Process calibrators
• Hot & Cold temperature baths
• Current Clamps
• Thermometers
• Impulse measuring system
(The above Equipments calibration tests are conducted at ID- Bangalore, STDS-
Bhopal)

Test :

 Relay
 UPS (Uninterrupted Power Supply) (1 KVA - 10 KVA & above)
 Single Phase Electromechanical / kWh / Static / Electronic Energy Meters
 Three Phase Four Wire / Three Phase Three Wire Electromechanical / kWh /
TVM Static / Electronic Energy Meters
 Single phase / Three phase Static watt-hour meters
 Electronic Trivector meters
 Static protective relays
 Smaller size UPS, SMPS, Inverters, Converters, Contactors etc
 All Electronic equipments, like Static Relays, Breakers, contactors, starters,
Electronic ballast, Medical equipments

(The above Equipments are tested at ID- Bangalore, STDS-Bhopal)

Battery Testing :

Lead acid storage Batteries, VRLA, LMLA, NICAD Batteries, Tubular Batteries

(The above Tests are Conducted at EATD-Bangalore)

Flame Proof Testing :
All flame proof electrical equipment

(The above Tests are Conducted at EATD-Bangalore)

Ingress Protection Test:

All types of electrical equipment enclosures such as-

 Outdoor distribution boards

 Relay units/Panels
 Control Cubicles for PCVCB
 Switching & Control System enclosures
 RMV panels
 HT Metering & Switching Panel
 AC Distribution Board
 EWM Enclosures
 Platform Power Supply
 LT Panel
 Disconnecting Switch Assembly
 Junction Boxes
 LV switch Board
 AD/DC Panel
 weatherproof Switch Enclosures
 Dry type Transformer enclosures
 PCC Panel,
 MCC Panel, Bus Ducts
 DOL Starters
 Integral Starter
 Control Panel
 Electricity Metering Equipment Enclosures
 Actuators
 Telecommunication Equipment Enclosures
 Antennas
 Cable Connector Assembly
 GPRS Equipment Enclosures
 Battery Charger Panels
 Medical Health Monitoring Equipment Enclosures
 Drive Mechanism Box
 Marshalling Kiosks
 Surge Monitors
 MOM's
 Belt sway Switch Enclosures
 Reactor assembly Enclosures
 Starter Motors
 Sot Starter Panels
 RAPCONS
  BAPCONS

Rotating Electrical Machinery Equipment Enclosures such as :

 Enclosures of Induction Motors

 Valve Actuators
 DC Machines
 AC Machines
 Alternators
 Generators
 Vibratory Electric Motors
 Large Motors
 Automobile Electrical Motors
 Traction Motors
 Power Tool Motors
 Pumps (motors) Etc.

Luminaries and Light Fitting Equipment Enclosures such as :

 Street light Fitting Enclosures

 Aviation Light Fitting Enclosures
 Domestic
 Industrial Light Fitting Enclosures
 Corridor/ Office Light Fitting Enclosures

 Solar Operated Light Fitting Enclosures Etc.

(The above Tests are Conducted at EATD-Bangalore, STDS-Bhopal)

Luminaries :
 Tubular fluorescent lamps with Starter
 Self Ballasted Lamps for General Lighting Service (CFL)
 Safety requirements and Performance requirements
 Lamp Ballast

(The above Tests are Conducted at EATD-Bangalore)

Fan Testing :
 Electrical Ceiling Fans and Regulator
 Electrical Table Type Fans and Regulator
 Electrical Pedestal Type Fans and Regulators
 Propeller Type AC Ventilating Fans
 (The above Tests are Conducted at EATD-Bangalore)

Refrigerators :
Direct cool and frost free refrigerators up to 600 lts. capacity.

(The above Tests are Conducted at EATD-Bangalore)

DCCD - DIAGNOSTICS LABORATORY

 DCCD Home

The Laboratory has facilities for conducting condition assessment / life

evaluation of HV Power Equipment like Power Transformers, Hydro & Turbo
Generators, Power Cables, Large AC Motors, Current Transformers (CTs),
Capacitance Voltage Transformers (CVTs) etc. in service. The Laboratory has
adequate experience & expertise in conducting Residual Life Assessment (RLA)
Studies on High Voltage Substation and Power Plant Electrical Equipment in service.
Diagnostic Laboratory is an accredited laboratory as per ISO 9001-2000 quality
management system for undertaking field engineering services and consultancy for
various utilities.

CPRI Mobile Field testing laboratory Partial Dis charge Test on 110MW Turbo Generator

TEST / EQUIPMENT FACILITIES :-

o Recovery Voltage meter

o Electromagnetic Core Imperfection detector (ELCID)
o HV Dielectric Spectroscopy
o VLF Cable Diagnosis system
o Transformer ratio arm bridge
o Standard Capacitor, 80kV
o Precision microprocessor based Insulation tester, up to 5 kV
o Automatic Capacitance & tan delta test system
o Surge comparison tester – 12 kV
o DC Test kit – 70kV
o Partial Discharge Detection system
o Electronic Wedge mapping equipment
SOLID DIELECTRIC LABORATORY
DCCD Home

The Dielectric laboratory has comprehensive testing and evaluation facilities on

insulating materials and systems. Insulating materials are evaluated and test for
electrical, mechanical, physical and electro chemical properties. The Dielectric
laboratory has undertaken consultancy work and sponsored projects for different
power utilities and industries. Evaluation of class “H” insulation for traction motors
and compatibility studies on enameled winding wires and varnished were two
projects completed for RDSO, Ministry of Railways. Assistance has been rendered to
BIS in formulation of various standards on insulating materials and systems and on
enameled winding wires.

Facilities available:

- Micro processor based UTM 50KN capacity (-700C to2000C).

- High resistance meter upto 10-16
- SIGMA Tester.
- Automatic tracking comparator upto 1000VAC.
- Arc resistance tester.
- Rubber glove tester
- Complete equipment for evaluation of enameled winding wires as per relevant
parts of IS/IEC standards.
- Power frequency capacitance and dissipation factor measuring bridges, NBS smoke
box
- High frequency capacitance and dissipation factor measuring bridges.
- Electrometer
- High pressure chamber for conducting investigation on gaseous dielectrics upto 5
bars
- Static Decay meter
- Tear Tester
- Surface Roughness Meter
- Gas Chromatography/Mass Spectrometer
- Impact Tester
- Stress Cracking Equipment
- Compression Molding machine (4000C)
- Micro - OHM Meter.
- Liquid contaminant tracking and erosion test equipment

AREAS OF WORK :

- Electrical and mechanical tests on conductors, electrical, mechanical and chemical

tests on various solid insulating materials like paper, press board, polymeric
molding materials. B stage epoxy mica and epoxy glass materials etc.
- All tests on enameled/winding wires including endurance tests.
- Studies on gaseous dielectrics.
- Electrical tests on cable filling compound, capacitor fluids etc.
- Tests on Teflon, polypropylene, polyester, kapton films.
- Electrical tests on antistatic materials.