120 kA ON

120 kA ON-LINE SHORT CIRCUIT TEST FACILITY

ELECTRICAL RESEARCH AND DEVELOPMENT ASSOCIATION
(ACCREDITED BY NABL, GOVT. OF INDIA. AND INTERTEK TESTING AND CERTIFICATION (ASTA BEAB), U.K)

T071

120 kA On-line Short Circuit Test Facility

Plot: K-V-2/A, GIDC Savli, Manjusar, Dist. Vadodara – 391 775

Tel. +91 02667 264347 / 49, Fax. +91 02667 264348, e-mail: erdasvl@erda.org

Head Office

ERDA Road, GIDC, Makarpura,
Vadodara – 390 010, India

Tel. +91(0265) 2642942, 2642964, 2642377,

3043128-3043131, Fax: +91 (0265) 2638382, 2644923

E-mail: erda@erda.org; dir@erda.org; plv@erda.org;

phv@erda.org; ene@erda.org; ins@erda.org;

mtd@erda.org; tdc@erda.org
Website: http://www.erda.org

Registered Office

Brabourne Stadium,
87, Veer Nariman Road,
Opp. Ambassador Hotel
Mumbai – 400 020, India
Tel.+91 022 22820622, 22815376
Tele Fax: +91 022 22815376
e-mail:berda@bom8.vsnl.net.in

OVER THREE DECADES OF SERVICE TO INDUSTRY AND UTILITIES

INTRODUCTION

A wide variety of electrical equipment such as Power Transformers, Current Transformers, Switchgear & Controlgear products, Cables etc. are used in transmission and distribution network of the power sector. The conformance of these products to standards/specification is crucial for the reliability and safety of electrical equipment. The availability and access to highly sophisticated testing facilities is a pre-requisite for ensuring high quality of materials and products. ERDA has established many testing facilities for testing large variety of materials and products.

“On-line Short Circuit Test Facility” for LT Switchgear upto 50 kA, 525 V and 1.6 MVA, 11 kV and 500 kVA, 22 & 33 kV Transformers is one such major facility set up by ERDA at its Makarpura, Vadodara complex. ERDA’s 50 kA Short Circuit Testing Laboratory is a well-known independent laboratory for testing and certification of medium and low voltage components used in the electrical infrastructure. It conducts tests and issues Type Test Certificates and Test Reports for tests on Cables and Connectors, Distribution Transformers, Instrument Transformers, Switchgear, Panels and other components. It is being utilized by the various industries, power utilities and certifying bodies, BIS for the last 10 years. Other prominent users include UL, Intertek Testing and Certification Ltd., (ASTA-BEAB), U.K. etc.

ERDA has now established an “On-line Short Circuit Test Facility” of capacity upto 120 kA, 570 V at Savli for LT Switchgear and Distribution Transformers up to 4 MVA, 33 kV rating. It is the largest on-line short circuit test facility in India. It has state-of-the-art equipment and infrastructure and happens to be one of the most modern Short Circuit Test Facilities in the world. It has two test bays available and two customers can work in parallel. Commercial testing of various electrical products has started in this laboratory. With this facility, ERDA is able to serve the electrical industry and utilities more efficiently.

RECOGNITIONS

· Intertek Testing and Certification Ltd., (ASTA-BEAB),UK

· Underwriters’ Laboratories (UL) , USA

· National Accreditation Board for Testing and Calibration Laboratories (NABL), Govt. of India, Dept. of Science & Technology

· Bureau of Indian Standards (BIS)

· Govt. of India, Ministry of Scientific & Industrial Research

· Govt. of India, Ministry of Finance, Dept. of Revenue

· Govt. of India, Director General Factory Advice & Labour Institute

· Govt. of Gujarat, Chief Inspector of Steam Boilers and Smoke Nuisances.

· Govt. of Maharashtra, Charity Commissioner

· Govt. of India, Petroleum Explosive and Safety Organization, Nagpur

· Utilities of Gujarat, Maharashtra, Rajasthan, Madhya Pradesh, Punjab, Haryana, Jammu & Kashmir, Tamil Nadu, Uttar Pradesh and Chhattisgarh etc.

Control Room

INFRASTRUCTURE

120 kA Short Circuit Laboratory at Savli	50 kA Short Circuit Laboratory at Makarpura
· 132/33 kV Short Circuit Transformer: Voltage variation from 82 % to 120 %	· 66/11 kV Short Circuit Transformer: Voltage variation from 82 % to 120 %
· 33/0.475 kV, 120 kA Short Circuit Transformer: Low impedance	· 11/0.436 kV, 50 kA Short Circuit Transformer: Low impedance
· Sequential Timer with timing of 0.1 millisecond to 9999 seconds & 32 Channels with point on wave switching.	· Sequential Timer with timing of 0.1 millisecond to 9999 seconds & 32 Channels with point on wave switching.
· Digitizer – 8 Channels	· Digitizer – 8 Channels
· Coaxial Shunt, Non-inductive, 150 kA rms.	· Coaxial Shunt, Non-inductive, 70 kA rms.
· 132 kV Sub station/Supply line at Savli.	· 66 kV Sub station/Supply line at Vadodara.
· Fault level of more than 3000 MVA at ERDA.	· Fault level of more than 1200 MVA at ERDA.

TESTS

Distribution Transformers:

· Thermal & Dynamic ability to withstand short circuit tests upto 33 kV, 4000 kVA distribution transformers

· Thermal & Dynamic ability to withstand short circuit tests upto 11 kV, 1600 kVA distribution transformers

· Thermal & Dynamic ability to withstand short circuit tests upto 22 kV, 1000 kVA distribution transformers

- Current Transformers:

· Short time withstand current test upto 400 kV class, 50 kA for 3 Seconds or 120 kA for 1 sec.

- Switchgear & Controlgear Products:

· 120 kA, 570 V Short circuit making & breaking capacity.

· 120 kA for 1 sec. or 70 kA for 3 sec. short time withstand current test

· 120 kA, 570 V breaking capacity for HRC fuse link.

· Performance of integrally fused circuit breaker.

· All other pre & post tests as per National and International Standards.

120 kA Short – Circuit Transformer

PRODUCTS COVERED

Sr No.	Products	Standard	Facilities at 50 kA, 525 V S.C. Test Laboratory at ERDA, Makarpura	Facilities at 120kA, 570 V S.C. Test Laboratory at ERDA, Savli
1	LV ACBs & MCCBs	IEC:60947-2-2006 IS/IEC: 60947-2-2003	2000 A, 415 V upto 50 kA	6300 A, 500 V upto 120 kA
2	LV Switches, Disconnectors, SFUs	IS/IEC: 60947-3-1999 IEC: 60947-3-2005	500 A, 415 V upto 50 kA	800 A, 500 V upto 120 kA
3	Contactors and Motor Starters	IS: 13947-4-1993 IEC: 60947-4-2005	800 A, 415 V upto 50 kA	800 A, 500 V upto 120 kA
4	Low Voltage Fuses (HRC)	IS: 13703-1-1993 IEC: 60269-1-2005	800 A, 415 V Upto 50 kA	800 A, 500 V upto 120 kA
5	Low Voltage Switchgear & Controlgear Assemblies	IS: 8623-1&3-1993 IEC: 61439-1-2009 IEC: 61439-2-2009	50 kA for 1 sec. & 31.5 kA for 3 secs.	120 kA for 1 sec. & 70 kA upto 3 secs.
6	Electric Power Connectors	IS: 5561-1970	50 kA for 1 sec. & 31.5 kA for 3 secs.	120 kA for 1 sec. & 70 kA upto 3 secs.
7	Distribution Transformers	IS: 2026-1-1977 IS: 1180-1989 IEC: 60076-5-2006	Upto 1600 kVA, 11 kV Upto 500 kVA, 22 kV Upto 500 kVA, 33 kV	Upto 1000 kVA, 11 kV Upto 1000 kVA, 22 kV Upto 4000 kVA, 33 kV
8	Current Transformers	IS: 2705 (Pt.1 to 4)-1992 IEC: 60044-1-2003	145 kV, 31.5 kA for 1 sec.	400 kV upto 120 kA for 1 sec. & 50 kA for 3 secs.
9	HT Isolators with and without Earth Switches, A.B. Switches	IS: 9920-2002, IS: 9921-1985 & IEC: 62271-102, 60265-1-1998 & 60265-2-1998	145 kV, 31.5 kA for 1 sec.	245 kV upto 40 kA for 3 secs.
10	HT/LT Cables	IEC: 60502-2-2005 IS: 7098-2-1985 IS: 9968-2-2002 IS: 1554-2-1988	Upto 26.3 kA for 3 secs.	Upto 70 kA for 3 secs.
11	MCBs	IS: 8828-1996 IEC: 60898-1-2003 & IEC: 60898-2-2003	All ratings	All ratings
12	RCCBs/RCBOs	IS: 12640-1-2008 & IS: 12640-2-2008/ IEC: 61008-1-2006 & IEC: 61009-1-2006	All ratings	All ratings
13	HT Panels	IS-3427-1997 IEC-62271-2007	50 kA for 1 sec. & 31.5 kA for 3 secs.	120 kA for 1 sec. & 70 kA upto 3 secs.
14	Panels - Internal Arc Tests	IEC-61641-2008	50 kA, 500 V	120 kA, 500 V
15	Rewirable Fuses	IS: 2086-1993	All ratings	All ratings

ASSOCIATED FACILITIES

· Impulse Test 1200 kV, 60 kJ

· High Voltage one minute Power Frequency Test Dry & Wet 600 kV, 350 kVA

· Type Test facilities for Distribution Transformers

· Type Test facilities for Current Transformers

· Temperature Rise Limit upto 10,000 A, 10 V

· Mechanical Durability

· Electrical Durability

· Rated Making & Breaking Capacities

· Conventional Operational Performance

· Time Current Characteristics

· Mechanical Strength of Terminals

· 28 Days Test – for MCB & RCCB

· Resistance to Abnormal Heat and Fire

· Protection against Electric Shock

· Resistance to rusting

· Environmental Tests

· Moisture Resistance (humidity) Test

· IP tests (Degree of protection) 40 Tonne

· Dynamic Testing of the Relays

· EMI/EMC Test Facilities for “CE” marking

· ERDA can witness tests on HV Circuit Breakers for Mechanical Endurance, Temperature Rise Test, Dielectric Test at manufacturer’s premises.

· 14 & 8 Tonnes Mobile Crane

· 3 Tonne and 5 Tonne Forklifts

· Shed with 10 Tonne crane for handling test samples

· Condition Monitoring

· RLA Studies

· Failure Investigation

· Calibration

· Enclosure test facility as per UL, NEMA and CSA Standards

RESEARCH & DEVELOPMENT ACTIVITIES

Upgradation of Short Circuit Level of Low Tension Air Circuit Breaker.
Remote operated 11 kV Load Break Switch and MCCBs.
Transient Response of 400 kV CT.
Development of DC MCBs for 5 kA, 130 V DC Fault Level.
Development of Fault Current Limiter (FCL) for LT Switchgear & Appliances
Internal Arc Test on Panels.
Short Circuit Withstand Test superimposed on Temperature Test at 50 kA for 1 sec.

SOME IMPORTANT VISITORS

· Mr. Joop Hooijmanns, Manager, High Power Laboratory, KEMA
Mr. Paul P. Leufkens, President and General Manager, High Power Laboratory, KEMA

· Mr. Schweiger, R&D Head, Siemens Germany

· Mr. Jun Harayama, Japan Electrical & Environmental Tech Laboratory, Japan

· Mr. Marco Liu, Pacific, MK, Malysia

· Mr. Sung Puay Kiang, President, Sunlight Electricals, Singapore

· Mr. Peter Yap, Evergrow Electrical Engineering, Malaysia

· Mr. Million Matusala & Mr. Jan-Erik Johnsson Hitaboy, Finland

EXPORT OF ELECTRICAL PRODUCTS

ERDA’s test facilities can be utilized for certification of products to be exported to European and Middle East markets, under the ASTA mark. Intertek testing and certification, UK has accredited ERDA test facilities for testing of electrical products for issuing ASTA-BEAB certificates. For further details, please contact Director, ERDA (dir@erda.org; erdasvl@erda.org).

Savli Map