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TEST FACILITIES

EVALUATION OF T & D HARDWARE AND CONDUCTORS 

T & D Hardware and Conductors play an important role in Distribution Lines.  Such hardware can be classified as below:

1. General hardware required for stringing of conductors such as strain clamps with accessories, yoke plates, turn buckles, shackles and links of various geometry, dead end clamps, mid-span joints, corona control rings, pins, fasteners, earth wires, stay wires, etc. 

2. Hardware required for spacing and / or damping of aeolian vibration of conductors such as spacers and dampers of various types and shapes well as spacer – dampers.

3. Conductors 

4. Insulators 

The main emphasis of evaluation of these items is their durability under all possible operational and environmental conditions.  These components are evaluated for mechanical strength, material specifications, coating /plating specifications, correctness of geometry, etc. ERDA has comprehensive facilities for the determination of physical, chemical, metallurgical and mechanical characteristics of all hardware items.

 Some details are highlighted as below:

Spacers, Dampers & Spacer-Dampers 

Apart from physical, chemical and metallurgical soundness, functional characteristics are also very important.  The aeoline vibrations cause heavy   damage    to    conductors   if   proper damping facilities are not provided.  Dampers and spacer-dampers serve this purpose.  However, if these are not properly designed and fixed to the conductors, they may cause more harm than solving the vibration problem.  For the evaluation of these products, ERDA has established a new vibration – testing laboratory, which can cater to the requirements of conductors upto twin Moose Conductors.  Facilities for testing of  dampers as per IS:9708 and spacers, spacer-dampers as per IS:10162 and conductor earth wire accessories for overhead power lines as per IS:2121 Pt.I to IV are available at ERDA. 

Conductors 

ERDA is carrying out following test for Dog, Rabbit, Zebra, Panther and Moose conductors. 

For Aluminium Conductors (Galvanised steel reinforced) as per IS: 398-2 & 5. 

• Measurement of diameter of individual Al wires and galvanized steel wires

• Breaking load test

• Ductility test 

• Wrapping test

• Resistance test

• Galvanising test

• Measurement of lay ratio/ Direction of lay

• Breaking load of complete conductor

•  Surface Condition

• Corona test

• Stress strain testing facility

For Aluminium Alloy Stranded Conductors as per IS: 398 (Part-4).

• Measurement of diameter

• Measurement of lay ratio / direction of lay

• Breaking load test

• Elongation test

• Resistance test

• Wrapping test

Insulators

(as per IS:731,2544,5621,IEC:60383,60575, 60797,60168,61109)

1.  Visual Examination
2.  Dimensional check
3.  Temperature cycle test
4.  Mechanical tests
5.  Porosity tests 
6.  Thermo-mechanical performance tests
7.  Mechanical load test
8.  Thermo-mechanical pre tests
9.  Sudden load release test
10.   Assembled core load time test
11.   Damage limit proof test of the tightness of the interface between and fittings and insulator housing
12.   Verification of tightness of interface between end fittings and the specified mechanical load (SML)
13.   Verification of mechanical load test
14.   Brittle fracture test
15.   Dye penetration test
16.   Tracking and erosion test
17.   Galvanizing test

Facilities 

Mechanical Tests 

1.  Slip strength
2.  Breaking load
3.  Dimensional checking
4.  Galvanising
5.  Chemical analysis
6.  Temperature rise
7.  Resistance
8.  Resonance Search
9.  Fatigue
10. Dynamic characteristics
11. Damper efficiency
12. Pull-out strength
13. Vibration

Electrical Tests 

1.   Short circuit
2.   Dry power frequency
3.   Wet power frequency
4.   Impulse voltage withstand
5.   Corona extinction voltage
6.   Radio interference voltage
7.   Fault current
8.   Magnetic power loss (under development)
9.   Steep wave front test 

The importance of evaluation of T&D hardware cannot be over emphasized.  Manufacturers of these items as well as utilities and T&D companies are welcome to utilize facilities established at ERDA. ERDA continuously upgrades its facilities.  New facilities are regularly created in consultation with prospective users.

UNI-AXIAL SEISMIC TEST FACILITY

For critical applications such as those encountered in the nuclear, chemical, & petroleum sectors where a high degree of component reliability & safety are mandated, electrical equipment and structural assemblies such as motors, panels, actuators, instruments, instrument packages, switchgear, power supplies, communication equipment, civil structures, control valves, piping systems etc. have to be qualified with respect to their behavior under dynamical conditions encountered in a typical earthquake. This is of special significance to the industrial belts/critical installations located in the western, northern, & northeastern regions in India which fall under the zones of severest seismic activity, namely those of categories IV & V.

The ground motion associated with a typical earthquake is characterized by an acceleration pulse of a short temporal duration, which can range from a few seconds to about a minute. The instantaneous ground acceleration vector exhibits stochastic behavior and undergoes rapid transitions in orientation and magnitude during the duration of the earthquake event.  Extensive analysis of ensembles of seismic records indicates that the upper bound magnitude of the peak ground acceleration is generally bounded to about 1 g.  The total energy content associated with a typical earthquake event is large.  However, a predominant fraction of this energy is concentrated in the frequency regime of less than 100 Hz.  Earthquake spectra are best characterized by stochastic measures such as expectation value, autocorrelation & covariance functions, as well as integral metrics such as the power spectral density.  The response of engineering machinery/civil structures to a earthquake event are predominantly determined by factors such as the vibrational eigenvalue content of the structure/equipment, the degrees of freedom available, as well as the degree of structural/internal damping present.  The destructive potential of an earthquake of even a moderate intensity (say intensity 5 on the Richter scale) can be huge in terms of loss to property & life.  Therefore, international & national regulatory & test agencies have developed guidelines for the seismic qualification of equipment/structures intended for critical applications using one, two, & three-dimensional dynamical testing techniques.   Sophisticated computer controlled vibration test equipment is required for conducting such tests.

The bi-axial seismic test facility at ERDA enables critical component manufacturers to qualify their equipment as per the seismic test requirements of various international test standards such as IEEE-344 (87), IEEE-382 (96), IEEE-323 (83),  IEEE-383 (74), as well as various other mandated specifications of Nuclear Power Corporation (NPC) of India.  This unique state-of-the-art seismic test facility enables precision control of the table motion under full multi-loop digital control. A wide variety of table motions ranging from sinusoidal to random can be programmed. The shake table is mounted on a trunion which enables its positioning from the horizontal (perpendicular to gravity) to the vertical (parallel to gravity).  The trunion can also be locked at an angular position of 45 degrees from the vertical to enable uni-axial seismic testing on an axis inclined to the gravity vector. These unique features enable the conduct of uni-axial seismic tests on two orthogonal axes in either the sequential un-correlated or the concurrent fully correlated test modes. The machine is designed to handle payloads up to 400 kgf with maximum (height) dimension of about a meter.

Manufacturers can now conduct three of the four qualifier tests mandated by NPC i.e. LOCA, Thermal Ageing, & Seismic Testing under one roof at ERDA.  The fourth mandated test, namely Radiation Ageing is conducted at BARC in association with the NPC.  All manufacturers of critical equipment requiring qualification of their products as per the guidelines of NPC are welcome to contact ERDA for a single point addressing of all their test certification needs.

Electrical (and other items) that could be qualified Motors, panels, actuators, instruments, instrument packages, switchgear, power supplies, communication equipment, civil structures, control valves, piping systems etc of up to 400 kg mass with height dimension limited to about one meter. 

The Test Facility (Shake Table Specifications)
 

Sr.No.	Description	Machine Characteristics
1	Maximum payload	400 kg
2	Platform size-mounting	0.6 m x 0.6 m
3	Dynamical force rating of actuator	1400 kgf (more than three times the maximum payload requirements)
4	No. of axes of motion	Uniaxial with a capability to rotate the actuator assembly from horizontal to vertical (parallel to gravity vector) and conduct sequential, uncorrelated, uni-axial test in these orientations as well as at 450 to the vertical.
5	Center of gravity of specimen with respect to table surface	0.5 m
6	Acceleration	1 g (within limitation of 300 mm stroke at low frequencies)
7	Frequency range	0.1 Hz to 100 Hz
8	Displacement	300 mm peak-to-peak
9	Input waveforms	Sinusoidal / sine beat sine sweep / random 0 ......
10	Control of table motion	Digital, multi-loop, PID control for generating TRS in close conformance to the RRS

ENERGY MANAGEMENT SECTION

The Energy Management Section (EMS) of ERDA was established in the year 1995 with the objective of providing energy conservation services to the Nation. Over the years, EMS has specialized in energy conservation related to conventional fuels such as coal, oil & gas. These conventional fuels are limited and will be exhausted shortly and thus the need arises to reduce their consumption by efficient utilization. The supply and demand gap of electric power is increasing every year and is expected to increase even further due to the huge cost required in setting up of Thermal Power Stations as well as the associated environmental pollution..

Energy conservation is an optimal operational practice, which improves the efficiency of the equipment associated with both supply side and demand side i.e. at the user end. Since the industries account for a greater share of power consumption the energy conservation programs will benefit them by reducing their Specific Power Consumption and making them more competitive in the market. ‘Negawatt’ (a negative ‘Megawatt’), a term coined by the renowned energy analyst Amory Lovins, highlights the fact that a Negawatt produced by reducing energy need saves more than a Megawatt generated.  Energy audits lead to the generation of “NEGAWATTS” and thus result in virtual augmentations to the installed power generation capacity of the Nation! 

Energy Audit Study: 

Energy Audit is the basic tool of energy conservation and is defined as a systematic exercise to identify the end-uses that consume a significant amount of energy, estimate the efficiency in each of these end uses and devise methods of improving efficiency and curbing losses and wasteful energy.  

A walk-through audit at the client’s place is undertaken to study the manufacturing process, the type of equipment available, their operating strategy and potential areas of energy conservation. The detailed list of  equipment is collected along with the electricity bill for the two previous months for working out a detailed quotation for the energy audit to be conducted at the client’s premises. 

EMS is having all sophisticated portable non-invasive instruments and highly skilled & experienced staff for conducting  measurements at site. The energy audit report is prepared on the basis of these  measurements and includes the saving potential, investment required and the payback period for investments made. Due emphasis is also  given to  “No Cost” measures that include good housekeeping practices, minor changes in the operation practices, etc. No cost saving potential of 11% to 100% was realized during the course of energy audit programs in addition to other energy conservation measures with payback period ranging from few days to 2 years.  

Areas of Work: 

• Energy audit study.

• Energy conservation measures.

• Seminars, workshops and in-house training programs on energy audit and energy conservation measures.

• Certification of energy efficient equipments.

• Research and development in the area of renewable energy.

Achievements in a Nutshell: 

• More than 250 comprehensive energy audits have been successfully completed.

• The list of auditees includes Navaratna companies such as ONGC, GAIL, NTPC, Jindal Steel etc.

• Other prestigious clients include IPCL, ESSAR Steel, General Motors, KRIBHCO, Heavy Water Plant of DAE, GNFC, GSFC, etc.

• Successfully completed the energy audit for both process and equipment at M/s Tata Steel, Jamshedpur, the largest steel maker in private sector, in India.

• The list includes 57 Power Generating Units of utilities such as National Thermal Power Corporation (NTPC), Nuclear Power Corporation of India Ltd., (NPCIL), Gujarat State Electricity Corporation Ltd., (GSECL)  Maharashtra State Power Generation Co. Ltd., M.P. Power Generating Co. Ltd., Torrent Power AEC Ltd., etc.

• Saving potential of up to 64% and 43% were identified for electrical and thermal energy, respectively.

• Annual recurring savings to the tune of Rs. 163 crores have been reported as achieved by the audited industries and utilities.

• The identified saving potential is equivalent to 49 MW.

Recognitions:

EMS, ERDA is recognized as authorized energy auditor by Bureau of Energy Efficiency (BEE), New Delhi (under Energy Conservation Act-2001), Petroleum Conservation Research Association (PCRA), Gujarat Energy Development Agency (GEDA), Maharashtra Energy Development Agency (MEDA), Energy Management Centre (EMC)-Kerala, Chhattisgarh State Renewable Energy Development Agency (CREDA), Commissioner of Electricity, Gujarat for  statutory energy audits in Gujarat state. 

Awards Received: 

• Best Improvement in Performance Award from PCRA consecutively for 3 years.

• Best Energy Auditor Award from PCRA consecutively for 2 years.

• MEDA  Award for the years 2004 & 2005

Above awards are received in recognition of the outstanding contribution made by ERDA in the area of Energy Conservation.

 Findings at a Glance:  

*: No Cost Saving Potential

REFRIGERATOR TEST L.ABORATORY

ERDA has established Refrigerator testing laboratory to meet the testing needs of the industry and to provide star marking facility under the Energy Labeling Programme of Bureau of Energy Efficiency (BEE), Govt. of India.   

This testing facility can take up concurrent testing of three refrigerators each of maximum capacity of 720 liters.  The test chamber ambient temperature can be controlled from +10^oC to +43^oC with  ± 0.5^oC accuracy. The humidity inside the chamber can be maintained in the range 45% to 75%. 

The chamber is designed for the certification of refrigerators under the standards and Labeling Programme of Bureau of Energy Efficiency (BEE), New Delhi. 

The chamber is also designed to meet customized test requirements of refrigerator manufacturers. 

Frost-free and Direct Cooled Refrigerators can be tested as per standards.  To facilitate manufacturers to export their products to countries like Australia, and Newzealand, testing as per their national standards can also be taken up. 

ENERGY STANDARDS & LABELING

 As the world becomes increasingly dependent on electrical appliances and equipment, energy consumption has risen rapidly.  One of the most cost-effective and proven methods to curb rising energy / electricity demand from electrical appliances and equipment is to establish energy efficiency standards and labels.  Such standards and labels are designed to improve energy efficiency without compromising on other features such as performance, quality and safety.  

Energy efficiency standards are procedures and regulations on the energy performance of manufactured products, sometimes prohibiting the sale of products, which are less energy-efficient than the minimum standard requirements. They are often called Minimum Energy Performance Standards (MEPS). 

TEST FACILITIES

Following tests can be carried out:

 1.    Energy consumption test, pull down test and volume measurement as per energy labeling guidelines given by
        Bureau of Energy Efficiency (BEE)

2.     Almost all the tests as per IS: 1476, IS: 15750 and AS/NZS 4474.1 

INFRASTRUCTURE 

1.       Controlled Environment Chamber

2.       Computerised Data Acquisition System

3.       High Accuracy Temperature Sensors

4.       Power Analysers

5.       Fixture for automated door opening and closing 

ACCREDITATION & RECOGNITIONS

The facility has been accredited by National Accreditation Board for Testing & Calibration Laboratories (NABL) for testing as per various national and international standards and has been recognized by Bureau of Energy Efficiency, Ministry of Power, Govt. of India as the nodal agency for Refrigerator Testing. Further, the Bureau of Indian Standards has given accreditation for testing as per IS:1476. 

ERDA’S MISSION STATEMENT 

ERDA’s mission is to provide technological support to the Indian Electrical Industry, Utilities and user organizations by way of product certification, type, developmental and special testing and evaluation as per National, International and Institutional standards and specifications.  ERDA also has a mission to conduct sponsored research, offer technical services such as inspection, consultancy, condition monitoring, life assessment, failure investigation, knowledge updation and market surveys in the areas of electrical materials, products and systems.  Further, through high quality research and development, it aims at providing scientific knowledge and technology needed to solve the problems of today and anticipate those of tomorrow. 

EMI / EMC

 Introduction 

Electrical / Electronics appliances, telecom equipments and control system used in domestic and industrial applications are nowadays available with improved versions. These are also becoming more and more user friendly. These things are possible due to the fuzzy logic controls and micro-controller based digital electronic control circuits. As more electronics is involved with the appliances more they become prone to EMI. The EMI/EMC effects may cause instantaneous or long term malfunctioning or permanently damage the equipment. 

All electronics appliances / systems manufactured in India must comply with the EMI / EMC standards for the purpose of exports and get ‘CE’ marking.  

Recognition 

ERDA facility for Energy meters & Electronic products are accredited by NABL, Govt.of India & BIS for its ISI marking scheme. 

Services 

ERDA provides solutions for EMI/EMC problems as per relevant standards under ‘product quality improvement projects’. More than 10 industries have already improved their products. 

EMI/EMC Test Facility 

EMI/EMC test facility at ERDA provides following tests:

*Test facilities in Sr. No. 7, 8 and 9 shall be operational by March 2009 & 10 by August 2009. 

LIST OF PRODUCTS TESTED FOR EMI/EMC  

Infrastructure  

Some of the related test facilities include: 

ENERGY METERS

Energy meters are the most important part of the electrical system.  The revenue of the utilities is dependent on the accuracy of energy meters.  The Government of India has decided to install meters in all the consumers premises.  In view of this, it is very important to check the quality and reliability of energy meters so that their performance is satisfactory and bill electricity accurately.  Earlier electro-mechanical meters having accuracy of class 1.0 and 2.0 were used and with the advancement of technology, static energy meters having accuracy class 1.0, 0.5 and 0.2 are available in the market. 

ERDA has complete type test facilities for testing energy meters as per Indian and International Standards.  ERDA can also calibrate 0.05 class reference energy meters using a 0.02 class reference energy meter. 

ERDA also takes up evaluation of energy meters as per the requirements of electricity boards and ranks them according to quality.

 Testing Facilities 

The type testing facility for Energy Meters is as given below: 

The tests for Insulation, accuracy, electrical and EMI/EMC, Mechanical and climatic requirements are performed as per relevant IS/IEC.  Endurance, impulse, climatic, vibration, shock, harmonic and ingress protection testing ensures the reliability of the energy meter.  ERDA has a reference standard meter of class 0.02 and a fully automatic test bench with a reference meter of class 0.02.  

EMI/EMC Test Facility 

ERDA has test facilities mainly for static electrical energy meters (1φ and 3φ).  This laboratory provides testing, developmental and certification facilities under the head “Tests for Electromagnetic Interference and Compatibility”.  The tests are carried out according to CBIP Publication No. 304, IS: 13779, IS:14697 and IEC-62052-11.  

The facility provides following tests: 

The facility is useful for energy meter manufacturers and users. 

Testing of Components 

The following components of energy meters can also be tested as per relevant standards. 

Calibration

Calibration of reference standards upto class 0.05 is undertaken at ERDA.  ERDA carries out calibration energy meters / refstand meters upto 0.05 class at site also.

Infrastructure

Some of the related test facilities include: 

1.      Solid-state substandard energy meter calibrator class 0.02, 3 phase static phantom source upto 100 Amps, stability 0.05%
2.      Fully automatic test bench upto 120 A with a reference energy meter of class 0.02
3.      Temperature rise test bench
4.      Life test bench
5.      Short time overcurrent test facility
6.      Test facilities for Influence quantities
7.      Glow wire test apparatus     
8.      Vibration test apparatus
9.      Shock test apparatus10.    IP 51 facility
11.    Cold cabinet (upto -40^oC)
12.    Ovens
13.    Humidity chamber
14.    Impulse test facility
15.    Non-flammability test apparatus
16.    Harmonic test facility
17.    EMI/EMC Test facility

Recognition

ERDA’s facility for Energy Meter is accredited by NABL, Govt. of India and BIS for its marking scheme. Electrical Inspectorate of Gujarat and other Electricity Boards have recognised the facilities.

Services

ERDA also provides technical services like condition monitoring, failure analysis, RLA, third party inspection, developmental testing and Technical Information Services. 

Consultancy for carrying out improvement in the design and quality of energy meters. 

Development of test equipment like impulse generators, voltage dips and interruptions setup, short time overcurrent setup, 3rd and 5th harmonic generators, surge testing generators, etc. 

Study the effects of harmonics, voltage variation and frequency variation on the performance of energy meters.

Evaluation of Batches 

ERDA carries out evaluation of the batch of energy meters for electricity boards tender samples and grades them according to their quality

HARMONICS - POLLUTION FOR POWER SYSTEM

Introduction

In the power distribution system harmonics in the mains are caused by connection of non-linear load to the system.  The presence of harmonics affects the behavior of the system in variety of ways such as: 

• Increase in losses and heating of Rotating Machines and Transformers 

• Overloading of power factor correction Capacitors 

•  Interference with Telecommunication circuits 

• Maloperation of Protection and Metering Systems 

There is a need to enhance the awareness of the damage the caused to connected equipment due to harmonics and necessary measures to eliminate the same to improve quality of power. 

Industrial users specially have to guard against the harmonics injected, which may damage connected equipment resulting in disruption of production and financial loss. 

Harmonic causing Devices 

• Controlled / uncontrolled converters

• Electric furnaces

• Traction load

• Solid state power electronic equipments

• Discharge lighting

• Television receivers

• Fluorescent lamps

• Transformer within supply system 

Harmonic Content 

The ‘Harmonic Content’ is defined as the ratio of the amplitude of the individual harmonic to the amplitude of fundamental component (50 Hz) supply system.  Where a number of harmonics are present, the combined effect of harmonic is expressed as “Total Harmonic Distortion (THD)” which is defined as the ratio sum of root square value of all the individual harmonics to the root mean square value of fundamental. In our country there is no statutory regulation (except CBIP Publication No. 251) governing the harmonic pollution. 

Services Provided by ERDA 

• Characterization of non-linear loads

• Identification and measurement of harmonics

• Development of methods and equipment for measurement of harmonics.

• Study the effects of switching inductive currents of transformers and motors

• Study the effects of harmonics on metering and protective equipment

• Study the effects of Arc furnace loads

• Equipment Reliability Assessment

• Design & Development of filters 

Infrastructure available at ERDA 

• Power quality analyzer, 4 power channel 0.03%.  Basic accuracy, capable of continuous monitoring of power quality parameter for more than one month

• Harmonic analyzer with 4 channel 64 kB / Channel, 100 kHz Sampling rate accuracy of 0.25%

• Differential module with 2 channel, ratio of 20 or 400 for each channel.

• Non-inductive shielded shunt 0.5W & 0.7W (nominal value).

• Digital storage oscilloscope with 4 channel, 8 bits 200 MS/s150 MHz.

• Digital storage oscilloscope with 8 channel, model no. DL 750

• 15 kV high voltage probe, 65 MHz bandwidth

• High voltage dividers

• Current probes for measurement of AC and DC current

•  Software support

• Qualified and experienced Engineers

Studies done at ERDA 

Some of the studies carried out at ERDA are: 

• Causes of overloading and failure of shunt capacitors in arc furnaces and electrolytic plant.

• Causes of overheating of neutral grounding resistors of generators and transformers

• Impact of the harmonics generated by energy conservation devices on the supply as well as other connected equipment.

Benefits 

Following are the benefits of reduction of harmonics in supply system. 

• Reduced losses and heating of Rotating Machines and Transformers 

• No overloading of power factor correction capacitors 

• Reduced Interference with Telecommunication circuits 

• No maloperation of Protection and Metering Systems 

• Improved efficiency of electrical equipment. 

• Reduction in nuisance tripping & breakdowns

 POWER ELECTRONICS & INSTRUMENTATION CELL

ERDA has established Power Electronics & Instrumentation Cell to undertake R&D activities in the related field and the expertise available can be utilised to develop products of interest, to Industries in public, private, medium and small-scale sectors, besides Govt. agencies. The cell is capable of developing products like:

•  SMPS

•  DC / AC drives

• Inverters

• HV DC Power Supplies

• UPS

• Microprocessor / Microcontroller based instruments like

(a)     Power Meter
(b)     Trivector Meter
(c)     V² hour Meter
(d)     Energy Meter
(e)     Energy Meter Testing Equipment 

• Static Reactive Power Controllers

• STATCOM

• Active Power Filters

•  Induction Heating

• Electronic Ballast

• Active Power Factor Correction Equipment

• Test Setup as per IS/IEC where electronics expertise is applicable

• Software Development related to power system / power electronics and instrumentation

 The power electronics group is engaged in a number of development projects sponsored by the government and non-government bodies.  Private companies have also come forward to sponsor these projects.  Apart from the products listed above any special equipment that is needed to satisfy the test requirements as per the relevant IS/IEC standards can also be developed, e.g., Low Voltage Impulse Generator, Short time Overcurrent Test Setup, Voltage Dips and Interruption Test Setup, Microcontroller based 3rd & 5th Harmonic Generator and DSP based 1- Phase Phantom Load Generator with Harmonic Source for Energy Meters, condition monitoring equipment and optoelectronics sensors / equipment.  The Cell also provide technical consultancy to industries in the fields of electronics and electrical engineering. 

Testing Facilities 

Apart from development activities, the cell is engaged in the type testing of power electronics equipments as per the relevant IS/IEC standards.  Some of the equipment, which can be tested include Regulated Power Supplies, UPS, Inverters, Stabilizers and AVR Battery charger.  Testing of combined wave generation. 

Commercialisation 

Technology transfer has already taken place for Electronic Ballast.  Static Energy Meter, Frequency Trend Meter, Short Time Over Current Test Set-up & Low voltage Impulse Generator. 

Projects Completed 

The group has successfully completed following R&D projects : 

1        Solid State Switching of LT Capacitors, Microprocessor based transient free switching  of 36 kVAr capacitor bank 
2      Development of Trivector Meter, accuracy class 0.5, as per CBIP Report No. 88/IEC687 
3      Development of V² Hour Meter, accuracy class 0.2, fully digital (Microcontroller based) with LCD Display, useful for lamp industries. 
4      Development of Harmonic Analyer, harmonic analysis upto 25th harmonic, displays individual harmonic, % THD and RMS,
       (Microcontroller based). 
5       Development of Recurrent Surge Generator, 600V, 50 Hz, 1.2µs/50µs (variable) 
6       Development of Electronic Ballast conforms to IS:13021-1991, THD <23% Power Factor  > 0.9, Power Consumption < 3W, Efficacy =55
7       Development of Short Time Overcurrent test setup for static energy meters upto 3000A  rms. (half-cycle) cl. No. 12.7.2.1, IS:13779,
       useful for static energy meter manufacturers. 
8        Development of Voltage Dips and Interruption test set-up for static energy meters as per cl.no. 12.7.2.1, IS:13779, useful for
        static energy meter manufacturers and laboratories. 
9         Shunt Active Power Filter for Elimination of Current Harmonic in Power Systems 
10     Development of Single-Phase and Three Phase Energy Meters as per IS:13779. 
11     Development of Solar Power Fountain 
13     15 kV Low Voltage Impulse Generator as per IS:13779:1999 for Testing of Static Energy Meter.
14     Transformer Winding Resistance Meter
15     State of Art Study on IGBT based STATCOMS
16     Ring Wave Test set up for RCCB as per IS:12640-1 (200 Amp. Peak, 0.5 µsec. Rise time,  100 kHz frequency)
17     Microcontroller based 3^rd & 5^th harmonic generator for Energy Meter Testing"
18     Series Active Filter for elimination of Voltage Harmonics
19     DSP based 0.1 class Reference Standard Energy Meter
20     DSP based, 1- Phase, Phantom Load Generator with Harmonic Source
21     Design and Development of Electronic Ballast for 150 watts HPSV lamps
22      Automatic Meter Reading Test setup for 5 energy meters simultaneously
23     Recurrent Surge Oscillograph Generator Rotor Testing
24     Development of fiber-optic based hot spot sensor for Electrical Equipment 

Future R&D Projects 

The following R&D projects are planned and will be taken up shortly:

1      Vector control of AC machines
2      Switched reluctance motor drive
3      Brushless PM DC drives
4       Soft switch inverters
5       Hybrid active filter
6       FACTS Devices
7       Direct AC to AC converter (Matrix Converter)
8       Condition Monitoring equipment
9       Optical Current Transformers
10     Optical Hotspot Sensor

TRANSFORMER OIL

Liquid dielectrics form an important part of insulating systems in electrical equipment.  One of its important use is in transformers, where mineral oil is used.  It acts as an insulating and heat transfer medium.  It is also an arc-quenching medium for power and distribution electrical equipments like switchgears, transformers and capacitors. 

ERDA’s facilities include a complete setup for testing and condition monitoring of transformer oil.  All activities from sample collection to analysis and consultancy are covered here. 

Testing & Analytical Services 

The condition of transformer oil as insulating materials has to be well monitored through routine testing & DGA.  It is a signature of some of the other insulating materials within a transformer and its analysis can help take preventive measures.  The tests covered in the national standards fall into the categories of evaluation, quality, reliability studies and life expectancy of transformer.  The following Indian Standards are currently followed for routine tests: 

 Special Tests 

•  PNA Analysis

• Gas content analysis

• Viscosity index test

• Aromatic content determination

• Dissolved Gas Analysis

• Furan measurement

• DP measurement

• Gassing tendency of insulating oil

• Compatibility of solid insulating materials with oil

• Lube oil testing

Technical Services 

The services offered by ERDA for transformer oil include : 

1. Third party inspection

2. Witness testing

3. Certification

4. Consultancy

5. Testing & Analytical Services

6.  Sampling of oil from transformer

Infrastructure 

This section is equipped with following important instruments: 

• Gas Chromatograph with auto sampler

• Oxidation stability test set up

• FT-IR spectrophotometer

• Resisitivity and tan delta bridge

• Liquid Chromatograph

• Rotating Bomb

• Automatic BDV tester

R&D activities 

Developmental work has always gone hand in hand with testing activities at ERDA. 

Ongoing projects 

• Evaluation of super absorbent for transformer oil reconditioning

• Field trial of Thermosyphon in Power Transformers in GEB grid

Completed Projects 

• Development of demonstration model of transformer oil reconditioning plant for Rural areas.

• Residual life assessment of power transformer by lab simulated studies

• Development of prototype Thermosyphon for Power Transformer

 The testing facilities for transformer oil are also available in our Mumbai Office, Sonepat and Rajahmundry Site Laboratories.

Certification 

The test facilities are approved by BIS for its ISI marking scheme and also accredited by NABL, Govt. of India. 

ERDA offers special rate contracts for transformer oil testing to its regular customers

CABLES

Cables are important elements of electrical systems as power is transmitted through them.  They are used for household wiring, domestic appliances, railways, industrial and urban distribution system and find special applications in lifts and conveyers. 

The variety of cables produced indigenously has increased from paper insulated to rubber, PVC and XLPE insulated cables.  Today even FRLS cables are produced in the country. ERDA has facilities for testing and evaluation of above types of cables and raw materials. 

Testing Facilities 

The facilities include accelerated ageing tests, ultraviolet weathering and thermal stability tests.  The other tests are performed in accordance with national and international standards. 

Raw Materials

Cables 

 Infrastructure 

• High Resistivity Meter

• Partial Discharge bridge & balance  detector

• High current source (Induction type)

• Tubular ageing ovens

• Kelvin bridge

• Impulse test facilities upto 1200 kV

• Flexing, bending, wear resistance testing apparatus

• Universal Schering Bridge

• Faraday Cage

• AC – DC high voltage testing equipment

• Universal testing machine

• Oxygen index and smoke density test apparatus

• Flammability test on bunched cable

• Fire survival test

• Flammability test as per IS, IEC, ASTM, SS-424/1475

Certification 

The facilities are approved by BIS for its ISI marking scheme with reference to standards – IS:692, 694, 1554, 2465, 4289, 7098, 9968, 9857, 14494. 

Research & Development 

Some of the important R&D projects completed include: 

• Development of fire resistant coating for cables

• Study of electrical treeing behaviour in XLPE cables used for working voltages upto 33 kV and remedial measures

• Development of FRLS cable compounds by chemical modification of PVC

• Study on the effect of UV radiation on fire resistance characteristics of FRLS cables

• Online condition monitoring of cables installed in Nuclear Power Plants

POLYMERS

A wide variety of polymeric materials are used as insulating materials in electrical equipment. More and more new materials are coming to the market and hence it is necessary to evaluate them as per various standards.  Characterization of polymeric materials for their structure and various properties requires sophisticated instrumentation.  At ERDA, the polymers section of Insulation Division has facilities for instrumental analyses of various polymers.  Facilities are also available for metallurgical analysis of steel and copper.  In addition, some special tests like Degree of Polymerization (DP) of paper and furan content in transformer oil are also conducted in this section. 

Materials/ Products Tested and Special Tests 

Some of the commonly tested polymeric materials / products and special tests are: 

Infrastructure  

• Infra-Red Spectrophotometer (FTIR)

• Liquid Chromatograph (LC)

• Thermal Analyser comprising of:
  - Thermo Gravimetric Analysis (TGA)
  - Differential Scanning Calorimetry (DSC)

• UV – VIS Spectrophotometer

• Brookfield Viscometer

• Optical Emission Spectrophotometer

• Penetrometer

• Melt Flow Index tester

• Hardness Testers (shore A & shore D)

R&D Activities 

R&D activities go hand in hand with testing in this section 

Ongoing Projects:

•  Development of eco-friendly dielectric fluid for application in transformer oil

• Development of high temperature resistant coating

•  Development of epoxy formulation with improved dielectric characteristic for indoor insulation application

Completed Projects

• Development low dielectric constant material

• Development of Alkyd based varnish

• Development of Heat shrinkable material

• Studies accelerated ageing of power capacitor dielectric system

• Development of Room Temperature Vulcanizing (RTV) silicone compound

• Development of Capacitor encapsulation material

• Development of Bird deterrent compound

LOSS OF COOLANT ACCIDENT (LOCA)

ENVIRONMENT SIMULATOR AND THERMAL AGEING TEST FACILITIES FOR LARGE SYSTEMS

Continuous cooling of fuel is an essential requirement not only for the safe operation of nuclear power plant but also when plant is in shutdown condition in order to remove decay heat.  In the event of a break in the Primary Heat Transport (PHT) System, reactor containment will be filled with steam because coolant pressure and temperature are quite high (87 kg/cm² and 250-280^oC respectively).  Peak temperature of containment could be as high as 120^oC by virtue of gushing out of hot water.  Under such a situation, a large number of systems need not work because reactor will promptly and automatically be set to shutdown condition by various tripping signals.  But safety related systems and associated sensors and cables must work and the operator in the control room must know the true situation.  This phenomena is known as LOCA and this is a design basis accident which means all the safety related systems must work under LOCA condition.  Unless safety related system and associated components and materials are tested under LOCA condition, one cannot be sure about their proper functioning during such an eventuality.  It is likely that a safety system may be able to withstand LOCA when it is new.  But we have to ensure its survival under LOCA condition when it has undergone ageing equivalent to 40 years (assumed reactor life) because LOCA can take place any time.  This necessitates that an aged safety system also must be tested under LOCA condition.  In view of above consideration, LOCA environment simulator and thermal ageing test facilities have been set-up at Electrical Research and Development Association (ERDA), Vadodara for testing of large systems, such as shutdown pump motors and containment building penetrations etc., with financial support of Rs. 114 lakhs from Board of Research in Nuclear Sciences (BRNS), Department of Atomic Energy.  India is one of the very few select countries in the world to setup such large test facilities with 100% indigenous efforts. 

Facilities 

Both the test facilities (LOCA Environment Simulator and Thermal Aging Chamber) are amongst the large sized facilities in the world and can handle 3 ton weight of test item.  Technical specifications of both the facilities are as follows: 

LOCA Environment Simulator
 

Thermal Aging Chamber 
 

LOCA environment simulator, thermal aging chamber and steam accumulator are covered by 5 cm thick ceramic wool and aluminium foil to minimize heat losses.  Both the chambers have been installed horizontally, co-axially and their doors are facing each other at spacing of 5.85 meters..  Test items are lifted with the help of chain pulley arrangement and kept on the trolley.  Test items can be easily pushed inside or pulled out of the chamber through the trolley. 

Electrical items that could be qualified 

Large pump motors (100 – 200 kW), Cables (1.1 kV), Motor operated valves (150 – 200 mm), Circuit Breakers, (upto 800A), Cable penetration (1.1 kV), instrumentation and Control Systems, Process Instruments, Solenoid valve, Pressure transducer valve etc.

SOLID INSULATION MATERIALS

A large variety of solid insulating materials are used in electrical equipments and products.  It is mandatory to test these materials for their functionality.  At ERDA, the solid dielectrics section of the insulation division has facilities for evaluation and testing to check their conformance to Indian and international standards. 

Insulating Materials / Products covered 

Some of the commonly tested solid insulating materials / products are:  

 Infrastructure

• INSTRON’ Universal testing machine

• Impact tester  (Izod and charpy)

• Comparative Tracking Index tester

• ‘HOUNSFIELD’ UTM

•  Inclined Plane Tracking & Erosion Tester

• Martins HDT Tester

• Vacuum oven

• RLC Digibridge

• Humidity Chamber

• Oven with HV bushings and ageing ovens

• Brookfield Viscometer

• VSP / HDT tester

• Arc resistance tester

• Accelerated weathering tester (UV ageing)

• Densometer

• Breakdown voltage tester

• High Resistance meter

• Conductivity / pH meters

• Oil bath for BDV test

• Molding Press

• Cold cabinet upto -40^oC

Special Tests 

1. ESDD/NSDD measurement for insulators. 

R&D Activities 

Developmental activities go hand in hand with testing in this section. 

Ongoing Projects 

•  Development of composite longrod insulators for HV transmission

Completed Projects 

Some of the completed projects are: 

• Determination of thermal endurance profiles of SMC / DMC

• Determination of optimum drying cycle for PT coils

• Development of a quicker method for temperature index determination of insulating varnishes

• Studies on accelerated ageing of power capacitor dielectric system

• Studies on the effect of UV radiation and condensation on polymer concrete

• Studies on the creep characteristics of polymer concrete

• Residual life assessment of Power Transformers by laboratory simulated study

• Thermal Endurance Profile of polymer concrete

• Development of Vinyl Ester Resin based non-ceramic insulators

• Ageing studies on polymeric insulators with and without surface coatings

• Field evaluation of 66 kV non-ceramic insulators

• Performance evaluation of polymeric housings

• Development of RTV silicone coating for outdoor insulator application

WINDING WIRES

Winding wire is an important constituent of practically every type of electrical product.  The variety of winding wires has grown from simple oleoresinous enamel coated to coatings like polyester, polyesterimide, polyurethane, single and dual coated and also PVC.  ERDA is actively involved in testing, evaluation and investigation of all types of winding wires as well as raw materials.  Relevant R&D activities accompany the regular testing activities. 

Test Facilities 

Raw materials that are tested include: 

Testing of the different kinds of winding wires include: 

Further, the quality of enamelled wires is tested by conducting long term ageing test as per IEC:60216 and IS: 5825. For enamelled wires determination of tip up temperature by measuring tan delta at various temperatures after impregnation and accelerated ageing tests is also done.

Infrastructure

• High resistivity meter

• Tan delta meter

• Ageing ovens

• ACDC high voltage testing equipments

• Kelvin bridge

• Instron tensile testing machine

• Cut through tester

• Pin-hole tester

• Unidirectional abrasion resistance tester

• Thermo gravimetric analyzer

• Abrasion resistance, springiness test setups

Certification 

The test facilities for winding wires at ERDA are recognised by BIS for its marking scheme and also accredited by NABL, Govt. of India.

R&D Activities 

Projects Completed :

• Evaluation of indigenously manufactured copper wires and development of quick quality control test

• Evaluation of enamelled wire/compound compatibility

• Comparative evaluation of enamelled Aluminium wire of Aluminium Pechiney and indigenous enamelled winding wires.

• Comparative evaluation of indigenous and imported enamelled winding wires

• To recommend a computerised quicker method for thermal class evaluation of insulating material

TRANSFORMER

Transformers are important component of the power system, and are expected to find increased demand with thrust on infrastructure development.  Instrument Transformers (CTs and PTs) have wide application in metering and protecting the power system. Indigenously manufactured distribution transformers have a wide range of ratings.  At ERDA transformers from 5 kVA to 2000 kVA at ERDA and upto 200 MVA/220 kV at site  can be tested.  Transformers are an important part of ERDA’s testing facilities and also R&D activities

 Test Facilities

 The establishment offers facilities for testing of raw materials, components, transformer and also its condition monitoring.

 Products

 Components

 Condition Monitoring 

 Field Studies 

Related to transformers, ERDA offers following field studies and measurements: 

• Condition monitoring by capacitance and Tan Delta measurements

• Measurement of no load and load loss at site

• Harmonic measurements of magnetizing current

• Partial Discharge measurement

• Failure Analysis

• Error Measurement

• DIRANA / DOMINO USS (For paper moisture determination)

•  Frequency Response Analysis

•  Third party testing using calibrated instruments

• Calibration of CT’s and PT’s

•  Testing of CT’s and PT’s

• Noise level measurement

• Online condition monitoring by acoustic emission method

 Infrastructure 

The major facilities include: 

1.     Routine and type testing facilities for Transformer upto 2000 kVA /33 kV
2.     Lightning impulse voltage test facility upto 1200 kV, 60 kJ for Transformers upto 100 MVA, 220 kV
3.     Wideband partial discharge bridge and Balance Detector, Biddle, USA with Faraday Cage
4.     Condition monitoring by capacitance and loss angle measurement by Automatic C & tan δ test set (Tettex, Switzerland
         &  Doble, USA)
5.     Short Circuit tests on Distribution transformer 11 kV, 1600 kVA and upto 22 kV or 33 kV and 500 kVA
6.     Short circuit tests on LT switchgear upto 50 kA, 1 sec. and 40 kA, 3 sec. at  525 V / 250V.
7.     Type test facilities for potential transformers upto class 0.2, 66 kV
8.     Type test facilities for current transformer upto class 0.1, 4500 A.
9.     Automatic microprocessor based error measuring test sets
10.   Measurement of harmonics (ZEWS ZIMMER, Japan).
11.   Loss measurement by using 0.1 class CT’s & PT’s and digital power meter of : Yokogawa  make
12.   Dissolved Gas Analysis (Netel, Agiland)
13.   Furan Analysis on HPLC (Shimadzu, Japan)
14.   Epstein test frame for core loss measurement
15.   Hysterisis graph plotter
16.   Franklin Insulation Tester
17.   Acoustic emission test set for online P.D measurement 

Calibration 

Calibration of CTs and PTs of class 0.2 for various ranges is also undertaken at site and at ERDA laboratory at Baroda. 

R&D Activities

Areas of work related to transformers include:

1.       Development of prototype hydrogen gas sensor
2.       Impulse breakdown studies on transformer oil
3.       Residual life assessment of transformer using laboratory
4.       Heat transfer studies on radiators
5.       Acoustic emission detection technique for discharge detection and location
6.       Accelerated ageing tests on distribution transformers to assess the insulation life

CAPACITORS

Capacitor is an important element of electrical system.  Its applications include power factor improvement of electrical load and reactive compensation of transmission and distribution systems, energy storage, starting of fan motors and fluorescent lamps. They are extensively used as energy storage elements in para electronic converters.  The indigenously manufactured capacitors’ ratings are from a few microfarads to 600 kVAr.  ERDA is engaged in the R&D activities covering materials, design, performance and reliability aspects, Quality improvement etc.

Testing Facilities 

Capacitors are tested at ERDA to the requirements of national and international standards. Endurance tests on HT Capacitors, accelerated ageing, endurance tests & destruction test on LT capacitors, thermal stability, self – healing, charge discharge and temperature coefficients tests ensure the quality and reliability of the product.  We can carry out testing of reactors as per IS: 5553-1989/90 and functional tests on APFC panels upto 100 kVAr. The reference standards are:

Evaluation of Components 
 

 Field Studies 

The group undertakes field studies, third party testing and witness inspection at  manufacturer’ s works.  Tests done at site include: 

• Condition monitoring of surge capacitor for generators

• Measurement of harmonics

• Failure analysis

• Field verification of optimized location

• Interlaboratory comparison of capacitance and tangent delta bridges

• Measurement of capacitance and tan delta at site

Infrastructure 

• C and tan delta test set – 3 nos. (Digital)

• Universal Schering Bridge (0.05% class) – TETTEX make

• Standard Capacitor 1x10^-5 tan delta value

• Transient overvoltage test facility

•  Constant voltage supply for thermal stability tests

• DC charge – discharge test facility

• Digital S.H. Tester

• Complete test facilities for LT Capacitors upto 50 kVAr

• Complete test facilities for HT Capacitors upto  11 kV, 450 kVAr (will be shortly upgraded to 33 kV, 800 kVAr)

•  Ageing ovens

• Cold chamber

• AC-DC high voltage testing equipments

• Wave analyzer with plotter

• Destruction tests facility for LT capacitors

• Endurance test facility for HT capacitors / Fan Motor Capacitor

•  Environmental (Humidity) chamber

• Fault current test facility

Certification 

The facilities are approved by BIS for its ISI marking scheme with reference to standards IS: 13340, 13341, 13585, 2993, 1569 and 1709. The facility is accredited by NABL, Govt. of India.

HIGH VOLTAGE IMPULSE TESTING

A wide range of electrical equipment, apparatus and components are used in transmission and distribution network of electrical power.  Equipments like transformers, reactors, instrument transformers, bushings, insulators, lightning arresters and isolators of different ratings are manufactured in India.  ERDA has equipped itself to undertake high voltage impulse testing on such equipment (rating upto 400 kV) as per Indian and International standards. 

Infrastructure 

§         Impulse voltage generator – 1600 kVp, 80 kJ, 1200 kVp, 60 kJ, 800 kVp, 40 kJ
§         Impulse voltage divider  – 1600 kVp,1200 kVp, 800 kVp, 300 kVp
§         Chopping gaps of 1600 kVp with chopping time control from 2-6 microseconds
§         750 mm Φ & 500 mm Φ sphere gaps for HV measurement
§         Digital Impulse analyzer – 14 bit, digital oscilloscope – 14 bit for analysis of impulse waveforms
§         700 kV & 600 kV AC Testing facility with 700 kV & 600 kV HV dividers
§         Wet test facility upto 400 kV equipment
§         R.I.V test facility
§         400 kV, 200 kV & 100 kV standard voltage dividers for high voltage AC and DC calibration
§         Test facilities for visible discharge test or visible corona test on insulators and transmission hardwares upto 400 kV system
§         Type test facilities for insulators as per IS & IEC
§         TRANSI-NOR LCM – II kit for online condition monitoring of lightning arrester at site
§         Reference impulse calibrator Model RIC 422 for calibration of impulse measuring system
§         Accelerated ageing studies on lightning arrester blocks
§         Software for designing of substation grounding
§         Puncture detector for disc insulators

Infrastructure facilities for bringing large trailer loaded apparatus to the testing lab, arrangement for lifting and mounting of bushings, conservator tank and provision for installing oil filtration facility also exist.

Equipment that can be tested include : 

ERDA provides facilities for type, developmental and certification testing of these equipment.  Also calibration of impulse voltage, A.C, D.C voltage at site. 

Site Testing / Condition Monitoring Encompassing investigative testing and diagnostics – is also undertaken by ERDA.  These include Tan Delta, Partial discharge and Polarization index measurement, corona test, Pollution studies, Radio Interference Tests, Rain Tests and calibration of CTs and PTs and on-site evaluation and certification of equipment. Lightning Arresters condition monitoring, Insulator leakage current measurement, Calibration of H.V test set impulse, P.D, Measurement of Earth Resistance of Earthing pits. Earthing design for substations, survey of lightning protection scheme etc. 

R&D Activities 

Studies in the area of impact of high voltage on equipment and their components are undertaken.  These include – 

§         Power System Grounding
§         Online condition monitoring of lightning arresters
§         Failure analysis of transformer during impulse test
§         On line condition monitoring of insulators

 Ongoing work includes: 

§         Study the effects of corona ring on polymer insulators
§         Studies on polymer insulators
§         Design of earthing grid for power stations
§         Accelerated aging test on metal oxide blocks
§         Aging studies on polymeric housing lightning arrester         

The HV impulse testing, Short Circuit testing facility, along with the insulating materials testing facilities at ERDA provide a complete set of facilities for testing some of the important electrical equipment.

SWITCHGEAR & CONTROLGEAR

Introduction 

The control and protection equipments like switchgear and controlgear are important components of power distribution system.  The conformance of these products to standards / specifications is crucial for the reliability and safety of electrical equipment.  ERDA has complete facilities for testing and evaluation of switchgear products like ACBs, HRC fuses, MCBs, MCCBs, RCCBs, RCBOs, contactors, starters and switch fuse units LT Panel, Switchboard, Distribution board. 

ERDA is one of India’s premier Testing Laboratories accredited by Intertek (ASTA),UK for  Type tests and certification of various electrical products.  The products covered under this accreditation are listed below. ERDA Switchgear test laboratories are also accredited by National Accreditation Board for Testing and Calibration Laboratories (NABL), Govt. of India and recognized by Bureau of Indian Standards (BIS).  

The above facilities are  utilised for testing as per UL,USA and CSA standards  for export of electrical products conforming to the requirements of UL & CSA standards.  

ERDA has also established Online Short Circuit Testing Laboratory for 120 kA, 575V LT Switchgear at Savli and Online Short Circuit Testing Laboratory for 50 kA, 500V at Makarpura.                                    

Switchgear and Controlgear products covered as per relevant IS/ IEC Standards are: 

Facilities for CE Marking and EMI / EMC testing are:  

 Infrastructure

The test facilities include: 

1.      Short circuit making & breaking capacities – 120 kA, 575V for LT Switchgear  at Savli and 50 kA, 500V for LT Switchgear at Makarpura.
2.      Short time withstand current test – 120  kA for 1 second or 70 kA for 3 second at Savli and 50 kA for 1 Sec, at Makarpura.
3.      Temperature rise limit upto 10000A
4.      a.   Impulse Test – 1200 kV
         b.   High Voltage one minute power frequency test – dry & wet – 600kV
5.      Mechanical durability
6.      Electrical durability
7.      Rated making & breaking capacities
8.      Conventional operational performance
9.      Time current characteristics
10.     Mechanical strength of terminals
11.     28 days test-For MCBs & RCCBs
12.     Resistance to abnormal heat and fire
13.     Protection against electric shock
14.     Resistance to rusting
15.     Environmental tests
16.     Moisture Resistance (humidity) test
17.     IP Tests (Degree of protection) – 40 Tonne
18.     Dynamic testing of the relays
19.     EMI/EMC test facilities for “CE” marking 

WITNESS TESTS : ERDA can witness tests on HV circuit breakers for mechanical endurance, temperature rise test, dielectric tests at manufacturer’s premises. 

Accreditation and Recognitions

ERDA is one of the premier testing laboratory in the country accredited by the National Accreditation Board for Testing & Calibration Laboratories (NABL), Govt. of India.  ERDA’s facilities and capabilities have been recognized by a number of National and International bodies and prominent amongst them are: 

•  Intertek (ASTA), UK.

• Bureau of Indian Standards (BIS)

• Underwriters Laboratories (UL)

•  Canadian Standards Association  (CSA)

• Directorate General Factory Advice

• Service & Labour Institute (DGFASLI)

• Commissionerate of Electricity, Govt.of Gujarat

• Chief Inspectorate of Steam Boilers and Smoke Nuisances, Govt. of  Gujarat

• Petroleum Conservation Research  Association (PCRA)

• Gujarat Energy Development Agency  (GEDA)

• Maharashtra Energy Development Agency (MEDA)

• Department of Explosives. Ministry of

• Commerce & Industry, Govt. of India

In-Situ Testing

Residual life assessment of H.T circuit breaker upto 220 kV class and relays of different types i.e generator protection, transformer protection, feeder protection, motor control centre etc., are carried out at site for steady state and dynamic testing.

 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

PUMP SETS

The ‘Pumpset’ – Ever since the device was first used for lifting water, the lifting of water has been one of man’s earliest needs and indeed the use of this device has proliferated exponentially.  There are large numbers of pumpset installations in India, such as in process plants, agricultural and domestic areas.  The energy consumption of pumpsets is as much as 40% of total consumption leaving large scope for improving energy efficiency of pumpsets.  Hence every pump regardless of size or classification, should be tested in the same way as in actual installation before final acceptance.   

The basic objective of testing the pumpset is to:

1. To verify the design and performance of pumpset 

2. To verify that the pumpset has been manufactured as per the recommendations and requirements of relevant standards 

ERDA has complete type test facilities for testing of all types of pumpsets as per relevant standards. ERDA can also carry out developmental testing and research on pumpset through its expertise and infrastructure. 

Testing facilities

The following types of pumps and foot valves are regularly type tested.  These are:

Infrastructure 

Major test facilities include: 

1. Digital precision grade power meter (basic accuracy 0.1%)

2. Magnetic Flow meters ( 5 & 20 & 70 lps), accuracy 0.25%

3. Vertical eddy current drive for testing