Electrical Research and Development Association
Specialised Testing Facility
120 kA On Line Circuit Test Facility
On Line Short Circuit and High Voltage Test Facility
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Mobile Test Laboratory
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120 kA On Line Short Circuit Test Facility
Introduction
A wide variety of electrical equipment such as power transformers, current transformers, switchgear & controlgear products, cables etc. are used in transmission and distribution networks of the power sector. The conformance of these products to standards/specifications 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.

ERDA has three On-line Short Circuit Test Stations for LT Switchgears. Station-1 was setup in 1998 and Station-2 has been setup in 2012 at ERDA’s Makarpura, Vadodara complex. These stations have test capabilities upto 50 kA, 525 V and 1.6 MVA, 11 kV Transformers. Station-3, which was setup in the year 2007, at Savli has an on-line short circuit test facility of capacity upto 120 kA, 570 V for LT Switchgears 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. With these three short circuit test stations ERDA is the largest low-voltage short circuit test facility in Asia. With these facilities, ERDA is able to serve the electrical industry and utilities more efficiently.

ERDA’s Short Circuit Testing Laboratories are well-known independent laboratories for testing and certification of medium and low voltage components used in the electrical industry. They conduct tests and issue Type Test Certificates and Test Reports for tests on Cables and Connectors, Distribution Transformers, Instrument Transformers, Switchgears, Panels, Busducts and other components and products. These laboratories are being utilized by various industries, power utilities and certifying bodies, BIS for more than 10 years. Other prominent users include, Intertek Testing and Certification Ltd., (ASTA), U.K., UL etc.

ERDA’s Recognitions
Intertek Testing and Certification Ltd., (ASTA),UK

Control Room
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.  
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   11/0.475 kV, 120 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:

Measuring System

  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, 1000 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.
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:60947-2-2009
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: 60947-3-2008
500 A, 415 V
upto 50 kA
800 A, 500 V
upto 120 kA
3 Contactors and Motor Starters IS/IEC: 60947-4-1-2000
IEC: 60947-4-1-2009
800 A, 415 V
upto 50 kA
800 A, 500 V
upto 120 kA
4 Low Voltage Fuses (HRC) IS: 13703-1-1993
IEC: 60269-1-2006
800 A, 415 V
Upto 80 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: 1180-1-2-1989
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
66 kV, 31.5 kA for 1 sec. 550 kV upto 120 kA for 1 sec. & 50 kA for 3 secs.
9 HT Isolators with and without Earth Switches, A.B. Switches IS: 9920-2-2001
IS: 9921-2-1982
IEC: 62271-102-2001
IEC: 60265-1-1998
IEC: 62271-104-2009
33 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/IEC:60898-1-2002
IEC: 60898-1-2003
IEC: 60898-2-2003
All ratings All ratings
12 RCCBs/RCBOs IS: 12640-1-2008
IS: 12640-2-2008
IEC: 61008-1-2009
IEC: 61009-1-2009
All ratings All ratings
13 HT Panels IS-3427-1997
IEC-62271-1-2007
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 1600 kVP, 80 kJ
High Voltage one minute Power Frequency Test Dry & Wet 700 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
10m Anechoic Chamber for EMI/EMC tests
EMI/EMC Test Facilities for “CE” marking
IP tests (Degree of protection) 40 Tonne
Dynamic Testing of the Relays
ERDA can witness tests on HV Circuit Breakers for Mechanical Endurance, Temperature Rise Test, Dielectric Test at manufacturer’s premises.
14 Tonne Mobile Crane
5 Tonne Forklift
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. Martin Eiselt, 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).

Short Circuit Station-2

 
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