ECP GROUND-MOUNTED SWITCHGEAR WITH PROTECTION RELAYS COMMISSIONING PROCEDURE
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1 ENGINEERING COMMISSIONING PROCEDURE ECP GROUND-MOUNTED SWITCHGEAR WITH PROTECTION RELAYS COMMISSIONING PROCEDURE Network(s): Summary: EPN, LPN, SPN This procedure details the testing and commissioning procedures for groundmounted switchgear, including ring main units and circuit breakers, with protection relays. Author: John Mason Approver: Paul Williams Date: 26/03/2018 This document forms part of the Company s Integrated Business System and its requirements are mandatory throughout UK Power Networks. Departure from these requirements may only be taken with the written approval of the Director of Asset Management. If you have any queries about this document please contact the author or owner of the current issue. Applicable To UK Power Networks External Asset Management G81 Website Capital Programme UK Power Networks Services Connections Contractors Health & Safety ICPs/IDNOs Legal Meter Operators Network Operations Procurement Strategy & Regulation Technical Training THIS IS AN UNCONTROLLED DOCUMENT, THE READER MUST CONFIRM ITS VALIDITY BEFORE USE
2 Revision Record Version 7.0 Review Date 04/12/2020 Date 26/02/2018 Author John Mason Why has the document been updated: Test form update What has changed: MiCOM P116 & Argus 7SR11 references added to the document. ECP i updated to illustrate customer trip connections. Version 6.0 Review Date 04/12/2020 Date 24/05/2017 Author Ian Marshall Why has the document been updated: To reference FPI function within protection relay when RMU Tee-off is used as part of the interconnected network. What has changed: Section 15.1 has note added mentioning use of test settings for FPI function, and test forms ECP g updated and new test forms ECP h, ECP i and ECP j created. Version 5.0 Review Date 04/12/2020 Date 09/09/2016 Author Ian Marshall Why has the document been updated: Updated in line with the introduction of new switchgear from Schneider and Lucy What has changed: New test form for Lucy VRN6a with Argus 7SR11 added (ECP g) Version 4.0 Review Date 04/12/2020 Date 04/12/2015 Author Stephen Tucker Why has the document been updated: Procedure and test forms updated to incorporate minor revisions following feedback from commissioning training course. What has changed: Test access continuity checks added (Section 10). HV insulation testing document reference updated (Section 9, 11and test forms). FPI test connections updated on form ECP f. Legacy test forms for Vip 200 (ECP b) and Sepam (ECP e) added. Requirement to send copy of the test form to the ART added (Section 22). Version 3.0 Review Date 30/05/2018 Date 09/07/2013 Author Stephen Tucker General revision following field staff feedback. Shunt trip tests added and minor corrections to test forms. Reviewed for G81 website Version 2.0 Review Date Date 23/08/2009 Author Stephen Tucker General revision and minor corrections to test forms Version 1.0 Review Date Date 10/11/2008 Author Stephen Tucker Original UK Power Networks 2018 All rights reserved 2 of 16
3 Contents 1 Introduction Scope References Abbreviations and Definitions Equipment Switchgear Designations Inspection Functional Checks Transformer Winding Insulation Resistance (Transformer-mounted Units Only) Switchgear Continuity Test High Voltage Insulation Test FPI CT Wiring Tests Protection CT Wiring Tests Relay CT Connections Relay Operation - Primary Injection Test Relay Settings Relay Operation Secondary Injection Tests Shunt Trip Coil and Emergency Trip (if fitted) Final Checks Test Equipment Certification Asset Data and Information UK Power Networks Independent Connection Provider (ICP) UK Power Networks 2018 All rights reserved 3 of 16
4 1 Introduction 1.1 This document details the testing and commissioning procedures for groundmounted switchgear, including ring main units and circuit breakers, with protection relays, that shall be satisfied before the unit can be accepted as fit for service and energisation. 1.2 This procedure shall be carried out by the Commissioning Engineer or his appointed representative, who shall be an Authorised Person having appropriate training and/or experience. 1.3 This procedure shall be carried out in accordance with the requirements of the UK Power Networks Distribution Safety Rules. 1.4 This procedure shall be carried out having regard to the requirements and recommendations of the manufacturer. If conflict exists between the requirements of the manufacturer and those of UK Power Networks the matter shall be referred to Asset Management (or your UK Power Networks nominated contact). 1.5 This procedure assumes the following: When the switchgear is attached to a distribution transformer, it is not possible to carry out primary injection tests of the protection CTs. In all other applications full testing shall be carried out. The ring switch cable boxes are not connected. The substation earth conductor is connected to the low voltage/high voltage switchgear earth bar. 1.6 The results of all observations, tests, adjustments and all relevant remarks shall be recorded on the appropriate test form. 1.7 Where possible testing shall be carried without disconnecting or disturbing any wiring. UK Power Networks 2018 All rights reserved 4 of 16
5 2 Scope 2.1 This generic procedure applies to 11kV and 6.6kV ring main units and circuit breakers as detailed below. Schneider (Merlin Gerin) RN2, RN6, RN2c and RN6c non-extensible ring main units with a Schneider (Merlin Gerin) Vip 300/MiCOM P116 relay. Schneider (Merlin Gerin) CE6 extensible circuit-breakers with a Schneider (Merlin Gerin) Vip 300/MiCOM P116 relay. Lucy VRN6a non-extensible ring main units with an Areva MiCOM P124S/Argus 7SR11 relay. 2.2 The associated test forms, which should be read in conjunction with this procedure, include specific schematic diagrams, connections and trip levels for the items of switchgear listed above. 2.3 This procedure is written with reference to a ring main unit but it can also be applied to individual switches and circuit-breakers. 2.4 Switchgear with TLF protection is covered in procedure ECP Air circuit-breakers are covered in procedure ECP The parasitic load trip unit (PLTU) is covered in procedure ECP Distribution transformer is covered in procedure ECP This procedure is intended for use by UK Power Networks field staff, contractors and external connection providers. UK Power Networks 2018 All rights reserved 5 of 16
6 3 References 3.1 This procedure should be read in conjunction with the following references: UK Power Networks Distribution Safety Rules. Installation & Commissioning manual - Commissioning Guidance Notes. ECS HV Insulation Testing. ECP Distribution Transformer. ECP Ground Mounted Switchgear. ECP ACB. ECP PLTU. Schneider Electric Ringmaster Range Installation, Operation & Maintenance Instructions, V5 December 1999 (RN2/RN6). Schneider Electric Ringmaster Range Installation, Operation & Maintenance Instructions, V10 July 2005 (RN2c/RN6c/RE2c). Schneider Electric Vip 300 Protection Relay Operation, Testing and Commissioning, V3 April Lucy Sabre VRN6a Installation, Operation & Maintenance Manual, Issue 3, November MiCOM P124S Technical Guide, P124/EN T01/A44. MiCOM P116 Technical Guide, P116/EN M/A11. Siemens Argus 7SR11 and 7SR12 Technical Manual. Schematic diagrams - see the relevant test form. 3.2 This procedure should be used with the following test forms: ECP b Schneider Vip 200. ECP c Schneider RN2, RN6, RN2c & RN6c with Vip 300. ECP d Schneider CE6 with Vip 300. ECP e Schneider CE6 with SEPAM ECP f Lucy VRN6A with MiCOM P124S. ECP g Lucy VRN6A with Argus 7SR11. ECP h Lucy VCE6A with Argus 7SR11. ECP i Schneider RN6c with MiCOM P116 Relay Test Form. ECP j Schneider CE6 with MiCOM P116 Relay Test Form. 4 Abbreviations and Definitions 4.1 The following abbreviations are used throughout this procedure. Term ART CT FPI RTU VT Definition UK Power Networks Asset Registration Team Current Transformer Fault Passage Indicator Remote Terminal Unit Voltage Transformer UK Power Networks 2018 All rights reserved 6 of 16
7 5 Equipment 5.1 The following equipment is required to carry out the tests detailed in this procedure: 1kV insulation resistance tester (e.g. Megger). 5kV insulation resistance tester (e.g. Megger). Multimeter (or other continuity checker). Note: Fused leads should not be used for measuring resistance as false readings can be obtained. Ductor tester. Injection test set (suitable for primary/secondary injection). 100A shorting-link or cable. RTU simulator. MiCOM P124S battery box (VRN6a only) (material code 13945R). 6 Switchgear Designations 6.1 The diagram below shows the switch/circuit-breaker and terminal designations referred to throughout this document. Circuit-breaker/ Tee-off (CB) L1 L2 L3 Ring Switch 1 (RSW1) L1 L2 L3 Ring Main Unit L1 L2 L3 Ring Switch 2 (RSW2) 7 Inspection 7.1 Record the substation, switchboard number, if applicable, transformer and current transformer (CT) details on the test form. 7.2 Carry out a visual inspection of the switchgear as detailed below. If possible the Commissioning Engineer shall rectify any non-conformances. However, all equipment defects shall be referred to Asset Management. Check that the switchgear is undamaged and is correctly mounted and secured to the plinth and to the transformer flange (if applicable). Check that the earth terminal(s) of the switchgear are securely connected directly to the substation earth electrodes. Check that all external surface finishes are undamaged. UK Power Networks 2018 All rights reserved 7 of 16
8 8 Functional Checks 8.1 Carry out the checks detailed below and record the results on the test form. In the event of non-conformance with the functional expectation the result shall be recorded on the test form and the equipment shall not be accepted into service. Check the opening and closing of door including the supporting struts if fitted. Check that the pointer of the SF 6 gas pressure indicator is in the healthy sector tap the site glass to overcome any stiction. 8.2 Check for correct operation of the circuit-breaker, ring switches, earth switches, test access covers and associated interlocks/switch position indicators are in accordance with the manufacturer's instructions. Open and close switches. Earth switches cannot be operated when service selected. Switch/circuit-breaker cannot be operated when earth selected. Open and close earth switches. Test access cannot be opened when switch/circuit-breaker in On and Off position. Test access can be opened when earth switch closed. Switch/circuit-breaker cannot be operated when test access open. 8.3 Carry out a functional check of each motorised actuator using an RTU simulator. UK Power Networks 2018 All rights reserved 8 of 16
9 9 Transformer Winding Insulation Resistance (Transformer-mounted Units Only) 9.1 Carry out the transformer wining insulation test as detailed below using the test voltages from ECS and record the results on the test form. 9.2 Measure HV winding insulation resistance as follows: Connect the LV windings together and to earth via the neutral link and substation earth. Connect an insulation resistance tester between the transformer HV winding and earth. The test may be carried out from terminals L1 or L2 or L3 on either ring switch with ring switch closed and the circuit-breaker closed. The insulation resistance should be greater than 100M. Note: For transformer-mounted units test from terminals L1 or L2 or L3 on ring switch 1 with ring switch 1 closed, ring switch 2 open and the circuit-breaker closed. 9.3 Measure LV winding insulation resistance as follows: If the transformer has a transformer-mounted LV fuse-cabinet it will be necessary to temporarily remove the neutral-earth link. Connect the HV windings together and to earth via the substation earth via the circuit-breaker earthing switch. Connect an insulation resistance tester between the transformer LV windings and earth. The test may be carried out from terminals L1 or L2 or L3. The insulation resistance should be greater than 100M. Replace the neutral-earth link if removed above. Note: For transformer-mounted units earth the HV winding via the circuit-breaker earthing switch and test with ring switch 1 open, ring switch 2 open and the circuitbreaker open. 9.4 The tests free-standing transformers these tests are covered by the transformer commissioning procedure (ECP ). UK Power Networks 2018 All rights reserved 9 of 16
10 10 Switchgear Continuity Test 10.1 Carry out a switchgear continuity test using a multi-meter or a Ductor tester (for extensible switchgear with site assembled busbars) as detailed below and record the results on the test form. Note: Ensure the cable box connection studs are tight otherwise high resistance readings may be encountered On transformer-mounted units as follows: Close both ring switches and open the circuit-breaker. Measure the continuity between each phase on ring switch 1 to each on phase ring switch 2. Close ring switch 1, open ring switch 2 and close the circuit-breaker. Measure the continuity between L1 to L2 and L2 to L3 on ring switch On free-standing units as follows: Close both ring switches and close the circuit-breaker. Measure the continuity between each phase on ring switch 1 to each phase on ring switch 2 and each phase on the circuit-breaker Close ring switch 1 to earth and open ring switch 2. Measure the continuity from phase L1, L2 and L3 on ring switch 1 to earth Close ring switch 2 to earth and open ring switch 1. Measure the continuity from phase L1, L2 and L3 on ring switch 2 to earth. 11 High Voltage Insulation Test 11.1 Carry out high voltage insulation test as detailed below using the test voltages from ECS and record the results on the test form Close both ring switches and open the circuit-breaker for transformer-mounted units (close the circuit-breaker for free-standing units). Measure the insulation between each phase and earth with the other two phases earthed Open ring switch 1, close ring switch 2 and open the circuit-breaker for transformermounted units (close the circuit-breaker for free-standing units). Measure the insulation between L1, L2, L3 on ring switch 1 and earth with L1, L2, L3 on ring switch 2 earthed (L1, L2, L3 on the circuit-breaker should also be earthed for free-standing units) Close ring switch 1, open ring switch 2 and open the circuit-breaker. Measure the insulation between L1, L2, L3 on ring switch 1 and earth with L1, L2, L3 on ring switch 2 earthed (L1, L2, L3 on the circuit-breaker should also be earthed for free-standing units). UK Power Networks 2018 All rights reserved 10 of 16
11 12 FPI CT Wiring Tests 12.1 Carry out the FPI wiring tests as detailed below and record the results on the test form Disconnect the RTU/FPI if fitted. Note: This will ensure the RTU/FPI is not damaged during insulation testing and will ensure that the RTU/FPI wiring is eliminated when measuring CT loop continuity Measure the CT insulation resistance as follows: If applicable 1 remove the CT shorting-link. Temporarily disconnect the CT wiring, earth link or CT star point as detailed on the relevant test form. Measure the insulation resistance to earth of the CTs using a 1kV insulation resistance tester. The insulation resistance should be greater than 100M. Reconnect any wiring or links removed above on completion of the test Measure the CT loop continuity as follows: If applicable 1 remove the CT shorting-link. At the CT wiring terminal block identify the terminals for L1 CT and measure the resistance of the CT. The resistance should be in the region of 1-2. Repeat for L2 and L3 CT circuits Repeat for all switches with FPI CTs Reconnect FPI wiring if applicable. 13 Protection CT Wiring Tests 13.1 Measure the CT circuit insulation resistance as follows (Note: Electronic relays must not be subjected to insulation testing): Disconnect the CT phase inputs. Remove the CT wiring earth link. Measure the insulation resistance to earth of the CTs using a 1kV insulation resistance tester. The insulation resistance should be greater than 100M. Replace the CT wiring earth link on completion of the test Measure the CT loop continuity as follows: Measure the continuity of the L1 CT and the CT wiring from the CT wiring terminal block. The resistance should be in the region of depending on the components in the circuit being measured. Repeat for L2 and L3 CT circuits. Reconnect the CTs to the relay. 1 Some modern switchgear (e.g. Lucy VRN2a/VRN6a) uses an electronic shorting-block in place of a physical link that automatically shorts the CTs when the output wiring is disconnected. UK Power Networks 2018 All rights reserved 11 of 16
12 14 Relay CT Connections 14.1 Depending on the type of relay fitted it may be necessary to select the appropriate CT ratio or change the relay CT connections to obtain the required current setting - see the specific relay test form for further details 14.2 Measure the earth resistance between the relay case and the switchgear earth. 15 Relay Operation - Primary Injection Test 15.1 Apply the overcurrent and earth fault test settings as specified on the test form to the relay. Note: for the FPI function setting install the test protection settings detailed within the associated test forms Once the test settings are installed, follow the procedure below Carry out the overcurrent pickup test as follows: Close ring switch 1, open ring switch 2 and close the circuit-breaker. Connect a shorting-link across L1, L2 and L3 on the circuit-breaker. Connect the injection test set between L1 and L2 on ring switch 1. Slowly increase the primary injection current from zero until the relay picks up. Record the value of current at which the relay picks up. Reset the relay and, if necessary, close the circuit breaker. Repeat the test with the test set connected between L2 and L3 on ring switch 1. Remove the shorting-link from the circuit-breaker Carry out the earth fault pickup test as follows: Close ring switch 1, open ring switch 2 and close the circuit-breaker. Connect the injection test set between L1 on ring switch 1 and L1 on the circuitbreaker. Slowly increase the primary injection current from zero until the relay picks up. Record the value of current at which the relay picks up. Reset the relay and, if necessary, close the circuit breaker. Repeat the test for L2 and L3. UK Power Networks 2018 All rights reserved 12 of 16
13 16 Relay Settings 16.1 Apply the in-service protection settings as specified by the planner/designer to the relay and record them on the test form Calculate the injection currents and operating times for 1.2, 2 and 5 times for both the overcurrent and earth fault settings. Also calculate the injection currents and operating times for instantaneous overcurrent and SEF settings if specified. 17 Relay Operation Secondary Injection Tests 17.1 Carry out the overcurrent test at 2x and 5x setting as follows: Close the circuit-breaker. Connect the injection test set across L1/L2 phase CTs. Connect the timing circuit across a pair of auxiliary contacts for the circuit breaker open position. Apply the appropriate 2x setting secondary injection current calculated above and measure the trip time. Connect the injection test set across L2/L3 phase CTs, reset the relay and close the circuit breaker. Apply the appropriate 2x setting secondary injection current calculated above and measure the trip time. Connect the injection test set across L3/L1 phase CTs, reset the relay and close the circuit breaker. Apply the appropriate 2x setting secondary injection current calculated above and measure the trip time. Repeat the test using 5x setting secondary injection current If instantaneous overcurrent settings are being used carry out the following tests: Reset the relay and close the circuit-breaker. Connect the injection test set across L1/L2 phase CT. Connect the timing circuit across a pair of auxiliary contacts for the circuit breaker open position. Apply the instantaneous overcurrent setting secondary injection current calculated above and measure the trip time. Reset the relay and close the circuit breaker. Repeat the test for L2/L3 and L3/L1 phase CTs. UK Power Networks 2018 All rights reserved 13 of 16
14 17.3 Carry out the earth fault test at 2x and 5x setting as follows: Reset the relay and close the circuit-breaker. Connect the injection test set between L1 phase CT and earth. Connect the timing circuit across a pair of auxiliary contacts for the circuit breaker open position. Apply the appropriate 2x setting secondary injection current calculated above and measure the trip time. Connect the injection test set between L2 phase CT/earth, reset the relay and close the circuit breaker. Apply the appropriate 2x setting secondary injection current calculated above and measure the trip time. Connect the injection test set between L3 phase CT/earth, reset the relay and close the circuit breaker. Apply the appropriate 2x setting secondary injection current calculated above and measure the trip time. Repeat the test using 5x setting secondary injection current If instantaneous earth fault settings are being used carry out the following tests: Reset the relay and close the circuit-breaker. Connect the injection test set between L1 phase CT and earth. Connect the timing circuit across a pair of auxiliary contacts for the circuit breaker open position. Apply the instantaneous earth fault setting secondary injection current calculated above and measure the trip time. Reset the relay and close the circuit breaker. Repeat the test for L2 phase CT/earth and L3 phase CT/earth If SEF settings are being used carry out the following tests: Reset the relay and close the circuit-breaker. Connect the injection test set between L1 phase CT and earth. Connect the timing circuit across a pair of auxiliary contacts for the circuit breaker open position. Apply the SEF earth fault setting secondary injection current calculated above and measure the trip time. Reset the relay and close the circuit breaker. Repeat the test for L2 phase CT/earth and L3 phase CT/earth. UK Power Networks 2018 All rights reserved 14 of 16
15 18 Shunt Trip Coil and Emergency Trip (if fitted) 18.1 Check that the correct voltage has been selected on the shunt trip coil Locate the shunt trip coil terminals Using an appropriate test set apply either 70% (dc) or 85% (ac) of the rated voltage to the shunt trip coil and the circuit-breaker should trip Close the circuit-breaker Using an appropriate test set apply 100% of the rated voltage to the shunt trip coil and the circuit-breaker should trip Check that the emergency trip button correctly trips the circuit-breaker. 19 Final Checks 19.1 On completion of the commissioning tests check the following: Check correct CT and interposing CT ratios selected. Check correct ratio labels have been fitted. Check correct protection settings applied. Check FPI CT shorting-link(s) 2 are replaced if CTs are not used or not connected to FPI or RTU. Reconnect umbilical cable to RTU (if fitted). 20 Test Equipment 20.1 Record the make, type, serial or asset number and calibration date of all test equipment used during commissioning on the test form. 21 Certification 21.1 When all the tests have been satisfactorily completed, sign and date the test form. The test form should be left on-site in a plastic wallet and in a secure location. 22 Asset Data and Information 22.1 UK Power Networks Send a copy of the completed test form and the asset data form to the Asset Registration Team (ART) via the appropriate mailbox below. ART.EPN@ukpowernetworks.co.uk. ART.LPN@ukpowernetworks.co.uk. ART.SPN@ukpowernetworks.co.uk. 2 Some modern switchgear (e.g. Lucy VRN2a/VRN6a) uses an electronic shorting-block in place of a physical link that automatically shorts the CTs when the output wiring is disconnected. UK Power Networks 2018 All rights reserved 15 of 16
16 22.2 Independent Connection Provider (ICP) Send a copy of the completed test form and the asset data form to the Competitionin-Connections Delivery Project Manager. UK Power Networks 2018 All rights reserved 16 of 16
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