BUS ASSEMBLY TESTING SWP

1. PURPOSE AND SCOPE

The purpose of this Standard Work Practice (SWP) is to standardise and prescribe the method for testing high voltage bus assemblies. This includes air insulated busbars and enclosed busbars (such as an oil insulated RMU). Additional Training Course Code 4445 4440 4430 4475 4435 Course Description Switching Operator and Authorised Switching Operator Assistant and Authorised Safe Entry to High Voltage Enclosures and Authorised Access &/ Test Permit Recipient Individual of a Work Group

2. STAFFING RESOURCES
EFM competent in the use of test equipment. Safety Observer. Required Training and Certificates Regulatory Training Course Code 2120 2130 2140 2160 3131 Course Description Cardio-Pulmonary Resuscitation Low Voltage/Switchboard Rescue Pole Top Rescue (if required) EWP Rescue and Escape (if required) Pole Testing for Safe Access (if required)

3. DOCUMENTATION
CS000501F115 Daily/Task Risk Management Plan ES000901R102 Health and Safety Risk Control Guide SP0515R01 Bus Assembly Testing Job Safety Analysis SP0515C01 Bus Assembly Test Report SP0515C02 Bus Assembly Testing Competency Assessment SP0515C03 Bus Assembly Inspection and Test Plan SP0515C04 Bus Protection Primary Injection Test Report SP0506 Substation Primary Plant and Secondary Systems Field Testing SWP P53 Operate the Network Enterprise Process AS 1931.1 High-voltage test techniques - General definitions and test requirements. AS 1931.2 High-voltage test techniques - Measuring systems. AS 2650 Common specifications for high-voltage switchgear and controlgear standards.

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Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN11 121 177 802

Standard Work Practice SP0515 Ver 3

BUS ASSEMBLY TESTING SWP

AS 2067 Switchgear assemblies and ancillary equipment for alternating voltages above 1 kV. AS 2467 Maintenance of electrical switchgear. Test Equipment Manual. Switchgear Manual / Manufacturers Drawings. If any risks cannot be managed or reduced to an acceptable level, do not proceed with the task and seek assistance from your Supervisor. 5.2 All work to be done with busbar de-energised All of the tests described in this SWP should be carried out with the bus assembly de-energised and appropriate control measures in place (eg barriers, matting) to prevent inadvertent contact with adjacent live plant or breaching exclusion zones. Furthermore, the P53 Operate the Network Process is applicable at all times for isolation and earthing. Issue a Test Permit and follow the requirements of P53 Operate the Network Process. As described in Substation Primary Plant and Secondary Systems Field Testing SWP SP0506 particular safety risks applicable to bus assemblies include: Contact with high voltage at primary connections. High fault current at primary connections. 5.3 Record identification details Manufacturers name, manufacturers type description and manufacturers serial number. Plant/Asset number. Rated voltage. Rated nominal and short-circuit current and duration. Insulating medium.

4. KEY TOOLS AND EQUIPMENT

Test Equipment within calibration date, tested and tagged insulation resistance meter (10 kV), micro-ohmmeter 50 amp minimum, high voltage test set. Safety Barriers. Switching and Access Operating Equipment PEDs, Live Line Tester, Class 0 gloves. All equipment to be inspected and confirmed within test date prior to use. Additional PPE as required: Leather work gloves, class 00 gloves, hearing protection, safety eyewear. All PPE to be inspected and confirmed within test date (where applicable) prior to use. Sun protection to be used when working outdoors.

5. TASK STEPS
5.1 Carry out an on site risk assessment Prior to performing this activity any hazards associated with prerequisite tasks at the worksite shall be identified and assessed with appropriate control measures implemented and documented in accordance with the Daily / Task Risk Management Plan (CS000501F115) and using the Health and Safety Risk Control Guide (ES000901R102).

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Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN11 121 177 802

Standard Work Practice SP0515 Ver 3

BUS ASSEMBLY TESTING SWP

5.4 Visual inspection of Bus Assembly condition 5.6 Measure Connection Resistance

Inspect the plant for any sign of damage. Confirm that the insulating medium level/pressure is correct before commencing tests and that assembly is complete and no transport bracing has been left in place. Inspect the external surfaces and ensure the plant is clean and dry. 5.5 Measure Insulation Resistance DC insulation tests are to be carried out on the completed bus assembly. The voltage applied will be as per Table 1 for a duration of 1 minute, and is to be applied to each phase in turn with the other two phases earthed. Minimum acceptance value for new plant is 1,000M. Table 1. Applied Voltages for IR Tests: Primary Voltage Rating Up to 1kV Above 1kV to 3.6kV Above 3.6kV to 12kV Above 12kV Test Voltage in kV (D.C.) 1 2 5 10

Measurement shall be made using D.C. current of at least 50A (100A preferred) and less than the nominal current rating of the bus assembly. The test shall be conducted as close as practical to ambient temperature. A four wire micro-ohmmeter should be used for measuring the resistance of each bolted connection. Where a connection has been previously tested at the manufacturers works and has been unaltered during assembly on site, there is no requirement to repeat this test. Typically, the resistance of a bolted joint should be less than 100 micro-ohms. In particular, there should be minimal variation between phases and between like connections. To limit any hazardous voltage rise due to induction, always maintain an operator earth or working earth on one side of the bus during this measurement where there is an adjacent live bus. Caution do not pass measurement current through any current transformer connected to the bus (such as a bus coupler CT). A DC current may cause inadvertent protection operation, and may also leave a residual magnetism in the CT which adversely affects CT performance. 5.7 Measure Busbar Main Earth Connection Resistance Measurement shall be made using a four wire micro-ohmmeter at a D.C. current of at least 50A (100A preferred). The test shall be conducted as close as practical to ambient temperature. The maximum allowable resistance is 0.5 ohms. Where there is a separate earth connection for each bus section, or a separate earth connection associated with frame leakage insulation, each earth connection shall be tested individually.

Where frame leakage insulation is installed, it shall also be subjected to insulation resistance measurement at 1 kV. The minimum acceptance value for new plant is 100M. If it is found that the frame leakage insulation has a low IR value, there may be inadvertent alternate paths to earth that need to be corrected. Such paths may exist via HV cable sheaths, control cable sheaths, VT primary star point, VT or CT secondary earths, data cable connections to protection relays etc.

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Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN11 121 177 802

Standard Work Practice SP0515 Ver 3

BUS ASSEMBLY TESTING SWP

5.8 Carry out HV Testing Um 100%
3.6 kV 7.2 kV 12 kV 24 kV 36 kV 72.5kV 10 kV 20 kV 28 kV 50 kV 70 kV 140 kV

AS 2067 specifies that a 90% power frequency withstand test be carried out on site after erection. The level of high voltage testing to be applied is therefore: a) Where no HV testing has been carried out at the manufacturers works 100%. This may apply to only a portion of the bus assembly, for example poured insulated joints, however because it is impossible to separate the untested portion from the rest of the assembly a 100% test is required for the entire assembly. b) Where HV testing has been carried out at the manufacturers works but subsequent assembly is required on site (for example connecting tested sub assemblies together) 90%. c) Where HV testing has been carried out at the manufacturers works and no on-site assembly of the insulating component is required No HV withstand test. d) If the bus assembly is aged or refurbished 75%. Where Um<=66kV the value of voltage applied shall be as per AS 2650 as listed in the table below. Refer to AS 2650 for voltages Um>66kV. Note that the test voltage used may be limited by the output capability of the test equipment. In this case a reduced test voltage for an extended duration as specified in Table 11.1 of AS 2067 may be used. The 1 minute power frequency withstand test voltage is to be applied to each phase in turn with the other two phases earthed.

Utest 75%
7.5 kV 15 kV 21 kV 37.5 kV 52.5 kV 105 kV

90%
9 kV 18 kV 25.2 kV 45 kV 63 kV 126 kV

The requirements of the test are satisfied if no disruptive discharge occurs. An insulation resistance test is to be repeated after the HV withstand test to confirm that no insulation degradation has occurred. 5.9 Check Expansion Joints Check that sufficient allowance in expansion joints for a 30 degree C temperature rise (typical) has been catered for. Typical coefficients of expansion are: Copper 0.0000173 mm per degree C. Aluminium 0.000023 mm per degree C. For example, an aluminium busbar 16 m long subjected to a 30 degrees C temperature rise above ambient will expand by 16 x 1000 x 0.000023 x 30 = 11 mm. (This equates to an expansion of 0.7 mm per m of busbar for aluminium, and 0.5 mm per m for copper).

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Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN11 121 177 802

Standard Work Practice SP0515 Ver 3

BUS ASSEMBLY TESTING SWP

5.10 Complete Pre-commissioning Checklist A bus assembly being placed in service for the first time or after refurbishment require that the following items are checked, where applicable, prior to energisation: a) Check insulation medium level/pressure. b) Check gas pressure alarm. c) Check earth connections. d) Check operational nameplate and labels are in place. e) Check padlocking/lockout facilities are operational. f) Check that all barriers, cover plates and guards preventing access to high voltage equipment are in place. g) Check phasing is correct.

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Page 5 of 5
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN11 121 177 802

Standard Work Practice SP0515 Ver 3