MV Switchgear Acceptance Test

SWG-MV-01 · Acceptance · NETA ATS-2025 · AI Generated

Main Substation Commissioning (26-001) · J. Smith, NETA Level III

In Progress

Execution Progress57%

Pass: 15 Fail: 1 Pending: 10Est. duration: 6-8 hours

1.1Visual

Conduct safety briefing — review arc-flash analysis per IEEE 1584. Incident energy: 12.4 cal/cm2 (CAT 3). Confirm all personnel have correct arc-rated PPE, face shield, and voltage-rated gloves. Review emergency rescue plan.

Expected: All personnel briefed, correct CAT 3 PPE donned, rescue plan reviewed

1.2Visual

Establish LOTO per OSHA 1910.147. De-energize switchgear from upstream source. Lock out utility breaker BKR-MV-UTIL and generator breaker BKR-MV-GEN. Verify zero energy state on all phases using Salisbury voltage detector rated for 15kV. Apply safety grounds on Bus Section 1 and Bus Section 2.

Expected: All sources locked out, zero energy verified A-G, B-G, C-G on both bus sections, grounds applied

1.3Visual

Verify all test instrument calibration certificates are current. Record serial numbers and calibration due dates for: (1) Megger S1-5010 5kV megger, (2) Megger DLRO-200 micro-ohmmeter, (3) Megger DELTA 4110 power factor test set.

Expected: All 3 instruments within calibration period

2.1Visual

Verify switchgear nameplate data matches specification and single-line diagram. Record: manufacturer, voltage class, BIL, continuous current rating, short-circuit withstand rating.

Expected: ABB UniGear ZS3.2, 15kV, 95kV BIL, 1200A, 25kA/3sec — matches spec

As-Found:Verified — all nameplate data matches Drawing E-001 Rev 3

2.2Visual

Inspect all 6 switchgear sections for shipping damage, proper alignment, and completeness of installation. Check all covers, barriers, and phase barriers are in place.

Expected: No damage, all sections aligned within 3mm, all barriers installed

2.3Visual

Verify all bus bar connections are torqued to manufacturer specification (ABB torque spec: 75 N-m for main bus, 45 N-m for ground bus) using calibrated torque wrench. Apply witness marks after verification.

Expected: All bus connections torqued to spec with Torqueleader TW-100 (S/N TQ-2024-001, cal due 2026-12-01)

2.4Mechanical

Rack each breaker (BKR-1 through BKR-6) through all positions: Connected, Test, Disconnected. Verify racking mechanism operates smoothly and position indicators are correct at each position.

Expected: All 6 breakers rack smoothly, position indicators correct, interlocks function

2.5Mechanical

Verify all shutters operate correctly on each cubicle. With breaker racked out, confirm shutters fully close. With breaker racked in, confirm shutters open to expose primary disconnect stabs.

Expected: Shutters close completely when breaker removed, interlocks prevent manual override

2.6Visual

Verify arc flash labels are installed on each cubicle per NFPA 70E 130.5(H). Confirm: incident energy, working distance, PPE category, shock hazard boundary.

Expected: Arc flash labels present on all 6 cubicles, match study Rev 2 (2024-09-15)

3.1Insulation ResistancePhase A-GTable 100.1

Perform insulation resistance test on Bus Section 1: Phase A to Ground. Apply 5000V DC using Megger S1-5010 for 1 minute. Record 1-minute IR value. Record ambient temperature for correction per IEEE 43.

Expected: IR >= 5,000 MO per NETA Table 100.1 for 15kV class

Tolerance: >= 5,000 MO

As-Found:12,500 MO @ 22C

3.2Insulation ResistancePhase B-GTable 100.1

Perform insulation resistance test on Bus Section 1: Phase B to Ground. Apply 5000V DC for 1 minute.

Expected: IR >= 5,000 MO per NETA Table 100.1 for 15kV class

Tolerance: >= 5,000 MO

As-Found:11,800 MO @ 22C

3.3Insulation ResistancePhase C-GTable 100.1

Perform insulation resistance test on Bus Section 1: Phase C to Ground. Apply 5000V DC for 1 minute.

Expected: IR >= 5,000 MO per NETA Table 100.1 for 15kV class

Tolerance: >= 5,000 MO

As-Found:3,200 MO @ 22C

DEFICIENCY: Phase C IR below NETA minimum. Recommend investigation of Phase C bus insulation. Possible moisture ingress.

3.4Insulation ResistancePhase A-BTable 100.1

Perform insulation resistance test: Phase A to Phase B on Bus Section 1. Apply 5000V DC for 1 minute.

Expected: IR >= 5,000 MO

Tolerance: >= 5,000 MO

As-Found:15,200 MO @ 22C

3.5Contact ResistancePhase A

Perform contact resistance test on BKR-1 primary disconnect contacts using DLRO-200 at 100A DC test current. Measure Phase A.

Expected: Contact resistance per ABB spec: < 150 uO, phase balance within 10%

Tolerance: < 150 uO

As-Found:85 uO

3.6Contact ResistancePhase B

Perform contact resistance test on BKR-1: Phase B.

Expected: Contact resistance < 150 uO

Tolerance: < 150 uO

As-Found:92 uO

3.7Contact ResistancePhase C

Perform contact resistance test on BKR-1: Phase C.

Expected: Contact resistance < 150 uO

Tolerance: < 150 uO

As-Found:88 uO

3.8Power Factor

Perform power factor test on Bus Section 1 insulation using DELTA 4110. Test each phase-to-ground and phase-to-phase. Temperature-correct results to 20C.

Expected: Power factor < 2.0% corrected to 20C for new equipment

Tolerance: < 2.0%