EP 99 00 00 02 SP

SYSTEM SUBSTATION
COMMISSIONING TESTS
Version 3.0

Issued May 2010

Owner:

Chief Engineer Electrical

Approved
by:

Wilfred Leung
Chief Engineer
Electrical

Authorised
by:

Wilfred Leung
Chief Engineer
Electrical

Disclaimer
This document was prepared for use on the RailCorp Network only.
RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be
sufficient to ensure safe systems or work or operation. It is the document users sole responsibility to ensure that the
copy of the document it is viewing is the current version of the document as in use by RailCorp.
RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes
any liability which arises in any manner by the use of this document.
Copyright
The information in this document is protected by Copyright and no part of this document may be reproduced,
altered, stored or transmitted by any person without the prior consent of RailCorp.

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Engineering Standard

Engineering Standard
Electrical

RailCorp Engineering Standard Electrical

System Substation Commissioning Tests

EP 99 00 00 02 SP

Document control
Version
3.0

RailCorp
Issued May 2010

Date
November 2001
May 2010

Summary of change
Last Technical Review
Application of TMA 400 format

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Version 3.0

RailCorp Engineering Standard Electrical

System Substation Commissioning Tests

EP 99 00 00 02 SP

Contents
1

Introduction .............................................................................................................................4

Documentation of Test Methods and Results......................................................................4

Tests for Installed Equipment and Sub-systems.................................................................4

3.1
Description of Tests ...................................................................................................4
3.1.1
Connections ...............................................................................................4
3.1.2
Continuity ...................................................................................................4
3.1.3
Control Voltages.........................................................................................4
3.1.4
Earthing ......................................................................................................5
3.1.5
Electrolyte...................................................................................................5
3.1.6
Insulation ....................................................................................................5
3.1.7
Leakage......................................................................................................5
3.1.8
Oil ...............................................................................................................5
3.1.9
Operation....................................................................................................5
3.1.10 Phase Check ..............................................................................................5
3.1.11 Protection ...................................................................................................5
3.2
Equipment and Sub-system Tests.............................................................................5
3.2.1
1500 V Links...............................................................................................5
3.2.2
1500 V Bus Isolating Switches...................................................................5
3.2.3
Air Break Switches, Manual .......................................................................6
3.2.4
Air Break Switches, Motor Operated..........................................................6
3.2.5
Battery ........................................................................................................6
3.2.6
Battery Charger ..........................................................................................6
3.2.7
Bus Bars, Outdoor......................................................................................6
3.2.8
Cables, DC .................................................................................................6
3.2.9
Cables, High Voltage..................................................................................6
3.2.10 Circuit Breakers, AC Feeder & Bus Section...............................................6
3.2.11 Circuit Breakers, AC Rectifier ....................................................................6
3.2.12 Circuit Breakers, DC Feeder Sectioning Hut..............................................6
3.2.13 Circuit Breakers, DC Feeder Substation ....................................................6
3.2.14 Circuit Breakers, DC Rectifier ....................................................................6
3.2.15 Earthing System .........................................................................................6
3.2.16 High Voltage Supplies ................................................................................6
3.2.17 Low Voltage Light & Power Circuits ...........................................................7
3.2.18 Rail-Earth Contactor...................................................................................7
3.2.19 Reactor.......................................................................................................7
3.2.20 Rectifiers ....................................................................................................7
3.2.21 SCADA system...........................................................................................7
3.2.22 Transformers, Auxiliary ..............................................................................7
3.2.23 Transformers, Rectifier & System ..............................................................7
3.2.24 Transformer, Rectifier and AC & DC Circuit Breakers as a
Unit .............................................................................................................7

Insulation Resistance Values ................................................................................................7

Continuity Test Values ...........................................................................................................8

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RailCorp Engineering Standard Electrical

System Substation Commissioning Tests

EP 99 00 00 02 SP

Introduction
This publication sets out the general requirements for the testing and the recording of test
results during the commissioning of a new system substation. The relevant sections of
this publication shall also apply when a new item of equipment is commissioned in an
existing system substation or an existing piece of equipment re-commissioned following
an overhaul.
This publication does not cover the actual testing methods. It requires that the tester
determine the necessary tests and the acceptable results. However some minimum
acceptable values for Insulation Resistance and Continuity tests are provided.
Before a new system substation, or a new item of equipment in an existing system
substation, can be livened up and placed into service, it is necessary to test and/or
check all equipment to ensure that the design and construction process has been
satisfactory.
All items of equipment shall be individually tested to the relevant Australian Standard at
the time of purchase. Where such a standard does not exist, the method of determining
the equipments suitability shall be stated.
Section 3 of this publication specifies the additional tests and/or checks that are
necessary to verify the performance of the installed equipment individually and as part of
various sub-systems (eg rectifier, rectifier transformer and rectifier AC and DC circuit
breakers operation as a whole).

Documentation of Test Methods and Results

The proposed method of carrying out all commissioning tests and the acceptable results
shall be documented for each type of equipment, and submitted to RailCorp for approval.
The test results shall be recorded.
Absolute minimum standards for Insulation Resistance and Continuity tests are stated in
Table 1 of Section 4 and Table 3 of Section 5, respectively.

Tests for Installed Equipment and Sub-systems

3.1

Description of Tests

3.1.1

Connections
All connections shall be checked for correct tightness.

3.1.2

Continuity
Continuity of circuits shall be tested with all switches and circuit breakers in the closed
position. The resistance of the contacts for each pole shall be tested. Continuity of all
transformer windings and tap changers shall be tested.

3.1.3

Control Voltages
Correct operation of equipment shall be tested at the minimum and maximum control
voltages.

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System Substation Commissioning Tests

3.1.4

EP 99 00 00 02 SP

Earthing
Equipment earths shall be tested by measuring the resistance from the equipment earth
to the substation earth mat.

3.1.5

Electrolyte
Batteries shall have electrolyte checked for correct level and density.

3.1.6

Insulation
Equipment insulation levels shall be tested using a suitable insulation resistance meter.
For ac equipment, the insulation shall be tested between phases, and each phase to
earth. For 1500 Vdc the insulation shall be tested between the 1500 V circuit and earth.

3.1.7

Leakage
High voltage and 1500 V cables shall be tested by applying a high dc voltage to each
core for 1 minute and measuring the leakage. Any screens must be earthed. The cables
are insulation tested before and after this test.

3.1.8

Oil
An oil sample shall be taken from all oil-cooled equipment and tested. The oil level shall
also be checked.

3.1.9

Operation
Correct operation of equipment shall be tested in response to all automatic controls,
safety interlocks, protection devices and alarms. Local and remote controls shall be
tested.

3.1.10

Phase Check
All high voltage supplies shall be tested to ensure that they are in phase. All auxiliary
supplies shall be tested to ensure that they are in phase.

3.1.11

Protection
Correct functioning of all protection devices shall be tested in response to all fault
conditions at appropriate magnitudes. Where appropriate, this may be tested by suitable
simulation techniques such as secondary injection.

3.2

Equipment and Sub-system Tests

The following is a list of equipment which must be tested in a typical system substation.
Appropriate tests for equipment not listed shall be determined by analysis and submitted
to RailCorp for approval on an individual basis.

3.2.1

1500 V Links
Insulation, continuity, operation, earthing.

3.2.2

1500 V Bus Isolating Switches

Insulation, continuity, operation, earthing.

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RailCorp Engineering Standard Electrical

System Substation Commissioning Tests

3.2.3

EP 99 00 00 02 SP

Air Break Switches, Manual

Insulation, continuity, operation, earthing.

3.2.4

Air Break Switches, Motor Operated

Insulation, continuity, operation, control voltages, earthing.

3.2.5

Battery
Insulation, voltage, connections, electrolyte.

3.2.6

Battery Charger
Insulation, voltage, connections, operation.

3.2.7

Bus Bars, Outdoor

Insulation, continuity, earthing.

3.2.8

Cables, DC
Insulation, continuity, leakage.

3.2.9

Cables, High Voltage

Insulation, continuity, leakage.

3.2.10

Circuit Breakers, AC Feeder & Bus Section

Insulation, continuity, operation, control voltages, protection, earthing.

3.2.11

Circuit Breakers, AC Rectifier

Insulation, continuity, operation, control voltages, protection, earthing.

3.2.12

Circuit Breakers, DC Feeder Sectioning Hut

Insulation, continuity, operation, control voltages, protection.

3.2.13

Circuit Breakers, DC Feeder Substation

Insulation, continuity, operation, control voltages, protection.

3.2.14

Circuit Breakers, DC Rectifier

Insulation, continuity, operation, control voltages, protection.

3.2.15

Earthing System
Visual inspection, earth resistance.

3.2.16

High Voltage Supplies

Phase check.

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RailCorp Engineering Standard Electrical

System Substation Commissioning Tests

3.2.17

EP 99 00 00 02 SP

Low Voltage Light & Power Circuits

Insulation, continuity, operation, control voltages, protection, earthing.

3.2.18

Rail-Earth Contactor
Continuity, connections, operation.

3.2.19

Reactor
Insulation, continuity, oil.

3.2.20

Rectifiers
Insulation, continuity, earthing, protection.

3.2.21

SCADA system
Operation, control voltages.

3.2.22

Transformers, Auxiliary
Insulation, continuity, operation, voltage, protection, earthing.

3.2.23

Transformers, Rectifier & System

Insulation, continuity, oil, control voltages, protection, earthing.

3.2.24

Transformer, Rectifier and AC & DC Circuit Breakers as a Unit

Operation, control voltages, protection.

Insulation Resistance Values

The minimum acceptable Insulation Resistance values for equipment shall be as shown
in Table 1.
Equipment Voltage

11 kV and above
1500 V incl. 600 V transf.
windings
415/240/120 V wiring & C.T. wiring

Test voltage of
Insulation Resistance
Meter
5 kV
2.5 kV

Minimum acceptable
value in dry
conditions @ 20 C
100 M
20 M*

500 V

10 M

Table 1 - Minimum acceptable Insulation Resistance

*

DC positive feeder cables shall have a minimum acceptable value of 100 M

between the core and screen. A minimum value of 20 M is acceptable between
the earth and screen.

Insulation Resistance is a function of temperature. Values measured at other than 20 C

can be converted to 20 C as follows:

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RailCorp Engineering Standard Electrical

System Substation Commissioning Tests

EP 99 00 00 02 SP

Temperature at which
measurement made
10 C
30 C
40 C
50 C

Multiply measured resistance

value by
0.5
2.0
4.0
8.0

Table 2 - Insulation Resistance temperature conversion

Continuity Test Values

The maximum acceptable resistances of closed contacts shall be as shown in Table 3.
Equipment Voltage
1500 V
11 kV
33 kV and above

Resistance @ 20C
20
30
100

Table 3 - Minimum resistances of closed contacts

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