At Technical Engineering Services, we specialize in the installation and testing of Medium Voltage (MV) Panels, which are integral to the safe and efficient operation of electrical distribution systems. Our MV panels are designed to handle voltages typically ranging from 1kV to 36kV, providing essential control and protection for electrical circuits. Below is an in-depth overview of the installation and testing services we offer for MV panels.

1. MV Panel Installation

   • Purpose: To ensure the safe and efficient installation of MV panels for power distribution and control.
   • Benefits: Proper installation ensures that the MV panels function optimally, offering reliable power distribution, protection, and control. Correct installation minimizes the risk of operational failures, ensuring the safety and longevity of the system.
   • Procedure: Our technicians install MV panels in accordance with international standards and manufacturer specifications. This involves careful placement, secure wiring, and the integration of protection devices, such as circuit breakers and fuses, to ensure safety and reliability. We also provide proper grounding and earthing to prevent electrical faults.

2. Visual and Mechanical Inspection

   • Purpose: To perform a detailed visual and mechanical check to ensure the correct assembly and integrity of MV panels.
   • Benefits: Detects potential issues like loose connections, damaged components, or misaligned parts that could affect the performance or safety of the MV panel. Early detection can prevent costly repairs and system downtimes.
   • Procedure: Technicians perform a comprehensive inspection of the physical condition of the MV panel, including checking for proper installation of components, alignment of busbars, and secure attachment of terminals and wiring. Any issues identified are addressed promptly to ensure optimal performance.

3. Insulation Resistance Testing

   • Purpose: To measure the resistance of the insulation in MV panels and ensure they can withstand electrical stresses.
   • Benefits: High insulation resistance ensures that the panel is safe to operate and prevents electrical leakage that could lead to system failure or fire hazards.
   • Procedure: Using an insulation resistance tester, we apply a DC voltage (typically 1000V or higher) across the insulation of the MV panel’s components. The resistance value is then measured and compared to industry standards to confirm that the insulation is intact and healthy.

4. Earth Continuity Testing

   • Purpose: To verify the integrity of the earthing system and ensure proper grounding of the MV panel.
   • Benefits: Proper grounding is essential to protect against electric shock, reduce the risk of fire, and prevent damage to equipment. Earth continuity testing ensures the safety of both the personnel and the electrical system.
   • Procedure: A continuity tester is used to verify that all earthing points in the MV panel are correctly connected to the ground. The test ensures that there are no open circuits or poor connections in the earthing system.

5. VCB Contact Resistance Testing

   • Purpose: To measure the resistance of the vacuum circuit breaker (VCB) contacts and ensure proper operation.
   • Benefits: Low contact resistance ensures that the VCB will perform efficiently, minimizing the risk of overheating or arcing. High contact resistance can cause poor breaker performance and overheating, potentially leading to damage or failure.
   • Procedure: A micro-ohmmeter is used to measure the resistance across the VCB contacts. The readings are compared to manufacturer specifications to ensure they fall within acceptable limits. High resistance values indicate the need for maintenance, cleaning, or replacement of contacts.

6. Circuit Breaker Testing

   • Purpose: To test the functionality of the circuit breakers installed in the MV panel.
   • Benefits: Circuit breakers provide protection against overcurrents and short circuits. Testing their operation ensures they will function correctly during fault conditions, protecting both the system and equipment from damage.
   • Procedure: We perform a series of tests on each circuit breaker, including tripping tests, timing tests, and contact resistance tests, to confirm that the breakers respond appropriately to various fault conditions. The results are compared to manufacturer specifications to ensure compliance.

7. Protective Relay Testing

   • Purpose: To verify the operation and accuracy of protective relays installed in the MV panel.
   • Benefits: Protective relays safeguard the electrical system by detecting faults and initiating corrective actions, such as tripping a circuit breaker. Testing ensures the relays are properly calibrated and responsive to system abnormalities.
   • Procedure: A protective relay tester is used to simulate fault conditions, such as overloads or short circuits. The relay’s response time and accuracy are checked against pre-established settings and manufacturer guidelines.

8. High Voltage (HV) Withstand Testing (Hi-Pot Testing)

   • Purpose: To evaluate the insulation’s ability to withstand high voltage stress without breaking down.
   • Benefits: Hi-pot testing ensures that the MV panel’s insulation can handle over-voltage conditions without failure, minimizing the risk of catastrophic breakdowns due to insulation weakness.
   • Procedure: A high-voltage test device is used to apply a voltage higher than the rated operational voltage to the insulation of the MV panel. The panel is then monitored for any breakdowns or leaks in the insulation. A pass/fail criterion is applied based on the specified duration and voltage level.

9. Functionality and Load Testing

   • Purpose: To confirm that the MV panel performs its intended function under operational conditions.
   • Benefits: This test ensures that the MV panel, including all its components, such as transformers, fuses, and breakers, operates as intended under normal and fault conditions.
   • Procedure: The MV panel is energized, and various load conditions are simulated to check the performance of the control and protection systems. Voltage, current, and power readings are monitored and compared to expected values to assess operational stability.

10. Busbar Temperature Rise Testing

    • Purpose: To measure the temperature rise in the busbars under normal operational conditions.
    • Benefits: Excessive temperature rise in busbars can indicate poor connections, high resistance, or excessive current, which can lead to equipment damage or fires. Testing ensures safe operating conditions and optimizes the longevity of the system.
    • Procedure: Busbar temperature is monitored under normal operational loads. If temperature rises above the safe threshold, further investigation is conducted to identify the cause, such as poor connections or undersized conductors.

11. SCADA System Integration and Testing

    • Purpose: To verify the functionality and integration of SCADA (Supervisory Control and Data Acquisition) systems with the MV panel.
    • Benefits: SCADA systems allow real-time monitoring and control of MV panels, ensuring efficient operation and quick response to faults. This test ensures that communication, data acquisition, and control functions are properly integrated into the system.
    • Procedure: We simulate operational conditions and monitor the data feedback to the SCADA system. Any discrepancies in real-time data or control signals are addressed to ensure seamless integration.

12. Vibration and Mechanical Stress Testing

    • Purpose: To assess the structural integrity of the MV panel under mechanical stress and vibration.
    • Benefits: This test identifies any mechanical weaknesses, such as loose components or potential damage, which could impact the long-term reliability of the system.
    • Procedure: The MV panel is subjected to mechanical stress or vibration conditions, and its response is monitored. Any abnormal movements or sounds are analyzed to detect potential issues in the panel’s construction or mounting.

13. No-Load and Short-Circuit Testing

    • Purpose: To assess the performance of MV panels during both no-load and short-circuit conditions.
    • Benefits: These tests provide valuable insights into the transformer and protection equipment’s ability to handle real-world operational conditions.
    • Procedure: Under controlled conditions, the MV panel is tested under no-load conditions to check for core losses and operational stability. Short-circuit conditions are then simulated to assess the panel’s fault tolerance and the performance of the protection devices.

14. Final Acceptance Testing

    • Purpose: To confirm that the MV panel meets all operational and safety requirements before it is handed over to the client.
    • Benefits: Ensures that all systems and components are functioning as expected, guaranteeing the client receives a fully operational and safe system.
    • Procedure: A final acceptance test is conducted where all systems are thoroughly checked, and test results are reviewed to confirm compliance with safety standards, manufacturer specifications, and client requirements.