hi-pot testing effective tbd - gwen holladay -...

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Subject: Hi-Pot Testing

Revision Number and Date: R-0;—TBD Procedure No.: LUM-FFA-MNT-0025

Use: In-Hand

Effective Date: TBD

Prepared by: Jerry Wayne Date: TBD

Reviewed by: ___________________________________________________ Date: ____________________

Approved by: ___________________________________________________ Date: ____________________

Required review frequency: TBD

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Table of Contents1. Purpose and Scope........................................................................................................................................ 42. Acceptance Criteria...................................................................................................................................... 43. Special Tools and Materials....................................................................................................................... 4

3.1 Special Tools.............................................................................................................................................................43.2 Materials..................................................................................................................................................................... 4

4. Precautions, Limitations, and Notes.......................................................................................................44.1 Precautions................................................................................................................................................................54.2 Limitations.................................................................................................................................................................54.3 Notes.............................................................................................................................................................................5

5. Prerequisites.................................................................................................................................................. 55.1 Planner........................................................................................................................................................................ 65.2 Electricians................................................................................................................................................................ 6

6. Definitions and Acronyms.......................................................................................................................... 77. Instructions..................................................................................................................................................... 7

7.1 Prepare for Test.......................................................................................................................................................77.2 Hi-Pot Testing...........................................................................................................................................................87.3 Post Test Activities..............................................................................................................................................11

8. References..................................................................................................................................................... 128.1 Development References..................................................................................................................................128.2 Performance References...................................................................................................................................12

9. Attachments.................................................................................................................................................. 12

Attachment A: Signoff/Data Sheet...................................................................................................................................13Attachment B: Verification Sheet.....................................................................................................................................14

List of FiguresFigure 1 Hi-Pot Test Set Connections................................................................................................................................9

List of TablesTable 1 Signature Box...............................................................................................................................................................6

Table 2 Maximum Test Voltage............................................................................................................................................8

Table 3 Torque Value Chart.................................................................................................................................................11

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ReviewsWriter completes this section and deletes from final version after approval. Review comments are stored in <type location where comments are stored.>.

< In the Name column, list the names of reviewers you plan to review your document.>

Internal ReviewName Position Date<type name of program owner>

<type title, organization> <m/d/yy>

Gwen Holladay Technical Writer, DCD 2/18/11

Stakeholder ReviewName Position Date<type name of organization manager>

<type title, organization> <m/d/yy>

<type name of reviewer> <type title, organization> <x/x/xx>

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1. Purpose and ScopeThe purpose of this procedure is to provide instructions to ensure DC Hi-Pot testing of power cables and busses buses is performed in a safely and competently manner.

2. Acceptance CriteriaThe following acceptance criteria must be met to complete the procedure.

Power cables or busses buses under test shall exhibit no breakdown of insulation resistance during the five five-minute test period at Maximum Test Voltage, as indicated by a sharply rising value of leakage current.

3. Special Tools and MaterialsUse the following special tools and materials to perform this procedure.

3.1 Special ToolsThe following special tools are required:

DC Hi-Pot Test Set Voltmeter, Simpson 260, Fluke 8020, or equivalent DMM Torque wrench (expected values 3.5 to 60 foot pounds, as applicable)

3.2 MaterialsThe following materials are required:

Class II Rrubber insulated gloves (high high-voltage) with leather protectors Hot stick Rubber mat or (7.5KV PVC Insulating Roll, (#20307, Mfgr: Certified Insulated Products) Grounds (4/0 or larger)

Gwen Holladay, 02/17/11,

Direct current? I put this on the abbrev. list.


Other docs "600V or greater." Should we specify voltage here?


Should this be more specific?


"being tested"?


In other docs, you used "consistently."

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4. Precautions, Limitations, and NotesBefore performing the procedure, ensure you understand the following precautions, limitations, and notes.

4.1 Precautions The following precautions shall be followed:

The output of this test set can be lethal. Observe Pproper electrical precautions should be observed to prevent personnel injuries or component damage when working on energized equipment.

Improper grounding may present a shock hazard to operator or cause damage to test equipment.

Wear the required Personal Protective Equipment, and Electrical Protective Equipment. Warn and keep other personnel away from equipment during Hi-Pot testing. Establish boundaries/ and barricades around the equipment being tested, and on remote

end if necessary. The surface of the high high-voltage module must be treated as part of the energized circuit

during tests. Keep HV terminal of specimen and test set's HV output cable grounded at all times except

when actually performing tests. Ground test specimen to discharge accumulated charge for a minimum of four times charge

time. Grounding is for safety of personnel, as well as for test accuracy. Discharge test specimen with a safety ground ("hot stick") to ground all live parts, then

solidly ground these parts with a ground bond. Specimen under test may retain a lethal electrical charge even when test set is turned off.

4.2 Limitations

None

4.3 NotesThe following information may be used while performing the procedure, but is not required:

Do not connect test set to energized equipment. Do not perform insulation test in a flammable or explosive atmosphere. Users of high voltage equipment should note that hHigh -voltage discharges and other

sources of strong electric or magnetic fields may interfere with the proper operation of


I have a hard time reading this. Would it make sense to say "Keep specimen's terminal and test set's output cable grounded…" ("HV" seems redundant)?


Suggest "may cause injury or death."

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heart pacemakers. Personnel havingIf you have a heart pacemaker, s should obtain expert advice on possible risks before using this equipment or being close to the equipment while it is in operationoperating.

Report Ddiscrepancies or unsatisfactory results should be reported to your supervisor for follow-up actions.

5. PrerequisitesThe following prerequisites must be met before performing this procedure.

5.1 PlannerThe planner must enter the following information:

Work Order No.: __________________________________ Component Tag No.: ______________________________ Unit No.: ____________________________________________ Serial No.: __________________________________________

Specify applicable drawings to be included in Work Order package. Identify on Attachment A: Signoff/Data Sheet Signoff/Data Sheet each cable or buss to be

tested with its line-to-line voltage. Record maximum test voltage on Attachment A: Signoff/Data SheetSignoff/Data Sheet.

[Note] Test voltages are based on equipment manufacturer's recommendations, or on the following equation: Maximum Test Voltage = 2.55 x (Rated Line-to-line Voltage).

5.2 ElectriciansPersonnel performing this procedure shall review all instructions, precautions, notes, and safety requirements prior to performing this procedure.

Ensure component has been megger tested prior to Hi-Pot testing.

Each person performing work using this procedure is required to record their name, signature, and initials in the following signature box. If a worker does not have a RACF ID is unavailable, then include ID their contact phone numberinformation of the individual.


Should we reference that procedure(s)?

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Print Name Sign Name Initials RACF ID

Table 1 Signature Box

6. Definitions and AcronymsThe following definitions and acronyms appear throughout this procedure. The first occurrence of each term and acronym appears in italics.

DC - direct current? (from Sect. 1)

DMM (from Sect. 3.1)

High Potential—Hi-Pot

KV - (from 7.2.4)

Live-Dead-Live—L-D-L

LockOut TagOut/Verify—LOTOV

7. InstructionsThe procedures below contain instructions for the following tasks:

Prepare for Test Hi-Pot Testing

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Post Test Activities

7.1 Prepare for Test

1. Check LOTOV to ensure equipment to be tested has been electrically isolated and properly tagged. Use L-D-L method.

2. Ensure equipment to be tested has been de-energized by electrical measurements.

[Caution] Work group should walk down both ends of any affected cables to be sure they are connected or isolated at their source to prevent any arcing. Barriers are to be established at both ends, with warnings to all personnel in immediate area before testing is to be performed.

3. Erect barriers or flagging and warn all area personnel of impending Hi-Pot testing.

4. Discharge equipment or circuit to be tested using a grounding jumper.

[5.] Disconnect leads or remove fuses as required to electrically isolate other components which are not to be tested. Verify, then, initial and date on Attachment B: Verification SheetVerification Sheet.

[6.] Document completion of Section 7.1 on Attachment A: Signoff/Data SheetSignoff/Data Sheet.


Same as next instruction.


Does this need italics?



An electrician term??

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7.2 Hi-Pot Testing

1. Test Hi-Pot equipment integrity by open circuit testing to a voltage equal to maximum test voltage to be used.

Line to Line Volts Max Test Voltage480 1224

2500 6375

4160 10 600

6900 17 600

13 800 35 200

Table 2 Maximum Test Voltage

2. Use Table 2 Maximum Test Voltage to choose the maximum test voltage based on the cable or bus, line-to-line voltage. Write this voltage on the Data Sheet on the same line as the cable test info.

[3.] Connect Hi-Pot Test Set to cable or bus to be tested. Refer to Figure 1 Hi-Pot Test Set ConnectionsFigure 1 Hi-Pot Test Set connections. Hook up ground lead first.


This looks like an overview statement rather than an instruction step.

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Figure 1 Hi-Pot Test Set Connections

[Note] If high high-voltage termination of test setup contains sharp points or corners or is in close proximity to grounded objects, adjacent air may be ionized by electrical stress when energizing test specimen. This can cause excessive leakage current, and since such current can be significant it may tend to mask the true sample current. To minimize this effect,


Is there a way to take the title off the top of the figure? It's repetitive to have it there and as the caption.

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exposed high high-voltage termination should be spaced as far as possible from grounded objects.

Note In the event of a specimen breakdown or an excessive leakage current, either the main breaker or line relay will trip out. The voltage control must be returned to "O," the reset position before high voltage can be applied again.

3.[4.] Increase test voltage at a rate of less than one KV per second to required maximum test voltage as chosen earlier.

Note Leakage current may rise slightly as voltage is increased then level off until voltage is increased again.

[Note] If excessive leakage current is observed, it may be due to a high corona high voltage termination. An effective method of preventing excessive leakage current is to wrap exposed high high-voltage termination with a thin plastic film or plastic bag.

[5.] Maintain maximum test voltage for at least five minutes, then record leakage current for cable or bus tested. A satisfactory result has is no sudden rise in leakage current.

4.[6.] Decrease test voltage to zero.

5.[7.] Ground the cable or bus tested with a grounding jumper for at least 20 minutes.

[8.] Disconnect the Hi-Pot test leads. (HV lead first, ground lead last).

6.[9.] Remove the grounding jumper which was installed in Step 7.2.7.

7.[10.] Repeat steps 7.2.5 through 7.2.9 for each cable or bus to be tested.

[11.] Initial and Date date on Attachment A: Signoff/Data SheetSignoff/Data Sheet for completion of Section 7.2.


When and why would you ground longer?


Should this be on the supply list?


"high-corona, high-voltage termination" ?


What is "excessive"? (also in second note below)

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7.3 Post Test Activities

1. Ensure any temporary grounds installed for testing have been removed.

[2.] Connect leads or install fuses which were removed in Step 7.1.5. Verify and record on Attachment B: Verification SheetVerification Sheet.

[3.] Torque electrical connections in accordance with Table 3 Torque Value Chart or as specified on Work Order. Record value used on Attachment A: Signoff/Data SheetSignoff/Data Sheet.

Bolt Material Torque in Foot / Pounds for Bolt Size 1/4 - 20 5/16 - 18 3/8 - 16 1/2 - 13 5/8 - 11

Silicone Bronze 5 10 15 40 55

Stainless Steel 3.5 7 13 30 60

Aluminum _ _ _ 25 40

All Other Materials 3.5 7 13 25 40

Torque tolerance is plus or minus 10%. Connections using hardware smaller than 1/4 inch shall be term tight. Westinghouse AR relay contact cartridge terminal screws shall be tightened to 9.5 inch-

pounds (8.0 – 11.0). Terminations made by compressing a wire /or cable strand with a bolt /or screw shall be

term tight. Internal wiring connections at terminal blocks and studs shall be term tight when not

otherwise specified on devices. Field cable connections made to terminal blocks, studs, or mechanical lugs shall be term

tight. Use the specific torque value on a device if given. If torque values are not given in Work Order use torque values listed in this table. Term Tight—Mating surfaces of terminations in full contact with each other with no

visible gap or space, and the wire or lug does not move with a slight pressure applied.

Table 3 Torque Value Chart


Definition given in Sect. 6


Suggest: "Use the torque values listed in this table unless the torque value for a specific device is giventhe torque value is given in the Work Order"and putting this note first.

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[4.] Remove Ssafety barriers and flagging. Inform area personnel of completion of Hi-Pot testing is complete.

[5.] Initial and Ddate on Attachment A: Signoff/Data SheetSignoff/Data Sheet for completion of Section 7.3.

8. ReferencesDevelopment references are documents used to develop the procedure. Performance references are documents referenced within the procedure.

8.1 Development References[1] MSE-G0-1209 Hi-Pot Testing (from Comanche Peak NPP)[2] STA-124 Electrical Safe Work Practices (from Comanche Peak NPP)

8.2 Performance References[1] Generation Safety Handbook[2] LUM-FFA-REL-0014 Standard of Human Performance Improvement

9. Attachments The following attachments are appended to this procedure.

Attachment A: Signoff/Data Sheet

Attachment B: Verification Sheet

LUM-FFA-MNT-0025, Hi-Pot Testing, R-0 of 17

Attachment A: Signoff/Data SheetWork Order No. ___________________________

Cable / Buss ID

Line to Line Volts

Max Test Volts

Leakage Current

Results Good Y / N

Component Torqued

Torque Value Used M&TE Cal Due Date

Comments: ________________________________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Acceptance Criterion: Test results have no sudden rise in leakage current.

Initial and date for completion of Section 7.2. _________/_________________________

Initial and date for completion of Section 7.3. _________/_________________________


Use same criteria as in Sect. 2 Acceptance Criteria.

LUM-FFA-MNT-0025, Hi-Pot Testing, R-0 of 17

Attachment B: Verification SheetUse this sheet to maintain plant configuration “as found” and “as left.”.

Equipment / Module /Device

Term / Wire Unique ID

Term / Wire Unique ID

Action Code

Test Performer Date Verifier Date

Action Codes:

DL = Determ Lead IJ = Install Jumper RO = Remove Device RO = Remove Old RC = Remove Card RL = Reland Lead RJ = Remove Jumper ID = Install Device IN = Install New IC = Install Card O = Other (explain)

OB = Open Breaker OV = Open Valve OS = Open Switch RF = Remove Fuse IT = Install Tubing CB = Close Breaker CV = Close Valve CS = Close Switch IF = Install Fuse RT = Remove Tubing

Comments: ________________________________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


or "Tester"

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Revision Number and Date: R-0,—TBD Procedure No.: LUM-FFA-MNT-0025

Use: In-Hand

Revision HistoryRevision Number Approval Date Name ChangesR-0 TBD Jerry Wayne Initial Release

hi-pot testing effective tbd - gwen holladay -...

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