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Laboratory experience in the testing of energy meters

By
Smart Energy International
-
Aug 27, 2009

By Ashok Kumar, Joint Director, Electronics Regional Test Laboratory (North) STQC
Directorate, Department of IT, New Delhi

Metering management in power ensures the effectiveness of power monitoring, controlling,

recording and data analysis resulting in optimum energy utilisation. Earlier when the energy cost
was low and power quality requirements were less stringent, the performance consideration of
instruments was secondary to the purchase price of instruments. The increase in the cost of
energy and requirement for enhanced quality of power has led to sharpen the difference between
commercial (less accurate) and expensive (accurate) instruments. To meet this challenge energy
meters have been developed with the state of the art technology which are capable of measuring
and registering data of loadings, reactive and apparent power, earth current, power quality
including the harmonic contents, warning and alarms in real time with the non-volatile memory.
These meters are compatible with the commercial GSM networks and with the latest information
systems used in power networks.

The Energy Meter being a critical item in Power Systems, its correct functioning is essential for
reliable operation of the System. The energy meters inside the sub-stations with state of the art
technology are used to acquire data of loading, reactive and apparent power, earth current, and
power quality including the harmonics. An utilities information centre uses this information to
take the action in the most efficient and cost effective manner.

The limited availability of electrical energy has focused a great deal of attention on power
generation, its application, monitoring and control. Power economics play an important role
inside the sub-station with the high cost of power generation, transmission and distribution. It is
of paramount concern to effectively register, monitor and control the use of energy. The
measuring and monitoring of electrical power has also become more complex.

Safety of personnel and property is the most important factor in the operation of electrical system.
The reliability of any electrical system depends upon design, preventive maintenance and also on
the equipment used to monitor the system. It is therefore, essential to test the power monitoring
equipment. Testing includes verification of the design, material and components. Ideally a perfect
design with error free assembly, proven material and 100% component quality would eliminate
testing altogether. Rapid changes in technology, design complexity for quality improvement
advanced manufacturing techniques and process improvements, cost control to maintain
competitiveness and customer satisfaction affects the quality of product and makes the testing
essential.
TESTING OF ENERGY METER
Electronics Regional Test Laboratory (North) is an independent accredited Government
laboratory under the Department of Information Technology providing services for testing of
Energy Meters according to National (IS) and International (IEC) specifications to Indian and
International manufacturers and utilities. We also provide services to other agencies like users,
regulatory and certification bodies etc.

Testing may be based upon structural, functional/ parametric requirements and application of the
equipment to ensure overall product performance and meet the requirements of specification.
Prior to testing it is necessary to understand and interpret the specifications as well as functional,
physical description, performance, modes of operations, description of methods of connections,
position and associated accessories to function EUT. It is also equally important to select the test
equipment for the relevant tests.

Classification of testing Broadly testing may be classified as:

 Developmental/Prototype testing
 Type testing
 Acceptance testing
 Routine testing
 Certification testing
 Third Party testing
 In-service check/On site testing
Specifications generally used for the testing of energy meters

Development testing is generally used as a part of investigations into the capabilities of

prototypes. The testing should be started from least severe tests so that maximum possible
information can be obtained before the test specimen is damaged.

Specification based type approval testing is carried out as per the test sequence so as to give the
most significant effect and reveal the failures which may not come out if not tested sequentially.
After completion of testing, a test certificate containing the following information is issued:

 Any modifications or limitations applied to test requirements.

 Details of test equipments used for testing and their calibration status
 Test methods/procedures followed
 Uncertainty of test parameter
 Observations
 Conformity to Specification statement and
 Opinion if required.
In India the National Accreditation Board for Test and Calibration laboratories is the authority to
accredit the laboratories. This accreditation confirms that the laboratory meets the requirement of
International Specification ISO/IEC 17025. This gives confidence to customers in the quality of
testing of laboratory for acceptance and third party certification.

 Failure in insulation properties

After revision of IS 13779:1993, the test severity of impulse voltage changed as given
above. Initially failure rate was 80%. It was due to change in source impedance from
500 Ohm to 2 Ohm and 12 Ohm. The energy transfer is more when source impedance
is low. Whereas as per pre-revised IS and prevailing IEC the source impedance is
500Ohm and energy is limited to 0.5J. IS also specifies insulation resistance test in
addition to impulse voltage and ac voltage tests. India being a tropical country the IR
test is performed to reveal the deterioration in insulation properties after the impulse
voltage and ac voltage test. To meet the requirement of IS for high energy transfer
designs are modified and failure has been reduced to 5%.
 Severe conditions for mechanical tests
The severity for vibration and shock tests is high in IS as compared to the requirement
in IEC. This has been done, keeping in view transportation conditions available in
India. Test severity for vibration test is 0.15mm/4mm amplitude and acceleration
2/2.2gn in IS as compared to 0.075mm amplitude and acceleration 1gn in IEC.
Severity of shock test in IS also 40gn as compared to 30gn in IEC. The meter meeting
IS requirements are found well suitable for Indian transportation conditions.
 Severe conditions for influence of magnetic induction of external origin tests
The revised IS and CBIP has included the additional test for abnormal magnetic
induction of external origin up to 0.2T for ac field and 0.27 T for dc field, as
compared to IEC. Initially failure rate of meters was 30%. The modified design of
meters has brought down the failure rate to 1%.
 Less severe conditions for harmonic tests
ISs specify test of the harmonic component to be carried out with 10% 3rd harmonic
current injection in-phase and out of phase in current circuit only whereas as per IEC
specs this test is carried out with 10% 5th harmonic voltage injection in-phase with
voltage circuit and 40% 5th harmonic current injection in-phase with current circuit
simultaneously. In addition, as per IEC the tests with phase fired (odd harmonics) and
burst fired (sub-harmonics) waveforms injection in current circuit are also to be
carried out which are not included in ISs. Nowdays most of the electricity used in
domestic commercial and industrial installations is controlled by controllers which
generate harmonics of higher orders in current circuits having significant amplitude of
 harmonics in comparison with fundamental and also distorts the waveform of the
voltage circuit. This energy has to be registered by energy meters. To meet the
requirements of installation/power supply conditions these tests may be included in
National Specifications.
 Repeatability of error test
Repeatability of error test is performed as per IS to verify the short term stability of
the energy meter with respect to time. This test is not included in IEC.
 Less severity for EMI/EMC tests
Severity for Test of immunity to electromagnetic RF field without current in current
circuit in IS is with field strength of 10V/m as compare to 30V/m in CBIP (Indian) &
IEC. In addition CBIP and IEC specify for test of immunity to conducted disturbances
induced by RF field, damped oscillatory waves immunity test, surge immunity test.
Keeping in view the existing environmental condition these tests may be included in
IS.
 Test for output device
Test for optical output device (LED blinking) is covered in IEC. The wavelength,
radiation strength, pulse frequency and transition time are verified to test the optimum
pulse transmission. Ambient light intensity up to 16000Lux shall not affect the optical
transmission of pulse. Poor quality of LED and very high pulse frequency may affect
the optical transmission and add a lot to measurement uncertainties. This aspect is not
covered in IS.
 Special test requirements
Some of the special test requirements by utilities/user are given below:
o Quantities to be measured and displayed
o MD reset
o MD integration period
o Communication/Data down loading capability
o TOD metering
o Load profiles
o Programming capabilities
o Self diagnostic features
o Monitoring and logging of system/installation abnormalities
o Battery back up
o Anti tamper and fraud protection tests.
The CBIP manual and other Utilities/State electricity boards also specify to test the meters
against temper and fraud protection tests. Anti tamper features requirements are changing rapidly.
Some of the utilities specify that the meter should be immune to 0.5T magnetic field obtained
from permanent magnet. Some specifications specify that meter shall register the energy based
upon the highest current flown through, either of two elements in case of single phase meter,
irrespective of phase and neutral. In case of proper wiring and no leakage, the specification holds
good. But some time it is observed that when neutral and ground wires inside the installation (ie
load side) are shorted or there is any leakage current, the meter records energy even if there is no
actual load connected to the meter, in some cases more energy than that of the maximum load
connected to the meter. Recently evolved IS 15707:2006 gives thrust on in service check/ testing
of consumer installation to protect the consumer against overbilling.

CONCLUSION
There are many parametric differences in IS and IEC for the similar type of energy meter. In the
present scenario of globalisation we must harmonise the Specifications with national deviations if
any.

Meter testing resulted in image building, statistical analysis, gaining confidence of customer,
minimising customer complaints, meeting regulatory requirements and performance of meters in
service. In-service/on-site testing is gaining momentum as a part of in-service compliance testing
or to carryout metrological testing and functional verifications of meter on receipt of customer’s
complaint or internal report. 15707:2006 covers on-site testing.

The primary objective of the meter to register the energy is becoming secondary. The importance
is being given to detect tamper and fraud, monitor the quality of supply, time of use billing,
demand analysis, outage management, remote metering, connect and disconnect. The existing
meter test facilities are being upgraded to keep pace with the change in technology requirements.
Anti tamper feature requirements are changing rapidly. To incorporate these features, the design
of meter is becoming complex. This is affecting cost as well as reliability of the meter.

It is important to note that reliability aspect of electronic/ static meters is not covered in most of
the specifications and no short-term test procedure is available which would fit into type test
sequence to satisfactorily check the reliability. Revised CBIP manual 304:2008 describes a test
procedure consisting of initial measurements, operational conditioning at maximum operating
temperature for 1000hrs and final measurements. Similar test specification requirement may also
be considered for inclusion in IS/IEC specification to ascertain the reliability of energy meters.

Recommended type test sequence

Appropriate test sequence which is almost same for IS and IEC is given below:

Test Parameter Objective

Test of insulation properties

Test the design and construction of meter for safety of personal /
Impulse voltage test
equipment in normal use and under normal conditions.
AC voltage test

Test of accuracy requirements

Test of meter Constant
Verify the metrological requirements of energy meters under normal
Test of starting condition
conditions of use and under the influence of influencing quantities.
Test of no load condition
Tests of Influence quantities

Test of electrical requirements Determine the suitability of energy meters to meet various electrical
Test of power consumption
Test of Influence of short time
current
Test of Influence of self heating
requirements of mains supply as well load condition.
Test of Influence of heating
Test of immunity to earth fault

Test for electromagnetic

compatibility (EMC)
Radio Interference suppression
Fast Transient burst test
Test of Immunity to HF field
Ensure electromagnetic compatibility of the energy meters in their
Test of electrostatic discharges
operational environments.
Test of immunity to conducted
disturbances induced by RF field
Damped oscillatory waves
immunity test
Surge Immunity test

Test of climatic influences

Dry heat test The effects of environment on energy meters which may be in the
Cold test form of insulation failures, physical failures, chemical physical and
Damp heat, cyclic test photo chemical reactions, discoloring etc.
Solar radiation test

Test of mechanical
requirement Principal effects of mechanical stress, fatigue, resonance resulting into
Vibration test mechanical failures, structural collapse etc.
Shock test

Test of protection against

The sealing effect
penetration of dust and water

Test of resistance to heat and

Personal and equipment safety against effect of excessive temperature
fire &
and spread of fire.
Heat deflection test