EDM Meter Testing Lab Final 1.0 - usaid.gov · PDF fileEDM Electricidade de Moçambique...

MOZAMBIQUE EDM Commercial Loss Reduction Efforts

METER TESTING LABORATORY ROAD MAP

SRUC PROJECT

CONTRACT NUMBER: AID-OAA-TO-14-00006

January 31, 2017

This publication was produced for review by the United States Agency for International Development (USAID). It

was prepared by Deloitte Consulting LLP (“Deloitte”) under a contract between Deloitte and USAID. This document

does not necessarily reflect the views of USAID or the United States Government. Information provided by USAID

and third parties may have been used in the preparation of this document but was not independently verified by

Deloitte. The document may be provided to third parties for informational purposes only and shall not be relied upon

by third parties as a specific professional advice or recommendation. Neither Deloitte nor its affiliates or related

entities shall be responsible for any loss whatsoever sustained by any party who relies on any information included in

this document.

SECTOR REFORM

AND UTILITY

COMMERCIALIZATION

PROJECT

MOZAMBIQUE EDM: METER TESTING LABORATORY ROAD MAP

CONTRACT NUMBER: AID-OAA-TO-14-00006

DELOITTE CONSULTING LLP

January 31, 2017

SECTOR REFORM AND UTILITY COMMERCIALIZATION PROJECT | i

ACRONYMS

The following table provides a list and description of acronyms used in this report.

Acronym Term

AC Alternating Current

ADC Alternating Direct Current

ALTL Accelerated Life Testing Laboratory

ANSI American National Standards Institute

ATC Aggregate Technical and Commercial Losses

BNC Bayonet Neill–Concelman

CSA Customer Service Area

EDM Electricidade de Moçambique

ICT Isolation Current Transformer

IEC International Electrotechnical Commission

LED Light Emitting Diode

MSVT Multi-Secondary Voltage Separating Transformer

MTL Meter Testing Laboratory

PMT Power Meter Technics

R&D Research and Development

RFP Request for Proposal

RSM Reference Standard Meter

SRUC Sector Reform and Utility Commercialization

TAR Test Accuracy Ration

TO Task Order

TTL Type Testing Laboratory

TTRM Three-Phase Reference Meter

TUR Test Uncertainty Ratio

USAID United States Agency for International Development

VAR Volt Ampere Reactive

VARh Volt Ampere Reactive-Hour

VST Voltage Separating Transformer

Wh Watt-Hour

SECTOR REFORM AND UTILITY COMMERCIALIZATION PROJECT | ii

TABLE OF CONTENTS

1. EXECUTIVE SUMMARY 1

2. INTRODUCTION AND CONTEXT 3

2.1 Deloitte’s Approach to the Project 4

3. EDM’S METER-RELATED PROBLEMS AND THEIR IMPACT ON COMMERCIAL LOSSES 5

3.1 EDM´s Customer Base, Service Territory, and Meter Inventory 5

3.2 EDM´s Current Meter Testing Capabilities and Need for Improved Capacity 6

4. TYPICAL SOLUTIONS FOR METER TESTING 10

4.1 Calibration Process 10

4.1.1 Calibration Theory 11

4.2 Accelerated Life Testing Laboratory 12

4.2.1 Concept 12

4.2.2 Design 12

4.2.3 Functions 15

4.2.4 Road Map 16

4.3 Type Testing Laboratory for Meter Calibration 17

4.3.1 Concept 17

4.3.2 Design 18

4.3.3 Functions 20

4.3.4 Road Map 20

4.4 Portable Meter Testing Equipment 21

5. BUSINESS CASE FOR EDM TO BUILD ITS OWN TYPE TESTING LABORATORY 23

5.1 Business Impacts 23

5.2 Financial Model 23

5.2.1 Scenario 1: EDM Builds an Expensive High-End Testing Laboratory 25

5.2.1.1 High-End Model Observations 25

5.2.2 Scenario 2: EDM Pursues a Low-Cost Testing Laboratory 26

5.2.2.1 Low-Cost Model Observations 26

6. CONCLUSION AND RECOMENDATIONS 28

SECTOR REFORM AND UTILITY COMMERCIALIZATION PROJECT | iii

ANNEX I — TEMPERATURE TEST PLAN 29

ANNEX II — AES ELETROPAULO CASE STUDY 30

ANNEX III — CALIBRATION CERTIFICATE 34

ANNEX IV — SPECIFICATIONS OF A TYPE TESTING LABORATORY 35

ANNEX V — PORTABLE EQUIPMENT FOR METER CALIBRATION 44

SECTOR REFORM AND UTILITY COMMERCIALIZATION PROJECT | iv

TABLE OF FIGURES

Figure 1. EDM’s Test Bench in Maputo .............................................................................................................. 7

Figure 2. Calibration Theory ........................................................................................................................... 11

Figure 3. ALTL Testing Station ........................................................................................................................ 15

Figure 4. Type Test Testing Bench .................................................................................................................. 19

Figure 5. Portable Meter Testing Equipment .................................................................................................... 22

Figure 6. AES Eletropaulo Meter Storage ......................................................................................................... 31

Figure 7. AES Eletropaulo Meter Testing Laboratory ........................................................................................ 32

Figure 8. AES Eletropaulo Calibrated Meter Storage ......................................................................................... 32

Figure 9. AES Eletropaulo Calibration Result Analysis ....................................................................................... 33

TABLE OF TABLES

Table 1. EDM’s Meter Inventory ....................................................................................................................... 6

Table 2. Meters Tested Using EDM’s Testing Bench Tables ................................................................................ 8

Table 3. Qualitative Analysis of Meter Problems ................................................................................................ 9

Table 4. Key Variables of the Model ................................................................................................................ 24

Table 5. Model for High-End Testing Laboratory .............................................................................................. 25

Table 6. Model for Low-Cost Testing Laboratory ............................................................................................ 26

SECTOR REFORM AND UTILITY COMMERCIALIZATION PROJECT | 1

1. EXECUTIVE SUMMARY

In 2015, Electricidade de Moçambique (EDM), Mozambique’s government-owned vertically integrated

electric utility, approached the US Agency for International Development (USAID) to request assistance

in pursuing a utility-wide transformation initiative. EDM provides power to more than 1.4 million

customers in a territory that spans 800,000 square kilometers. But EDM is losing an estimated

14 percent of revenue from power generation each year — approximately $34.3 million — due to

customer theft and poor management practices. Such losses inhibit EDM’s ability to pursue investments

that could improve service quality to existing customers, extend the network to unserved communities,

and expand power generation capacity.

EDM reqeuested USAID support in evaluating the best way to address the meter failures it has

experienced during the implementation of large-scale meter replacement (for existing customers) and

network expansion (to connect new customers) programs. EDM has removed many newly installed

meters from the system due to nonperformance, and believes the establishment of an in-house meter

testing capability would help mitigate meter failure in the future.

Under the USAID-funded Sector Reform and Utility Commercialization (SRUC) program, EDM’s

Commercial Directorate engaged a team of Deloitte consultants to collect data on new meter

procurement processes, installation programs, and maintenance activities, as well as the types and

frequency of meter tampering by customers. The team also gathered data on distribution network

performance, including EDM’s ability to provide power and regulate voltage.

It is important to note that the meter, as the recorder of electricity sales, serves as a cash register for

the utility. Any problems that undermine the proper functioning of the meter — poor meter quality,

installation, or maintenance, or tampering of meters by customers — can result in significant commercial

losses that affect the revenue and financial viability of the utility.

To address its rising meter failure rate, EDM wants to build an in-house meter testing laboratory. There

are two types of meter testing laboratories:

Type Testing Laboratory (TTL) — Used to conduct acceptance testing when a utility procures

new meters. TTLs are used to calibrate meters and verify meter measurement errors. Turn-key

services to establish a TTL cost between $50,000 and $250,000, but these services are already

ubiquitous at most electric utilities. Usually, TTLs are supported by portable equipment that

allows simple meter testing to take place in the field.

Accelerated Life Testing Laboratory (ALTL) — Used to conduct meter performance testing

under stress conditions. ALTLs cost in excess of $1 million to build and maintain and, therefore,

are rarely found at small- and medium-sized utilities.


This report finds that EDM’s current meter failures are the result of several issues, including:

Poor Network Performance — The ability to provide quality power and regulate voltage are

limited, resulting in the vast majority of meter failures.

Meter Model — One specific type of poor quality meter was used throughout the installation. If

more rigorous testing had been done prior to installation, the quality issues could have been

identified as problematic earlier.

Recommendations for EDM:

Do not establish an ALTL. The costs to establish and maintain an ALTL are significant, and an

ALTL will not address the core issues affecting EDM. If and when accelerated life testing is

needed, EDM can contract ALTL services from already existing laboratories (i.e., independent

laboratories or laboratories at large nearby utilities such as Eskom).

Establish a TTL to test 100 percent of newly procured meters. It costs between $50,000 and

$250,000 to build a TTL, much less than the costs to build an ALTL. EDM plans to procure and

install 100,000 to 300,000 new meters annually, and conducting type testing in-house will save

approximately $1 per meter; therefore, given the expected demand for new meter testing, EDM

will recoup the costs of building the TTL is less than two years.

Contract a vendor who can provide a turn-key TTL solution. A qualified vendor will ensure all

TTL equipment operates effectively, all TTL staff are fully trained, and the software used to

generate reports functions as required.

Consider a vendor who can offer a comparatively less expensive solution. EDM does not need a

premium turn-key solution. There are vendors who offer quality TTL equipment at a fraction of

the price of high-end solutions.

Purchase portable meter testing equipment to use in the field in order to evaluate

nonperforming meters in situ and be more responsive to customer complaints.

For TTL installation, identify a 50-square-meter temperature-controlled area that is adjacent to

the meter warehouse and protected from dust and other airborne particles.

Do not consider a reduction in meter damage as a benefit of TTL or ALTL construction,

especially in regions with poor power quality.

Building the TTL should be the first step toward establishing a technological center to improve

EDM’s knowledge base.


2. INTRODUCTION AND CONTEXT

USAID established the SRUC program to promote utility commercialization and effective reforms that

enhance the financial viability and long-term sustainability of electricity systems in developing countries,

thereby enabling their expansion and growth and establishing the preconditions necessary for clean

energy investment.

EDM requested assistance from USAID to improve its meter-to-cash management system and its meter

maintenance capabilities (the “Loss Reduction Project”). In response, USAID is using a SRUC Task

Order to support EDM in reducing commercial (nontechnical) losses throughout Mozambique’s

electricity system.

As part of the Loss Reduction Project, Deloitte designed a plan to improve EDM’s meter testing

capabilities. This plan specifies the facilities, equipment, staffing, and training necessary to effectively and

efficiently test meters, along with the financing required for the project. This report contemplates

various options EDM could pursue toward its goal, including developing in-house capabilities or pursuing

outside services on an ad hoc basis to:

Conduct stress testing of newly procured meters

Calibrate newly procured meters

Conduct field testing of meters in situ

The plan describes meter testing practices that EDM may adopt in order to implement the Commercial

Metering Strategy and Road Map in support of its overall utility-wide transformation initiative. The plan

includes the following sections:

A description of the practices EDM currently uses to test metering equipment

A gap analysis comparing EDM’s current practices with the practices required to implement the

new Commercial Metering Strategy and Road Map

A road map that defines the steps needed for EDM to make the changes necessary to adopt

these practices, including setting up a new meter testing laboratory

Considerations about the various technical standards for meters and recommendations on the

adoption of standards, regulations, rules, and procedures for meters used by EDM

The organizational structure, including a suitable mix of staffing and skills, needed to successfully

operate the new meter testing laboratory

A simplified estimate of costs and investments needed to successfully set up and operate the

new meter testing laboratory.


2.1 DELOITTE’S APPROACH TO THE PROJECT

The Deloitte team engaged EDM from July 2016 to January 2017under the Loss Reduction Project. On

July 20, 2016, a kickoff meeting was held. In attendance were senior staff from EDM, including Fatima

Arthur, Director of Management and Corporate Performance1; Sergio Parruque, Commercial

Department Director; Leonardo Uamu, Technical-Commercial Department Leader; and Rogerio

Bungane from EDM’s Technical-Commercial Department. In addition, John Irons, Senior Program

Officer for USAID/Mozambique, participated in the meeting.

A series of meetings, field visits, and discussions were held over the next five months to accomplish the

objectives of the Loss Reduction Project. During this period Deloitte, successfully engaged EDM staff at

the senior, mid-, and field level to:

Gauge expectations regarding the project, including desired outcomes

Learn EDM’s current meter testing strategy and the utility’s ideas on where failures exist

Collect metering data and evaluate failure rates by type of meter, vendor, region, etc.

Gain an understanding of EDM’s overall commercial metering strategy, including plans to replace

existing meters with new meters (by type and quantity)

Assess EDM’s infrastructure, including current meter testing facilities and equipment

Evaluate and catalog EDM’s meter testing processes and operating systems

Engage EDM’s staff and evaluate their capabilities to operate sophisticated meter testing

equipment and manage a technical laboratory

Conduct site visits to learn first-hand about technologies used in the field, processes followed by

crews to install or maintain meters, and challenges faced by EDM

Using data collected from September 2016 to November 2016, this report presents Deloitte’s

assessment of EDM’s current meter testing capabilities — including Deloitte’s views on EDM’s actual

need for meter testing services — and provides cost-effective recommendations for improving meter

quality, while still meeting regulatory requirements and senior management’s expectations. In this

report, Deloitte outlines its approach to the Loss Reduction Project, as well as EDM’s perceived need

for in-house meter testing capabilities, and presents various models of testing solutions, along with

staffing needs and illustrative budgets.

1 Since the kickoff meeting on July 20, 2016, Eng. Fatima Arthur has been promoted to EDM’s Board of Administration.


3. EDM’S METER-RELATED PROBLEMS AND THEIR IMPACT ON

COMMERCIAL LOSSES

The purpose of the Loss Reduction Project is to reduce EDM’s commercial losses related to meter

failures. EDM has made some progress on loss reduction over the past five years through

implementation of community and customer communications and the modernization of metering and

customer service systems. The utility has appealed to the community in general and, more specifically, to

community leaders to assist with loss reduction by reporting electricity theft. EDM maintains a list of

fines on its website for equipment destruction, meter tampering, fraud, electricity theft, and

nonpayment. EDM haD a 21 percent aggregate technical and commercial (ATC) loss rate in 2015, but

this rate remains above EDM’s target rate of 16 percent ATC losses per year. If EDM wants to hit its

target ATC loss rate by 2019, it must achieve a marked improvement in year-over-year loss reduction.

Of the 21 percent ATC losses reported in 2015, 7 percent were technical losses and the remaining

14 percent were commercial (nontechnical) losses within the distribution network.

In August 2015, EDM announced it hired a new CEO, Dr. Mateus Magala, to transform the utility.

Dr. Magala has begun the transformation process at EDM, which he hopes will result in a more modern

and better performing utility. Commercial improvement is a cornerstone of Dr. Magala’s strategy, and

he has placed special emphasis on improving collections and reducing power loss. Current plans are to

introduce 7,000 automatic meter reading (AMR) meters to high-consuming customers and 1.2 million

split prepaid meters to residential customers by 2030. In total, EDM will install new meters for the

majority of its current 1.4 million customers, as well as for the additional 1.2 million customer it expects

to connect in the next 12 years.

3.1 EDM´S CUSTOMER BASE, SERVICE TERRITORY, AND METER INVENTORY

As part of its overall Loss Reduction Project, EDM is pursuing an aggressive customer remetering

program, a central component of which is to shift customers to prepaid electronic meters. Table 1

shows the number of prepaid and postpaid (demand) meters currently installed by EDM. Approximately

88 percent of all customers have prepaid meters, most of which have been procured for residential

customers within the past five years in compliance with EDM’s remetering program. EDM acquires

prepaid meters from multiple vendors, including well-known manufacturers such as Itron, CashPower,

and Iskra, as well as newer entrants to the prepaid meter market such as Star Instruments.

Type of Meter

Meter Characteristics

Meter Expected

Life Meter Manufacturers

# of Meters

Installed

% of Total Meter

Installed Postpaid Electromechanical,

Electronic, Analog,

Digital Electronic

10 to 30

years

Landis&Gyr, Schlumberger,

Actaris, M2X, Reguladora, Ganz,

Bruno Janz, CHINT, Vectron,

SL700, ACE6000, ZMD405, Iskra

179,611 12%


Type of Meter

Meter Characteristics

Meter Expected

Life Meter Manufacturers

# of Meters

Installed

% of Total Meter

Installed Prepaid Digital Electronic 10 to 15

years

Actaris, Star Instruments, Taurus,

Genus, Iskra, Itron, Landis&Gyr,

Conlog, CashPower

1,271,342 88%

TOTAL 1,450,953 100%

Table 1. EDM’s Meter Inventory

Available on a mass scale starting in 2005, prepaid electronic meters are relatively new to the market

compared to postpaid (demand) meters. As such, the manufacturing technology used to produce

prepaid meters is less established, resulting in a less reliable meter; thus, it is possible to find prepaid

meters with greater propensity for errors from some manufacturers.

3.2 EDM´S CURRENT METER TESTING CAPABILITIES AND NEED FOR IMPROVED

CAPACITY

EDM has not defined the process for calibrating 100 percent of newly purchased meters prior to

delivery by manufacturers, nor does it request accelerated life test results from manufacturers that

would show the reliability of meters. There is a risk that meter procurement without calibration tests

or accelerated life test results may increase the meter failure rate.

EDM has also experienced meter failures as a result of unstable voltage levels in some parts of its

distribution network. Sudden drops in voltage have greatly affected EDM’s meters, especially prepaid

electronic meters regardless of manufacturer. The most common voltage-related problem of prepaid

electronic meters is relay operation failure in which the meter ceases to function due to improper

opening of the relay, resulting in an interruption in electricity. In such instances, EDM cannot evaluate

whether a meter stopped working because it burned out or as a result of a relay operation failure

because EDM does not have the portable equipment needed to conduct field tests. As such, faulty

meters must be removed from their current locations and taken to a meter test bench at a customer

service area (CSA) to verify their functionality.

EDM currently has test benches at CSAs in Maputo, Matola, Beira, and Nampula. Figure 1 shows the

Maputo test table where tests are carried out to determine if a meter is damaged. The test performed

at CSAs basically involves applying a nominal voltage to the meter in order to evaluate whether the

meter returns to operation under normal conditions (i.e., if the relay has been reset and the meter

display is functioning normally). It is important to note that a CSA test does not include verification of

meter calibration or conformity, such as the measurement error.


Figure 1. EDM’s Test Bench in Maputo

Current protocol dictates that EDM discard meters if they are found to be damaged. If a meter is

determined to be operating within acceptable parameters, it is placed in storage until it is needed in the

field to establish a new connection or replace a damaged meter.

EDM has removed a significant number of meters due to suspected poor performance or proven

nonperformance. Table 2 shows the total number of meters removed from the field by meter type and

manufacturer.

Item METER MANUFACTURERS EDM Sub-

Total 2010 2011 2012 2013 2014 2015

A Itron Actaris 7,423 12,295 10,816 7,663 8,767 8,067 55,031

B Cash Power 3,922 9,908 8,184 6,320 5,424 5,160 38,918

C Cash Power (split) 690 1,542 1,078 1,361 2,784 2,755 10,210

D Taurus 25 861 514 529 2,477 2,982 7,388

E Conlog 0 135 431 493 1,813 2,440 5,312

F Conlog (split) 1,016 3,122 3,438 2,608 3,991 2,586 16,761

G Genus 0 0 2,193 3,636 3,827 2,402 12,058

H Iskra 0 2,184 1,991 1,597 1,327 2,994 10,093

I Srat (split) 0 842 1,813 1,578 1,058 2,185 7,476

J Srat (split) 0 84 80 0 0 2,579 2,743

K Itron Actaris (split) 0 0 0 0 0 1,791 1,791

SUB-TOTAL 13,076 30,973 30,538 25,785 31,468 35,941 167,781

Item METER MANUFACTURERS

EDM Sub-Total 2010 2011 2012 2013 2014 2015

L Reguladora 196 300 214 179 428 327 1,644


M Brono Janz 191 243 225 211 891 262 2,023

N Schlumberger 182 183 183 155 141 207 1,051

O ITRON 128 138 138 136 622 182 1,344

P Chint 243 248 246 209 221 264 1,431

Q Ganz 155 171 169 152 302 199 1,148

R Landis & Gyr ZMD405CT44 37 37 37 37 589 39 776

S SL700 94 93 93 93 354 121 848

T Vectron 74 134 112 67 92 143 622

U Iskra 122 248 148 137 87 181 923

V ACE600 108 109 121 104 57 92 591

SUB-TOTAL 1,530 1,904 1,686 1,480 3,784 2,017 12,401

TOTAL GLOBAL 14,606 32,877 32,224 27,265 35,252 37,958 180,182

Table 2. Meters Tested Using EDM’s Testing Bench Tables

Specifically, EDM has experienced significant difficulties with the performance of prepaid meters

procured over the past five years. Considering the total inventory of EDM meters installed in the field to

date, prepaid meters are associated with more than 2.5 times more problems than postpaid meters.

If one looks at the growth trend of meter failures, it is clear that the number of prepaid meter problems

has increased both in absolute and relative terms in relation to postpaid meters. It should be noted that

all meters mentioned in the above table did not fail outright; the meters were only withdrawn from the

system for verification because they stopped working2.

In 2016, EDM conducted a qualitative analysis in response to the growing number of prepaid meter

failures. The resulting report outlined the main causes of meter failures and proposed mitigating actions

that, if taken, would correct the issue. Although the analysis examined the types of failures that

occurred, the failures were not mapped against meter type or manufacturer. As a result, the analysis is

of limited value. The results of this qualitative analysis are presented in Table 3.

Problem Description Primary Cause Mitigating Action

Hardware:

- Defective keyboard

- Broken glass

- Burned viewfinder

- Burned motherboard

- Meter burned

- Damaged anti-tampering mechanism

Hardware:

- Poor handling of meter

- Oscillations and voltage drops in

distribution network

- Distribution network overload

- Meter tampering (manipulating

counting equipment)

Hardware:

- Improvement in distribution

network

- Increase the number and

frequency of meter inspections

2 In many cases meters, stop operating due to fluctuations in the system’s voltage levels.


Problem Description Primary Cause Mitigating Action

Software:

- Meter blocked

- Meter does not power installation

- Meter does not accept refills

- Disarmed anti-tampering mechanism

- Meter does not display credit

- Meter provides electricity with zero

credit

- Meter does not reduce credits

when dispensing electricity

- Frozen keyboard

- Meter does not accept codes

(energy credits)

- Communication failure between

keyboard and meter for split meter

- Meter tampered with or destroyed

Hardware:

- Oscillations and voltage drops in

distribution network

- Distribution network overload

- Attempted fraud (manipulating

counting equipment)

- Manufacturing error

- Incorrect “Supply Group Code”

- Exhausted lifetime

Hardware:

- Improvement in distribution

network

- Increase the number and

frequency of meter inspections

- Install control meters in ASCs

- Replace all meters older than

10 years

- Ensure all meters are subject to

factory calibration testing

- Continuously update technical

specifications to suit the

challenges faced by EDM

- Train the metering technicians

Table 3. Qualitative Analysis of Meter Problems

EDM had a significant issue with one meter provider. The Chinese meter “Star” presented two types of

problems:

1. The meter’s energy counter did not work. Instead of decreasing energy credits with customer

consumption, the meter’s energy counter increased credits, actually providing the customer with

more credits the more he or she consumed and effectively giving unlimited electricity to the

customer.

2. There was a failure in the operation of the meter relay. The relay failed to interrupt electricity

supply after purchased credits had expired. Again, this effectively gave unlimited electricity to

the consumer.

These faults with Star meters were identified from field visits initiated after EDM realized that some

customers had stopped purchasing meter credits altogether.

Star meters have contributed to EDM’s commercial losses. In addition to the problems with the meters

themselves, the location of the meters on the distribution network and with particular customers at

specific locations was never properly mapped and logged. Consequently, EDM has experienced

difficulties locating and removing these faulty meters, which has exacerbated efforts to replace them

with functioning meters that eliminate the problem. EDM still has approximately 37,000 Star meters in

the field that need to be replaced.

Finally, considering the problems mentioned above with EDM’s meters, even though many problems

were found to be related to poor power quality, EDM should look for solutions to reduce its meter

problems.


4. TYPICAL SOLUTIONS FOR METER TESTING

An electric utility’s inventory of energy meters is perhaps its most important asset. The meters function

as the utility’s cash register, and a problem with a meter means a potential loss in revenue. In addition,

utilities must follow guidance and directives provided by the regulatory agency overseeing the power

sector, as well as demonstrate to its customers that it maintains an accurate and efficient system. All of

these are strong reasons to procure meters that meet or exceed established performance standards,

and then maintain those meters in perfect operating condition.

Therefore, performing the appropriate tests on meters to ensure proper operation is essential. These

tests are performed in two different types of meter testing laboratories: an accelerated life testing

laboratory (ALTL) and a type testing laboratory (TTL). Each type of laboratory serves a very different

purpose, is supported by different rationales, and has different costs associated with its procurement,

establishment, and operation.

4.1 CALIBRATION PROCESS

An electricity meter or energy meter is a device that measures the amount of electric energy consumed

by a residence, business, or an electrically powered device. Electricity meters are typically calibrated in

billing units, the most common of which is the kilowatt hour (kWh). Periodic readings of electricity

meters establish billing cycles and the energy used during a cycle. An electronic energy meter is based

on digital micro technology (DMT) and uses no moving parts. Its accurate functioning is controlled by a

specially designed integrated circuit.

The meter software is responsible for storing all measured electrical quantities in the meter memory.

Each manufacturer usually has its own software that defines the electrical quantities accessible on the

serial port of the meter, as well as the format of the measurement reports the meter will generate.

Both electromechanical meters and electronic meters can be tampered with, so they must be sealed to

prevent irregular access by unauthorized people in an attempt to modify the normal operating condition

of the meters, mainly in order to steal energy.

Electrical calibration refers to the process of verifying the performance of, or adjusting, any instrument

that measures or tests electrical parameters; in other words, the process of trimming the meter so its

error are minimal.

An electricity meter measures the electrical energy passing through the meter. There are single-phase

and poly-phase meters. Calibrating the meter ensures that measurement errors can be kept within

desired limits.

The normal calibration method is to generate the desired power level and compare the measured

energy of the meter under test with the power measured in a reference system, usually by comparing

the frequency of pulse outputs.


Calibration is necessary to ensure readings from an instrument are consistent with other measurements,

to determine the accuracy of the instrument readings, and to establish the reliability of the instrument

(i.e., that it can be trusted to adjust to measurements errors).

A meter testing laboratory uses testing benches to test and calibrate both single-phase and three-phase

meters. The meters are connected to the benches, which have model scanning heads designed to detect

the light emitting diodes (LEDs) of electronic meters. The duration of optical impulse signals generated

from electric meters is detected and evaluated. The scanning head has a precision optical lens designed

to make it insensible to external light.

The meter under test is supplied with a known quantity of the current being calibrated, and the meter is

examined in order to ascertain the amount of impulses it displays. The amount of impulses is then

compared with the amount of impulses generated by the reference system, and the measurement error

is calculated.

There is software installed on the testing bench, and the meter’s specifications must be added to this

software. Also, users must select the type of test they want to perform on the meter.

After confirming all of the meter’s specifications have been added to the testing bench software and

defining the tests to be done, the calibration process can begin. It is possible to watch the progress of

the test being run in the window. The percentage of errors present in all meter readings are shown

alongside their slots. The time remaining for the test to be completed is also shown. The calibration

process gives the user specific details about the meter and the percentage of errors present in the

meter’s reading. The data can be exported to Microsoft Excel or a specific report.

4.1.1 CALIBRATION THEORY

A typical meter has phase and gain errors as shown by φ S, AXI, and AXV in Figure 2. Following the

typical meter convention of the current phase being in the lag direction, the small amount of phase lead

in a typical current sensor is represented as -φ S.

Figure 2. Calibration Theory


The errors shown in Figure 2 represent the sum of all gain and phase errors. They include errors in

voltage attenuators, current sensors, and alternating direct current (ADC) gains. In other words, no

errors are made in the “input” or “meter” boxes.

While the meter is still in the testing bench, in addition to measuring errors during the calibration phase,

it is possible to adjust the meter with correction factors that nullify the effects of the errors and reduce

them to a minimum value.

A testing bench is able to calibrate any electronic meter once its specifications are entered into the

testing bench software.

4.2 ACCELERATED LIFE TESTING LABORATORY

4.2.1 CONCEPT

Reliability is defined as the ability of a product to perform as designed for its expected lifespan under

stated operating conditions. Reliability engineering deals with the application of engineering principles

and techniques to evaluate the reliability of a product and find potential areas for improvement by

identifying the most likely failures and the appropriate actions to mitigate the effects of those failures.

Reliability engineering also deals with the study of failure data, which includes times to failure and causes

of failure. This data is acquired over the course of many years of field testing and from products

returned under warranty. In order for a product to maintain its competitive edge, engineers must obtain

failure data quickly. For this purpose, a set of accelerated life tests were devised.

For accelerated life tests in the world of electricity metering, meters are subjected to elevated stresses

such as temperature, humidity, voltage, etc., causing them to fail or degrade more quickly. Stress levels

are chosen that lie within the elevated stress zone and not outside the limits in which the meter

normally operates.3 With data analysis, the inferences can be extrapolated to normal usage conditions.

4.2.2 DESIGN

In terms of reliability, electronics have improved tremendously over the years, and many electronic

meter manufacturers have strong reliability programs. Still, electric utilities often request third-party

verification of a meter’s reliability in order to gain a higher level of confidence before investing significant

amounts of money into new meters that are expected to operate for the next 15 to 30 years.

In the first phase of reliability testing, estimating the performance life of electronic meters in the field is

required, including the impact of environmental conditions. Accelerated testing is performed by

3 A stress test performed outside the range in which the meter normally operates will provide no useful information.


subjecting a sample set of meters to high temperatures for extended periods in an environmental

chamber. Other stresses such as voltage and humidity will follow in later phases.

There are certain organizations that provide qualification standards and specifications for the

performance of a product, such as the International Electrotechnical Commission (IEC) and the

American National Standards Institute (ANSI). However, qualification standards and specifications are

only good for confirming that a product is qualified to function in a particular range of operating

parameters. In some cases, especially for new products and technologies for which no prior experience

has been accumulated, general qualification standards based on the previous experience of older

products may be too stringent.

Specifications for qualification tests must be set accurately as there are negative consequences for

setting parameters too high or too low. A qualification test with specifications that are too severe

(i.e., one that does not reflect actual field conditions) may result in the rejection of an acceptable

product that would have performed properly for an extended period of time. On the other hand, a

qualification test with specifications that are not severe enough for particular use conditions may result

in an unreliable product passing the qualification test.

Since qualification tests are not destructive, they do not provide the required information about product

reliability (i.e., the time-to-failure data under given operating conditions).

It is clear that to predict and optimize the life cycle characteristics of a product, reliability testing needs

to be carried out. The problem with implementing reliability engineering techniques is that they require

time-to-failure data on the product.

Time-to-failure data includes failure times for a specific product collected from the start of operations

for a large quantity of that product, as well as the causes of eventual failures. Time-to-failure data is

generally available from field testing and from products returned through claims made against a

manufacturer’s warranty program. Analysis of this data can lead to reasonably accurate projections

regarding the life and quality of the products.

In order to maintain a competitive edge, a manufacturer must reduce the time gap between the research

and development (R&D) stage of a product and its market release so that the product reaches the

market before competitors’ products. This effectively reduces available testing time.

For electric utilities, this problem can be overcome by deliberately operating the meter under an

elevated stress condition so that failures are induced quickly. Reliability analysis can then be performed

using the failures induced at this elevated stress condition, and the results can be mapped to stress usage

levels. This entire technique is called accelerated life testing analysis.

The cause-effect phenomena due to which the failure occurred is called a failure mechanism. Every kind

of applied stress produces different phenomena, and sometimes a combination of two or more stressors


are applied to simulate real-life operating conditions. The most common elevated stress conditions used

in accelerated life testing analysis are:

High and low temperatures

Temperature cycling and thermal shock

Mechanical shock and fatigue tests

Vibration tests

Voltage extremes

High humidity

An ALTL is generally used by meter manufacturers and research institutions because these laboratories

can evaluate the comparability of equipment subjected to extreme conditions.

Large meter manufacturers generally have an ALTL to perform all of the meter compliance tests set

forth in international standards. Due to the cost of an ALTL, smaller manufacturers generally do not

procure their own on-site ALTLs, but rather contract out to qualified and certified independent

laboratories with all of the necessary equipment to complete the required accelerated life testing.

Accelerated life testing is very important to ensuring meter quality; however, only a small number of

utilities around the world have invested in their own ALTLs primarily due to cost. Generally, before

purchasing the meters, utilities request a certificate of accelerated life tests done in compliance with IEC

and ANSI international standards from the meter manufacturer.

Each type of accelerated test requires a specific chamber or equipment. Figure 3 shows pictures of

chambers used to perform temperature and humidity tests on electronic meters in an ALTL.


Figure 3. ALTL Testing Station

Also, each type of accelerated test must have a defined written testing protocol that must be followed.

An example of a plan to conduct a temperature stress test is shown in Annex I.

4.2.3 FUNCTIONS

The conditions under which a product will operate are called its “usage condition,” and the time for

which the product is expected to function without defects is called its “product lifetime.”

The following are a few reasons why reliability studies needs to be carried out:

Predict the lifetime of a product

Determine optimal burn-in time

R&D for the product (i.e., materials and components used, design, etc.)

Minimize production and lifecycle costs

Determine optimal usage conditions

Optimize warranty policies

The underlying assumption of such tests is that the failure mechanism remains the same in both normal

and elevated stress conditions. Some failures that occur in electronic systems may be due to the

evaporation of electrolytes in capacitors, solder crack formation on circuit boards, delamination of

ceramic components, ctromigration, and damage to microelectronic devices.


4.2.4 ROAD MAP

One of EDM’s major concerns is the performance of its meters, particularly when subjected to extreme

operating conditions — especially oscillation and high voltage drops — in its distribution network. To

address this issue, EDM is considering establishing an in-house ALTL to help mitigate meter failure.

There are vendors who provide turn-key solutions and can build complete ALTLs. If EDM pursues an in-

house ALTL, Deloitte recommends it seek out a vendor to provide a complete solution. This will ensure

all equipment and software is fully integrated and compatible, and all training is provided. To prepare a

request for proposal (RFP) to send to multiple vendors to solicit bids, EDM should prepare a

specification containing, at a minimum, the following:

Type of stress tests to be conducted

Number of units to be tested in the sample group

Kind of results expected

Report information needed and desired format

ALTL costs can vary significantly. The final costs will depend largely upon the types and, more so,

number of tests the laboratory must be equipped to conduct. For each type of test, EDM will need a

specific chamber. A standard ALTL with three different chambers to perform the most standard tests

(i.e., temperature, vibration, and humidity) is estimated to cost $500,000. If more specific tests such as

voltage level and harmonics are included, the costs can reach $1 million.

But few utilities invest in creating their own ALTLs due to the costs associated with such laboratories

and the plethora of less expensive alternatives available. Deloitte believes EDM falls into this category

and recommends the utility pursue less expensive options rather than building out an in-house ALTL.

Basically, EDM needs to procure the results of accelerated life tests for the meters under purchase

consideration to ensure it buys the highest quality and most reliable meters available in order to reduce

its meter failure rate and retain as much of its power generation revenue as possible.

The most direct option is for EDM to specify at the procurement stage that the meter manufacturer

must present the certificate of accelerated life tests for the meters under purchase consideration. The

certification must be completed by an internationally accredited laboratory or another utility that has a

certified laboratory and accredited staff. This is the most efficient and least costly option as it puts all

responsibility for the tests on the manufacturer.

If EDM wants the comfort of having its own ALTL to perform electrical and electromagnetic stress tests,

there are many equipment options available to perform such tests. The cost for each piece of equipment

will be at least $100,000.

Another possibility for EDM to meet its need for accelerated life tests is to contract an independent

laboratory or another utility with a certified ALTL already in place to conduct the tests. Eskom is a

utility that has experience performing accelerated life tests. Generally, Eskom uses a sample of


24 meters to perform the tests, and the test are carried out over a period of approximately 10 months.

If EDM contracts an independent laboratory, it is typically requested that the laboratory complete the

tests within a six-month period.

In an accelerated life test, the meter is usually exposed to the following stressors:

Temperature and humidity cycling (primary stress)

Electrical stresses (i.e., over-voltage, under-voltage, dips and swells in voltage)

Electromagnetic stresses (i.e., lightning surges, transients, and electrostatic discharge)

Over and above these environmental stressors, the meter functionality is exercised throughout the

accelerated life testing process. For example, remote meter reading is conducted on a weekly basis on

smart meters while the meters are being stress tested.

Regardless of whether EDM chooses to build an in-house ALTL or contracts an independent laboratory

or other third party to conduct the tests, it is important to intimately involve the meter manufacturer in

assessing the test results and provide in-depth engineering reports on the root causes on the failures

detected.

4.3 TYPE TESTING LABORATORY FOR METER CALIBRATION

4.3.1 CONCEPT

Meter calibration sets the accuracy in energy registration of a watt-hour meter. When measuring

accuracy, the term “percentage registration” is used rather than “percentage error.” In

electromechanical meters, a direct correlation exists between the speed of the spinning disk and the

register (display). In electronic meters, a separate internal circuit uses an infrared LED to produce

infrared pulses proportional to the energy consumed, as calculated by the digital signal processor. These

sources are used to independently measure the accuracy of a meter.

A TTL can be used to test for metrological verification. These tests are done to certify that a meter fits

the type standards defined in the IEC metering standards (i.e., IEC62053-21, etc.) or to verify possible

meter errors and recalibrate them to meet the needs of the utility.

Generally, utilities require meter vendors to provide type test certificates for their products. The

records of the metrological verification process must be dated and approved by a person authorized to

attest to the correctness of the results, as well as maintained and available.

In the event the utility procures its own TTL, it is recommended to store test records in specific

reports. Generally, EDM receives the software that generates reports from the turn-key supplier of the

laboratory. It is recommended that the reports include, at a minimum, the following:

Description and unique identification of equipment manufacturer, type, serial number


Date on which the test was completed

Results of metrological verification

Interval set for metrological verification

Identification of the metrological verification procedure

Permissible maximum errors defined

Relevant environmental conditions and statement of any necessary corrections

Uncertainties involved in equipment calibration

Identification of persons performing calibration tests

Evidence of traceability of calibration results

Metrological requirements for the intended use of the meter

Calibration results, if required, before any adjustment, modification, or repair is made

A copy of a metrological record of meters with the above information is provided in Annex III.

4.3.2 DESIGN

A laboratory for testing electric energy meters has a calibration system of electric power meters (active

or reactive) that include one or several positions for testing the meters, three-phase, with test currents

generally up to 200A, fully electronic. The laboratory must have the capacity to test single-phase,

biphasic, or three-phase meters using the single-phase or three-phase method to two-wires, 3-wires, or

4-wires, with quick connection Type A (BOTTOM), without the need to open the meter elos, and with

controlled harmonic generation by the operator.

The calibration system rack of electric power meters may have modules in various positions depending

on the lab manufacturer. These can include 5, 10, or 20 or more positions for testing single-phase or

three-phase meters with test currents up to 120A or 200A. The racks are totally electronic and

generally easy to operate.

Figure 4 below shows a typical calibration system used at Power Meter Technics, an independent testing

laboratory based in Johannesburg, South Africa.


Figure 4. Type Test Testing Bench

If the meters under test do not allow the I-P links to open, then there is an unwanted connection

between the voltage and current path at every meter position. Because of these connections, the line

(input) and load (output) of each current measurement element is forced to be at the same potential.

An effective short-circuit path exists across the current measuring circuit of every meter under test

causing a large measurement error. It is, therefore, impossible to test multiple meters with closed I-P

links on a conventional meter test installation without additional facilities.

To test these types of meters, galvanic isolation must be provided between the current and voltage

circuits of each meter under test. This isolation must ensure that the closed I-P links in the meters do

not cause unwanted short circuits and the resultant measurement errors.

With single-phase meters, galvanic isolation can theoretically be carried out using either voltage or

current isolation transformers. With the help of such tools, a connected I-P link will not cause a short

circuit as the connection is now made on the secondary side of the transformer, thus, avoiding any

direct connection with the other meters in the circuit.

The following steps and individual test modules are integrated into the calibration system:

Function and high voltage test

Voltage and current connection/meter calibration

Meter configuration and examination of displays

Automatic laser printing of name plates

Meter testing equipment must be fully compatible with international standards, such as IEC 60736,

IS 12346, and IS 15707. For safety, meter testing must follow international standards, such as IEC 62052-

11, IEC 62053-11, IEC 62053-21, IEC 62053-22, IEC 62053-23, and IEC 61010.


4.3.3 FUNCTIONS

Each utility that chooses to invest in an in-house meter testing laboratory for calibration has reasons to

justify the investment. Some benefits of an in-house meter testing laboratory include:

Calibration of meters that have been removed from the field and reconditioned by the utility

itself or a contracted company in order to avoid buying new meters of similar type

Appraisal of meter errors in response to customer complaints or regulatory requirements

Calibration of 100 percent of newly procured meters as well as meters that were removed from

customers (for various reasons) before being reintroduced into the field

Asset management over the life cycle of the meters

To test a sample of meters provided by a manufacturer in order to evaluate the quality of the

meters with the aim of prequalifying the manufacturer to supply meters to the utility

The high cost to calibrate meters in an independent laboratory or MTB of another utility

It is very important to emphasize that this type of laboratory only evaluates the measurement error and

calibrates meters that are in perfect condition. As such, this type of laboratory cannot evaluate the error

if the meter has been tampered with or is otherwise damaged with the aim of assessing the amount of

energy the utility lost due to fraud or meter tampering.

4.3.4 ROAD MAP

To prepare an RFP to send to multiple vendors to solicit bids to build an in-house TTL, EDM should

prepare a TTL specification containing, at a minimum, the following:

Number of meters to be tested per day and annually

Number of meters per class to be tested (i.e., Class A, B, C, or D)

Types of meters to be tested (i.e., electromechanical and/or electronic meters; single-phase

and/or three-phase meters)

Standards to be followed

Report information needed and desired format

A complete technical standard based on international standards is attached in Annex IV.

Considering the types of meters used by EDM and the anticipated need to calibrate approximately

100,000 meters annually, EDM needs at least 40 positions for performing the tests. This could be done

with two racks with 20 positions per rack. The building that houses the laboratory should be at least

60 square meters and be temperature- and humidity-controlled according to the laboratory

manufacturer’s specification.

To operate a TTL, it is necessary to have at least six people dedicated to performing the tests: one

person to supervise the work, two people to operate the tests, one person to prepare the meters for


tests, one person to generate reports and store documentation, and one person to place the seal on

accepted meters and store them. All these people must be adequately trained.

The cost of a TTL varies depending on the requirements/specifications of the buyer and the quality of

equipment and services offered by the laboratory manufacturer. For traditional laboratory suppliers such

as Zera that furnish high-precision laboratories for metrological purposes, the cost of a laboratory with

two test benches with 20 positions each is approximately $275,000. For manufacturers in alternative

markets, such as China, the same laboratory can be procured for close to $50,000.

In its laboratory specifications, EDM should specify that the lab manufacturer must deliver and install the

equipment at EDM. The manufacturer must also deliver training to the technicians who will work at the

laboratory, as well as commission the laboratory by completing a run of meter testing and producing the

necessary reports.

This specification should also set the guaranteed time and maintenance procedures.

4.4 PORTABLE METER TESTING EQUIPMENT

The use of portable meter testing equipment to conduct meter calibration in the field is done by most

major utilities. Although portable meter testing equipment does not fully replace the need for a TTL, it

is a quick, cost-efficient, and effective way to check on the performance of meters installed in the field

when addressing customer complaints, completing regular meter calibration tests, and complying with

regulations. Most utilities that have full meter testing laboratories usually have some portable meter

testing equipment to support field inspections.

In addition to measuring meter error, portable meter testing equipment can also meet a variety of other

needs, such as current and voltage measurement, active and reactive power measurement, power factor

measurement, and many other electrical quantities.

Even in the case of EDM attempting to acquire a TTL, purchasing some portable meter testing

equipment can satisfy many of its needs with a very small investment, since portable meter testing

equipment costs from $1,000 to $5,000, depending on the functions of the equipment.

Annex V presents some options for portable meter testing equipment easily accessible for purchase by

EDM, with approximate costs noted in South African Rand (R).

Figure 5 below shows some photos of portable meter testing equipment, which can be used by

inspection teams in the field.


Figure 5. Portable Meter Testing Equipment


5. BUSINESS CASE FOR EDM TO BUILD ITS OWN TYPE TESTING

LABORATORY

5.1 BUSINESS IMPACTS

Building an in-house meter testing laboratory for meter calibration (or even equipment to do

accelerated life testing) is a strategic decision, and one that should not only take into account the

financial return in terms of cost benefit.

Considering EDM’s utility-wide transformation initiative, which aims to modernize the utility to make it

both more efficient and better prepared to supply good quality power to the entire population of

Mozambique, having an on-site TTL can add the following benefits:

First step toward establishing a technological center to improve EDM’s knowledge base

Development of a training program for EDM employees

Provide services to other utilities

Calibrate 100 percent of newly procured meters purchased at competitive costs

Deploy meter asset management

Reset the software on EDM’s prepaid meters to apply timely tariffs in the future

Prequalification of meter manufacturers as future suppliers of meters

More responsive to customer complaints

Also, establishing an in-house meter testing laboratory is compatible with EDM’s strategic decision to

use smart meters (AMR and AMI meters) to meter customers and automate the meter reading process,

as well as supports the evaluation of meter-related problems and helps ensure that meters are

maintained in perfect operating condition.

5.2 FINANCIAL MODEL

Considering it costs approximately $1 per meter for the manufacturer to calibrate the meters,

depending on the amount of meters to be calibrated, and it costs $2 per meter, double the

manufacturer’s cost, to have an independent laboratory calibrate the meters, it is possible to compare

an in-house meter testing laboratory with the two others mentioned above.

A specific business case was developed to assess whether it would be feasible for EDM to build its own

laboratory or whether it should continue relying on meter manufacturers to provide services. The

financial model provides a view into the business case outcomes for two types of laboratories: a low-

cost testing laboratory and a high-end testing laboratory. The key outcomes include:

1. What is the annual benefit?

2. How long is the payback period?


Variables Units

Cost Per Calibration by Manufacturer (USD) $1.00

Current Annual Installation Rate (No. of Meters) (USD)

$100,00

0

Desired Calibration (% of Total Units) 25%

Number of Meters Per Test Bench 48

Cost of Test Bench (USD)

$275,00

0

Calibration Rate Per Test Bench Per Day (No. of Meters) 500

Calibration Rate Per Year (No. of Meters) 120,000

Table 4. Key Variables of the Model


5.2.1 SCENARIO 1: EDM BUILDS AN EXPENSIVE HIGH-END TESTING LABORATORY

Table 5. Model for High-End Testing Laboratory

5.2.1.1 HIGH-END MODEL OBSERVATIONS

The cost estimate to build an in-house high-end testing laboratory is $275,000 for equipment procurement and site preparation. In this high-end

model, the average cost for EDM to calibrate its own meters is $0.77 per meter, which is 23 percent cheaper than having the manufacturer

calibrate the meters. The total cumulative financial benefit resulting from EDM conducting its own calibration activities over a 10-year period (as

opposed to paying a third party for calibration) is $227,500. As such, the savings generated from completing in-house calibration and the

expected volume of meters to be calibrated year-over-year in the future is sufficient to generate a payback on the investment over a six-year

period. In other words, it will take six years for EDM to accrue sufficient financial benefits to cover the cost of the initial capital investment to

build the high-end testing laboratory, as well as cover the operational costs associated with the laboratory over that same period.

y1 y2 y3 y4 y5 y6 y7 y8 y9 y10

TOTALS for 10 yr period

no of installations/callibrations 1 000 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000

EDM does not build their own lab, and asks manufacturer to do it

callibration cost per meter 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00

cost to calibrate 100% with vendor 1 000 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000

Cost to callibrate desired callibration rate 250 000

EDM builds their own lab but considers the cost of people

capex (USD) 302 500 275 000 27 500

o&M costs (USD) 470 000 47 000 47 000 47 000 47 000 47 000 47 000 47 000 47 000 47 000 47 000

salaries (USD) 420 000 42 000 42 000 42 000 42 000 42 000 42 000 42 000 42 000 42 000 42 000

other costs (USD) 50 000 5 000 5 000.0 5 000.0 5 000.0 5 000.0 5 000.0 5 000.0 5 000.0 5 000.0 5 000.0

Average cost of single meter callibration per year 0.77 3.22 0.47 0.47 0.47 0.47 0.75 0.47 0.47 0.47 0.47

no of benches required for EDM yearly meter volume 1

Benefit: Callibration savings from doing it yourself as opposed to

using vendor (USD) 227 500 -222 000 53 000 53 000 53 000 53 000 25 500 53 000 53 000 53 000 53 000

Cumulative NPV of benefit for 10 year period (USD) -222 000 -169 000 -116 000 -63 000 -10 000 15 500 68 500 121 500 174 500 227 500

Payback Period (years) 6


5.2.2 SCENARIO 2: EDM PURSUES A LOW-COST TESTING LABORATORY

Table 6. Model for Low-Cost Testing Laboratory

5.2.2.1 LOW-COST MODEL OBSERVATIONS

The cost estimate to build an in-house low-cost testing laboratory is $55,000 for equipment procurement and site preparation. In this low-cost

model, the average cost for EDM to calibrate its own meters is $0.53 per meter, which is 47 percent cheaper than having the manufacturer

calibrate the meters. The total cumulative financial benefit resulting from EDM conducting its own calibration activities over a 10-year period (as

opposed to paying a third party for calibration) is $469,500. As such, the savings generated from completing in-house calibration and the

expected volume of meters to be calibrated year-over-year in the future is sufficient to generate a payback on the investment over a two-year

period. In other words, it will take two years for EDM to accrue sufficient financial benefits to cover the cost of the initial capital investment to

build the low-cost testing laboratory, as well as cover the operational costs associated with the laboratory over that same period.

y1 y2 y3 y4 y5 y6 y7 y8 y9 y10

TOTALS for 10 yr period

no of installations/callibrations 1 000 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000

EDM does not build their own lab, and asks manufacturer to do it

callibration cost per meter 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00

cost to calibrate 100% with vendor 1 000 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000 100 000

Cost to callibrate desired callibration rate 250 000

EDM builds their own lab but considers the cost of people

capex (USD) 60 500 55 000 5 500

o&M costs (USD) 470 000 47 000 47 000 47 000 47 000 47 000 47 000 47 000 47 000 47 000 47 000

salaries (USD) 420 000 42 000 42 000 42 000 42 000 42 000 42 000 42 000 42 000 42 000 42 000

other costs (USD) 50 000 5 000 5 000.0 5 000.0 5 000.0 5 000.0 5 000.0 5 000.0 5 000.0 5 000.0 5 000.0

Average cost of single meter callibration per year 0.53 1.02 0.47 0.47 0.47 0.47 0.53 0.47 0.47 0.47 0.47

no of benches required for EDM yearly meter volume 1

Benefit: Callibration savings from doing it yourself as opposed to

using vendor (USD) 469 500 -2 000 53 000 53 000 53 000 53 000 47 500 53 000 53 000 53 000 53 000

Cumulative NPV of benefit for 10 year period (USD) -2 000 51 000 104 000 157 000 210 000 257 500 310 500 363 500 416 500 469 500

Payback Period (years) 2


6. CONCLUSION AND RECOMENDATIONS

Analysis of meter-related issues at EDM indicates that a large percentage of its meter failures have been

the result of poor power quality in the distribution network; a situation about which EDM is aware.

However, analysis also indicates that EDM’s concerns regarding a lack of quality control related to

meter procurement as well as in situ meter performance when subjected to more severe operating

conditions (especially, voltage fluctuation and a high level of voltage drops) is justified.

Basically, EDM has two issues to resolve: The calibration of meters and the procurement of test results

that evaluate the reliability of meters. It is recommended that 100 percent of newly procured meters be

calibrated before installation, and to do that, the business plan shows that purchasing a meter testing

laboratory for meter calibration can be a good investment. Also, it is recommended that EDM have

manufacturers conduct accelerated life testing prior to EDM’s purchase of new meters. EDM should

include in its meter specification the obligation of the manufacturer to present EDM with certificates of

the accelerated life testing for those models under purchase consideration.

Considering the fact that EDM intends to replace all prepaid integrated meters with prepaid split smart

meters (AMI), and is also replacing postpaid meters used to supply large consumers with new AMR

meters, the problems with its meter inventory will be solved in the medium or long term.

In the immediate term, if EDM wants to be more comfortable with the quality of its existing meters

already procured and installed in the field, it might contract Eskom from South Africa, a utility with

suitable accelerated life testing facilities, or an independent laboratory that specializes in accelerated life

testing and has extensive experience with prepaid meters to conduct specific tests of interest to EDM.

This would not preclude EDM from pursuing an ALTL and conducting accelerated life testing for

electrical and electromagnetic stress if senior management determines such a laboratory is needed. It

would, however, allow EDM to address the issue now as the procurement and installation of such a

laboratory certainly will take several months.


ANNEX I — TEMPERATURE TEST PLAN

The following recommended strategies may improve the probability of obtaining useful data in a timely

fashion:

1. Conduct a pilot test with a few samples to gain insight into the failure mechanism.

Such pilot tests can provide information that can be used in deciding the number of samples to

be tested and the appropriate stress levels for testing. For example, a pilot test conducted on a

few samples may show that a stress level of 125°C induced failures in the control transformer

for a particular brand of meters.

2. A decision needs to be made on the number of samples to be tested. The failure

distribution parameters can be more closely predicted when a large number of failure times are

available. Since we cannot expect all the meters to fail, a large number of samples must be

tested. The samples to be tested should be of the same manufacturer and model so that the

failure mode occurs in all of them. For example, if 20 times-to-failure is required, at least

40 meters should be tested.

3. Two temperature levels need to be determined based on the pilot tests. The pilot

test conducted at 125°C showed that it would be sufficient to induce failures. 125°C was chosen

because it is 150 percent of the design stress level and is neither too low nor falls into the

destruct levels. Hence, 125°C can be chosen as one elevated level. In order to map the

relationship to the usage level, another mid-level temperature is required, and 100°C should be

chosen. The data acquisition (DAQ) can be used to continuously monitor the meters while

testing at these temperatures.

4. Test more samples at a lower temperature (100°C) so that more failures may be

observed. The probability of failure is greater at high temperatures. As a result, testing only a

few samples at higher temperatures is advisable. The decision on distribution of the samples

relies on previous distribution data. For example, if 100 meters were available for testing and

20 meters are required to fail at each stress level, then 30 meters should be placed at 125°C

and 70 meters at 100°C.

5. Use a steeper ramp rate for the thermal cycling test so as to induce thermal stress

on solder joints. This is a limitation of the environmental chamber, and hence, a new smaller

chamber may need to be procured.


ANNEX II — AES ELETROPAULO CASE STUDY

This case study presents very briefly the decision-making process of AES Eletropaulo, a Brazilian utility,

to purchase a Class A laboratory as well as a Class B laboratory. These laboratories were purchased as

part of the utility’s strategy aimed at, among other things, the following objectives:

1. Calibrate meters that had been removed from the field for various reasons and had been

refurbished by the utility in order to reduce investments in new meters. AES Eletropaulo had a

large favela4 electrification program that required a large volume of meters, approximately

500,000 meters, to be installed in five years. The cost of a recovered meter was about

25 percent that of a new meter. The utility planned to reclaim and later calibrate

500,000 meters.

2. Most of the meters installed in the field were more than 10-years old with no recalibration.

Responding to pressure from the regulator, AES Eletropaulo prepared an inspection and

calibration plan to reach more than 2 million meters.

3. Inspect meters at the request of customers as required under Brazilian law, and recalibrate

meters with errors higher than the limit established by the regulator.

4. Structure an asset management plan to control the performance of meters throughout their life

cycle, by meter type and manufacturer, from receipt of meters in AES Eletropaulo’s warehouse

to the disposal of meters that were beyond recovery. It should be noted that at the time the

utility procured the laboratory, most meters installed in the system were electromechanical

meters (albeit from various manufacturers).

In view of the large volume of calibrations foreseen, the business plan AES Eletropaulo developed

indicated that it was advantageous to purchase a laboratory for the utility to complete all tests covered

therein instead of paying for external firms to conduct the calibrations.

At present, AES Eletropaulo’s meter storage facility, as shown in Figure 6, has been using these

laboratories for its asset management process in which all care is taken to keep the meters in perfect

operational condition and prevent the loss of revenue resulting from meter malfunction. All newly

acquired meters, as well as those removed from the field, are sent to a specific meter storage facility

located near the metering laboratory where they are properly stored until undergoing the verification

and calibration process.

The laboratory is also used to support the procurement of new meters. During the supplier

prequalification process (i.e., before a manufacturer can be registered with the utility as an acceptable

meter vendor), the vendor must send a sample meter for testing and certification by the utility.

4 A densely populated urban area with a high concentration of poor customers.


The purchase, operation, and maintenance of a TTL requires high investments and operating costs and is

only justified if the financial benefits are favorable compared with all alternatives.

Figure 6. AES Eletropaulo Meter Storage

The meters that serve the residential segment and small commercial and industrial consumers furnished

with low voltage are calibrated in a laboratory with a 2 percent accuracy class.

The meters that serve large consumers furnished with medium and high voltage are calibrated in a

laboratory with a 0.5 percent accuracy class.


Figure 7. AES Eletropaulo Meter Testing Laboratory

All calibrated meters receive a stamp with the calibration expiration date and are properly stored until

their installation in the field.

Figure 8. AES Eletropaulo Calibrated Meter Storage

Reports are generated noting results from various meter tests and the analysis of the calibration

process. These reports help to evaluate the current situation and help in the decision-making process in

determining if failures lie predominantly with one manufacturer, one model, one area of a CSA, etc. For

example, if a large number of one type of meter model is failing, the utility may engage the


vendor/manufacturer, noting significant deviations in the calibration of the meters or other types of

defects.

Figure 9. AES Eletropaulo Calibration Result Analysis


ANNEX III — CALIBRATION CERTIFICATE


ANNEX IV — SPECIFICATIONS OF A TYPE TESTING

LABORATORY

Typically, utilities have a meter testing laboratory (MTL) dedicated to their meter calibration

needs, and thus, in order to support EDM in the preparation of a technical specification for the

acquisition of an MTL, this Annex IV will present the main information that must be part of the

technical specification to purchase a TTL for performing the meter calibrations.

i. SUPPORTED METERS

The equipment should be designed to test a diverse range of electric meters, including, but not

be limited to:

Active and reactive energy meters

Electromechanical (also with impulse outputs) and electronic meters

Meters with closed I-P links

Multi-tariff meters with up to 16 tariffs

Multifunctional and multi-quadrant meters with active/reactive energy and power

registers

Prepaid meters

Smart meters with data communication

Reference standard meters, including portable meters and stationary multifunction

multimeters

Other EDM-specific meters should be added

ii. SUPPORTED TESTS

The equipment should enable performing tests as required by international standards,

including, but not be limited to:

Basic error (accuracy) test

Starting current test

No-load run test

Testing energy registers (dial test) and maximum demand indicators

Constant test

Checking the maximum demand registers (electromechanical or electronic)

Checking the pulse outputs

Preheating test

Creep test


Testing the influence of frequency, harmonic distortion, voltage, current, reverse phase

sequence, voltage unbalance, harmonic component in voltage and current circuit, odd

and subharmonic, DC and even harmonics, voltage dip, interruption test, and other

parameters on meter under test error

Others specific tests requested by EDM

iii. GENERAL COMPOSITION OF THE MTL

The meter test equipment should have a modular construction and the major parts of the

system should include:

Power Source: Single and three-phase power sources with different output powers and

different harmonics ability as required by EDM specification.

Reference Standard Meter (RSM): Single and three-phase RSMs with accuracy of 0.04,

0.02, or 0.01 as required by EDM specification.

Suspension Rack (SR): Single and three-phase suspension racks with the number of test

positions requested by EDM, different test position arrangements, manual or pneumatic

meter clamping, optional IP separating transformers, and a vast range of accessories.

Windows®-Based Executive AsTest Software: Windows®-based operating software with

wizards, rich libraries, automatic meter adjustment routines, reporting, and scripting

available in many languages. EDM’s specific features should be added upon request.

iv. REFERENCE STANDARD METER (RSM)

The class of accuracy of the RSM should be 0.02 percent for active and reactive ranges over the

entire load range and independent of the measuring mode.

The current range of the RSM should be 1 mA-120 A direct connected, and the voltage range

should be 10-500 V (phase to neutral), selectable through the PC.

The RSM should have an auto-range selection facility, a dial test facility (power dosing), and an

RS 232 serial communication port for communicating with the PC.

The RSM must be frequency output proportional to the power to calibrate against a better

standard.

Technical Data RSM:

a. Measuring Modes: 2-wire active; 3-wire active/reactive; 3-wire apparent; 4-wire

active/reactive; 4-wire apparent

b. Frequency Range: Basic frequency range of 40-70 Hz and total detectable frequency

range of 0-3500 Hz.

c. Voltage Range: 10-500 V phase to neutral


d. Current Ranges: 1 mA to 120 Amps (working range) and 20 mA to 120 Amps

(measurement range)

e. Accuracy:

• Voltage: 0.01 percent for the range of 10 V to 500 V (P-N)

• Current: 0.01 percent (50 mA to 120 A); 0.02 percent (10 mA to 50 mA);

0.05 percent (1mA to 10 mA)

• Power/Energy (for active and reactive):

- Percent at cos Ѳ= 1 or sin Ѳ= 1 (mA to 1 A)

- Percent at cos Ѳ= . or sin Ѳ= .

- Percent for the range of 1 mA to mA at cos Ѳ= 1 or sin Ѳ

= 1 (the accuracy shall be the same for active and reactive measurement)

• Phase Angle Accuracy: A common modular cabinet with doors on the front and

rear should be used to house the source meter and RSM

f. Display: The RSM shall have following parameters displayed:

• True RMS value of each voltage and current input

• Phase angle between voltage/current and defined reference

• Power factor of each phase

• Active, reactive, and apparent power of each phase

• Total active, reactive, and apparent power

• Phase sequence

• Frequency

• Integration time

g. The selection facility may be requested to conduct any or all of the five parameters

noted below. The RSM shall have the facility to maintain its last setting when it is

switched off.

1. Integration Time: The facility to select an integration time between 1 to

99 seconds shall be provided in the RSM.

2. Operation: A membrane keyboard with membrane push button to operate the

RSM shall be provided in front of the RSM.

3. Reference Channel: The RSM shall have the facility to select reference data for

phase angle measurement; the selection of reference data shall be provided

manually and automatically.

4. Frequency Output: This shall provide power proportional to the frequency output

to calibrate the RSM against a higher or lower precision RSM; this output shall be

a commonly used a Bayonet Neill-Concelma (BNC)-type socket.


5. Temperature Coefficient: The temperature coefficient of the reference meter

should be 1 ppm/K.

The bidder should submit a certificate of the RSM along with a bid to specify the

temperature coefficient of the RSM.

v. SPECIFICATION OF HARMONIC INJECTION UNIT

Over the second to the 40th harmonics range to the test voltage and test current, the

magnitude of each harmonic shall be adjustable from 0-40 percent of the fundamental wave,

and the maximum peak value of the wave form shall be 130 percent of the magnitude of the

fundamental wave.

The facility to control the phase angle of harmonics shall also be provided.

Necessary proof for a generation of wave forms and desired harmonics shall be submitted along

with the offer. The superimposition of harmonics shall make it possible to carry out all the tests

as prescribed.

vi. SPECIFICATION OF METER MOUNTING RACK

The number one. meter mounting rack shall consist of a lightweight aluminum frame for

mounting sensor heads, display devices, and meters under test.

Meters under test shall get connected to the voltage and current circuits by means of

connecting leads.

Design of the frame should be such that 10 energy meters of any type, single or three-

phase, 3-wire or 4-wire, whole or current, or CT-VT, can be safely operated and easily

accommodated on the frame. One rack shall have the capacity to mount all 10 energy

meters on one side shall be supplied along with the test bench.

Necessary BNC-type socket to test the three-phase reference meter (TTRM) against a

precision standard of higher accuracy shall be provided on the meter mounting rack.

Necessary BNC-type socket or any other suitable arrangement shall be provided on the

meter mounting rack to test the inbuilt TTRM against a precision standard of higher

accuracy without removing the inbuilt TTRM from the source cabinet.

Meter mounting racks shall be provided with a minimum of one BNC-type sockets for

the simultaneous testing of the minimum one TTRM of lower accuracy. The offered

software shall have facility to test these TTRM in automatic mode by using these

BNC-type sockets.

Necessary cables shall be provided along with equipment to test TTRM with frequency

output on the BNC-type socket.

There should be a warning lamp and two emergency push buttons fitted on the meter

mounting rack.


The offered meter test system should be capable of carrying out the following tamper

tests simultaneously:

• Accuracy test for single-phase meter on phase and neutral channel for same

magnitude of current

• Accuracy test for single-phase meter in case of reverse power on phase and

neutral channel for same magnitude of current

• Facility to disconnect neutral simultaneously for all meter

• CT open and reverse current test for three-phase meters

Test Position: As a standard, each test position should be equipped with:

• Error calculator IPO-S

• Photoelectric scanning head GS

• Relays for ON/OFF switching of the test voltage to the meter

• Voltage connection panel IPO

Scanning Heads Positioning: The scanning heads’ mechanical construction should enable

its trouble-free positioning, including up/down, right/left, forward/backward, and

horizontally rotating. All scanning heads should be moved aside together.

Separation for Closed Link Meter Testing: Testing meters with closed I-P links must be

possible with optional separating transformers installed. The rack should be equipped

with a multisecondary voltage separating transformer (MSVT), a voltage separating

transformer (VST), or a current separating transformer (CTS-D1), and can also be

equipped with CTS current separating transformers, depending on EDM’s specification.

Safety Features: The rack must comply with IEC 61010 and be equipped with:

• Emergency stop buttons

• Indicators for the presence of dangerous voltage on the terminals of tested

meters

• Fuses protecting individual voltage lines on each test position

• Others safeguards such as light curtains and protective shields if requested by

EDM

Optional Accessories:

• Current cross-connection panel

• Meter power consumption module

• Mains sockets

• Shelves

vii. SPECIFICATION OF SCANNING HEADS AND ERROR INDICATION UNITS

a. One photoelectric scanning head for each position suitable for reading the LED pulse

output of the meters under test shall be provided.

b. The scanning head shall have a vacuum/mechanical type fixing arrangement so that

same can be fixed directly on the meter body. Each scanning head shall be designed in

such a way that it can be fixed easily in a position that would facilitate accurate and

proper testing of the meters under test.


c. The scanning head should be insensitive to ambient light. It should give optical

indications of pulses by LED.

d. The scanning head must be able to measure LED pulse output (as per IEC 62052-11,

Clause 5.11) of frequencies up to 1 kHz.

e. An error indication device shall be mounted on each test position. The resolution of

error indication shall be 4 1/2 digits with decimal points configurable by software. There

shall be a provision on the error indication unit to reset the error or repeat it if

something is wrong. The same should have an acknowledgement function while doing

testing of starting current and creep tests manually.

viii.SPECIFICATION OF DIGITAL PROCESS UNIT

For the simultaneous error measurement of 10 meters under test, the basic unit shall be

equipped with:

a. Ten inputs for scanning head pulses

b. One input for reference output

c. One interface for connection with PC

d. Controlled output for dosage operation (Dial Test)

ix. ISOLATING CURRENT TRANSFORMER

a. Nominal primary current lprim = 100 A

b. Maximum primary current = 120 A

c. Nominal secondary current lsec = 100 A

d. Maximum secondary current = 120 A

e. VA rating = 50 VA at normal current (100 Amp)

f. Accuracy ratio error:

± 0.01% (1 A to 120 A) ± 0.03% (0.15 A to ˂1 A) ± 0.15% (0.02 A to ˂0.15 A) ± 0.3% (0.01 A to <0.02 A

g. Phase angle error:

± 3 min (0.15 A to <1 A) ± 10 min (0.02 A to <0.15 A) ± 20 min (0.01 A to <0.02 A)

The meter test system shall have an isolating current transformer (ICT) to test single-phase and

three-phase closed link whole current meters.


There shall be a provision to bypass the ICT automatically when a secondary ICT is kept open.

The secondary ICT shall be designed in such a way that it can be connected directly to the meter

under test. The ICT’s primary connection should be a fixed type, and all primary connections on

each ICT terminal shall be connected permanently using links. A ring type of design with a loose

primary type of connection will not be acceptable. LED indication shall be provided on the ICT

to indicate the healthiness of the ICT.

Associated software shall have the facility to indicate fault in an ICT-like open circuit and

overload on PC. A detailed layout and catalog of offered ICTs shall be submitted along with the

offer. The bidder should submit a certificate for the ICT along with the bid. In the absence of a

certificate for ICT, the bid shall be treat as nonresponsive. As and when desired by the purchaser

during evaluation, samples of the ICT shall be submitted for verification of features and

functions of the offered ICT model.

x. SPECIFICATION OF COMPUTER SYSTEM (DESKTOP PC, PRINTER, MONITOR, SOFTWARE,

AND ACCESSORIES)

The operating of the test equipment; the display of the actual values; the processing and display

of the test results; and the print out of the test results, reports, etc., should be effected by the

associated desktop personal computer (PC) system complete with a licensed Windows-based

operating system, licensed proprietary software for the meter testing equipment, and a LaserJet

printer with the minimum specifications outlined to be supplied along with the meter testing

system by the successful bidder.

The desktop PC shall be connected to the measuring device and power source, and any

necessary leads and cables for making these connections shall be provided by the vendor at his

or her cost.

The licensed proprietary software of the meter-testing equipment shall be installed on the PC.

This software should be Windows based, user friendly, menu driven, and operated with the help

of a mouse and keyboard in manual or automatic mode.

The manual mode of operation of the meter-testing equipment’s licensed proprietary software

shall allow, at a minimum, performance of the following tasks:

Control of the source

Display of test parameters (actual values) on the PC screen

Display of the wave form of output voltage and current and harmonics analysis

Performance of the accuracy tests

The automatic mode of the meter-testing equipment’s licensed proprietary software should

have different modules to prepare the meter for the test sequence to be carried out in fully

automatic mode. These modules shall be designed in such a way that a user can prepare the


test sequence very easily. The meter-testing equipment’s licensed proprietary software shall

allow or include, at a minimum, the following:

User interface to operate the system

Easy-to-prepare test tables using the drag-and-drop concept

Supervision and control of the test procedure

Supervision and display of the test current and voltage

Indication of the errors of the meters under test — Evaluation of the test results and

generation of test reports

Manual testing and an automatic testing facility

Facility to define test parameters in terms of percentage and absolute terms

Facility to define the error limit in two levels

Facility to protect the system from over voltage in manual and automatic modes

Facility to check meters for short circuit and open circuit conditions prior to starting the

testing for each sequence in fully automatic mode

Facility to interrupt and restart the testing

Password facility for administrators and operators with different levels

Print out facility for test reports with desired header

Facility to create a backup of data

Absolute measurement with higher precision and a more accurate standard in fully

automatic mode using a BNC-type socket provided on the meter mounting rack

Testing facility for at least 20 different meters with 20 different constants

Software shall have the facility to display different output voltages and currents

Facility to display the curve of test voltage and current in the presence of harmonics

Protection of meters under test from high voltage and current

Software shall have the facility to indicate fault in the ICTs (e.g., open circuit and

overload) on the PC for easy identification by the operator. The meter-testing

equipment’s licensed proprietary software shall have the capacity to display the

following parameters:

• Individual phase voltage

• Individual phase current

• Phase angle and power factor of symmetrical or asymmetrical star system

• Total Power Factor — Individual phase power (active, reactive, and apparent)

• Total Power — (active, reactive, and apparent) — Frequency — Phase

Sequence — Measurement mode

• Vectorial display


xi. CALIBRATION AND TESTING

The meter testing system shall be supplied, along with the test certificate and calibration

certificate of the RSM. The calibration certificate shall be issued by a nationally or internationally

recognized and accredited laboratory.

xii. DOCUMENTATION

Two set of the following documents shall be supplied along with each test system:

Operating manual for each component of test equipment, such as RSM, amplifier, etc.

Wiring diagram

Service manual

Calibration certificate for the RSM

Test certificate for the complete test system

xiii. INSTALLATION AND COMMISSIONING

The supplier shall be responsible for installing and commissioning the meter test equipment at

the EDM location. The supplier shall submit the layout plan, installation proposal, and electric

supply requirements within four weeks of receiving the purchase order. EDM will arrange the

allocation of a room, location, electric supply, etc., as defined in IEC 62052-11. The allocated

room shall be renovated with an interior partition wall with door, floor tiling, false ceiling, air

conditioning, lighting, and power sockets as required for the meter testing laboratory.

xiv. TRAINING

The supplier shall train EDM’s technicians free of charge at their workplaces to familiarize them

with the design, application, operation, and maintenance of the test bench.


ANNEX V — PORTABLE EQUIPMENT FOR METER

CALIBRATION

The Metes 12 and Metes 32 Ranges

1. Metes 12.1 Single-Phase Electricity Dispenser Accuracy Verifier — This unit has internal current

sensing with current ranges of 1A, 5A, and 15A (meant for a normal 15A plug outlets). Price Per

Unit: R11,788 (excluding value-added tax (VAT)).

2. Metes 12.2 Single-Phase Electricity Dispenser Accuracy Verifier — This unit has an external

clamp-on current sensor with current ranges of 1A, 10A, and 100A. Maximum cable diameter of

10 mm. Price Per Unit: R14,965 (excluding VAT).

3. Metes 32.1 (100) Three-Phase Electricity Dispenser Accuracy Verifier — This unit has three

external clamp-on current sensors with current ranges of 1, 10, and 100A. Maximum cable

diameter of 10 mm. Price Per Unit: R28,550 (excluding VAT).

4. Metes 32.1 (200FL) Three-Phase Electricity Dispenser Accuracy Verifier — This unit has three

external flexible sensors with current ranges of 20 and 200A. Maximum cable diameter of


5. Metes 32.1 (1000FL) — Three-Phase Electricity Dispenser Accuracy Verifier. This unit has three

external flexible sensors with current ranges of 100 and 1000A. Maximum cable diameter of


6. Memory Option and PC Software Database for Each of the Above — This allows the user to

store test results and download them to the supplied PC for printing and archiving. (Only R984,

if memory only, for cases in which the user has already purchased the software). Price Per Unit:

R3,400 (excluding VAT).

Metes 320+ Accessories

These are meant for LPU metering point work, particularly for LPU metering installations in which the

current sensors have the ratio and phase correction to provide prime power/energy calibration

verification accuracies. The power lies in the fact that a user can place the LV primary sensors over the

cable or bus bar and do an energy balance to the pulsing LED on the meter, meaning the whole

metering installation is being verified, including the CTs. The ratio of the CT is also measured and the

phase error displayed. All of the above information is stored in an onboard database for later download

to the central database for viewing, printing, reporting, and archiving.

1. Metes 320 Metering Ref Standard and Installation Certifier with Onboard Database and PC

Software — The unit has a large graphical screen for vector display. Price Per Unit: R46,800

(excluding VAT).

2. Smartprobes SP100 for Metes 320 — External current sensors 3x external clip-on current

sensors for Metes 320 with ratio and phase error correction and current ranges of 1, 5,

and100A. Maximum cable diameter of 10 mm. Price Per Set: R11,320 (excluding VAT).


3. Smartprobes SP1000FL for Metes 320 — External current sensors 3x external flexible current


and 1000A. Maximum cable diameter of 140 mm. Price Per Set: R12,480 (excluding VAT).

4. Smartprobes SP2000FL for Metes 320 — External current sensors 3x external flexible current


and 2000A. Maximum cable diameter of 140 mm. Price Per Set: R13,640 (excluding VAT).

Higher Accuracy External Current Sensors for Metes 320

1. Smartprobes SP1000 for Metes 320 — High accuracy external current sensors 3x external Mu

metal core clip-on current sensors for the Metes 320 with ratio and phase error correction and

current ranges of 100, 300, and 1000A. Maximum cable diameter of 52 mm. Price Per Set:

R18,640 (excluding VAT).

2. Smartprobes SP5KY for Metes 320 — High accuracy external current sensors 3x external slim

line clip-on current sensors for Metes 320 with ratio and phase error correction and current

ranges of 0.1A, 1A, and 5A. Maximum cable diameter of 8 mm. Ideal for panel operations in

which space is limited, as well as for low-current sensing at the highest level of accuracy. Price

Per Set: R16,820 (excluding VAT).

3. Ferraris Meter Optical Eye for All Instruments Above — A lightweight laser optical light with a

quick-fitting bracket for all Ferraris meter calibrations. Price Per Set: R4,400 (excluding VAT).

4. Three-Phase Load Box — This load box is strongly recommended for field verification work at

metering points. It includes a three-phase load for testing metering installations in which there is

too low of a load or no load. It introduces 3x 25A load at a 0.866 power factor to enable Wh

and volt ampere reactive-hour (VARh) testing. It includes a five-minute timer and two industrial

cooling fans, as well as over current protection. Price Per Unit: R25,355 (excluding VAT).


About Deloitte

Deloitte refers to one or more of Deloitte Touche Tohmatsu Limited, a UK private company limited by guarantee (“DTTL”), its network of member firms, and their related

entities. DTTL and each of its member firms are legally separate and independent entities. DTTL (also referred to as “Deloitte Global”) does not provide services to clients.

Please see www.deloitte.com/about for a detailed description of DTTL and its member firms. Please see www.deloitte.com/us/about for a detailed description of the legal

structure of Deloitte LLP and its subsidiaries. Certain services may not be available to attest clients under the rules and regulations of public accounting.

Copyright © 2016 Deloitte Development LLC. All rights reserved.

Member of Deloitte Touche Tohmatsu Limited

http://www.deloitte.com/about

http://www.deloitte.com/us/about

EDM Meter Testing Lab Final 1.0 - usaid.gov · PDF fileEDM Electricidade de Moçambique...

Documents

Transcript of EDM Meter Testing Lab Final 1.0 - usaid.gov · PDF fileEDM Electricidade de Moçambique...