1. Partial Discharge Testing – Ensuring Electrical Insulation Integrity
At KC India Test Laboratories LLP, we specialize in providing precise and reliable Partial Discharge (PD) Testing for a wide range of electrical equipment. Partial discharge is a localized dielectric breakdown in an electrical insulation system under high voltage stress, which does not completely bridge the space between two conductors. While it may appear minor initially, electrical testing if left undetected, partial discharges can deteriorate insulation, leading to equipment failure, fire hazards, and costly downtime.
What is Partial Discharge Testing?
Partial discharge testing is a critical diagnostic method used to detect, locate, and evaluate weak spots or faults in the insulation of medium and high-voltage equipment. It is especially important in evaluating:
● Power transformers
● Switchgear
● Rotating machines (motors and generators)
● Cables and accessories
● Bus ducts
● Insulators and bushings
These discharges are symptoms of defects such as voids, cracks, or contaminations within the insulation, and over time, they can evolve into complete breakdowns.
1. Prevention of Failures: Early detection of partial discharge allows maintenance teams to address insulation degradation before it results in costly damage or failure.
2. Quality Assurance: For manufacturers, PD testing ensures that products meet design and quality specifications before dispatch.
3. Asset Life Extension: By continuously monitoring and maintaining electrical insulation systems, the operational lifespan of assets can be significantly increased.
4. Compliance and Safety: Adhering to international standards (like IEC 60270 and IEC 60034) through PD testing helps ensure regulatory compliance and workplace safety.
At KC India Test Laboratories LLP, our facility is equipped with advanced test setups that support both online and offline partial discharge measurements. We utilize:
● High voltage AC sources
● Coupling capacitors
● Detection and measurement units
● Calibrators for precise measurements
● Spectrum analyzers and time-domain reflectometry
We perform testing as per IEC, IS, IEEE, and other international standards, offering both type and routine tests.
We cater to various sectors including:
● Power generation and transmission
● Electrical equipment manufacturers
● Railways and metros
● Renewable energy (solar and wind)
● Oil and gas industries
● Heavy machinery and industrial plants
Why Choose KC India Test Laboratories LLP?
● State-of-the-art Facility: Our lab is ISO/IEC 17025 accredited and follows stringent quality and calibration protocols.
● Expert Engineers: Backed by experienced electrical engineers and PD specialists.
● Comprehensive Reports: Detailed, standards-compliant reports that support decision-making and corrective actions.
● Client-Centric Approach: We offer custom testing solutions based on your equipment, operating conditions, and risk profiles.
2. Heat Cycle Testing – Validating Thermal Endurance of Electrical Components
At KC India Test Laboratories LLP, we offer precise and standards-compliant Heat Cycle Testing services for electrical and cable systems. This test is essential for evaluating how materials and components withstand thermal stresses over repeated heating and cooling cycles—mimicking real-world load conditions that can affect the durability, performance, and safety of electrical infrastructure.
Heat Cycle Testing, also known as Thermal Cycling Test, involves subjecting electrical conductors, joints, terminations, and cable systems to repeated cycles of heating and cooling. These cycles simulate the thermal stresses that occur in actual service conditions, particularly when electrical load is switched on and off repeatedly.
The test is designed to verify:
● Thermal stability of conductors
● Mechanical endurance of joints and terminations
● Integrity of insulation material under varying temperatures
● Resistance to expansion and contraction-related damage
The components are monitored throughout the test to identify signs of thermal degradation, loosening of connections, cracking of insulation, or failure in performance due to repeated expansion and contraction.
Purpose and Importance of Heat Cycle Testing
1. Assess Long-Term Durability: Detects potential failure mechanisms caused by temperature variations and ensures materials can withstand years of service.
2. Prevent Overheating and Failures: Ensures that joints and cables maintain consistent electrical performance under thermal load, minimizing fire and breakdown risks.
3. Conformance to International Standards: Helps manufacturers and utilities meet testing requirements under standards such as IEC 61238-1, IEC 60840, IS 13573, and others.
4. Improve Product Reliability: Testing validates product design and assembly processes, particularly for high-voltage and heavy-duty applications.
KC India Test Laboratories LLP is equipped with advanced heat cycle test setups that allow us to simulate a wide range of operating temperatures and cycle durations. Our setup includes:
● High-capacity power supplies for controlled current flow
● Infrared thermal sensors and thermocouples for real-time temperature tracking
● Customized environmental chambers (if needed)
● Data acquisition systems to record performance throughout the test
We can perform tests on:
● Power cables (LT and HT)
● Cable joints and terminations
● Lugs and connectors
● Busbars and switchgear components
● Metal-clad assemblies
A typical heat cycle test includes:
● Mounting the sample as per standard test configurations
● Passing rated or overload current to heat the conductor
● Monitoring temperature rise
● Allowing the sample to cool down under specified conditions
● Repeating the cycle (up to 100 or more cycles depending on the standard)
The sample is evaluated before, during, and after the test for any mechanical or electrical degradation, visual deformities, or loss of insulation integrity.
● Cable Manufacturers
● Electrical Jointing Kit Manufacturers
● Transmission and Distribution Companies
● Renewable Energy Plants
● Heavy Electrical Equipment Manufacturers
Why Choose KC India Test Laboratories LLP?
● Standardized Testing: Conducted in compliance with international testing standards.
● Modern Infrastructure: High-accuracy monitoring and data capture systems.
● Fast Turnaround: Efficient scheduling and detailed reporting.
● Experienced Team: Professional engineers and test operators with expertise in high-current testing.
3. Tracking Resistance Test – Evaluating Surface Insulation Performance
At KC India Test Laboratories LLP, we conduct precise and reliable Tracking Resistance Testing to determine the ability of insulating materials to resist electrical tracking. This test is crucial for manufacturers and users of electrical components, especially those exposed to moisture, contaminants, or high voltage stresses in demanding environments.
Electrical tracking is a surface degradation phenomenon that leads to the formation of carbonized conductive paths across an insulating material due to electric discharges. If not prevented or detected early, it can result in insulation failure, equipment damage, or even fire.
What is Tracking Resistance Testing?
Tracking Resistance Testing, also referred to as the Comparative Tracking Index (CTI) test, measures the material’s resistance to surface tracking when subjected to high voltage and a contaminating electrolyte. The test is performed using standard methods defined under IEC 60112, ASTM D3638, and IS 2824.
During the test, a liquid contaminant (commonly ammonium chloride solution) is dropped between two electrodes placed on the test sample, while a gradually increasing voltage is applied. The Comparative Tracking Index (CTI) is defined as the maximum voltage at which the material can withstand 50 drops of electrolyte without tracking or breakdown.
Why Tracking Resistance Testing is Important
1. Ensures Safety: Prevents electrical fires and breakdowns caused by surface tracking on insulators or plastic enclosures.
2. Material Qualification: Essential for certifying the suitability of plastic or polymer materials in high-voltage and moist environments.
3. Standards Compliance: Required for safety certification in accordance with IEC, UL, and IS standards.
4. Design Improvement: Helps manufacturers select and improve insulating materials for better performance and durability.
Tracking resistance testing is essential in:
● Electrical connectors and terminals
● Switchgear and distribution boxes
● Printed circuit boards (PCBs)
● Lighting fixtures and enclosures
● Home appliances and consumer electronics
● Automotive electrical systems
● Outdoor electrical systems and insulators
Our Tracking Resistance Testing Capabilities
At KC India Test Laboratories LLP, we perform CTI and PTI (Proof Tracking Index) testing using fully automated, microprocessor-controlled test setups. Our facility includes:
● Precision electrode arrangement with calibrated droppers
● High-voltage test sources up to 600V and beyond
● Programmable contaminant drop rate
● Real-time data logging for voltage, current, and number of drops
● Climate-controlled conditions for consistent and repeatable results
We test a wide variety of polymeric materials, thermoplastics, thermosets, and composite insulators in accordance with international testing procedures.
The results of the test classify materials into different tracking resistance categories:
● CTI > 600 V: Category I (highest resistance)
● CTI 400–599 V: Category II
● CTI 250–399 V: Category IIIa
● CTI 100–249 V: Category IIIb
● CTI < 100 V: Low tracking resistance
This classification helps product designers choose the right insulation material based on application voltage and pollution levels.
Why Choose KC India Test Laboratories LLP?
● NABL Accredited Facility: Trusted by top manufacturers across India.
● Precision Testing Equipment: Assures accurate, repeatable, and standards-compliant results.
● Detailed Certification Reports: With visual observations and voltage classification.
● Technical Expertise: Team of professionals with deep knowledge of insulation material behavior under electrical stress.
4. High Voltage Test – Ensuring Electrical Safety and Insulation Strength
KC India Test Laboratories LLP offers advanced and reliable High Voltage (HV) Testingservices to evaluate the dielectric strength and insulation integrity of electrical components, cables, and equipment. This test is a fundamental requirement in quality assurance, safety compliance, and performance verification in high-voltage systems.
High Voltage Testing is essential to confirm that an electrical system can safely handle operating voltages and occasional overvoltage conditions without breaking down or leaking current through its insulation.
High Voltage Testing—also known as Dielectric Strength Testing or Hipot Testing—is performed by applying a controlled overvoltage to an electrical product for a specific duration to verify insulation resistance and leakage current levels. The test helps determine whether the equipment can withstand operating conditions without failure.
There are two primary types of HV tests:
1. AC High Voltage Test: Uses alternating current to evaluate insulation under real-world stress conditions.
2. DC High Voltage Test: Uses direct current and is suitable for testing certain types of cables and equipment with lower leakage tolerance.
Objectives of High Voltage Testing
● Verify insulation quality and strength
● Detect manufacturing defects, voids, or cracks in insulation
● Ensure compliance with national and international safety standards
● Prevent future failures due to insulation breakdown
● Ensure equipment is safe for operation in high-voltage environments
Our laboratory provides HV testing services for a wide range of products, including:
● Low and High Voltage Cables
● Electrical Panels and Switchgear
● Transformers
● Motors and Generators
● Circuit Breakers and Contactors
● Capacitors and Bushings
● Insulation Materials and Cable Accessories
● Industrial Machines and Wiring Assemblies
At KC India Test Laboratories LLP, all High Voltage Testing is conducted as per international and Indian standards such as:
● IEC 60243 (Electrical strength of insulating materials)
● IEC 60060 (High-voltage test techniques)
● IS 2099, IS 13573, IS 694, IS 7098, and others
● IEEE and ASTM standards, depending on application
Our High Voltage Testing Capabilities
Our state-of-the-art laboratory is equipped with:
● AC & DC high voltage sources (up to 300 kV)
● Digital meters for precise leakage current measurements
● Automatic safety interlocks and emergency trip systems
● Data logging and real-time monitoring systems
● Insulated test bays for high-voltage applications
We offer both type tests for product development and certification, as well as routine production tests for batch quality checks.
Why Choose KC India Test Laboratories LLP?
● NABL Accredited Facility: Our HV test lab meets ISO/IEC 17025 standards for high-voltage testing.
● Trained Professionals: Experienced engineers and technicians who specialize in high-voltage safety.
● Fast Turnaround: Efficient scheduling with minimal lead times.
● Comprehensive Test Reports: Detailed results, graphs, observations, and pass/fail status with applicable standards.
Applications Across Industries
● Power Generation & Distribution
● Electrical Manufacturing
● Renewable Energy Systems
● Railways and Metro Projects
● Construction and Infrastructure
● Automotive & Industrial Controls
5. Impulse Test – Verifying Equipment Performance Under Transient Overvoltages
At KC India Test Laboratories LLP, we provide precise and standard-compliant Impulse Testing services for high-voltage equipment and insulation systems. This test is crucial to simulate lightning strikes and switching surges that electrical components may be subjected to during their operational life. By recreating these extreme transient events in a controlled environment, we help manufacturers and utilities verify the durability and design integrity of their electrical assets.
Impulse Testing, also known as Lightning Impulse Test or Switching Impulse Test, evaluates the capability of an electrical device to withstand extremely high voltage transients (typically lasting a few microseconds). These impulses replicate the effect of:
● Lightning strokes (1.2/50 μs waveform)
● Switching surges in high-voltage systems (250/2500 μs waveform)
Impulse tests help determine the insulation strength and reveal any weak points or manufacturing defects that may not show up during regular high-voltage or dielectric tests.
1. Simulates Real-World Overvoltages: Assesses equipment response to natural and operational high-energy transients.
2. Ensures Insulation Coordination: Helps in designing systems that can safely manage expected overvoltage stresses.
3. Validates Design & Quality: Confirms equipment durability before dispatch or installation.
4. Standard Compliance: Mandatory for high-voltage components as per IS, IEC, and IEEE standards.
5. Reduces Field Failures: Detects internal flaws like voids, cracks, and poor connections before equipment is deployed.
Impulse testing is typically conducted on:
● Power and distribution transformers
● Bushings and insulators
● Circuit breakers and switchgear
● Cables and cable terminations
● Arresters and capacitors
● Rotating electrical machines
● High-voltage connectors and joints
We conduct impulse tests as per global standards, including:
● IEC 60076-3 (Transformers – Insulation levels, dielectric tests)
● IEC 60060-1 (High-voltage test techniques)
● IS 2071, IS 10028, IS 13573, and others
● IEEE Std C57.98, ASTM D1868 for material evaluation
Our Impulse Testing Capabilities
KC India Test Laboratories LLP is equipped with a modern impulse test setup, including:
● High-energy impulse generators (up to several hundred kV)
● Precision voltage dividers and digital oscilloscopes
● Waveform control systems to achieve standard front and tail times
● Automated recording and analysis tools
● Shielded and grounded impulse testing bays for safety
Each test includes waveform verification (wave shape, peak voltage, time to front, and time to half-value) and fault observation using oscillographic or digital monitoring.
We offer:
● Full-wave and chopped-wave testing
● Impulse voltage polarity reversal (for certain applications)
● Failure analysis and post-test evaluation
Why Choose KC India Test Laboratories LLP?
● NABL Accredited Facility with ISO/IEC 17025 certification
● Experienced Engineers in high-voltage and insulation diagnostics
● Precision Equipment ensuring accurate waveform generation and measurement
● Comprehensive Test Reports with waveform traces, data logs, and pass/fail status
● Custom Test Solutions for transformers, switchgear, and specialty components
6. UV Test – Assessing UV Resistance for Long-Term Outdoor Durability
At KC India Test Laboratories LLP, we offer advanced and standards-compliant UV Testing (Ultraviolet Testing) services to evaluate the weathering resistance of materials and products exposed to sunlight and harsh environmental conditions. This test is essential for manufacturers who need to ensure their products can withstand prolonged exposure to UV radiation without degradation, discoloration, cracking, or loss of mechanical integrity.
UV Testing involves exposing materials to controlled ultraviolet (UV) light under simulated environmental conditions to assess how they age or deteriorate over time. It is a form of accelerated weathering test designed to replicate the effects of natural sunlight—especially the UV spectrum, which is most damaging to plastics, rubbers, coatings, paints, and electrical insulation materials.
We perform this test using UV chambers equipped with fluorescent or xenon arc lamps, replicating months or years of sunlight exposure within days or weeks. The test may also involve cycles of UV radiation, heat, humidity, and water spray to simulate real-world outdoor conditions more accurately.
1. Evaluates Product Lifespan: Helps predict how long a product will last in outdoor environments.
2. Ensures Safety and Performance: Detects early signs of cracking, fading, or surface degradation that could affect product performance.
3. Supports Material Selection: Assists in choosing UV-stabilized materials for outdoor use.
4. Complies with Industry Standards: Mandatory in sectors like solar energy, automotive, electrical enclosures, and construction.
5. Avoids Costly Field Failures: Ensures durability before product deployment, reducing warranty claims or recalls.
Our UV test services cover a wide range of materials and finished products, including:
● Cable sheaths and insulation
● Plastic enclosures and housings
● Solar panel components and junction boxes
● Electrical switchgear and control panels
● Street light covers and outdoor signage
● Automotive interior and exterior parts
● Industrial coatings, paints, and films
● Roofing membranes and construction polymers
We conduct UV Testing as per national and international standards such as:
● ASTM G154 / ASTM G155 – Standard practice for UV exposure using fluorescent/ xenon arc lamps
● ISO 4892-2 / ISO 4892-3 – Plastics exposure to UV light
● IEC 60216-4-4, IEC 60587, and IEC 62217 – For electrical insulation and polymeric materials
● IS 6746 – Plastic materials for cable sheaths
● UL 746C – Polymer testing for electrical components
KC India Test Laboratories LLP uses high-performance UV weathering chambers that allow:
● Accelerated aging from 100 hours to 2000+ hours
● Simulation of natural sunlight using UVA/UVB or xenon lamps
● Temperature and humidity control during exposure
● Water spray and condensation cycling
● Regular monitoring and evaluation of physical, color, and mechanical changes
Post-exposure, we analyze:
● Color changes (ΔE)
● Surface cracking or chalking
● Gloss loss
● Mechanical property degradation (e.g., tensile strength, elongation)
● Electrical insulation breakdown (for cable and polymer testing)
Why Choose KC India Test Laboratories LLP?
● NABL Accredited Lab following ISO/IEC 17025 guidelines
● Custom Test Durations based on client specifications and application needs
● Expert Evaluation and detailed reporting with before/after comparisons
● Application-Specific Recommendations for material selection and product improvement
7. Dynamic Penetration Test – Assessing Mechanical and Impact Resistance
At KC India Test Laboratories LLP, we offer certified and reliable Dynamic Penetration Testing to evaluate the impact strength and mechanical durability of materials and components under sudden dynamic loads. This test is critical for assessing how a material behaves when struck by a high-speed object or force, making it especially important for components used in protective enclosures, cable jackets, electrical housings, and safety equipment.
What is a Dynamic Penetration Test?
Dynamic Penetration Testing is a type of mechanical test where a pointed or blunt object is dropped or forced against a material or component at a high velocity to simulate real-world impact conditions. The objective is to assess the resistance of the test specimen to puncture or failure when subjected to a fast, concentrated force.
This test is particularly useful for:
● Verifying protective qualities of cable sheaths
● Evaluating material strength for underground and armored cables
● Ensuring durability of plastic enclosures, panels, or insulation
● Assessing components intended for outdoor, industrial, or hazardous environments
Why is Dynamic Penetration Testing Important?
1. Simulates Real-World Hazards: Accurately mimics mechanical damage from dropping tools, falling debris, or impacts in transit or installation.
2. Determines Safety Margins: Identifies material failure points before the product enters the field.
3. Ensures Product Reliability: Enhances customer trust and reduces field failures.
4. Standards Compliance: Required for various industry standards including IS, IEC, and UL.
5. Supports R&D and Material Selection: Helps engineers choose or improve materials for specific mechanical strength.
Dynamic Penetration Testing is applicable across multiple sectors:
● Power Cables & Electrical Wiring
● Telecommunication Cables
● Polymer Enclosures & Distribution Boards
● Energy and Utility Infrastructure
● Automotive Components
● Industrial Equipment and Tool Casings
KC India Test Laboratories LLP conducts this test according to national and international standards such as:
● IEC 60794-1-21 – Mechanical tests on optical fibre cables
● IEC 60229 – Tests on cable oversheaths
● IS 7098, IS 1554, and IS 694 – For power and control cables
● ASTM D3763 – High-speed puncture testing of plastic films and sheeting
● UL and BIS guidelines – Where applicable
We use precise impact test rigs and penetration equipment featuring:
● Controlled drop weights from various heights
● Adjustable impact heads (conical, hemispherical, flat)
● Real-time force and displacement sensors
● High-speed data acquisition and result logging
● Optional temperature-conditioned testing (to simulate real-world environments)
After testing, our engineers evaluate:
● Depth and shape of penetration
● Presence of cracks or rupture
● Material displacement and deformation
● Pass/fail compliance as per test standard
Why Choose KC India Test Laboratories LLP?
● NABL Accredited Testing Facility ensuring trusted, standard-compliant results
● Experienced Mechanical Engineers to conduct and interpret tests accurately
● Modern Equipment capable of simulating a wide range of mechanical stresses
● Detailed Test Reports with photographic documentation and data analysis
● Quick Turnaround Time and support for custom testing