Testing & Comm Procedure-Rev 10-Enppi

Projects & Services Execution Division
Field Operations Services
__________________________________________________________________________________
Procedure For
Pre-Commissioning, Commissioning & Startup of
Electrical Equipment
Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Rev.10
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Index
Table Of Contents
Page
1. INTRODUCTION
2. SAFETY
3. Medium Voltage Equipment
3.1.1. Pre-Commissioning visual & mechanical inspection
3.1.2. Commissioning
3.1.3. Pre-Energization Checks
3.1.4. Energization Precautions and procedures
3.1.4.1. Precautions
3.1.4.2 .Procedures for Energization
10
3.2 MV Circuit Breakers
11
14
3.2.2. Vacuum C.B
11
15
3.2.2.1 Pre-Commissioning visual & mechanical inspection
11
16
3.2.2.2. Commissioning
11
17
3.3 Protective Relays
12
18
12
19
12
20
3.4 Current Transformers
13
21
13
22
13
23
3.5 Voltage Transformers
14
24
14
25
14
26
3.6 Power Transformers
15
27
3.6.1. Liquid Filled Transformers
15
28
15
29
15
30
3.6.1.3. Pre-Energization Checks
16
31
3.6.2. On Load Tap Changer (OLTC)
17
32
17
33
17
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34
3.7 Capacitors (Power factor Correction)
19
35
19
36
19
37
20
38
3.8 MV Motor Starters & Power Feeders
21
39
21
40
21
41
23
42
4. Low Voltage Equipment
24
43
4.1 LV Switchgear (Metal Enclosed)
24
44
24
45
24
46
25
47
4.2 LV Circuit Breakers
26
48
4.2.1. Insulated Case / Molded Case
26
49
26
50
26
51
4.2.2. LV Power (Air C.B)
52
27
53
27
54
4.3 LV Motor Starter& Power Feeders
28
55
28
56
28
57
29
58
4.4 Interposing Relay Panel
30
59
30
60
30
61
4.5 Active Harmonic Filter (AHF)
31
62
31
63
31
54
4.6 Neutral Earthing Resistor (NER)
32
27
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65
32
66
32
67
4.7 AC/DC power Distribution Boards.
33
68
33
69
33
70
5. Safe Energization Precautions
34
71
6. Appendix A: List of tables
35
72
7. Appendix B: Norms
40
73
8. Appendix C: List of used equipment in Pre-commissioning

Commissioning Phase
41
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1. INTRODUCTION
The purpose of these specifications is to assure that all tested electrical equipment and systems supplied by SEE
(SCHNEIDER ELECTRIC EGYPT & NEA) are operational and within applicable standards and tolerances
And that equipment and systems are installed in accordance with design specifications.
The need for acceptance testing of electrical power systems is very clear to those with extensive start-up and/or
operating experience. Shipping and installation damage, field and factory wiring errors, manufacturing defects,
And systems and components not in accordance with drawings and specifications are some of the many
problems that can be detected by appropriate testing. When these defects are found before start-up they can
be corrected under warranty and without the safety hazards and possible equipment and consequential damages
of loss of use/production that can occur if discovered after startup or energizing. In addition, test results obtained
during acceptance testing are invaluable as base reference data for the periodic testing that is an essential element
of an effective maintenance program.
This document lists a majority of the field test available for assessing the suitability for service and reliability of
the power distribution system.
As a further note, it is important to follow the recommendations contained in the manufacturers instruction
manuals. Many of the details of a complete and effective acceptance testing procedure can only be obtained from
that source.
This document details the Field inspection, testing and commissioning procedures that must be followed during
commissioning and startup of electrical equipment. These inspections and tests are performed on new
Equipment, after installation and prior to energizing, in order to confirm that:
1. The equipment has not been damaged during shipment or installation.
2. The equipment is in compliance with the purchase specification and design intent.
3. Documented test records that can serve as benchmarks for future tests.
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2. SAFETY
Proper safety procedures shall be reviewed and followed before each activity listed in this procedure. Job Safety
Analysis followed by a toolbox/pre-job meeting shall be conducted prior to any activity listed in this procedure.
Services Employees are NOT authorized to work on live equipment. There may be occasions in which you are
taking measurements or checking voltages within an energized enclosure, but you are NOT authorized to do
Hands on Live repairs.
Company representative does not typically perform shutdown and/or switching operations, because these
operations may result in damage to property or persons downstream of the equipment as a result of conduct,
errors, or omissions made by others. If a customer requests Company representative to perform such services,
technicians must contact their Manager for approval and proper procedures.
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3. Medium Voltage Equipment

3.1 MV Switchgear (Metal enclosed): from 1 up to and include 40.5 KV
3.1.1. Pre-Commissioning visual & mechanical inspection:
1. Verify that equipments name plates are according to the corresponding drawings.
2. Inspect physical and mechanical condition of the equipments and all components for clear damage.
3. Verify appropriate anchorage, required area clearances, physical damage, and correct alignment and
cleanliness.
4. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware.
5. Verify that the barriers and shutters are installed and operating correctly.
6. Inspect insulators for evidence of physical damage or contaminated surfaces.
7. Verify that filters are in place and all ventilation openings are clear from any kind of obstacles.
8. Verify that main bus bar is connected between the cells.
9. Verify that the earth bars is connected between the cells and connected to the earth.
10. Verify the tightness of accessible bolted electrical connections using the calibrated torque-wrench
method in accordance Table 1
11. Using conductivity test, check the bolted electrical connections for high resistance.
12. Confirm that lubricants have been correctly applied at the recommended locations.
13. Inspect all mechanical indicating devices for correct operation.
14. Attempt closure on locked-open devices. Attempt to open locked-closed devices.
15. Verify key exchange with devices operated in off- normal position.
16. Verify that draw out disconnecting contacts, grounding contacts and interlocks are functioning correctly.
17. Verify that fuse and/or circuit breaker size and type correspond to drawings.
18. Verify that current and potential transformer ratios correspond to drawings.
19. Verify that all the interconnection control wires between the cells have been made correctly reference to
the control drawings.
20. Verify that customer connections to remote power, operators, interlocks, and indicators have been made.
3.1.2. Commissioning:
1. Check the availability of the required auxiliary supply for control operation.
2. Make sure that cables (Inc/Out) are centered inside the toroide (if found) and the toroide
direction and connection are according to the catalogue.
3. Check the phase sequence of the incoming cables using phase sequence device on the secondary
connection of the potential transformer.
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4. Perform a control wiring performance test by applying control voltage and verify that the equipment
operates as intended.
5. Test individual circuit breakers or switches in accordance Section 3.2MV C.B.
6. Test protective relays in accordance with Section 3.3Protective Relays
7. Tests instrument transformers in accordance with Section 3.4: Current Transformers and Section 3.5:
Voltage Transformers
8. Perform function operation test to prove correct interaction of all sensing, processing and protecting
devices also proves that the control/auxiliary supply is connected properly and alarms and indications are
appearing correctly.
9. Perform functional interlock test to prove the proper operation and indications of interlock scheme
(electrical / mechanical)
10. Test the anti-condensation heaters by connecting the power supply and measure the consumed current
using clamp meter and check the settings of the thermostat.
11. Check ventilation fans operation.
12. Perform insulation-resistance tests (Megger Test) on each bus section, phase-to-phase and phase-toground, at the DC test voltage appropriate for the equipments Maximum Rated Voltage in accordance
with Table 2. Record the resistances. If the resistance is lower than the recommended values in Table 2,
visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not
reveal the causes, clean the equipment well, then re- measure. If cleaning does not reveal the causes, dry
the equipment for a minimum of 4 hours using heat and fans. Then re-measure.
13. Perform insulation-resistance tests (Megger Test) at the DC test voltage appropriate for control wiring in
accordance with Table 2.
14. Perform a dielectric test (Hi-Pot) on each bus section; each phase to ground with phases not under test
grounded .Test voltage shall be 80% of the values indicated in table 4. When performing dielectric
tests, all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic
equipment that may cause erroneous results or cause damage to equipment shall be isolated before the
test and put back in place after completing the test.
Important Notes regarding Megger& Hi-Pot tests:

1. Megger test and HI-POT test will be performed on the switchgear including main B.B, C.B, Current
transformers, bushings and insulators.
2. Megger Test and HI-POT test to be performed directly (with in the same day/max 24 hours) before
startup (Energization). If the startup phase will not follow the comm. Phase (there will be time gap in
between), these tests will be delayed to be performed directly before Energization.
3. Insulation-resistance tests (Megger Test) to be performed BEFORE and AFTER the HI-POT test.
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3.1.3. Pre-Energization Checks:
1. Check that Panels has been appropriately cleaned (including C.B, insulators, B.B compartment, and
cable compartments).
2. Check that lubricants have been applied to the recommended places.
3. Check that Barriers, covers and shutters are installed in its place.
4. Check that P.T fuses are installed correctly.
5. Incoming cables to the switchgear are connected with the right phase sequence.
6. Megger test has been performed successfully
7. Hi-pot test has been performed successfully.
3.1.4. Energization precautions & procedures:

3.1.4.1 Precautions:
1. Safety fence and fire extinguisher or fire fighting system must be present around the switchgear.
2. Area around the switchgear must be cleared from any kind of obstacles.
3. Any unnecessary crowd around the switchgear during initial Energization must be cleared.
4. All openings and cut outs must be sealed.
5. All doors and windows in the substation must be installed and closed to protect the switchgear from
unnecessary access.
3.1.4.2: Procedure for Energization:

1. All Incoming C.Bs must be in TEST position.
2. All earthing switches must be OFF.
3. All motor charging MCB must be switched OFF.
4. Discharge the C.B manually to make sure it is not charged.
5. Protection relay settings must be set to MINIMUM values for (Over current, short Circuit and earth
fault).
6. After rack in the C.B, switch ON the motor charging MCB.
7. After energizing the C.B and everything is stable, re-adjust the protection relay settings to be according
to customer/ study values.
For outgoing C.B:

1. All outgoing C.Bs must be in TEST position.
2. All earthing switches must be OFF.
3. All motor charging MCB must be switched OFF.
4. Discharge the C.B manually to make sure it is not charged.
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5. After rack in the C.B, switch ON the motor charging MCB.
6. Adjust protection relay settings to be according to customer/study values.
7. If the outgoing will energize transformer, make sure that LV side C.B is in TEST position.
1
0
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3.2 MV Circuit Breakers:

3.2.1. Vacuum C.B:
3.2.1.1 Pre-Commissioning visual & mechanical inspection:
1. Verify that circuit breakers name plates are according to the corresponding drawings.
2. Inspect the physical and mechanical condition of the breaker.
3. Inspect anchorage and grounding.
4. Inspect and verify adjustment of the mechanism and alignment.
5. Inspect the mechanical operation of the breaker.
3.2.1.2. Commissioning:
1. Verify trip, close, trip-free, and ant pump functions.
2. Trip the circuit breaker by operating each protective device.
3. Perform insulation-resistance tests on each bus section, phase-to-phase and phase-to-ground, at the DC
test voltage appropriate for the equipments Maximum Rated Voltage in accordance with Table 2.
Record the resistances. If the resistance is lower than the recommended values in Table 2, visually
inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal
the causes, clean the equipment well, then re- measure. If cleaning does not reveal the causes, dry the
equipment for a minimum of 4 hours using heat and fans. Then re-measure.
1
1
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3.3 Protective Relays:

1. Inspect the physical, electrical, and mechanical condition of the equipment for any damage.
2. Verify that protection relay type matches the drawings.
3. Tighten accessible wires and verify correct connection as per the drawings.
1. Inspect Outputs and indicators for correct operation according to protection relay control matrix included
in the drawings or in the relay coordination study.
2. Control Verification: Verify that each of the relay contacts performs its intended function in the control
scheme, including breaker trip tests; close inhibit tests, 86 lockout tests, and alarm functions using
secondary injection test kit.
3. Verify that all pickup/dropout parameters are on each operating element.
1
2
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3.4 Current Transformers:

2. Inspect the physical and mechanical condition of the equipment for any visual damage.
3. Verify correct connection of transformers with system requirements.
4. Verify that all required grounding and shorting connections provide contact.
5. Verify that all shorting blocks are in the correct position, either grounding or open, as required
grounded .Test voltage shall be 80% of the values indicated in table 4. When performing dielectric tests,
all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic
1. Megger test and HI-POT test will be performed along with the switchgear (As a part of the switchgear at
the same time unless the C.Ts are supplied separately or as spare)
1
3
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3.5 Voltage Transformers:

3. Verify correct connection of transformers with system requirements.
4. Verify correct operation of transformer draw out mechanism and grounding operation.
5. Verify correct primary and secondary fuse size.
1. Perform turns ratio verification test.
1
4
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3.6 Power Transformers:

3.6.1. Liquid Filled Transformers:
2. Make a close examination for shipping brackets or fixtures that may not have been removed during
installation.
3. Verify appropriate anchorage, fixation, required area clearances, physical damage, and cleanliness.
5. Verify correct equipment grounding.
7. Verify the presence of transformer surge arrestors.
8. Verify correct liquid level and oil level indicators.
9. Inspect for any oil leaks.
10. Check Silica Gel installation, level and color.
11. Verify that fixed tap connections are as per the drawings.
12. Check C.Ts ratings and polarity (Visual).
13. Check Buckolz relay physical condition and assembly.
14. Check oil sampling facility physical condition and assembly.
15. Verify connection of all alarm, control, and trip circuits for temperature indicators, level indicators,
pressure relief device, pressure fault relay and any other if found.
16. Verify that the control and alarm settings for temperature indicators are as specified.
2. Verify that cooling fans operate correctly and check temperature module settings (If found).
3. Verify the operation of tap changer (On load/ off load) if any.
Record the resistances. If the resistance is lower than the recommended values from the vendor
1
5
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documents (if available) or If not, refer to the formula in page 37; visually inspect the equipment for
cleanliness and other potential causes. If the visual inspection does not reveal the causes, clean the
equipment well, then re- measure. If cleaning does not reveal the causes, dry the equipment for a
minimum of 4 hours using heat and fans. Then re-measure.
6. Perform a transformer turns-ratio test. Verify that winding polarities are in accordance with nameplate.
7. Remove a sample of the insulating oil to perform insulating oil testing (Breakdown test).
8. Perform phase sequence check.
3.6.1.3. Pre-Energization Checks:

1. Check that transformer is cleaned.
2. Check that barriers and covers are installed in its place (if found).
1
6
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3.6.2. On Load Tap Changer (O.L.T.C):
2. Make a close examination for shipping brackets or fixtures that may not have been removed during
installation.
3. Verify appropriate anchorage, fixation, required area clearances, physical damage, and cleanliness.
5. Verify correct equipment grounding.
7. Verify correct liquid level and oil level indicators.
8. Inspect for any oil leaks.
9. Verify that customer connections to remote power, operators, and indicators have been made
10. Control panel check:
Check for padlock able incoming supply switch.
Check for manual operating facility.
Check for local/remote selector switch facility.
Check for local mechanical tap changer position indicator.
Check for tap status indication.
Check for space heater.
3. Make sure that applied voltage to the motor connection terminals has a Clock wise phase
sequence.
4. Test tap change operations to check the mechanical function of the OLTC and the motor drive.
Operations must be done over the entire operating range. Make sure that the position indicators
of the motor-drive and the OLTC have the same reading in every operating position.
5. Test manual operation of the OLTC. Make sure that all mechanical indicators are matching the
position of the tap.
6. Check that automatic switch off is working in both ends positions.
1
7
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7. Make sure that the OLTC completes the tap change operation before the motor drive stops.
8. Check that the motor drive switches off automatically after performing one operation and the
pointer of the tap change indicator stops within the gray field.
9. Operate the motor drive using hand crank while the motor protective switch is activated. Check
that the motor protective switch trips after a max of 4 sections.
10. Initiate the OFF push button (test tripping) of the OLTC protective relay. Make sure that the
C.B is tripped.
11. Initiate the IN SERVICE (reset) push button of the OLTC protective relay. Make sure that the
C.B can be switched on again.
12. Make sure that flap valve (flag indication) is changing with the two positions.
13. Trigger any other protection functions from the transformer side and verify that MV cell is
responding as indicated and vice versa.
14. Perform turns-ratio test on all tap positions.
15. Perform insulation resistance test.

16. Remove a sample of the insulating oil to perform insulating oil testing (Breakdown test).
1
8
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3.7 Capacitors ( Power Factor Correction):

2. Inspect the physical and mechanical condition of the equipment
3. Verify appropriate anchorage, fixation, required area clearances, physical damage, and correct alignment
and cleanliness.
5. Verify that bus bar connections are connected properly.
6. Verify that earth bars connects between the cells if any.
11. Verify that all protection and measuring devices are corresponding to drawings.
12. Verify that fuse and/or circuit breaker or contactor size and type are corresponding to drawings.
13. Verify that current and potential transformer ratios are corresponding to drawings.
14. Verify regulator connection (current, voltage and earthing) as per drawings.
15. Verify that all the interconnection control wires between the cells have been made correctly referred to
the control drawings (If any).
16. Verify that capacitors are electrically connected in their specified configuration as per the drawings.
the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure
1
9
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5. Measure the capacitance of each capacitor unit.
6. Test the unbalance relay using secondary injection test kit and make sure that tripping accurse.
7. Apply the settings of the regulator as per the drawings (steps).
8. Perform function operation test for C.B/Contactors, Remote operation, protection, alarms and tripping
indications.
10. Perform a dielectric test (Hi-Pot) on main B.B connection.

1. Check that Panels has been appropriately cleaned.
3. Check that Barriers, covers and shutters are installed in its place.
4. Check that P.T fuses are installed correctly.
5. Incoming cables to the panels are connected with the right phase sequence.
2
0
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3.8 MV Motor Starters & Power Feeders:

cleanliness.
5. Verify that the barriers and shutters are installed and operating correctly.
9. Verify that the earth bars is connected between the cells and connected to the earth electrode.
13. Attempt closure on locked-open devices. Attempt to open locked-closed devices.
14. Verify key exchange with devices operated in off- normal position.
15. Verify that draw out disconnecting contacts, grounding contacts and interlocks are functioning correctly.
the control drawings.
2. Make sure that cables are centered inside the toroide (if found) and the toroide direction and
connection are according to the catalogue.
3. Perform a control wiring performance test by applying control voltage and Verify that the equipment
4. Test individual circuit breakers or switches in accordance Section 3.2MV C.B.
5. Test protective relays in accordance with Section 3.3Protective Relays.
2
1
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6. Tests instrument transformers in accordance with Section 3.4: Current Transformers and Section 3.5:
Voltage Transformers
grounded .Test voltage shall be 80% of the values indicated in table 4. When performing dielectric tests,
all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic

1. Megger test and HI-POT test will be performed along with the switchgear (As a part of the switchgear at
the same time unless the feeder is supplied separately)
2
2
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1. Check that Panels has been appropriately cleaned.
3. Check that barriers and covers are installed in its place.
2
3
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4. Low Voltage Equipment

4.1 LV Switchgear (Metal enclosed):
cleanliness.
5. Verify that the barriers and covers are installed correctly.
8. Verify that the earth bars is connected between the cells and connected to the earth.
12. Verify that draw out disconnecting contacts and interlocks function correctly.
the control drawings
4. Test protective relays in accordance with Section 3.3Protective Relays if found.
2
4
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10. Perform contact resistance test (conductivity test) through all main busbar joints as per project specs.
11. Perform secondary injection test on LV protection relays (Tsys-T). test the thermal over load and earth
fault of each device and monitor trip time.

1. Check that Panels has been appropriately cleaned
4. Check that fuses are installed correctly.
2
5
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4.2 LV Circuit Breakers:

4.2.1. Insulated Case / Molded Case C.B:
1. Inspect circuit breaker for correct mounting.
2. Operate circuit breaker to insure smooth operation.
3. Inspect case for cracks or other defects.
4. Verify tightness of accessible bolted connections and/or cable Connections by calibrated torque-wrench
method in accordance with Table 1.
5. Verify that trip units, shunt trip coils, auxiliary contacts and all other accessories are in accordance with
the drawings.
6. Exercise the push to trip button to verify trip and reset.
7. If the circuit breaker contains a MICROLOGIC trip unit, perform the following inspections:
Verify that the breaker is equipped with the correct rating plugs and current sensors.
Verify that the breaker has the specified trip unit, LI, LS, LSI, and LSIG.
Verify that the breaker has the specified accessories, such as Auxiliary Contacts, Cell
Switches, Shunt Trip Devices, and under voltage Release.
8. If it is a withdrawable ( MASTERPACT) circuit breaker, perform the following inspections:
Confirm that lubricants have been correctly applied at the recommended locations.
Inspect anchorage, alignment, and grounding.
Inspect moving and stationary contacts for condition and alignment.
Check the racking mechanism.
4.2.1.2 Commissioning:
1. Verify trip and close functions.
2. Trip the circuit breaker by operating protective device (if found).

3. Make adjustments for the final settings in accordance with the customer requirements.
the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure.(that is
done as part of switchgear Megger test)
Note: Megger test will be performed along with the switchgear (As a part of the switchgear at the same
time unless the C.B is supplied separately or as spare)
2
6
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4.2.2. Low Voltage Power (Air C.B):
1. Inspect circuit breaker for correct mounting.
2. Operate circuit breaker to insure smooth operation.
3. Verify that trip units, shunt trip coils, auxiliary contacts and all other accessories are in accordance with
the job specifications.
4. If the circuit breaker contains a MICROLOGIC trip unit, perform the following inspections:
Verify that the breaker is equipped with the correct rating plugs and current sensors.
Verify that the breaker has the specified trip unit, LI, LS, LSI, and LSIG.
Verify that the breaker has the specified accessories, such as Auxiliary Contacts, Cell
Switches, Shunt Trip Devices, and under voltage Release.
5. If it is a withdrawable MASTERPACT circuit breaker, perform the following inspections:
Confirm that lubricants have been correctly applied at the recommended locations.
Inspect anchorage, alignment, and grounding. Inspect arc chutes.
Inspect moving and stationary contacts for condition and alignment.
Check the racking mechanism.
4.2.2.2 Commissioning:
the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure.
2. Verify trip, close, trip-free, and anti pump functions.
3. Trip the circuit breaker by operating protective device.

4. Make adjustments for the final settings in accordance with the customer requirements.
Note: Megger test will be performed along with the switchgear (As a part of the switchgear at the same
time unless the C.B is supplied separately or as spare)
2
7
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4.3 LV Motor Starter & Power feeders:

cleanliness.
5. Verify that the barriers and covers are installed correctly.
8. Verify that the earth bar is connected between the cells and connected to the earth.
12. Verify that draw out disconnecting contacts and interlocks function correctly.
13. Verify that fuse and/or circuit breaker sizes and types correspond to drawings.
the control drawings
4. Test protective relays in accordance with Section 3.3Protective Relays if found.
2
8
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1. Check that Panels has been appropriately cleaned
4. Check that fuses are installed correctly.
2
9
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4.4 Interposing Relay Panel:

cleanliness.
5. Verify that the earth bar is connected between the cells and connected to the earth (if found).
the control drawings (If any)
7. Verify that customer connections to remote power, operators, and indicators have been made.
3. Check that ventilation Fans are working properly.
3
0
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4.5 Active Harmonic Filter (AHF):

cleanliness.
4. Inspect all doors and sections for paint, dents, scratches, fit, and missing hardware.
5. Verify that the earth bar is connected to the earth (if found).
the control drawings (If any).
7. Verify that customer connections to remote power, operators, and indicators have been made.
3. Check that ventilation Fans are working properly.
5. Apply the required settings/ratings for the AHF.
3
1
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4.6 Neutral Earthing Resistor (NER):

1. Verify that equipments name plate is according to the corresponding drawings.
cleanliness.
4. Verify that the connection of the resistor is as per the attached drawings.
5. Verify that customer connections to voltage terminal blocks are as per the attached drawings.
1. Check the availability of the required auxiliary supply for heater.
2. Test the anti-condensation heater by connecting the power supply and measure the consumed current
3. Perform insulation-resistance tests at the DC test voltage appropriate for the equipments Maximum
Rated Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the
recommended values in Table 2, visually inspect the equipment for cleanliness and other potential
causes. If the visual inspection does not reveal the causes, dry the equipment for a minimum of 4 hours
using heat and fans. Then re-measure.
3
2
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4.7 AC/DC Power distribution boards:

1. Verify that equipments name plate is according to the corresponding drawings.
2. Verify that ratings and arrangement of inside components is according to the corresponding drawings.
cleanliness.
1. Make sure that incoming cables are connected correctly.
2. Make sure that covers are installed again after all cable works has been finished.
3. Make sure that setting for the MCCB has been applied if applicable.
4. Perform insulation resistance teat.
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3
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5. Safe Energization precautions:

1. Safety fence and fire extinguisher or fire fighting system must be present around the switchgear.
2. Area around the switchgear must be cleared from any kind of obstacles.
3. Any unnecessary crowd around the switchgear during initial Energization must be cleared.
4. All openings and cut outs must be sealed.
5. All doors and windows in the substation must be installed and closed to protect the switchgear from
unnecessary access.
3
4
P
Projects
& Services Execcution Divission
Field Operations
O
Seervices
__________
_
___________
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6.
6 APPENDIX A:
A List of
o tabless:
ndard Bolt Torques
T
forr Bus and C
Cable Conneections
Table 1: Stan
Bo
olt
Siize
( / )

Geneeral mechaniical & electrrical assembly ( N.m)
Nylsstop lock nutt +
Hex.n
nut + contacct Flanged nut
Hex.nnut + Flat
or picot washer
conntact or picott
or split washer
with teeeth
used wiith
washers
steel
M5
7.5
M6
13
13.5
14.5
8.5
M8
28
25
31
19
M 10
50
50
54
37.5
3
M 12
75
79
83
62
M 14
120
125
132
98
M 16
185
180
200
155
M 18
260
270
280
2
210
M 20
370
390
410
2
290
Schneider
S
Ellectric Egyptt-Projects & Services Exxecution Divvision-Field Operations Rev.10
3
5
__________________________________________________________________________________
Table 1: Standard Bolt Torques for Bus and Cable Connections (Contd)

Component Assembly (N.m)
Bolt
Size
MV insulators
Current / Voltage Trans. Surge Arrestors

(AREVA)
/
=S= or ALCE MAGRINI INSULA
INSULA
or ALCE
M5
M6
2 - 2.5
13
M8
6.4
15
15
20
30 - 40
M 10
50
32
M 12
75
45
185
110
40
70
20
M 14
M 16
M 18
M 20
3
6
__________________________________________________________________________________
Table 2: Insulation-Resistance Test Voltage for Electrical Apparatus and Systems
Voltage Rating
Minimum DC Test
Voltage
Recommended Minimum
Insulation Resistance In
Megohms
Duration
0 - 250
251 - 600
601 - 5,000
5,001 - 8,000
8,001 - 15,000
15,001 - 25,000
25,001 - 69,000
500
1000
2500
2500
2500
5000
15000
50
100
1000
2000
5000
20000
100000
60 SEC
60 SEC
60 SEC
60 SEC
60 SEC
60 SEC
60 SEC
Actual test results are dependent on the length of the conductor being tested, the temperature of the
insulating material, and the humidity of the surrounding environment at the time of the test. In addition,
insulation resistance tests are performed to establish a trending pattern and a deviation from the
baseline information obtained during maintenance testing enabling the evaluation of the insulation for
confined use.
Table 3: Transformer Insulation-Res. Acceptance Test Voltage and
Transformer Winding Rated Voltage

0- 600
601-5000
>5000
Minimum DC Test Voltage

1000
2500
5000
Duration
60 SEC
60 SEC
60 SEC
Min. Result:
Recommended Minimum Transformer Insulation Resistance Results:
In the absence of consensus standards for minimum acceptable transformer insulation resistance, the
NETA Standards Review Council recommends the use of the following formula. Although the origin of
this formula is not identified, NETA recognizes its wide use in the electrical testing industry.
IR = CE/KVA
IR = Minimum recommended one minute insulation resistance
C = Constant
E = Phase-to-phase voltage for delta connected windings; phase-to-neutral voltage for
star connected windings.
3
7
__________________________________________________________________________________
kVA = Rated kVA of transformer
Values of C @ 20C:
Oil-filled C = 1.5
Dry-type C = 30
Insulation Resistance Conversion Factors For Conversion of Test Temperature to 20C
Temperature
Multiplier
20
25
30
35
40
45
50
55
60
65
70
75
80
68
77
86
95
104
113
122
131
140
149
158
167
176
Apparatus
Containing
Immersed Oil
Insulation
1.00
1.40
1.98
2.80
3.95
5.60
7.85
11.20
15.85
22.40
31.75
44.70
63.50
Apparatus
Containing Solid
Insulation
1.00
1.30
1.60
2.05
2.50
3.25
4.00
5.20
6.40
8.70
10.00
13.00
16.00
3
8
__________________________________________________________________________________
Table 4: Rated insulation levels for rated voltages:
Rated Voltage
Rated short-duration
power-frequency
withstand voltage
Ur
Ud
KV( r.m.s. value)
KV( r.m.s. value)
3.6
7.2
12
17.5
24
36
52
10
20
28
38
50
70
95
Duration
60 SEC
60 SEC
60 SEC
60 SEC
60 SEC
60 SEC
60 SEC
3
9
__________________________________________________________________________________
7. APPENDIX B: NORMS
IEC 56 High voltage alternating current circuit breaker (frequencies 60 Hz)
IEC 70 Power capacitors
IEC 71 Insulation co-ordination
IEC 76 Power transformers
IEC 99 Surge arresters
IEC 157 Low voltage switchgear and control gear (= IEC 947.2)
IEC 185 Current transformers
IEC 186 Voltage transformers
IEC 254 Lead-acid traction batteries
IEC 255 Electrical relays. Contact performance of electrical relays.
IEC 298 AC metal enclosed switchgear and control gear for rated voltages between 1 KV and up to
and Including 52 kV.
IEC 364 Electrical installation of buildings
IEC 408 Low voltage switches
IEC 439 Low voltage switchgear and control gear assemblies.
IEC 694 Common specifications for high-voltage switchgear and control gear standards
Acceptance Testing Specifications for Electrical Power Distribution Equipment and

Systems (NETA ATS 1999).
Dielectric tests ANSI/IEEE C37.20.2 & C37.20.3 Metal-Clad, Station-Type Cubical and
Metal Enclosed MV Switchgear, C37.23 Bus, Outdoor Circuit Breakers, and ANSI
C37.32 Air Switches
4
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__________________________________________________________________________________
8. APPENDIX C: List of used equipment in Pre-commissioning

& Commissioning Phase
123456789-
Secondary Injection test kit.

Hi-pot test kit
Insulation resistance test kit (Megger)
Contact resistance test kit (Conductivity test kit)
Phase sequence check kit.
Torque wrench.
Avo meters.
110 AC power supply
110 DC power supply
4
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Projects & Services Execution Division

Field Operations Services

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Rev.10

Projects & Services Execution Division

Field Operations Services

3. Medium Voltage Equipment

3.1.1. Pre-Commissioning visual & mechanical inspection

3.1.3. Pre-Energization Checks

3.1.4. Energization Precautions and procedures

3.1.4.2 .Procedures for Energization

3.2 MV Circuit Breakers

3.2.2. Vacuum C.B

3.2.2.1 Pre-Commissioning visual & mechanical inspection

3.3 Protective Relays

3.3.1. Pre-Commissioning visual & mechanical inspection

3.4 Current Transformers

3.4.1. Pre-Commissioning visual & mechanical inspection

3.5 Voltage Transformers

3.5.1. Pre-Commissioning visual & mechanical inspection

3.6 Power Transformers

3.6.1. Liquid Filled Transformers

3.6.1.1 Pre-Commissioning visual & mechanical inspection

3.6.1.3. Pre-Energization Checks

3.6.2. On Load Tap Changer (OLTC)

3.6.2.1 Pre-Commissioning visual & mechanical inspection

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Rev.10

Projects & Services Execution Division

Field Operations Services

3.7 Capacitors (Power factor Correction)

3.7.1. Pre-Commissioning visual & mechanical inspection

3.7.3. Pre-Energization Checks

3.8 MV Motor Starters & Power Feeders

3.8.1. Pre-Commissioning visual & mechanical inspection

3.8.3. Pre-Energization Checks

4. Low Voltage Equipment

4.1 LV Switchgear (Metal Enclosed)

4.1.1. Pre-Commissioning visual & mechanical inspection

4.1.3. Pre-Energization Checks

4.2 LV Circuit Breakers

4.2.1. Insulated Case / Molded Case

4.2.1.1 Pre-Commissioning visual & mechanical inspection

4.2.2. LV Power (Air C.B)

4.2.2.1 Pre-Commissioning visual & mechanical inspection

4.3 LV Motor Starter& Power Feeders

4.3.1. Pre-Commissioning visual & mechanical inspection

4.3.3. Pre-Energization Checks

4.4 Interposing Relay Panel

4.4.1. Pre-Commissioning visual & mechanical inspection

4.5 Active Harmonic Filter (AHF)

4.5.1. Pre-Commissioning visual & mechanical inspection

4.6 Neutral Earthing Resistor (NER)

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Rev.10

Projects & Services Execution Division

Field Operations Services

4.6.1. Pre-Commissioning visual & mechanical inspection

4.7 AC/DC power Distribution Boards.

4.7.1. Pre-Commissioning visual & mechanical inspection

5. Safe Energization Precautions

6. Appendix A: List of tables

8. Appendix C: List of used equipment in Pre-commissioning

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Rev.10

Projects & Services Execution Division

Field Operations Services