03 Electrical PDF

INDICATIVE INSPECTION &
HPCL, Visakh TEST PLAN

TOYO ENGINEERING INDIA LTD.
ISSUED :29.12.2008 JOB NO. : 6261
DOC.No. 6261-CD-303 DHT PROJECT Sheet 1
INDEX
Indicative Inspection & Test Plans
SL.No. DESCRIPTION
C. ELECTRICAL WORKS
I Transformer.
II Motor.
III Generator.
IV Switch Gears / PCC / MCC / EMCC
V EHT/HT Main Bus & Allied Equip.

ISSUED :29.12.2008 JOB NO. : 6261
HP : HOLD POINT.
A point which requires inspection/verification and acceptance by Owner/ Consultant
before any further processing is permitted. Contractor shall not process the activity
beyond a Hold Point without written approval by Owner/ Consultant.
W : WITNESS POINT.
An activity which requires witnessing by Owner/ Consultant when activity is performed.
Suppose, after proper notification has been provided, the contractor not obliged to
hold further processing, if Owner/ Consultant is not available to witness the activity or
does not provide the comments before the date notified.
Rw : REVIEW of contractors documentation.
S : SURVEILLANCE Inspection by Owner/ Consultant.

Monitoring or making observations to verify whether or not material/ Items or services
conform to specified requirements. Surveillance Activities may include audit,
inspections, witness of testing, review of quality documentation & records, field visit,
personnel qualifications etc.
WC : 100% Examination by CONTRACTOR.
NDT : NON DESTRUCTIVE TESTING.
PWHT : POST WELD HEAT TREATMENT.
NOTE :-
Contractor to submit required formats and job procedures for each activity listed in
ITPs and submit to Owner/ Consultant for approval. Responsibility for execution of the
inspection/ testing is with the contractor. Owner/ Consultant only verify examination or
testing done by the Contractor at important stages. Activities for which ITPs are not
given, contractor to develop and get the same approved by Owner/ Consultant well
before start of the work.
ISSUED :29.12.2008 JOB NO. : 6261
SL.
NO. ACTIVITY CONTRACTOR PMC
I POWER TRANSFORMER
1 Check foundation, its cleanliness, level and centre lines, WC Rw

Anchor bolts, their position & straightness, flatness of
contacting surface for transformer skid. In case of Rail
mounted type, check centre line and levels of rails.
2 Check the equipment no. And rating as per drawings and WC S

purged gas / air pressure & oil leakage.
3 Check availability of all accessories and filling oil. WC S
4 Check sequence of installation e.g. main tank first + WC S

accessories + internal check as per installation flow chart.
5 Ensure the cleanliness of connecting part e.g. flange WC S

parts and maintenance of duly tight Blank flanges until
just before commencement of assembly.
6 Check bushing of cracks, cheaps or presence of paint WC S

or dirt. Bushing should be cleaned as per vendors
instruction. Check explosion vent assembly & healthiness
of diaphragm.
7 Ensure the internal check is done by vendors supervisor WC Rw

and he submits the reports to PMC duly signed by him
and contractor.
8 Check oil filling of tank and OLTC, prior to filling, oil from WC Rw
each drum to be tested against di-electric strength for
minimum value of 50 KV - no breaking (2mm gap)
9 Ensure cable connection at the cable and box their colour WC S

coding & tightness (if required, use of spring and flat
washers on the appropriate faces to be confirmed) and
cleanliness of lapping surfaces. For multiple cable
ISSUED :29.12.2008 JOB NO. : 6261
connection, check for correctness of RR. YY, BB grouping.
10 Check oil (tested) filling to the cable end box and ensure WC S
oil levels.
11 Check the use of proper size conductors / cable for WC S

HV/LV neutral connection and their connection to NGR or
grid / earth point. Measure earth resistance of earth
points.
12 Check equipment earthing, connections, tightness and WC W

earth resistance value.
13 Ensure earthing of tertiary winding. WC W
14 Check leakage and oil level. WC S
15 Check proper installation of Dessicauts

(Reactivate the silicagel to blue; oil traps to be filled up) WC S
16 Measure Winding resistance. WC S
17 a. Test insulation resistance & PI. WC S
b. Assure heat run/dehydration of transformer in the WC S

event of low insulation resistance.
c. Check final IR value after dehydration and temp. Vs IR WC S

curve to ensure drying.
18 Test Vector group & Polarity. WC W
19 Test transformation ratio at each tap points WC S

(injecting 3 dia. 415 V at primary)
20 Assure laying, termination & connection of all control WC S

cables.
21 Check Buchhelzs relay operation by air injection for both WC W

transformer & OLTC, alarm and trip contacts actuation.
ISSUED :29.12.2008 JOB NO. : 6261
22 Check setting of Fan control (auto & manual). OTI, WTI - WC W

alarm and trip.
23 Check tap changer, control operation both auto & manual WC S

- without energising the transformer, Ensure master /
followers correct functioning.
24 Final residual check to confirm removal of all temp. WC HP

supports / spacers, tags, accumulation of air in Buchhelz
relay, oil, if any, etc., which might have been used as
protection / and identification during transportation and
erection.
25 Check operation of cooling system. WC S
26 Mechanical acceptance. WC HP
27 Check transformer protection relay settings as WC W

per Relay Setting diagram
28 Check & ensure bus duct connection at both ends. WC S
INSPECTION & TEST DOCUMENTS.
Review Test and Inspection Documents. HP Rw

ISSUED :29.12.2008 JOB NO. : 6261
SL.
II MOTOR.
1 Check foundation, its level and centre line markings, WC S

ensure the depth of anchor grouting pockets and
straightness of anchor bolts. Foundation should be
thoroughly cleaned before placement of equipment.
2 Check equipment name plate, identify the equipment WC S

referring to vendors shopfloor test certificate and
construction drawing.
3 Check area classification. WC S
4 Assure sealing of all exposed outlets during erection / WC HP

assembly.
5 Check installation of equipment, its leveling, alignment WC S

and coupling with driven equipment (before coupling
magnetic centring must be ensured)
6 Ensure fixing of all accessories temp. Indicators, cooling WC S

system lubricating pumps, etc.
7 Ensure pedestal insulation. WC S
8 Check lubrications of bearing, their suitability and level. WC S

For lubricants vendor instruction and specifications to be
followed.
9 Ensure Air-gap as per vendor instruction (for big WC HP

machines assembled at site).
10 Ensure all spacers and blockings used for transportation WC HP

and erection have been removed.
11 Check earthing of the equipment and earth connection.

Ensure earth resistance. WC S
ISSUED :29.12.2008 JOB NO. : 6261
12 a. Check IR and PI for the equipment and IR for auxiliary WC S

circuits like heaters and thermal detectors, excitor
(for system motor only) etc.`
b. In case of low IR/PI, dehydrate the equipment by WC S

suitable method as per vendors recommendation.
13 Measure winding Resistance (if specified). WC W
14 Inspect space heater and control cable connections. WC S

Ensure the tightness of connection, proper glanding and
earthing of armour, correct phase sequence of supply
cable as per hire mark and closing the covers of terminal
boxes.
15 Check dis-coupling of equipment for no-load run and WC HP

ensure re-establishing the same without disturbing
original alignment.
16 Set the temperature indicators (alarm / trip) and vibration WC S

monitors.
17 Mechanical Acceptance Test. WC W
18 Check motor protection relay settings as per WC W

Relay setting diagram

ISSUED :29.12.2008 JOB NO. : 6261
SL.
III GENERATOR.
1 Check foundation, its level and centre line markings, WC S

ensure the depth of anchor grouting pockets and
straightness of anchor bolts. Foundation should be
thoroughly cleaned before placement of equipment.
2 Check equipment name plate, identify the equipment WC S

referring to vendors shopfloor test certificate and
construction drawing.
3 Check area classification. WC S
4 Assure sealing of all exposed outlets during erection / WC S

assembly.
5 Check installation of equipment, its levelling, alignment WC S

and coupling with driven equipment
(before coupling magnetic centring must be ensured)
6 Ensure fixing of all accessories temp. Indicators, cooling WC S

system lubricating pumps, etc.
7 Ensure pedestal insulation. WC HP
8 Check lubrication of bearing, their suitability and level. WC S

For lubricants vendors instruction and specifications to
be followed.
9 Ensure Air-gap as per vendor instruction (for big WC HP

machines assembled at site).
10 Ensure all spacers and blockings used for transportation WC HP

and erection have been removed.
ISSUED :29.12.2008 JOB NO. : 6261
11 Check earthing of the equipment and earth connection. WC S

Ensure earth resistance.
12 a. Check IR and PI for the equipment and IR for auxiliary WC S

circuits like heaters and thermal detectors, excitor
PMG etc.
b. In case of low IR/PI, dehydrate the equipment by WC S

suitable method as per vendors recommendation.
13 Measure winding Resistance (if specified) WC S
14 Inspect exciter control panel / space heater and control WC HP

cable connections. Ensure the tightness of connection,
proper glanding and earthing of armour correct phase
sequence of supply cable as per hire mark and closing
the covers of terminal boxes.
15 Set the temperature indicators (alarm/trip) and vibration WC S

monitors.
16 Check the generator P.T. WC S
17 Check generator control panel, its wiring as per drg. WC HP

Relay & their calibration & setting functional checks etc.
18 Perform short circuit test and ensure WC HP
a. Diff. relay operation. WC HP
b. O/C relay operation. WC HP
c. Short circuit O/C relay operation. Draw short CRT WC W

curve & compare with shop test results.
19 Perform Negative phase sequence test & confirm the WC W

operation of the relay.
20 Perform Earth fault test & see the operation of E/F relay. WC W
21 Perform open circuit test & draw the open CRT curve for WC W
comparison.
ISSUED :29.12.2008 JOB NO. : 6261
22 Check for synchronising & manual excitation behavior. WC W
23 Check AVR operation & setting. WC HP
24 Mechanical acceptance test. WC W
NOTE:- Activities pertaining to SI. No. 5 and 15 will be checked by Mechanical Group.
ISSUED :29.12.2008 JOB NO. : 6261
SL.
IV SWITCH GEARS / PCC / MCC / EMCC.
1 Check the layout of base channels and assure the correct WC S

provisions for grouting and cable entry openings.
2 Ensure level and centre lines are within the prescribed WC S

limits and they match with the requirements of incoming
Bus-ducts if any.
3 Assure proper grouting of the base channels. WC S
4 Ensure proper handling of the panels WC S
5 Check sequence wise (starting from centre of Bus-duct WC S

panel) installation, final leveling and bolting up.
6 Check main bus bar connection and shrouding. WC S
7 Check inter panel control wiring, fixing of loose WC S

accessories and wiring.
8 Assure the level of flooring for smooth opening of panel WC S

doors and drawing out and in operation of Breaker
Trolleys.
9 Check interchargibilities of C.B. WC S
10 Check equipment earthing & continuity of earth bus. WC S
11 Ensure thorough cleaning, removal of temporary spacers, WC S

supports, any foreign materials and dusting the panels.
12 Verify the correctness, in accordance with the drawings WC S

of all type of relays, test blocks, control switches, meters
and instruments, motor starters, fuses, space heaters etc.
ISSUED :29.12.2008 JOB NO. : 6261
13 Check name plate for each breaker, inspect and test the WC S
operating mechanics (Mechanically), interlocks, contacts,
arc chutes, auxiliary devices and adjustments as
required.
14 Visually check all relays and meters for removal of WC S

shipping blocks and for mechanical damage. Ensure
their range against drawings, inspect calibration, testing
and setting for each relay and meter.
15 Visually check name plates of CTs and PTs and ensure WC S

their ratio accuracy, class and proper grounding against
drawings. Test their polarity and ratio at three points on
the characteristics curve submitted by the manufacturers.
16 Test and witness I.R value of the power and control bus. WC W
17 Test and witness high pot tests, if specified. WC W
18 Ensure tightness of connection of control wiring. WC S
19 Inspect secondary injection test and ensure tripping of WC W

C.B. through protection relays.
20 Inspect primary injection & check the breaker tripping WC S

through protective relays, check ammeter indications.
21 Switch on AC & DC control supply, Check the sequence WC HP

of operation of breakers electrically, local and remote
interlock, ensure proper alarm and annunciation and
indications in SW/GR/MCC/Control Panel. Auto Change
over should be ensured. Verify tripping of breakers at
70% of nominal control voltage.
22 Measure contact resistance and ensure simultaneous WC S

closing and making of breaker contacts, if specified.
23 Mechanical acceptance. WC W

ISSUED :29.12.2008 JOB NO. : 6261
SL. NO. ACTIVITY CONTRACTOR PMC
V EHT / HT MAIN BUS & ALLIED EQUIPMENT.
1 Check the insulators wall bushing for any damage like WC S

cheaps or cracks. Ensure proper installation of the
insulation & bushing.
2 Check the clearance between conductor to ground & WC S

conductor to floor level. Ensure minimum clearance
between two conductor Bus.
3 Check the anchoring of the conductor bus and terminal / WC S

Tap. Off connections.
4 Ensure phase sequence markings. WC W
5 Check earth connections and earth resistance of the WC S

supporting structures of insulators.
6 Check IR value of the conductor bus, phase to phase and WC S

each phase to earth.
7 Check high voltage tests keeping all the CBs and WC W

isolators closed but PTs should be disconnected.
8 Check hot line insulator washing equipment and system- WC S

Nozzle position & resistivity of water.
9 Check type and class of lightning arrestor, its earth WC S

connection and earth resistance.
10 Check air compressor pipeline and receiver against WC S

correct installation, rated pressure, Ensure the leak
proofness of the system.
11 Mechanical acceptance. WC W

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INDICATIVE INSPECTION &

HPCL, Visakh TEST PLAN

Indicative Inspection & Test Plans

IV Switch Gears / PCC / MCC / EMCC

V EHT/HT Main Bus & Allied Equip.

Rw : REVIEW of contractors documentation.

S : SURVEILLANCE Inspection by Owner/ Consultant.

WC : 100% Examination by CONTRACTOR.

NDT : NON DESTRUCTIVE TESTING.

PWHT : POST WELD HEAT TREATMENT.

1 Check foundation, its cleanliness, level and centre lines, WC Rw

2 Check the equipment no. And rating as per drawings and WC S

4 Check sequence of installation e.g. main tank first + WC S

5 Ensure the cleanliness of connecting part e.g. flange WC S

6 Check bushing of cracks, cheaps or presence of paint WC S

7 Ensure the internal check is done by vendors supervisor WC Rw

9 Ensure cable connection at the cable and box their colour WC S

connection, check for correctness of RR. YY, BB grouping.

11 Check the use of proper size conductors / cable for WC S

12 Check equipment earthing, connections, tightness and WC W

13 Ensure earthing of tertiary winding. WC W

14 Check leakage and oil level. WC S

15 Check proper installation of Dessicauts

16 Measure Winding resistance. WC S

17 a. Test insulation resistance & PI. WC S

b. Assure heat run/dehydration of transformer in the WC S

c. Check final IR value after dehydration and temp. Vs IR WC S

18 Test Vector group & Polarity. WC W

19 Test transformation ratio at each tap points WC S

20 Assure laying, termination & connection of all control WC S

21 Check Buchhelzs relay operation by air injection for both WC W

22 Check setting of Fan control (auto & manual). OTI, WTI - WC W

23 Check tap changer, control operation both auto & manual WC S

24 Final residual check to confirm removal of all temp. WC HP

25 Check operation of cooling system. WC S

27 Check transformer protection relay settings as WC W

28 Check & ensure bus duct connection at both ends. WC S

INSPECTION & TEST DOCUMENTS.

Review Test and Inspection Documents. HP Rw

1 Check foundation, its level and centre line markings, WC S

2 Check equipment name plate, identify the equipment WC S

3 Check area classification. WC S

4 Assure sealing of all exposed outlets during erection / WC HP

5 Check installation of equipment, its leveling, alignment WC S

6 Ensure fixing of all accessories temp. Indicators, cooling WC S

7 Ensure pedestal insulation. WC S

8 Check lubrications of bearing, their suitability and level. WC S

9 Ensure Air-gap as per vendor instruction (for big WC HP

10 Ensure all spacers and blockings used for transportation WC HP

11 Check earthing of the equipment and earth connection.

12 a. Check IR and PI for the equipment and IR for auxiliary WC S

b. In case of low IR/PI, dehydrate the equipment by WC S

13 Measure winding Resistance (if specified). WC W

14 Inspect space heater and control cable connections. WC S

15 Check dis-coupling of equipment for no-load run and WC HP

16 Set the temperature indicators (alarm / trip) and vibration WC S

17 Mechanical Acceptance Test. WC W

18 Check motor protection relay settings as per WC W

INSPECTION & TEST DOCUMENTS.

Review Test and Inspection Documents. HP Rw

1 Check foundation, its level and centre line markings, WC S

2 Check equipment name plate, identify the equipment WC S

3 Check area classification. WC S