All Test Procedures (31121016-000-Gap-00023-000)

ELECTRICAL TEST PROCEDURE
Page 1 of 155
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
1- 13.8 kv MV SWG. Site test plan……………………………………………3-4

2- 13.8 kv MV SWG. Site test procedure…………………………………….5-23
3- 4.16 kv MV SWG. Site test plan………………………………………….24-25
4- 4.16 kv MV SWG. Site test procedure………………………....................26-45
5- 480 v SWG. Site test plan………………………………………................46-47
6- 480 v SWG. Site test procedure………………………………... ...............48-60
7- Testing procedure of Medium Voltage bus duct…………………………...61-64
8- Testing procedure of Medium Voltage CB……………………..................65-72
9- Transducers and metering:
A-Transducers :
1-Testing procedure Current Transducer……………………............73-74
2- Testing procedure Voltage Transducer…………………................75-76
3- Testing procedure Power Transducer……………………….........77-78
B- Metering :
1-Testing procedure Ammeter………………………………………...79-80
2- Testing procedure Voltmeter ……………………………................81-82
3- Testing procedure Frequency meter……………………….............83-84
4- Testing procedure power meter…………………………….............85-86
5- Testing procedure power factor……………………………….........87-88
6- Testing procedure Energy meter…………………………………....89-90
10- Power Cable Site test procedure
(a) Low voltage power cable …………………………………….............91
(b) midium voltage power cable………………………………….............92-93
11- Transformers .
(a) Auxiliary transformer (BAT-BOB trans. )……………….95-97
(b) Power transform (GSU –ST –SAT trans.)………….........98-109
(c) Low voltage &dry type transformer………………..........110-112
12- Testing procedure Tripping/lockout Relay…………………………………………...113-115
13- Testing procedure Trip Coil supervision Relay………………………………………116-118
14- Protective relays:
(a) Testing procedure Phase and Ground Over Current Relay………………119-125
(b) Testing procedure Over voltage and Under Relay……………….............126-131
(c)Testing procedure Synchronous Check Relay……………………..............132-137
(d) Testing procedure Differential Current Relay…………………………….138-145
(e) bus bar protection relay
15- Disconnctor switch test procedure…………………………………………………146-152

16- NGR Test procedure………………………………………………………………..153
17- Bus bar protection relay……………………………………………………………..154-155
18- Inter lock test procedure ( later)
19- Inter trip test procedure ( later )
20- Stability test procedure ( later )
21- Test Equipment List ( see the attached file )
22- Test Equipment Calibration Certificates (Each tester will contains its certificate.)
Page 2 of 155
1-MEDIUM VOLTAGE (13.8KV) SWITCHGEAR SITE TEST PLAN
1) VISUAL INSPECTION
2) WIRING AND FERRULING CHECK
3) BUS CONTINUITY AND PHASING TEST
4) MAIN CIRCUIT RESISTANCE TEST
5) CURRENT TRANSFORMER CHECKS

5.1 Visual Inspection
5.2 Insulation resistance test
5.3 Winding resistance measurement
5.4 Polarity test
5.5 Ratio test by current primary injection
5.6 Magnetizing current test (minimum 2 points above )
5.7 Loop resistance measurement test (burden test)
5.8 Phase identification test
5.9 Verify secondary circuits, terminals, shorting/isolating links by primary injection
5.10 High voltage test.
5.11 Single point earthing check
5.12 Demagnetize CT cores after all tests
6) VOLTAGE TRANSFORMER CHECKS

6.1 Winding resistance test
6.2 Insulation resistance test HV/LV/G
6.3 Ratio test
6.4 Polarity test
6.5 Check VT HV neutral solidly grounded
6.6 Verify secondary circuits, terminal to terminal for correctness and tightness
6.7 Loop resistance test and burden test
7) CIRCUIT BREAKER CHECKS

7.1 Visual inspections.
7.2 Contact resistance measurements.
7.3 High- Pot Test.
7.4 Insulation resistance test of all low voltage wiring and cabling at 500 V.
7.5 Functional check of trip free and anti pump circuits.
7.6 Functional checks of breaker operation counter.
7.7 Check correct operation of all auxiliary contacts (for breaker open/closed positions).
7.8 Timing test using an electronic oscillograph.
7.9 Measure spring charge time and motor current.
7.10 Check the correct functioning of interlocks and limits switches.
8) TESTING OF METERING ACCURACY BY SECONDARY INJECTION
8.1 Ammeter check
8.2 Voltmeter check
8.3 KWH meter check
8.4 Current transducer check
8.5 Voltage transducer check
9) TEST OF PROTECTION RELAYS BY SECONDARY INJECTION.

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9.1 Over Current And Earth Fault Relay
9.2 Synchro-Check Relay
9.3 Residual .Voltage Earth Fault Relay
9.4 Trip Circuit Supervision Relay
9.5 Tripping Relay
10) PRIMARY INJECTION TEST
11) HIGH- POT TEST
12) FUNCTIONAL CHECK
Page 4 of 155
2-MEDIUM VOLTAGE (13.8KV)SWITCHGEAR SITE TEST PROCEDURE
1. VISUAL INSPECTION
1.1 Check nameplate information for correctness.
1.2 Inspect enclosures for proper alignment, foundation fixing and grounding.
1.3 Inspect all covers, panels section and doors for paint work and proper fit.
1.4 Check for smooth and proper movement of racking mechanisms for alignment, shutters, rollers,
rails and guides.
1.5 Check for proper alignment of the breaker primary and secondary contacts.
1.6 Check operation of all mechanical interlocks.
1.7 Check tightness of all bolted connections (torque wrench method).
1.8 Check bus and supports for defects such as cracked welds, chipped porcelain, cracked insulation,
etc., and free of dust accumulation.
1.9 All bus bar shall be continuously insulated &all joints are silver plated.
1.10 Check the quality of paint work of the panels and check the thickness of it.
1.11 Verify that all front panel mounted devices (meters, push buttons, switches, indicator lamps,
mimic buses, etc.) are installed as per drawings
1.12 Perform mechanical check and visual inspection on all circuit breakers.
1.13 Perform mechanical check and visual inspection on all current transformers.
1.14 Perform mechanical check and visual inspection on all voltage transformers.
1.15 Perform mechanical check and visual inspection on all disconnected and grounding switches.
1.16 Check for correct breaker position indication.
1.17 Check for correct spring status indication (spring charged/discharged).
1.18 Perform all specific checks on the breaker and spring operating mechanism.
1.19 Check that all control wiring is correct according to the approved drawing and terminal
connections are secure.
2-WIRING AND FERRULING CHECK

2.1 Ensure the numbers on the ferules are from left to right beginning at the terminal block i.e. at
the end of the wire and from bottom to top.
2.2 The wire nos. should be checked against the wiring table and the schematic drawing.
3- BUS CONTINUITY TEST
3.1 This test should be performed after bus bar complete erection and before cable connection.
3.2 Check the continuity for each phase.
3.3 Check the resistance for all the bus bar joint using micro-ohm meter 100 A.
3.4Check the overall resistance of the bus bar for each phase using micro-ohm meter 100A.
MICRO OHM
METER
CONTACT RESISTANCE TEST ARRANGEMENT FOR

PRIMARY CIRCUITS
Page 5 of 155
4 MAIN CIRCUIT RESISTANCE TEST
4.1. Check the switchgear has finally been erected but not yet connected to the cables. Perform
the resistance test as under.
4.2. The main circuit resistance test shall be performed by 10A or 100 Ampere DC by
micro-ohmmeter from panel to panel on each phase from cable spouts with all circuit breakers
racked in service and on position.
4.3. For judgment, the resistance values from panel to panel should not vary too much if the number
of joints and length of bus bar remains the same.
5. CURRENT TRANSFORMER CHECKS
1. Visual Inspection
 Inspect for physical damage / defects
 Check nameplate information for correctness
 Check that all grounding cables are securely connected
 Check color coded for secondary wiring and size of wires against specs.
 Check proper lugs has been used in termination
 Check CT’s location physically and secondary terminal labeling printed
2. Insulation Resistance Test
 The insulation resistance shall be checked at the terminals with respect to ground / earth with
a 1KV DC Voltage for One minute.
P1
S1
MEGGER
S2
P2
INSULATION TEST ARRANGEMENT
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3. Winding Resistance Measurement
 Take CT Resistance measurements at the CT Terminals or at the Terminal Blocks in the LV
compartment using a Micro-ohm meter.
P1
S1
MILIOHMMETER
S2
P2
CT RESISTANCE MEASURING ARRANGEMENT
4. Polarity Test
 Check the CT polarities on the Terminals as per the Schematic Drawing in the LV -compartment
for correct polarity.
P1
S1
+
SENSITIVE
SWITCH
AMMETER A
S2
-
+
BATTERY
-
P2
CT POLARITY TEST ARRANGEMENT
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5. Ratio Test By Current Primary Injection
 Check the CT ratio by injecting 25%, 50%, 75%, & 100% (if possible) of the normal current on
the CT primary winding and measure the corresponding secondary winding current.
P1
S1
AMMETER A
PRIMARY S2
INJECTION
TEST SET
P2
CT RATIO TEST ARRANGEMENT
6. Magnetizing Current Test (Minimum 2 Points Above )

 Check the Magnetization Curves by applying gradually increasing voltage to the CT Secondary
and noting the magnetization currents.
 Apply the potential at the Terminal Block.
 The Readings are entered in the form and the program will automatically print the curves.
 The purpose of this test is to ensure that the Knee Point Voltage is correct and most important to
ensure the protections and instrumentations are connected to the relevant cores.
 The knee point is the point on the magnetization curve at witch 10 % increase in excitation voltage
produces 50 % increase in excitation current.
 Minimum two points over the knee point shall be taken.
P1
STEP UP
VARIAC TRANSFORMER S1
A
AC SUPPLY V
S2
P2
PLOTTING OF THE MAGNETIZATIOM CURVE
ARRANGEMENT
Page 8 of 155
7. Loop Resistance Measurement Test (Burden Test)
 Check the CT Loop Resistance with a Micro-ohm-meter at the extreme end terminals to ensure
the complete loop.
P1
P1
S1
S1
RELAY
S2
RELAY V
S2
A
MILIOHMMETER
CURRENT
SOURCE
P2 P2
LOOP RESISTANCE MEASURING ARRANGEMENT BURDEN TEST ARRANGEMENT
8. Phase Identification Test

 Check Phase identification test by injecting single-phase primary current.
 Check the secondary current in all phases.
 The secondary current should be zero in all phases except the one we injecting current on.
9. Verify Secondary Circuits, Terminals, Shorting/Isolating Links By Primary Injection

 After primary injection test and with the same arrangement check that the secondary
circuit CT terminal shorting / isolation is actually working by closing the shorting link / open
the slide link and check the current.
10. High Voltage Test

 During normal HV tests on switchgear or GIS, the CT’s are included in the HV test.
 Shorted the CT’s secondary to ground and isolated from relays and meters.
11. Single Point Earthing Check

 It is imperative to ensure that only one end of the CT Secondary is earthed, especially
where CT’s are paralleled.
12. Demagnetize CT Cores After All Tests

 After performing all the mentioned tests for the CT, apply voltage greater than the knee
point voltage gradually to the CT secondary winding.
 Go back gradually to zero voltage.
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6. VOLTAGE TRANSFORMER CHECKS
 Check VT’s location physically and secondary terminal labeling printed
2. Winding Resistance Test

 Check the VT Resistance at the VT terminals or at the Terminal Blocks in the
LV compartment using a Micro-ohm-meter.
A
a1
MILIOHM
METER
n1
a2
N
n2
VT RESISTANCE TESTING
ARRANGEMENT
3. Insulation Test
 Check the insulation resistance at the terminals with respect to ground / earth.
 The test voltage is 1 KV DC for one minute.
A
a1
MEGGER
n1
a2
N
n2
INSULATION TESTING ARRANGEMENT
4. Ratio Check
 Apply one, 2 & 3 KV on VT primary terminal.
 Measure the corresponding out put on VT secondary terminal.
 Calculate VT turns ratio.
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A
a1 STEP UP
TRANSFORMER VARIAC
V
n1
SUPPLY
AC
a2
V
N
n2
VT RATIO TESTING ARRANGEMENT
5. VT Polarity Checks
 Check the VT polarities on the LV compartment terminals as per the Schematic Drawing
A
a1
+
SWITCH A
- n1
+
BATTERY a2
-
N
n2
VT POLARITY TESTING ARRANGEMENT
6.5 Check VT HV Neutral Solidly Grounded

6.6 Verify Secondary Circuits, Terminal To Terminal For Correctness And Tightness
6.7 Loop Resistance Test And Burden Test
 Check the VT Loop Resistance with an ohmmeter at the extreme end terminals to ensure
the complete loop.
S1 S1
RELAY RELAY V
S2 S2
A
OHMMETER
VOLTAGE
SOURCE
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7 CIRCUIT BREAKER CHECKS
7.1 Visual Inspections.

 Check nameplate information for correctness.
 Check tightness of all bolted connections (torque wrench method).
 Check all wiring is correct according to approved drawings terminal connections are
secured.
 Check quality of paintwork.
 Check that all grounding cables are securely connected.
 Check breakers, truck, rails, for proper alignment and smooth movement.
 Check operation of all mechanical interlocks with associated disconnects, grounding
switches, racking truck mechanism, cubicle doors, etc.
 Check for correct breaker position indication (breaker open/closed).
 Check manual spring charge operation.
 Verify correct spring status indication (spring charge d/discharged).
 Verify that correct Dispatch Numbers have been installed.
7.2 Contact Resistance Measurements.
 Close the CB.
 The micro ohmmeter test is conducted with a current of 100 ADC.
 Connect the test set to the first phase of the CB.
 Record the reading.
 Repeat it for all CB phases.
Page 12 of 155
CB MAIN CONTACTS
MICRO OHM
METER R Y B
CB CONTACT RESISTANCE TESTING ARRANGEMENT
7.3 High- Pot Test.
7.3.1 Insulation Resistance Test At 5kv DC.

 At the CB Closed
 Connect the phases Y, B to ground and apply the test voltage between phase R and ground.
 Connect the phases B, R to ground and apply the test voltage between phase Y and ground.
 Connect the phases R, Y to ground and apply the test voltage between phase B and ground.
 Record the corresponding leakage current readings.
 At the CB Open
 Connect the phases R, Y, B Cable side to the ground.
 Connect the phases R, Y, B Bus side to the test set.
 Record the corresponding leakage current readings.
7.3.2 High-Pot Test

 AC high- pot test shall be carried out in accordance with IEC standard at site.
 The test will carry out at test voltage 38 KV fore 60 second.
 If the test have been done at factory at 38 kV it will be done at site at 80% of the last time.
 Connect the phases Y, B to ground and apply the test voltage between phase R and ground.
 Connect the phases B, R to ground and apply the test voltage between phase Y and ground.
 Connect the phases R, Y to ground and apply the test voltage between phase B and ground.
CB MAIN CONTACTS
HIGH POT
TESTER R Y B
AC WITHSTAND VOLTAGE TESTING ARRANGEMENT
 At the CB Open
Page 13 of 155
CB MAIN CONTACTS
HIGH POT
TESTER R Y B

 At the CB Open
7.4 Insulation Resistance Test Of All Low Voltage Wiring And Cabling At 500 V DC.
7.5 Functional Check Of Trip Free And Anti Pump Circuits.
 The Anti- Pump feature in the Breakers were tested as follows:

 The Breaker was closed and the control switch was held in close position.
 It was ensured that the breaker closes
 The Breaker was tripped as below while the control switch was held in
Close position: A: Manually B: Electrically
 It will be noted from the results that the Breaker does not attempt to re-close if a permanents
closing signal is applied.
7.6 Functional Checks Of Breaker Operation Counter.
7.7 Check Correct Operation Of All Auxiliary Contacts (For Breaker Open/Closed Positions).
7.8 Timing Test Using An Electronic Oscillograph.
 Connect the test set to the CB.

 Perform the following operations at the rated DCV.
 Close ( C ) , Open ( O ) , Close - Open ( C – O ) & Open – Close – Open ( O – C – O )
 Record the corresponding readings.
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CB MAIN CONTACTS
CH. 1
R Y B
CH. 2
CH. 3
CLOSING
CB CLOSING TERMINALS
ORDER
TRIPPING
CB TRIPPING TERMINALS
ORDER
DC SUPPLY +
CB TIMING TEST ARRANGEMENT
7.9 Measure Spring Charge Time And Motor Current.
7.10 Check The Correct Functioning Of Interlocks And Limits Switches.
8. TESTING OF METERING ACCURACY BY SECONDARY INJECTION
 Metering calibration shall be tested via front panel mounted test facilities.
 Maximum demand indicator (MDI) meters shall be tested at 10% and 100% of full scale.
 Current and voltage metering and transducers calibration shall be tested at 0, 25, 50, 100% of scale.
 Watt and VAR metering and transducers calibration shall be tested at (+/- when bi-directional) 0, 25,
50,100% of rated load and with rated voltage and current at angles of
0, 45,180, 225, 270 and 315 degrees.
 KWH and KVARH metering calibration shall be tested at 10% and 100% of rated current at angles of
0, 45, 90, 180, 225, 270 and 315 degrees.
 Power Factor metering and transducers calibration shall be tested at rated voltage and at 50% lead,
unity, 50% lag power factors at 10, 50, 100% rated current.
8.1. Ammeter Check

 Connect the current test set on the ammeter terminals.
 Inject 25, 50 & 100 % of the full-scale current of the ammeter.
 Record the corresponding ammeter readings.
 Inject 100 % of the normal current.
 Record corresponding ammeter reading.
RELAY TEST SET

TERMINALS
CURRENT
N
A
AMMETER TESTING ARRANGEMENT
8.2. Voltmeter Check

 Connect the voltage test set on the voltmeter terminals.
 Apply 25, 50 & 100 % of the full-scale voltage of the voltmeter.
 Record the corresponding voltmeter readings.
 Apply 100 % of the normal voltage.
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 Record corresponding voltmeter reading.
RELAY TEST SET
TERMINALS
VOLTAGE
R
N
V
VOLTMETER TESTING ARRANGEMENT
8.3. Energy Meter Check

 Connect the current test set terminals to the Energy meter current terminals.
 Connect the voltage test set terminals to the Energy meter voltage terminals.
 Apply 0, 25, 50,100% of rated load and with rated voltage and current at angles of
0, 45,180, 225, 270 and 315 degrees.
 Record the corresponding Energy meter readings.
RELAY TEST SET TEST PLUG KWH METER
R R
TERMINALS
CURRENT
TERMINALS
CURRENT
Y Y
B B
N N
R R
TERMINALS
TERMINALS
VOLTAGE
VOLTAGE
Y Y
B B
N N
KWH METER TESTING ARRANGEMENT
8.4. Current Transducer Check

 Connect the current test set on the Current Transducer terminals.
 Inject 25, 50 & 100 % of the full-scale current of the Current Transducer.
 Record the corresponding Current Transducer out put.
 Inject 100 % of the rated current.
 Record corresponding Current Transducer out put.
CURRENT
RELAY TEST SET
TRANSDUCER
TERMINALS
TERMINALS
CURRENT
R
INPUT
N
TERMINALS
OUTPUT
CURRENT TRANSDUCER TESTING ARRANGEMENT
8.5. Voltage Transducer Check

 Connect the Voltage test set on the Voltage Transducer terminals.
 Inject 25, 50 & 100 % of the full-scale Voltage of the Voltage Transducer.
 Record the corresponding Voltage Transducer out put.
 Inject 100 % of the rated Voltage.
 Record corresponding Voltage Transducer out put.
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VOLTAGE
RELAY TEST SET
TRANSDUCER
TERMINALS
TERMINALS
VOLTAGE
R
INPUT
N
TERMINALS
OUTPUT
V
VOLTAGE TRANSDUCER TESTING ARRANGEMENT
9. Test Of Protection Relays By Secondary Injection.

Notes:
.
1- All outputs / indications to be tested.
2- Initial tests of new protective relays must include operating characteristics checks for
a representative range of available settings with Company approved computer operated test
equipment running routines developed for the specific relay and test set involved.
3- Relay auxiliary devices such as external resistors, metrosils, etc. to be tested to conform to
required ratings and manufacturer’s information.
4- Final calibration test of all protective relays must be carried out on approved settings, by
secondary injection at the front panel mounted test facilities.
5- Auxiliary and tripping relay testing shall include,
6- Pickup and dropout voltage, verification of all contacts.
7- Operation timing at 80% and 100% nominal voltage.
8- Time delay relays shall be tested at 0%, set point and 100% delay.
9- Use of red and green tags for tested relays, meters, etc.
10- All the relays and meters which have been tested and found ok must have green tags
11- The relays and meters found defective during tests should be tagged red.
9.1. Over Current Relay
9.1.1. Over Current Pick-Up

 Apply the testing relays setting for over current on the relay as following.
o Definite Time Curve with minimum time delay.
o Disable All other protection elements.
 Connect the current test set on the relay current terminals one at a time as following.
o Red phase to Neutral.
o Yellow phase to Neutral.
o Blue phase to neutral.
 Connect the timer to the relay tripping contact
 Slowly increase the current until the relay picked-up.
 Record the operating current.
9.1.2. Operating Time Verification

o Disable all other protection elements.
o DT curve with 500ms delay.
o IEC SI curve with 0.1 TMS.
o IEC VI curve with 0.1 TMS.
o IEC EI curve with 0.1 TMS.
o IEC STI curve with 0.1 TMS.
 Select the time over current curve one at a time on the relay.
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 Inject testing current and monitor the operating time of the relay.
 Record the operating time.
9.1.3. Instantaneous Unit Verification

 Connect the timer to the relay tripping contact.
 Slowly increase the current until the pick-up indication operates.
RELAY TEST SET TEST PLUG OC & EF RELAY
R R
TERMINALS
CURRANT
TERMINALS
CURRANT
Y Y
B B
N N
CONTACT
TIMER
TRIP
OVER CURRENT AND EARTH FAULT RELAY TESTING ARRANGEMENT
9.2. Earth Fault Relay
9.2.1. Earth Fault Pick-Up

 Apply the testing relays setting for Earth Fault on the relay as following.
o Any phase to Neutral.
 Select the time Earth Fault curve one at a time on the relay.
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R R
TERMINALS
CURRANT
TERMINALS
CURRANT
Y Y
B B
N N
CONTACT
TIMER
TRIP
9.3. Synchro-Check Relay
9.3.1. Differential Voltage Test.

 Apply the testing relay setting on the relay noting that.
o Only live line live bus function is enabled.
 Connect the voltage test set on the relay voltage terminals
 Connect test set stop input to the relay output contact
 Apply the line and bus voltage with
o Zero differential voltage
o Zero differential frequency
o Zero differential phase angle
 The relay should operate now giving CB close permissive signal.
 Slowly increase the voltage difference until the DV out put relay operate
 Record the differential voltage
9.3.2. Differential Frequency Test
 Slowly increase the frequency difference until the DF out put relay operate
 Record the differential Frequency
9.3.3. Differential Phase Angle Test

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 Slowly increase the phase angle difference until the DPH out put relay operate
 Record the differential phase angle
9.3.4. Under Voltage Blocking Test

 Apply rated voltage to the line and bus voltage with
 Slowly reduce both of line and bus voltage simultaneously till the under voltage blocking output
relay operate
 Record the under voltage blocking voltage
9.3.5. Dead Line Live Bus Test

o Enable live line live bus function
o Enable Dead line live bus function
 Slowly reduce line voltage till the differential voltage blocking output relay operate
 Continue reduce bus voltage till the under voltage blocking output relay operate
 Continue reducing the line voltage till the dead line live bus out put relay operate
 Record the dead line voltage
9.3.6. Dead Bus Live Line Test

o Enable Dead bus live line function
 Slowly reduce bus voltage till the differential voltage blocking output relay operate
 Continue reduce bus voltage till the under voltage blocking output relay operate
 Continue reducing the line voltage till the dead line live bus out put relay operate
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 Record the dead line voltage
SYNCH. CHECK
RELAY TEST SET TEST PLUG
RELAY
R
BUS
TERMINALS
VOLTAGE
VOLTAGE
Y
B
LINE
VOLTAGE
N
CONTACT
TIMER
RELAY
SYNCHRO-CHECK RELAY TESTING ARRANGEMENT
9.4. Residual Voltage Earth Fault Relay
9.4.1. Over Voltage Verification

 Apply the testing relays setting on the relay
 Slowly increase the applied voltage until the relay pick-up
 Record the pick-up voltage
9.4.2. Delay Time Verification

 Select the operating time on the relay
 Apply the testing voltage and monitor the operating time of the relay
RES. VOLTAGE
E/F RELAY
TERMINALS
VOLTAGE
R
TERMINALS
VOLTAGE
N
CONTACT
TIMER
TRIP
RESIDUAL VOLTAGE E/F RELAY TESTING ARRANGEMENT
9.5. Trip Circuit Supervision Relay
9.5.1. Voltage Pick-Up Verification

 Slowly increase the voltage until the relay pick-up
 Record the pick-up voltage.
9.5.2. Voltage Drop-Out Verification
 While relay is still picking-up slowly reduce the voltage until the relay dropout.
 Record the dropout voltage.
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9.5.3. Function Check
 All the internal and external wiring should be completed
9.5..3.1. The CB Is In Open Position
 At the CB control panel / box open tripping coils circuit one by one
 The trip circuit supervision relay should operate in each time
9.5..3.2. The CB In Close Position
RELAY TEST SET TEST PLUG TCS RELAY
DC VOLTAGE
TERMINALS
+
TERMINALS
+
COIL
-
-
CONTACT
TIMER
RELAY
TRIP CIRCUIT SUPERVISION RELAY TESTING ARRANGEMENT
9.6. Tripping Relay
9.6..1. Voltage Pick-Up Verification

9.6..2. Voltage Drop-Out Verification
 While relay is still picking-up slowly reduce the voltage until the relay dropout
 Record the dropout voltage
9.6..3. Delay Time Verification
TRIPPING
RELAY
DC VOLTAGE
TERMINALS
+
TERMINALS
+
COIL
-
-
CONTACT
TIMER
TRIP
TRIPPING RELAY TESTING ARRANGEMENT
10) Cable HIGH- POT TEST

The equation which we used to test HI-POT for the power cable
V)test = ( V)r Line / √3 ) X 3 X √2 x M
V)test : voltage value for test
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V)r line : rated voltage which the cable will used for
M : factor used for how many times this cable exposed to test ( it is =1 for first time to test , and = 0.8 for
2nd time to test .)
Example
V)r line : 13.8 KV

M : 1 as it 1st time to test the cable
From the above equation
=( 13.8 / 1.732 ) X 3 X 1.41 X 1 = 33. 7 34 KV
11) Bus bar and CBs Hi-Pot test

The equation which we used to test HI-POT for the bus bar
V)test = ( V)r Line ) X 2.5 X 0 .8
V)r line : rated voltage which the bus will used for
Example
V)r line : 13.8 KV

V)test = ( V)r Line ) X 2.5 X 0.8
=( 13.8 ) X 2.5 X 0.8 = 22. 46 22.5 KV
1- Check local electrical close for CB

2- Check local electrical open for CB
3- Check remote close for CB from DCS TB
4- Check remote open for CB from DCS TB
5- Check motor of spring charging works after each close and open command
6- Check the trip signals from relays trips the LOR and the CB
7- Manual close and open to CB
8- Charge the mechanism manually
9- Check manual open and close for E/S
Page 23 of 155
3- 4.16 kV SWITCHGEAR SITE TEST PLAN
1- VISUAL INSPECTION
3-BUS CONTINUITY AND PHASING TEST
4-MAIN CIRCUIT RESISTANCE TEST
5-CURRENT TRANSFORMER CHECKS

2. Insulation resistance test
3. Winding resistance measurement
4. Polarity test
5. Ratio test by current primary injection
6. Magnetizing current test (minimum 2 points above )
7. Loop resistance measurement test (burden test)
8. Phase identification test
9. Verify secondary circuits, terminals, shorting/isolating links by primary injection
10. High voltage test.
11. Single point earthing check
12. Demagnetize CT cores after all tests
6-VOLTAGE TRANSFORMER CHECKS

1. Winding resistance test
2. Insulation resistance test HV/LV/G
3. Ratio test
4. Polarity test
5. Check VT HV neutral solidly grounded
6. Verify secondary circuits, terminal to terminal for correctness and tightness
7. Loop resistance test and burden test
7-CIRCUIT BREAKER CHECKS

1. Visual inspections.
2. Contact resistance measurements.
3. High- Pot Test.
4. Insulation resistance test of all low voltage wiring and cabling at 500 V.
5. Functional check of trip free and anti pump circuits.
6. Functional checks of breaker operation counter.
7. Check correct operation of all auxiliary contacts (for breaker open/closed positions).
8. Timing test using an electronic oscillograph.
9. Check the correct functioning of interlocks and limits switches.
8 -TESTING OF METERING ACCURACY BY SECONDARY INJECTION

8.1 Ammeter check
8.2 Voltmeter check
8.3 KWH meter check.
8.4 KW meter check.
8.5 Current transducer check
8.6 Voltage transducer check
8.7 KW transducer check
Page 24 of 155
9-TEST OF PROTECTION RELAYS BY SECONDARY INJECTION.
1. Over Current And Earth Fault Relay
2. Earth Fault Relay
3. Under / Over Voltage Protection Relay
4. R.E.F. Protection Relay
5. Trip Circuit Supervision Relay
6. Tripping Relay
4- CABLE HIGH- POT TEST
5- Bus Bar HIGH- POT TEST
6- FUNCTIONAL CHECK
7- PRIMARY INJECTION TEST
Page 25 of 155
4- 4.16kV SWITCHGEAR SITE TEST PROCEDURE
1. VISUAL INSPECTION
1. Check nameplate information for correctness.
2. Inspect enclosures for proper alignment, foundation fixing and grounding.
3. Inspect all covers, panels section and doors for paint work and proper fit.
4. Check for smooth and proper movement of racking mechanisms for alignment, shutters, rollers,
rails and guides.
5. Check for proper alignment of the breaker primary and secondary contacts.
6. Check operation of all mechanical interlocks.
7. Check tightness of all bolted connections (torque wrench method).
8. Check bus and supports for defects such as cracked welds, chipped porcelain, cracked
insulation, etc., and free of dust accumulation.
9. Verify that all front panel mounted devices (meters, push buttons, switches, indicator lamps,
mimic buses, etc.) are installed as per drawings
10. Perform mechanical check and visual inspection on all circuit breakers.
11. Perform mechanical check and visual inspection on all current transformers.
12. Perform mechanical check and visual inspection on all voltage transformers.
13. Perform mechanical check and visual inspection on all disconnected and grounding switches.
14. Check for correct breaker position indication.
15. Check for correct spring status indication (spring charged/discharged).
16. Perform all specific checks on the breaker and spring operating mechanism.
17. Check that all control wiring is correct according to the approved drawing and terminal
2.WIRING AND FERRULING CHECK

1. Ensure the numbers on the ferules are from left to right beginning at the terminal block i.e.
at the end of the wire and from bottom to top.
2. The wire nos. should be checked against the wiring table and the schematic drawing.
3-BUS CONTINUITY TEST
1. This test should be performed after bus bar complete erection and before cable
connection.
2. Check the continuity for each phase.
3. Check the resistance for all the bus bar joint using micro-ohm meter 100 A.
Page 26 of 155
4. Check the over all resistance of the bus bar for each phase using micro-ohm meter 100A.
MICRO OHM
METER

PRIMARY CIRCUITS
1. Check the switchgear has finally been erected but not yet connected to the cables. Perform the
resistance test as under.
2. The main circuit resistance test shall be performed by 10A or 100 Ampere DC by micro-ohmmeter
from panel to panel on each phase from cable spouts with all circuit breakers racked in service
and on position.
3. For judgment, the resistance values from panel to panel should not vary too much if the number
2. Insulation Resistance Test

 The insulation resistance shall be checked at the terminals with respect to ground / earth with
a 1KV DC Voltage for One minute.
Page 27 of 155
P1
S1
MEGGER
S2
P2
3. Winding Resistance Measurement

P1
S1
MILIOHMMETER
S2
P2
Page 28 of 155
4. Polarity Test
P1
S1
+
SENSITIVE
SWITCH
AMMETER A
S2
-
+
BATTERY
-
P2
5. Ratio Test By Current Primary Injection

P1
S1
AMMETER A
PRIMARY S2
INJECTION
TEST SET
P2
Page 29 of 155
6. Magnetizing Current Test (Minimum 2 Points Above )
 The knee point is the point on the magnetization curve at witch 10 % increase in excitation voltage
produces 50 % increase in excitation current.
P1
STEP UP
A
AC SUPPLY V
S2
P2
ARRANGEMENT
7. Loop Resistance Measurement Test (Burden Test)

the complete loop.
P1
P1
S1
S1
RELAY
S2
RELAY V
S2
A
MILIOHMMETER
CURRENT
SOURCE
P2 P2
Page 30 of 155
8. Phase Identification Test
9. Verify Secondary Circuits, Terminals, Shorting/Isolating Links By Primary Injection
10. High Voltage Test

 During normal HV tests on switchgear or GIS, the CT’s are included in the HV test.
 Shorted the CT’s secondary to ground and isolated from relays and meters.
11. Single Point Earthing Check

12. Demagnetize CT Cores After All Tests


6.2 Winding Resistance Test

Page 31 of 155
A
a1
MILIOHM
METER
n1
a2
N
n2
ARRANGEMENT
6.3 Insulation Test

A
a1
MEGGER
n1
a2
N
n2
6.4 Ratio Check

A
a1 STEP UP
TRANSFORMER VARIAC
V
n1
SUPPLY
AC
a2
V
N
n2
6.5 VT Polarity Checks

Page 32 of 155
A
a1
+
SWITCH A
- n1
+
BATTERY a2
-
N
n2

the complete loop.
S1 S1
RELAY RELAY V
S2 S2
A
OHMMETER
VOLTAGE
SOURCE
Page 33 of 155
secured.

 Close the CB.
Page 34 of 155
CB MAIN CONTACTS
MICRO OHM
METER R Y B
7.3 High- Pot Test.

 At the CB Open
7.3.2 High-Pot Test
 AC high- pot test shall be carried out in accordance with IEC standard at site.
 The test will carry out at test voltage 38 KV fore 60 second.
 If the test have been done at factory at 38 kV it will be done at site at 80% of the last time.
 Connect the phases Y, B to ground and apply the test voltage between phase R and ground.
 Connect the phases B, R to ground and apply the test voltage between phase Y and ground.
 Connect the phases R, Y to ground and apply the test voltage between phase B and ground.
CB MAIN CONTACTS
HIGH POT
TESTER R Y B
 At the CB Open
Page 35 of 155
CB MAIN CONTACTS
HIGH POT
TESTER R Y B

 At the CB Open
7.5 Functional Check Of Trip Free And Anti Pump Circuits.
 The Anti- Pump feature in the Breakers were tested as follows:

 The Breaker was closed and the control switch was held in close position.
 It was ensured that the breaker closes
 The Breaker was tripped as below while the control switch was held in
Close position: A: Manually B: Electrically
 It will be noted from the results that the Breaker does not attempt to re-close if a permanents
closing signal is applied.
7.6 Functional Checks Of Breaker Operation Counter.
7.8 Timing Test Using An Electronic Oscillograph.

 Connect the test set to the CB.
 Perform the following operations at the rated DCV.
 Close ( C ) , Open ( O ) , Close - Open ( C – O ) & Open – Close – Open ( O – C – O )
 Record the corresponding readings.
Page 36 of 155
CB MAIN CONTACTS
CH. 1
R Y B
CH. 2
CH. 3
CLOSING
CB CLOSING TERMINALS
ORDER
TRIPPING
CB TRIPPING TERMINALS
ORDER
DC SUPPLY +
CB TIMING TEST ARRANGEMENT
8-TESTING OF METERING ACCURACY BY SECONDARY INJECTION

0, 45,180, 225, 270 and 315 degrees.
0, 45, 90, 180, 225, 270 and 315 degrees.
8.1 Ammeter Check

RELAY TEST SET

TERMINALS
CURRENT
N
A
8.2 Voltmeter Check

Page 37 of 155
RELAY TEST SET
TERMINALS
VOLTAGE
R
N
V
8.3 Energy Meter Check

 Connect the current test set terminals to the Energy meter current terminals.
 Connect the voltage test set terminals to the Energy meter voltage terminals.
 Apply 0, 25, 50,100% of rated load and with rated voltage and current at angles of
 0, 45,180, 225, 270 and 315 degrees for time.
 Record the corresponding Energy meter readings.
R R
TERMINALS
CURRENT
TERMINALS
CURRENT
Y Y
B B
N N
R R
TERMINALS
TERMINALS
VOLTAGE
VOLTAGE
Y Y
B B
N N
8.4 Power Meter Check

 Connect the current test set terminals to the Power meter current terminals.
 Connect the voltage test set terminals to the Power meter voltage terminals.
 Apply 0, 25, 50,100% of rated load with rated voltage and current at angles of
0, 45,180, 225, 270 and 315 degrees.
 Record the corresponding Power meter readings.
RELAY TEST SET TEST PLUG KW METER
R R
TERMINAL
CURRENT
TERMINAL
CURRENT
Y Y
S
S
B B
N N
R R
TERMINAL
VOLTAGE
TERMINAL
VOLTAGE
Y Y
S
S
B B
N N
KW METER TESTING ARRANGEMENT
8.5 Current Transducer Check

Page 38 of 155
CURRENT
RELAY TEST SET
TRANSDUCER
TERMINALS
TERMINALS
CURRENT
R
INPUT
N
TERMINALS
OUTPUT
A
8.6 Voltage Transducer Check

VOLTAGE
RELAY TEST SET
TRANSDUCER
TERMINALS
TERMINALS
VOLTAGE
INPUT
N
TERMINALS
OUTPUT
V
8.7 Power Transducer

 Connect the current test set terminals to the Power Transducer current terminals.
 Connect the voltage test set terminals to the Power Transducer voltage terminals.
0, 45,180, 225, 270 and 315 degrees.
 Record the corresponding Power Transducer O/P readings.
Power
Transducer
R R
TERMINAL
CURRENT
TERMINAL
CURRENT
Y Y
S
S
B B
N N
R R
TERMINAL
VOLTAGE
TERMINAL
VOLTAGE
Y Y
S
S
B B
N N
Power Transducer TESTING ARRANGEMENT
9-Test Of Protection Relays By Secondary Injection.

Notes:
1. Testing Engineer should provide the commissioning manuals and have the detailed
understanding for testing and commissioning procedure.
2. All outputs / indications to be tested.
Page 39 of 155
3. Initial tests of new protective relays must include operating characteristics checks for a
representative range of available settings with Company approved computer operated test
4. Relay auxiliary devices such as external resistors, metrosils, etc. to be tested to conform to
5. Final calibration test of all protective relays must be carried out on approved settings, by
6. Auxiliary and tripping relay testing shall include,
7. Pickup and dropout voltage, verification of all contacts.
8. Operation timing at 80% and 100% nominal voltage.
9. Time delay relays shall be tested at 0%, set point and 100% delay.
10. Use of red and green tags for tested relays, meters, etc.
11. All the relays and meters which have been tested and found o.k must have green tags
12. The relays and meters found defective during tests should be tagged red.
9.1. Over Current Relay
9.3.7. Over Current Pick-Up

 Slowly increase the current until the relay picked-up.
9.1.1 Operating Time Verification

 Select the time over current curve one at a time on the relay.
Page 40 of 155
9.1.2 Instantaneous Unit Verification

R R
TERMINALS
CURRANT
TERMINALS
CURRANT
Y Y
B B
N N
CONTACT
TIMER
TRIP
9.2. Earth Fault Relay
9.2.1. Earth Fault Pick-Up


Page 41 of 155
R R
TERMINALS
CURRANT
TERMINALS
CURRANT
Y Y
B B
N N
CONTACT
TIMER
TRIP
9.3. Under / Over Voltage Protection Relay
9.3.1 Under Voltage Verification

 Apply the testing relays setting with instantaneous tripping time on the relay
 Slowly Decrease the applied voltage until the relay pick-up
9.3.2 Delay Time Verification

9.3.3 Over Voltage Verification

 Apply the testing relays setting with instantaneous tripping time on the relay

Page 42 of 155
RES. VOLTAGE
E/F RELAY
TERMINALS
VOLTAGE
R
TERMINALS
VOLTAGE
Y
CONTACT
TIMER
TRIP
RESIDUAL VOLTAGE E/F RELAY TESTING ARRANGEMENT
9.4. R.E.F. Protection Relay
9.4.1. Pickup Voltage Verification.

9.4.2. Drop Out Voltage Verification.

 Apply voltage 1.5 of the setting voltage.
 Slowly decrease the applied voltage until the relay o/p contact open.
 Record the drop out voltage
9.4.3. Trip Timing Test.

 Record the relay tripping time.
9.5. Trip Circuit Supervision Relay
9.5.1. Voltage Pick-Up Verification

 Record the pick-up voltage.
9.5.2. Voltage Drop-Out Verification

 While relay is still picking-up slowly reduce the voltage until the relay dropout.
 Record the dropout voltage.
9.5.3. Function Check

 All the internal and external wiring should be completed
9.5..3.1. The CB Is In Open Position

Page 43 of 155
9.5..3.2. The CB In Close Position
RELAY TEST SET TEST PLUG TCS RELAY
DC VOLTAGE
TERMINALS
+
TERMINALS
+
COIL
-
-
CONTACT
TIMER
RELAY
TRIP CIRCUIT SUPERVISION RELAY TESTING ARRANGEMENT
9.6. Tripping Relay
9.6.1 Voltage Pick-Up Verification

9.6.2 Voltage Drop-Out Verification


TRIPPING
RELAY
DC VOLTAGE
TERMINALS
+
TERMINALS
+
COIL
-
-
CONTACT
TIMER
TRIP
10) Cable HIGH- POT TEST

Page 44 of 155
V)test = ( V)r Line / )X3 X x M
M : factor used for how many times this cable exposed to test ( it is =1 for first time to test , and = 0.8 for
2nd time to test .)
Example
V)r line : 4.16 KV

V)test = ( V)r Line / )X3 X x M
=( 4.16 / 1.732 ) X 3 X 1.41 X 1 = 10. 2 11 KV
11) Bus bar and CBs Hi-Pot test
The equation which we used to test HI-POT for the bus bar
V)test = ( V)r Line ) X 2.5 X 0 .8
V)r line : rated voltage which the bus will used for
Example
V)r line : 4.16 KV

V)test = ( V)r Line ) X 2.5 X 0.8
=( 4.16 ) X 2.5 X 0.8 = 8. 32 9 KV
1- Check local electrical close for CB

2- Check local electrical open for CB
3- Check remote close for CB from DCS TB
4- Check remote open for CB from DCS TB
5- Check motor of spring charging works after each close and open command
6- Check the trip signals from relays trips the LOR and the CB
7- Manual close and open to CB
8- Charge the mechanism manually
9- Check manual open and close for E/S
Page 45 of 155
5- LV SWITCHGEAR SITE TEST PLAN
1- VISUAL INSPECTION
3-BUS CONTINUITY AND PHASING TEST

2. Insulation resistance test
3. Winding resistance measurement
4. Polarity test
5. Ratio test by current primary injection
6. Magnetizing current test (minimum 2 points above )
7. Loop resistance measurement test (burden test)
8. Phase identification test
9. Verify secondary circuits, terminals, shorting/isolating links by primary injection
10. High voltage test.
11. Single point earthing check
12. Demagnetize CT cores after all tests

1. Winding resistance test
2. Insulation resistance test HV/LV/G
3. Ratio test
4. Polarity test
5. Check VT HV neutral solidly grounded
6. Verify secondary circuits, terminal to terminal for correctness and tightness
7. Loop resistance test and burden test
7-CIRCUIT BREAKER CHECKS

1. Visual inspections.
2. Contact resistance measurements.
3. Insulation resistance test of all low voltage wiring and cabling at 500 V.
4. Functional check of trip free and anti pump circuits.
5. Functional checks of breaker operation counter.
6. Check correct operation of all auxiliary contacts (for breaker open/closed positions).
7. Check the correct functioning of interlocks and limits switches.

1) Ammeter check
2) Voltmeter check
3) KWH meter check.
4) KW meter check.
5) Current transducer check
6) Voltage transducer check
Page 46 of 155
9-TEST OF PROTECTION RELAYS BY SECONDARY INJECTION.
1) Earth Fault Relay
2) R.E.F. Protection Relay
3) Tripping Relay
10-PRIMARY INJECTION TEST
11-FUNCTIONAL CHECK
Page 47 of 155
6- LV SWITCHGEAR SITE TEST PROCEDURE
1-VISUAL INSPECTION
1-Check nameplate information for correctness.
2-Inspect enclosures for proper alignment, foundation fixing and grounding.
3-Inspect all covers, panels section and doors for paint work and proper fit.
4-Check for smooth and proper movement of racking mechanisms for alignment, shutters,
rollers, rails and guides.
5-Check for proper alignment of the breaker primary and secondary contacts.
6-Check operation of all mechanical interlocks.
7-Check tightness of all bolted connections (torque wrench method).
8-Check bus and supports for defects such as cracked welds, chipped porcelain, cracked
insulation, etc., and free of dust accumulation.
9-Verify that all front panel mounted devices (meters, push buttons, switches, indicator lamps,
etc.) are installed as per drawings
10-Perform mechanical check and visual inspection on all circuit breakers.
11-Perform mechanical check and visual inspection on all current transformers.
12-Perform mechanical check and visual inspection on all voltage transformers.
13-Perform mechanical check and visual inspection on all disconnected and grounding
switches.
14-Check for correct breaker position indication.
15-Check for correct spring status indication (spring charged/discharged).
16-Perform all specific checks on the breaker and spring operating mechanism.
17-Check that all control wiring is correct according to the approved drawing and terminal
1-Ensure the numbers on the ferules are from left to right beginning at the terminal block i.e. at
the end of the wire and from bottom to top.
2-The wire nos. should be checked against the wiring table and the schematic drawing.
3-BUS CONTINUITY TEST
1- This test should be performed after bus bar complete erection and before cable connection.
2-Check the continuity for each phase.
3-Check the resistance for all the bus bar joint using micro-ohm meter 100 A.
4-Check the over all resistance of the bus bar for each phase using micro-ohm meter 100A.
MICRO OHM
METER

PRIMARY CIRCUITS
Page 48 of 155
1- Check the switchgear has finally been erected but not yet connected to the cables. Perform the
resistance test as under.
2- The main circuit resistance test shall be performed by 10A or 100 Ampere DC by micro-ohmmeter
from panel to panel on each phase from cable spouts with all circuit breakers racked in service and
on position.
3- For judgment, the resistance values from panel to panel should not vary too much if the number
5.1Visual Inspection

5.2 Insulation Resistance Test

 The insulation resistance shall be checked at the terminals with respect to ground / earth with a
1KV DC Voltage for One minute.
P1
S1
MEGGER
S2
P2
Page 49 of 155
5.3 Winding Resistance Measurement
P1
S1
MILIOHMMETER
S2
P2
5.4 Polarity Test

P1
S1
+
SENSITIVE
SWITCH
AMMETER A
S2
-
+
BATTERY
-
P2
Page 50 of 155
5.5 Ratio Test By Current Primary Injection
P1
S1
AMMETER A
PRIMARY S2
INJECTION
TEST SET
P2
5.6 Magnetizing Current Test (Minimum 2 Points Above )

 The knee point is the point on the magnetization curve at witch 10 % increase in excitation
voltage produces 50 % increase in excitation current.
P1
STEP UP
A
AC SUPPLY V
S2
P2
ARRANGEMENT
5.7 Loop Resistance Measurement Test (Burden Test)

the complete loop.
Page 51 of 155
P1
P1
S1
S1
RELAY
S2
RELAY V
S2
A
MILIOHMMETER
CURRENT
SOURCE
P2 P2
5.8 Phase Identification Test

5.9 Verify Secondary Circuits, Terminals, Shorting/Isolating Links By Primary Injection
5.10 Single Point Earthing Check

5.11 Demagnetize CT Cores After All Tests

6 VOLTAGE TRANSFORMER CHECKS

Page 52 of 155
6.2 Winding Resistance Test
A
a1
MILIOHM
METER
n1
a2
N
n2
ARRANGEMENT
6.3 Insulation Test

A
a1
MEGGER
n1
a2
N
n2
6.4 Ratio Check

A
a1 STEP UP
TRANSFORMER VARIAC
V
n1
SUPPLY
AC
a2
V
N
n2
Page 53 of 155
6.5 VT Polarity Checks
A
a1
+
SWITCH A
- n1
+
BATTERY a2
-
N
n2

the complete loop.
S1 S1
RELAY RELAY V
S2 S2
A
OHMMETER
VOLTAGE
SOURCE
Page 54 of 155
secured.
 Close the CB.
CB MAIN CONTACTS
MICRO OHM
METER R Y B
Page 55 of 155
7.6 Tripping Test

 Connect the current injection test set to one of the breaker phases.
 Connect the timer contact to any of the other phases.
 Inject the testing current.
 Record the associated tripping time.

0, 45,180, 225, 270 and 315 degrees.
0, 45, 90, 180, 225, 270 and 315 degrees.
8.1 Ammeter Check
RELAY TEST SET
TERMINALS
CURRENT
N
A
8.2 Voltmeter Check

RELAY TEST SET

TERMINALS
VOLTAGE
N
V
Page 56 of 155
8.3 Energy Meter Check
 Connect the current test set terminals to the Energy meter current terminals.
 Connect the voltage test set terminals to the Energy meter voltage terminals.
 Apply 0, 25, 50,100% of rated load and with rated voltage and current at angles of 0, 45,180,
225, 270 and 315 degrees for time.
 Record the corresponding Energy meter readings.
R R
TERMINALS
CURRENT
TERMINALS
CURRENT
Y Y
B B
N N
R R
TERMINALS
TERMINALS
VOLTAGE
VOLTAGE
Y Y
B B
N N
8.4 Power Meter Check

 Connect the current test set terminals to the Power meter current terminals.
 Connect the voltage test set terminals to the Power meter voltage terminals.
0, 45,180, 225, 270 and 315 degrees.
 Record the corresponding Power meter readings.
RELAY TEST SET TEST PLUG KW METER
R R
TERMINAL
CURRENT
TERMINAL
CURRENT
Y Y
S
S
B B
N N
R R
TERMINAL
VOLTAGE
TERMINAL
VOLTAGE
Y Y
S
S
B B
N N
KW METER TESTING ARRANGEMENT
8.5 Current Transducer Check

CURRENT
RELAY TEST SET
TRANSDUCER
TERMINALS
TERMINALS
CURRENT
R
INPUT
N
TERMINALS
OUTPUT
Page 57 of 155
8.6 Voltage Transducer Check
VOLTAGE
RELAY TEST SET
TRANSDUCER
TERMINALS
TERMINALS
VOLTAGE
R
INPUT
N
TERMINALS
OUTPUT
V
9-Test Of Protection Relays By Secondary Injection.

Notes:
1- Testing Engineer should provide the commissioning manuals and have the detailed understanding for
testing and commissioning procedure.
2-All outputs / indications to be tested.
3-Initial tests of new protective relays must include operating characteristics checks for a
representative range of available settings with Company approved computer operated test
4-Relay auxiliary devices such as external resistors, metrosils, etc. to be tested to conform to
5-Final calibration test of all protective relays must be carried out on approved settings, by
6-Auxiliary and tripping relay testing shall include,
7-Pickup and dropout voltage, verification of all contacts.
8-Operation timing at 80% and 100% nominal voltage.
9-Time delay relays shall be tested at 0%, set point and 100% delay.
10-Use of red and green tags for tested relays, meters, etc.
11-All the relays and meters which have been tested and found o.k must have green tags
12-The relays and meters found defective during tests should be tagged red.
9.1 Earth Fault Relay
9.1.1 Earth Fault Pick-Up

9.1.2 Operating Time Verification
Page 58 of 155
9.1.3 Instantaneous Unit Verification

R R
TERMINALS
CURRANT
TERMINALS
CURRANT
Y Y
B B
N N
CONTACT
TIMER
TRIP
9.2 R.E.F. Protection Relay
9.2.1 Pickup Voltage Verification.

9.2.2 Drop Out Voltage Verification.

 Slowly decrease the applied voltage until the relay o/p contact open.
 Record the drop out voltage
9.2.3 Trip Timing Test.
Page 59 of 155
 Record the relay tripping time.
9.3 Tripping Relay

9.3.1 Voltage Pick-Up Verification
9.3.2 Voltage Drop-Out Verification
TRIPPING
RELAY
DC VOLTAGE
TERMINALS
+ TERMINALS
+
COIL
-
-
CONTACT
TIMER
TRIP
Page 60 of 155
7- Testing procedure of Medium Voltage bus duct
1.0 Task
The purpose of this procedure is to test and document the integrity of metal enclosed medium voltage
bus duct assemblies of 13.8 KV ,18 KV and 4.16kv level using an ac/dc source.
2.0 Preconditions
2.1 Work status
• Erection has been completed.

• Labelling of the equipment and designation of live enclosed plant sections has been
carried out.
2.2 Documentation
• The bus duct diagram is available

• Commissioning checklists ( attached test sheet TS-BD01 )
2.3 Personnel
• 1 Commissioning engineer: Engineer or technician with experience in commissioning

of types of the electrical equipment systems employed in the plant.
• 1 Helper: skilled worker with adequate on-the-job training.
2.4 Measuring instruments and tools
• Torque wrench
• Micro ohm meter 10A and 100A
• Insulation Tester 5000V dc
• High voltage tester AC (up to 50 KV or DC (up to 80 KV)
• Discharge hot stick
3.0 Precautions
The work will only proceed when a Permit to Work (PTW) in work permit area has been obtained.
The PTW will be kept on site for consultation during the testing works.
Special attention will be given to:
• Due to high voltage being used, adequate safety precautions should be taken to avoid injury to
personnel and damage to property.
• Cordoning off specified working area and provision of applicable safety warning sign board.
• Ensure that all the necessary test equipment are made available at the test area and with valid
calibration stickers and certificate.
• Hand insulating gloves and grounding sticks / wire jumpers shall be provided for safe handling and
draining of residual voltage.
• Switch gear and transformer should be disconnected from flexible connection with the bus duct.
Switchgear and transformer should be connected to ground.
• Ensure that all voltage transformers are disconnected for the duration of the test and that all current
transformers are short-circuited.
• Immediately after testing of each phase, voltage residue shall be drain by using grounding stick / wire
which is directly connected to earth.
Test equipment operation shall be in accordance with the manufacturer's instructions.
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• Closing of the work permit after completion of the work (if the test area is to be considered in work
permit area).
4.0 Scope
• Testing of bus bar

• High voltage test on complete Bus duct assembly
• Circuit resistance for complete Bus duct assembly
• Checking that the bus bar mounting position is correct,
• Checking of the phase and continuity
• Checking of correct earthing,
5.0 Execution
5.1 Visual checks

• Checking of the bus bar for damage and that they are bolted correctly,
• Checking of insulator for any cracks or damage.
• Inspection for cleanliness, connections etc.
5.2 Testing the Bus bar

Enter the rating plate data in check list TS-BD01 and compare the bus duct data with the data contained
in the diagram. The following test shall be carried out
1. Bus continuity and phasing test

2. Torque test
3. Contact Resistance test
4. Main Circuit Contact Resistance test
5. Insulation resistance test before hi pot
6. High Voltage test
7. Insulation resistance test after hi pot
8. Protective earthing check
5.2.1 Continuity and Phasing test
Continuity and phasing test can be done by simple ohm meter or fluk
Connect the extreme end of the single phase of the bus with ground and check the resistance between
phases and ground. All the phases should read infinity except the grounded phase. Thus the phase is
identified and continuity is checked. Repeat the test on remaining two phases.
5.2.2 Torque test

Torque shall be applied to all joints made at site. The bolts shall be tightened according to manufacturer
instruction after the bus bar erection completion. Spot check shall be carried out using a calibrated
torque wrench.
Following is reference in case data from manufacturer is not available
Bolt tighten maximum value,

Bolt Maximum
Size value
M 6 8 Nm
M 8 20 Nm
M 10 40 Nm
M 12 70 Nm
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M 16 140 Nm
Tolerance : ± 20 %
NOTE : Bolt tightening torque values shall be as manufacturer recommended ( construction will confirm
this point )
5.2.3 Contact resistance test
The contact resistance test will be carried out after torque completion and will be applied to all bus bar
joints. The test requires to measure very small fluctuations in resistance while simulating actual operating
conditions. A DC power source will inject the test current up to 100 A and digital voltmeter will measure
the voltage drop across the joints under test, Thus V/I gives Resistance
Contact resistance can also be measured using micro ohm meter as shown in figure below.
• Check the resistance for all the bus bar joints using micro-ohm meter at 100
Amps.
• Check the over all resistance of the bus bar for each phase using micro-ohm
meter at 100Amps.
5.2.4 Insulation Resistance test Before High Voltage Test

Before performing high voltage test perform the Insulation resistance test with 5000Vdc insulation tester
as under
• Isolate the VTs and short the CTs secondary if installed on bus duct
• Connect the phases Y, B to ground and apply the test voltage between
phase R and ground and note down the readings.
• Connect the phases B, R to ground and apply the test voltage between
phase Y and ground and note down the readings.
• Connect the phases R, Y to ground and apply the test voltage between
phase B and ground and note down the readings.
5.2.5 High Voltage Test

AC high- pot test shall be carried out in accordance with IEC standard at site. The test shall be carried
out on MV Bus bar as under
• Bus duct is isolated from the transformer and switch gear

• Voltage transformers primary disconnected if it is installed on the bus duct.
• Current transformer secondary shorted if it is installed on the bus duct.
• The test voltage to carry out the test is mention in table below against
different voltage levels
• Connect the phases Y, B to ground and apply the test voltage between
phase R and ground. Record the leakage current
• Connect the phases B, R to ground and apply the test voltage between
phase Y and ground. Record the leakage current
• Connect the phases R, Y to ground and apply the test voltage between
phase B and ground. Record the leakage current
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5.2.6 Insulation Resitance test after High Voltage Test
After performing high voltage test Perform the Insulation resistance test with 5000Vdc for MV switch gear
as describe in 5.2.4
5.2.7 Checking the protective earthing

Bus duct protective earthing bond must be earthed in order to afford protection to human beings.
Protective earthing bond should be checked for it continuity.
Shorting plate between the bus duct enclosures at transformer end and switch gear end should
be checked for firm connection and grounding. The shorting bar between bus duct enclosures carries the
circulating current induced on the bus enclosures.
5.2.8 space heater test
6.0 Documentation
A check list ( attached test sheet TS-BD01) is to be completed.
♪-----end of the procedure -----♪
Page 64 of 155
8- Testing procedure of Medium Voltage CB (52G –GCP)
1.0 Task
The purpose of this procedure is to test, commission and document feeder and MV circuit breaker in
metal enclosed switchgear assemblies of 4.16kV , 13.8 kV and 18 KV levels.
2.0 Preconditions
2.1 Work status

• Labelling of the equipment and designation of live enclosed plant sections has been carried out.
2.2 Documentation
• The schematic and single line diagram of the medium voltage switchgear are available
• Commissioning checklists ( attached test sheet TS – MB01)
2.3 Personnel
• 1 Commissioning engineer: Engineer or technician with experience in commissioning of types of

the electrical equipment systems employed in the plant.

• Secondary Injection
• Fluke-2 Nos
3.0 Precautions
The work will only proceed when a Permit to Work (PTW) in work permit area has been obtained.
The PTW will be kept on site for consultation during the testing works.
• Due to high voltage being used, adequate safety precautions should be taken to avoid injury to
personnel and damage to property.
• Cordoning off specified working area and provision of applicable safety warning sign board.
• Ensure that all the necessary test equipment are made available at the test area and with valid
calibration stickers and certificate.
• Hand insulating gloves and grounding sticks / wire jumpers shall be provided for safe handling and
draining of residual voltage.
• Breaker should be withdrawn from the cubicle during breaker testing.
• Immediately after testing of each phase, voltage residue shall be drain by using grounding stick / wire
which is directly connected to earth.
•Closing of the work permit after completion of the work (if the test area is to be considered in work
permit area).
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4.0 Scope
• Testing of CB
• Testing of Anti pumping facility
• Operation of CB inside the feeder
• Operation of Earting switch
• Checking CB mounting.
NOTE: if there are specific tests ( SF6 gas pressure low alarm & trip ) ,,,etc it will be don by vendor
during gas filing.
5.0 Execution
5.1 Visual checks
• Check nameplate information for correctness.

• Inspect enclosures for proper alignment, foundation fixing and grounding.
• Inspect covers, panel section and door for paint work and proper fit.
• Check for smooth and proper movement of racking mechanisms for alignment, shutters, rollers, rails and
guides.
• Check for proper alignment of the breaker primary and secondary contacts.
• Check operation of all mechanical interlocks.
• Check tightness of all bolted connections (torque wrench method).
• Check bus and supports for defects such as cracked welds, chipped porcelain, cracked insulation, etc.,
and free of dust accumulation.
• Verify that all front panel mounted devices (meters, push buttons, switches, indicator lamps, mimic
buses, etc.) are installed as per drawings
• Perform mechanical check and visual inspection on the circuit breaker.
• Perform mechanical check and visual inspection on disconnect and grounding switches.
• Check for correct breaker position indication.
• Check for correct spring status indication (spring charged/discharged).
• Perform all specific checks on the breaker and spring operating mechanism.
• Check that all control wiring is correct according to the approved drawing and terminal connections are
secure.
WIRING AND FERRULING CHECK
• Ensure the numbers on the ferules are from left to right beginning at the terminal block i.e. at the end of
the wire and from bottom to top.
• The wire nos. should be checked against the wiring table and the schematic drawing.
5.2 Testing of CB and Feeder
Enter the rating plate data in check list TS-MB01 and compare the CB data with the data contained in
the circuit documentation. The following test shall be carried out
1. Contact Resitance test
2. Insulation resistance test before hipot
3. High Voltage test
4. Insulation resistance test after hipot
5. Minimum operating voltage for close and trip coil
6. Breaker operating time
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7. Breaker operation
a. Stored energy and spring charge mechanism

b. Alarm and indication for the breaker operation
c. CB Racking IN and OUT Checks
d. CB operation in service position
e. CB operation in test/disconnect position
f. Anti pumping functional check
8. Inter lock test

9. Operation of Earth Switch
10. Electrical control and protection/Measuring Devices
a. Control power and current measurement

b. Testing of protection devices
c. Testing of CT and VT
d. Testing of Transducer
11. Protective earthing check
12. Checks before and After initial energization
5.2.1 Contact resistance test
Breaker Contact resistance can be measured using micro ohm meter on each pole of the breaker when
breaker is closed
• Connect the current and voltage leads of the micro ohmmeter across the pole of the breaker
• Apply a current of 100 amps and note down the reading
• Repeat the test for other two pole also
• For judgment, the resistance values from one pole to another pole should not vary with big difference
and the value should also be cross checked with manufacturer recommendation.
5.2.2 Insulation Resitance test Before High Voltage Test
Before performing high voltage test, perform the Insulation resistance test with 5000Vdc insulation tester.
• Close the breaker.
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•Connect the phases Y, B to ground and apply the test voltage between phase R and ground and note
down the readings.
• Connect the phases B, R to ground and apply the test voltage between phase Y and ground and note
down the readings.
• Connect the phases R, Y to ground and apply the test voltage between phase B and ground and note
down the readings.
• Open the breaker,
• Connect the phases R, Y, B Cable side to the ground on all the breakers.
• Connect the phases R, Y, B Bus side to the test set.
• Record the corresponding leakage current readings.
5.2.3 High Voltage Test Note: high voltage test shall be done only in case breaker is not tested for
high voltage along with the bus
AC high- pot test shall be carried out in accordance with IEC standard at site. The test shall be
carried out on MV CB in both close and open position. Test is performed as under

􀂾When the CB is Closed( shown in figure below)
• The test voltage to carry out the test is as per below table.
• Connect the phases Y, B to ground and apply the test voltage gradually between phase R and ground.
Record the leakage current
• Connect the phases B, R to ground and apply the test voltage gradually between phase Y and ground.
• Connect the phases R, Y to ground and apply the test voltage gradually between phase B and ground.
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5.2.4 Insulation Resitance test after High Voltage Test
After performing high voltage test Perform the Insulation resistance test with 5000Vdc insulation tester
as describe in 5.2.2
5.2.5 Minimum operating Voltage for close and trip Coil
5.2.5.1 Close coil

Minimum voltage required to close the breaker is measured by applying variable DC voltage to
the closing coil of the breaker
• Connect the DC source to the closing coil of the breaker in series with dc ammeter
• Increase the voltage slowly till the breaker get closed , note down voltage and current readings
5.2.5.2 Trip coil

Minimum voltage required to Trip the breaker is measured by applying variable DC voltage to the Trip
coil of the breaker
• Connect the DC source to the Trip coil of the breaker in series with dc ammeter
• Increase the voltage slowly till the breaker get opened , note down voltage and current readings
• Test should be repeated for both trip coils
5.2.6 Breaker Operating Time
Breaker closing and tripping time can be measured either by a timer or a breaker analyzer
Timing Test Using An Electronic Oscillograph.
• Connect the test set to the CB.
• Perform the following operations at the rated DC
• Close ( C ) , Open ( O ) , Close - Open ( C – O ) & Open – Close – Open ( O – C – O )
• Record the corresponding readings.
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5.2.7 Breaker operation
5.2.7.1 Stored energy and spring charge mechanism
Stored energy and spring charging is checked by performing several operation
5.2.7.2 Alarm and indication for the breaker operation

• Alarm Indication for spring charging once the spring is charged should be checked
• Alarm for mal function of the drive should be checked by interrupting the dc power to charging motor
while charging
5.2.7.3 CB Racking IN and OUT Checks

CB Racking IN and OUT must be checked for a smooth movement. This should be checked several times
5.2.7.4 CB operation in service position

• Put the breaker in service position
• Perform several Close and Open operation of the breaker manually by operating mechanical buttons
•Performer several Close and Open operation of the breaker electrically both local and remote
5.2.7.5 CB operation in test/disconnect position

• Put the breaker in service position
• Performer several Close and Open operation of the breaker Manually by operating mechanical buttons
• Performer several Close and Open operation of the breaker electrically both local and remote
5.2.7.6 Anti pumping functional check
Anti pump Relay function should be checked as per table below
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From the above table it is noted that
o When the breaker is closed and the control switch is held in CLOSE position. The breaker was still
closed.
o when the breaker was tripped either Manually or Electrically, the breaker does not attempt to re close
if a permanent closing signal is applied
5.2.8 Check The Correct Functioning Of Interlocks and Limits Switches

Following Interlock should be checked as per manufacturer instruction manual
Positive interlock
Negative interlock
Spring discharge interlock
Interference interlock
Closing spring gag interlock
Limits switches should be checked for its proper operation and function an adjustment is made if
necessary
5.2.9 Operation of Earth Switch

Operation of earth switch for closing and opening to be checked, also indication to be checked
5.2.10 Electrical control and protection/Measuring Devices

Insulation resistance test for control wiring and auxiliary circuit should be done with 500V dc
Insulation tester.
5.2.10.1 Control power and current measurement
• Current on MCB of each circuit to be measured when all the devices are in service
• Mixing of voltage between the two circuits should be checked by keeping off MCB of one circuit and
checking the voltage on other circuit MCB towards load side +V and –V terminals with repect ground
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• Above test should be done for closing, tripping, charging and power to the devices circuits.
5.2.10.2 Testing of protection devices

All the protection and monitoring relays to be tested, please refer to related test procedure
5.2.10.3 Testing of CT and VT

All the CTs and VTs to be tested, please refer related test procedure
5.2.10.4 Testing of Transducer

All the CTs and VTs to be tested, please refer to related test procedure
5.2.11 Protective earthing check

Switch gear protective earthing bond must be earthed in order to afford protection to human beings.
5.2.12 Checks After initial energization

After energization service load checks to be performed as under
• Current should be measured on all the secondary terminal of the current transformer
• Phase to phase and phase to ground Voltage measurment should be done on all the phase and core
of the voltage transformer
• Phase sequence checks to be done on Voltage transformer
• All the measuring devices including protective relay to be checked for their metering function
6.0 Documentation
A Test Sheet ( attached test sheet TS-MB01) is to be completed.
♪------- End of the Procedure --------♪
Page 72 of 155
9-Transducers and metering:
(A) Transducers :
1-Testing procedure Current Transducer

1.0 Task
All the Current transducers shall be calibrated to check the accuracy for their output.
2.0 Preconditions
2.1 Work status

• Labelling of the equipment
2.2 Documentation
• The circuit diagrams of the electrical equipment cabinets are available

• Commissioning checklists ( attached test sheet TS-AX01 )
2.3 Personnel

• Standard Ammeter or Fluke

• Secondary Injection test set
• DC milli ammeter
3.0 Precautions
• Observe the rules for handling electronic components sensitive to electrostatic discharge (ESD
measures).
• Special safety arrangements shall be made for all areas which are not explicitly designated as” electrical
operating areas” when performing tests at voltages in excess of 50V.
4.0 Scope
• Testing cable connections,

• Checking that the mounting position is correct,
5.0 Execution
5.1 Visual checks
• Checking of the cables for damage and that they are connected correctly,
• Inspection for physical connection as per approved drawings.
• Inspection for correct tightness for connection
• Checking ferrules
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5.2 Testing of Current Transducer
Transducer calibration shall be done via front panel mounted test facilities.
• Enter the rating plate data in check list TS-AX01 and compare the transducer data
with the data contained in the circuit documentation. The following test shall be
carried out
1. Electrical Function test

2. Secondary Injection
5.2.1 Electrical Function test
• Check function of test switch or plug for correct function
5.2.2 Secondary Injection
• Connect the current test set on the Current Transducer terminals.

• Inject 25, 50, 75 & 100 % of the full-scale current of the Current Transducer.
• Record the corresponding Current Transducer out put.
• Inject 100 % of the rated current.
• Record corresponding Current Transducer output.
6.0 Documentation
A Test Sheet TS-AX01 is to be completed for each and every transducer.
♪---------End of the Procedure---------
Page 74 of 155
2-Testing procedure Voltage Transducer
1.0 Task
All the Voltage transducers shall be calibrated to check the accuracy for their output.
2.0 Preconditions
2.1 Work status

• Labeling of the equipment
2.2 Documentation

• Commissioning checklists TS-VX01
2.3 Personnel
• 1 Commissioning engineer: Engineer or technician with experience in commissioning of

types of the electrical equipment systems employed in the plant.

• DC Milli ammeter
3.0 Precautions
measures).
• Special safety arrangements shall be made for all areas which are not explicitly designated as”
electrical operating areas” when performing tests at voltages in excess of 50V.
4.0 Scope

5.0 Execution
5.1 Visual checks
Page 75 of 155
5.2 Testing of Voltage Transducer
• Enter the rating plate data in check list TS-VX01 and compare the transducer data
carried out

• Connect the Voltage test set on the Voltage Transducer terminals.

• Inject 25, 50, 75 & 100 % of the full-scale Voltage of the Voltage Transducer.
• Record the corresponding Voltage Transducer out put.
• Inject 100 % of the rated Voltage.
• Record corresponding Voltage Transducer out put.
6.0 Documentation
A Test Sheets ( attached test sheet TS – VX01) is to be completed for each and every transducer.
♪---------End of the Procedure------------♪
Page 76 of 155
3-Testing procedure Power Transducer
1.0 Task
All the Power transducers shall be calibrated to check the accuracy for their output.
2.0 Preconditions
2.1 Work status

carried out.
2.2 Documentation

• Commissioning checklists ( attached test sheet TS-PX01 )
2.3 Personnel


• DC Milli ammeter
3.0 Precautions
measures).
4.0 Scope

5.0 Execution
5.1 Visual checks
Page 77 of 155
5.2 Testing of Power Transducer
• Enter the rating plate data in check list TS-PX01 and compare the transducer data
carried out

•Connect the current test set terminals to the Power Transducer current terminals.
• Connect the voltage test set terminals to the Power Transducer voltage terminals.
• Apply 0, 25, 50, 75,100% of rated load with rated voltage and current at angles of
0, 45,180, 225, 270 and 315 degrees.
• Record the corresponding Power Transducer O/P readings.
6.0 Documentation
A Test Sheet ( attached test sheet TS-PX01 ) is to be completed for each and every
transducer.
Page 78 of 155
(B) Metering :
1-Testing procedure Ammeter
1.0 Task
All the moving coil, moving iron or digital ammeters shall be calibrated to check their accuracy
2.0 Preconditions
2.1 Work status

2.2 Documentation

• Commissioning checklists ( attached test sheet TS-AM01)
2.3 Personnel


3.0 Precautions
measures).
• Special safety arrangements shall be made for all areas which are not explicitly designated as
” electrical operating areas” when performing tests at voltages in excess of 50V.
4.0 Scope

5.0 Execution
5.1 Visual checks
• Inspection of isolating terminals and earthing connections
Page 79 of 155
5.2 Testing of Ammeter
Metering calibration shall be done via front panel mounted test facilities.
• Enter the rating plate data in check list TS-AM01 and compare the ammeter data with the data
contained in the circuit documentation. The following test shall be carried out

• Check the function of ammeter selector switch

• Connect the current test set on the ammeter terminals.

• Inject 25, 50, 75 & 100 % of the full-scale current of the ammeter.
• Record the corresponding ammeter readings.
• Inject 100 % of the normal current.
• Record corresponding ammeter reading.
5.2.3 Checking the protective Earthing

Check the earthing on the meter
6.0 Documentation
A Test sheet ( attached test sheet TS-AM01) is to be completed for each and every ammeter.
Page 80 of 155
2-Testing procedure Voltmeter
1.0 Task
All the moving coil, moving iron or digital Voltmeters shall be calibrated to check their accuracy
2.0 Preconditions
2.1 Work status

• Labeling of the equipment .
2.2 Documentation

• Commissioning checklists ( attached test sheet TS – VM01 )
2.3 Personnel

• Standard Voltmeter or Fluke

3.0 Precautions
measures).
4.0 Scope

5.0 Execution
5.1 Visual checks
Page 81 of 155
5.2 Testing of Voltmeter
• Enter the rating plate data in check list TS-VM01 and compare the voltmeter data with
the data contained in the circuit documentation. The following test shall be carried out 
• Check the function of voltmeter selector switch

• Connect the Voltage test set on the voltmeter terminals.

• Inject 25, 50, 75 & 100 % of the full-scale Voltage of the ammeter.
• Inject 100 % of the normal Voltage.
• Record corresponding voltmeter reading.

6.0 Documentation
A Test Sheet ( attached test sheet TS – VM01) is to be completed for each and every voltmeter.
Page 82 of 155
3-Testing procedure for measure Frequency
1.0 Task
All the moving coil, moving iron or digital Voltmeters shall be calibrated to check their accuracy
2.0 Preconditions
2.1 Work status

• Labeling of the equipment .
2.2 Documentation

• Commissioning checklists ( attached test sheet TS-EM01)
2.3 Personnel

• Standard Frequency meter or Fluke

3.0 Precautions
measures).
4.0 Scope

5.0 Execution
5.1 Visual checks
Page 83 of 155
5.2 Testing of Frequency
• Enter the rating plate data in check list TS-EM01 and compare the Frequency data with
the data contained in the circuit documentation. The following test shall be carried out 
• Connect the Fluke set on the frequency terminals.

• Inject fixed voltage with variable frequency
• Inject normal frequency
• Record corresponding frequency reading.
6.0 Documentation
A Test Sheet ( attached test sheet TS-EM01) is to be completed .
♪------- End of the Procedure
Page 84 of 155
4-Testing procedure Power meter
1.0 Task
The all analogue or digital Power meters shall be calibrated to check their accuracy
2.0 Preconditions
2.1 Work status

• Labelling of the equipment.
2.2 Documentation

• Commissioning checklists ( attached test sheet TS-EM01 )
2.3 Personnel

3.0 Precautions
measures). • Special safety arrangements shall be made for all areas which are not explicitly
designated as” electrical operating areas” when performing tests at voltages in excess of 50V.
4.0 Scope

5.0 Execution
5.1 Visual checks
Page 85 of 155
5.2 Testing of Power meter
• Enter the rating plate data in check list TS-PM01 and compare the power meter data
carried out

♦ Connect the current test set terminals to the Power meter current terminals.
♦ Connect the voltage test set terminals to the Power meter voltage terminals.
♦ Apply 0, 25, 50, 75 &100% of rated load and with rated voltage and current at
angles of 0, 45,180, 225, 270 and 315 degrees.
♦ Record the corresponding Power meter readings.
♦ Compare the calculated reading like power factor, VAR, and WATTS with meter
reading.

6.0 Documentation
A Test Sheet ( attached test sheet TS-EM01 ) is to be completed for the Power meter
Page 86 of 155
5-Testing procedure Power Factor
1.0 Task
The all analogue or digital Power meters shall be calibrated to check their accuracy
2.0 Preconditions
2.1 Work status

• Labelling of the equipment.
2.2 Documentation

2.3 Personnel

3.0 Precautions
measures). • Special safety arrangements shall be made for all areas which are not explicitly
designated as” electrical operating areas” when performing tests at voltages in excess of 50V.
4.0 Scope

5.0 Execution
5.1 Visual checks
Page 87 of 155
5.2.1 Testing of Power Factor
• Enter the rating plate data in check list TS-EM01 and compare the power factor data
carried out
♦ Connect the current test set terminals to the Power meter current terminals.
♦ Connect the voltage test set terminals to the Power meter voltage terminals.
♦ Apply 100% of rated load and with rated voltage and current at angles of 0,
45,180, 225, 270 and 315 degrees.
♦ Record the corresponding power factor meter readings.
♦ Compare the calculated reading like power factor with meter reading.

6.0 Documentation
A Test Sheet ( attached test sheet TS-EM01) is to be completed for the Power meter
Page 88 of 155
6-Testing procedure Energy meter
1.0 Task
The entire analogue or digital Energy meter shall be calibrated to check its accuracy
2.0 Preconditions
2.1 Work status

2.2 Documentation

2.3 Personnel


• Standard energy meter
3.0 Precautions
measures).
4.0 Scope

5.0 Execution
5.1 Visual checks
Page 89 of 155
5.2 Testing of Energy meter
• Enter the rating plate data in check list TS-EM01 and compare the energy meter data
carried out

• Check function pf test switch or plug for correct function
♦ Connect the current test set terminals to the Energy meter current terminals.
♦ Connect the voltage test set terminals to the Energy meter voltage terminals.
♦ Apply 0, 25, 50, 75 &100% of rated load and with rated voltage and current at
angles of 0, 45,180, 225, 270 and 315 degrees for time.
♦ Record the corresponding Energy meter readings and time duration.
♦ Compare the calculated reading with energy meter reading obtained.

6.0 Documentation
A Test Sheet ( attached test sheet TS-EM01) is to be completed for the energy meter.
Page 90 of 155
10-LOW VOLTAGE POWER CABLES SITE TEST PROCEDURE
A. Mechanical Checks and Visual Inspection

1. Inspect for physical damage/defects
2. Check for proper cable support ,clamping, trays, blocking
3. Verify all cable connections as per approved drawing
4. Verify that all cables and cores are labeled correctly
5. Check tightness of terminals and confirm the cables are secured.
6. Check that all cable trays are secure and correctly grounded
7. Check cable entry path trench as ducts are to be properly sealed
8. Check all cables are securely supported throughout
9. Visual Insulation, size and rating confirmation
10. Size checking against rating required
B. Electrical Test
1. Phasing and Continuity check
2. Insulation Resistance Test by 2.5 kV DC for 1 minute between the core another cors with
grounded shield
Documentation
A check list ( attached test sheet TS-LC01) is to be completed.
Page 91 of 155
11-MEDIUM VOLTAGE CABLES SITE TEST PROCEDURE
A. Mechanical Check and Visual Inspection
1. Inspect for physical damage/defects. Check irregularities of outer jacket caused by

non-uniform shield wire distribution
2. Verify all cable connections as per drawing
3. Check for proper cable support ,clamping ,trays, blocking
4. Check cable bends to ensure that the bending radius is equal to or greater than the minimum
bending radius specified
5. Verify shield grounding as per design ( single point, both ends, via voltage limiters, etc)
6. Check tightness of all bolted connections ( torque wrench method)
7. Single Core Cable connected between Power Transformer and SWGR shall be single point
earthed at SWGR side and at floating side
8. Check that phases are identified and color coded
9. Check cable entry path trench as ducts are to be properly sealed
10. Verification of exact route length as per approved drawings from termination to termination.
11. Check for proper cable arrangement in the path (RYB) in order to prevent circulating current.
B. Electrical Test
1. Sheath armor continuity test

2. Sheath insulation resistance test
3. Main conductors insulation resistance test ( 5KV DC insulation tester ) before & after Hi-pot Test .
4. Phasing and continuity test of main conductor
5. AC- high voltage test
VLF at 0.1Hz at test voltage level of 3Uo for one hour can be performed.
M : factor used for how many times this cable exposed to test ( it is =1 for first time to test ,
and = 0.8 for 2nd time to test .)
Example
V)test : ?????
V)r line : 4.16 KV
Page 92 of 155
=( 4.16 / 1.732 ) X 3 X 1.41 X 1 = 10. 2 11 KV
Documentation
A check list ( attached test sheet TS-MC01) is to be completed.
Page 93 of 155
11- AUXILIARY TRANSFORMER SITE TEST PLAN
 1. CONSTRUCTION AND DIMENSION CHECK

 2. WINDING RESISTANCE MEASUREMENTS
 3. RATIO CHECK
 4. PHASE RELATIONSHIP CHECK
 5. INSULATION RESISTANCE MEASUREMENTS
 6. SEPARATE SOURCE VOLTAGE WITHSTAND TEST
 7. OIL DIELECTRIC TEST
 8. AUXILIARY EQUIPMENT CHECK
Page 94 of 155
AUXILIARY TRANSFORMER SITE TEST PROCEDURE
3. CONSTRUCTION AND DIMENSION CHECK
3.1 Dimension will be measured in accordance with the approved specification.

3.2 Construction, painting and welding condition will be inspecting visually.
4. WINDING RESISTANCE MEASUREMENTS
4.1 The winding resistance will be measured by the dc voltage drop method with resistance measuring
system.
4.2 This test shall be made on the rated tap position.
0.4KV 13,8KV
R R
Y
TR. WINDING
RESISTANCE Y
B
MEASUREMENT
DEVICE
N B
TRANSFORMER WINDING RESISTANCE MEASUREMENTS

ARRANGEMENT
5. RATIO CHECK
5.1 The voltage ratio shall be measured by means of voltage ratio measuring bridge and on single phase,
phase by phase.
5.2 The applied voltage to HV winding will be about 220 V.
5.3 The test will be made on all windings and tap positions.
0.4KV 13,8KV
V R R V
Y
3PH , 380 VAC
V Y SUPPLY
B
V N B V
TRANSFORMER RATIO TESTING ARRANGEMENT
Page 95 of 155
6. PHASE RELATIONSHIP CHECK
6.1 The phase relationship shall be checked at rated voltage tap connection.
6.2 Three phase 220V will be applied to HV winding and the voltage shall be measured between terminals.
6.3 Vector diagram will be drawn and confirmed.
0.4KV 13,8KV
V R r V
Y
3PH , 380 VAC
V y SUPPLY
B
V N b V
V
V
V
V
TRANSFORMER PHASE RELATIONSHIP (VECTOR GROUP) TESTING ARRANGEMENT
7. INSULATION RESISTANCE MEASUREMENTS
The test shall be made between HV winding and LV winding, HV winding and earth, LV winding and
earth with 2000V megger tester.
0.4KV 13,8KV
R R
Y
MEGGER
Y
B
N B
TRANSFORMER INSULATION RESISTANCE MEASUREMENTS

ARRANGEMENT
8. SEPARATE SOURCE VOLTAGE WITHSTAND TEST
8.1 The single-phase AC voltage shall be applied to each winding with other winding and tank solidly
grounded.
8.2 Test frequency: 60 Hz
8.3 Test duration : 60 sec
8.4 Test voltage : 38 KV (HV winding to earth)
Page 96 of 155
0.4KV 13,8KV
R R
Y HIGH VOLTAGE
Y TEST SET
B
N B
TRANSFORMER SEPARATE SOURCE VOLTAGE WITHSTAND

TESTING ARRANGEMENT
9. OIL DIELECTRIC TEST
Samples from different location are tested.

Six breaks down values of one sample are observed with an interval of 5 minutes.
Average of these six values is the dielectric of oil.
Gap between electrodes 2.5 mm
Diameter of electrodes 12.5 mm
Minimum strength 60 KV
10. AUXILIARY EQUIPMENT CHECK
All auxiliary equipment such as pressure relief device, lights, outlets, oil level gauges, temperature
indicators and others shall be subjected to an operation test to assure the proper coordinated functioning.
Documentation
A check list ( attached test sheet TS-PT02) is to be completed.
Page 97 of 155
(B) Testing procedure Generator Step up Transformer (GSU ,UAT , ST , SAT )
1. Task.
These instruction comprise a complete description of the testing of the generator step up
transformer GSU
2. Preconditions
2.1. Work status

carried out.
2.2. Documentation
• Product manual of the transformer
• Commissioning checklists ( attached test sheet TS-PT01)
2.3. personnel
• Commissioning engineer: - (1) engineer with experience in commissioning of

transformer and switch gear.
• Technician or helper:- (2) skilled worker with adequate on -the-job training
• Witness from the client‘s concern department
2.4. Measuring instrument
• Ratio meter (calibrated)---1

• Millimeter (calibrated)—2
• Insulation resistance meter –megger(calibrated)—1
• CT tester( calibrated)-1
• DC shunt 100 amps( calibrated)--1
• Mini clamp(calibrated)—2
• Tan delta measurement test equipment—1
• Current injection set(calibrated)—1
• 3 phase relay tester(calibrated)—1
3. Precautions
• The work will only proceed when a Permit to Work (PTW) in work permit area has been
obtained. The PTW will be kept on site for consultation during the testing works.
measures).
• Closing of the work permit after completion of the work (if the test area is to be considered in
work permit area).
• Before test voltages are applied a check shall be carried out to ensure that no unauthorized
persons are working at the corresponding load-where ever necessary barriers should be provided
4. Scope
• Testing of Transformer
• testing of protective device ( calibration of winding and oil temperature devices )
Page 98 of 155
• check the adjustments of OLTC AVR for final operation
• Checking Auxiliaries and cooling system
• Testing of bushing CT
• Checking of correct earthing
,
5. Execution
5.1. Visual Inspection.

Prior to carrying out electrical tests, a visual check of the transformer should be carried out
paying particular attention to the following points
• Correct labeling of devices and cables
• Equipment and cables are undamaged
• Correct execution of the cable gland/sealing end
• Name plate data, match with drawing and ambient condition
• Firm cable termination/terminal connection and ferruling
• All mechanical checks and visual inspection specified at site test report
shall be checked
• Check of impact recorder records shall be conducted for deserving any abnormal
impact during transportation
• Checking of tightness of all bolted connection (torque wrench method) shall be
conducted
• Checking of horizontal/vertical clearance of live parts to adjacent ground parts to
conform to standard shall be conducted
• Checking of bushing , bushing CT's, neutral CT's for damages and completeness
of accessories shall be conducted
• Check winding terminal identification shall be according SEC approved manufacturer
name plate drawing
5.2. Commissioning of OLTC

Commissioning of OLTC will ease the testing of transformer as tap changer can be operated
electrically. Prior to power up OLTC control panel with auxiliary 3 phase/single phase/dc voltage,
following check up shall be carried out.
• Winding insulation resistance and winding resistance for the motor should be carried out.
• Insulation resistance test for the control circuit should be carried out.
• After obtaining all the results and found satisfactory auxiliary power can be switched on
• voltage/phase sequence measurement shall be entered in test form
• Complete operational check including interlock and alarm shall be checked
5.3. Testing of Transformer
Following tests to be carried out
1. Core insulation test

2. insulation resistance / Polarization index test
3. Voltage Ratio Measurement
4. Vector Group/Phase Displacement
5. Winding Resistance Test
6. impedance measurement
a. Single phase impedance measurement
b. Zero sequence impendence measurement
Page 99 of 155
7. Excitation current Measurement
8. Insulation Power factor or Tan delta measurement
9. Temperature indicator and sensor Calibration
a. Winding Temperature
b. Oil Temperature
10. Bushing Current Transformer
11. Testing and commissioning of cooler control cabinet
12. Transformer protection devices functional check
13.measurment of neutral current in no load condition
5.3.1. Core Insulation Test
The insulation resistance between core and earth should be done for one minute with 1000 v dc
megger, as per following connection
Core – Earth
5.3.2. Insulation resistance/polarization index test
Testing of insulation resistance and polarization index should be carried out as under
Apply the test voltage on following Connection and note down the readings
Two Winding Transformer
HV – LV + Earth
LV – HV + Earth
Two Winding Transformer
HV – LV1+LV2 + Earth
LV1 – LV2+HV + Earth
LV2 - LV1+HV+Earth
The insulation resistance measurement is done from 15 seconds to 1 minute with 15 seconds
interval and then for every minute up to ten minutes. Value obtained at 10 minute divided by
value at 1 minute gives polarization index
Please refer below figures for connection and test arrangement
Page 100 of 155

Page 101 of 155
5.3.3. Voltage Ratio Measurement
The voltage ratio measurement for two or three winding power transformer can be done either by
conventional method using Voltmeters or by using Turns ratio Meter
The test will be mad for each and every phase at all tap position as follows.
For Two winding Transformer
• Apply 3 phase Voltage more then 220V on HV Winding and measure the
corresponding voltages at the LV winding
• Note down both HV and LV winding side voltages on all the three phase
at tap position
Page 102 of 155

For Three winding Transformer
• Apply 3 phase Voltage more then 220V on HV Winding and measured the
corresponding voltages at the LV1 and LV2 windings.
• Noted both HV ,LV1and LV2 winding side voltages on all the three phase at
all tap positions
5.3.4. Vector group check

The vector group or phase relationship can be checked by injecting three phase supply and
measuring the voltages as per the figure below
One of the phase say 1U and 2U between HV and LV should be shorted together and three
phase low voltage is applied on HV terminals.
Then the voltage between various pairs of line terminal should be measured and compared
Example: condition for Yn1d1d1 is, the voltage between

1V-2W> 1W-2W=1W-2V=1V-2W
Page 103 of 155

5.3.5. Winding Resistance Measurement
The Winding resistance measurement can be done by either conventional method using 2V DC
battery with voltmeter and Ammeter or by Transformer resistance meter.
The winding resistance will be measured by a drop of potential method on all windings by injecting
direct current through the winding as shown below.
Page 104 of 155

For the Y connected transformer the measurement should be made between each line and
neutral bushing and for the delta connection, the measurement should be made between each
pair of bushing and then single phase value is three half of the measured value.
The measured values should be compared with factory value, for that a conversion for the
temperature correction should be done by following formula.
R75 = Ra x 234.5+75
234.5+Ra
Where as R75 = Corrected Resistance in ohms
Ra = Measured Resistance at ambient temperature in ohms
0
Ta = Ambient temperature in C
5.3.6. Impedance Measurement
5.3.6.1. Single phase impedance Measurement
The impedance should be measured at lowest, nominal, and highest tap position as follows.
Connection will be made as shown in below figure. Apply about 200 Vac to the transformer HV
terminals and measured the current, single phase Impedance can be calculated as follows
Zu =1/2(Zuv+Zwu-Zvw)
Zv =1/2(Zvw+Zuv-Zwu)
Zw = 1/2(Zwu+Zvw-Zuv)
Page 105 of 155

In case, exclusively single phase measurement required where some experts do not agree with
above test, follow the figure given below
Impedance voltage will be calculated to the rated current
5.3.6.2. Zero sequence Impedance Measurement

The Zero sequence impedance is usually measured for all star or zig-zag connected winding of
the transformers
Measurement connection will be made as shown in the following drawing. Apply about 200 Vac to
the transformer HV terminals.
Note down the readings of ammeter and voltmeter
Zzq = 3V/I
Page 106 of 155

5.3.7. Magnetization Current Measurement.
Test connection will be done as shown in the following drawing. Apply 200 V to the transformer
HV terminals and measure the current and corresponding voltage for all the tap position
5.3.8. Insulation power factor or tan delta measurement
• The test shall be made on each winding to ground and between the windings with
Doble tester.
• The test shall be made on each bushing to ground with Double tester.
5.3.9. Oil Testing

Oil sample should be taken from bottom, top of the main tank, OLTC chamber and also from
the conservator tank,
De-electric test for the oil should be performed as per IEC 156 using de-electric machine
Samples should also be sent to Lab for Dissolved gases analysis
5.3.10. Temperature indicator and sensor.
5.3.10.1. Oil Temperature

The oil and winding temperature indicators shall be calibrated by heat sink with thermometer.
Page 107 of 155

5.3.10.2. Winding Temperature
The winding temperature indicator shall be checked by current injection at the heater element.
5.3.11. Bushing current transformer

Following tests should be done on all the bushing transformers
• Ratio test
• Magnetization curve
• Polarity test
• Insulation test
• Winding resistance test
• Loop resistance test
All the test results shall be entered in the test form No.TS-CT01of the transformer.
Refer TP-CT01 for the test procedure
5.3.12. Testing and commissioning of cooler control cabinet

Prior to power up cooler control cabinet with auxiliary 3 phase/single phase/dc voltage, following
check up shall be carried out.
􀂾Winding insulation resistance and winding resistance for the fan motors should be
carried out.
􀂾Insulation resistance test for the control circuit should be carried out.
􀂾After obtaining all the results and found satisfactory auxiliary power can be
switched on and voltage/phase sequence measurement should be carried out.
􀂾Manual/auto operation of the fans should be checked
􀂾Heater and lighting circuit should be checked and made functional.
5.3.13. Transformer protection devices functional check
􀂾Trip and alarm should be simulated from buchholz relay. tripping of protection
relay and breakers should be observed, alarms on local and remote annunciation
shall be observed
􀂾Trip and alarm should be simulated from pressure relay. tripping of protection
shall be observed
􀂾Trip and alarm should be simulated from pressure relief relay. tripping of protection
shall be observed
􀂾Trip and alarm should be simulated from oil and winding temperature indicator.
tripping of protection relay and breakers should be observed, alarms on local and
remote annunciation shall be observed
􀂾Results for above tests shall be entered in the test form No.TS-PT01 of the power
transformer.
5.3.14. Testing and commissioning of Remote tap changer control panel(RTCC)

Prior to power up RTCC with auxiliary Single phase/dc voltage, following check up shall be
carried out.
􀂾Insulation resistance test for the control circuit should be carried out.
Page 108 of 155

􀂾After obtaining all the results and found satisfactory auxiliary power can be
switched on and voltage/phase sequence measurement shall be entered in test
form No TS-TP01.
􀂾AVR should be calibrated
􀂾Manual/auto operation of the tap changer should be checked
􀂾Alarm on annunciation shall be checked
􀂾Remote operation that is from DCS and SCADA should be checked
􀂾Tap position indication should be checked both on local panel and DCS/SCADA.
􀂾Heater and lighting circuit should be checked and made functional.
Page 109 of 155

c) DRY TYPE TRANSFORMER SITE TEST PLAN
1. CONSTRUCTION AND DIMENSION CHECK
2. WINDING RESISTANCE MEASUREMENTS
3. RATIO CHECK
4. PHASE RELATIONSHIP CHECK
5. INSULATION RESISTANCE MEASUREMENTS
DRY TYPE TRANSFORMER SITE TEST PROCEDURE
1- CONSTRUCTION AND DIMENSION CHECK

1.1 Dimension will be measured in accordance with the approved specification.
1.2 Construction, painting and welding condition will be inspecting visually.
2- WINDING RESISTANCE MEASUREMENTS

2.1 The winding resistance will be measured by the dc voltage drop method with resistance measuring
system.
R R
Y
TR. WINDING
RESISTANCE Y
B
MEASUREMENT
DEVICE
N B
TRANSFORMER WINDING RESISTANCE MEASUREMENTS

ARRANGEMENT
3- RATIO CHECK
3.1 The voltage ratio shall be measured by means of voltage ratio measuring bridge and on single
phase, phase by phase.
3.2 The applied voltage to HV winding will be about 220 V.
3.3 The test will be made on all windings.
Page 110 of 155

V R R V
Y
3PH , 380 VAC
V Y SUPPLY
B
V N B V
TRANSFORMER RATIO TESTING ARRANGEMENT
4- PHASE RELATIONSHIP CHECK
4.1 The phase relationship shall be checked at rated voltage tap connection.
4.2 Three phase 220V will be applied to HV winding and the voltage shall be measured between
terminals.
4.3 Vector diagram will be drawn and confirmed.
V R r V
Y
3PH , 380 VAC
V y SUPPLY
B
V N b V
V
V
V
V
TRANSFORMER PHASE RELATIONSHIP (VECTOR GROUP) TESTING ARRANGEMENT
Page 111 of 155

5- INSULATION RESISTANCE MEASUREMENTS
The test shall be made between HV winding and LV winding, HV winding and earth, LV winding
and earth with 2000V megger tester.
R R
Y
MEGGER
Y
B
N B
TRANSFORMER INSULATION RESISTANCE MEASUREMENTS

ARRANGEMENT
Page 112 of 155

12-Testing procedure Tripping/lockout Relay
1.0 Task
All the tripping or lockout relays shall be tested for correct operation
2.0 Preconditions
2.1 Work status

2.2 Documentation

• Commissioning checklists ( attached test sheet TS-CR04 / TS-CR02)
2.3 Personnel
• 1 Commissioning engineer: Engineer or technician with experience in

commissioning of types of the electrical equipment systems employed in
the plant.
• Three or single phase Secondary Injection test set

• Fluke
3.0 Precautions
• Observe the rules for handling electronic components sensitive to electrostatic

discharge (ESD measures).
• Special safety arrangements shall be made for all areas which are not explicitly
designated as” electrical operating areas” when performing tests at voltages in excess
of 50V.
4.0 Scope

5.0 Execution
5.1 Visual checks
Page 113 of 155

5.2 Testing of Trip Circuit Supervision Relay.
Relay can be tested by using single phase secondary injection test set at the front panel mounted
test facilities.
Enter the rating plate data in check list TS-LR01 and compare the Relay data with the data
1. Manual operation checks

1. Minimum Voltage Pick-Up Verification
2. Operating time Measurement
3. Measurement of coil Resistance

5.2.1.1 Manual operation checks
Lockout or tripping relay should be checked for manual operation by operating plunger or
the lever
And also the manual rest shall be checked

Connection between the relay and secondary injection set is made as per figure below.
5.2.2.1 Voltage Pick-Up Verification

♦ Connect the voltage test set on the relay voltage terminals
♦ Connect the timer to the relay tripping contact
♦ until the relay pick-up
♦Slowly increase the voltage
♦ Record the pick-up voltage
Page 114 of 155

.2.2.2 Delay Time Verification 5
♦Apply the testing voltage and monitor the operating time of
the relay
♦ Record the operating time.
5.2.2.3 Coil Resistance Measurement.
♦ Connect the fluke across the terminal of the coil and measure
the Resistance
6.0 Documentation
A Test sheet (attached test sheet TS-CR04 / TS-CR02) is to be completed for each and every
lockout or tipping Relay.
Page 115 of 155

13-Testing procedure Trip Coil supervision Relay
1.0 Task
All the Trip circuit supervision relays shall be tested for Breaker trip circuit supervision in for both
breaker open and close position
2.0 Preconditions
2.1 Work status

2.2 Documentation

• Commissioning checklists (attached test sheet TS-CR01)
2.3 Personnel


• Fluke
3.0 Precautions
measures).
4.0 Scope

• Checking that the mounting position is correct.
5.0 Execution
5.1 Visual checks
• Checking of the cables for damage and that they are connected correctly.
Page 116 of 155

5.2 Testing of Trip Circuit Supervision Relay.
Relay can be tested by using single phase secondary injection test set at the front panel mounted test
facilities.
Enter the rating plate data in check list TS-CR01 and compare the Relay data with the data contained in
1. Functional check of Test Plug
1. Voltage Pick-Up Verification

2. Voltage Drop-Out Verification
3. Function Check
i. The CB Is In Open Position

ii. The CB In Close Position
5.2.1.1 Functional check of Test Plug
Test Plug should be checked for its correct function. Terminals should be checked for its correct ,
auxiliary power and tripping assignment as per the circuit drawing
5.2.2.1 Voltage Pick-Up Verification
♦ Slowly increase the voltage until the relay pick-up

♦ Record the pick-up voltage.
Page 117 of 155

5.2.2.2 Voltage Drop-Out Verification
♦ Slowly increase the voltage until the relay pick-up

♦ While relay is still picking-up, slowly reduce the voltage until the relay
dropout.
♦ Record the dropout voltage.
.2.2.3 Function Check 5

All the internal and external wiring should be completed
5.2.2.3.1 When CB Is In Opened Position
♦ At the CB control panel / box open tripping coil circuit.

♦ The trip circuit supervision relay should operate.
5.2.2.3.2 When CB In Close Position.
♦ At the CB control panel / box open tripping coil circuit.

♦ The trip circuit supervision relay should operate.
6.0 Documentation
A Test sheet (attached test sheet TS-CR01) is to be completed for each and every trip circuit supervision
Relay.
Page 118 of 155

14-Protective relays:
General concepts should be follow for testing any relay :

1- by SEC injection ,verify relay operation over the setting ranges , 3 points check , but note in the test sheet
the value of final setting or any chosen setting
2- check relays for tightness , and the shorting terminals are making proper contacts (remove relays from cases
if available )
3- check that all the test switch operate properly and all are labeled
4- check operation of the three phase target indicators of relay
5- perform a reduced voltage trip for all trip relays
6- after applied the final setting ,perform that the secondary injection will operate and trips each elements and
devices according to the schematic DWG .
7- for O/C & E/F relays , check zero setting by setting set time multiplier to zero and verifying closing of relay
contacts
8- relays shall be tested as the recommendation of manufacture .
a) Testing procedure Phase and Ground Over Current Relay
1.0 Task
All the over current shall be tested to check their functions
2.0 Preconditions
2.1 Work status

2.2 Documentation

• Commissioning checklists ( attached test sheet TS-AR01 )
• Approved relay settings should be available
2.3 Personnel

• Three phase Secondary Injection test set

• Fluke
3.0 Precautions
measures).
Page 119 of 155

4.0 Scope

5.0 Execution
5.1 Visual checks

5.2 Testing of Phase and Ground over Current Relay.

Relay can be tested by using three or single phase secondary injection test set at the front panel
mounted test facilities. Final calibration test of all protective relays must be carried out on approved
settings, Enter the rating plate data in check list TS-AR01 and compare the Relay data with the data

2. Shorting of links on relay case when relay is withdrawn
1. Relay Power measurement

2. Testing of LEDs
3. Testing of out put relays
4. Testing of input Devices
5. Metering function
6. Over current Pickup/Dropout test
7. Time current characteristics
i. IEC-Normal inverse
ii. IEC-Very inverse
iii. IEC- Extremely Inverse
iv. Long time Inverse
v. Definite Time
8. Testing of Instantaneous element

Test Plug should be checked for its correct function, terminals should be checked for its correct current,
5.2.1.2 Shorting of links on relay case when relay is withdrawn

In case of withdrawal type relay, shorting facility on the relay case should be checked as under.
• Connect the fluke to check the continuity across the current terminal on
the relay case which shows some resistance.
• Pull the relay out and check the fluke which shows now resistance less
then when relay was inside.
• Repeat the test for other two phases too.
Page 120 of 155
5.2.2.1 Relay Power measurement

Apply rated DC or AC auxiliary voltage to the power terminal of the relay through suitable ammeter and
voltmeter
Measure the current and voltage. Product of two gives power consumption of the relay.
5.2.2.2 Configuration of the relay
Relay should be configured for inputs, outputs, and LED assignment as per final setting either through
front panel of the relay or through lap top communicating with relay.
5.2.2.3 Testing of LEDs

Check the operation of LEDs first by pressing reset button, all the LEDs should light for 2 to 3 seconds
Check the operation of LEDs for their function by injecting current or by simulating the software.
5.2.2.4 Testing of out put relays
By simulation or by performing secondary injection, check the operation of output relays as per the relay
configuration.
Measure the contact resistance of the each output relay with fluke
5.2.2.5 Testing of Digital Inputs
Connect a variable auxiliary DC or AC voltage to each and every Digital input

Increase the voltage till the digital input picks up (a temporary LED may be assigned to see the pickup)
thus a minimum voltage required to operate digital input is noted.
Page 121 of 155

5.2.2.6 Metering function
Configure the relay for Phase CT, neutral CT and VT ratio

Apply three phase 25%, 50%, 75% and 100% of nominal current on phase over current relay and note
down the corresponding readings on the relay.
Apply Single phase 25%, 50%, 75% and 100% of nominal current on Ground over current relay and note
down the corresponding readings on the relay.
5.2.2.7 Over current Pickup/Dropout test
Apply the testing relays setting for over current on the relay as follows.
• Definite Time Curve with minimum time delay.

• Disable all other protection elements.
• Connect the current test set on the relay current terminals one at a time
as follows.
o Red phase to Neutral.( for Phase over current relay)
o Yellow phase to Neutral. ( for Phase over current relay)
o Blue phase to neutral. ( for Phase over current relay)
o Single phase current on Ground element(ground over current relay)
o Connect the timer to the relay tripping contact
• Slowly increase the current until the relay picked-up.
• Record the operating current.
• Slowly decrease the current until relay reset
• Record the operating current
5.2.2.8 Time current characteristics
• Apply the testing relays setting for over current on the relay as follows.
o IEC NI curve with 0.1 TMS.
o IEC LT curve with 0.1 TMS.
o IEC DT Curve with 1.0 TMS
• Select the time over current curve one at a time on the relay.
• Connect the current test set on the relay current terminals one at a time
as follows.
• Connect the timer to the relay tripping contact
• Inject testing current 2 times, 5 times and 10 times of the pickup settings
and note down the operating time of the relay.
• Record the operating time.
• Cross check the time as per figure below or calculate the time using
below formula.
• Test shall be done for all the characteristics and all the phase and
ground element
Page 122 of 155

Page 123 of 155
5.2.2.8.1 Instantaneous Unit Verification
• Apply the testing relays setting for phase and ground over
current on the relay as follows.
• Connect the current test set on the relay current terminals one
at a time as follows.
o Single phase current on Ground element(ground over
current relay)
􀂾Pickup/dropout test



Page 124 of 155

• Inject testing current 2 times the pickup settings and note down
the operating time of the relay.
• Tripping time should be actual definite time multiply by TMS
setting
• Test shall be done for all the phase and ground element
6.0 Documentation
A Test Sheet ( attached test sheet TS-AR01 ) is to be completed for each and every Phase and Ground
Over Current Relay.
Page 125 of 155

b)Testing procedure Over voltage and Under Relay
1.0 Task
All the voltage relays shall be tested for under and over voltage function
2.0 Preconditions
2.1 Work status

2.2 Documentation

• Commissioning checklists ( attached test sheet TS-VR01)
2.3 Personnel


• Fluke
3.0 Precautions
measures).
4.0 Scope

5.0 Execution
5.1 Visual checks
5.2 Testing of Over and under Voltage Relay.
Relay can be tested by using three or single phase secondary injection test set at the front panel mounted
test facilities. Final calibration test of all protective relays must be carried out on approved settings,
Page 126 of 155
Enter the rating plate data in check list TS-VR01 and compare the Relay data with the data contained in

2. Testing of LEDs
6. Under Voltage Function
i. Pickup/dropout test
ii. Timing test
7. Over voltage test
i. Pickup/dropout
ii. Timing test



voltmeter
front panel of the relay or through lap top, communicating with relay.
Page 127 of 155

Check the operation of LEDs for their function by injecting Voltage or by simulating the software.

configuration.


Configure the relay for VT ratio
Apply three phase 25%, 50%, 75% and 100% of nominal Voltage on Voltage relay and note down the
corresponding readings on the relay.
5.2.2.7 Under Voltage Function
i. Pickup/dropout test
♦ Apply the testing relays setting with instantaneous tripping time
on the relay
♦ Slowly Increase the applied voltage until the relay Drop out
♦ Record the Drop out voltage
♦ Slowly Decrease the applied voltage until the relay pick-up
♦ Record the pick-up voltage
ii. Timing test

♦ Select the operating time on the relay
Connect the voltage test set on the relay voltage terminals
♦ Apply the testing voltage(fault Voltage) and monitor the operating
time of the relay
5.2.2.8 Over voltage test
iii. Pickup/dropout test

♦ Apply the testing relays setting with instantaneous tripping time
on the relay
♦ Slowly Increase the applied voltage until the relay Picks up.
♦ Record the Pick-up voltage
♦ Slowly Decrease the applied voltage until the relay Drops out
♦ Record the Drop-out voltage
Page 128 of 155

Iv. Timing test
♦ Select the operating time on the relay
♦ Apply the testing voltage(fault voltage) and monitor the operating
time of the relay
5.2.2.9 Voltage Relay testing by SVERKER-750

To test the voltage relay by SVERKER-750 fallow the below procedure
Page 129 of 155

Page 130 of 155
6.0 Documentation
A Test sheet ( attached test sheet TS-VR01) is to be completed for each and every Voltage Relay.
Page 131 of 155

c)Testing procedure Synchronous Check Relay
1.0 Task
All the Synchronous check relays shall be tested for their correct function
2.0 Preconditions
2.1 Work status

2.2 Documentation

• Commissioning checklists ( attached test sheet TS-SY01 )
2.3 Personnel


• Phase Shifter
• Fluke
3.0 Precautions
measures).
4.0 Scope

5.0 Execution
5.1 Visual checks
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5.2 Testing of Synchronous check Relay.
settings, Enter the rating plate data in check list TS-SR01 and compare the Relay data with the data

2. Testing of LEDs
6. Live line- Live bus (synchronous ) test
i. Difference in voltage test

ii. Difference in frequency
iii. Difference in phase angle
iv. Under voltage blocking test
7. Dead line –Dead bus test

8. Dead Bus-Live line test
9. Dead Line – Dead Bus


Page 133 of 155

voltmeter

front panel of the relay or through lap top, communicating with relay.

Check the operation of LEDs for their function by injecting Voltage or by simulating the software.

configuration.


Configure the relay for VT ratio
Apply three phase 25%, 50%, 75% and 100% of nominal Voltage on Voltage relay and note down the
corresponding readings on the relay.
5.2.2.7 Live line- Live bus (synchronous ) test
5.2.2.7.1 Difference in voltage test
♦ Apply the testing relay setting on the relay noting that.

Only live line- live bus function is enabled.
Page 134 of 155

♦ Connect test set stop input to the relay output contact
♦ Apply the line and bus voltage with
o Zero differential voltage.
o Zero differential frequency.
o Zero differential phase angle.
♦ The relay should operate now giving CB close permissive signal.
♦ Slowly increase the bus voltage in order to increase the voltage difference until out put relay for
CB close permissive drops out.
♦ Record the differential voltage
♦ Slowly decrease the bus voltage in order to reduce voltage difference until the out put relay for
CB close permissive picks up.
♦ Slowly increase the line voltage in order to increase the voltage difference until out put relay for
CB close permissive drops out.
♦ Record the differential voltage
5.2.2.7.2 Difference in frequency

o Zero differential phase angle.
♦ Slowly increase the Frequency of bus voltage in order to increase the Frequency difference until
out put relay for CB close permissive drops out.
♦ Record the differential Frequency
♦ Slowly decrease the Frequency of bus voltage in order to decrease the Frequency difference until
out put relay for CB close permissive picks out.
♦ Slowly increase the Frequency of line voltage in order to increase the Frequency difference until
out put relay for CB close permissive drops out.
♦ Record the differential Frequency
5.2.2.7.3 Difference in phase angle


♦ Slowly increase the phase angle difference until out put relay for CB close permissive drops out.
♦ Record the differential phase angle
Page 135 of 155

5.2.2.7.4 Under voltage blocking test

♦ Apply rated voltage to the line and bus voltage with
♦ Slowly reduce both of line and bus voltage simultaneously till the under voltage blocking output relay
operate
♦ Record the under voltage blocking voltage
5.2.2.8 Dead line –Live bus test

o Enable Dead line live bus function
♦ Slowly reduce line voltage until the out put relay for CB close permissive drops out.
♦ Continue reducing line voltage until the out put relay for CB close permissive picks up
♦ Record the dead line voltage
5.2.2.9 Dead Bus-Live line test

o Enable Dead bus live line function
♦ Slowly reduce bus voltage until the out put relay for CB close permissive drops out.
♦ Continue reducing bus voltage until the out put relay for CB close permissive picks up
5.2.2.10 Dead Line – Dead Bus

o Enable Dead line Dead bus function
Page 136 of 155

♦ Slowly reduce line and bus voltage simultaneously until the out put relay for CB close permissive drops
out.
♦ Continue reducing line and bus voltage simultaneously until the out put relay for CB close permissive
picks up.
5.2.2.11 MCB for bus and line voltage trip blocking

o Enable live line-live bus function
o Enable Dead Bus –live line function
o Enable Dead Line –live bus function
o Enable Dead line Dead bus function
♦ Simulate MCB Trip input to the relay and Reduce Bus voltage
♦ Check there should not be any permissive from the relay for CB close
♦ Repeat the test for Line voltage MCB trip
6.0 Documentation
A Test sheet ( attached test sheet TS-SY01) is to be completed for each and every Voltage Relay.
Page 137 of 155

d)Testing procedure Differential Current Relay
1.0 Task
All the Differential current Relays shall be tested to check their functions
2.0 Preconditions
2.1 Work status

2.2 Documentation

• Commissioning checklists ( attached test sheet )
2.3 Personnel

• Three phase Secondary Injection test set

• Fluke
3.0 Precautions
measures).
4.0 Scope

5.0 Execution
5.1 Visual checks

Page 138 of 155

5.2 Testing of Differential Current Relay.
settings, Enter the rating plate data in check list TS-DR01 and compare the Relay data with the data

2. Shorting of links on relay case when relay is withdrawn

2. Testing of LEDs
6. Differential Function
i. Differential current Function

ii. Differential restraint characteristic
iii. Harmonic Function
iv. Instantaneous Differential current function
v. Timing Test
7. Backup over current
i. current Pickup/Dropout test

ii. Time current characteristics
1. IEC-Very inverse
2. IEC- Extremely Inverse
3. Long time Inverse
4. Definite Time
iii. Testing of Instantaneous element

5.2.1.2 Shorting of links on relay case when relay is withdrawn

In case of withdrawal type relay, shorting facility on the relay case should be checked as under.
• Connect the fluke to check the continuity across the current terminal at low side on the relay case which
shows some resistance.
• Pull the relay out and check the fluke which shows now resistance less then when relay was inside.
• Repeat the test for other two phases at low side too.
• Repeat the test for all three phases at high side current of the relay
Note: Above test can also be checked with secondary current injection. Relay can be pulled out while
injecting the current and reading on the relay must show zero.

Page 139 of 155

voltmeter

front panel of the relay or through lap top communicating with relay.

Check the operation of LEDs for their function by injecting current or by simulating the software.

configuration.


Configure the relay for Phase CT Ratio at low and high side
Apply three phase 25%, 50%, 75% and 100% of nominal current on high and low side CT connection of
the relay and note down the corresponding readings on the relay.
5.2.2.7 Differential Function

Page 140 of 155
5.2.2.7.1 Differential Current Function
• Disable the harmonic restraints, and enable the differential function
• Apply the testing relays setting.
• Apply current to High side and low side windings .so that the relay will have a differential current of 0.00.
• Increase the current in the High side, and check that it trips when the differential occur.
• Check that it trips with an error margin of less than 5% for different through currents, and different
sensitivity and percentage restraint settings.
5.2.2.7.2 Differential Restraint Characteristic.

• Disable the harmonic restraints, and enable the differential function
• Apply current to High side and low side windings.
• Increase the current in High side, and check slope1 is achieved according to the relay specification.
• Repeat the test to check slope2 is achieved.
5.2.2.7.3 Harmonic Function
• Enable the harmonic restraints, and the differential function.

• Apply current to High side and low, so that the relay will have a differential current of 0.00.
• Apply a second harmonic current at high side, besides the current it already had.
• Increase the current in the High side, and check that it trips when the differential occur.
• Check that it trips with an error margin of less than 5% for different through currents, and different
sensitivity and percentage restraint settings
5.2.2.7.4 Differential Instantaneous Function
• Disable the harmonic restraints, and the differential function, and enable the instantaneous function.
• Set the instantaneous function to 4 times the tap.
• Apply current to High side, and check that it trips when the differential current reaches the set value.
• Check that it trips with an error margin of less than 5% for different differential currents, and different
instantaneous function settings.
5.2.2.7.5 Timing Test

Check that it trips with an error margin of less than 5% for different through currents, and different
sensitivity and percentage restraint settings
5.2.2.8 Backup Over Current Function

While checking Backup over current function differential function has to be disabled
5.2.2.8.1 Over current Pickup/Dropout test

Apply the testing relays setting for over current on the relay as follows.
• Definite Time Curve with minimum time delay.
• Connect the current test set on the relay current terminals one at a time as follows.

o Connect the timer to the relay tripping contact
Page 141 of 155

5.2.2.8.2 Time current characteristics
• Apply the testing relays setting for over current on the relay as follows.

o IEC NI curve with 0.1 TMS.
o IEC LT curve with 0.1 TMS.
o IEC DT Curve with 1.0 TMS
• Select the time over current curve one at a time on the relay.


• Inject testing current 2 times, 5 times and 10 times of the pickup settings and note down the operating
time of the relay.
• Record the operating time.
• Cross check the time as per figure below or calculate the time using below formula.
• Test shall be done for all the characteristics and all the phase and ground element
Page 142 of 155

Page 143 of 155
5.2.2.8.2.1 Instantaneous Unit Verification
• Apply the testing relays setting for phase and ground over current on the relay as follows.




Page 144 of 155




• Inject testing current 2 times the pickup settings and note down the operating time of the relay.
• Tripping time should be actual definite time multiply by TMS setting
• Test shall be done for all the phase and ground element
6.0 Documentation
A Test sheet ( attached test sheet ) is to be completed for each and every differential Relay.
Page 145 of 155

15) M V Disconnect switch & Ground switch test procedure
TABLE OF CONTENT
1. Task
a. Work Status
b. Documentation
c. Personnel
d. Measuring Instrumentation
2. Preconditions
3. Precautions
4. Scope
5. Execution
a. Visual Inspection
b. Testing of MV DS and Feeder
1. Test on Disconnect switch
a. Contact Resistance test.
b. Insulation resistance test before hi pot
c. High Voltage test.
d. Insulation resistance test after hi pot
e. Switch operating time /motor current measurement
f. Minimum voltage operation (open/close) at 90V dc.
2. Disconnect switch operation
a. Disconnect Switch operation at rated Voltage.
b. Functional test of local controls, alarm and indication.
c. Functional test of Remote controls, alarm and indication.
d. Correct settings of motor limit switches.
e. Check correct operation of auxiliary switches.
f. Automatic disconnection of supply to the motor on insertion of handle
3. Operation of Earth Switch.
4. Correct Functioning of Interlocks
a. Insulation resistance measurement for control circuit
b. Control power and current measurement
6. Commissioning of Heater Circuit
7. Protective earthing check.
6. Documents
7. Reference
8. Attachment
1.0 Task
The purpose of this procedure is to test, commission and document feeder and MV Disconnect
and Ground switch in metal enclosed switchgear assemblies of 4.16kV and 13.8 kV levels.
2.0 Preconditions
2.1 Work status

• Labelling of the equipment and designation of live enclosed plant sections has
Page 146 of 155
been carried out.
2.2 Documentation
• The schematic and single line diagram of the medium voltage switchgear are
available
• Commissioning checklists ( attached test sheet )
2.3 Personnel
• 1 Commissioning engineer: Engineer or technician with experience in
commissioning of all types of the electrical equipments.
2.4 Measuring Instruments and Tools
3.0 Precautions
The work will only proceed when a Permit to Work (PTW) in work permit area has been
obtained. The PTW will be kept on site for consultation during the testing works.
• Due to high voltage being used, adequate safety precautions should be taken to avoid
injury to personnel and damage to property.
• Cordoning off specified working area and provision of applicable safety warning sign
board.
• Ensure that all the necessary test equipment are made available at the test area and
with valid calibration stickers and certificate.
• Hand insulating gloves and grounding sticks / wire jumpers shall be provided for safe
handling and draining of residual voltage.
• Breaker should be withdrawn from the cubicle during breaker testing.
• Immediately after testing of each phase, voltage residue shall be drain by using
grounding stick / wire which is directly connected to earth.
• Closing of the work permit after completion of the work (if the test area is to be
considered in work permit area) is necessary.
4.0 Scope
• Testing of Disconnect switch

• Testing Ground Switch
• Operation of Disconnect switch
• Checking Disconnect switch mounting.
5.0 Execution
5.1 Visual Checks

• Check nameplate information for correctness.
• Inspect enclosures for proper alignment, foundation fixing and grounding.
• Inspect covers, panel section and door for paint work and proper fit.
• Check for smooth and proper movement of closing and opening mechanisms for
alignment,.
• Check operation of all mechanical interlocks.
• Check tightness of all bolted connections (torque wrench method).
• Check bus and supports for defects such as cracked welds, chipped porcelain,
cracked insulation, etc., and free of dust accumulation.
• Verify that all front panel mounted devices (meters, push buttons, switches, indicator
lamps, mimic buses, etc.) are installed as per drawings.
• Perform mechanical check and visual inspection on the Disconnect switch.
Page 147 of 155
• Check that all control wiring is correct according to the approved drawing and
terminal connections are secure.
• Check simultaneous closing of all the three poles.
• Check that end of travels stops are correctly adjusted, set and locked in position.
• Check open gap and minimum clearance between phases and ground.
• Check that the switch can be pad locked in both closed and open position.
• Check that switch operating handle is grounded properly.
WIRING AND FERRULING CHECK
• Ensure the numbers on the ferules are from left to right beginning at the terminal
block i.e. at the end of the wire and from bottom to top.
• The wire nos. should be checked against the wiring table and the schematic drawing.
5.2 Testing of Disconnect and Feeder
Enter the rating plate data in check list TS-DM01 and compare the DS data with the
data contained in the circuit documentation. The following test shall be carried out
8. Test on Disconnect switch
c. Contact Resitance test.
d. Insulation resistance test before hipot.
e. High Voltage test.
f. Insulation resistance test after hipot
g. Switch operating time /motor current measurement
h. Minimum voltage operation (open/close) at 90V dc.
9. Disconnect switch operation
i. Disconect Switch operation at rated Voltage.
j. Functional test of local controls, alarm and indication.
k. Functional test of Remote controls, alarm and indication.
l. Correct settings of motor limit switches.
m. Check correct operation of auxiliary switches.
n. Automatic disconnection of supply to the motor on insertion of
handle
10. Operation of Earth Switch.
11. Correct Functioning of Interlocks
o. Insulation resistance measurement for control circuit
p. Control power and current measurement.
13. Commissioning of Heater Circuit
q. Visual Checks
r. Measurement of insulation resistance of heater and lamp circuit
s. Functional checks of thermostat , Heaters,
t. Measurement of Current and voltage
14. Protective earthing check.
5.2.1 Contact Resitance Test.
Disconnect switch Contact resistance can be measured using micro ohm
meter on each pole of the Disconnect switch when it is closed
• Connect the current and voltage leads of the micro ohmmeter across
the pole of the disconnect switch.
• Apply a current of 100 amps and note down the reading
• Repeat the test for other two pole also
• For judgment, the resistance values from one pole to another pole
should not vary with big difference and the value should also be cross
checked with manufacturer recommendation.
Page 148 of 155

5.2.2 Insulation Resistance Test before Hipot.
Before performing high voltage test, perform the Insulation resistance test
with 5000Vdc insulation tester.
• Close the disconnect switch.
• Connect the phases Y, B to ground and apply the test voltage
between phase R and ground and note down the readings.
• Connect the phases B, R to ground and apply the test voltage
between phase Y and ground and note down the readings.
• Connect the phases R, Y to ground and apply the test voltage
between phase B and ground and note down the readings.
5.2.3 High Voltage Test
Note: high voltage test is to be done only in case disconnect switch is not
tested for high voltage along with the bus.
AC high- pot test shall be carried out in accordance with IEC standard at site.
The test shall be carried out on MV Disconnect switch in close position. Test
is performed as under
􀂾 When the Disconnect Switch is Closed( shown in figure below)
• The test voltage to carry out the test is as per below table.
• Connect the phases Y, B to ground and apply the test voltage
gradually between phase R and ground. Record the leakage current
• Connect the phases B, R to ground and apply the test voltage
gradually between phase Y and ground. Record the leakage current
• Connect the phases R, Y to ground and apply the test voltage
gradually between phase B and ground. Record the leakage current
Page 149 of 155

5.2.4 Insulation Resistance test after hipot
After performing high voltage test Perform the Insulation resistance test with
5000Vdc insulation tester as describe in 5.2.2
5.2.5 Switch Operating Time/Motor Current Measurement
DS closing and tripping time can be measured either by a timer or a breaker
analyzer
Timing Test Using An Electronic Oscillo graph.
• Connect the test set to the DS.
• Perform the following operations at the rated DC
• Close ( C ) , Open ( O )
• Record the corresponding readings.
• From the graph check the simultaneous touch of the contact of all the
Phases
Page 150 of 155

5.2.6 Minimum Voltage Operation (Open/Close) at 90V dc.
5.2.6.1.1 Closing
Minimum voltage operation is checked at 90 volts
• Connect the DC source to the closing circuit of the
disconnect switch in series with dc ammeter
• Maintained voltage at 90 volts and check the operation of
the disconnect switch , note down the current
5.2.6.1.2 Opening
Minimum voltage operation is checked at 90 volts
• Connect the DC source to the opening circuit of the
disconnect switch in series with dc ammeter
• Maintained voltage at 90 volts and check the operation of
the disconnect switch , note down the current
5.2.7 Disconnect Switch Operation Tests.
5.2.7.1 Switch Operation at Rated Voltage
o Perform several Close and Open operation of the Disconnect
switch manually by operating mechanical Levers
o Performer several Close and Open operation of the
disconnect switch electrically both local and remote
5.2.7.2 Functional Test of Local Controls, alarm and indication.
• Alarm and indication for DC supervision relay shall be
checked..
• Indication for closing, opening, of the disconnect switch shall
be checked.
5.2.7.3 Functional test of Remote Controls, alarm and Indication.
• Alarm and indication for DC supervision relay shall be checked
on DCS or remote
• Indication for closing, opening, of the disconnect switch shall
be checked on DCS or Remote.
5.2.7.4 Correct Settings of Motor Limit Switches.
Limits switches should be checked for its proper operation and
function an adjustment is made if required.
Page 151 of 155
5.2.7.5 Check Correct Operation of auxiliary Switches.
Contacts of auxiliary switches for switch operation, earth switch
etc shall be checked for its correct operation, and contacts
resistance is measured for each and every contacts output.
5.2.7.6 Automatic Disconnection of Supply to the Motor on Insertion
of Hand
While Operating Handle is inserted in to the notch, operation of
the disconnect switch checked electrically, no operation should
occur.
5.2.8 Operation of Earth Switch.
Operation of earth switch for closing and opening to be checked, also
indication to be checked
5.2.9 Correct Functioning of Interlocks
Interlock should be checked as per manufacturer instruction manual
5.2.10 Electrical control and protection/Measuring Devices
5.2.10.1 Insulation Resitance measurement for control wiring and
cabling with 500 V DC
Insulation resistance test for control wiring and auxiliary circuit
should be done with 500V dc Insulation tester.
5.2.10.2 Control Power and Current Measurement.
• Current on MCB of each circuit to be measured when all the
devices are in service
• Mixing of voltage between the two circuits should be checked
by keeping off MCB of one circuit and checking the voltage on
other circuit MCB towards load side +V and –V terminals with
respect ground
5.2.11 Commissioning of Heaters

Space heater shall be commissioned as under.
5.2.11.1 Visual Checks of Heaters
• Check the rating of the heater match with the supply voltage.
• Check the KW rating of the heater match with drawing.
• Check the breaker which supplying power to heater circuit for
correct rating with respect to total load of the heaters.
5.2.11.2 Measurement of Insulation Resistance
Perform insulation resistance measurement on space heater
circuit with 500 VDC megger
5.2.11.3 Measurement of Current and Voltage
Switch on the breaker and measured the total current and
individual heater load with mini clamp meter
5.2.11.4 Functional Checks of Thermostat
Check the operation of the thermostat and hygrometer for cut in
and cut out operation
5.2.12 Protective Earthing Check
Switch gear protective earthing bond must be earthed in order to afford
protection to human beings.
6.0 Documents
Test Sheet ( attached test sheet TS-MD01 ) shall be completed.
7.0 References
***End of the Procedure *
Page 152 of 155
16)NGR SITE TEST PROCEDURE
1. Mechanical Check and Visual Inspection

a. Inspection for physical damages/ defects/ welding.
b. Identification of the equipment (Name Plate).
c. Check quality of paint
d. Check tightness of all bolted connections
e. Check that all grounding are securely connected
f. Environment class check (IP)
2. Measurement of DC Resistance mΩ
The resistance will be measured by the dc voltage drop method with resistance measuring system.
LOW DC
RESISTANCE
MEASUREMENT
DEVICE
DC RESISTANCE MEASUREMENTS ARRANGEMENT
3. Measurement of the Impedance Ω

The impedance of the NGR will be measured by injecting (10 A) AC current through the winding and measure
the voltage across it.
The Impedance will be calculated as follow Z = V / I
Z The calculated Impedance
V The voltage across the winding
I The injected current
I
AC Current
Source
V
IMPEDANCE MEASUREMENTS ARRANGEMENT
4. Insulation Resistance Check

a. The insulation shall be checked by a 5 kV megger.
b. Record the corresponding readings.
5- Documents
Test Sheet ( attached test sheet TS-NGR01 ) shall be completed.
Page 153 of 155

17 ) PROCEDURE – SITE TESTING & COMMISSIONING BUSBAR PROTECTION
1. WIRING AND FERRULING CHECKS
2. BUSBAR PROTECTION bus A
2.1 SINGLE POINT EARTHING CHECKS
2.2 HIGH IMPEDANCE RELAY BUSBAR PROTECTION CHECKS
2.3 PRIMARY INJECTION TEST
2.4 VERIFICATION OF METRISOL / NON LINEAR RESISTOR CURRENTS
2.5 VERIFY FUNCTION OF IN/OUT SWITCH
3. BUSBAR PROTECTION bus B
SAME BUS (A)
1. WIRING AND FERRULING CHECK
1.1 Ensure the numbers on the Ferrules are from left to right beginning at the Terminal Blocks
i.e. at the end of the wire and from bottom to top.
1.2 Ensure the internal wiring should be the “Cross Reference Type” i.e. the remote end designation
should appear at the local end and vise versa.
1.3 The interpanel wiring should comprise of the following references beginning at the Terminal Block
End Local End Terminal # / Interconnecting Cable # / Remote End Terminal #.
1.4 The wire nos should be checked against the wiring table and schematic drawings.
1.5 The nos’ shall be checked against the Schematic Drawings and verified with the Wiring Table.
1.6 Only 10% Ferruling shall be checked.
2. BUSBAR PROTECTION ZONE A & B
2.1 SINGLE POINT EARTHING CHECKS
The wiring of the CT Circuit shall be checked and tested to confirm that the CTS are Earthed at one
point only
2.2 HIGH IMPEDANCE RELAY BUS BAR PROTECTION CHECKS
Page 154 of 155

2.2.1 Operating Values
The relay shall be tested for Operating Values of the Relay in the Test and Intermediate Positions.
2.2.2 Primary Operating Values
The Primary Operating Current shall be calculated from the Total Operating Current and CT Ratio
Primary Operating Values shall be recorded
2.2.3 CT Supervision Checks
The CT Supervision Circuit shall be checked for Pickup and Reset. The Time Delay shall be checked and
recorded.
It shall be ensured that the operation of the CT Supervision shorts all the CT Circuits and recorded.
2.3 PRIMARY INJECTION TEST
The Test shall be conducted to ensure the Stability during External Faults Sensitivity on Internal Faults.
Each Zone shall be checked separately and the result recorded in Form “ BBPRINJ ”
Note: The Tripping logic shall be checked as per the applicable Logic Drawings and Schematic for
the Sub – Station
2.4 VERIFICATION OF METRISOL / NON LINEAR RESISTOR CURRENTS
The Non linear Resistors for CT overvoltage Protection shall be checked and the current recorded in
form “ METRISOL “
2.5 VERIFY FUNCTION OF IN/OUT SWITCH
The Function of the IN/OUT Switch shall be checked to ensure that the Bus-Bar and Check Zone
Protection can be blocked for Energisation after Maintenance etc.
***End of the Procedure *
Page 155 of 155

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ELECTRICAL TEST PROCEDURE

1- 13.8 kv MV SWG. Site test plan……………………………………………3-4

(e) bus bar protection relay

15- Disconnctor switch test procedure…………………………………………………146-152

2) WIRING AND FERRULING CHECK

3) BUS CONTINUITY AND PHASING TEST

4) MAIN CIRCUIT RESISTANCE TEST

5) CURRENT TRANSFORMER CHECKS

6) VOLTAGE TRANSFORMER CHECKS

7) CIRCUIT BREAKER CHECKS

9) TEST OF PROTECTION RELAYS BY SECONDARY INJECTION.

10) PRIMARY INJECTION TEST

11) HIGH- POT TEST

12) FUNCTIONAL CHECK

2-WIRING AND FERRULING CHECK

3- BUS CONTINUITY TEST

CONTACT RESISTANCE TEST ARRANGEMENT FOR

5. CURRENT TRANSFORMER CHECKS

6. Magnetizing Current Test (Minimum 2 Points Above )

8. Phase Identification Test

9. Verify Secondary Circuits, Terminals, Shorting/Isolating Links By Primary Injection

10. High Voltage Test

11. Single Point Earthing Check

12. Demagnetize CT Cores After All Tests

2. Winding Resistance Test

INSULATION TESTING ARRANGEMENT

VT RATIO TESTING ARRANGEMENT

VT POLARITY TESTING ARRANGEMENT

6.5 Check VT HV Neutral Solidly Grounded

LOOP RESISTANCE MEASURING ARRANGEMENT BURDEN TEST ARRANGEMENT

7.1 Visual Inspections.

CB CONTACT RESISTANCE TESTING ARRANGEMENT

7.3 High- Pot Test.

7.3.1 Insulation Resistance Test At 5kv DC.

7.3.2 High-Pot Test

AC WITHSTAND VOLTAGE TESTING ARRANGEMENT

AC WITHSTAND VOLTAGE TESTING ARRANGEMENT

7.3.3 Insulation Resistance Test At 5kv DC.

7.5 Functional Check Of Trip Free And Anti Pump Circuits.

 The Anti- Pump feature in the Breakers were tested as follows:

7.6 Functional Checks Of Breaker Operation Counter.

7.8 Timing Test Using An Electronic Oscillograph.

 Connect the test set to the CB.

CB TIMING TEST ARRANGEMENT

7.9 Measure Spring Charge Time And Motor Current.

7.10 Check The Correct Functioning Of Interlocks And Limits Switches.

8. TESTING OF METERING ACCURACY BY SECONDARY INJECTION

8.1. Ammeter Check

RELAY TEST SET

AMMETER TESTING ARRANGEMENT

8.2. Voltmeter Check

RELAY TEST SET

VOLTMETER TESTING ARRANGEMENT

8.3. Energy Meter Check

KWH METER TESTING ARRANGEMENT

8.4. Current Transducer Check

CURRENT TRANSDUCER TESTING ARRANGEMENT

8.5. Voltage Transducer Check

VOLTAGE TRANSDUCER TESTING ARRANGEMENT

9. Test Of Protection Relays By Secondary Injection.

9.1. Over Current Relay

9.1.1. Over Current Pick-Up