CONTENTS

1. OBJECTIVE

1. REFERENCE

2. PRE-REQUISITES

3. PRECAUTION AND NOTES

4. TEST EQUIPMENT

5. COMMISSIONING AND TESTING PROCEDURE

6. COMMISSIONING REPORT
1. OBJECTIVE

The objective of this procedure is to provide guidelines to commission 6.6kV

Switchgear.

2. REFERENCE

HT Switchgear drawing
Make: Siemens India.
(Drawing Nos. refers to Siemens drawings)

G71570-S5465- General Arrangement and PF plan drawing for 6.6 kV

1
F004 Switchgear.
G71570-S5465-
2 Schematic Diagram for Incomer-1 Panel (GTG 1A-UAT)
W101
G71570-S5465-
3 Schematic Diagram for Incomer-2 Panel (GTG 1B-UAT)
W102
G71570-S5465-
4 Schematic Diagram for Bus coupler Panel.
W103
G71570-S5465- Schematic Diagram for Station Transformer (STR 1 &
5
W106 STR 2) feeder.
G71570-S5465- Schematic Diagram for Station Transformer (STR)
6
W111 feeder and River Water Pump House Feeder.
G71570-S5465-
7 Schematic diagram for Excitation transformer feeder.
W107
G71570-S5465-
8 Schematic diagram for SFC transformer feeder.
W107
G71570-S5465-
9 Schematic diagram for motor feeders.
W108
G71570-S5465-
10 Schematic diagram for outgoing feeders.
W109
G71570-S5465-
11 Schematic diagram for Bus-1 PT panel.
W105
G71570-S5465-
12 Schematic diagram for Bus-2 PT (adapter PT) panel.
W104
G71570-S5465-
13 Schematic diagram Bus bar Earthing truck
W113
G71570-S5465-
14 Schematic diagram for cable earthing truck
W112
G71570-S5465- Schematic diagram for fast bus transfer (Popular
15
Z005 switchgear make)
G71570-S5465-
16 Bill of Materials.
M003
3. PRE REQUISITES

3.1 Sufficient lighting inside the switchgear Room.

3.2 Completion of civil works.
3.3 Check the floor leveling is measured with good precision and it must meet the
Siemens requirement.
3.4 Completion of Erection of panels (includes fixing of panel to foundation, bus bar
interconnection and visual completeness checks)
3.5 Agreement reached upon punch points.
3.6 HT switchgear earthing termination with plant grid and inter panel in place.
3.7 Completions of inter panel bus wiring and inter connection with the field
devices.
3.8 Special tools like handles and keys to withdraw breaker from the panel are
available and kept in switchgear room.
3.9 220 V DC and 230 V AC Auxiliary supplies are available.

4. PRECAUTION AND NOTES

4.1 Area under commissioning shall be completely barricaded with barricading

tape.
4.2 To protect personnel and the equipment in the area of commissioning, area
restrictions shall be displayed.
4.3 Prior to the commencement of the commissioning, the total area around the
equipment is to be totally cleaned.
4.4 Safety equipments such as fire extinguishers/fire detection systems are at
place.

5. TEST EQUIPMENT

1. Digital Multimeter –3 ½ digit

2. 2.5 kV Meggar / 500 V Meggar
3. 0-25 KV High Voltage Tester
4. Secondary injection test kit
5. Micro ohm resistance meter
6. Analog Multimeter
7. Variac 0-440 Volt AC, 3 phase or 0-230 V AC with step up transformer
8. Phase sequence meter

GENERAL GUIDELINES FOR INSTALLATION.

 1. Floor and foundation leveling should be checked.

2. Each panel is shipped in separate packing. After unpacking, panel should

be transported up to foundation on rollers pads. These panels should be
positioned as per the GA drawing, at correct level and absolutely vertical. If
necessary, Sims may be placed either under the frame or under the bottom
rail near the 30 mm X 30 mm cut-out for foundation bolts.

3. Breaker truck should be removed with putting the panel number marking on
it. After this, another panel should to be installed in the same fashion. Side
bolts of the first panel are required to be removed. Second panel should be
placed very near to the first panel and aligned this on the foundation. It
should be matched with the side bolts hole of the first panel. Perfect
matching will take place only when the second panel is properly aligned on
the foundation and it is perfectly vertical. Sims may be used as per
requirement. Both the panel should be bolted. Install all HT panels by
following this sequence.

4. Fixing of panels with the foundation bolts is required to be done either by

welding the channel of the foundation at the 30 mm X 30 mm cutout with
inserting Sims to avoid weld across air gap or embedding the anchor bolts
in the foundation through 30 mm X 30 mm cut out or drilling the appropriate
hole in the foundation channel.

Before finalizing the welding, it is required to check that all the breakers can
be easily racked in and racked out, with the proper operation of shutter drive
mechanism and breaker earthing contact. Finalize the welding after
satisfactory rack in rack out operations.

5. Bus bars of the adjacent panels should be joined together using the bus
bars and hardware supplied. Bolts should be torque tightened. The support
insulators should be cleaned properly.

6. Main earth bars of the panels must be bolted together.

7. Power Cables are terminated in the cable compartment. Cable opening at

the bottom of the panel are properly sealed. Check earthing of cable shield.
The shield shall be earthed at one point only.

8. Ensure that HT cables are well supported with clamps so that the weight of
the cable should not be exerted on the cable terminal.

6. TESTING AND COMMISSIONING PROCEDURE

 Testing and commissioning procedure includes:
Pre commissioning checks.
Pre commissioning tests.
Commissioning.

1) Pre commissioning checks to be carried out as per attached checklist " HT

switchgear Check list ".

2) Pre commissioning tests

i) Contact resistance of bus bar joint checks:

Contact resistance of bus bar joints should be checked with Micro

ohmmeter.

ii) Circuit Breaker checks:

1. All the breakers should be checked for smooth rack-in, rack-out, locking
of transfer operating mechanism, proper fixing of interlocking plate, door
interlock during service position and cable compartment back cover
opening interlock. Bus bar and cable earthing trolley should also be
checked.
2. Insulation resistance of the breaker should be checked.
3. Contact resistance of each phase of the circuit breaker shall be measured
by micro ohmmeter.
4. Breaker operation (manual and electrical) should be checked. Tripping
should be checked through lock-out.
5.
5. Spring charging time should be measured with stopwatch.
6. Anti pumping operation should be checked.
7. Safety shutters operations should be checked.
8. Moving breaker earth continuity should be checked.

iii) Insulation resistance check (before HV test)

Prior to carrying out insulation resistance measurement, all PTs should be

racked out. Insulation resistance of each phase bus bar with respect to
earth and between the phases should be measured with 2.5 kV meggar.

iv) HV test
 High Voltage withstand test is required to be carried out at 16 kV for each
phase of the bus bar with respect to earth.

v) Insulation resistance check (after HV test)

After carrying out high voltage test, it is required to measure the insulation
resistance of each phase bus bar with respect to earth and between the
phases to check the healthiness of bus bar support insulators during high
voltage test. It should be measured with 2.5 kV meggar.

vi) CT/PT testing.

Ratio and polarity check of CT/PT should be carried out.

Magnetizing characteristic test should be done for PS class CT.

vii) Energizing of Control supply AC/DC.

Control compartment of all the cubicles should be energised with auxiliary

AC and DC power supply. It is to be measured and to be ensured that it is
within tolerance limit.

viii) Secondary injection test on relay

Secondary injection test should be carried out for the protective relays.
Relay setting should be done as per co-ordination chart.

ix) Insulation resistance and continuity checks for outgoing cables

Healthiness of all the outgoing cables should be checked by measuring insulation

resistance. Continuity should be checked for correct identification. In case of HT
cables, high voltage test should also require to be carried out.

x) Operation check

Remote operation of the following feeders should be checked either by simulation

or by actual operation depending upon the readiness of control desk.

Motor feeders through DCS

Transformer feeders through ASCP

Outgoing feeders through ASCP

Incomer-1/ Incomer-2 and Bus Coupler through ASCP and ABT panel.

Breaker closing and tripping interlock.

 3) Commissioning

Commissioning checklist should be completed before energizing.

Incomer breaker should be racked-in. Line PT secondary and phase sequence is

required to be checked.

Incomer breaker should be closed locally. Switchboard should be observed for any
abnormal humming sound. Bus PT and its phase sequence should be checked.

Ensure that other incomer breaker is racked-out. Bus coupler should be racked in
and closed locally. Observation should be continued for this portion of switchboard
also for any abnormal humming sound. Bus PT and its phase sequence should be
checked.

Outgoing feeder can be closed as per the commissioning schedule of individual

equipments.
 Date:…………

HT switchgear Check list

Pre commissioning Checks

1. Panels are positioned as per GA drawing. : OK / NOT OK

2. No gap between adjacent sections. : OK / NOT OK
3. Fixing with base frame. : OK / NOT OK
4. Provision and inter connection of earth bus : OK / NOT OK
between panels.
5. Earthing of panel to plant Grid. : OK / NOT OK
6. Proper gasket / tight closing of door. : OK / NOT OK
7. All insulators and barriers are cleaned. : OK / NOT OK
8. Electrical clearances are adequate. : OK / NOT OK
9. Proper identification of phases. : OK / NOT OK
10. Earthing of doors, protective relays and other : OK / NOT OK
equipment mounted on the control
compartment.
11. Rack in / out of beaker trolley : OK / NOT OK
12. Phase sequence colour code of incomer : OK / NOT OK
cable
13. Earthing of breaker. : OK / NOT OK
14. Mounting of relays and meters. : OK / NOT OK
15. Proper labels for relays, switches, lamps : OK / NOT OK
16. Bus bar joints tightened with factory specified : OK / NOT OK
torque.
17. Panels are vermin proof after fitting the : OK/ NOT OK
covers.
18. Proper rating of fuses, relays, contactors : OK / NOT OK
19. VT fuses are intact. : OK / NOT OK
20. Relay front covers are intact and no damage : OK / NOT OK
observed during transit. Remove rubber
 bands used to lock the moving part during
transit.
21. No damage observed to CT and VT epoxy. : OK / NOT OK
22. No visible damage on VCB. : OK / NOT OK
22. Manual operation checks on each breaker, : OK / NOT OK
safety shutter, and circuit breaker racking
mechanism,

1. Contact resistance of bus bar joints

 Joint No. /Identification Resistance value ( milli ohm )

2. Contact Resistance, Insulation resistance and HV test of

breaker.

Ambient temp……….
 Insulation HV Contact
Resistance TEST Resistance
Breaker
Sl. No. Feeder details
Ph Ph to
-Ph Earth

1
.

2
.

3
.

4
.

5
.

6
.

7
.

8
.

9
.

1
0
.

1
1
.
1
2
.

1
3
.

1
4
.

1
5
.

1
6
.

1
7
.

1
8
.

1
9
.

2
0
.

2
1
.

2
2
.
2
3
.

2
4
.

2
5
.

2
6
.

2
7
.

2
8
.

2
9
.

3
0
.

3
1
.

3
2
.

3
 3. Insulation resistance of bus bar (Before H.V. test):

Meggar Make/ Type/ Sr. No. :

Ambient temperature:
Meggar Volts I.R. (M.Ω.)
U –(V+W+ E) 2500 V
V – (U+W+E) 2500 V
W – (U+V+E) 2500 V
U-V 2500 V
V-W 2500 V
W-U 2500 V

4. High voltage test:

Test Kit Make/ Type/ Sr. No.

Ambient temperature:
Voltage applied Leakage current
(mA)
U –(V+W+ E) 16 kV
V – (U+W+E) 16 kV
W – (U+V+E) 16 kV

5. Insulation resistance (After H.V. test):

Meggar Make/ Type/ Sr. No.

Ambient temperature:
Meggar Volts I.R. (M.Ω.)
U –(V+W+ E) 2500 V
V – (U+W+E) 2500 V
W – (U+V+E) 2500 V
U-V 2500 V
V-W 2500 V
W-U 2500 V

6. C.T. Testing:

Feeder No. / Details

CT Serial No.

Description R Phase Y Phase B Phase

Ratio
Class
Burden
Insulation Resistance
In M Ohm
Secondary- E
Primary- Secondary

Polarity Check
Ratio Test Pri. Sec. Pri. Sec. Pri. Sec.
Curr. Curr Curr Curr Curr Curr

Knee Point Voltage Checking (for Cl. PS CT):

Sr. No. Secondary Voltage Secondary Current

 7. P.T. Testing:

Feeder No. / Details

PT Serial No.

Description R Phase Y Phase B Phase

Ratio
Class
Burden
Insulation Resistance
In M Ohm
Secondary- E
Primary- Secondary

Polarity Check
Ratio Test Pri. Sec. Pri. Sec. Pri. Sec.
Volt. Volt. Volt. Volt. Volt. Volt.

8. Relay testing (secondary injection)

Sr. Fdr No: Relay Model Function Result

No
 9. Outgoing feeder cables checking

Meggar Make/ Type/ Sr. No. :

Ambient temperature:

Insulation Resistance Continuity for

Feeder No. R-E Y-E B-E R-Y Y-B B-R correct phase
sequence
Three Phase Over current & Earth Fault Relay

Relay Type : Relay Sr. No…………………….

Test Kit Details:………………………………………….

………………………………………….

Table: 1

A. Relay Pick up test:

Sr. Phase Setting in Measured Measured Remark

No. Amp. Pick up - I Drop off –I
Amp. Amp.
1 R Phase
2 B Phase
3 Neutral

( I - Current.)
Check Operation of output contacts : …………………………………

B. Relay Timing Characteristic test:

Table: 2 NI -Normal Inverse Time Characteristics

Phase Type of TMS Relay Operating time Remark

Charact.
2xIS 5xIS 10 x I S
R NI 1.0
R NI 0.1
B NI 1.0
B NI 0.1
N NI 1.0
N NI 0.1
C. High Set Element Pick up Test:

Table: 5

Sr. Phase Setting in Relay Pick Remark

No. Amp. up – I
Amp.
1 R Phase
2 B Phase
3 Neutral

Record High set Relay Op. Time at 2 * Setting current:

High Set Operating Time: ………..m. Sec.

Core Balance Current transformer operated relay

Relay Type : Relay Sr. No…………………….

Test Kit Details:………………………………………….

………………………………………….
A. Relay Pick up test:

Table: 1

Sr. Phase Setting in Measured Measured Remark

No. Amp. Pick up - I Drop off –I
Amp. Amp.
1 Neutral

Motor Protection Relay

Relay Type : motPRO Relay Sr.No :

Test Kit Details:………………………………………….

NOTE: Recheck the settings in all the service codes and configuration of output
relays. It should be as per the application and schematic drawing.
Disconnect CT inputs from the relay.

A. Short circuit and Earth fault Pick up/drop off test:

Set the earth fault trip time settings (Code-32) to minimum. Keep the other
protection settings high so that it should not disturb the protection under test.
Inject single-phase current into each of the phase and earth fault inputs, in turn.
Slowly increase the current until the trip LED glows. Check the output relay contact
on which this protection id configured. Record the pick-up current. Reduce the
current until the trip contact drops off. Record the drop off level.
Original time setting should be resumed.
Operating time should be measured by injecting 2 times the set current into the
relay.

Sr. Phase Setting in Measured Measured Remark

No. Amp. Pick up – Drop off –
Amp. Amp.
1 R Phase
2 Y Phase
3 B Phase
4 Neutral

Sr. Phase Time Measured Remark

No. setting Pick up –
Time
1 R Phase
2 Y Phase
3 B Phase
4 Neutral

Operation of output contacts : …………………………………

Restore the phase and earth fault trip settings to recommended value.

B. Thermal Characteristics test:

This test checks the accuracy of the thermal characteristics and that the relay has
been correctly set. The relay should be fully programmed to the calculated settings,
output relays mapped to the protection scheme being used for this test.
Code-10 and 22 is to be set for required thermal setting. Code-18 to be set as
1111. Code-26 to be set at 06. Code-24 to be set as OFF. Code-46 is to be
selected as 56. Before testing and during consecutive tests at different values,
thermal content is to be cleared.
Thermal characteristic is to be tested for 1.5 times and 3 times the setting.
When the single-phase current is injected, it gets split into one-third magnitude of
positive and negative sequence current. So to inject a thermal equivalent current,
the single phase current required is 3XIeq/ sqrt 7
Keep the other protection settings high so that it should not disturb the protection
under test.

Sr. Heating Equivalent Current Theoretical Actual

No. Time current as injected operating operating
constant multiple of time time
(code-22) Is (Ieq/Is)

Hot running condition of motor is envisaged when service code-56 shows 100. Hot
operating characteristic is verified by calculating the time the relay takes to trip from
100% thermal content.

Current is injected higher than the thermal setting and thermal content is allowed to
build up above 100%. Current is switched off without reducing the level. Current
injection is restarted the moment thermal content reaches 100% and the time is
calculated from this moment to tripping moment.

Sr. Hot to cold Current Actual

No. ratio injected operating
time

C. Phase Unbalance Protection (Negative phase sequence) :

The Phase unbalance/Negative Phase sequence (NPS) protection can be verified

by injecting single phase current only in one phase at a time.

The relationship between single phase current and Negative Phase sequence
current is Negative Phase seq. current= 1/3 ( I injected current)

Set the relay for recommended unbalance current (code-13). Set withstands time
(code-31) setting to 0.1 second. Also set NPS characteristic (code-30) as 1111 i.e.
definite time. Keep the other protection settings high so that it should not disturb the
protection under test.

Inject single-phase current into each of the phase, in turn. Slowly increase the
current until the trip LED glows. Check the output relay contact on which this
protection is configured. Record the pick-up current. Reduce the current until the
trip contact drops off. Record the drop off level.

Original time setting should be resumed.

Operating time should be measured by injecting at least 1.3 times the set current
into the relay.

Sr. Phase Unbalance Measured Measured Remark

No. current Pick up – Drop off –
Setting in Amp. Amp.
Amp.
1 R Phase
2 Y Phase
3 B Phase

Sr. Phase NPS Measured Remark

No. definite Pick up –
Time Time
setting
1 R Phase
2 Y Phase
3 B Phase

Now set NPS characteristic (code-30) as 2222 i.e. inverse time. Inject the multiple
of NPS setting and measure the operating time.

Sr. Neg. Injected Theoretical Relay Operating time.

No. Phase current operating
Seq. Amp. time
Setting
R Y B
Phase Phase Phase
1.
2.

D. Stalling Protection

Set the relay for recommended stalling current (code-12). Set stall withstand time
(code-28) setting to 1 second. Also set starting time (code-29) to 1 sec. Keep the
other protection settings high so that it should not disturb the protection under test.

Inject single-phase current into each of the phase, in turn. Slowly increase the
current until the trip LED glows. Check the output relay contact on which this
protection is configured. Record the pick-up current. Reduce the current until the
trip contact drops off. Record the drop off level.
Original time setting should be resumed.

Operating time should be measured by injecting at least 1.3 times the set current
into the relay.

Sr. Phase Stalling Measured Measured Remark

No. current Pick up – Drop off –
Setting in Amp. Amp.
Amp.
1 R Phase
2 Y Phase
3 B Phase

Sr. Phase Stall Time Measured Remark

No. setting Pick up –
Time
1 R Phase
2 Y Phase
3 B Phase

E. Prolonged starting Protection

Ensure that code-6 is set for 1111. Set the relay for recommended starting current
(code-16). Set starting time (code-29) 1 second. Set stall withstand time (code-28)
more than 1 sec. Keep the other protection settings high so that it should not
disturb the protection under test.

Inject single-phase current into each of the phase, in turn. Slowly increase the
current until the trip LED glows. Check the output relay contact on which this
protection is configured. Record the pick-up current. Reduce the current until the
trip contact drops off. Record the drop off level.
Original time setting should be resumed.

Operating time should be measured by injecting at least 1.3 times the set current
into the relay.

Sr. Phase Starting Measured Measured Remark

No. current Pick up – Drop off –
Setting in Amp. Amp.
Amp.
1 R Phase
2 Y Phase
3 B Phase
Sr. Phase Starting Measured Remark
No. Time Pick up –
setting Time
1 R Phase
2 Y Phase
3 B Phase

Successful start is considered when current is injected higher than starting current
setting and reduced gradually below 80% of the setting before the set time delay.
Without switching off, if the current is increased more than set starting current, for
the time more than starting time, relay should not operate.

HT switchgear Check list

Commissioning Checks

1 All the covers are in place and fully secured : OK / NOT OK

& recheck cover interlock solenoid is giving
permissive to operate the breaker.
2 Power cables terminated properly : OK / NOT OK
3 Pre-commissioning test results : OK / NOT OK
4 All the panel fuse are at its place : OK / NOT OK
5 IR and continuity of cables done : OK / NOT OK
6 All the CT secondary are properly terminated : OK / NOT OK
or shorted.
7 Both the bus PT trolleys are racked in. : OK / NOT OK
8 All the breakers are racked out. : OK / NOT OK
9 All the breakers checked for operation : OK / NOT OK
10 220 V DC available in all the panels : OK / NOT OK
11 230 V AC available in all the panels. : OK / NOT OK
12 Trip circuit supervision healthy : OK / NOT OK
13 All the relay setting are checked : OK / NOT OK

14 All the relays are tested. : OK / NOT OK

15 All the CTs are tested. : OK / NOT OK
16 Arrangement available for closing the : OK / NOT OK
incomer and bus coupler breaker through T-
N-C switch.
17 Motor Protection relay has been : OK / NOT OK
programmed.