VOLTECH ENGINEERS PRIVATE LIMITED.

OPERATIONAL CONTROL PROCEDURE

OCP NO: 10

PRE COMMISSIONING TEST PROCEDURE FOR WAVE TRAP

1.0 Purpose
This procedure is prepared to carry out various pre- commissioning tests to be conducted in systematic
manner for Wave trap to ensure the healthiness and performance of the Device.
2.0 Scope
This procedure covers the Pre commissioning test for wave trap as for the following
1. Insulation Resistance Value Test
2. Contact Resistance Measurement Test

3.0 Responsibility
Unit Head / Regional managers:
Unit heads / Regional managers have overall responsibility for health and safety management and role
includes:
 Planning and scheduling of activities with a view to execute the project
 Identify significant health and safety and eliminate or minimize them
 Maintaining all legal and statutory requirement
 Assist the safety team to conduct the safety training and audit at sites
 Ensure all safety rules and regulations are followed at work sites

Site Engineers:
Site engineers are responsible for all aspects of health and safety on site and are accountable to the Unit
head / Regional manager. Their roles include:
 Report any issue affecting health and safety issues at the work sites to the regional manager / unit
head / safety team
 Coordinate with end customer / client for the taking work permit and returning work permit
 Communicating the work content / hazard involved to working group through the medium of
Toolbox meeting before commencement of work every day
 Initiating proactive measures to minimize / eliminate accidents
 Reporting in detail in the event of incident
 Ensure effective use of appropriate PPE
 Ensure the quality of job at all times without any compromise on safety
 “Stop Work” in the event of any serious safety violation

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 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 10

Safety Manger / Regional Safety Engineers:

Safety manger / Regional safety engineers are responsible for providing health and safety advice and
guidance to their Unit head/ Regional manager, site engineers and their roles include:
 Ensuring implementation of all instruction and procedures based on the occupational health and
safety
 Communicating all safety rules, regulations and practices to all site engineers / regional manager/
unit head
 Follow up for the closure of audit non conformances and help regional mangers / unit head to take
corrective action and preventive action
 Report and investigate all the incidents / Near misses to the top management
 Create awareness amongst site engineers / regional managers and also organize the regular training
program.
 Ensure that Tool box talk meetings are in being conducted daily at site and the workers are aware of
all the hazards at the work site
 Ensure adequate PPE’s and safety equipment as are required are available at sites and are being
used at site appropriately
 Reporting of any issues affecting the health and safety at the work site to the unit head / Regional
managers
 Ensure basic first aid facilities are available at sites
 Ensure that no unsafe act is performed at any site
 Ensuring that any unsafe condition observed at site is eradicated at the earliest
 Issuing of safety challans in the event of any safety violations.

4.0 Working Activity and descriptions

4.1 Pre-Testing Checks
 Check out the working condition of ELCB(30 mA)
 Check the insulation of power cable for equipment
 Ensure proper earthing and rubber mats available at the work location.
 Calibrated Testing equipment should be used and calibration reports available with engineers for
the same
 Check out the insulates hand tools available with the technician
 Ensure the board is totally isolated from the live parts
 Ensure appropriate PPE’s available at sites

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 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 10

4.2 Resources – Tools and Equipment Required

For IR Test:
a. Digital Multimeter
b. Clamp meter
c. 500 V, 5000 V Insulation Tester
d. Test Lead
e. Insulated Hand Tools

For CRM Test:

a. Digital Multimeter
b. Clamp meter
c. CRM Test Kit : 0-2000milliohm
d. Test Lead
e. Insulated Hand tools

4.3 Operational Sequence of work(Test Procedure)

Insulation Resistance Value Test
IR test is to be conducted at the following points
a. Across the upper terminals of wave trap & Earth
b. Across Lighting arrester of wave trap & Earth

a. Across the upper terminals of wave trap & Earth

 Take the work permit from the client
 Ensure all power supply is dead
 Access to the wave trap by using ladder
 Connect the test lead to the earth
 Connect the test lead across the upper terminals
 Switch ‘ON’ the megger
 Take down the reading
b. Across the Lighting arrestor of wave trap & Earth
 Take the work permit from the client
 Ensure the Earth is disconnected in the circuit end
 Connect the megger across the LA of wave trap and Earth
 Switch ‘ON’ the megger
 Take down the reading

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 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 10
Contact Resistance Measurement

 Connect the earth from CRM kit to earth plate or earth pit
 Connect the CRM kit Voltage leads to across the Jumper contact
 Connect the CRM kit Current leads to across the jumper contact and keep the Voltage leads
inside the current leads
 Ensure the tightness of the connections
 Apply the rated current across the jumper contact
 Note down the value from CRM kit
 Repeat the above steps for all remaining jumper contact
 After completion the test Switch off the supply to the CRM kit and disconnect the temporary
connections

4.4 Control Measures

 OCP for all test of Wave trap is available with testing engineers
 Ensure PTW system in place for the particular location
 Ensure all supply to the equipment is dead
 Unauthorized persons should not be allowed to enter Testing area
 If work above 2mtr height safety belt shall be used
 Less than 2Mtr height shall be used the standard insulated ladder
 Inspect the ladders prior to work, keep both feet below 3rd rung from top, keep one hand on
ladder minimum at all times and suggested for complying with fall arrester
 Proper supervision, conduct job specific toolbox meeting and barricading the entire area
 Calibrated equipment shall be used
 Insulated hand tools shall be used
 Avoid joints for power cable and supply has to be taken via ELCB
 Avoid alone working
 Use appropriate insulated hand gloves

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 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 10

5.0 Final Checks & Restoration of work area after completion of work:
 Disconnect the temporary supply and remove the barricading tapes
 Ensure no loose materials / tools are kept in and around the area
 Leave the place by keeping it tidy and clean

6.0 Personal Protective Equipment (PPE):

Personal
Protective
Equipment

YES / NO Yes Yes Yes Yes

Personal
Protective
Equipment

YES / NO No No Yes Yes

7.0 Communication and signing off register:

Communicate to all employees in Tool box talk and ensure it is signed by all personnel

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