OCP - 03 Circuit Breaker (SWYD)

VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE

OCP NO: 03
PRE COMMISSIONING TEST PROCEDURE FOR
CIRCUIT BREAKER
1.0 Purpose
This procedure is prepared to carry out various pre- commissioning tests to be conducted in systematic
manner for Circuit Breaker to ensure the healthiness and performance of the equipment
2.0 Scope
This procedure covers the Pre commissioning test for Circuit Breaker as for the following
1. CRM Test
2. Timing Test
3. Insulation Resistance 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
Prepared by Approved by
Doc No: VEPL /OHSAS/D11 Rev.No:00 Page 1 of 9
OCP NO: 03
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 Healthiness of the test leads (Check for any insulation Damages)
 Ensure appropriate PPE’s available at sites
OCP NO: 03
4.2 Resources – Tools and Equipment Required

For CRM Test:
a. CRM kit
b. Connecting Leads
c. Multimeter
For Timing Test:

a. Timer Kit
b. Test Leads
c. Multimeter
For Insulation Resistance measurement Test (IR Test):

a. Test Leads
b. 500 V, 5000 V Insulation Tester
c. Insulated Hand Tools
d. Multimeter
4.3 Operational Sequence of work(Test Procedure)
 Obtain the work permit from the client
 Ensure zero energy in the Circuit Breaker
 Ensure the all connections are in tight before testing
Contact Resistance Measurement Test:
 Keep the Breaker in closed condition

 Connect the earth from CRM kit to earth plate or earth pit
 Connect the CRM kit Current Leads(C+ & C-) across the RØ Breaker contact
 Then Connect the CRM kit Voltage leads (V+ & V-) across the RØ Breaker contact. Voltage leads
should be connect inside the Current leads
 Connect the CRM kit in A.C supply extension board with ELCB rated with 30 mA
 Inject the rated current to the Circuit Breaker
 Note down the contact resistance value from the CRM kit
 Repeat the above steps for the other phases (YØ & BØ)
 Switch off the power supply to the CRM Kit and disconnect them
OCP NO: 03
CONTACT RESISTANCE MEASUREMENT TEST
Timing Test:
 Keep the Breaker in closed condition

 Connect the earth from Timer kit to earth plate or earth pit
 Connect the Timer kit feedback cables R and R’ leads across the RØ Breaker contact
 Connect the Timer kit feedback cables Y and Y’ leads across the YØ Breaker contact
 Connect the Timer kit feedback cables B and B’ leads across the BØ Breaker contact
 Connect the Timer kit in A.C supply extension board with ELCB rated with 30 mA
 Give The open command and note down the value from the timer kit
 Give the close command and note the value from the timer Kit
 Give the close/open command and note the value from the timer kit
 Switch off the power supply to the Timer Kit and disconnect them
OCP NO: 03
R R’ Y Y’ B B’
TIMER KIT
TIMING TEST
OCP NO: 03
i) IR TEST (BREAKER OPEN CONDITION)
 Keep the Circuit Breaker in open position
 Connect the Megger across the RØ Breaker contact (R & R’)
 Select the required voltage range in megger
 Switch ON the megger and press the test button take down the reading
 Discharge the voltage from the Circuit Breaker with respect to earth.
ii) IR TEST BETWEEN PHASE TO EARTH (BREAKER CLOSED CONDITION)
 Keep the Circuit Breaker in closed position
 Connect the Megger Positive lead with RØ Breaker contact
 Connect the Megger Negative lead with earth
i) BREAKER OPEN POSITION ii) BREAKER CLOSED POSITION
MEGGER MEGGER
(R – R’), (Y – Y’) & (B – B’) R, Y, B
OCP NO: 03
iii) IR TEST BETWEEN PHASE TO PHASE (BREAKER CLOSED POSITION):

 Keep the Circuit Breaker in closed position
 Connect the Megger Positive lead with RØ Breaker contact
 Connect the Megger Negative lead with BØ Breaker contact
 Repeat the above steps for the other phases to phase (RØ-YØ), (YØ & BØ) & (RØ-BØ)
MEGGER
(RØ –YØ), (YØ – BØ) & (RØ – BØ) (PHASE TO PHASE)
OCP NO: 03
4.4 Control Measures
 OCP for CRM, Timing and IR test for Circuit Breaker is available with testing engineers
 Ensure PTW system in place for the particular bay
 Ensure all supply to the equipment is dead
 Unauthorized persons should not be allowed to enter Testing area
 Barricade the testing area with warning tape
 More than 2Mtr height shall be used safety belt or full body hardness and proper working plat
form or man lifter
 Less than 2Mtr height shall be used 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.
 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 Lone working
 Use appropriate insulated hand gloves
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
OCP NO: 03
6.0 Personal Protective Equipment (PPE):
Personal
Protective
Equipment
YES / NO Yes Yes Yes Yes
Personal
Protective
Equipment
YES / NO Yes 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

OCP - 03 Circuit Breaker (SWYD)

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VOLTECH ENGINEERS PRIVATE LIMITED.

OPERATIONAL CONTROL PROCEDURE

4.0 Working Activity and descriptions

4.2 Resources – Tools and Equipment Required

For Timing Test:

For Insulation Resistance measurement Test (IR Test):

Contact Resistance Measurement Test:

 Keep the Breaker in closed condition

CONTACT RESISTANCE MEASUREMENT TEST

 Keep the Breaker in closed condition

(R – R’), (Y – Y’) & (B – B’) R, Y, B

iii) IR TEST BETWEEN PHASE TO PHASE (BREAKER CLOSED POSITION):

(RØ –YØ), (YØ – BØ) & (RØ – BØ) (PHASE TO PHASE)

4.4 Control Measures

 Disconnect the temporary supply and remove the barricading tapes

6.0 Personal Protective Equipment (PPE):

YES / NO Yes Yes Yes Yes

YES / NO Yes No Yes Yes

7.0 Communication and signing off register:

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