VOLTECH ENGINEERS PRIVATE LIMITED.

OPERATIONAL CONTROL PROCEDURE

OCP NO: 06
PRE COMMISSIONING TEST PROCEDURE FOR LT PANEL
1.0 Purpose
This procedure is prepared to carry out various pre- commissioning tests to be conducted in systematic
manner for LT Panel to ensure the healthiness and performance of the LT Panel
2.0 Scope
This procedure covers the Pre commissioning test for LT Panel as for the following
1. CRM Test for Circuit Breaker
2. IR Test for Circuit Breaker
3. Timer Test for Circuit Breaker
4. CRM Test for Bus Bar
5. IR Test for Bus Bar
6. CT Test
7. PT 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 10
 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 06

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

Prepared by Approved by
Doc No: VEPL /OHSAS/D11 Rev.No:00 Page 2 of 10
 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 06
4.2 Resources – Tools and Equipment Required

For CRM Test:

a. CRM kit
b. Connecting cables
c. Insulated Hand tools
For Insulation Resistance measurement Test (IR Test):
a. Test Leads
b. 500 V, 5000 V Insulation Tester
c. Insulated Hand Tools
For Timing Measurement Test
a. Timer Kit
b. Testing leads
c. Insulated Hand Tools

Winding resistance test

a. Multimeter with leads

Polarity test

a. 9V battery
b. Galvano meter
c. Connecting leads

Ratio test

a. Variac / auto transformer

b. Step-up Transformer
c. Multimeter
d. Connecting leads

4.3 Operational Sequence of work(Test Procedure)

Contact Resistance Measurement Test (Pole to Pole):

 Take the work permit from the client

 Ensure zero energy in the Bus Bar
 Keep the Breaker in closed condition
 Connect the earth from CRM kit to earth plate or earth pit
 Connect the CRM kit Current and Voltage leads across the Breaker contact R & R’

Prepared by Approved by
Doc No: VEPL /OHSAS/D11 Rev.No:00 Page 3 of 10
 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 06
 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 test for another phases (Y & Y’) & (B & B’)
 Switch off the power supply to the CRM Kit and disconnect them

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
 Repeat the above steps for the other phases (YØ & BØ)
 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
 Select the required voltage range in megger
 Switch ON the megger and press the test button take down the reading
 Repeat the above steps for the other phases (YØ & BØ)
 Discharge the voltage from the Circuit Breaker with respect to earth.

Timing Test for circuit Breaker:

 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

Prepared by Approved by
Doc No: VEPL /OHSAS/D11 Rev.No:00 Page 4 of 10
 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 06
Contact Resistance Measurement (CRM) Test – Bus Bar

 Take the work permit from the client

 Ensure zero energy in the Bus Bar
 Disconnect Bus bar from the transformer
 Connect the earth from CRM kit to earth plate or earth pit
 Connect the CRM kit voltage leads to across the(R-Phase) Bus Bar joint
 Connect the CRM kit current leads to across the(R-Phase) Bus Bar Joint, at the same time Voltage
leads should be connected inside the current leads
 Ensure that all the connections are connected properly
 Connect the CRM kit in A.C supply extension board with ELCB rated with 30 mA
 Apply the rated current to the Bus bar
 Note down the resistance value from the CRM kit
 Repeat the above procedures for remaining (YØ & BØ)Phases for CRM Test
 Switch off the supply to the CRM Kit and disconnect the connections

BUS BAR CRM TEST

IR TEST BETWEEN PHASE TO EARTH (BUS BAR):

 Check the Bus Bar tightness and panel earthing

 Connect the Megger Positive lead with RØ Bus Bar
 Then connect the Megger Negative lead with earth
 Select the required voltage range in megger
 Switch “ON” the megger and press the test button take down the reading
 Switch “OFF” the Megger
 Discharge the potential from the bus bar with respect to earth
 Repeat the above steps for the other Bus bar phases (YØ & BØ)

Prepared by Approved by
Doc No: VEPL /OHSAS/D11 Rev.No:00 Page 5 of 10
 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 06

IR TEST BETWEEN PHASE TO PHASE (BUS BAR):

 Connect the Megger across the RØ-YØ Bus Bar

 Select the required voltage range in megger
 Switch “ON” the megger and press the test button take down the reading
 Switch “OFF” the Megger
 Discharge the potential from the Bus bar with respect to earth
 Repeat the above steps for the other Bus bar phases (YØ-BØ) &( BØ-RØ)

Insulation Resistance (IR) Test for CT

Primary to Earth:
 Connect the Earth lead of the Megger to the earth Terminal
 Connect HV lead of the Megger to either P1 or P2 of the current Transformer
 Switch “ON” the Megger and Select the required voltage range in megger
 press the Test button take down the readings
 Switch “OFF” the Megger

Primary to Secondary:

 Connect HV lead of the Megger to either P1 or P2 of the current Transformer

 Connect Earth lead of the Megger to either S1 or S2 of the current Transformer
 Switch “ON” the Megger and Select the required voltage range in megger
 press the Test button take down the readings
 Switch “OFF” the Megger

Secondary to Earth:

 Connect Earth lead of the Megger to the earth terminal

 Connect HV lead of the Megger to either S1 or S2 of the current Transformer
 Switch “ON” the Megger and Select the required voltage range in megger
 press the Test button take down the readings
 Switch “OFF” the Megger

Prepared by Approved by
Doc No: VEPL /OHSAS/D11 Rev.No:00 Page 6 of 10
 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 06
Between Secondary Cores:

 Connect HV lead of the Megger to either S1 or S2 of the current Transformer

 Connect Earth lead of the Megger to either S1 or S2 of the other core of the current
Transformer
 Switch “ON” the Megger and Select the required voltage range in megger
 press the Test button take down the readings
 Switch “OFF” the Megger
 Discharge the voltage from the CT with respect to earth.

Polarity test for CT:

Connect the secondary S1 terminal to galvanometer positive terminal and S2 to the negative
terminal
 Touch the battery positive terminal to P1 in and negative terminal to the P2 terminal at the
CT primary winding Terminals
 Check the deflection in the galvanometer
 It must be in clock-wise direction

Ratio test for CT

 Connect the variac and loading transformer

 Connect the loading transformer across the
primary terminals(P1,P2)
 Connect the variac in A.C supply extension board
With ELCB rated with 30mA

 Inject the current across the primary terminals.

Prepared by Approved by
Doc No: VEPL /OHSAS/D11 Rev.No:00 Page 7 of 10
 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 06
 Note down the corresponding secondary current
at various cores.
 Switch off the supply to the primary injection kit

Winding resistance test for CT

 Connect the multimeter leads to the CT secondary winding Terminals

 Note down the winding resistance value
 Repeat the above procedure for remaining cores

Continuity test for CT

 Connect the multimeter leads to the CT secondary winding Terminals

 Observe the beep sound in multimeter
 Repeat the above procedure for remaining cores

Knee point test for CT:

 Connect the variac to the step-up transformer

 Connect the step-up transformer output to the CT secondary terminal
 Inject the rated voltage to the CT
 Measure the leakage current in that core using leakage current tester with different voltages
 Repeat same procedure to all other core if applicable
Insulation Resistance (IR) Test for PT:

 Connect the Megger earth lead with earth and connect Positive lead with CVT primary side
 Connect the positive lead to primary and earth lead to secondary each core
 Connect the positive lead to core and earth lead to earth
 Connect the positive lead to any core and earth lead to another core if applicable
 Select the required voltage range in megger and apply the voltage to the CVT
 Note the IR values from Megger
 Discharge the voltage from the CVT with respect to earth.

Polarity test for PT:

 Connect the primary P1 terminal to galvanometer positive terminal and P2 to the negative
terminal
 Touch the battery positive terminal to S1 in and negative terminal to the S2 terminal at the CVT
secondary winding Terminals

Prepared by Approved by
Doc No: VEPL /OHSAS/D11 Rev.No:00 Page 8 of 10
 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 06
 Check the deflection in the galvanometer
 It must be in clock-wise direction

Ratio test for PT:

 Connect the variac and step-up transformer

 Connect the step-up transformer across the primary terminals(P1,P2)
 Connect the variac in A.C supply extension board with ELCB rated with 30 mA
 Inject the voltage across the primary terminals.
 Note down the corresponding secondary voltage at various cores.
 Switch off the supply to the primary injection kit

Winding resistance test for PT:

 Connect the multimeter leads to the CVT secondary winding Terminals

 Note down the winding resistance value
 Repeat the above procedure for remaining cores

Continuity test for PT:

 Connect the multimeter leads to the CVT secondary winding Terminals

 Observe the beep sound in multimeter
 Repeat the above procedure for remaining cores

4.4 Control Measures

 OCP for LT Panel is available with testing engineers
 Ensure PTW system in place for the particular Panel
 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
 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

Prepared by Approved by
Doc No: VEPL /OHSAS/D11 Rev.No:00 Page 9 of 10
 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 06

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 N0 Yes 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

Prepared by Approved by
Doc No: VEPL /OHSAS/D11 Rev.No:00 Page 10 of 10