Testing & Commissioning Manual

TESTING & COMMISSIONING MANUAL SSES/QSP/QC/1: A
WORK INSTRUCTIONS /PROCEDURE FOR

EQUIPMENT TESTING Date: 01/11/2019
TABLE OF CONTENTS
S.NO. CONTENTS
1 INTRODUCTION
2 MEASUREMENT OF INSULATION RESISTANCE
3 MEASUREMENT OF WINDING RESISTANCE TEST
4 POLARITY TEST
5 RATIO TEST
6 MEASUREMENT OF BURDEN
7 CONTACT RESISTANCE TEST
8 BREAKER TIMING TEST
9 GAS LEAKAGE TEST
10 PROTECTIVE RELAY TEST
11 VECTOR GROUP TEST
12 MAGNETIC CORE BALAANCE TEST
13 MAGNETIZING CURRENT TEST
14 BDV TEST
15 HIGH VOLTAGE TEST
16 PANEL INSTALLATION INSPECTION
17 CABLE CONNECTION INSPECTION
18 VISUAL INSPECTION
19 SEQUENCE TEST
20 MEASURING OF VOLTAGE, SPECIFIC GRAVITY, ELECTROLYTE

TEMPERATURE
SURGE COUNTER CHECK
21
Prepared by Checked by Approved by


1. INTRODUCTION
It is department’s (Quality Control Dept.) responsibility to execute SRI SHANMUKHA
ENGINEERING SERVICES and its associated company’s electrical projects. Electrical
equipment testing and commissioning is the part of project execution.
The purpose of the document is to specify specific procedures for conducting site
routine tests at the time of Testing & Commissioning of electrical equipments before
energizing them. Apart from the electrical tests other tests like Visual examination &
Mechanical routine tests are also have to be carried before placing the equipment in
the location. Typical procedures for the erection, testing & commissioning of standard
equipments is briefly explained in the following document. However it may vary for
different types of equipments or different manufacturers where manufacturer/product
technical guidelines will be followed.


2. MEASUREMENT OF INSULATION RESISTANCE

1．
．Purpose
To measure the insulation resistance between main circuit and earth to prove sound
Insulation.
2．
．Documents required
(1) Factory test data of the equipment
(2) Schematic diagram.
3．
．Instrument required
(1) Insulation resistance tester (Megger) (0-5kv)
(2) Stop watch.
4．
．Procedure
1) Clean the equipment before test.

2) Disconnect the electronic devices are which are connected to the test under circuit.
3) Insulation resistance will vary depending on temp, humidity, dust etc.
4) When measurement of the insulation resistance for individual equipment is required,
the resistance is to be measured individually.
5) Megger may be preferably kept on a flat wooden board or stool. Megger leads should
be strong and have a very good insulation.
6) First, zero correction is to be made
7) The Resistance between Winding to Body , Winding to Winding of the Equipment
values are taken & check the results with in specified values or not .
8) Principally, the resistance during 1 minute to be recorded. However, when the
Value is floating, extend the testing time for more than 1 minute obtain a stable
Value. Required time is to be recorded.


5．
．Judgment
(a) MAIN CIRCUIT:

1) The measurement shall be made with an Insulation Tester (Megger) power operated
of not less than 1000 volts capacity.
2) The value measured shall not be less than 2 (Two) Mega ohm per KV rating.
(b) CONTROL CIRCUIT
1) The measurement may be made with a 500 V hand operated Megger or at the most
1000 volts Megger. The value so obtained shall be not less than 5 (Five) mega ohms.
Referring to the followings, judge that the circuit is insulated from the earth.
・Factory records of respective equipment

・Reference value of from relevant equipment standard
6. Caution
1) Before commencement of the meggering, all the Engineers and Staff of different
Wings around must be cautioned that the equipment is going to be Meggered and
none is to come into contact with the Megger leads or any part of the transformer.
Release the jumpers from the transformer if already provided before
Commencement of meggering.
2) Measures to be taken before measuring insulation resistance for Transformer:
3) If the transformer has been under hot oil circulation, the insulation resistance has
to be measured after the transformer has sufficiently cooled.
4) The transformer neutral is to be disconnected from ground.
5) It should be ensured that there are no jumpers connected on to the transformer
bushings. The line lead of the Megger is to be connected to the bushing of the
winding under test and the earth lead, connected to one of Transformer tank.


6) The line lead between the transformer bushing connection and Megger terminal
must be kept Suspended in the air by holding with a sufficiently long and good and
flexible insulation tape (glass tape or dry cotton tape for instance) so that no part of
the line lead comes into contact with the earth or transformer body.
7) For two winding transformers, HV to earth, LV to earth and HV to LV insulation
resistance values are to be taken.
8) For three winding transformers, HV to Earth, IV to earth, LV to earth, HV to IV, HV
to LV and IV to LV values have to be taken. Along with the IR values, the
winding/oil temperatures at the time of test, Date and time, details of the Megger
used and the weather condition are to be noted.
Note:
1) Measuring insulation resistance of C.T., P.T. secondary windings (Caution: only 500 V
Megger should be used)
2) For high voltage multi core cable: measure the resistance between cores also.
.


3. MEASUREMENT OF WINDING RESISTANCE TEST
1．
．Purpose
To measure the Winding resistance of all phases of the Equipment can be checked.
2．
(1) Factory test data & Erection check list
(2) Test report of equipment
3．
(1) Digital Multimeter or Micro Ohm Meter suitable for measuring resistance
4．
．Procedure
1) Using the Winding Resistance Kit or Multimeter the HV & LV Winding Resistance of
the Equipment can be checked.
2) The DC resistance of HV windings on all taps and the LV windings are to be
measured.
3) In case of Auto-transformers, DC resistance of HV, IV and LV windings have to be
measured.
4) Winding resistance of all phases has to be measured.
5) For the winding with taps, the winding resistance for all taps has to be measured. For
Transformers with OLTC, the OLTC may be operated starting from one extreme tap
and taking measurement at each tap without breaking the circuit. For transformers
with off load tap changer the DC supply is to be switched off before moving on to the
next tap.


5. Caution
1) The transformer winding is highly inductive. When DC supply is switched off, a heavy
back emf will be induced which can damage instruments and cause accident to personnel
coming into contact with the back emf. So, sufficient caution should be exercised while
carrying out this test. Voltmeter/multimeter in the voltage range must be disconnected
before breaking the circuit to prevent damage to the instrument.
2) As the windings, particularly the 110KV and 230 KV Windings have a large time
constant, sufficient time must be allowed for the current to stabilize to get true resistance
values. This applies to measurement using bridge instruments also. If it is desired to
reduce the current stabilization time, series resistance may be introduced to reduce the
time constant in which case the voltage should be read at a point beyond the resistor so
as not to include the voltage drop across the resistor in the voltage measurement.
3) Unless the resistance measurement is made using a Kelvin’s double bridge, the
measured resistance includes lead resistance also which must be subtracted from the
measured value to get true resistance of the windings. Resistances of Windings of the
order of Milli ohms like that of 11KV Windings for instance will be affected by contact
resistance. So due care must be taken to eliminating the contact resistance or atleast to
reduce them to micro level before taking measurement. The date and time of
measurement, weather condition, winding/oil temperature, the Instrument used for
measurement must all be recorded.
4) If voltage conditions warrant change of tap in a power transformer with off load tap
changer, in service the dc resistance of the winding after changing the tap must be
measured. In old transformers, long years of service may have caused coating of oil
sludge in the tap switch contact, resulting in some deviation of the d.c. resistance from the
expected value. Any hasty conclusion will be ill advised. Instead, the tap switch may be
operated a number of times and then the winding resistance measured at the set tap.


This should clear the contact surface giving the true value of winding resistance. The tap
switch should be locked in the new position.
6．
．Judgment
Measured resistance should be in order of micro ohms


4. POLARITY TEST
1．
．Purpose
To show the relative instantaneous directions of current flow one primary and one
secondary terminal are identified with a distinctive polarity marker, these indicate that at
the instant when the primary current is flowing into the marked primary terminal the
secondary current is flowing out of the marked secondary terminal
2．
1) Factory test data & Erection check list
2) Test report of equipment
3．
1) Multimeter suitable for measuring resistance

2) AC / DC ampere meter or voltmeter
3) Dry battery 1.5V or 3.0 V
4．
．Procedure
1) Using the Center Zero Galvanometer & DC voltage the Polarity of the Winding
of equipment is checked in which direction the current is flowing i.e. in Positive
Direction or Negative Direction.
2) If in HV winding Current is Flowing from ‘P1’ to ‘P2’, then in Secondary it
Should also go from ‘s1’ to ‘s2’ in case of CT,In Case of VT If in HV winding Current is
Flowing from ‘PH’ to ‘N’ then in Secondary it Should also go from ‘a’ to ‘n’.
3) The DC voltage test momentarily imposes a small DC voltage on one side of a
C.T and the direction of the momentary deflection of a Galvonometer on the opposite
side of the CT is noted and compared with polarity marks.


4) Polarity check is necessary to see the relative polarity of the primary and
secondary terminals when terminals are not marked or to establish the correctness of
the marking if already marked. In otherwords the polarity checking consists actually in
making sure that the designations P1 and P2 made on the leads of the primary
winding and S1 and S2 made on the leads of the secondary winding corresponds to
the winding start and Finish ends.
5. Judgment
Test results shall conform to the sequence diagram.


5. RATIO TEST
1．
．Purpose
To obtain the required accuracy a ratio meter may be used to determine the voltage
/current ratio of the equipment
2．
3．
1) Three phase Auto transformer (0-500V AC )

2) Current injection kit 0 -250 A
4．
．Procedure
CT RATIO TEST:
1) Primary injection kit is to be used for this test. Before going to perform this test
connect terminal ‘C’ and earth should be properly connected.
2) Phase terminal of equipment to be connect to CT P1 and neutral connect to
P2.
3) Gradually increase the Primary current in steps of 25 %, 50%, 75% and 100%,
measure the current in secondary with clamp meter in milli ampere range.
4) At any point the ratio of injection current to the secondary measured current
should be equal to the ratio of rated primary current to the rated secondary
current.
.


PT RATIO TEST:
1) Single phase AC supply through dimmer is to be used for this test. Before perform
this test connect terminal ‘N’ and earth should be connect properly.
2) Phase terminal of equipment to be connect to primary terminal, neutral terminal
connect to primary ‘N’.
3) Gradually increase the primary voltage in steps of 5 %, 50%, 75% and 100%,
measure the voltage in secondary with multi meter /voltmeter.
4) The same should be proceeding for all phases.


TRANSFORMER RATIO TEST
1) Earth the transformer body properly and keep tap at rated position.
2) Connect the 3 phase supply to the HV winding of the transformer.
3) Measure the voltages in the secondary of the transformer.
4) The ratio may be determined by energizing the HV winding of the transformer with 3-
Phase LT supply from the mains and measuring the voltage applied to the H.V. side
and the voltage induced in the LV Windings by taking measurement at the LV
terminals, keeping the LV terminals open circuited.
5) The ratio is to be determined at all the taps. If OLTC is available, the test can be
started from one extreme tap and measurement taken for each tap up to the other
extreme by operating the OLTC without switching off supply voltage while operating
the OLTC.
6) For transformers not provided with OLTC, the supply is to be switched off while
operating the OFF LOAD tap switch.
7) The increase or decrease in the LV side voltage for each tap should more or less
correspond to the percentage mentioned for that tap in the name-plate.
5. Judgment
Test results shall conform to the sequence diagram.


6. MEASUREMENT OF BURDEN
1．
．Purpose
To measure consumed VA by the secondary circuit Injection method when rated

voltage and rated current of PT or CT are injected to a measured circuit
2．
3．
1) Voltage and current regulator set

2) AC ampere voltmeter or AC ampere meter and AC voltmeter
3) DC ampere voltmeter or DC ampere meter and DC voltmeter
4．
．Procedure
1) As shown in the following drawing, measure consumed VA by the secondary
Circuit Injection method when rated voltage and rated current of PT or CT are
injected to a measured circuit, and confirm that each consumed VA remains below
the rated VA of PT and CT.


Note:
In the case of a three phase circuit, measure the line current (A) and line
Voltages (V) with three phase input applied to lines and calculate consumption.
VA formula = 3 × (A) × (V)

Example
A line marked by a sign × shall be separated at a terminal.
／110V
R T PT T.Tm R T ／5A T.Tm
CT
ＶＶ
ＡＡ
TEST VOLTAGE TEST CURRENT

POWER REGULATOR POWER REGULAT
SOURCE SOURCE OR
Judgment: Judgment:
Rated VA of PT A × V Rated VA of CT A × V
(Fig-1)
5．
．Judgment
Measured value should match with the rated value of the equipment


7. CONTACT RESISTANCE TEST

1．
．Purpose
To measure the contact resistance between incoming and outgoing contacts
2．
3．
1) Digital micro ohm meter (0-1000µΩ), 230V AC
4．
．Procedure
1) Contact Resistance of the Equipment like Breaker is measured by using

the Contact Resistance kit.
2) The measurement of contact resistance shall be made by voltage drop
method by passing a direct current (D.C.) of not less than 100 Amps
through the Circuit Breaker (in closed position) and measuring the
voltage drop across the breaker terminals (incoming – outgoing).
3) The A.C. resistance. Value is taken & compared with Standard Values.
5．
．Judgment
Measured value should be as per Manufacturer criteria.




8. BREAKER TIMING TEST

1．
．Purpose
To measure the speed of operation of Circuit breaker (O-C-O)
2．
3．
1) Breaker Timing test kit
4．
．Procedure
1) The measurement may be made at normal control voltage and the values obtained
shall be not more than the ones given below: -
2) Opening time less than or equal to 35 milli seconds.
3) Closing time less than or equal to 60 milli seconds.
4) The above values are applicable to minimum oil, SF6 and vacuum circuit breakers.
5) In the case of Bulk oil circuit breakers, however, a tripping time of upto 100 milli
seconds is permissible.
5．
．Judgment
Measured value should match with the manufacturer test report.


9. GAS LEAKAGE TEST

1．
．Purpose
To check for any leakages in SF6 Circuit breaker
2．
3．
1) Gas leakage analyzer Kit
4．
．Procedure
1) SF6 GAS Pipe line, is thoroughly checked by using Gas leakage analyzer kit or by
applying soap water and observe for any bubbles .
3) To make sure that any leak paths for SF6 are quickly pinpointed
3) True cause of the leak, be it corrosion, exposure to harsh environments, fitting
Tightness, porosity, misuse.
5．
．Judgment
Ensure no gas leakages


10. PROTECTIVE RELAY TEST
1. Purpose
The purpose of this test is to confirm that the protection relay system is
normal in performance and appearance (free from transporting and installing
damage).
2. Documents required
(1) Sequence diagram
(2) Protection relay setting calculation & setting list
(3) Protection relay factory test data
3. Instruments required
(1) Three phase secondary injection test set
(2) AC.DC Volt-ammeter
(3) Digital multi meter
4. Procedure
1) It should be checked that the DC 110V power bus has been supplied to
protection digital relay system.
2) Three phase secondary injection test set should be connected to each relay
input, and digital tester should be connected to relay output terminal.
3) Adjusting the input value (current, voltage, etc.) and when the input value
reached to setting value, it should be checked that the relay output should
be activated, by means of digital tester.
4) Individual relay test should be carried out on all of relays as listed in equipments
tests .
5. Judgment
Activated value should be conformed to setting value that is Indicated on the

setting list.


11. VECTOR GROUP TEST
1. Purpose
To determine the vector group of the transformer
4. Procedure
1) The primary and secondary windings are connected together at one point
as indicated in figure .Phase L.T. supply is applied to the HV terminals.
2) Voltage measurements are then taken between various pairs of terminals
as indicated in the diagrams
3) Readings obtained should be the vector sum of the separate voltages of
each winding under consideration


5. Judgment
To verify the whether the vector group is matched with Name plate details or as per
technical specifications.


12. MAGNETIC CORE BALANCE TEST
1. Purpose
This test is done to find out whet her the magnetic paths of the
transformer core are balanced
4. Procedure
1) Single-phase voltage is applied across one phase and neutral on the star winding
2) The voltages developed across the other two phases are read.
3) Ideally for voltage applied to the middle phase, the voltage in the two outer phases
should be equal to half the voltage applied to the middle winding.
4) However there may be some difference due to variation in the magnetic paths.
5) The measured values may be used as a parameter for future comparison
5. Judgment
The values are taken for future comparison


13. MAGNETIZING CURRENT TEST
1. Purpose
The purpose of this test is to find out the excitation current (Ied &I hy)

(3) Digital milli ammeter
4. Procedure
1) The magnetizing current drawn by the transformer at LT mains supply voltage may be
measured for both the HV and LV Winding for all phases.
2) For Delta-Star transformers, it is essential to measure the magnetizing currents on the
star side.
3) As the middle limb has a lower net reluctance (as the fluxes traverse a shorter
distance), the magnetizing current drawn by the middle limb Winding will be lower.
5. Caution
1) When measuring on the star side, the neutral point of the star connected windings
should not be connected to supply neutral and instead should be kept floated, as
otherwise third harmonic currents on the three phases which will be phase coincident
will flow through the neutral back to the supply source thereby giving higher values
which will not be a true measure of the magnetizing currents.


2) Abnormal value of magnetizing current can indicate inter turn short in the windings or
problem in the core like core shifting etc., So magnetizing current is a very important
parameter to be taken not only for commissioning a new unit but also for comparison
with future values of the transformer during its life period.
3) While measuring the magnetizing current, if only one set of readings are taken, the
transformer tap must be kept at minimum to include 100% of the winding irrespective
of the side from which measurement is taken. The measurement can as well be made
for all the taps during pre-commissioning test.
6. Judgment
To generate an open-circuit voltage


14. BDV TEST
1. Purpose
The purpose of this test is to check break down dielectric strength of the
Transformer oil.
1) Oil BDV test kit
4. Procedure
1) The dielectric strength of an oil still ranks as the most common field test.
2) The significance of the test it will detect free water, dirt and conductive particles.
3) However, acid or sludge is undetected.
4) The test set applies an A.C voltage of frequency 40 to 60Hz. through two polished
electrodes of 12.5mm to 13.0 mm. diameter with a gap of 2.5mm.
5) Between the electrodes at a rate of uniform increase of the voltage equal to
approximately 2kV/Sec.
6) Starting from zero to the value producing breakdown.
7) The test shall be carried out six times on the same cell filling.
8) The electric strength shall be the arithmetic mean of the six results which have
been obtained.
9) The permissible limit for various voltage levels are given below:
Equipment voltage class permissible limit for satisfactory use


A-- >170kV >50kV

B -70 to 170kV >40kV
C-< to 70kV >30kV
Ref: IEC-156-1963, IS-335-1983, IS-6792-1972-Table 1
5. Judgment
If the breakdown value is less than the limits specified above, the oil shall be reconditioned or
filtration should be carried out again.


15. HIGH VOLTAGE TEST
1. Purpose
The purpose of this test is to confirm that the Withstand capacity of the
insulation level in respective equipment.
1). High voltage test kit
2) Connecting probes
4. Procedure
1) The test voltages specified shall be applied connecting each phase conductor of the main
circuit in turn to the high voltage terminal of the test supply .all other conductors of the
main circuit and the auxiliary circuits shall be connected to the earthing conductor or the
frame and to the earth terminal of the test supply
2) Auxiliary and control circuits of switchgear and control gear shall be subjected to dielectric
Test.
3) Each test shall be performed:
a) Between the auxiliary and control circuits connected together as a whole and the frame
of the switching device;
b) If practicable, between each part of the auxiliary and control circuits, which in normal
use may be insulated from the other parts, and the other parts connected together and
to the frame.
4) Below table specifics the dielectric withstand voltage should be applied as per relevant
Standards. The auxiliary and control circuits of switchgear and control gear shall be


Considered to have passed the tests if no disruptive discharge occurs

during each test.
Rated insulation voltage Ui (V) Dielectric test voltage a.c r.m.s V

Ui ≤60 1000
60< Ui ≤300 1500
300< Ui ≤690 2000
690 < Ui ≤800 2200
5) Note that electronic devices (Relays, PCB etc) connected to the equipment under test
Should be disconnected before applying the High voltage test.
6) The high voltage test should be performed for one minute to verify the clearance and
Insulation level of the equipment.
5. Judgment
1) No disruptive discharge occurs


16. PANEL INSTALLATION INSPECTION
1. Purpose
(1) This test will be executed for confirming that the panel is ready for testing andalso
detecting possible faults due to vibrations and impacts during transportation.
(2) This test will be executed for confirming that each cable connection part is correctly
connected and tightened at the cable connection work.
(1) Outline Drawing for each panel
(2) Panel Check Manual & Panel Check Sheet
(1) Megger (for 1000V and 500V).

(2) Torque wrench.
(3) Screw driver.
4. Procedure
(1) Check the panel and cable connection according to the attached check sheet after
Installation and assembly of each panel.
(2) Check whether the tightening torque of the bolts in main circuit connection parts is
suitable or not.
(3) Measure the earth resistance.
5. Judgment
As per the approved drawings.


S.No Conditions Check points Judgment

1. Outline Check dimensions at each part to As per relevant approved
dimensions measure the drawing from the customer
Outline dimensions according to the
drawings.
2. Painting 1) Checks whether painting color is as As per relevant approved

specified on the drawings, and compare drawing from the customer
it with the standard color sheet
2) Check painting for scratches and
scars by visual inspection.
3. Each nameplate of 1) Check materials, color, entry of As per relevant approved

panel ,finish ,graphic character, mounting method, etc. of drawing from the customer
Structure nameplates, referring to the drawings. 1) construction drawings or
2) The doors are opened and closed approved drawing
normally, and Mounting devices can be
maintained sufficiently
4. Arrangement and 1) Check arrangement, outline view, As per relevant approved

specifications type, Specifications and functions drawing
for devices and against the drawings and specifications.
parts
5. Wiring system, 1) Check whether wiring system is the

Wiring and route same as the duct or bundled wire system
conditions as specified on the drawings.
Termination 2) Check the wires for designated cables,
sizes, colors, compensating lead wire,
molded wire according to the wiring
specifications
3). Check termination torque of tighten style
terminal, screw torque, soldering, wire
numbers, Color identification, external
terminations


17. CABLE CONNECTION INSPECTION
1. Purpose
This test will be executed for confirming that each cable connection part is correctly
connected and tightened at the cable connection work.
1) Cable termination sheet

2) Cable schedule
1) Torque wrench.
2) Screw driver.
4. Procedure
(1) Check the cable is laid and connection are connected according to the Cable
termination sheet and cable schedule
(2) Check whether the tightening torque of the bolts in main circuit connection parts is
Suitable or not.
5. Judgment
As per the approved drawings.


18. VISUAL INSPECTION
1. Purpose
To know the correctness of the respective equipment and condition of equipment

Visually
1) Outline General alignment drawing of the equipment

2) Name plate details drawing
3. Procedure
1) All the equipments will be inspected to identify the physical damages.

2) Dimensions will be checked as per drawings.
3) Nameplate details will be checked as per specifications.
4) Accessories for respective equipment will be checked and identified as per packing list.
5) Equipment unloading and temporary storage.
4. Judgment:
As specified in the equipment drawing and technical specification


19. SEQUENCE TEST
1．
．Purpose
This test will be executed to confirm that there are no abnormality in the
Sequence circuit of each equipment and the device.
2．
．Document required
(1) Schematic diagram

(2) Control and Interlock block diagram
3．
(1) Circuit tester

(2) Buzzer
4．
．Procedure
1) After completion of all related works, check the panel conditions in advance
according to the panel check sheet.
2) Measure the insulation resistance.
3) Take a countermeasure for preventing a charge to unnecessary circuit.
4) Remove the lock for transportation.
5) Check the control power supply.
6) Check for short-circuit and abnormal contact.
7) Supply the control power.
8) Sequentially execute the test according to sequence diagram.
9) After satisfying the pre-conditions such as Gas pressure, Air pressure
etc., the circuit breaker may be operated in the following manner :-
(i) Manual closing and tripping
(ii) Local electrical closing and tripping at normal control voltage.
(iii) Remote electrical closing and tripping at normal control


Voltage.
(iv) Above operations at the minimum control voltage. (i.e.
at 80% of normal voltage for closing and 70%of normal control voltage for
tripping).
(v) Measurement of trip coil current & voltage dip during coil energisation – the
values so obtained shall be comparable to the coil rating specified by the
manufacturer.
5．
．Judgment
Electric wiring shall be correctly connected and each Instrument (EX. Aux. Relay
Timer, Solenoid, etc.) fitted in the panel shall be correctly and sequentially activated in
according with the sequence diagram.
6．
．Remarks
1) Regarding the field test plan of unrelated devices (including those which are
out of the scope of supply), a necessary action shall be taken by making
arrangement with customer, in advance.
2) If a unit is already alive, confirm it, and take a safety measure against it.


20. MEASURING OF VOLTAGE, SPECIFIC GRAVITY, ELECTROLYTE TEMPERATURE
1．
．Purpose
To measure the Specific gravity, electrolyte temperature of the cell.
2．
(1) Factory test data of the battery (cells test report) /Erection check list
(2) Test report.
3．
4) Multimeter (0-1000V AC& DC )

5) Hydrometer
6) Thermometer (0-180 ℃)
4．
．Procedure
1) Measure the Open circuit voltage between ‘+ ‘VE and ‘–‘VE terminal of cell and
record the Value.
2) Measure the specific gravity of each cell and record the value .Ensure that while
measuring the specific gravity the electrolyte is free from the bubbles.
3) Measure the temperature using thermometer and record value.
Note:
• For maintenance free batteries ,as there is no provision of opening the

vent caps measuring the Specific Gravity and electrolyte temperature
is not Applicable .
• Below table shows the criteria for the cell
5. Judgment
Each individual cell Type of

Type of battery Specific gravity
Voltage (v) Electrolyte
Lead acid 2.30-2.35V Dilute H2S04 1.21
Ni-Cad 1.30-1.35V KOH 1.21


21. SURGE COUNTER CHECK

1．
．Purpose
To check the working of the counter in Lightning arrestor
2．
(1) Factory test & Erection check list
(2) Test report
3．
1) Surge Fault simulator
4．
．Procedure
1) Flow the test current through the monitor as per the rating and observe the
deflection of current needle and it should be in clock wise direction.
2) Counter reading should be incremented to one number.
5．
．Judgment
Counter value should change from the previous value when fault is simulated

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TESTING & COMMISSIONING MANUAL SSES/QSP/QC/1: A

WORK INSTRUCTIONS /PROCEDURE FOR

2 MEASUREMENT OF INSULATION RESISTANCE

3 MEASUREMENT OF WINDING RESISTANCE TEST

7 CONTACT RESISTANCE TEST

8 BREAKER TIMING TEST

9 GAS LEAKAGE TEST

10 PROTECTIVE RELAY TEST

11 VECTOR GROUP TEST

12 MAGNETIC CORE BALAANCE TEST

13 MAGNETIZING CURRENT TEST

15 HIGH VOLTAGE TEST

16 PANEL INSTALLATION INSPECTION

17 CABLE CONNECTION INSPECTION

20 MEASURING OF VOLTAGE, SPECIFIC GRAVITY, ELECTROLYTE

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WORK INSTRUCTIONS /PROCEDURE FOR

ENGINEERING SERVICES and its associated company’s electrical projects. Electrical

equipment testing and commissioning is the part of project execution.

different types of equipments or different manufacturers where manufacturer/product

technical guidelines will be followed.

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WORK INSTRUCTIONS /PROCEDURE FOR

2. MEASUREMENT OF INSULATION RESISTANCE

(1) Factory test data of the equipment

(2) Schematic diagram.

(1) Insulation resistance tester (Megger) (0-5kv)

(2) Stop watch.

1) Clean the equipment before test.

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WORK INSTRUCTIONS /PROCEDURE FOR

(a) MAIN CIRCUIT:

・Factory records of respective equipment

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WORK INSTRUCTIONS /PROCEDURE FOR

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WORK INSTRUCTIONS /PROCEDURE FOR

3. MEASUREMENT OF WINDING RESISTANCE TEST

(1) Factory test data & Erection check list

(2) Test report of equipment

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WORK INSTRUCTIONS /PROCEDURE FOR

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WORK INSTRUCTIONS /PROCEDURE FOR

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WORK INSTRUCTIONS /PROCEDURE FOR

1) Factory test data & Erection check list

2) Test report of equipment

1) Multimeter suitable for measuring resistance

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WORK INSTRUCTIONS /PROCEDURE FOR

Test results shall conform to the sequence diagram.

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WORK INSTRUCTIONS /PROCEDURE FOR

1) Factory test data & Erection check list

2) Test report of equipment

1) Three phase Auto transformer (0-500V AC )

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WORK INSTRUCTIONS /PROCEDURE FOR

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WORK INSTRUCTIONS /PROCEDURE FOR

TRANSFORMER RATIO TEST

Test results shall conform to the sequence diagram.

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Testing & Commissioning Manual

Testing & Commissioning Manual