1150-41-004 - R0 - 040920 - Technical Specification Electrical Installation

Doc. No.
1150-41-004
Project No: 1150
Sheet 1 of 40
Bergen Engines India Private Limited Revision 0
A Rolls-Royce Power Systems Company
TECHNICAL SPECIFICATIONS FOR

ELECTRICAL INSTALLATION
CONFIDENCE CEMENT
01 X 5.6MW GAS BASED POWER PALNT
©2020 Rolls-Royce plc

The information in this document is the property of Bergen Engines India Private Limited - A Rolls-Royce Power Systems Company. The document
is not to be copied or communicated to any third party or used for the purpose of manufacture without prior permission. Such copyright must not be
infringed, and the document must be treated as private and confidential
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Contents
1 DOCUMENT REVISION HISTORY ......................................................................................................... 5
2 INTRODUCTION ...................................................................................................................................... 6
3 SCOPE ..................................................................................................................................................... 6
4 PRE COMMISSIONING ........................................................................................................................... 6
4.1 CIRCUIT BREAKER ................................................................................................................................. 7
4.1.1 Preliminary Checks: ........................................................................................................................7
4.2 CURRENT TRANSFORMER ................................................................................................................... 7
4.3 VOLTAGE TRANSFORMER .................................................................................................................... 7
4.4 ISOLATOR ............................................................................................................................................... 8
4.5 LIGHTNING ARRESTER ......................................................................................................................... 8
4.6 HIGH VOLTAGE, MEDIUM VOLTAGE AND LOW VOLTAGE SWITCH GEAR ....................................... 8
4.7 BATTERY AND BATTERY CHARGER .................................................................................................... 9
Battery: 9
Battery Charger: .................................................................................................................................................9
4.8 BUS DUCT ............................................................................................................................................... 9
4.9 MOTOR CONTROL CENTRE, POWER/ LIGHTING DISTRIBUTION BOARD, UPS ............................10
4.9.1 Preliminary Check: ....................................................................................................................... 10
4.10 EMC (ELECTROMAGNETIC COMPATIBILITY) ................................................................................................10
4.10.1 No EMC immunity or emission tests are required on final assemblies if the following
conditions are fulfilled: ..................................................................................................................................... 10
4.10.2 Tests for EMC .............................................................................................................................. 10
4.11 CONTROL & RELAY PANEL, SYNCHRONISING PANEL, NGR CT & PT PANEL ...............................13
4.11.1 Preliminary Checks: ..................................................................................................................... 13
4.12 METERS .................................................................................................................................................13
4.13 CABLES .................................................................................................................................................13
4.14 MOTORS ................................................................................................................................................13
4.14.1 Pre-commissioning checks: ......................................................................................................... 13
4.15 EARTHING SYSTEM .............................................................................................................................14
4.15.1 Pre-commissioning Inspection and Checks ................................................................................. 14
GENERAL CHECK ................................................................................................................................................14
EARTHING ELECTRODES......................................................................................................................................14
EARTH CONTINUITY STRIPS AND EARTHING CONDUCTORS......................................................................................14
CONNECTIONS AND JOINTS..................................................................................................................................15
4.16 TRANSFORMER ....................................................................................................................................15
4.16.1 Pre-commissioning checks: ......................................................................................................... 15
4.16.2 General Checks: .......................................................................................................................... 16

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4.16.3 Terminations: ............................................................................................................................... 16

4.16.4 Perfections of Connections: ......................................................................................................... 16
4.16.5 Earthing:....................................................................................................................................... 16
4.16.6 Control Cable Connections: ......................................................................................................... 17
4.16.7 Cooler Units, Fans and Pumps: ................................................................................................... 17
4.16.8 Winding Temperature indicator (WTI) and oil temperature Indicator (OTI): ................................ 17
4.16.9 Buchholz Relay: ........................................................................................................................... 18
4.16.10 Dehydrating Breather: .................................................................................................................. 18
4.16.11 Magnetic Oil Level Gauge: .......................................................................................................... 18
4.16.12 Bushings / Arcing horn gap:......................................................................................................... 18
4.16.13 Tap Changer: ............................................................................................................................... 18
4.16.14 Pre-commissioning Tests: ........................................................................................................... 19
4.16.15 Relay Tests: ................................................................................................................................. 19
4.17 GENERATOR .........................................................................................................................................19
4.17.1 Pre-Commissioning Checks: ....................................................................................................... 20
GENERAL CHECKS ...............................................................................................................................................20
ELECTRICAL CHECKS ..........................................................................................................................................20
4.17.2 Measurement of insulation resistance of armature winding ........................................................ 21
4.17.3 Insulation Resistance measurement of field winding................................................................... 22
4.17.4 High voltage test .......................................................................................................................... 22
5 SWITCHGEAR INSTALLATION ...........................................................................................................22
DELIVERY, TRANSPORT AND ASSEMBLY OF ELECTRICAL SWITCHGEAR / PANELS. .......................22
5.1 TRANSPORTATION ....................................................................................................................................22
5.2 DELIVERY .................................................................................................................................................23
5.3 TEMPORARY STORAGE ..............................................................................................................................24
5.4 ASSEMBLY................................................................................................................................................24
5.4.1 General ........................................................................................................................................ 24
5.4.2 Remove packaging ...................................................................................................................... 25
5.4.3 Anchorage to the floor ................................................................................................................. 25
5.4.4 Assembly in the line-up ................................................................................................................ 25
5.4.5 Receipt and handling ................................................................................................................... 26
5.4.6 Storage: ....................................................................................................................................... 31
5.4.7 General Safety: ............................................................................................................................ 33
5.4.8 Installation: ................................................................................................................................... 34
5.4.9 Installation: ................................................................................................................................... 34
5.4.10 Site Preparation: .......................................................................................................................... 35
5.4.11 Erection: ....................................................................................................................................... 35
5.4.12 Floor preparation and Panel mounting: ....................................................................................... 35
5.4.13 Power Cable Installation: ............................................................................................................. 36
5.4.14 Power Cable Termination ............................................................................................................ 37
5.5 CABLE TESTING ........................................................................................................................................37
5.5.1 Voltage Test ................................................................................................................................. 37
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5.5.2 Testing of Cable Installation ........................................................................................................ 38

5.6 CABLE TERMINATION AND JOINTING ...........................................................................................................38
5.6.1 MV cables .................................................................................................................................... 38
5.6.2 LT / Control cables ....................................................................................................................... 39
5.6.3 Instrumentation cables ................................................................................................................. 39
ANNEXURE – 1 ................................................................................................................................................40

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1 DOCUMENT REVISION HISTORY
REVISION:
0 DATE REASON FOR CHANGE SIGNATURE
AUTHOR P.R.
CHECKED
(Mech.)
CHECKED
04.09.2020 Issued for Preliminary
(Elect.)
APPROVED 04.09.2020 Issued for Preliminary

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2 INTRODUCTION
This specification defines the minimum requirement for Electrical Installation in a Gas
Based engine installation.
An electrical installation work is complete only when the prescribed pre-commissioning

tests are conducted on different components and the test results are found satisfactory.
By carrying out the pre-commission tests, it is ensured that different components of the
system have their declared specification / characteristics and also the system is fit for
safe and reliable operation. The pre-commission tests for different components of an
electrical system are prescribed by International Electro-technical Commission. The
manufacturers also recommend certain site tests before commissioning their equipment.
The Electrical Inspector who is the authority to certify the safety of an electrical
installation may insist on the owner / contractor of the installation to carry out such
additional tests as may be necessary before commencing the supply / energising the
system.
In addition to the functional requirements itemised in this specification, if the supplier

deemed a more viable/economic solution is available, details would be welcome and
should be submitted with quotation for approval.
3 SCOPE
The scope of supply shall include but not limited to the following items:-
ITEM 001 Pre-Commissioning of Equipment’s

ITEM 002 Annexure – 1 (Installation Drawing)
4 PRE COMMISSIONING
Before a utility will connect an installation to its supply network, strict pre-commissioning
electrical tests and visual inspections by the site engineer / site manager, must be
satisfied.
These tests are made according to local (governmental and/or institutional) regulations,
which may differ slightly from one country to another. The principles of all such
regulations however, are common, and are based on the observance of rigorous safety
rules in the design and realization of the installation.
IEC 60364-6 and related standards included in this technical specification are based on
an international consensus for such tests, intended to cover all the safety measures and
approved installation practices normally required for industrial electrical installation.
The pre-commissioning electrical tests and visual-inspection checks for installations are
as follows:
• Electrical continuity and conductivity tests of protective, equipotential and earth

bonding
• Conductors Insulation resistance tests between live conductors and the protective
conductors connected to the earthing arrangement
• Check of phase sequence
• Functional test of switchgear and control gear by verifying their installation and
adjustment

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• Voltage drop to be checkout between at source & instrument side
After verification and testing an initial report must be provided including records of
inspection, records of circuits tested together with the test result and possible repairs or
improvements of the installation.
4.1 CIRCUIT BREAKER

4.1.1 Preliminary Checks:
• Check nameplate details according to specification / data sheet
• Check for physical damage. Inform concerned engineer immediately if damage
occurred to any instrument / part during transit.
• Check tightness of all bolts, clamps and connecting terminals.
• Check oil level and leakage if any, in case of oil circuit breaker.
• Check continuity of earth connections.
• Check cleanliness of insulators and bushings.
• Check all moving parts are properly lubricated.
• Check heaters provided.
• Carryout preliminary checks as per the manufacturer’s instruction manuals.
• Review the test certificates of breaker and all associated equipment/ components.
Discrepancy, if any, shall be brought into notice of engineer / site-in- charge.
4.2 CURRENT TRANSFORMER

• Check nameplate details according to specification.
occurred to any instrument / part during transit
• Check for oil level and leakages.
• Check continuity of earth connections.
• Check cleanliness of insulators and bushings.
• Review the test certificate. Discrepancy, if any, shall be brought into notice of
engineer/ site-in-charge.
4.3 VOLTAGE TRANSFORMER

• Check for any physical damage. Inform concerned engineer immediately if damage
• Check cleanliness of insulators.
• Check continuity of earthing connections.
• Insulation resistance test.
• Polarity test.
• Ratio test on all cores.
• Line connections as per connections diagram.
• Dielectric test of oil (wherever applicable)
• Check oil level and leakages.
• Carryout preliminary checks as per the supplier’s instruction manuals.
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engineer / site-in-charge.
4.4 ISOLATOR
• Assemble all spare parts supplied loose at the time of dispatch and make assembly.
• Check cleanliness of insulators.
• Insulation resistance of each pole.
• Manual and electrical operation and interlocks.
• Contract resistance of each pole / gap between male and female contacts.
• Continuity of earth connections of structures and operating handle.
• Clearances in open and closed positions.
• Carryout preliminary checks and alignments as per the manufacturer’s instruction
manuals.
• Review the test certificates. Discrepancy, if any, shall be brought into notice of
engineer / site-in-charge.
4.5 LIGHTNING ARRESTER

• Check nameplate details as per specification.
• Assemble all spare parts sent loose at the time of dispatch from the factory.
• Check for correct mounting of the arresters with its vent port away from the
equipment.
• Ensure that proper clearances are provided all-round the arresters with respect to
any earthed Objects.
• Check continuity of earthing connection.
engineer/ site-in-charge.
4.6 HIGH VOLTAGE, MEDIUM VOLTAGE AND LOW VOLTAGE SWITCH GEAR
• Check details of equipment / components according to specification / data sheet.
• Check continuity of earthing system.
• Assemble all parts of the switchgear which have been sent loose at the time of
despatch from the switchgear factory.
• Remove packing’s provided at the time of dispatch to arrest the movements inside
relays and Meters.
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• Dust shall be wiped from the terminals of equipment, Bus-bar supports, contact
surfaces of relays, breakers, contactors etc. and entire interior of the
switchgear/panels shall be cleaned, if necessary by the use of vacuum cleaner.
• Review the test certificates of all equipment/instruments/components provided by
individual manufacturer and forwarded by panel manufacturer along with panel.
Discrepancy, if any, shall be brought into notice of engineer / site-in-charge.
4.7 BATTERY AND BATTERY CHARGER

Battery:
• Check the battery cells for proper level of electrotype by using a hydrometer.
Terminals of Battery shall be cleaned and Vaseline applied.
• Check cell connection and wiring for continuity and polarity.
• Sp. Gravity test.
• Cell voltage check.
• Initial charging cycle.
Battery Charger:
• Check nameplate details according to specification / data sheet.
• Check connection.
• Functional check of auxiliary devices, such as alarms, indicating lamps etc.
• Insulation resistance test of all circuits.
• Dust shall be wiped out from terminals, contacts, equipment etc. by vacuum cleaner.
• Review the test certificates of all equipment / instruments / components provided by
individual manufacturer and forwarded by panel manufacturer along with panel.
4.8 BUS DUCT

• Check for components as per specification / data sheet
occurred to any, instrument / part during transit.
• Check tightness of all bolts, clamps and in particular flexible.
• Check for phase sequence with respect to switchgear terminals and the transformer
terminals.
• Assemble all parts sent loose at the time of dispatch from bus duct factory.
• Carryout preliminary checks as per the manufacturer’s instruction manual.
• Check for adequate phase to phase and phase to earth clearances especially at the
adaptor boxes housing flexible connections.
• Check the insulation value with megger.

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4.9 MOTOR CONTROL CENTRE, POWER/ LIGHTING DISTRIBUTION BOARD, UPS

4.9.1 Preliminary Check:
• Check name plate details of every associated equipment/components according to
specification / data sheet.
• Check for physical damage and inform concerned engineer immediately if there is
damage occurred to any instrument / part during transit.
relays and meters.
• Review the test certificates of all equipment / instruments / components provided by
individual manufacturer and forwarded by panel manufacturer alongwith panel.
4.10 EMC (Electromagnetic compatibility)

4.10.1 No EMC immunity or emission tests are required on final assemblies if the following
conditions are fulfilled:
a) The incorporated devices and components are in compliance with the
requirements for EMC for the stated environment (see J.9.4.1) as required by the
relevant product or generic EMC standard.
b) The internal installation and wiring is carried out in accordance with the devices
and Components Manufacturers ‘instructions (arrangement with regard to mutual
influences, cable, screening, earthing etc.)
In all other cases the EMC requirements are to be verified by tests as per J.10.12.
4.10.2 Tests for EMC

The emission and immunity tests shall be carried out in accordance with the relevant
EMC Standard. However, the ASSEMBLY manufacturer shall specify any additional
measures necessary to verify the criteria of performance for the ASSEMBLIES if
necessary

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Table J.1 – Emission limits for environment A

Frequency range
Item Limits Reference standard
MHz a)
30 dB (μV/m) quasi peak at
30 – 230
Radiated 30 m b)
emissions 37 dB (μV/m) quasi peak at
230 – 1000
30 m b)
79 dB (μV) quasi peak

0,15 – 0,5 IEC 61000-6-4 or
66 dB (μV) average CISPR 11, Class A,
Group 1
Conducted 0,5 – 5
60 dB (μV) average
emissions

5 – 30
60 dB (μV) average
a) The lower limit shall apply at the transition frequency.

b) May be measured at a distance of 10 m with the limits increased by 10 dB or at a
distance of 3 m with the limits increased by 20 dB
Table J.3 – Tests for EMC immunity for environment A

Performance
Type of test Test level required
criterion c)
Electrostatic discharge immunity ± 8 kV / air discharge
test IEC 61000-4-2 or ± 4 kV / contact discharge B
Radiated radio-frequency
electromagnetic field immunity test 10 V/m on enclosure port A
IEC 61000-4-3 at 80 MHz to 1 GHz
and 1,4 GHz to 2 GHz
Electrical fast transient/burst immunity ± 2 kV on power ports
test IEC 61000-4-4 ± 1 kV on signal ports including B
auxiliary circuits and functional
1,2/50 μs and 8/20 μs surge immunity earth
± 2 kV (line to earth) on power
test IEC 61000-4-5 a) ports, B
± 1 kV (line to line) on power ports,
Conducted radio-frequency immunity ± 1 VkVon(line
10 to earth)
power ports, on signal
signal ports
test IEC 61000-4-6 at 150 kHz to 80 portsfunctional earth.
and A
MHz
Immunity to power-frequency magnetic 30 A/m A
fields IEC 61000-4-8 b) on enclosure port
Immunity to voltage dips and 30 % reduction for 0,5 cycles BCC
interruptions IEC 61000-4-11 d) 60 % reduction for 5 and 50
Cycles >95 % reduction for 250
cycles
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Immunity to harmonics in the supply No requirements

IEC 61000-4-13
a) For equipment and/or input/output ports with a rated d.c. voltage of 24 V or less tests
are not required.
b) Applicable only to apparatus containing devices susceptible to magnetic fields.
c) Performance criteria are independent of the environment. See Table J.5.
d) Applicable only to mains input power ports.
Table J.5 – Acceptance criteria when electromagnetic disturbances are present

Acceptance criteria (performance criteria during tests)
Item
A B C
No noticeable changes Temporary Temporary degradation
Overall of the operating degradation or loss of or loss of performance
performance characteristic performance which is which requires operator
Operating as intended self-recoverable intervention or system
reset a)
Operation of No mal operation Temporary degradation Temporary degradation

power and or loss of performance or loss of performance
auxiliary circuits which is self- which requires operator
recoverable a) intervention or system
reset a)
Operation of No changes to visible Temporary visible Shut down.
displays and display information changes or loss of Permanent loss of
control panels Only slight light intensity information. display or wrong
fluctuation of LEDs, or Undesired LED information
slight movement of illumination Unpermitted operating
characters mode Not self-
recoverable
Information Undisturbed Temporarily Disturbed Erroneous processing of
processing and communication and data communication, with information Loss of data
sensing interchange to external possible error reports and/or information
functions devices of the internal and Errors in communication
external devices Not self-recoverable
a ) Specific requirements shall be detailed in the product standard.
Environment A: relates to low-voltage non-public or industrial networks/locations/installations

including highly disturbing sources.
NOTE 1 Environment A corresponds to Equipment Class A in CISPR 11 and to IEC 61000-6-4.
NOTE 2 Industrial locations are characterized by one or more of the following conditions:
- industrial, scientific and medical apparatus, e.g. working machines are present;
- heavy inductive or capacitive loads are frequently switched;
- currents and associated magnetic fields .

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4.11 CONTROL & RELAY PANEL, SYNCHRONISING PANEL, NGR CT & PT PANEL
• Check name plate details of every associated equipment according to specification /
data sheet.
• Check for physical damage and inform concerned engineer if there is damage to
any instrument / part during transit.
relays and meters.
• Review the test certificates of all equipment/instruments/ components provided by
individual manufacturer and forwarded by panel manufacturer alongwith panel.
Discrepancy, if any, shall be brought into notice of engineer / Site - in - charge.
4.12 METERS
• Check name plate details according to specification / data sheet.
• Physical check for any damage and inform concerned engineer if damage occurred
to any meter during transit.
• Megger all insulated portions.
• Check C.T. and V.T. connections with particular reference to their polarities for
power type meters.
• Carryout preliminary checks as per the manufacturers’ instruction manuals.
4.13 CABLES
• Check details as per specification / data sheet / drum schedule.
• Check for physical damage and inform concerned engineer if damage occurred to
any cable / cable drum during transit.
• Check cables are dispatched as per drum schedule, if any. Also check length and
size are as per drum schedule.
4.14 MOTORS
4.14.1 Pre-commissioning checks:
• Check equipment for free movement of rotor, Check lubrication and for any other
mechanical defects.
• Check stop push button is providing with facility with the approved cable schedule.
• Check the size of cable for conformity with the approved cable schedule.
Check the cable Termination for

• Proper crimping of cable conductors, check whether cable glands are of proper site
and glanding is done properly
• Proper seating of conductor sockets at motor terminals - check whether spring
washers are used.
• Clamping of cable at a distance of 40-45 cm from the termination.
• Check whether cable is taken straight from the termination at the terminal box.
There shall not be any targeterial stream at the glands.

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• Check whether duplicate earthing is provided for the body of the motor from
diametrically opposite sides. Check the size of the earthing conductor for adequacy.
Also check the earth lead terminations and connections for
• Socketing of the earth lead ends (if round conductor)
• Proper surface contact.
• Removal of the paint of the body of the equipment
• Tinning of copper flats at termination
• Effectiveness of bolting.
• Check the rating of switch, back-up fuses and setting of overload relay provided in
starter panel / MCC for respective sizes of motors.
• Check commutators, slip rings, brushes, brush-holders etc. for satisfactory
conditions.
4.15 EARTHING SYSTEM

4.15.1 Pre-commissioning Inspection and Checks
General Check
• Check whether the earthing layout is as per the scheme approved by the
department of Electrical Inspectorate.
• Check whether the number of plate electrodes / pipe electrodes and spacing
between them are as per the approved scheme / drawings.
• Measure earth resistance of each electrode separately insulating the same from
station grid as well as from other earth electrodes. If a number of earth electrodes
are interconnected with one another, combined earth resistance shall also be
measured. The earth resistance of each electrode and / or a group of electrodes
shall not exceed 1.0 ohm.
• Carryout line earth loop impedance test. The loop comprises the conductor from the
point of fault, back to the supply transformer, the path through transformer winding,
the earthed neutral point of the transformer and path from that point to the point of
fault through the earthing system.
• Continuity test for earth continuity conductors with ELV tester.
• All test results shall be recorded for future reference
Earthing Electrodes
• Check whether all earth electrode terminals are visible and numbered
• Check size and material of earth electrode (Plate or pipe) is as per approved
scheme/ drawings.
• Check the construction of earth electrode/station is as per approved
scheme/drawings/ IEEE-80/BS-7430
• Check the size of earth mat of sub-stations with designed values (spread of earth
mat, mesh size, conductor size, size of riser, depth of laying etc.)
• Check whether all the earth electrodes are interconnected to form a closed mesh.
Earth continuity strips and earthing conductors.

• Check whether two continuity strips have been taken from the plate electrode to the
connector link provided in masonry chamber.
• Check the size of main earth bus for conformity with approved size.

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• Check whether duplicate earthing of adequate size is provided for equipment rated
415V and above. However, all equipment located in hazardous areas shall have
duplicate earthing connections with adequate size conductors.
• Check whether duplicate earthing is provided for the neutral of the transformers and
generators. There shall be one direct connection from each neutral to a separate
earth electrode interconnecting the earthing strip.
• Check whether the bottom of each high voltage bushing is earthed using strip.
• Check whether outdoor CT, PT breaker units, isolators, lightning arresters etc. are
directly earthed to the risers of the earthing mat / earthing grid.
Connections and Joints.

• Check whether connections in the earthing system are made properly. The Contact
surface shall be properly tinned and contacts perfectly bonded and seated; riveting,
bracing or bolting shall be done effectively.
• Inspect the welded joints of GI earth strips and conductor, brazing joints of copper
earth strips and conductor. Joint surfaces shall be covered with zinc dichromate
painting / bituminous coating.
• Check the quality of galvanization of bolts and nuts used for earth lead connections.
Hot dip galvanized, rust free bolts and nuts shall be used.
• In case of earth mats, check the perfection of welding of mesh joints.
4.16 TRANSFORMER
4.16.1 Pre-commissioning checks:
• Check nameplate details with the specifications / Data sheet.
• Check for any physical damage, in particular of bushings. Inform concerned
engineer / Site - in-charge immediately if damage occurred to any instrument / Part
during transit.
• Check cleanliness of bushings, oil level in the bushings if sealed bushings are used.
Release air from bushings if air release plugs are provided.
• Assemble all parts of transformer which have been removed and sent loose at the
time of dispatch from factory. Finally check fittings and accessories as per approved
drawings.
• Oil leakage particularly along the welds if the transformer is dispatched filled with oil
or reduction in pressure of inert gas if the transformer is dispatched gas filled. When
the transformer is dispatched gas filled, the temperature and the pressure at the
time of gas filling is marked on a tag. The temperature and pressure should be
checked to ascertain whether there was any leakage of atmospheric air into the tank
during transit. In case of leakage it is possible that the winding may have absorbed
moisture and the transformer will have to be dried out. If the pressure is positive and
varies with the temperature of the surrounding air, the seal can be taken to be
effective.
• Drum containing transformer oil which have been dispatched separately, should be
examined carefully for leaks and any shortage should be reported.
• Check the radiator for release of air and positions of valves. Ensure that all radiator
valves. Ensure that all radiator valves are opened.
• Check the oil level in the main conservator & OLTC Conservator. The conservator
Shut-off valve in the Buchholz relay pipe line shall be in open position.
• Check the transformer is correctly installed with reference to its phasing.
• Check external connection of the transformer in accordance with diagram of
connection and phase sequence.
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• Review the test certificates of transformer and all associated equipment /

components. Discrepancy, if any, shall be brought into notice of engineer / site - in-
charge.
4.16.2 General Checks:

• Size of Cables.
• Size of bus-bars
• Size of bus trunking
• Size of earthing conductors
• Adequacy of various clearances
• Spacing between supports
• Ventilation
• Oil drain facilities
• Fire Protection Walls
• Firefighting arrangements.
4.16.3 Terminations:
• The transformer terminal connection may be checked for the following:
• Flexibility and area of cross - section of flexible connections at bushings.
• Clearances of live jumper connections from transformer tank and accessories.
• Perfection of Crimping.
• Tinning of contact surfaces to prevent bimetallic action.
• Clearances inside cable end box
• Clearances of bus-bar trunking
• Conformity of cable end box with the relevant IP (Ingress Protection) classification.
• Correctness of cable glanding and adequacy of cable gland earthing or pig tail.
• Support of cables at termination and unsupported lengths.
4.16.4 Perfections of Connections:

Connections to the following shall be checked for proper surface contact, seating and
tightness.
• To bushings
• To the tap changer
• To earth leads.
• To control and protective cables.
• To thermometers.
4.16.5 Earthing:
Check the size of earthing conductors, tinning of contact surfaces area of contact and
seating, effectiveness of bolting, riveting, welding etc. for the earthing of the following.
• Duplicate earthing for neutral and body
• Main tank and top cover
• Fan Motors, Pumps.
• OLTC chamber
• Tap changer driving gear
• Diverter Switch
• Cable gland/Termination.
• Marshalling Box

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4.16.6 Control Cable Connections:

Check the control cable connections between the following:
• Transformer accessories and marshalling box
• Marshalling Box and Sub-station / Power plant - Panel
• OLTC cubicle and RTCC Panel.
4.16.7 Cooler Units, Fans and Pumps:

Check fans and pumps for proper mounting. The number of fans and their positions on
the radiators shall be in conformity with the general arrangement drawings.
• Check the direction of rotation of cooling fans and pumps
• Check the direction of oil flow.
• Check flow of water in heat - exchanger.
• Measure the insulation resistance ( IR) of Fans and pumps
• Check the settings for operation of fan motors and oil Pumps.
• Check the cooler unit for correct indication of oil flow and setting of the thermometer
4.16.8 Winding Temperature indicator (WTI) and oil temperature Indicator (OTI):
• Check whether thermometer pocket is filled with oil
• Check whether the connection of the CT for winding temperature indicator to the
thermometer pocket is properly made as per the instructions given on the WTI
terminal box.
• Check whether the contacts of WTI and OTI for alarm and trip are set at required
temperatures depending upon ambient temperature and loading condition. For oil
filled transformers, the maximum permissible temperature rise above the ambient
temperature is usually taken as 45°C for oil and 55°C for winding. In case of cast
resin transformers, the alarm contact of the winding temperature relay is usually
designed to operate at 140°C and trip contact at 160°C for transformer upto
1000KVA. For higher ratings, the temperatures are 160°C and 180°C respectively.
• The hottest -spot temperature rise corresponding to a winding temperature rise (by
resistance) of 55°C for a transformer with natural oil circulation is calculated as
follows;
Average winding temperature rise = 55°C

(By resistance)
Top oil temperature rise = 50°C
Mean oil temperature rise = 50°C X 0.8 = 40°C
Gradient = 55°C - 40°C

= 15° C
Hottest - Spot temperature rise. = 50°C + 1.1 X 15°C

= 66. 5°C say 66°C
The recommended settings of the alarm and trip contact of WTI and OTI relay are
as follows;
ALARM TRIP
WTI: 88°C 98°C
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Sheet 18 of 40
OTI: 67°C 77ºC
The above settings are based on a weighted average annual ambient temperature of
32°C as per relevant IEC/BS
Guide for loading of oil immersed transformers’. At another ambient, the temperatures
settings will have to be correspondingly changed.
4.16.9 Buchholz Relay:

• Check that the arrow on the casing points towards the conservator.
• Check that the inclination of pipe is proper by placing a spirit level on the top of the
relay
• Check alarm and trip circuits by injecting air through the test petcock.
• Check that there is no air trapped in the relay.
• In case of forced oil cooled transformer, make sure that the Buchholz relay does not
operate when the pumps are switched on.
4.16.10 Dehydrating Breather:

Check that the colour of the Silica gel is blue.
4.16.11 Magnetic Oil Level Gauge:

Move the float level of the oil level indicator up and down between the end positions to
ensure that the mechanism does not get stuck at any point. The low oil level alarm of
the gauge shall be checked.
4.16.12 Bushings / Arcing horn gap:

Check whether line connections have been properly done. Also check arcing horn gaps
of bushings for conformity with standard values. The standard values are given below.
Transformer Winding Arcing Horn

Impulse Level (KV) Setting (mm)
325 380
550 635
650 800
950 1250
1050 1400
4.16.13 Tap Changer:

Check that the taps operate simultaneously on all the phases. For transformers provided
with off circuit tap switch, check whether the mechanical operation including the locking
arrangement is satisfactory. Check the sequence of operation of the on load tap changer
(OLTC) for the following:
• Manual Operation
• Local Electrical operation
• Remote Electrical operation
• Parallel operation
Also check whether all lamps, buzzers etc. are working satisfactorily.

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4.16.14 Pre-commissioning Tests:
Insulation Resistance (IR):

Insulation resistance test is the simplest and most widely used test to find out the
soundness of insulation between two windings or between windings and ground.
Insulation Resistance is measured by means of ‘Megger’.
The insulation test reveals the condition of the insulation inside the transformer. The
insulation resistance values are affected by temperature, humidity and presence of dirt
on insulators and bushings.
Selection of Insulation Tester:

Insulation testers with test voltage of 500, 1000, 2500 and 5000V are available. The
recommended ratings of the insulation testers are given below:
Insulation Voltage Recommended Rating

Level of Insulation Tester
650V 500 V
1.1 KV 1000 V
3.3KV 2500 V
6.6 KV and above 5000 V
Minimum Value of IR:

The following values of IR at 30°C can be considered to be the minimum requirement for
new oil filled transformer.
System Voltage Minimum 1 Min.

IR Valve at 30°C
400/415V 100 Meg Ohm
6.6 KV to 22 KV 300 Meg Ohm
Less than 6.6 200 Meg Ohm
33KV 400 Meg Ohm
66KV and above 500 Meg Ohm
4.16.15 Relay Tests:

All protective relays, CTs, PTs and control wiring shall be tested as explained under
relevant chapters. The relays shall be set to suit the operating conditions and to co-
ordinate with other sections of the system. The relay test results shall be documented
for future reference.
4.17 GENERATOR
During the pre-commissioning checks and tests, each component of the generator
installation is checked for proper installation and correct assembly. The electrical
connections are verified for conformity with the approved diagrams at every stage of the
installation. Pre-commissioning tests of generators include testing of the protective
devices and relays, auxiliary equipment and control circuitry.

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4.17.1 Pre-Commissioning Checks:

General checks
• Inspect the generating station/generator room and premises for conformity with the
approved site plan.
• Verify the inside layout of the generating station / generator room for conformity with
the approved scheme.
• Check whether the buildings are of fire-proof construction.
• Check the physical layout of the generator, prime mover, control panels, auxiliary
equipment etc. for conformity with approved plan. Measure the ground clearances of
equipment and control panel / switchgear.
• Check the firefighting arrangements and devices in the generator room and ensure
their adequacy.
Electrical Checks
• Verify all electrical connections to ensure that they are as per the approved electrical
schematic Diagram.
• Check the tightness of all electrical connections.
• Check the connections to the AVR. The connections should be as per the diagram
of connections and the instructions of the supplier of AVR.
• Check the power cables connections at the generator terminal box and the control
panels for proper clamping and terminations.
• Check the control cable connections for proper terminations and glanding.
• Check whether the neutral formation and neutral earthing have been done correctly.
• Check whether the Neutral Grounding Register (NGR) / Neutral Grounding
Transformer (NGT) is as per approved scheme.
• Check the voltage grade of the cable used for NGR / NGT. The voltage grade of the
cable shall be same as that for unearthed system.
• Check whether neutral switching gear is rated for the same voltage as that of the
generator.
• Check whether remote switching facility is provided for the neutral switching device.
• Check whether the frame work of NGR is insulated from its enclosure for the same
voltage as that of the generator.
• Check the connection of governor. The connection should be as per the diagram
given by manufacturer.
Inspect the control panel / switchgear etc. for the following :

• Layout of panels, ground clearances, breaker rating etc. for conformity with the
approved scheme.
• Proper connections of power cables.
• Internal arrangement of panels, control wiring, control wire trough / bunching of
control wires, segregation of potential and current leads, working of control
contactors etc.
• Proper working of relays.
• Proper working of meters. Separate fuses shall be provided for the pressure coil
leads of the energy meter so that testing of the energy meter is possible by
removing the fuses.
• Finish and neatness of panel assembly.
• Working clearances inside and around panel assembly.
• Clearances of live parts

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• Facility for maintenance and testing.

• Safety aspects such as shrouding, earthing of panel / panel door etc.
• Check the various protection schemes provided for the generator. The protection
arrangements shall be as per the approved scheme.
• Check all the embedded temperature detector and indicating instruments to ensure
that they are connected properly and are in working condition.
• Check whether window annunciation arrangement is provided for both the prime
mover and generator protection schemes.
• Check sounding of hooter and visual indication of window annunciators.
• Check the secondary circuits of instruments transformers and measuring
instruments for proper connections.
• Check the manual interlock for trouble free and safe operation.
• Wherever generators are intended for parallel operation, check the arrangements for
parallel operation.
• Check whether the electrically operated remote switching breakers are used for
synchronisation.
• Check whether the speed control and excitation control arrangements are suitable
for synchronisation.
• Check whether remote control is available at the synchronisation panel.
• Where generators are synchronised directly without using generator transformers,
check the neutral switching of the generators. Only the neutral of the largest
capacity generator shall be connected to the system and earthed. Neutral of the
other generators shall be kept floating.
• Check the condition of the battery / charger provided for protective relays / breaker.
• Check the earthing of the neutral and body of the generator, generator transformer,
station transformer and main switchgears. The earth connections shall be done
direct to the earthing system / earth mat.
• Check whether anti-condensation heaters are provided for generator. Check the
thermostats and supply arrangement for the space heaters.
• Check bearing temperature indicator, cooling water temperature indicator etc. for
proper functioning.
Check DC supply arrangement of the generating station for the following.

• Whether station type batteries of adequate capacity are provided.
• Whether battery room is ensured not to communicate directly to the generator and
control room.
• Check the adequacy of firefighting arrangements.
• Review the test reports provided by manufacturers of alternator and Prime mover.
4.17.2 Measurement of insulation resistance of armature winding

The insulation resistance between phases, between each phase and earth and among
all phases together and earth are measured using insulation tester of appropriate
voltage. Detailed description of insulation testers and procedure for testing is given in
chapter for transformer. The recommended voltage rating of insulation testers are as
given below:
MV Generators - 1000V tester
HV Generators - 2.5KV/5KV tester
The minimum insulation resistance of generators shall be as follows.

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Voltage Level Insulation resistance in meg. Ohm

415V 1.5 in Meg. Ohm
3.3KV 4.5 in Meg. Ohm
6.6KV 7.6 in Meg. Ohm
11KV 12.0 in Meg. Ohm
If the measured value of insulation resistance is less than the value indicated above it is
an indication of presence of moisture and condensation of vapour in the windings. The
windings should therefore be dried out as per the instructions of the manufacturer. The
measured values of insulation resistance may be recorded for future reference. The AVR
connections shall be removed before measuring the insulation resistance.
Polarisation Index:
(Please refer chapter for transformer)It is necessary to measure and record the
polarisation index of HV generators. Measurement of polarisation index is a conclusive
test for ascertaining the quality of insulation of HV generators. The value of insulation
resistance after 1 minute and 10 minutes of starting the measurement are measured
using HV insulation tester of appropriate voltage. The polarisation index (PI value) which
is the ratio of the 10 minute value to the 1 minute value shall be more than 2.
4.17.3 Insulation Resistance measurement of field winding.

Insulation resistance of the field winding is measured using 500V insulation Tester. The
insulation value shall be more than 1meg ohm. Care shall be taken to measure the
insulation resistance on both sides of rectifier unit in the case of brushless alternators.
Insulation resistance of the excitation transformer shall be measured and verified in the
case of static excitation systems. Insulation resistance of exciters and pilot exciters may
be measured and verified where these are installed.
4.17.4 High voltage test

High voltage test of generators is normally done only once at the manufacturer’s works
and not repeated at the site of installation. However, in some special cases, HV test is
conducted as a supplementary to the test conducted at the manufacturer’s works site.
Value of the test voltage shall be limited to 75-80% of the test voltage prescribed for HV
test. The manufacturer shall be consulted before conducting the HV test. The insulation
resistance may be measured before and after the HV test and the measured values shall
be recorded for future reference.
5 SWITCHGEAR INSTALLATION
DELIVERY, TRANSPORT AND ASSEMBLY OF ELECTRICAL SWITCHGEAR /
PANELS.
5.1 Transportation
Position during transport
Switchgear/ panels may only be transported upright. If local conditions require
transportation in a different position, it must be coordinated with the manufacturer in
advance.
Protection against vibrations and shocks

Protect the Switchgear / panels during transport to prevent excessive impact and
vibration.

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Load securing
Observe the general rules and regulations for securing cargo for transport by road, rail or
sea.
Suitability for crane use

Switchgear / panels are fitted with lifting eyes at the top. Suitable lifting equipment for
loading and unloading and suspended transport, for example in halls equipped with
gantry cranes, can be hooked onto these.
Caution
The lifting eyes are designed for a single load of no more than 700kg. Thus, taking a
margin of safety into account, panels or transport units up to a maximum total mass of
2,500 kg can be lifted by the lifting eyes. The lifting eyes are not removed from the
panels also after assembly at the installation site.
Alternatively, angle irons can be bolted along the top edges of very large and heavy
panels to spread the tensile force to more points on the housing to handle heavier loads
than which the lifting eyes can do only on the corners.
These crane brackets have to be removed after the panel has been transported, for one
thing because they could obstruct the functioning of the pressure-relief dampers.
The length of the chains/belts must be such that an angle of 30 ° vertical or 60°
horizontal is not exceeded.
Switchgear/panels are factory-fitted with transport timber bolted to the bottom. These
allow the lifting and transport by lift truck, forklift or crane fork.
They are bolted through the holes for floor installation and have to be removed during
installation.
Attention
When transporting by forklift, lift truck or crane fork, the forks must go in all the way
under the Switchgear/panels. If the forks stop under the base plate, the latter can get
damaged when being lifted. In the worst case, the Switchgear/panels can tilt and fall
from the forklift, causing serious damage.
5.2 Delivery
When the switchgear/Panels are delivered, responsibilities lie on customer which
includes the following:
• Checking the delivery for completeness and integrity (e.g. also for moisture and its
adverse effects). In case of doubt, the packaging must be opened and then sealed
again properly if stored temporarily; new bags with desiccant must then be placed
in the packaging, if any were present.
• Documentation and reporting of damage and defects. If any parts are missing or
defects or transport damage is found, customer have to do the following:
• Note the relevant event or defect on the delivery note.
• Notify the relevant carrier or forwarding agent immediately, in accordance with the
applicable liability provisions.
• Always document damage by taking photographs of it.

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5.3 Temporary storage

Should temporary storage be necessary, optimal storage without negative effects
depends on ensuring a number of minimum conditions for the switchgear / Panels and
installation materials.
Panels with basic packaging or without packaging:

• A dry, well-ventilated storage area whose ambient conditions meet the requirements
according to IEC 62271-1
• The room temperature must not fall below -5 °C
• There must be no other negative environmental influences
• The switchgear / Panels must be stored upright
• The switchgear / Panels may not be stacked
• switchgear/Panels with basic packaging: open the packaging, at least partially
• switchgear/Panels without packaging: cover the control panels loosely with protective
film
• Ensure adequate air circulation
• Check the switchgear / Panels regularly for condensation until they are installed.
Control panels with seaworthy or similar packaging with protective film:

• Store the transport units:
• protected from the weather
• in a dry place
• protected against damage
• Check the packaging for damage.
• Check the desiccant (see also section 5.2):
• on delivery
• periodically thereafter
• After expiry of the maximum storage time from the date of packaging:
• The protective effect of the packaging can no longer be guaranteed.
• Take appropriate measures if the temporary storage needs to be continued.
5.4 Assembly
5.4.1 General
Before starting the installation, the proposed switchgear room must be fully completed,
have lighting and power supply, be lockable, dry and equipped with ventilation devices.
All necessary preparations such as wall openings, conduits, etc. for the routing of power
and control cables to the switchgear must be completed.
The ground or the supporting structure (intermediate floor) must be strong enough to
support the weight of the switchgear.
Attention
When planning the room for the switchgear, sufficient distance to the ceiling must be
ensured, so that the pressure-relief dampers can be opened unobstructed in an
emergency. The ceiling height must conform to the IEC standard.
In some cases, additional measures to protect the operator at the control panel may be
required, e.g. deflector plates or discharge channels.
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Also take note of prescribed or technically required minimum clearances to side and rear
walls in accordance with the contract documents /Statutory Requirements.
5.4.2 Remove packaging

Remove the packaging from the Switchgear / panel with suitable tools without damaging
it. Remove all packaging and transport material from the assembly area.
Clean the assembly area of all packaging waste and dirt.
Dispose of packaging according to local regulations.
5.4.3 Anchorage to the floor

It is recommended that the installation of a steel base frame in the floor. Also possible is
the retrofitting of flat iron bars on a concrete base, to which the control panels are bolted.
Alternatively, the Switchgear / panels can also be installed directly on precisely levelled
concrete floors or on raised floors.
Refer to the project documents for the relevant measurements of the unit footprint.
Please refer to the individual measurements in the construction drawing for the bottom
plate relating to the order.
In an ideal situation, the base for the installation of the Switchgear / panels has been
measured before installation. Before anchoring the Switchgear / panels to the base, the
measurement log can be evaluated and, if necessary, an absolutely horizontal surface
can be created with shims for the installation of the Switchgear / panels.
When a line-up is installed, the entire surface under all Switchgear / panels / transport
units of the line-up must be uniformly level and horizontal. This is primarily the current-
free connection line-up elements to be assembled side by side; uneven surfaces will
also twist the frames causing Switchgear / panel doors to stick or not close tightly.
5.4.4 Assembly in the line-up

When assembling line-ups customer should follow the following sequence:
1st After having placed the Switchgear / panels in place by forklift or crane, align the
first panel of the line-up on the base frame according to the drawing. The
other Switchgear/ panels are placed at a short distance parallel to the first control
panel.
2nd Next, screw the panels together.
• The partitions are pre-assembled to a respective panel. The existing lead

screws are used to determine the positioning of adjacent panels to each other
and stay in place.
• The sealing material is already attached to the open side of the adjacent
panel, if the panels are intended for assembly soon.
• Rear walls, roof panels or parts may have to be removed to gain access to
screw connections if access is not possible through the doors.

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When a longer storage period is envisaged, the sealing material is not pre-assembled,
but included in the delivery and must be applied on the sealing surfaces before
assembly.
3rd Now comes the connection of the bus bars.

• In switchboards with bus bar partitions, the feed through are pushed onto the
bus bars beforehand.
• Grease the joints of bus bars with suitable grease. If necessary, pull
insulating covers over the bus bars. Install and connect the bus bars with the
included or pre-assembled fasteners.
4th Then the panels are screwed onto the bottom. Rear walls or parts may have to
be removed to gain access to screw connections if access is not possible
through the doors.
Attention
The rear walls of panels of higher internal arc classification are very heavy due to the
double plates. This needs to be taken into account during handling.
If necessary, the individual Switchgear/panels or transport unit must be realigned to each

other to compensate for gaps that occur by having been screwed to the bottom. Gaps up to
2.5 mm wide can be sealed with sealant.
5th Finally, reinstall rear walls or other housing covers necessary for floor anchoring
where applicable.
5.4.5 Receipt and handling

Receiving:
On receipt of the Switchgears/Panels at site:
• Verify the following details on packing case (Fig. 01):
• Item no.:
• Description of material:
• Package No.:
• Gross weight:
• Net weight:
• Dimensions:
• Volumes:
• Storage of goods:
• Special instruction:
• Verify the quantity of Panels & loose material as per the packing list.
• If the packing case is damaged, open the case and inspect the Switchgears / Panels
Report any damage or loss of components to the transport/carrier and lodge a claim
with the insurance agency or inform BEAS.

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Fig 01
Handling:
• Panels can be handled either by fork-lift or overhead cranes in an upright position
depending on where they have to be placed. Care should be taken to see that the
panels don’t topple during transportation.
• Avoid tilting of Panels.
• While transporting the panel using a forklift, ensure that the distance between the legs
of the forklift and ground is at least 12 cm.
• Limit the speed of the forklift to 10 kmph.
• Use both legs of the forklift.
• If Switchgears/Panels are to be installed at higher elevations, shift them from the
unloading spot through the opening planned in the building for this purpose. This
should be done with all safety precautions and strict supervision by trained personnel.
Fig 02

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Fig 03
Receipt and handling:
In case of handling by lifting crane,
• Suspend ropes from the hook and pass them under the wooden pallet at the bottom
of the Panel.
• Centre of gravity indicators and chain marks are provided on the Panel as shown in
Figure 04.
• Use PP (Poly- propylene) ropes of minimum 1” diameter for this purpose. Choose
the diameter of the rope according to the weight of the Switchgear/Panels which is
mentioned in Packing List.
• Verify that the route from the unloading spot to the erection spot has free access.
• Unload the Panels after reaching the unloading spot.

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Fig. 04

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Fig. 05
We recommend handling and shifting panels in packed condition only.

DO NOT MOVE THE PANEL BY INSERTING A CROWBAR BELOW THE BASE
FRAME
(Fig-07)
This may cause damage to the base frame.
In case the Panel is unpacked before reaching the site, use the lifting channel provided
at the top of the panel for easy transportation.
Fig. 06

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Fig. 07
To facilitate transportation and handling, the Switchgears / Panels is split into multiple
sections / transport units (Panels). Each section is wrapped with a HDPE (High Density
Polyethylene) cover and packed in a wooden case. To arrive at the approximate overall
dimensions of the packing cases, add 300 mm to the dimensions of the respective
section
List of equipment’s and special tools for site erection and assembly
• Crane and truck for equipment shifting.
• Slings and ropes - As per requirement.
• Rolling pipes - 10 Nos.
• Channels - 10 m.
• Crowbars - 4 Nos.
• Welding machines - 1 No.
• Spanner sets - 1 Set.
(Ring & Open spanner size 13mm, 17mm, 19mm, and 24mm. Box or pipe spanner
13mm.)
For safe handling lifting angle (θ) should be greater than 45°.
(Ring & Open spanner size 13mm, 17mm, 19mm, and 24mm. Box or pipe spanner
13mm.)
For safe handling lifting angle (θ) should be greater than 45°.
5.4.6 Storage:
If Switchgears / Panels are to be commissioned at a later date, the following precautions
should be taken.
• OUTDOOR STORAGE SHOULD BE AVOIDED. Store all cases indoors, in a
clean, dry and well ventilated place where seepage of water and condensation
does not occur.
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• Maintain a minimum temperature of - 5 C and humidity of less than 50%.

• If civil construction is being carried out in the vicinity, ensure that the
Switchgears/Panels is completely protected from debris and dust.
• Keep proper tags/markings on the panels for easy traceability.
• Unpacking of the TUs at site is preferable. In case it becomes necessary to unpack
the TUs during storage, make sure that packing of all the internal components e.g.
covers on the relays and meters mounted on the door etc. remain intact
(Highlighted in the figure below). Also inspect the Switchgears / Panels for
scratches, if any. Please use paint supplied with the loose materials to touch up
scratch marks, if any.
• The switchboard/Panels should be stored indoors with proper ventilation. Moist/
corrosive environments may affect the metallic parts and cause their insulation to
deteriorate.

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5.4.7 General Safety:

All working personnel must be aware of safety at site:
• Use a lifting crane to load the panel on to the truck.
• Ensure that Panels are placed in a vertical position on the truck.
• Tie the Panels properly to prevent unwanted movement.
• Refer the previous section for Panels handling instructions.
• Personnel handling the equipment must be skilled and authorised to handle the
intended voltage level.
• All working personnel must be aware of safety.
• Safety shoes should be worn so as to avoid the risk of any electric shock while at
work.
• Gloves and goggles should be used while working in the proximity of hot and
hazardous materials to avoid bodily injury.
• Appropriate tools and instruments should be used as stated for precise
workmanship.
• Suitable Caution labels and sign boards should be erected at the time of
installation and testing of boards as a mark of caution.

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5.4.8 Installation:
Typical Switchgear/ Panel Front View:
5.4.9 Installation:
Tools
• Torque wrench
• Bush Ratchet
• Hydraulic jack
• Rubber mallet
• Clamps

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5.4.10 Site Preparation:

• The installation site must be clean and the surface even. Use shims if the floor is
uneven. An uneven foundation may cause misalignment of sections, bus-bars and
hinged doors of the unit.
• Walls and ceilings must be plastered with painting completed.
• Doors and windows must be installed.
• Openings in the floor, wall and ceiling for cables, conductor pipes, bars and
ventilation must be accordance with the construction drawings provided.
• Supporting brackets, beams, enclosures and foundation frames must be assembled
and painted.
• lf necessary, braces appropriate to the basic dimensions of the switchgear
installation with cross struts corresponding to the panels must be assembled.
• Suitable indoor conditions must be maintained and necessary emergency exits must
be provided in the switchgear room.
• Excessive temperature fluctuations and high humidity should be prevented.
• Condensation should be prevented.
• If the plants atmosphere is likely to contain excessive steam or reactive gases
comprising Sulphur or chlorine, ensure that the Switchgears/Panels are placed in a
separate pressurized room.
5.4.11 Erection:
• After Switchgear / Panels have reached the installation site, unpack the panels and
move the packing material to its allocated area.
• Check if all components are in place as per the drawings and the packing list.
• Vertical sections should be shifted sequentially into the installation site for ease of
installation.
• The panels must be carried in an upright position to avoid the risk of toppling.
• Place the first TU over the base channel frames erected in the floor concrete by the
civil contractor. Check correctness of leveling (± 1 mm tolerance per meter is
allowed) and alignment of panels & proceed as per General Arrangement (GA)
Drawings.
• Maintain clearances as mentioned in GA drawings. Provide sufficient space on all
sides of the panel for personnel to work conveniently.
5.4.12 Floor preparation and Panel mounting:

• Panel can be mounted on the floor either by bolting or tack welding with the ISMC
Base Channel / Base Frame.
• The panel is provided with integral 100 mm base Frame made of 3mm sheet metal.
• Follow the steps listed below to mount the panel.
I. Grout / weld the ISMC Base Channel / Base Frame on the inserts in the floor.
Make sure that it is perfectly leveled.
II. Place the panel on to the ISMC Base Channel / Base Frame.
III. Refer Figure 08 for placing the panel on to the ISMC Base channel / Base frame

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Panel-1 Panel-2 Panel-3
Fig-08
• Tack-weld or bolt the panel with the ISMC Base Channel / Base Frame.
• When bolting the panel, drill the required holes in the ISMC Base Channel / Base
Frame, so that it matches with the holes provided in the integral base Frame.
5.4.13 Power Cable Installation:

• For ease of cabling, a cable alley is provided on the front right hand side of the
panel.
• A removable gland plate is provided at the bottom of the cable alley to facilitate cable
entry from the bottom.
• While routing cables in the cable alley, adequate bending radius of at least 12*R
(where R is the radius of the cable) should be maintained. This will prevent cables
from exerting pressure on their terminations. The wide cable alley helps in easy
bending and termination of cables.
For cabling follow the instructions given below:

• Remove the gland plate and punch the required holes depending on cable size and
gland type.
• Remove insulation from cable ends without damaging the conductor strands.
• Clean the conductor and coat immediately with inhibiting compound like petroleum
jelly.
• The lug terminals have to be crimped properly so as to avoid higher temperature rise
at the joints.
Ensure no cables are free hanging.

All cable wires should be supported appropriately and rigidly where required.
Ensure cables are at a safe distance (min 50 mm) from live parts.
All cable wires should be supported appropriately and rigidly where required.
Ensure bus bars are properly aligned so that there is no strain on any of the support
insulators

Doc. No. 1150-41-004
Project No: 1150
Sheet 37 of 40
5.4.14 Power Cable Termination
Power Cable Termination (Fig-09)

Typical Details of Power Cable Termination.
5.5 Cable Testing

5.5.1 Voltage Test
The voltage test shall be carried out with A.C. at test voltage specified below
Alternatively, by agreement between the purchaser and the manufacturer, the test may
be made with direct current.
In A.C. test the current shall be of approximately sine wave form at nay frequency from
40 to 60Hz inclusive and the rms value of the applied voltage shall be as below. When
carrying out the test, voltage shall be applied and increased gradually to the full value.
The test voltage shall be maintained continuously for 5 minutes between conductors and
between each conductor and sheath without any failure.

Doc. No. 1150-41-004
Project No: 1150
Sheet 38 of 40
Voltage Belted Cables Single core SL, and

designation Screen cables. Between
KV Between Between any any conductor and sheath
conductor conductor and sheath
0.65/1.1 3 3 3
1.1/1.1
1.9/3.3 9.5 5.5 5.5
3.3/3.3 9.5 9.5 9.5
3.8/6.6 17 19.8 9.8
6.6/6.6 17 17 17
6.35/11 25 14.4 17
11/11 25 25 25
12.7/22 - - 30
19.33 - - 45
5.5.2 Testing of Cable Installation

DC Test voltages after installation (before Commissioning) Ref. IEC: 60502-2
Test Voltage between

Any Conductor and Conductor to
Rated Voltage Metallic Sheath / Conductor (For Duration
of Cable (U/U) Screen / Armour Unscreened Cables) Minutes
KV cable KV KV
0.65/1.1 3 3
1.9/3.3 5 9
3.3/3.3 9 9
3.8/6.6 10.5 18
6.6/6.6 18 18 5
6.35/11 18 30
11/11 30 30
12.7/22 37.5 -
19.33 60 -
Note: DC voltages for old cables is 1.5 times rated voltage or less depending on the age
of the cables, repair work or nature of Jointing Work carried out etc. In any case
the test voltage should not be less than the rated voltage.
5.6 Cable Termination and Jointing
5.6.1 MV cables
• All MV (3.3KV and above) Cables shall be terminated with Raychem/Equivalent Heat
Shrinkable Termination Kit. Termination kit shall be provided with elastic barrier self-
amalgamating insulating tape which will relief stress, long barrel compression type lugs
which permit more than one compression shall be provided.
• In outdoor Raychem/Equivalent kit addition to the above mentioned a pre-cast Tropolin
rain shield should be provided which offers longer creepage path.
• Non-magnetic cable glands and gland plates will be used with single core cable.

Doc. No. 1150-41-004
Project No: 1150
Sheet 39 of 40
5.6.2 LT / Control cables

• All LT power, control and lighting cables will be XLPE insulated, armoured and PVC
sheathed overall with aluminium / copper conductor.
• LT Power, Control and lighting cables shall be terminated on the electrical equipment
through suitable size of nickel / cadmium plated double compression type, extruded
brass, industrial weather proof IP 65(min.) as per IEC 60529,cable glands. If installed in
hazardous area, it shall be dual certified (Exd & EExe certified). Type of certification shall
be according to the selected method of equipment protection.
• All bolts, studs and other fastening devices on the outside of the motor enclosure/any
equipment shall be made of corrosion-resistant material or to be plated or treated with
corrosion-resistant material.
• All end terminations of cables on equipment terminals shall be lugged with heavy duty
tinned copper lugs of suitable size. The lugs of suitable sizes shall be crimped on to the
conductors using appropriate crimping tools and dies.
• The different cores of a cable at the equipment terminal connection shall be provided
with identification labels/ ferrules in accordance with relevant wiring diagram.
• Upon completion of the gland termination, the gland shall be fitted with a UV resistant
PVC shroud in case of outdoor installation or PVC shroud in case of indoor installation.
• Cable termination glands shall enter the equipment from below, or from the sides or top
as specified in relevant drawings/documents. All gland entries that are not threaded shall
be fitted with a sealing washer and back nut.
5.6.3 Instrumentation cables

• Cable entry into field mounted cabinets/local panels shall be through certified cable
glands. The cable glands (HAWKE or equivalent) shall be nickel plated brass type. All
cable glands shall be provided with lock nuts, earth lugs and neoprene or nylon sealing
gaskets. If installed in hazardous areas; shall be dual certified (Exd & EExe certified).
Type of certification shall be according to the selected method of equipment protection.
NOTE: PVC Cable Glands are not acceptable.

Doc. No. 1150-41-004
Project No: 1150
Sheet 40 of 40
ANNEXURE – 1
Installation of Equipment, Earthing, Cable Tray, Cable Trench, Lightning Arrestor etc. should
be as per attached drawing with Annexure–1 (All the Drawings/Documents will be furnished to
successful Bidder)
Sl.No. Description Drawing No.

1 Typical Sections of Cable Trays arrangement in Cable Cellar Room & 1150-41-001
Control Room
2 Typical Section of Cable tray running in MV/LV Room & Engine Hall 1150-41-001
3 Typical Section Detail Of Cable Pipe Road Crossing and MV Cables buried 1150-41-001
underground
4 Installation of Direct Buried Cable & Details Of Cable Marker Plate 1150-41-001
5 Typical Installation Detail For Trefoil Cable Clamp 1150-41-001
6 Cable Installation : Marshalling of Auxiliary Device 1150-41-001
7 Typical Section of Cable Trays For Alternator 1150-41-001
8 Typical Section of Cable Trays Running for ECC Panel 1150-41-001
9 Typical Fabrication Details For Perforated Type Cable Tray 1150-41-001
10 Typical Fabrication Details For Ladder Type Cable Tray 1150-41-001
11 Typical Fabrication Details For Horizontal / Vertical Tee & Elbow 1150-41-001
12 General Notes for Earthing 1150-41-001
13 Installation Detail For Copper Rod Earth Electrode 1150-41-001
14 Installation Detail for Earthing Plate Electrode 1150-41-001
15 Installation Detail For Earth Bus 1150-41-001
16 Installation Detail For Earth Conductors (braze joint) & Earth Riser 1150-41-001
17 Installation Detail For Lug Connection 1150-41-001
18 Installation Detail For Motor & LCS Earthing 1150-41-001
19 Installation Detail For Stranded & Flat Conductor For Equipment Earthing 1150-41-001
20 Installation Detail For Earthing & Lightning Protection For Aviation Light 1150-41-001
21 Installation Detail For Earthing & Lightning Protection For Chimney 1150-41-001
22 Installation Detail for Test Link 1150-41-001
23 Installation Detail For Neon Spiral Aviation Light 1150-41-001
24 Typical Earthing for Electrical Equipment 1150-41-001
25 Typical Earthing Detail For Panel / DB Etc. 1150-41-001
26 Typical Details For Electronic Earthing 1150-41-001
27 Installation Detail For Alternator & Engine Earthing 1150-41-001
28 Cross Sectional Area Of Earthing Cables 1150-41-001
29 Installation Detail For PB Station & Others 1150-41-002
30 Installation of PB Station & Cable Mounted on Wall / RCC Column 1150-41-002
31 Installation of PB Station & Cable Mounted on Steel Column 1150-41-002
32 Cable Installation To Motor To PB 1150-41-002
33 Cable Installation To Roof Extractor 1150-41-002
34 Installation Details For Water Proof Compound Sealing 1150-41-002
35 Installation Details For Fire Proof Sealing 1150-41-002


1150-41-004 - R0 - 040920 - Technical Specification Electrical Installation

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1150-41-004 - R0 - 040920 - Technical Specification Electrical Installation

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TECHNICAL SPECIFICATIONS FOR

©2020 Rolls-Royce plc

©2020 Rolls-Royce plc

4.16.3 Terminations: ............................................................................................................................... 16

5.5.2 Testing of Cable Installation ........................................................................................................ 38

©2020 Rolls-Royce plc

1 DOCUMENT REVISION HISTORY

0 DATE REASON FOR CHANGE SIGNATURE

APPROVED 04.09.2020 Issued for Preliminary

©2020 Rolls-Royce plc

An electrical installation work is complete only when the prescribed pre-commissioning

In addition to the functional requirements itemised in this specification, if the supplier

ITEM 001 Pre-Commissioning of Equipment’s

• Electrical continuity and conductivity tests of protective, equipotential and earth

©2020 Rolls-Royce plc

• Voltage drop to be checkout between at source & instrument side

4.1 CIRCUIT BREAKER

4.2 CURRENT TRANSFORMER

4.3 VOLTAGE TRANSFORMER

4.5 LIGHTNING ARRESTER

4.7 BATTERY AND BATTERY CHARGER

4.8 BUS DUCT

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4.9 MOTOR CONTROL CENTRE, POWER/ LIGHTING DISTRIBUTION BOARD, UPS

4.10 EMC (Electromagnetic compatibility)

4.10.2 Tests for EMC

©2020 Rolls-Royce plc

Table J.1 – Emission limits for environment A

79 dB (μV) quasi peak

73 dB (μV) quasi peak

a) The lower limit shall apply at the transition frequency.

Table J.3 – Tests for EMC immunity for environment A

Immunity to harmonics in the supply No requirements

Table J.5 – Acceptance criteria when electromagnetic disturbances are present

Operation of No mal operation Temporary degradation Temporary degradation

Environment A: relates to low-voltage non-public or industrial networks/locations/installations

©2020 Rolls-Royce plc

Check the cable Termination for

©2020 Rolls-Royce plc

4.15 EARTHING SYSTEM

Earth continuity strips and earthing conductors.

©2020 Rolls-Royce plc

Connections and Joints.

• Review the test certificates of transformer and all associated equipment /

4.16.2 General Checks:

4.16.4 Perfections of Connections:

©2020 Rolls-Royce plc

4.16.6 Control Cable Connections:

4.16.7 Cooler Units, Fans and Pumps:

Average winding temperature rise = 55°C

Top oil temperature rise = 50°C

Mean oil temperature rise = 50°C X 0.8 = 40°C

Gradient = 55°C - 40°C

Hottest - Spot temperature rise. = 50°C + 1.1 X 15°C

OTI: 67°C 77ºC

4.16.9 Buchholz Relay:

4.16.10 Dehydrating Breather:

4.16.11 Magnetic Oil Level Gauge:

4.16.12 Bushings / Arcing horn gap:

Transformer Winding Arcing Horn

4.16.13 Tap Changer:

©2020 Rolls-Royce plc