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TCS P 105 00 R0
TCS P 105 00 R0
1.0 INTRODUCTION
Proper pre-commissioning of new electrical equipment is important to prove that new equipment has
been properly shipped and correctly erected and installed. This Procedure highlights the necessary steps
related to proper pre-commissioning of new electrical equipment.
As a general practice, all equipment is tested in the factory before delivery to the site. Pre-commissioning
testing at site is done to prove that:
1.1 Purpose
1.2 Procedure
This Procedure is divided to two parts: the first part describes organizing the work at site before,
during and after pre-commissioning tests.
The second part concerns the mechanical checks, inspections and electrical tests to be
performed on the equipment before commissioning the equipment into service.
Pre-commissioning tests for a new or reinforcement project are to be checked thoroughly and witnessed
by SEC Commissioning engineer or technician. During the course of the commissioning it has been
observed that at many stages the contractors are not ready and consequently the Commissioning
personnel have to wait with the result that some tests may be missed or ignored. A procedure is required
to check the complete readiness of the contractor before the pre-commissioning tests and prepare the
commissioning engineer/technician for applying commissioning tests as per SEC commissioning
Procedure. This document briefly outline the necessary steps to be followed to ensure that contractors
are ready to start the pre -commissioning in order to reduce or maintain the approved project milestones
and control the quality of the commissioning test.
The main purpose of this procedure is to provide necessary guidelines to ensure the readiness of the
contractors to start the pre-commissioning testing of new or reinforcement projects and how to apply and
perform the pre-commissioning tests ensuring that:
2.0 PROCEDURES
Project Management shall confirm the readiness of the contractor from all aspects. A joint
inspection shall be conducted with commissioning personnel and the contractor to ensure the
contractor’s readiness to start the project after written confirmation is received from Project
Management.
• Equipment is installed and has been inspected and satisfied by the SEC Project
Quality section.
• Availability of contractor’s qualified manpower and testing engineers.
• Availability of tools and test equipment with one-year valid calibration certificate.
• Insulation Resistance test and pre check of all wiring.
• Stable power supply for testing
• The site is safe for testing.
• Approved relay settings and drawings.
• Site office as per SEC requirements.
• Over-all approved schedule along with approved outages.
• Substation HVAC system is in service; required for protection/control testing.
The contractor, Project Engineer and commissioning personnel shall visit the substation
jointly two weeks prior to the start of the pre commissioning testing and the following
points shall be confirmed.
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PART I: ORGANIZATION OF THE WORK T-PreCom-1000-R0
After confirmation of all the items of Section 2.1.2, witnessing can begin after two weeks.
Sometimes differences have been noted in the S.I.s issued by different engineers on a particular
point. Therefore guidelines are required for issuing S.I.s. This document briefly describes the
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PART I: ORGANIZATION OF THE WORK T-PreCom-1000-R0
Any items contrary to SEC Standards, SOW, workmanship and safety will be reflected in the
deficiency section of the Register File, see Attachment No. 1. The Register File has two sections,
one section belongs to the activities (Attachment No. 2) along with the single line diagram to help
an engineer to visualize the project and the other section for the deficiencies. After one week
from the registration of a deficiency in the book, all outstanding items will be sent to the Project
Engineer via Site Instructions/Records (Attachment No. 3). Bi-weekly, the status of the punch list
has to be issued by the contractor on the SEC format, Attachment No. 4. One month prior to the
scheduled energizing of the equipment, the categorized deficiency list shall be issued by the
commissioning personnel to identify the items which must be corrected prior to energization
(Attachment No. 5).
ATTACHMENTS TABLE
ATTACHMENT
DESCRIPTION REMARKS
NO.
1. Register The Commissioning engineer/technician shall record all the
Book/Deficiency items contravening safety, SEC Standards, Scope of Work and
Record workmanship on the Deficiency Record.
2. Register Book/Activity The Commissioning engineer/technician is responsible to daily
Record update site activities to help any engineer to familiarize him
with the status of the project.
3. Site Instructions After one week from recording in the Deficiency Record,
incomplete items will conveyed to the Project Engineer via the
Site Instructions Form.
4. Status of the Punch Bi-weekly the status of the punch list shall be updated by the
List contractor.
5. Categorization of the One month prior to energizing the equipment, the categorized
Punch List deficiency list shall be issued by the commissioning personnel
to identify the items to be done before energization.
6. Pre-Commissioning The commissioning engineer/technician shall fill in this sheet on
Time Utilization a daily basis.
Statistic Sheet
7. Final Pre- The Commissioning engineer/technician shall issue a final Pre-
Commissioning Report commissioning Report at the end of the project.
8. Sample Check In order to reduce the pre-Commissioning time the “sample
(Optional check” procedure may be exercised based on the contractor’s
Agreement) previous performance and the last time utilizations status
sheet. This shall be based on agreement between the
contractor and SEC Transmission.
9. Check List The check list is intended to provide information to the
commissioning engineer/technician who are assigned to
inspect the contractor’s work and witness commissioning
testing on behalf of SEC.
10. Contractor’s The commissioning engineer/technician shall fill this form at the
Performance Report end of the project to evaluate the performance of the
contractor.
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The contents of the S.I. can be categorized under various headings as noted below. The common
Snags/Punch list mentioned will be issued once in one S.I. for the whole substation and repetition of the
same for different bays shall be avoided.
This consists of the following deficiencies relating to protection, metering and control equipment.
• Missing equipment.
• Physical damage to the equipment.
• Rating is not matching with relevant specifications.
• Equipment with internal fault causing incorrect test results.
• The equipment is not on the SEC Approved Manufacturer’s List.
• Protection or a part of it is not in line with SEC relevant Specifications and/or Protection
requirements.
• Work has not been executed in line with general requirements or has not had approval
during the design stage.
• Design comments have not been implemented for the protection scheme and other
equipment.
• Segregation of protection CT and VT cables is not maintained and color coded cables are
not used.
• Poor ferrule printing quality which will fade over time.
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The following Punch list/ snags are found repeatedly in substation construction. Most of them are
clearly mentioned in the SEC Specifications/General Requirements. Irrespective of this fact, they
are usually repeatedly discovered. When these types of points are raised at site, the contractor
generally tries to avoid implementation. Every effort should be made to have the contractor
promptly correct the inadequacies. Some examples are listed as follows:
• Color-coded cables shall be used for control and/or alarm functions and black ones shall
be used for CT, PT or AC circuits.
• Quality of printing and the placement of ferrules is poor in many cases.
• While terminating cables, the contractor does not leave any margin inside/outside the
panel for re-terminating the cables in another location in the same panel, in case it is
required.
• While laying cables, segregation is not maintained section-wise, so that in case of fire in
one section the other sections will also be affected.
• Paralleling of alarms is done with software, whereas it is necessary to do this with help of
wiring for system reliability.
• Equipment lists do not correlate with the installed equipment and details such as ordering
number and the numbers of NO/NC contacts, etc., are not correct.
• More than one earth point has been made for the CT’s feeding the unit protection, e.g.,
Restricted Earth fault, Differential, Breaker Failure and Bus bar protection.
• From the maintenance point of view the access to relay terminal blocks is very important;
some contractors do not pay enough attention to this.
• Positive (+), Negative (-) and trip marked in red are not provided on the relevant wires.
• Contractors do not allocate fault recorder channels as per SEC specifications.
• Site modifications are not properly reflected in the drawings.
• CT shorting and isolating arrangement is not in line with SEC standard arrangements
including shorting/isolating, instruction and caution notices.
• Lack of proper labeling to the protection and control equipment in different location, e.g.,
relay panels, control panels, LCC and AVC panels, AC/DC distribution boards, power
transformer marshalling kiosks, CB isolators and earth switches, etc. This equipment
includes main relays, auxiliary relays, contactors, trip relays, MCB’s terminal blocks,
points on the test switch (MMLG or ABB type), trip links and other links used for other
specific functions.
• CT and VT protection cables are not segregated.
• Terminal block wiring is too low for convenient access, especially CT shorting and
isolating switches. These shall be at working height level.
• Crimping of terminal lugs is not done properly, particularly for CT and VT wires.
• Length of the metallic part of CT and VT lugs is not enough to provide proper grip when
they are tightened in the terminal blocks.
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It is very important to clear the Punch List/Snag items as soon as possible after confirming their
implementation. Sometimes it is very difficult to confirm their implementation once the substation
is energized, if they are not cleared during the pre-commissioning stage. It is very useful that the
witnessing engineer/technician keeps the site instruction records updated by putting his signature
with date without any delay after inspecting and approving the relevant snag.
The following sections listed below elaborate the techniques to ensure that all equipment tests are done
with optimal use of the time available.
The Check List is intended to provide information to commissioning personnel who are assigned
to inspect the contractor’s work and witness commissioning testing on behalf of SEC to verify that
substation and transmission line equipment and system are acceptable as per SEC- Standards
and Specifications. The listing of commissioning checks and tests are based on the SEC-
Commissioning Procedure T-PreCom-1000-01.
A time utilization statistics sheet is being included in this Procedure. This sheet must be filled in
daily. The contents of this sheet will be used for planning future projects by using the total time
consumed. Moreover this sheet will also allow corrective measures to be taken to reduce the pre-
commissioning time. The number of hours lost should be filled correctly, see Attachment No. 6.
In order to start witnessing after two weeks from confirmation, the contractor shall submit to SEC
the testing schedule, giving details for each test of the time and the commissioning personnel
required. Every week, the contractor shall submit a three-week testing program giving details of the
previous week’s completed jobs and the current and following week’s proposed jobs. If in the
previous week, some job was not completed, a reason for the deferral and its effect on the overall
schedule should also be mentioned.
The contractor is responsible to provide enough qualified manpower to prepare three sets of marked-
up drawings during the pre-commissioning testing period in order to expeditiously finalize the as-built
drawings without using the substation marked-up drawing. The three copies of the marked up
drawing shall be distributed as the following:
In order to reduce the pre-Commissioning time, “sample checks” could be exercised based on the
following criteria, see Attachment No. 8.
• If the overall rating of the contractor performance in his immediately previous contract
was GOOD.
• If the hours lost due to the contractor is less than 5% of the work, for the last time
utilization statistic sheet.
Project completion depends on the pre commissioning report, which has to be issued by the
commissioning engineer/technician (Attachment No. 7). In case of separate contractors working on the
same substation (lines and substation), the line-commissioning engineer/technician shall provide a copy
of the final reports to the substation-commissioning engineer/technician and vise versa. Each
commissioning engineer/technician shall evaluate the contractor at the end of the project, see Attachment
No. 10.
The commissioning engineer/technician shall issue the Report based on but not limited to the
following.
• The status of the Punch List (A, B) for which “A” refers to any deficiency requiring an
outage to clear it or equipment damage or a safety requirements. “B” is any deficiency
other than “A”.
• Marked up drawing are available at site in good condition.
• Emergency contact list provided.
• Operation spare parts are available.
• Operation and Maintenance Manuals are available.
• Test results provided.
The commissioning engineer/technician shall use SEC format to evaluate the contractor using the
following criteria:
The following steps need to be given special consideration, for implementation of this procedure:
1.0 INTRODUCTION
This Procedure describes the tests and checks to be performed during the pre-commissioning stage of
SEC Transmission projects. It deals primarily with the pre-commissioning tests to be followed for
protection schemes and main equipment such as cables, transformers and switchgear, etc., keeping in
view the SEC standard practices for various types of tests. Further, this listing of tests and checks is
based on the requirements and recommendations of international standards such as IEC, ANSI, etc.
They are the minimum tests and checks to be performed during pre-commissioning.
2.0 PURPOSE
The main purpose of this Procedure is to present a list of checks and tests to be performed on
transmission equipment. They shall be performed by the project contractor and witnessed by SEC
Precommissioning personnel.
3.0 PROCEDURE
AC HV tests on main circuit of GIS are performed with all CB’s and disconnect switches in the closed
position at 80% of the factory routine test voltage for one minute. Partial discharge measurements (If
applicable and possible to be performed) are performed at 1.2 X Un (Un = phase to neutral voltage).
Check and confirm following points and condition to be met before high voltage tests.
i. The Switchgear shall be erected completely and filled with gas at rated pressure.
ii. Some part may be disconnected before test, such as:
High Voltage cables and overhead lines.
Power transformer and most voltage transformers.
Surge arrestors and protective spark gaps.
Current transformer secondary windings should be shorted and grounded.
iii. Every newly erected part of GIS shall be tested with high voltage.
iv. The test should be performed at rated frequency (60 Hz.). If such arrangement is not
possible, then the frequency should be limited to the range of 30 to 300 Hz.
v. AC voltage tests are sensitive in detecting contamination and abnormal field
configuration.
vi. Tests with switching impulse voltages are useful especially for high rated voltage to
detect the presence of contamination as well as abnormal field configuration
Contractor can adopt one of the two procedures A or B to perform high voltage test on GIS after erection
at site
i. Procedure A
Site AC test voltage level shall be equal to the 80% of the factory routine test voltage.
This test may be performed through series resonance method
Or by a test transformer with sufficient capacity. PD measurements are possible to be measured
in this case at test voltage level = 1.2 Un (Un = phase to neutral rated voltage) during the
HV Test process.
Electrical conditioning at voltage equal to U/√3 for longer period such as 30 minutes may be
performed to move and trap the contamination in areas where they become harmless.
Partial discharge measurements may be helpful in detecting some kind of faults.
Site AC test voltage level equal to 1.2 Un for 5 minutes followed by Impulse Voltage test
at a test level equal to 64% of the rated lightening impulse withstand level specified in
IEC-517. Three positive and three negative polarity impulses shall be applied.
Sometime in extension projects due to practical and technical reason of joining new and old GIS together,
the test may be performed at reduced voltage level for an extended duration subject to agreement
between SEC and supplier.
V. Assessment of Tests
i. Test is considered passed if no disruptive discharge occurs during the test period.
ii. If disruptive discharge occurs in solid insulation, the compartment should be opened and
repaired. After fault repair, again, test with full site test voltage.
iii. If disruptive discharge occurs in gas, the test may be repeated and if discharge again
takes place, then compartment should be opened to clean out the compartment.
iv. If the discharge occurs and second time it disappears, it should be considered acceptable
after repeating one test more at full site test voltage mentioned in Table 1.
Test may be repeated several times to listen and locate the location of fault point subject to the
agreement between SEC and Contractor.
Table-1 on the next page describes the exact test voltage levels, time and kind of tests to be applied after
erection of GIS at site.
i. For 132 kV GIS the test voltage shall be 220 kV AC 60 Hz for one minute as per
Procedure A clause 7.107.1.5 of IEC 517- 1990
ii. For 380 kV GIS and GIBs shall be 416 kV AC 60 Hz for one minute as per procedure A
clause 7.107.1.5 of IEC 517-1990.
iii. In case of procedure B as per clause 7.107.1.5 of IEC 517-1990 the test voltage for 132
kV rated GIS shall be 84 kV AC for 5 minutes and followed by 416 kV Impulses of three
positive and three negative polarities.
iv. In case of procedure B to be applied for high voltage tests on 132 kV GIS special VT
should be used as Test voltage source. GIS VTs shall not be used as HV test voltage
source.
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Table 1. Test Voltage Levels for Metal-Enclosed Gas Filled Switchgear (GIS)
System Rated
Impulse level
Conditioning
REMARKS
Switching.
Discharge
Electrical
Impulses
Swing or
Measure
AC Test
AC Test
Time Of
Voltage
Voltage
Voltage
Voltage
Method
Of Test
No. Of
Partial
Freq.
No.
KV
kV
Leakage
10 kV for 10 current
A 13.8 30 60 Hz 1 min. - - -
min. < 1000
mA
Leakage
22 kV for 15 current
A 33 56 60 Hz 1 min. - - -
min. < 0.86
mA
Electrical
60 Hz. At 48 kV conditioni
44 kV for 30 ng is a
A 69 128 or 10- 1 min. - - less than
min. cleaning
300 Hz. 10 pC process
only.
3
positive
B 69 - 44 60 Hz. 5 min. 248 kV
3
negative
Electrical
60 Hz. At 92 kV conditioni
84 kV for 30 ng is a
A 110 220 or 10- 1 min. - - less than
min. cleaning
300 Hz. 10 pC process
only.
3
positive
B 110 - 84 60 Hz. 5 min. 416 kV
3
negative
Electrical
60 Hz. At 92 kV conditioni
84 kV for 30 ng is a
A 115 220 or 10- 1 min. - - less than
min. cleaning
300 Hz. 10 pC process
only.
3
positive
B 115 - 84 60 Hz. 5 min. 416 kV
3
negative
Electrical
60 Hz. At 92 kV conditioni
84 kV for 30 ng is a
A 132 220 or 10- 1 min. - - less than
min. cleaning
300 Hz. 10 pC process
only.
3
positive
B 132 - 84 60 Hz. 5 min. 416 kV
3
negative
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ii. For vacuum breakers, test across open contact and live parts to ground. Precautions
shall be taken against emission of X-rays.
iii. For all other breakers. Test in conjunction with breaker racked in the switchgear and in
the closed position.
• New switchgear should be tested as a whole unit with all circuit breakers in the closed position
and not connected to cables.
• All back shutters must be closed.
• Gas circuit breaker interrupters should be checked to be within limits of correct pressure.
• VTs, cables or any other voltage indication should be disconnected and VTs secondary side
fuses should be removed.
• VTs, cables or any other voltage indication should be in out position and VTS secondary side
fuses should be taken out.
• CTs secondary terminals should be short-circuited and earthed.
• Test voltage should be applied on each phase to ground with other phases in earthed position.
The test should be repeated on other phases similarly.
• The test period should not be more than one minute at full test level and the test voltage
frequency should be kept at 60 Hz.
• Charging current for each test is noted and recorded.
• HV Test is considered successful if no breakdown occurs during test period.
• HV Test levels and time for pre-commissioning testing of switchgear are given in Table 2.
Voltage shall be applied on each phase with all other phases and then frame grounded.
• Tests shall be performed with the CB in both the closed and open position
• In the open position, the cable contacts are to be grounded.
• Test voltage levels are given in Table 2 below.
• After the high voltage test on main circuit is finished, rack the voltage transformers in service
position and apply a test voltage on the primary side equal to 1.5Un (Un = phase to neutral rated
voltage) on each phase consecutively and measure the secondary output voltage same time
during the test.
• Make sure the VTs secondary side MCBs are switched off and any resistor in open delta winding
should have been removed.
• Compare the observed ratio with actual ratio.
• The HV Test should be repeated with circuit breakers in open position keeping cable spouts in
earthed condition in all panels.
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11 kV 25 kV 60 Hz 60 Sec
13.8 kV 30 kV 60 Hz 60 Sec
3.26 LV Cables
(Standard Reference is IEC 60227-2 and relevant SEC Transmission Specifications)
REFERENCES
Test Voltage levels for LV Cables, Control Cable and Pilot Cables
Cable testing requires at least two personnel with a means of communication between
the cable/wiring ends. Spare cores shall be clearly identified and of sufficient length to be
terminated at the farthest terminal in the panel.
CAUTION: Before conducting any external wiring or cable tests, ensure that all sources
of supply to the circuits involved have been de-energized or disconnected.
3.30.6 Energization
Witnessing of civil work is the responsibility of the CTA/DTA Support Facility Project Division to
witness the work of the civil contractor. Transmission witnessing personnel shall check the
accesses and ventilation that affects the main equipment.
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The reliability of air-conditioning is very important for the SVC controller, so this part of the equipment
should be tested thoroughly. For details of its pre-commissioning please refer to Section 3.38, HVAC
Systems.
The reliability of fire detection and suppression systems is very important for the SVC System, like any
other substation component. This equipment should be thoroughly tested. For details of its pre-
commissioning please refer to Section 3.40, Fire Detection and Suppression Systems
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Mechanical Check & Visual Inspection and Electrical Test T-PreCom-1000-R0
Page Number:
Page 101 of 124
The following is an example of a Test Record Form submitted by the contractor for the Substation
9009 SVC pre-energization checks:
1. General
2. Pre-Energization Checklist
With bus bar energized voltage response to VAR Control was checked.
For each phase it was checked that the signals were as below: ----------------------- □
6. Energization of TCR
-------------------------------------------------------------------------------------------------------------
Voltage Current
Sec
Prim
Voltage Current
Sec
Prim
Max inductive is: ___________ MVAR Max capacitive is: ______________ MVAR
Time
Time
Test with Max load on cooling system, SVC operated at __________ MVAR.
Time
Increase and decrease ramp of control signals for all phases checked: ------------------- □
_____________ ______________
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Measurement of load-sharing:
_____________ ________________
Current limit
ILIMGAIN: ____________
Parameters corresponds to _______ A primary TCR current and __________ sec time constant
Prim. Values Bus Voltage (kV) Delta Current (A) Impedance (Ω)
Q-tot Ph. a-b b-c c-a a-b b-c c-a a-b b-c c-a
Prim. Values Bus Voltage (kV) Delta Current (A) Impedance (Ω)
Q-tot Ph. a-b b-c c-a a-b b-c c-a a-b b-c c-a
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Parameter
Switch-
U (kV) I (A) B (mS) B (p. u.)
Point
Name Value
Parameter
Switch-
U (kV) I (A) B (ms) B (p. u.)
Point
Name Name
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____________ _____________
____________ _____________
____________ _____________
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Switching from MAN to AUTO and from AUTO to MAN works correctly
SLOPE: ____________
Measurement of slope:
MLOSST: ____________
It was checked that the SVC operates correct during the following change-overs to redundant functions.
Checked
___________________________: ------------------- □
________________________: --------------------- □
___________________________: ------------------
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COMMISSIONING TIME REDUCTION AGREEMENT T-PreCom-1000-R0
1. Site Conditions
All the tools and equipment with valid calibration certificate shall be available at site.
3. Documents
The following documents shall be available at site before start of SEC witnessing:
a. Approved drawings bearing very clear name and signature of the approving authority with
approval stamp on each sheet along with complete approval correspondence.
b. The manuals giving detailed test procedure of each equipment, technical data of all
electrical equipment, factory test records of all equipment, cable schedules, equipment
interconnection wiring schedule and wiring tables/diagrams.
c. SEC approved test procedure and test formats carrying approval stamp with name and
signature of the approving authority.
d. The project specifications and protection requirements.
e. List of deviations from SEC specs and SEC approval letters for the same.
4. Relay Settings
a. The contractor shall submit his proposed relay settings for all settable relays one month
before starting of pre-commissioning witnessing.
b. SEC-Engineering Protection Division shall provide final approved settings before pre-
commissioning witnessing is started.
c. Pre-commissioning witnessing will not be started in the absence of approved relay
settings, in order to avoid re-setting.
d. Commissioning Program.
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COMMISSIONING TIME REDUCTION AGREEMENT T-PreCom-1000-R0
f. A three-week testing program based on the approved overall program shall be submitted
every Tuesday indicating the proposed activities for the following two weeks and this
program will indicate activities completed in the current week and the reasons for not
completing any planned activity and its impact on the overall program with proposed
remedial measures.
5. Pre-commissioning Procedures
Pre-commissioning of all equipment shall be carried out in line with SEC Pre-commissioning Procedure
and in line with this agreement.
The contractor shall demonstrate a sample test for each equipment mentioned under (I-V) according to
the approved test procedure in presence of SEC-Commissioning Personnel and record the results on the
approved test format. If the SEC Commissioning personnel are satisfied with test procedures and results,
the contractor can complete the tests of the remaining equipment under (I-V) accordingly without SEC
present.
I. Secondary injection of all the aux. Relays, MCBs, Timers and O/C or E/F relay.
II. CT’s magnetic curves.
III. AC/DC Distribution boards.
IV. All VTs.
V. The contractor shall prepare the detailed test procedure and format to perform the
functional tests.
The contractor shall carry out on his own 100% functional tests for all relay panels, control panels, LCCs,
AVC panels and transformer-marshalling kiosk etc. The tests shall ensure the following:
k. All DC functional checks and the test results for the same shall be tabulated in special
formats and this format shall include the following items:
a. The SEC witnessing personnel will select 20% of the equipment covered under I-IV and
the contractor will test all this equipment under SEC witnessing. SEC commissioning
personnel will sign only those test results which will be done under his presence.
b. SEC witnessing engineer/technician will do sample test by 20% of each type of panels
with minimum of 1 of each type. The contractor will carry out all the functional tests as
mentioned under V for these sample-selected panels under witnessing of SEC
commissioning personnel. SEC engineer will sign only those test results, which will be
done under his presence. SEC engineer has the right to witness complete bay in respect
of all panels, i.e., LCC, relay and control panels, etc.
a. Secondary injection of all main protection relays except O/C and E/F relays.
b. All indicating and recording meters.
c. All transducers.
d. Primary injection and stability and sensitivity test of all unit protections, i.e., BBP,
transformer differential and REF protection and underground cable protection, etc.
e. Final trip tests, closing tests, SCADA alarm tests. End to end tests, operation and
interlock checks and on-load tests, etc.
f. All tests relating to the fault recorder.
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COMMISSIONING TIME REDUCTION AGREEMENT T-PreCom-1000-R0
a. The test record formats will be duly signed by the contractor’s testing engineer and SEC
Commissioning personnel simultaneously at the completion of formats for any test. No
formats shall be left unsigned for signing next day for quite obvious reasons.
b. SEC Commissioning personnel shall clear the snags after confirming satisfactory
completion and such clearance shall not be deferred to a later date in any case.
11. The contractor will submit complete test record to SEC. This test record will include all the tests
conducted by the contractor on his own and all those tests conducted by him under SEC
witnessing.
12. This agreement can also be applied by the contractor to other substations under the same contract.
13. This agreement will be considered null and void at the end of Contract No. _________ and the
contractor will have to make a fresh agreement for any other contract/substation in the future.
For SEC
For Contractor
Names Signature Names Signature
PMD
CSD
Contract No.
Project Title.
Date:
S/S NAME/NUMBER
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PART I
Title: Index Number:
T-PreCom-1000-R0
FINAL PRE COMMISSINING REPORT
ATTACHMENT No. 7 Page Number:
Page 117 of 124
The following items have to be confirmed at the end of the pre commissioning tests:
Further Remarks:
Signature:
Name:
:اﻟﺘﻮﻗﻴﻊ
SIGNATURE:
NAME : :اﻻﺳﻢ
DATE : :اﻟﺘﺎریﺦ
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Title: Index Number:
SITE INSTRUCTION T-PreCom-1000-R0
ATTACHMENT No. 3 Page Number:
Page 119 of 124
Substation Circuit
Contract No رﻗﻢ اﻟﻤﺸﺮوع
Project Title اﺳﻢ اﻟﻤﺸﺮوع
Contractor Name اﺳﻢ اﻟﻤﻘﺎول
Attention Mr.. ﻟﻌﻨﻠﻴﺔ اﻟﺴﻴﺪ
Snag/ Confirmed By
S.I. Expected Time of
Punch Description of the Deficiency Issued Date Issued By Commissioning Remark
# Completion by
list No. Personnel
* To be filled by SEC Commissioning engineer/technician. Legend: CSD: Comm. Services Department PMD: Project Management SOD: System Operation
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PART I
Title: Index Number:
Categorization of Punch List T-PreCom-1000-R0
Type of
Snag/ Date to be
Deficiency Issued
S.I. # Punch Description of the Deficiency Issued By Completed by the Remarks
Date
list No. Contractor
“A” or ”B”
A. INTRODUCTION
The check list is intended to provide information to commissioning engineer/technician who are
assigned to inspect the contractor work and witness commissioning testing on behalf of SEC to verify
that substation and transmission line equipment and system are acceptable as per SEC- standard and
specifications. The listing of commissioning checks and tests are based on the SEC- Commissioning
standard.(attachment#9)
TABLE 1
SYSTEM DONE
RATED TEST
RATED
LOAD VOLTAGE FREQUENCY TIME PERIOD REMARKS
VOLTAGE
FACTOR (KV)
(KV)
11 1.5 9.5
13.8 1.5 12 These tests
33 1.5 28 are applicable
69 1.5 60 to
110 1.5 95 60 Hz I Minute electromagneti
115 1.5 99.5 c VT’s
132 1.5 114
230 1.5 199
380 1.5 329
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Page 18 of 96
AC HV tests on main circuit of GIS are performed with all CB’s and disconnect switches in the closed position
at 80% of the factory routine test voltage for one minute. Partial discharge measurements (If applicable and
possible to be performed) are performed at 1.2 X Un (Un = phase to neutral voltage).
Check and confirm following points and condition to be met before high voltage tests.
i. The Switchgear shall be erected completely and filled with gas at rated pressure.
ii. Some part may be disconnected before test, such as:
High Voltage cables and overhead lines.
Power transformer and most voltage transformers.
Surge arrestors and protective spark gaps.
Current transformer secondary windings should be shorted and grounded.
iii. Every newly erected part of GIS shall be tested with high voltage.
iv. The test should be performed at rated frequency (60 Hz.). If such arrangement is not
possible, then the frequency should be limited to the range of 30 to 300 Hz.
v. AC voltage tests are sensitive in detecting contamination and abnormal field configuration.
vi. Tests with switching impulse voltages are useful especially for high rated voltage to detect the
presence of contamination as well as abnormal field configuration
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III. Two Test Procedures are Utilized to Test the GIS
Contractor can adopt one of the two procedures A or B to perform high voltage test on GIS after erection at
site
i. Procedure A
Site AC test voltage level shall be equal to the 80% of the factory routine test voltage.
This test may be performed through series resonance method
Or by a test transformer with sufficient capacity. PD measurements are possible to be measured in
this case at test voltage level = 1.2 Un (Un = phase to neutral rated voltage) during the HV
Test process.
Electrical conditioning at voltage equal to U/√3 for longer period such as 30 minutes may be
performed to move and trap the contamination in areas where they become harmless.
Partial discharge measurements may be helpful in detecting some kind of faults.
Site AC test voltage level equal to 1.2 Un for 5 minutes followed by Impulse Voltage test at a
test level equal to 64% of the rated lightening impulse withstand level specified in IEC-517.
Three positive and three negative polarity impulses shall be applied.
In case the GIS VTs are not suitable to be used as test transformer; a special voltage
transformer shall be used to perform such tests. GIS VT can only be used as a test
transformer if the manufacturer guarantees its safety and capability to perform such tests
otherwise it shall not be used as a test source.
Sometime in extension projects due to practical and technical reason of joining new and old GIS together, the
test may be performed at reduced voltage level for an extended duration subject to agreement between SEC
and supplier.
V. Assessment of Tests
i. Test is considered passed if no disruptive discharge occurs during the test period.
ii. If disruptive discharge occurs in solid insulation, the compartment should be opened and
repaired. After fault repair, again, test with full site test voltage.
iii. If disruptive discharge occurs in gas, the test may be repeated and if discharge again takes
place, then compartment should be opened to clean out the compartment.
iv. If the discharge occurs and second time it disappears, it should be considered acceptable
after repeating one test more at full site test voltage mentioned in Table 1.
Test may be repeated several times to listen and locate the location of fault point subject to the agreement
between SEC and Contractor.
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Table-1 on the next page describes the exact test voltage levels, time and kind of tests to be applied after
erection of GIS at site.
i. For 132 kV GIS the test voltage shall be 220 kV AC 60 Hz for one minute as per Procedure A
clause 7.107.1.5 of IEC 517- 1990
ii. For 380 kV GIS and GIBs shall be 416 kV AC 60 Hz for one minute as per procedure A
clause 7.107.1.5 of IEC 517-1990.
iii. In case of procedure B as per clause 7.107.1.5 of IEC 517-1990 the test voltage for 132 kV
rated GIS shall be 84 kV AC for 5 minutes and followed by 416 kV Impulses of three positive
and three negative polarities.
iv. In case of procedure B to be applied for high voltage tests on 132 kV GIS special VT should
be used as Test voltage source. GIS VTs shall not be used as HV test voltage source.
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Table 1. Test Voltage Levels for Metal-Enclosed Gas Filled Switchgear (GIS)
System Rated
Impulse level
Conditioning
REMARKS
Switching.
Discharge
Electrical
Impulses
Swing or
Measure
AC Test
AC Test
Time Of
Voltage
Voltage
Voltage
Voltage
Method
Of Test
No. Of
Partial
Freq.
No.
KV
kV
Leakage
10 kV for 10 current
A 13.8 30 60 Hz 1 min. - - -
min. < 1000
mA
Leakage
22 kV for 15 current
A 33 56 60 Hz 1 min. - - -
min. < 0.86
mA
Electrical
60 Hz. At 48 kV conditioni
44 kV for 30 ng is a
A 69 128 or 10- 1 min. - - less than
min. cleaning
300 Hz. 10 pC process
only.
3
positive
B 69 - 44 60 Hz. 5 min. 248 kV
3
negative
Electrical
60 Hz. At 92 kV conditioni
84 kV for 30 ng is a
A 110 220 or 10- 1 min. - - less than
min. cleaning
300 Hz. 10 pC process
only.
3
positive
B 110 - 84 60 Hz. 5 min. 416 kV
3
negative
Electrical
60 Hz. At 92 kV conditioni
84 kV for 30 ng is a
A 115 220 or 10- 1 min. - - less than cleaning
min.
300 Hz. 10 pC process
only.
3
positive
B 115 - 84 60 Hz. 5 min. 416 kV
3
negative
Electrical
60 Hz. At 92 kV conditioni
84 kV for 30 ng is a
A 132 220 or 10- 1 min. - - less than
min. cleaning
300 Hz. 10 pC process
only.
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3
positive
B 132 - 84 60 Hz. 5 min. 416 kV
3
negative
10-300
142 kV
Hz.
A 230 for 30 316 1 min. - - -
Better
min.
60 Hz.
10-300 3
Hz. positive
B 230 - 142 5 min. 608 kV
Better at 3
60 Hz. negative
Impulse
PD or HF test is
10-300 3
detection applied
245 kV Hz. positive
A 380 416 1 min. 840 kV techniques in
for 30 min. Better at 3
to be special
60 Hz. negative
applied cases
only
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ii. For vacuum breakers, test across open contact and live parts to ground. Precautions shall be
taken against emission of X-rays.
iii. For all other breakers. Test in conjunction with breaker racked in the switchgear and in the
closed position.
• New switchgear should be tested as a whole unit with all circuit breakers in the closed position and
not connected to cables.
• All back shutters must be closed.
• Gas circuit breaker interrupters should be checked to be within limits of correct pressure.
• VTs, cables or any other voltage indication should be disconnected and VTs secondary side fuses
should be removed.
• VTs, cables or any other voltage indication should be in out position and VTS secondary side fuses
should be taken out.
• CTs secondary terminals should be short-circuited and earthed.
• Test voltage should be applied on each phase to ground with other phases in earthed position. The
test should be repeated on other phases similarly.
• The test period should not be more than one minute at full test level and the test voltage frequency
should be kept at 60 Hz.
• Charging current for each test is noted and recorded.
• HV Test is considered successful if no breakdown occurs during test period.
• HV Test levels and time for pre-commissioning testing of switchgear are given in Table 2.
• Voltage shall be applied on each phase with all other phases and then frame grounded.
• Tests shall be performed with the CB in both the closed and open position
• In the open position, the cable contacts are to be grounded.
• Test voltage levels are given in Table 2 below.
• After the high voltage test on main circuit is finished, rack the voltage transformers in service
position and apply a test voltage on the primary side equal to 1.5Un (Un = phase to neutral rated
voltage) on each phase consecutively and measure the secondary output voltage same time during
the test.
• Make sure the VTs secondary side MCBs are switched off and any resistor in open delta winding
should have been removed.
• Compare the observed ratio with actual ratio.
• The HV Test should be repeated with circuit breakers in open position keeping cable spouts in
earthed condition in all panels.
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11 kV 25 kV 60 Hz 60 Sec
13.8 kV 30 kV 60 Hz 60 Sec
26.0 LV Cables
(Standard Reference is IEC 60227-2 and relevant SEC Transmission Specifications)
REFERENCES
Test Voltage levels for LV Cables, Control Cable and Pilot Cables
Cable testing requires at least two personnel with a means of communication between the
cable/wiring ends. Spare cores shall be clearly identified and of sufficient length to be
terminated at the farthest terminal in the panel.
CAUTION: Before conducting any external wiring or cable tests, ensure that all sources of
supply to the circuits involved have been de-energized or disconnected.
DONE
ITEM DESCRIPTION REMARKS
1. Check rating of all motors, magnetic contactors, relays and
accessories is 220 V, 3-phase, 60 Hz.
2. Check all wiring is in rigid steel conduit, is standard type THW
and color coded.
3. Check that the size of all wires and circuit breakers are suitable
for requirement of the system.
4. Check that all wires splices are made with wire connectors of
approval type or soldered and insulated with two layers of
rubber and friction tape.
5. Check interlock to stop the compressor when:
a. Condenser blower motor fails.
b. Air handling unit (AHU) blower motor fails.
c. Suction and discharge operating pressure
exceeds predetermined level.
d. Overload operation of compressor.
e. Low and high voltage in the power supply.
f. Single phase of power supply.
g. Compressor lubrication fails.
h. When desired room temperature required is
attained.
6. Contractor shall perform the following tests prior to start
commissioning of the system:
a. Preliminary test.
b. Pressure test.
c. Leak test.
d. Control test.
e. Operation test.
7. Measure compressor continuous line current and power supply
voltage. Note compressor’s discharge and suction pressure
(PSIG).
8. Check indoor fan and heater current.
9. Functional check of the system.
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Loss Prevention Department is responsible for fire detection and suppression systems, but
transmission witnessing personnel shall check the alarms and trip signals (if applicable) which affect
the main equipment such as power transformer, GIS, etc.
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Bay No:……………………… Page Number:
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Witnessing of civil work is the responsibility of the Civil Department to witness the work of the civil
contractor. Transmission witnessing personnel shall check the accesses and ventilation that affects
the main equipment.
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Bay No:……………………… Page Number:
Page 87 of 96
The reliability of air-conditioning is very important for the SVC controller, so this part of the equipment should
be tested thoroughly. For details of its pre-commissioning please refer to Section 3.38, HVAC Systems.
The reliability of fire detection and suppression systems is very important for the SVC System, like any other
substation component. This equipment should be thoroughly tested. For details of its pre-commissioning
please refer to Section 3.40, Fire Detection and Suppression Systems