Professional Documents
Culture Documents
Dokumen - Tips - Testing Commissioning Manual Sec
Dokumen - Tips - Testing Commissioning Manual Sec
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
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.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
PART I: ORGANIZATION OF THE WORK
Page Number:
AT SITE FOR PRE-COMMISSIONING
Page 2 of 124
1.0 INTRODUCTION
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.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
PART I: ORGANIZATION OF THE WORK
Page Number:
AT SITE FOR PRE-COMMISSIONING
Page 3 of 124
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
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
PART I: ORGANIZATION OF THE WORK
Page Number:
AT SITE FOR PRE-COMMISSIONING
Page 4 of 124
guidelines to be followed by all Commissioning personnel to issue S.I.s in order to achieve
uniformity and consistency. It should be kept in mind that this is a guideline only and it will not
supercede any SEC relevant Specification in any manner.
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.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
PART I: ORGANIZATION OF THE WORK
Page Number:
AT SITE FOR PRE-COMMISSIONING
Page 5 of 124
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.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
PART I: ORGANIZATION OF THE WORK
Page Number:
AT SITE FOR PRE-COMMISSIONING
Page 6 of 124
• Cables are directly terminated on terminal blocks without providing adequate clearances
for access during troubleshooting or maintenance.
• Equipment or terminals are not sufficiently accessible to allow maintenance.
• Ferruling method does not meet relevant specifications.
• Apparatus is not properly labeled.
• Wiring has either wrong ferrules or no ferrules.
• Improper use of terminal lugs.
• Control cables do not carry proper number tags.
• Proper wiring dressing has not been done in panels.
• Labels with incorrect spelling, uneven engraved letters, improperly aligned, letters too
small, badly cut edges, etc.
• Alarm annunciator labels/text with letters too small to read from a distance, and
acknowledge/reset/test push buttons at difficult to reach locations.
• Congested wiring obstructs other terminals on a terminal block.
• Very loose plug/socket arrangement. These should always be locking type.
• Improper locking of panel doors has caused frequent breaking of the panel door locking
mechanism.
• Adequate illumination does not reach all working places, terminals, in the panel, in front
of relays, etc.
• Terminals, auxiliary relays, flag relays mounted at very low level or very high level.
• Wiring not supported properly causing undue termination tension, which may result
eventually slipping of wire/breaking off from crimp.
• Bad crimping of wires. For CT circuit this is most dangerous as this may lead to open
circuiting of energized circuits. Open circuited energized CT circuits may cause fires and
serious electrical hazards.
• Inadequately rated relays used for continuously energized relays in fail safe, scheme, etc.
A protection scheme may not operate properly in spite of implementation of the relevant
specification. Examples are listed as follows:
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
PART I: ORGANIZATION OF THE WORK
Page Number:
AT SITE FOR PRE-COMMISSIONING
Page 7 of 124
• Rating, contact arrangement and ordering number is incomplete.
• Cross-references are missing or incorrect.
• Correct catalogues have not been provided.
• Testing procedures are not available for some relays.
• Three copies of drawings are required to be updated for modifications and corrections,
using red for addition and green for deletion. This has not been done correctly.
• Proper test record forms are not available to record the test results.
• Some drawing sheets missing.
• Factory test results not available at site.
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.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
PART I: ORGANIZATION OF THE WORK
Page Number:
AT SITE FOR PRE-COMMISSIONING
Page 8 of 124
• Plug in type miniature relays are used in tripping and interlock circuits. After a period of
time, these relays do not function properly, due to displacement from their original
position.
• Normal earth switch was used on the line instead of high-speed type.
• In one substation, the backup main protection was found not working when the DC
supply to the first main protection was switched off since the isolator image was
controlled by the first main DC supply.
• Power cables for the fans from the AC distribution board to the transformer marshalling
kiosk were found underrated.
• Protection coordination of MCB’s installed in the DC distribution board was not
maintained, so the contacts of an ON/OFF switch were burnt due to a short circuit in the
DC wiring.
• During on-load checks 12 volts were observed across the CT terminals of feeder cable
protection.
• The manual mode status of the Halon was found not annunciated.
• As per SEC specifications it is necessary to install an independent synchrocheck relay for
manual and auto re-closing for each CB rated 110 kV and above.
• The bus-bar protection trip logic for double bus-bar substations does not conform with
SEC specifications.
• The annunciator output contacts did not follow the initiation when the input was reset as
per SEC specifications.
• Remote end breakers also trip in case the HV E/F relay of transformer operates. It
should only trip the local breaker.
• The A/R did not close the breaker when the D.E.F. tripped the breaker. It was due to the
tripping of the breaker in advance before the initiation of the A/R.)
• The phases R and B were found interchanged for the reactors.
• Two phases of earth switch were on one side of the CT’s whereas the third one was on
the other side of CT’s.
• CT polarity if it was left reversed on one of the spare feeders and the loading of the spare
feeder led to operation of BBP.
• The anti pumping circuit is not operational for CBs. This deficiency will lead to re-closing
of the CB on to fault when a long duration closing pulse is initiated.
• The pilot wire protection 87PW is commissioned with reverse pilot; this will lead to
indiscriminate tripping.
• The DEF relay for one circuit is commissioned with wrong direction this will lead to
indiscriminate tripping of the circuit.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
PART I: ORGANIZATION OF THE WORK
Page Number:
AT SITE FOR PRE-COMMISSIONING
Page 9 of 124
• Labeling of relays, pressure relief devices, oil temperature gauges and winding
temperature gauges, etc.
• Blocking of spare plugs.
• Avoiding use of plug in connections and plug-in type auxiliary relays.
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:
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
PART I: ORGANIZATION OF THE WORK
Page Number:
AT SITE FOR PRE-COMMISSIONING
Page 10 of 124
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:
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
PART I: ORGANIZATION OF THE WORK
Page Number:
AT SITE FOR PRE-COMMISSIONING
Page 11 of 124
7.0 IMPLEMENTATION
The following steps need to be given special consideration, for implementation of this procedure:
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 12 of 124
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
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 13 of 124
3.35 LVAC Auto-Transfer Schemes/Switches
3.36 Grounding Systems
3.37 Switchgear Air Compressor System s
3.38 HVAC Systems
3.39 Dry Transformer s
3.40 Fire Detection and Suppression System s
4.41 Civil Work
4.42 Static VAR Compensation Syst ems
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 14 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 15 of 124
are accessible from ground level.
22. Check oil level in main tank, conservator, tap changer tank and
bushings, etc. Test the oil level gauges and their alarms.
23. Bleed trapped air at the bushing turrets and radiators.
24. Check flow of oil in flow meter in correct direction and proper
rate (if applicable).
26. Check all external wiring for correctness and tightness.
27. Check on-line insulating oil dissolved gas and moisture
monitoring system (if installed).
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 16 of 124
master.
h. Parallel Operation Disturbed–check alarm.
i. Check that the windings are not open circuited during
tap changing. This should be done during the winding
resistance test.
16. Bushing Current Transformer Tests:
a. Polarity.
b. Insulation Resistance.
c. Secondary Winding Resistance (all windings and all
taps).
d. Current Ratio (inject current)
e. Magnetization Characteristics (minimum five points
below and two points above the knee point).
f. Verify secondary circuits, terminal to terminal.
g. Burden Test.
Demagnetize CT cores after all tests. Ensure no open circuit on
CT secondary side.
17 Functional Checks for the Following:
a. Liquid level (alarm and trip).
b. Top Oil Temperature Device: fans/pumps (stop, start
alarm and trip).
c. Winding Temperature Device.
d. Buchholz Relay (alarm and trip).
e. Oil / Gas Surge (pressure) relay (alarm and trip).
f. Pressure Relief Device (alarm and trip)
18. Insulating Oil Tests:
Prior to energization, the contractor shall submit insulating oil
test reports tested at an independent laboratory, for the
following:
a. Dielectric Strength
i. ASTM D 877 (2.5 mm gap) for unprocessed oil
and for OLTC oil
ii. ASTM D 1816 (1.0 mm gap) for oil in main
tank
b. Neutralization Number (ASTM D 974)
c. Interfacial Tension (ASTM D 971)
d. Color (ASTM D 1500)
e. Moisture Content (ASTM D 1533)
f. Power Factor Test (ASTM D 924)
g. Dissolved Gas in Oil Analysis (ASTM D3 612)
h. (Dielectric Dissipation Factor, Resistivity, Sediment
and/or Precipitable Sludge).
Another oil sample shall be given to SEC transmission for their
own analysis and comparison purposes. A syringe oil sample
shall be taken by contractor.
19. A main tank insulation oil sample for dissolved gas analysis
shall be taken immediately prior to first energizing a power
transformer and another sample three days after continuous
energization.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 17 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 18 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 19 of 124
shall be taken by contractor.
12. Cooling system checks and measure for fan motors and pumps
(as applicable), etc., for current, supply voltage and air flow
direction.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 20 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 21 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 22 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 23 of 124
Another oil sample shall be given to SEC transmission for their
own analysis and comparison purposes. . A syringe oil sample
shall be taken by contractor.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 24 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 25 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 26 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 27 of 124
T ABLE 1
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 28 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 29 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 30 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 31 of 124
24. Ensure that all disconnect switches are provided with viewing
windows or mechanical indicators for verification of contact
positions and that all grounding switch positions can be visually
verified.
25. Verify that correct Dispatch Numbers have been installed.
27. Check the closed barriers at the ends of each gas zones are
externally colored yellow or orange. The zone gas density
gauges shall have a zone marking plates fixed over the gauges.
28. Check GIS over pressure relief discs are not cracked or
deformed.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 32 of 124
Disconnect and grounding switches.
17. Perform high voltage test at 10 kV AC for 1 minute on all
grounding switches’ external insulating bushings.
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 U n (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 U n (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.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 33 of 124
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.
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.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 34 of 124
Table 1. Test Voltage Levels for Metal-Enclosed Gas Filled Switchgear (GIS)
d l
e g . e
t l i
n t f t e r g v e e S
d a e a n s e t
. s e o i e f s l g r K
g c e g O s n l e a r u
o . R
h a V i o
r t
i a q e g
a
e g
a g h e O s
l
i
t a R
t o m t t l V
T t e
r T t
e T t n t . r h s A
e N e l
o K
c i k l l i c l
s o u a c a
t V e d
l n C o F f o m
i C o i
w w u p
N m s e
P i M
M A V O V T A V S S p E
s
y
E o I D M R
C m
I
S
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
conditioni
60 Hz. At 92 kV
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
conditioni
60 Hz. At 92 kV
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
conditioni
60 Hz. At 92 kV
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
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 35 of 124
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
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 36 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 37 of 124
28. Check that all special tools, devices, etc., as per specification
have been provided.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 38 of 124
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 1.5U n (U n = 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.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 39 of 124
11 kV 25 kV 60 Hz 60 Sec
13.8 kV 30 kV 60 Hz 60 Sec
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 40 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 41 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 42 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 43 of 124
without replenishment: 5X CO, or O + CO + 3min. +
CO
j. Air leakage test (pressure drop method over 24 hours,
CB closed and open).
14. For hydraulic operating mechanisms:
a. Check, the pump, piping, valves, gauges and switches
for damage/defects/blockage.
b. Bleed air from hydraulic system.
c. Calibrate the fluid pressure gauges.
d. Check the Nitrogen pre-charge pressure in
accumulators.
e. Check for correct hydraulic fluid level in the reservoir.
f. Check the setting of air pressure switches (pump
start/stop, alarm, lockout).
g. Perform all specific checks on the hydraulic system
according to the manufacturer’s instructions.
h. Check for oil leaks
i. Check pump-up time.
j. Check safety relief valve operating and resetting
pressure.
k. Measure pressure drop for C, O, CO and OCO
operations.
l. Stored energy test – perform O + CO + 3min + CO
without replenishment.
m. Oil leakage test (pressure drop method over 24 hours,
CB closed and open).
n. Check operation of the nitrogen low pressure switch.
15. Verify that correct Dispatch Numbers have been installed.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 44 of 124
16. For motor/spring operating mechanisms, measure spring
charge time and motor current.
17. For pneumatic or hydraulic mechanisms:
a. Measure compressor/pump motor starting and running
currents.
b. Verify electrically the low stored energy (fluid pressure)
alarm and lockout functions.
c. Functional check of the motor excessive running alarm
circuit.
18. Verify the electrical operation of the breaker racking truck.
Check the correct functioning of interlocks and limit switches.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 45 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 46 of 124
c. Check for correct hydraulic fluid level in the reservoir.
d. Check the setting of air pressure switches (pump
start/stop, alarm, lockout).
e. Perform all specific checks on the hydraulic system
according to the manufacturer’s instructions.
f. Check for oil leaks
g. Check pump-up time.
h. Check safety relief valve operating and resetting
pressure.
i. Measure pressure drop for C, O, CO and OCO
operations.
j. Stored energy test – perform O + CO + 3min + CO
without replenishment.
k. Oil leakage test (pressure drop method over 24 hours,
CB closed and open).
l. Check operation of the nitrogen low pressure switch.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 47 of 124
charge time and motor current.
18. For pneumatic or hydraulic mechanisms:
a. Measure compressor/pump motor starting and running
currents.
b. Ensure that all air is bled from the hydraulic system.
c. Verify electrically the low stored energy (fluid pressure)
alarm and lockout functions.
d. Functional check of the motor excessive running time
alarm circuit.
19. AC HV test (applicable to SF6 breakers, if the tank is opened at
site, e.g., to install bushings.
20. Bushing current transformer test (applicable to dead tank
breakers)
21. Insulation and bushing power factor tests.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 48 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 49 of 124
e. Minimum voltage operation (close and open) at
90 V DC.
f. Functional check of thermostat and space
heaters. Measure heater current.
g. Insulation test all control and power
wiring/cables at 500 V DC/
h. Check that in the manual mode, insertion of the
operating handle automatically disconnects the motor
DC supply.
5. For bus bar isolators, carefully check make and make before
brake contact function for auxiliary switch contacts used for CT
switching schemes during open close time test on disconnect
main contacts.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 50 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 51 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 52 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 53 of 124
12. Cable jacket test.
13. Cable profile test.
14. AC High voltage test. See table 2-1
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 54 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 55 of 124
4. SVL (surge voltage limiter)test by 2.5 kV DC insulation tester.
5. Anti corrosion sheath test.
6. Measure the ground resistance at all link box positions (less
than 10 Ω).
7. Zero and positive sequence impedance measurement.
8. Insulation resistance test for conductor.
9. Cross – bonding verification test. Sheath current <3%
10. Contact resistance test on link boxes. less than 20 µΩ
11. Oil pressure gauge function test.
12. Shield continuity test.
13. Cable Jacket test.
14. Cable profile test.
15. Insulation oil dielectric breakdown test and water content test.
16. AC High voltage test. See table 2-1
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 56 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 57 of 124
11. Cable Jacket test.
12. Cable profile test.
13. AC high voltage test. See table 2-1
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 58 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 59 of 124
4. Conductor insulation resistance test.
5. Cross – bonding verification test. Sheath Current < 3 %
6. Link box tightness check.
7. SVL (sheath voltage limiter) test with 2.5 kV DC insulation
tester.
8. Inspection of label inside link boxes and water proofing test.
9. Measure the ground resistance at all link box positions. less than 10 Ω
10. Contact resistance test on link boxes.
11. Oil pressure gauge function test.
12. Shield continuity test.
13. Cable Jacket test.
14. Cable profile test.
15. Insulation oil dielectric breakdown test and water content test.
16. AC high voltage test. See table 2-1
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 60 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 61 of 124
12. Cable Jacket test.
13. Cable profile test.
14. AC High voltage test. See table 2-1
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 62 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 63 of 124
3.26 LV Cables
(Standard Reference is IEC 60227-2 and relevant SEC Transmission Specifications)
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 64 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 65 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 66 of 124
REFERENCES
Test Voltage levels for LV Cables, Control Cable and Pilot Cables
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 67 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 68 of 124
20. Check that all jumpers are installed correctly. Ensure correct
clearances between jumper and structure as well as with other
phases.
21. Check that overhead shield wire/OGW(Optical Ground Wire)
and associated joint box are grounded to towers as specified.
22. Ensure that sags for phase and overhead ground conductors
are even and to specification.
23. Check that ground clearances meet company standards.
24. Check circuit/phase identification plates, structure numbers,
danger sign plate, etc., have been correctly installed at each
structure.
25. Check line/phase correctly transposed at the specified locations
(if applicable).
26. Check that washing platform and pumping system has been
installed as per specification (if applicable).
27. Check solar unit for tower lighting (if applicable).
28. For terminal compound, check the following, if available, as per
contract:
a. Outdoor equipment such as surge arresters, CVTs,
etc.
b. Equipment structure.
c. Foundation.
d. Bonding of equipment / structures.
e. Gravelling inside terminal compound.
f. Circuit identification.
g. Conductor dropper and connectors.
h. Fence and gate are complete and grounded.
29. Ensure that the site has been properly cleaned up and all
earthwork profiles are correct before acceptance.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 69 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 70 of 124
ground. Temporarily isolate the ground point on each
circuit individually and retest to confirm that each CT
and VT circuit is grounded at a single point.
h. Check the burden of each DC circuit with an ohmmeter
to confirm absence of short circuits.
i. Check auxiliary power supply polarity and magnitude at
the supply side of all circuit breakers/fuses to be
correct as per schematics and relay/meter ratings.
j. All wiring including CT, VT, AC, control, alarm and
earthing shall be confirmed terminal to terminal and
wire by wire using an ohmmeter.
k. Operate all switches and relay contacts confirming
connection terminal numbers and contact status using
an ohmmeter.
l. Confirmed wiring is to be highlighted in yellow on the
schematic diagram. Corrections/changes in the
schematics shall be marked up using red pencil for
additions and green for deletions.
m. For all MCBs, confirm ratings as per approved
drawings; operate several times by hand. Inject 150%
of rated current and record the timing for trip operation.
n. Confirm that each internal and external wire is properly
ferruled at termination points.
2. CT Circuit Confirmation
a. Inject AC current at about 50% of the rated current into
one phase to neutral of the current circuit at the
incoming CT cable connection using a suitable meter
and isolated current source (for each phase of each
current circuit).
b. At each current test facility, confirm current flow and
polarity in the subject phase and neutral as appropriate
and according to the approved schematics. Confirm
no current in the other two phases.
c. Withdraw each relay in the current circuit one at a time
and confirm that the case shorting facility is working
and that at no time during its withdraw is the current
circuit opened. Check test facility shorting and
isolating devices for proper operation.
d. Confirm current flow in the relay by opening the case
shorting manually and confirming the meter to read
zero.
e. Confirm that any phase selector switch for metering is
connected in the correct phase being tested. (for each
phase of each current circuit).
3. VT Circuit Confirmation
a. Connect a fused or current limited adjustable three
phase, four wire voltage source to the VT circuit and
slowly increase the voltage to the rated value.
b. Using a voltmeter and phase angle meter, confirm the
phase angle and magnitude at each terminal in the
voltage circuit according to the approved schematics.
c. Check total burden per phase to conform to expected
loading as per connected relay/metering specifications.
d. Confirm that any phase selector switch for metering is
connected in the correct phase being tested for each
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 71 of 124
phase of each current circuit.
4. DC Circuit Confirmation
a. Withdraw all removable relays and meters from the
panel.
b. Apply normal DC supply (insert fuses/close breaker) to
the circuit and use a DC voltmeter to confirm all direct
connections to the positive and negative supply
between the fuse/breaker and the device terminals are
made correctly. Confirm power supply at each
relay/meter case terminals is correct.
c. Disable the DC supply and reinstall the relays and
meters in the panel. Restore the DC supply.
d. Test the panel by operating (or simulating operation for
external devices) each switch/coil/contact separately
while monitoring correct circuit operation. Use a
voltmeter to confirm DC voltages at progressive
locations in the panel wiring. Proceed in such a way
as to confirm that each contact operates only the
intended devices in the panel. Confirm all contacts of
control switches/relays including spares.
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.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 72 of 124
testing.
CAUTION: When working with electronic devices, never
remove modules with the DC supply energized. Use
precautions to prevent static discharge damage to the modules.
Grounded wrist strap, anti-static work surface and electrically
conductive storage bags should be used.
a. Check condition of internal wiring and solder joints.
b. Case cover and gasket for proper seal against dust.
c. Condition of any connectors, contacts, alignment and
travel.
d. Operation of moving parts, mechanical target
operation and reset.
2. Relay Tests
Relay tests shall be conducted in accordance with the approved
site test procedure. Additional tests may be required as
recommended by the manufacturer, by Company Standard or
as deemed necessary by the Company from operational
experience.
a. 500 V insulation tests shall be conducted between the
AC circuits and from AC circuits to the relay frame. All
outputs/indications shall be tested.
b. For electromechanical relays, the DC circuits shall be
insulation tested to AC circuits and to the frame of the
relay.
c. Initial tests of new protective relays shall include
operating characteristics checks for a representative
range of available settings with Company approved
computer operated test equipment running routines
developed for the specific relay and test set involved.
d. Relay auxiliary devices such as external resistors,
metrosils, etc., to be tested to conform to required
ratings and manufacturer’s information.
e. Proper electrical operation of targets/indicators shall be
confirmed.
f. Final calibration test of all protective relays must be
carried out on approved settings with the relays
mounted in their cases, by secondary injection at the
front panel mounted test facilities.
g. Auxiliary and tripping relay testing shall include:
i. Insulation testing as above.
ii. Pickup and dropout voltage, verification of all
contacts.
iii. Operation timing at 80% and 100% nominal
voltage.
iv. Time delay relays shall be tested at 0%, set
point and 100% delay.
h. Use of red and green tags for tested relays, meters,
etc.
i. All the relays and meters which have been tested and
found acceptable shall have green tags.
j. The relays and meters found defective during tests
shall be tagged red.
3. Metering Tests
Panel metering calibration shall be tested via front panel
mounted test facilities. The following represent the minimum
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 73 of 124
test points required.
a. Maximum demand indicator (MDI) meters shall be
tested at 10% and 100% of full scale.
b. Current and voltage metering and transducers
calibration shall be tested at 0, 25, 50 and 100% of
scale.
c. Watt and VAR metering and transducer calibration
shall be tested at (+/- when bi-directional) 0, 25, 50 and
100% of rated load and with rated voltage and current
at angles of 0, 45,180, 2270 and 315 degrees.
d. KWH and KVARH metering calibration shall be tested
at 10% and 100% of rated current at angles of 0, 45,
90, 180, 225, 270 and 315 degrees.
e. Frequency metering and transducers calibration shall
be tested at minimum, nominal, and maximum rated
scale.
f. Power Factor metering and transducer calibration shall
be tested at rated voltage and at 50% lead, unity, 50%
lag power factors at 10, 50 and 100% of rated current.
g. Tap position indicators shall be checked and confirmed
for the entire range of transformer tap positions.
4. Annunciator Tests
a. Confirm dual supply operation by disabling primary and
backup supplies one at a time.
b. Confirm operation of Acknowledge, Reset and Lamp
Test push buttons.
i. Alarm indication lamp flashes on receipt of
alarm.
ii. Pressing Acknowledge does not reset the
alarm points.
iii. Alarm does not reset until Reset is pressed.
c. Confirm Annunciator Failure alarm to SCADA.
d. Check operation of each alarm point one at a time by
simulating input at the marshalling panel.
e. Confirm individual alarm identification for each point
during functional testing of remote panels’ output
contacts.
5. Digital Disturbance (DDR) Tests
a. DDR shall be inspected and calibrated as
recommended by the manufacturer.
b. Calibration of voltage and current channels shall be
confirmed by secondary injection.
c. Each digital input shall be confirmed by operation of
the associated auxiliary contact in the remote panel.
d. Program and electrically confirm trigger levels and
initiating contacts.
e. All alarm/SOE/SCADA outputs shall be tested and
confirmed.
f. Verify accuracy of all channel descriptions.
g. Verify operation to the local printer if available.
h. Verify proper communication and software
i. Update/installation at all concerned locations by
establishing communications with each unit and
downloading event data.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 74 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 75 of 124
d. Raise and lower operation of the tap changer from the
AVR relay in Independent/Auto and Master/Auto both
when the RTCC is in Local and in SCADA control
modes.
e. Check of blocking and reset of operating modes when
breakers are opened or paralleling is disturbed.
f. Operation of all alarm, SCADA and SOE outputs from
the panel and control panel.
7. Automatic control switching equipment panel
a. Check the proper scheme for automatic closing of third
transformer 13.8 kV incomer circuit breaker in case of
tripping of any transformer in service.
b. Check all alarms, command and back indication of the
system with SCADA.
8. Trip On Parallel scheme
a. Check the manual tripping of one circuit breaker and
selection of the circuit breaker to be closed and in time
of tripping of that selected circuit breaker the fifth circuit
breaker will closed accordingly (13.8 kV three
transformers and two bus section circuit breakers).
b. Check all alarms, command and back indication of the
scheme to SCADA.
9. Automatic Bus Transfer Scheme (ABTS) Panel
a. Operation in service for tripping of each transformer
individually when paralleled with a second transformer
to demonstrate automatic paralleling of the third
transformer. If possible, offload one bus at a time so
that it is possible to prove operation for loss of the
independent transformer without loss of customer load.
b. Prove that protection blocking interlocks (bus
differential, transformer high side time overcurrent etc.)
prevent operation of the ABTS.
c. Prove scheme for opening of bus section breaker to
break parallel of three transformers is functioning.
d. Test blocking and forced operation of the RTCC by the
ABTS.
e. Operation of all alarm, SCADA and SOE outputs from
the panel.
10. Automatic Transfer Schemes (ATS)
a. Confirm proper operation of station service (AC and
DC) automatic transfer schemes by simulating incomer
failures.
b. Confirm operation of interlocks to prevent/limit
paralleling of incomer sources as per approved
scheme.
c. Test automatic and manual controls for all possible
operating conditions.
11. Switchgear Control Panel Functional Tests
a. Checks of all interlocking and blocking functions (synch
check, lockout block closing, ground switch, etc.)
b. Tests of open and close operation and indication of the
associated switchgear.
c. Operation of all alarms, SCADA and SOE outputs from
the panel.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 76 of 124
3.30.6 Energization
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 77 of 124
provide a range of simulated fault conditions.
e. For REF and bus differential relays, check to ensure
minimal spill currents in service. Test the differential
circuit by isolating one service current from the
summation to force operation and prove the
summation circuit is not shorted.
f. For transformer differential circuits, check spill currents
and minimum, center and maximum transformer taps.
Spill current at minimum and maximum taps should be
similar with near zero spill current on the center tap
position if the auxiliary CTs are selected to the correct
tap.
g. Check transformer AVR operation in independent and
parallel modes as applicable. Manually raise (lower)
the transformer(s) two taps and place them back in
AUTO to observe the automatic return to the correct
voltage tap. Confirm operation from SCADA and in all
possible operating modes.
h. Functionally test the ABTS scheme by operating
transformer protection to trip the breakers and initiate
the system.
i. Check in service reclosing for OHTL circuits by
operating the protection to initiate trip and reclose.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 78 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 79 of 124
c. Disconnect the battery charger and any other load on
the battery.
d. Record the initial voltage of each unit and battery
terminals.
e. Select the discharge rate based upon the battery
capacity (ampere-hour) and the time period the test
shall be carried out for 10 hours.
f. With the variable load bank (dummy load) with an
ammeter in series and a voltmeter across the battery
terminals, connect the load while simultaneously
starting the timing device.
g. Maintain the correct current while periodically reading
and recording total battery voltage. After 10 hours
record the final unit voltage and compare the test result
with the manufacturer’s recommended voltage chart to
confirm the battery end voltage.
5. Fully recharge the battery according to the manufacturer’s
instructions.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 80 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 81 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 82 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 83 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 84 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 85 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 86 of 124
change over switch, hour meter.
6. Check interlock against overload operation, single phasing of
power supply, continuous operation not attended for 1-hour.
7. Check low pressure alarm, high pressure alarm, compressor
faulty alarm.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 87 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 88 of 124
15. Check that thermostat control with temperature indicator is
provided and suitable to operate the system automatically.
16. Check that the thermostat is equipped with independent switch
to operate the air supply fan continuously if required.
17. Check that the thermostat control is protected by a clear plastic
transparent guard cover with standard lock and key.
18. Check that the belt driven blower and fan motors are protected
by a belt guard cover.
19. Check that the air filters are easily removable from unit and
washable type and check that the frame is 18 gauge galvanized
iron with welded or screw type corners.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 89 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 90 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 91 of 124
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.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 92 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 93 of 124
7. Capacitance and Dissipation factor measurement test.
8. Insulation power factor (Doble) test –115 kV and above.
9. Perform all specific tests per manufacturer’s instructions.
10. Megger test phase to phase.
11. Capacitance bank neutral unbalance measurement.
12. Test the inductance of the harmonic filter inductors.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 94 of 124
8. Check tightness of all joints and couplings of the coolant circuit
(torque wrench method).
9. Check all pipe network and cooling system to stand test
pressure and operating pressure.
10. Check the unobstructed coolant circuits in all parallel paths.
11. Check the provision of control valve for inlet and outlet for all
parallel paths.
12. Check the provision of control valve for all equipment in the
cooling system for replacing or repairing without any interruption
to the cooling system.
13. Check the availability of pressure regulating valves at the outlet
of the pumps.
14. Check the availability of shut off valve at the inlet and outlet of
the pumps.
15. Check provision of replacing the pump while system is on line.
16. Check the provision of air bleeding valve at the top of all parallel
paths and at the ion exchanger/ deionizer.
17. Check the provision of leak-water collection (drainage) on the
floors.
18. Check the provision to replace the resin while system is on line.
19. Check the provision to replace filters/strainer while system is on
line.
20. Check the availability of the filters at the inlet and out let of the
deionizer.
21. Check the availability of the strainers at the outlet of the
deionizer and at the inlet of the valves with bypass circuit.
22. Check the availability of the control valves at the inlet and outlet
of each heat exchanger.
23. Ensure the outdoor piping network is stainless steel.
24. Ensure unobstructed ventilation for all heat exchangers.
25. Ensure the availability of vibration shocks for the all heat
exchangers.
26. Check, calibrate and functional test of the all temperature
gauges.
27. Check and calibrate all pressure gauges, flow switches,
differential pressure gauges and liquid level switches.
28. All the cooling system should be flushed over several hours,
including all branches, heat exchangers, deionizers, etc.
29. Verify no leakage in the cooling system.
30. Test the coolant for purity, proper percentage of anti freezing
and anti algae before filling the cooling system.
31. Check the rotation of pumps and cooling fans.
32. Run the pumps on and off repeatedly, until no more particles
accumulate in the filters.
33. Vibration check of cooling network.
34. Sound level check.
35. Check the auto operation of ion exchanger/bypass valves with
the conductivity meter (if applicable).
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 95 of 124
2. Visual check of electrical panel.
3. Insulation resistance test of motors.
4. Winding resistance measurement of motors.
5. Check the proper rating of the motor protection breakers and
perform the functional trip test by current injection, under
voltage, and phase reversal.
6. Verification of current, overload, thermal, under voltage, and
phase reversal settings of motor protection.
7. Check the operation of the pumps from local pump station PLC,
and SCADA. Ensure the alarm signal when pump is on local
mode.
8. Record the power supply input voltage and phase rotation.
9. Record starting and running motor current.
10. Check the redundancy of auxiliary power supply and operate
the pumps one by one by both power sources.
11. Check the alarm and status by simulating the breaker open/
loss of auxiliary power sources.
12. Verify overload trip time of all motors by artificial single phasing
of all three-phase motors.
13. Simulate the operation of pumps by loss of power, pump failure,
differential pressure and running hours completion cycle and
ensure automatic changeover.
14. Ensure automatic changeover time is coordinated with loss of
cooling alarm time.
15. Verify start-up of standby pump on loss of supply to running
pump and record the time.
16. Check PLC of cooling system for measurement of pressure,
temperatures, Levels, resistively and status of pumps, heat
exchanger fans and valves.
17. Check to see that monitoring signals show correct values or
correctly indicate alarms.
18. Check the alarm/trip signal on loss of input voltage, pump
failure, low coolant level, high and low resistivity, pressure,
fellow, and temperature from all gauges, sensors and meters.
19. Check the cooling fans auto-changeover and auto operation by
temperature.
20. Check the cooling fans operation from Manual and Auto from
PLC control panel.
21. Check the cooling fan’s minimum run time, and on-off
hysteresis.
22. Check the simulated operation of all electrical operated valves.
23. Ensure the full cooling capacity is available with one cooler
failed or out of service.
24. Display messages check for alarms and trips.
25. PLC internal battery check if present and note the date of
replacement.
26. Check Automatic operation of de-ionizer by resistivity. Check
the conductivity measurement of the coolant to see that it drops
below alarm level when new water is circulated, if applicable.
27. Check the deionizer time for recovering the resistivity, if
applicable.
28. Check the minimum activation time of deionizer, if applicable.
29. Ensure that liquid coolant is electrically grounded.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 96 of 124
3.42.6 SVC System Controller Computer
(Standard Reference is IEEE 1303-1994, IEEE Guide for Static VAR Compensator Field Tests and relevant
SEC Transmission Specifications)
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 97 of 124
13. Complete wiring checking.
14. Cooling system alarm checks from controller.
15. All alarms and trips initiation checks.
16. Trouble shooting guide verification with initiation of alarms.
17. Check of disconnects and low voltage switchgear by control
panel operation.
18. Check of print-out on the printer and alarm on the annunciator.
19. Check of alarms and trips to controller, annunciator and to even
recorder.
20. Check of cooling system ready.
21. Check of temperature normal.
22. Check of SVC ready.
23. Check of alarms at controller due to alarms of the transformer.
24. Check of all controller cards.
25. Low voltage tests for SVC with different firing angles, i.e., B=0
to B=90 (LI MAX=0 TO –1.0.
26. Stability test of differential protection thyristor bypass switch
closed.
27. Emergency trip operation check.
28. SCADA point list testing.
29. Check of thyristor monitoring software operation.
30. Check of CB fail to close and fail to open alarm.
31. Controller over current protection level-1 tests, if applicable.
32. Controller over current protection level-2 tests, if applicable.
33. Secondary under voltage level –70% protection for immediate
trip, if applicable.
34. Primary under voltage –30% protection for 100 msec and no
trip, if more the system to trip, if applicable.
35. Primary under voltage 0.6 p.u. for more than 1 sec. CB trips.
36. Secondary under voltage 0.6 p.u., TCR blocks if more than 1
sec. then CB trips.
37. UPS operation time to be checked if ac is off to the UPS.
38. UPS alarm and trip level tests.
39. Controller cards battery replacement date check.
40. Check of Remote communication with modem to SER.
41. Final trip tests.
42. Annunciator AC and DC supply MCB operation check.
43. Watch dog of SER check.
44. Operational check of thyristor bypass switch.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 98 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 99 of 124
20 MVAR (-ve for capacitance).
22. Close the CB with filter H7 and take the similar measured
above, but this time the load is –10 MVAR.
23. Open the CB.
24. Return the firing optical connections back to thyristors.
25. Open CB and close with TCR and Vref to =401 KV so that no
current flows in TCR.
26. Check the cooling starting on close command of CB from SVC
room or control room or from the Control Center.
27. Check the alarm with thyristor address on removing of indication
pulses fibers in PC and alarm on annunciator.
28. Check that on removing more than two fibers the SVC trips.
29. After CB open and all disconnect switches are closed.
30. Give close command to CB for TCR, H5, and H7 in service with
manual mode.
31. Make all the measurements with different loads, such as HV,
MVAR, LV, SVC I, synch pulses graphs.
32. On cooling system PLC panel check all the pressures and
temperatures, running of pumps and running of cooling fans,
etc.
33. Keep running for one day in auto mode.
34. Vary the voltage reference from mimic panel and check the
MVAR and alarm svc reached max capacity.
35. Check and record all the currents in protection relay panels.
36. Check current limitation/protection in SVC controller.
37. Check of regulation with full load to no load and with different
slopes.
38. Check of step response with Vref settings for 1% voltage
difference and gain of 0.2,1,1.5, 3, etc.
39. Check auto recloser operation.
40. Check joint SVC operation with different bus bar configuration.
41. Check thyristor by-pass configuration mode.
42. Check of strip-chart recorder operation.
43. Check Event recorder alarms having responsibilities added.
44. Check the start inter-lock sequence.
45. Check stop sequence.
46. Record temperature measurements of TCRs at different joints
with temperature sensor stickers.
47. Auto/manual change over test.
48. Harmonic content tests.
49. Pump change over test by simulating fault in one pump.
50. Check cooling fans change over.
51. Check LV incomers change over
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 100 of 124
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
TRANSMISSION
Pre-commissioning test procedure
PART II
Title: Index Number:
T-PreCom-1000-R0
Mechanical Check & Visual Inspection and Electrical Test
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: ----------------------- □
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 102 of 124
5. Energization of Filters
6. Energization of TCR
-------------------------------------------------------------------------------------------------------------
Voltage Current
Sec
Prim
Voltage Current
Sec
Prim
Max inductive is: ___________ MVAR Max capacitive is: ______________ MVAR
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 103 of 124
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: ------------------- □
_____________ ______________
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 104 of 124
Measurement of load-sharing:
_____________ ________________
Current limit
ILIMGAIN: ____________
Parameters corresponds to _______ A primary TCR current and __________ sec time constant
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 105 of 124
Q-tot Ph. a-b b-c c-a a-b b-c c-a a-b b-c c-a
Q-tot Ph. a-b b-c c-a a-b b-c c-a a-b b-c c-a
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 106 of 124
12. Static Characteristic
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
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 107 of 124
____________ _____________
____________ _____________
____________ _____________
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 108 of 124
Final measurement of B-prim versus BREF:
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 109 of 124
Switching from MAN to AUTO and from AUTO to MAN works correctly
SLOPE: ____________
Measurement of slope:
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 110 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 111 of 124
Step Response Test for Gain Optimization
MLOSST: ____________
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART II
Title: Index Number:
T-PreCom-1000-R0
MECHANICAL CHECKS, VISUAL INSPECTIONS
Page Number:
AND ELECTRICAL TESTS
Page 112 of 124
It was checked that the SVC operates correct during the following change-overs to redundant functions.
Checked
___________________________: ------------------- □
________________________: --------------------- □
___________________________: ------------------
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
REGISTER BOOK/FILE T-PreCom-1000-R0
DEFICIENCY FILE
Page Number:
ATTACHMENT No. 1
Page 113 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
REGISTER BOOK ACTIVITY RECORD T-PreCom-1000-R0
Page Number:
ATTACHMENT NO. 2
Page 114 of 124
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
SITE INSTRUCTION T-PreCom-1000-R0
Page Number:
ATTACHMENT No. 3
Page 115 of 124
Substation Circuit
Contract No اﻟﻤﺸﺮوع رﻗﻢ
Project Title اﻟﻤﺸﺮوع اﺳﻢ
Contractor Name اﻟﻤﻘﺎول اﺳﻢ
Attention Mr.. اﻟﺴﻴﺪ ﻟﻌﻨﻠﻴﺔ
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
STATUS OF PUNCH LIST
Page Number:
ATTACHMENT No. 4
Page 116 of 124
Snag/ Confirmed By
S.I. Expected Time of
Punch Description of the Deficiency Issued Date Issued By Commissioning Remark
# Completion by
list No. Personnel
TRANSMISSION
Pre-commissioning test procedure
PART I
Title: Index Number:
T-PreCom-1000-R0
Categorization of Punch List
Page Number:
Attachment# 5
Page 117 of 124
CONTRACT #:
PROJECT TITLE:
DATE:
S/S NAME/NUMBER :
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”
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
PRE-COMMISSIINING TIME UTILIZATION STATISTICS SHEET T-PreCom-1000-R0
Page Number:
ATTACHMENT No. 6
Page 118 of 124
* To be filled by SEC Commissioning engineer/technician. Legend: CSD: Comm. Services Department PMD: Project Management SOD: System Operation
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
FINAL PRE COMMISSINING REPORT
Page Number:
ATTACHMENT No. 7
Page 119 of 124
The following items have to be confirmed at the end of the pre commissioning tests:
Further Remarks:
Signature:
Name:
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
COMMISSIONING TIME REDUCTION AGREEMENT
Page Number:
ATTACHMENT NO. 8
Page 120 of 124
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.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
COMMISSIONING TIME REDUCTION AGREEMENT
Page Number:
ATTACHMENT NO. 8
Page 121 of 124
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:
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
COMMISSIONING TIME REDUCTION AGREEMENT
Page Number:
ATTACHMENT NO. 8
Page 122 of 124
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.
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
T-PreCom-1000-R0
COMMISSIONING TIME REDUCTION AGREEMENT
Page Number:
ATTACHMENT NO. 8
Page 123 of 124
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
TRANSMISSION
PRE-COMMISSIONING TEST PROCEDURE
PART I
Title: Index Number:
CONTRACTOR’S PERFORMANCE REPORT T-PreCom-1000-R0
ﺗﻘﺮﻳﺮ ﻟﻤﻘﺎول د
Page Number:
ATTACHMENT No. 10
Page 124 of 124
اﻟﻤﻨﺎﺳﺐ اﻟﺮﻗﻢ ﺡﻮل ةﺮﺋاد ﺑﻮﺿﻊ اﻟﻤﻘﺎول أدا ﺗﻘﻴﻴﻢ
EVALUTE THE CONTRACTOR’S PERFORMANCE NY CIRCLING APPROPRIATE NUMBER
یﺤﺘﺎج
ﺟﺪا ﺟﻴﺪ ﻡﺮﺿﻲ ﻏﻴﺮ
ﺟﻴﺪ ﻡﻘﺒﻮل ﻟﺘﺤﺴﻴﻦ
CATEGORY VERY UNSATISFAC اﻟﻔﺌﺔ
GOOD SATISFACTORY NEEDS
GOOD TORY
IMPROV.
QUALITY OF THE
25 21 19 15 11 اﻟﻌﻤﻞ ﺟﻮدة
WORK
AVAILBILTY Of
ة آﻔﺎ ﺗﻮاﺟﺪ
QUALIFIED 22 19 16 13 10
اﻟﻤﻬﻨﺪﺳﻴﻦ
TESTING ENG.
اﻟﺘﺰاﻡ
PUNCTUALITY 20 17 15 12 9
ﺑﺎﻟﺤﻀﻮر
SAFTEY 15 13 11 9 7 اﻟﺴﻼﻡﺔ
COOPERATION 10 9 7 6 5 اﻟﺘﻌﺎون
AVAILABILITY OF
اﻷدوات ﺗﻮﻓﺮ
PROPER TOOLS
8 7 6 5 4 واﺟﻬﺰة
AND TEST
اﻻﺧﺘﺒﺎرات
EQUIPMENT
100- 92- 79-68 67- 53-46
TOTAL POINTS اﻟﻨﻘﺎ ﻡﺠﻤﻮع
93 80 54
( اﻟﺘﺸﻐﻴ ﻗﺒﻞ ﻡﺎ اﺧﺘﺒﺎرات ﺑﺎﻟﺘﻘﻴﻴﻢ )ﻡﻬﻨﺪس ﻗﺎﻡ
Evaluated By (Comm. Eng)
:اﻟﺘﻮﻗﻴﻊ
SIGNATURE:
NAME : :اﻻﺳﻢ
DATE : :اﻟﺘﺎریﺦ