Guidelines For Electrical Testing and Co

Guidelines for Electrical Testing and Commissioning
INDEX
1. Inspection, Test and Measurement Procedures for LV and MV (up to 36kV) Switchgears Importance
of checks and maintenance.
2. Test on 110kV Power Cable after Installation
3. Impulse withstand Voltage test
4. High voltage testing – Direct current (DC) Test
5. High Voltage Transformer Testing.
6. Basic Transformer Routine Test
7. Inspection and Test procedures for Instrument Transformers
8. Inspection and test procedures for Rotating Machinery, Synchronous Motors and Generators
9. Testing and Commissioning Procedure for Motors
10. Field Inspection and Testing of Medium-Voltage Motor Control Centers (MCCs)
11. Commissioning of HV Panel – Operational and Functional Checkup
12. Erection procedure for HV switchgear
13. Testing and Commissioning of MV/HV Cables
14. Testing and Commissioning of Substation DC System
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1. Inspection, Test and Measurement Procedures for LV and MV (up to 36kV) Switchgears
Importance of checks and maintenance.
Installed in clean, well ventilated or air-conditioned locations, switchgear will require little
routine maintenance.
Major inspection should be scheduled for power plant shutdowns and concentrate for low voltage
switchboards on identifying contact wear, correct operation of interlocks, correct overload settings and
fuse sizes, signs of overheating, and undue dirt or corrosion. For MV switchgear similar considerations
apply although more extensive checks on protective devices, circuit breaker oil, and vacuum bottle
contact distances are required as specified by the Manufacturer
Gas Insulated Switchgear (GIS) shall be maintained in accordance with the manufacturer’s
recommendations. Where extensive (intrusive) maintenance is required, the Manufacturer should be
involved in the activity.
For older switchgear, a condition assessment should be performed to establish that the equipment
remains in a suitable condition for further service.
Partial discharge testing and infrared scanning can be used to obtain data on the performance of the
insulation system and the integrity of the switchgear bus-bars and cable terminations. The frequency
of such tests will depend on the duty, age and condition of the switchgear.
1.1. LV switchgear
1. INSPECTION General external condition. 1Y All

Motor starters and outgoing feeders, internal. 4Y
Incomers, internal.
Bus-bar compartments 8Y
Metering: 4Y
- Correctness main voltmeters.
- Correctness main ammeters.
2Y
2. TEST AND Incoming feeders, bus section, switches: Y All
MEASUREMENT - Operating mechanism.
- Interlocks. 4Y
- Control equipment.
- Electrical protection/tripping (2).
Bus-bar systems:
- Torque bolts (1) 8Y
- Insulation resistance.
- Continuity (ductor).
Motor feeders:
- Draw-out system/interlocks. 4Y
- Cable connection tightness.
Thermal and earth fault protection. 4Y 10%
Certified Ex ‘e’ thermal protection (4). 3Y All
Restart system. 10%
Insulation resistance of motor + cable. selected
Plain feeders: All
- Draw-out system/interlocks.
- Cable connection tightness.
Protection/tripping. (2) 10%
R.C.D. for fixed load (e.g. trace heating). All
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1.2. MV Switchgear (up to 36 kV)
General external condition. 1Y

Cable boxes internal.
Circuit breakers internal. 4Y
Fused contactors internal.
1. INSPECTION Bus-bar compartments 8Y All
Metering:
- Correctness main voltmeters.
- Correctness main ammeters.
4Y
- Correctness of other measuring systems.
Circuit breakers in/outgoing and fused
contactors (3):
- Operating mechanism.
- Draw-out system/interlocks. 4Y
- Control equipment.
- Insulation resistance All
Bus-bar compartments (1) internal. 8Y
Ductor test across closed contacts.
4Y
Electrical protection/tripping (2).
2. TEST AND Certified Ex ‘e’ thermal protection (4). 3Y
MEASUREMENT Contact distance. Vacuum,
4Y SF6
Dielectric test oil. Oil-immersed
Insulation resistance of cable (incl. motor if
4Y All
applicable).
Restart system. 4Y Motors
Bus-bar systems:
- Torque bolts (1).
- Insulation resistance. 8Y
- Dielectric strength. All
- Continuity (ductor).
Greasing of operating mechanisms.
3. RESTORATION
Oil filtering/replacement. As
Component replacement. necessary
2.Test on 110kV Power Cable after Installation
2.1. Mechanical Check and visual Inspection
Item Description Remark

1 Inspection for physical damage or defects
2 Check tightness of all bolted connections (torque wrench method)
3 Check for proper cable bolted connections
4 Check cable bends to ensure that bending radius is equal to or greater
than the minimum bending radius specified
5 Check for proper cable support, clamping, trays arrangements
6 Link box tightness check
7 Verify that shields are terminated as specified (through link box or
directly grounded)
8 Verify the exact route length as per approved drawings from terminations
to terminations
9 Check that all grounding points are securely connected to ground grid as
specified
10 Check that phases are identified and color coded
11 Single core cable connected between power transformer and switchgear
shall be single point earthed as switchgear side and at floating side SVL
(sheath voltage limiter) should be installed
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12 Check single point or both ends, via voltage limiter as per approved
design
13 Inspection of label inside link boxes and water proofing
14 Check cable entry path trench as ducts are properly sealed
15 Check irregularities of outer jacket formed by non-uniform shield wire
distribution
16 Check/inspect the transposition of cable phases
17 Check the cable outer jacket for any physical damage during and after
installation
18 Check for the cross connection of cable metallic sheath in cross bonding
system
19 Check the rubber seal in cable clamps to avoid any damage to cable
outer jacket
20 Check the insulating shrouds are installed at the base of the cable
terminations
21 For accessories (sealing terminations, instrument panels and link boxes)
check the following:
a. Name plates installed and data is correct
b. Danger signs
c. Bolt tightness check and paint work conditions
2. 2. Electrical Test
(Standards Reference is IEC 60840 and relevant SEC Transmission specifications 11-TMSS-02, TCS-
P-104.08).
1 Check Phasing for Conductor and sheath

bonding
2 Sheath DC high voltage test (10 kV DC for
1 min.) and 5 kV DC insulation test before
and after high voltage/24 hour soaking test
3 Conductor resistance, capacitance and
inductance measurement test
4 Conductor insulation resistance test
5 Cross-bonding verification test The sheath current should be <3% the current due
to induction neighboring circuits should be
considered and limit should be 3%+current due to
external circuits
6 Zero and positive sequence impedance
measurement
7 SVL (Sheath/Surge voltage Limiter) test
by 2.5 kV DC insulation tester
8 Measure the ground resistance at all link box
positions as per SEC standards TES-P-
104.08)
9 Contact resistance test on link boxes (less
than 20 μΩ)
10 Metallic sheath continuity test
11 Cable profile test- during jointing
12 In case of Double Circuit (110 kV and
above), check the separate grounding pit
13 AC High voltage test for all new cables, but
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if old portion are involved then soaking for

24 hours at rated voltage
2.3. Phase indication test
After complete installation, the cables are to be identified with respect to their phases and are to be reconfirmed
whether they are correctly marked or not.
Equipment / Instruments Used
Battery operated KYORITSU, High Voltage Insulation Resistance Tester, and MODEL-3125
Instructions
Ø The screens of all cables at one end are to be shorted and grounded.
Ø The conductor of the cable under test is to be connected to the negative pole of the meter.
Ø The positive pole of the meter is to be grounded.
Ø Through a switch ground the other end of this conductor of the cable under test and measure the
resistance.
Ø If the resistance becomes zero, the phase identification is ok and checks whether the correct color
coding is applied or not.
Ø To cross check, open the switch, the meter shall read high resistance (Tending to infinity).
Ø Similarly repeat the test for other phases and verify the correctness of color coding.
2.4. DC Conductor Resistance Measurement
The DC resistance of conductors of the cables, to be measured at ambient temperature before

conducting any other test, and the values are to be computed for 20ºC.
Schematic layout for measurement of DC resistance for long cable
References
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IEC 60228 – Conductors of insulated cables
Equipment / Instruments used
Ø Any Wheatstone bridge, micro Ohm-Meter.

Ø Any industrial type thermometer to measure the ambient temperature.
Instructions
Ø The conductors are short circuited at the far end by minimum 95 mm2 cable.
Ø The other ends of the cable are connected to the bridge according to equipment instructions.
Ø Note down the measured value.
Ø The resistance of conductor at 20ºC/km is obtained by substituting the measured value in
the formula.
Formula for Temperature Correction:
For Copper R20 = R/L (1 + 0.00393*(T-20)) Ω/KM
Where,
R20 – Conductor resistance at 20ºC *(ohm/km

R – Measured resistance of one phase (ohm)
L – Exact length (km)
0.00393 – Temperature coefficient at 20ºC for copper (K)
T – Temperature of conductor when measured in ºC
2.5. Capacitance Test
The capacitance shall be measured between conductor and metallic screen. According to IEC, the measured
value shall not succeed the normal value specified by the manufacturer by more than 8%.
Schematic layout for capacitance measurement
Omicron – for zero positive sequence test and capacitance measurements
Instructions
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Ø Connections are made as per below schematic.

Ø Connect the instrument cable between conductors and metallic screen and take the measurements.
Ø The capacitance is measured between each individual conductor and sheath.
Ø A capacitance bridge is used for this measurement.
Ø The value obtained can be converted t o μF/ km
Formula for Capacitance:
C = Cm/L (μF/km)
Where:
C – Capacit ance in μF/ k
Cm – M easured Capacitance in μF
L – Length of Cable in km.
2.6. DC sheath test on outer sheath
The test is applied when the cable sheath can be isolated from the earth to permit a voltage to be
applied to the over-sheath to check the integrity of the covering.
This testing is generally applied at certain stages of cable system installation at specified parameter
as follows:
1. When the cable is still on reel. The applied test voltage is 10 kV for 10 seconds, if a proper test
lead is provided.
2. Once the cable are laid, dressed and tied together in trefoil configuration a test voltage of 10 kV
for 30 seconds is applied.
3. Following backfilling sand beddind-2, a test voltage of 10 kV is applied for 1 minute on each cable.
This is a formal testing with test records and signed by representatives of the responsible parties
as witnesses.
4. Following completion of jointing activities between two cable sections in a joint bay and after
backfilling of the joint bay, the jointed cable sections are then tested by applying 10 kV for 30
seconds.
5. Following the completion of cable system installation and prior to acceptance testing, as a pre-
check testing a test voltage of 10 kV is applied for 1 minute.
References
Ø IEC 60840 - Power cables with extruded insulation and their accessories for rated voltages
above 30 KV.
Ø IEC 60229 - Electric cables // Tests on extruded over sheaths with a special protective function
Ø TES-P-104.08 – Bonding and grounding of insulated metallic sheath of power cable system
The DC HV 25kV Tester, Model No. PGK 25 manufactured by BAUR Germany. The test is applied
only to cables covered with conductive layer over outer sheath. (Read more about HI potential
Testing)
DC Hipo Tester, BAUR PGK 25
Instructions:
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Ø The covering under sheath is exposed about 2 cm length at one end of the cable so that the
negative polarity shall be applied to it.
Ø The conductive layer on outer sheath shall be removed about 20 cm wide at a distance of 30
cm from both ends of the cable.
Ø The positive terminal of the DC source is connected to a copper band wound on the conductive
layer of the sheath at one end of the cable (60 cm away from the end).
Ø The 25 kV testers can be operated by choice either from the power supply source of220/110 v-
50/60 Hz supply or can be charging its in-built battery set-up.
Ø Switch on the timer in clockwise direction, a lamp indicator will be indicated ‘ON’ position to a
desired test period.
Ø Select the voltage selector switch to 5 kV or 25 kV.
Ø Select the range of current measurement to position corresponding to the current value intended
for charging the test cable.
Ø Slowly rotate the voltage selector to the desired voltage value on the scale (1 kV per second
in intervals). Watch carefully the voltmeter while charging. If required re-adjust voltage
selector before the desire test voltage is reached.
Ø Set range switch for current measurement to the desire range after charging has been completed.
Ø After the time has elapsed the high voltage brings down to zero, switch off the timer
and discharge the cable through ground wire.
DC Sheath Test diagram
Reference:
IEC 60840 – Applies to cable voltage ratings between 30 kV and 150 kV. It includes a regular type
test sequence for cables and a separate sequence for the cable accessories.
Requirements
The cable is considered to have passed if it withstands the required voltage (10 kV) during the test
for 1 minute without break down. During the test, the leakage current shall be recorded. During the
testing, safety regulations on electric hazards should be strictly observed. The measurements /
reading are recorded in the available format in company.
2.7. Insulation resistance measurement
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The insulation resistance shall be measured between conductor and metallic screenaccording to
IEC 60840.
References:
IEC 60229 - Electric cables – Tests on extruded oversheaths with a special protective function
TES-P-104.08 - Bonding and grounding of insulated metallic sheath of power cable system
Equipment / instruments used
Battery operated -KYORITSU High Voltage Insulation Resistance Tester, and MODEL-3125.
KYORITSU High Voltage Insulation Resistance Tester
Instructions
Ø Cable should be free from all system connections.

Ø Connect the cables between conductor and metal sheath.
Ø Measure the resistance at the required voltage and charging time (1 minute).
Insulation resistance test diagram
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The insulation resistance (Ri) measured between each individual conductor and metal sheath. The
insulation resistance per kilometer is calculated from:
Rl = Ri x L (GΩ Km)
Where:
Rl – Insulation resistance in GΩ Km.
Ri – Measured insulation resistance in GΩ.
L – Cable length in Km.
2.8. Cross bonding check
With the cross bonding checks, the right connection of the cables can be checked and when
correctly bonded, no current may flow in the metal sheath of the cable in case of an ideal situation.
The actual site requirements and situation dictate what the actual cable section lengths that may
differ from section to section.
380 V Generator.
3-Phase Current Transformer
Clamp Meter
Instructions:
ØScreen is to be grounded at both ends.

ØThe conductors are short circuited at the far end firmly by minimum 95 mm2 cable.
ØThe conductors under test are connected as shown in figure below.
ØIncrease the current gradually insteps by balancing the phases individually to desired value.
ØNote down the current induced in all the link boxes.
ØReduce the current gradually and switch off the breaker.
Cross bonding check diagram
2.9. Zero sequence and positive sequence impedance test
Positive sequence impedance are calculated assuming that there are no metallic elements that are
placed within an influential distances of cable (Railway lines, pipe lines or buried equipment’s etc.).
The presence of other metals or metallic objects influences the sequence impedance. Because of
influence of other unknown factors, it is recommended that the impedance should be measured in the
field after the circuits are installed. Positive and negative sequence impedance for cables is same
value, because the impedance of these in uncharged if a symmetrical voltage system with reverse
sequence is applied to them.
Usually the zero sequence impedance can be assumed as 3 times the positive sequence impedance
value as a practice for initial approximation.
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The three currents of zero sequence system, equal in magnitude and direction, are opposed by
impedance that is determined by the loops formed by the three cable cores and returned by the
metallic sheaths and earth in parallel. The effective AC resistance of the zero sequence system
includes both the effective resistance of the line conductor as well as that of earth return.
The zero sequence impedance can be determined by measurement or calculation when the three
phase of the system are connected in parallel and single phase AC current is applied to them.
Instruments / Equipment used
3-phase variable transformer (up to 100 Amps supply capacity).

Impedance measurement equipment – Digital.
CP-CU1 Omicron for Zero positive sequence test and capacitance measurements
Instructions:
Measurement of positive/negative sequence impedance:
Ø The measurement is done between two phases of the circuit once the complete circuit is installed,
cable may be transposed and cross bonded between the terminations. There should be electric
accessibility to the cable cores at terminations.
Ø The connections should be made as per schematic diagram 1A.
Ø Turn up the power with the variable transformer until 25 Amps of current starts flowing. Switch the
impedance measurement equipment and record the voltage, current and angle (power factor).
Ø Switch off after the measurement and turn the variable transformer down.
Ø The measurement is to be repeated three times: between R & Y, between R & Band between Y &
B phases.
Ø Measurement of zero sequence impedance.
Ø The measurement is done by connecting the three phases of circuit connected in parallel and a
single phase AC voltage is applied to them.
Ø The connections should be made as per Figure 1B.
Ø Turn up the power with the variable transformer until 25 Amps of current starts flowing. Switch the
impedance measurement equipment and record the voltage, current and angle (power factor).
Ø Switch off after the measurement and turn the variable transformer down.
Repeat for each phase.
Precautions: safety precautions should be taken prior to switching by putting up warning tapes and
stationing personnel at critical point to ensure that no one is within reach of system parts where high
current are applied.
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Schematic diagrams:
Figure 1A – Schematic layout for measurement of Positive/Negative Sequence Impedance
Figure 1B – Schematic layout for measurement of Zero Sequence Impedance
2.10. Earth resistance measurement at link boxes
The measurement of earth resistance is mainly intended for the purpose of grounding the links of
bonding system of high voltage cable screen.
Analogue Earth tester Model-04102A, Make-KYORITSU.
Analogue Earth tester Model-04102A, Make-KYORITSU

Instructions:
Ø Check the battery voltage, set the range switch to battery check position and press test button and
make sure the indicator is at right of BATT GOOD position.
The connections as per the figure bellow.
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Ø Check the earth voltage by setting switch to earth voltage position, make sure the voltage is
10V or less. If the earth voltage is higher, the result may be with excessive high errors.
Ø Measure the earth resistance by setting the switch to resistance range position and press
test button.
Ø The earth resistance must not exceed 5Ω for outside substation and 3Ω for inside substation.
Schematic diagram
Earth resistance measurement at link boxes
2.11. Link box contact resistance measurement
This test is basically carried out after installation of link boxes and connecting leads
Megger DLRO-200 for contact resistance and DC resistance measurements
Megger DLRO-200 for contact resistance and dc resistance measurements
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Instructions:
Ø All the bolts are to be tightened firmly

Ø Connect the micro-ohmmeter with the link box as shown in figure below.
Ø The micro-ohmmeter shall be applied between earth copper bar and each disconnect able copper
bars.
Ø Test shall be repeated for individual connections.
Ø The values should being micro-ohm range.
Link box contact resistance schematic layout
3. Impulse withstand Voltage test
Impulse withstand voltage test performed on assemblies Rated impulse withstand voltage.
Only optional in the past, the impulse test which allow defining the rated impulse withstand voltage Uimp,
is now a necessity thus demonstrating the strategy of the Standards directed to increasing the
importance of such performance.
In addition to the ordinary temporary overvoltages, usually incoming from the supply line, the plants and
the relevant assemblies are prospective victims of peaks and transient not-linear overvoltages due to
atmospheric causes (fulminations) both direct, when they affect materially the structure, as well as
indirect, when their effect is generated by the electromagnetic fields induced around the impact point of
the lightning.
The capability of the assemblies to withstand such stresses depends all on thedielectric strength of the
air between the two live parts carrying the impulse. Formerly such performance was defined only by
experimental testing; according to the new standard IEC 61439 also verification by “design rule” is
possible as an alternative and with the same validity of testing.
The test requires the application of the impulse withstand voltage 1.2/50 μs (see Figure 1) in compliance
with a particular procedure.
Figure 1 – Application of the impulse withstand
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The impulse voltage shall be applied five times at intervals of 1 second minimum between:
Ø All the circuits connected together and the enclosure connected to earth.
Ø Each pole, the other poles and the earthed enclosure connected together.
Ø Once defined the profile of the impulse, the other value allowing the verification is the peak one,
which represents the absolute maximum of the function.
Ø The present tendency, which is evident in the Tables of the IEC 61439-1, enhances some round
figures such as six, eight, ten and twelve kV.
Ø The direct test is performed according to a specific table (Table 10 of the IEC 61439-1, shown
below) which suggests the alternative between effective impulse, alternating voltage (r.m.s. value)
and direct voltage, with the value defined as a function of the altitude and consequently of the quality
of the ambient air around the assembly under test.
The test is passed if no discharges are detected.
Table 1 – IEC 61439-1, Impulse withstand voltages
The verification by design rule (in alternative to test) shall confirm that the clearances between all the
live parts and the parts subject to the risk of discharge are at least 1.5 times the values specified in
Table 1 of the IEC 61439-1 shown hereunder.
The safety factor 1.5 takes into consideration manufacturing tolerances.
Table 2 – Safety factor (minimum clearance in air)
The minimum clearances shall be verified by measurement or verification of measurements on design

drawings.
Figure 3 – Clearances in ai
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It is evident that to guarantee that the whole assembly has a determined Uimp, in addition to the test or
to the design rule verification which confirm this characteristic, also each component installed inside the
assembly shall have an equal or higher Uimp value.
For example, the ABB’s ArTu system guarantees both 50 Hz dielectric withstand as well as impulse
voltage withstand. In particular versions L and M have:
Un = 690 V
Ui = 1000 V
Uimp = 6 kV
Wall-mounted and 8 kV floor-mountedand version K has:
Un and Ui = 1000 V * Uimp = 8 kV
4. High voltage testing – Direct current (DC) Test
DC tests are used mainly to do “pressure tests” on high voltage cables. Although the cables operate with AC, AC
testing is not practical.
The high capacitance of the cables necessitates AC test sets with a high kVA rating to be able to supply the
capacitive current. In the case of DC, once the cable is charged, only the losses have to be supplied.
DC test sets usually consist of half wave rectification, using HV selenium rectifiers.
Typical DC test set-up is shown in Figure 1.
Figure 1 - Typical circuit for DC tests
An AC high voltage test transformer is again supplied via a variac and a rectifier is used together with a filter
capacitor C to limit the ripple to acceptable values. The earthing switch ES is a safety feature and closes
automatically when the power is switched off to discharge the capacitor C.
Note that the peak inverse voltage required of the rectifier is 2 Vm.
Figure 2 - Typical doubling circuit for DC tests
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Doubling and multiplier circuits (as used in TV’s and household appliances) are also used to obtain an even
higher voltage. A typical Cockcroft-Walton (in Germany: Greinacher) doubling circuit is shown in Figure 2.
Figure 3 - Typical waveforms and a typical doubling circuit DC test sourceCondition Monitoring of Transformers
5. High Voltage TransformerTesting.
5.1.Content
Ø Equipment required for testing

Ø General inspection
Ø Insulation Resistance Test
Ø Polarity Test
Ø Transformer Turns ratio test
5.2. Equipment required
Following equipment is necessary to perform testing’s:

Ø Polarity test kit
Ø Megger 500-5000V
Ø Ohmmeter
Ø Multimeter
Ø Autotransformers & Step-up transformers
Ø Go up to the Content
5.3. General inspection
Mechanical checks
Ø General visual inspection and compliance with the drawings and manuals.
Ø Check nameplate ratings and HV, LV terminal markings.
Ø Check that all parts of the transformer are properly assembled and tight.
Ø Check the HV connections are tight.
Ø Check the cable connections on the LV side and the markings.
Ø Check the oil levels and inspect for leakage. (Where applicable)
Capacitor dividers type
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Ø Check that all parts of the transformers are properly assembled.
Electromagnetic type
Ø Check the installation of different sections.
Electrical Checks
Ø Check the equipment grounding (Continuity and connection)

Ø Check the fuse rating of secondary side.
Ø Perform the operation described in the following
Ø Go up to the Content
5.4. Insulation Resistance Test
To obtain values as close as possible to the manufacturer’s specifications the insulators must be very
clean. Select the megger range corresponding to the ratings of the equipment under test.
For Primary side, apply voltage depending on rating of voltage rating of VT.
Ø For 6.6 kV VT (example), apply 2.5 kV and

Ø For 132 kV VT (example), apply 5.0 kV.
Measurement between primary and secondary
Measurement between primary and ground
Measurement between secondaries and between secondary and ground
5.5. Polarity Test

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The polarity is checked using the flick method (application of direct current) and check of deflection on
a bi-directional milliammeter. The test is also used to check primary and secondary circuit continuity.
Ø When switch k is closed, the milliammeter pointer deflects positive.

Ø When the circuit is opened, the milliammeter pointer deflects in the negative direction.
VT Polarity test
5.6. Transformer Turns ratio test
The turn’s ratio test is an AC low voltage test which determines the ratio of the high voltage winding to all
other windings at no-load. The turns ratio test is performed on all taps of every winding.
The Transformer Turns Ratio tester (TTR) is device used to measure the turns ratio between the
windings (example shown below).
Voltage is applied on the H marked leads and measured of the X marked lead by the test set.
Ratio measurements are conducted on all tap positions and calculated by dividing the induced voltage
reading into the applied voltage value. When ratio tests are being made onthree-phase transformers, the
ratio is taken on one phase at a time with a three-phase TTR until the ratio measurements of all three
phases are completed.
Figure-1 Three-phase Transformer Turns Ratio (TTR) Connection diagram.
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Measured ratio variations should be within 0.5% of the nameplate markings.Some TTR can perform
transformer ratio measurement and also assess if on-load tap changer contacts are making
satisfactorily during its transition from one tap position to the next position.
Example of single phase, hand-cranked TTR – Transformer Turns Ratio Test Set (Measures the turns ratio and exciting current of windings in
power, potential and current transformers.)
5.6.1 Turns Ratio Test Procedure, Step by Step
Step 1.
Isolate the equipment, apply working grounds to all incoming and outgoing cables and disconnect all
incoming and outgoing cables from the transformer bushing terminals connections.
Disconnected cables should have sufficient clearance from the switchgear terminals greater that the
phase spacing distance. Use nylon rope to hold cable away from incoming and outgoing terminals as
required.
Step 2.
Connect the H designated three-phase test lead with the military style connector at one end to the
mating connection on the test set marked with an H. Ensure that the connector’s index notch lines up
properly.
Step 3.
Connect the X designated three-phase test of lead military style connector at one end to the mating
connection on the test set marked with an X. Ensure that the connector’s index notch lines up
properly.
Step 4.
Connect the H1, H2, H3 designated test lead to the corresponding H1, H2, H3 transformer terminal /
bushing. Connect the H0 test lead if H0 terminal/bushing is present.Refer to Figure 1.
Step 5.
Connect the X1, X2, X3 designated test leads to the corresponding X1, X2,X3 transformer terminals /
bushings. Connect the X0 test lead if X0 terminal/bushing is present.
Step 6.
Perform turns ratio measurements for all tap positions.
Step 7.
Confirm that the measured ratios is within 0.5% of the calculated ratios.
Important Note:
Transformers that have wye connections but do not have the neutral of the wye brought out shall be
tested for ratio with three-phase power supply.
Any inequality in the magnetizing characteristics of the three phases will then result in a shift of the
neutral and thereby cause unequal phase voltages. When such inequality is found, the connection
should be changed, either to a delta or to a wye connection, and the line voltages measured.
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When these are found to be equal to each other and the proper values (1.732 times the phase
voltages when connected in wye), the ratio is correct.
5.7. Polarity Detection
This is needed for identifying the primary and secondary phasor polarities. It is a must for poly phase
connections. Both AC. and DC methods can be used for detecting the polarities of the induced emfs.
The dot method is used to indicate the polarities.
The transformer is connected to a low voltage a.c. source with the connections made as shown in
the Figure 1 (a). A supply voltage Vs is applied to the primary and the readings of the
voltmeters V1, V2 and V3 are noted. V1 : V2 gives the turns ratio.
If V3 reads V1−V2 then assumed dot locations are correct (for the connection shown).
Transformer polarity test scheme
The beginning and end of the primary and secondary may then be marked by A1 − A2 anda1 − a2
respectively. If the voltage rises from A1 to A2 in the primary, at any instant it does so from a1 to a2 in
the secondary.
If more secondary terminals are present due to taps taken from the windings they can be labeled as
a3, a4, a5, a6. It is the voltage rising from smaller number towards larger ones in each winding. The
same thing holds good if more secondaries are present.
Figure 1 (b) shows the DC. method of testing the polarity. When the switch S is closed if the
secondary voltage shows a positive reading, with a moving coil meter, the assumed polarity is correct.
If the meter kicks back the assumed polarity is wrong.
5.8. Transformer Routine Dielectric (Insulation) Test
Insulation tests to be performed
The following insulation tests are performed in order to meet the transformer insulation strength
expectations. Unless otherwise requested by the customer, the following tests are performed in the
following order (IEC 60076-3).
(i) Switching impulse test
To confirm the insulation of the transformer terminals and windings to the earthed parts and other
windings, and to confirm the insulation strength in the windings and through the windings.
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(ii) Lightning impulse test
To confirm the transformer insulation strength in case of a lightning hitting the connection terminals.
(iii) Separate source AC withstand voltage test
To confirm the insulation strength of the transformer line and neutral connection terminals and the
connected windings to the earthed parts and other windings.
(iv) Induced AC voltage test (short duration ACSD and long duration ACLD)
To confirm the insulation strength of the transformer connection terminals and the connected windings to
the earthed parts and other windings, both between the phases and through the winding.
(v) Partial discharge measurement
To confirm the “partial discharge below a determined level” property of the transformer
insulationstructure under operating conditions.
According to standards, the transformer windings are made to meet themaximum operating voltage Um
and the related insulation levels.
The transformer insulation levels and the insulation test to be applied according to IEC 60076-3 is
shown in the below table.
Winding Maximum operating Tests

structure voltage
Um kV Lightning Switching Long Short Applied
impulse impulse duration AC duration AC voltage test
(LI) (SI) (ACLD) (ACSD)
uniform Um ≤ 72,5 type na na routine routine

insulated (note 1) (note 1)
uniform 72,5 < Um ≤ 170 routine na special routine routine

and
gradually 170 < Um ≤ 300 routine routine routine special routine
insulated (note 2) (note 2)
≥ 300 routine routine routine special Routine
Note 1: In some countries, in transformers with Um ≤ 72.5 kV applied as routine test and the ACLD test is applied
as routine or type test.
Note 2: If the ACSD test is defined, the SI test is not applied.
In case of a transformer with one or more thanone gradual insulation, if foreseen by the
induced voltage test, the switching impulse test isdetermined according to the maximum Umvoltage
winding.
22
The foreseen test voltage cannot be reached in lower Um voltage windings. In this case, the
ratio between the tap changer’s optimum tap position and the windings shall be such arranged that,
the lowest Um voltage winding reaches the most appropriate value. This is acceptable (IEC 60076-3).
If chopped wave is requested during lightning impulse (LI) test, the peak value of the chopped
wave is 1.1 times the full wave value (10% higher). For transformers with the high voltage
winding Um> 72.5 kV, the lightning impulse (LI) test is a routine test for all windings of the
transformer.
5.9. Erection Procedure for Power Transformer
This technical article deals with transformers and their installation so we restrict ourselves here to the
procedures associated with their commissioning. Transformers should be inspected for internal or
external damage, particularly if they have been dropped or tipped over.
This should include such items as:
1. Drain valves, selector switches,

2. Conservator tanks,
3. Buchholz relays and
4. Winding temperature indicators.
All transformers must be tested for winding insulation resistance and the readings confirmed as
acceptable.
However HV D.C. tests on a cable connected transformer cannot be done because the windings of
the transformer short out the DC test set.
If between-core tests are required on transformer feeder cables after installation then a link box must
be provided to disconnect the cable from the transformer windings. If transformer covers are taken off
to achieve internal disconnection the tools used must be clean and secured externally by white tape
so that they may be recovered if inadvertently dropped.
All nuts and washers must be accounted for and all operatives should be asked to empty their
pockets while working over the open tank.
Waterproof covers should be provided during the period when the transformer tank is open. If it is not
possible to disconnect the cables after jointing they must be tested beforehand. This means that the
jointing and testing program must be carefully planned to avoid leaving cable ends unsealed for long
periods.
Transformer diagrams should be inspected and the phasing diagram confirmed as correct. Also
before energizing, the voltage selector must be set on the appropriate tapping having regard to the
voltage level of the system.
Transformers which are to operate in parallel must be set on the same tapping and they should be
checked as having the same impedance. Voltage selectors should be locked in their set position and
if they are of the ‘off-circuit’ type they must not be adjusted without the supply being first switched off.
Earthing arrangements for the tank and the neutral or other system earthing must be confirmed and
completed before testing and commissioning.
Where special tests for losses, ratio, phase angle or winding resistances are specified the assistance
of the manufacturer should be sought.
The following points should be checked on the particular type of transformer as appropriate:
23
5.9.1. Oil immersed naturally cooled (ON)
Erection of oil immersed transformer
Ensure that the oil level is adequate and that breather tubes are clear. Commission silica gel units by
removing the airtight seals from the canisters and filling the oil sealing-well to the correct level with
transformer oil.
The color of the silica gel must be checked and the filling changed if it shows dampness (red for wet,
blue for dry).
5.9.2. Dry-type transformers
Erection of dry-type power transformer
As dry-type transformers are more susceptible to external damage they must be carefully handled
and stored on site.
They must also be kept in a dry, warm atmosphere until they are put in service, to prevent ingress of
moisture.
Satisfactory insulation tests are imperative before commissioning. Because they are wholly
dependent on surface radiation and air convection for cooling, they must be checked for any
accumulation of dust or dirt which can block the air ducts and reduce the flow of air. Cleanliness is
essential, particularly where the connection leads leave the windings and at the terminal supports.
Damp dust leads to tracking and causes expensive damage.
24
It is particularly important to check such transformers for dust in package substations which may
escape the notice of commissioning staff.
5.10.Do Not Energize Oil-Filled Transformer Without Performing These 15 Tests and Checks!
The following tests and checks should be performed at a minimum to ensure that the transformer is
ready to be energized. Do not energize the transformer without performing these tests and checks.
If any of below explained tests fail and transformer is energized anyway, it may lead to the serious
hazard, and that’s not good that’s not what we want.
Let’s see these 15 tests…
(i). Insulating Fluid Test
Draw a fluid sample and test its dielectric strength. Dielectric strength of new fluid should be 26 kv or
greater.
The breakdown voltage indicates how well insulating oil can withstand an electrical load and is therefore decisive for the operational
efficiency of a transformer. The breakdown voltage is measured according to VDE 0370 part 5 (IEC 60156)
(ii). Pressure Test
Check the transformer tank for leaks by pressurizing the tank with dry air or dry nitrogen through the
pressure test fitting to a pressure of 3 to 4 PSIG. Let the tank stand under pressure for one to two
hours, then examine the tank and fittings for leaks. Leaks above the fluid level can be detected by
applying soap solution to all welds, joints, pipe fittings, and cable connections.
Upon completion of this test, reduce the internal pressure to 1 or 2 PSIG.
Repairing transformer oil-tank for leakage
25
(iii). Insulation Megger Test
Perform a 1000-volt Megger test and a power factor test to ensure that none of the windings is
grounded.
Regular insulation testing is one of the most cost effective methods of identifying aging of transformer
(iv). Ratio Test
Perform a ratio test at each tap position to ensure that transformer coil ratios and tap changer
connections are correct. Read the complete procedure of transformer turns ratio test step by step.
(v). Continuity Test and Resistance Test
Perform a continuity check on each winding. Measure the winding resistance of each winding and
compare results to factory test values. An increase of more than 10% could indicate a loose internal
connection.
(vi). Line Connections
In preparation for making line connections, check to make sure that all mating connector surfaces
are clean and smooth. Connections must be tightened appropriately to prevent overheating and
possible subsequent failure of the connection.Connections to should be made with care to avoid
placing undue stress on the bushings.
Oil-filled transformer bushings
26
(vii). Tap Changer Setting
Check the tap changer setting to ensure it is set to the proper position for the required voltage.
See an example of transformer tap-changer correct adjustment.
On-Line Oil Filtration for Load Tap Changer Compartment
(viii). Delta/Wye and Series/Multiple Switch Settings
Check delta/wye and series/multiple switch settings to make sure they are set correctly.
If these connections are made using an internal terminal board, check to ensure that these
connections are made properly according to the chart on the transformer nameplate
GE distribution transformer nameplate
(ix). Grounding
Check to ensure that the transformer tank is permanently and effectively grounded. The transformer
tank ground pad is located near the bottom of the tank.
(x). Wiring
Check wiring of control and alarm circuits (if provided) to make sure there are no loose connection
and no damage to insulation.
Oil filled transformer Terminal Box
27
(xi). Fluid Level
Check to make sure the fluid level as indicate by the fluid level gauge is as follow:
The fluid level gauge indicates the fluid level inside the tank. The transformer tank is filled at the
factory to the normal level at a reference temperature of 25° C.
Liquid Level Gauge
(xii). Tank Finish
Check all painted surfaces to make sure that there is no damage or corrosion.
(xiii). Bolted connection
Check all bolted connection for tightness.
Oil transformer bolted connections
(xiv). Tools
Check to make sure that all tools and equipment are accounted for and have been removed from the
transformer
28
(xv). Fluid Temperature
Read the fluid temperature gauge and make sure the temperature is no lower than minus 20° C before
the unit is energized
Liquid Temperature gauge
6. Basic Transformer Routine Test
6.1. Measurement of Winding Resistances
Purpose of the measurement: The resistances between all pairs of phase terminals of each
transformer windings are measured using direct current. Furthermore the corresponding winding
temperature is measured.
The measured resistances are needed in connection with the load loss measurementwhen the load
losses are corrected to correspond to the reference temperature. The resistance measurement will
also show whether the winding joints are in order and the windings correctly connected
Apparatus and basic measuring circuit
The measurement is performed by TETTEX 2285 transformer test system.
Tettex 3 Channel Winding Resistance Meter
This device is an automatic winding analyzer, optimized for three phase power and distribution
transformer measurements.
29
Figure 1 – Circuit for resistance measurement
Where:
T1 - transformer under test,

A – Ammeter,
U – Voltmeter
B – DC supply,
Th - Thermometer
The principle of the measurement is as follows:
The voltage drop Udc caused by the direct current Idc an by the resistance RAB, RAC and RBC is
measured. The resistances are then calculated from Udc and Idc using correction for the error caused
by the internal resistance of the voltage measuring equipment.
The temperature is measured from oil filled thermometer pockets situated in the transformer cover by
means of an electronic thermometer connected to the computer.
Test report:
The resistance values and the average temperature are calculated. In the report the terminals,
between which the resistances are measured, the connection, the tapping position and the average
temperature of the windings during the measurement are stated.
6.2. Partial Discharge Measurement
Transformer insulation structure:
This routine test aims to measure the partial discharges which may occur in the transformer
insulation structure during test.
30
Partial-discharges are electrical arks which form the surges between electrodes of any area of the
insulating media of a transformer between the conductors. These discharges may occur
in airbubbles left in the insulating media, gaps in the solid materials or at the surfaces of two
different insulators.
Although these discharges have small (weak) energy, the thermal energies due to these discharges
can cause aging, deformation and tear of the insulating material.
The following conditions can be determined during partial-discharge measurement:
Ø To determine whether a partial-discharge above a certain value has occurred in the transformer
at a pre-defined voltage.
Ø To define the voltage values where the partial-discharge starts by increasing the applied voltage
(partial-discharge start voltage) and the value where the partial-discharge ceases by decreasing
the applied voltage (partial-discharge cease voltage).
Ø To define the partial-discharge strength at a pre-defined voltage.
How Partial-Discharge occurs and measured magnitudes?
The structure where a partial-discharge occurred in an insulating media is shown in the simplified
Figure 1. As seen on the simplified diagram, the impulses forming on the discharge point cause
a ΔU voltage drop at the transformer line terminals. This forms a measurable “q” load at the
measuring impedance.
This load is called apparent load and given in pC (Pico-Coulomb) units.
During measurements: ΔU voltage drop, average value of apparent partial-discharge current,

partial- discharge power, impulse count within a time unit, partial-discharge start and cease voltages
can also be determined.
Figure 1 – a) simple schematics of an insulator with gas gap b) equivalent circuit
31
Measuring circuit and application
Partial-discharge measurement structure of a transformer and related circuit in accordance with IEC
60270 is explained below.
Figure 2 – Partial discharge measuring connection circuit
Where:
1. Supply generator
2. Supply transformer
3. Test transformer
4. Voltage transformer and measuring circuit
5. Filter
6. Measuring impedance
7. Selective switch
8. Measuring instrument and oscilloscope
9. Calibration generator
The measurement circuit in Figure 2 is formed according to Bushing-tap method stated in standards.
Application of the test
After the calibration operations are completed, the calibration generator is taken away from the
measuring circuit. When the power system is connected (supply generator switch is closed), the
voltage level will be too low (remenance level).After the calibration operations are completed, the
calibration generator is taken away from the measuring circuit. When the power system is connected
(supply generator switch is closed), the voltage level will be too low (remenance level).
Voltage Level
After the calibration operations are completed, the calibration generator is taken away from the measuring circuit.
When the power system is connected (supply generator switch is closed), the voltage level will be too low
(remenance level).
Where:
gm= load read at the measuring instrument m

k = Correction factor
q = Real apparent load
32
Evaluation
The test considered to be successful if the partial-discharge value measured at the transformer’s
measuring terminals is lower than predefined values or values stated in the standard and no
increasing tendency is observed during test.
In addition to the measured partial-discharge level, the below condition should also be considered in
transformer’s
Ø Partial-discharge start and cease voltage are above the operating voltage.
Ø Depending on the test period, partial-discharge level stays approximately stable.
Ø Increasing the test voltage causes almost no partial-discharge level change
6.3. Measurement of Zero-Sequence Impedance Earth-fault protection
Purpose of the measurement
The zero-sequence impedance is usually measured for all star-connected windings of the
transformer. The measurement is carried out by supplying a current of rated frequency between the
parallel connected phase terminals and the neutral terminal.
The zero-sequence impedance per phase is three times the impedance measured in this way.
The zero-sequence is needed for earth-fault protection and earth-fault current calculations.
Measuring circuit and performance of measurement
Circuit for zero-sequence impedance measurement in shown below, where:
G1 = supply generator
T1 = transformer to be tested
T2 = voltage transformer
T3 = current transformer
P2 = voltmeter
P3 = ammeter
I = test current
Figure 1 – Circuit for zero-sequence impedance measurement
33
The zero-sequence impedance is dependent on the current flowing through the winding. Usually the
value corresponding to rated current IN is stated. This implies that the measurement is carried out
with a test current of 3 x IN.
However, this is not always possible in practice since the current must be limited to avoid excessive
temperature of metallic constructional parts.
The zero-sequence impedance is measured as function of test current, and when necessary the final
result is obtained by extrapolation.
Test Result
The zero-sequence impedance is usually given as a percentage of the rated phase impedance.
When the transformer has a three-limb core and no delta-connecter windings, the zero-sequence
impedance is about 30…60 %. When the transformer has a delta-connected winding, the zero-
sequence impedance is 0.8…1.0 time the corresponding short-circuit impedance.
In the test report the zero-sequence impedance values at the principal and extreme tapping’s are
stated.
7. Inspection and Test procedures for Instrument Transformers
Visual and Mechanical Inspection
1. Compare equipment nameplate data with drawings and specifications.

2. Inspect physical and mechanical condition.
3. Verify correct connection of transformers with system requirements.
4. Verify that adequate clearances exist between primary and secondary circuit wiring.
5. Verify the unit is clean.
6. Inspect bolted electrical connections for high resistance using one or more of the
following methods:
ØUse of low-resistance ohmmeter in accordance with Section 2.1 and 2.2.
Ø Verify tightness of accessible bolted electrical connections by calibrated torque-wrench method
in accordance with manufacturer’s published data or Table 100.12.
Ø Perform thermography survey.
7. Verify that all required grounding and shorting connections provide contact.
8. Verify correct operation of transformer withdrawal mechanism and grounding operation.
9. Verify correct primary and secondary fuse sizes for voltage transformers.
10. Verify appropriate lubrication on moving current-carrying parts and on moving and sliding surfaces.
7.1 Electrical Tests:
7.1.1. Electrical Tests – Current Transformers
Ø Perform resistance measurements through bolted connections with a low-resistance ohmmeter, if

applicable, in accordance with Section 1.
Ø Perform insulation-resistance test of each current transformer and its secondary wiring with respect
to ground at 1000 volts dc for one minute. For units with solid-state components that cannot tolerate
the applied voltage, follow manufacturer’s recommendations.
Ø Perform a polarity test of each current transformer in accordance with ANSI/IEEE C57.13.1.
Ø Perform a ratio-verification test using the voltage or current method in accordance with ANSI/IEEE
C57.13.1.
Ø Perform an excitation test on transformers used for relaying applications in accordance
with ANSI/IEEE C57.13.1.
Ø Measure current circuit burdens at transformer terminals in accordance with ANSI/IEEE C57.13.1.
Ø When applicable, perform insulation-resistance tests on the primary winding with the
secondary grounded. Test voltages shall be in accordance with Table 100.5.
Ø When applicable, perform dielectric withstand tests on the primary winding with the
secondary grounded. Test voltages shall be in accordance with Table 100.9.
Ø Perform power-factor or dissipation-factor tests in accordance with test equipment manufacturer’s
published data.
34
Ø Verify that current transformer secondary circuits are grounded and have only one grounding point
in accordance with ANSI/IEEE C57.13.3. That grounding point should be located as specified by
the engineer in the project drawings.
7.1.2Electrical Tests – Voltage Transformers

Ø Perform insulation-resistance tests winding-to-winding and each winding-to-ground. Test voltages
shall be applied for one minute in accordance with Table 100.5. For units with solid-state
components that cannot tolerate the applied voltage, follow manufacturer’s recommendations.
Ø Perform a polarity test on each transformer to verify the polarity marks or H1- X1 relationship as
applicable.
Ø Perform a turns-ratio test on all tap positions.
Ø Measure voltage circuit burdens at transformer terminals.
Ø Perform a dielectric withstand test on the primary windings with the secondary windings connected
to ground. The dielectric voltage shall be in accordance withTable 100.9. The test voltage shall be
applied for one minute.
Ø Perform power-factor or dissipation-factortests in accordance with test equipment manufacturer’s
published data.
Ø Verify that voltage transformer secondary circuits are grounded and have only one grounding point
in accordance with ANSI/IEEE C57.13.3. The grounding point should be located as specified by the
engineer in the project drawings.
7.1.3.Electrical Tests – Coupling-Capacitor Voltage Transformers

Ø Perform insulation-resistance tests winding-to-winding and each winding-to-ground. Test voltages
shall be applied for one minute in accordance with Table 100.5. For units with solid-state
components that cannottolerate the applied voltage, follow manufacturer’s recommendations.
Ø Perform a polarity test on each transformer to verify the polarity marking. SeeANSI/IEEE C93.1 for
standard polarity marking.
Ø Perform a turns-ratio test on all tap positions, if applicable.
Ø Measure voltage circuit burdens at transformer terminals.
Ø Perform a dielectric withstand test on the primary windings with the secondary windings connected
to ground. The dielectric voltage shall be in accordance with Table 100.9. The test voltage shall be
applied for one minute.
Ø Measure capacitance of capacitor sections.
7.2. Test Values:
7.2.1.Test Values: Visual and Mechanical
Ø Compare bolted connection resistance values to values of similar connections. Investigate values
which deviate from those of similar bolted connections by more than 50 percent of the lowest value.
(1.6.1)
Ø Bolt-torque levels shall be in accordance with manufacturer’s published data. In the absence
of manufacturer’s published data, use Table 100.12.
Ø Results of the thermo graphic survey.
Ø Perform power-factor or dissipation-factor tests in accordance with test equipment manufacturer’s
published data.
Ø Verify that the coupling-capacitor voltage transformer circuits are grounded and have only
one grounding point in accordance with ANSI/IEEE C57.13.3. That grounding point should
be located as specified by the engineer in the project drawings.
35
7.2.2Test Values: Current Transformers – Electrical
which deviate from those of similar bolted connections by more than 50 percent of the lowest
value.
Ø Insulation-resistance values of instrument transformers shall not be less than values shown
in Table 100.5.
Ø Polarity results shall agree with transformer markings.
Ø Ratio errors shall be in accordance with C57.13.
Ø Excitation results shall match the curve supplied by the manufacturer or be in accordance
with ANSI C57.13.1.
Ø Measured burdens shall be compared to instrument transformer ratings.
Ø Insulation-resistance values of instrument transformers shall be in accordance with manufacturer’s
published data. In the absence of manufacturer’s published data, use Table 100.5.
Ø If no evidence of distress or insulation failure is observed by the end of the total time of
voltage application during the dielectricwithstand test, the primary winding is considered to
have passed the test.
Ø Power-factor or dissipation-factor values shall be in accordance with manufacturer’s
published data. In the absence of manufacturer’s published data, use test equipment
manufacturer’s published data.
Ø Test results shall indicate that the circuits have only one grounding point.
7.2.3. Test Values: Voltage Transformers – Electrical
Ø Insulation-resistance values of instrument transformers shall be in accordance with manufacturer’s
published data. In the absence of manufacturer’s published data, use Table 100.5.
voltage application during the dielectric withstand test, the primary windings are considered to
Ø Power-factor or dissipation-factor values shall be in accordance with manufacturer’s published data.
In the absence of manufacturer’s published data, use test equipment manufacturer’s published
data.
Ø Test results shall indicate that the circuits are grounded at only one point.
7.2.4 Test Values: Coupling Capacitor Voltage Transformers
Ø Insulation-resistance values of instrument transformers shall not be less than values shown in Table
100.5.
voltage application during the dielectric withstand test, the test specimen is considered to have
passed the test.
Ø Capacitance of capacitor sections of coupling-capacitor voltage transformers shall be in accordance
with manufacturer’s published data.
Ø Power-factor or dissipation-factor values shall be in accordance with manufacturer’s published data.
In the absence of manufacturer’s published data, use test equipment manufacturer’s published
data.
Ø Test results shall indicate that the circuits are grounded at only one point.
36
TABLE 100.5
Transformer Insulation Resistance Acceptance Testing
Table 100.5 – Transformer Insulation Resistance Acceptance Testing
(In the absence of consensus standards, the NETA Standards Review Council suggests the above representative values.
NOTE: Since insulation resistance depends on insulation rating (kV) and winding capacity (kVA), values obtained should be compared to
manufacturer’s published data.)
TABLE 100.9
Instrument Transformer Dielectric Tests Field Acceptance
Table 100.9 – Instrument Transformer Dielectric Tests Field Acceptance

Table 100.9 is derived from Paragraph 8.8.2 and Tables 2 of ANSI/IEEE C57.13-1993, Standard Requirements for Instrument Transformers.
* Periodic dc potential tests are not recommended for transformers rated higher than 34.5 kV.
* DC potential tests are not recommended for transformers rated higher than 200 kV BIL. DC tests may prove beneficial as a reference for
future testing. In such cases the test direct voltage shall not exceed the original factory test rms alternating voltages.
37
7. Inspection and Test procedures for Power Transformers
Figure 4.1 – Circuit for the impedance and load-loss measurement
Purpose of the measurement
The measurement is carried out to determine the load-losses of the transformer and theimpedanse
voltage at rated frequency and rated current.
The measurements are made separately for each winding pair (e.g., the pairs 1-2, 1-3 and 2-3 for a
three- Figure 4.1 – Circuit for the impedance and load-loss measurement
Apparatus and measuring circuit
On Figure 1 above (Circuit for the impedance and load-loss measurement) there are following figures:
G1 – Supply generator
T1 – Step-up transformer
T2 – Transformer to be tested
T3 – Current transformers
T4 – Voltage transformers
P1 – Watt meters
P2 – Ammeters (r.m.s. value)
P3 – Voltmeters (r.m.s. value)
C1 – Capacitor bank
The supply and measuring facilities are not described here. Current is generally supplied to the h.v.
winding and the LV. winding is short-circuited
Performance of the measurement
If the reactive power supplied by the generator G1 is not sufficient when measuring large transformers,
a capacitor bank C1 is used to compensate part of the inductive reactive power taken by the
transformer T2.The voltage of the supply generator is raised until the current has attained the required
value (25…100 % of the rated current according to the standard 4.1).
In order to increase the accuracy of readings will be taken at several current values near the required
level. If a winding in the pair to be measured is equipped with an off-circuit or on-load tap-changer. the
measurements are carried out on the principal and extreme tapping’s.
The readings have to be taken as quickly as possible, because the windings tend to warm up due to
the current and the loss values obtained in the measurement are accordingly too high.
It the transformer has more than two windings all winding pairs are measured separately.
38
Results
Corrections caused by the instrument transformers are made to the measured current, voltage and
power values. The power value correction caused by the phase displacement is calculated as follows:
Equation 4.1
Where:
Pc = corrected power
Pe = power read from the meters
δu = phase displacement of the voltage transformer in minutes
δi = phase displacement of the current transformer in minutes
ϕ = phase angle between current and voltage in the measurement (ϕ is positive at inductive load)
K = correction
The correction K obtained from equation 4.1 is shown as a set of curves in Figure 4.2.
The corrections caused by the instrument transformers are made separately for each phase, because
different phases may have different power factors and the phase displacements of the instrument
transformers are generally different.
If the measuring current Im deviates from the rated current IN, the power Pkm and the voltage Ukm at
rated current are obtained by applying corrections to the values Pc and Ucrelating to the measuring
current.
The corrections are made as follows:
Equation 4.2
Equation 4.3
The correction caused by the phase displacement of instrument transformers (Figure 2):
Figure 4.2 – Phase displacement of instrument transformers
39
Where:
K – correction in percent,
δu – δi – phase displacement in minutes
cosδ – power factor of the measurement.
The sign of K is the same as that of δu – δi.
Mean values are calculated of the values corrected to the rated current and the mean values are
used in the following. According to the standards the measured value of the losses shall be
corrected to a winding temperature of 75° C (80° C, if the oil circulation is forced and directed).
The transformer is at ambient temperature when the measurements are carried out. And the loss
values are corrected to the reference temperature 75° C according to the standards as follows.
The DC losses POm at the measuring temperature ϑm are calculated using the resistance values
R1m and R2m obtained in the resistance measurement (for windings 1 and 2 between line
terminals):
Equation 4.4
The additional losses Pamat the measuring temperature are:
Equation 4.5
Here Pkm is the measured power, to which the corrections caused by the instrument transformer
have been made, and which is corrected to the rated current according to equation (4.2).
The short-circuit impedance Zkm and resistance Rkm at the measureing temperature are:
Equation 4.6
Equation 4.7
Ø Ukm is the measured short-circuit voltage corrected according to Equation (4.3);

Ø UN is the rated voltage and
Ø SN is the rated power.
The short circuit reactance Xk does not depend on the losses and Xk is the same at the measuring
temperature (ϑm) and the reference temperature (75 °C), hence:
Equation 4.8
When the losses are corrected to 75° C, it is assumed that d.c. losses vary directly with resistance
and the additional losses inversely with resistance. The losses corrected to 75° C are obtained as
follows:
40
Equation 4.9
Where:
ϑs = 235° C for Copper

ϑs = 225° C for Aluminium
Now the short circuit resistance Rkc and the short circuit impedance Zkc at the reference
temperature can be determined:
Equation 4.10
Equation 4.11
Results
The report indicates for each winding pair the power SN and the following values corrected to 75° C
and relating to the principal and extreme tappings
Ø D.C. losses POc (PDC)
Ø Additional losses Pac (PA)
Ø Load losses Pkc (PK)
Ø Short circuit resistance Rkc (RK)
8. Inspection and test procedures for Rotating Machinery, Synchronous Motors and Generators
Procedures (Index)
7.1 Visual and Mechanical Inspection

7.2 Electrical Tests
7.3 Test Values
7.4 Visual and Mechanical Tests
7.5 Electrical Tests
7.6 Pictures:
7.7 Electrical machine wired for electrical testing
7.8 The Electrical Machines Laboratory
7.9 TABLE 100.10 – Maximum Allowable Vibration Amplitude
7.10 TABLE 100.12 – US Standard Fasteners
8.1 Visual and Mechanical Inspection
Ø Compare equipment nameplate data with drawings and specifications.

Ø Inspect physical and mechanical condition.
Ø Inspect anchorage, alignment, and grounding.
Ø Inspect air baffles, filter media, cooling fans, slip rings, brushes, and brush rigging.
Ø Inspect bolted electrical connections for high resistance using one or more of the following
methods:
· Use of low-resistance ohmmeterin accordance with procedure for LR ohmmeterusage.
· Verify tightness of accessible bolted electrical connections by calibrated torque-wrench method
in accordance with manufacturers published data or Table 100.12(see below).
Ø Perform thermographic survey.
41
Ø Perform special tests such as air-gap spacing and machine alignment.

Ø Verify the application of appropriatelubrication and lubrication systems.
Ø Verify that resistance temperature detector (RTD) circuits conform to drawings.
8.2. Electrical Tests
Ø Perform resistance measurements through bolted connections with a low-resistance ohmmeterif

applicable.
Ø Perform insulation-resistance tests inaccordance with ANSI/IEEE Standard 43.
· Machines larger than 200 horsepower (150 kilowatts):
· Test duration shall be for ten minutes. Calculate polarization index.
· Machines 200 horsepower (150 kilowatts) and less:
· Test duration shall be for one minute. Calculate dielectric-absorption ratio.
Ø Perform dc dielectric withstand voltage tests on machines rated at 2300 volts and greater in
accordance with ANSI/IEEE Standard 95.
Ø Perform phase-to-phase stator resistance test on machines 2300 volts and greater.
Ø Perform insulation power-factoror dissipation-factor tests.
Ø Perform power-factor tip-up tests.
Ø Perform surge comparison tests.
Ø Perform insulation-resistance test on insulated bearings in accordance with manufacturerspublished
data, if applicable.
Ø Test surge protection devices.
Ø Test motor starter.
Ø Perform resistance tests on resistance temperature detector (RTD) circuits.
Ø Verify operation of machine space heater, if applicable.
Ø Perform vibration test.
Ø Perform insulation-resistance tests on the main rotating field winding, the exciter-field winding, and
the exciter-armature winding in accordance with ANSI/IEEE Standard 43.
Ø Perform an AC voltage-drop test on all rotating field poles.
Ø Perform a high-potential test on the excitation system in accordance with ANSI/IEEE Standard
421.3.
Ø Measure resistance of machine-field winding, exciter-stator winding, exciter-rotor windings,and field
discharge resistors.
Ø Perform front-to-back resistance tests on diodes and gating tests of silicon-controlled rectifiersfor
field application semiconductors.
Ø Prior to re-energizing, apply voltage to the exciter supply and adjust exciter-field current
tonameplate value.
Ø Verify that the field application timer and the enable timer for the power-factor relay have
beentested and set to the motor drive manufacturers recommended values.
Ø Record stator current, stator voltage, and field current for the complete acceleration periodincluding
stabilization time for a normally loaded starting condition. From the recordingdetermine the following
information:
· Bus voltage prior to start.
· Voltage drop at start.
· Bus voltage at machine full-load.
· Locked-rotor current.
· Current after synchronization but before loading.
· Current at maximum loading.
· Acceleration time to near synchronous speed.
· Revolutions per minute (RPM) just prior to synchronization.
· Field application time.
· Time to reach stable synchronous operation.
Ø Plot a V-curve of stator current versus excitation current at approximately 50 percent load tocheck
correct exciter operation.
Ø If the range of exciter adjustment and machine loading permit,reduce excitation to cause
powerfactor to fall below the trip value of the power-factor relay. Verify relay operation.
42
8.3. Test Values
8.3.1. Visual and Mechanical Test Values
(i). Inspection
Ø Air baffles shall be clean and installed in accordance with manufacturers publisheddata.
Ø Filter media shall be clean and installed in accordance with manufacturers publisheddata.
Ø Cooling fans shall operate.
Ø Slip ring alignment shall be within manufacturers published tolerances.
Ø Brush alignment shall be within manufacturers published tolerances.
Ø Brush rigging shall be in accordance with manufacturers published data.
(ii).Compare bolted connection resistance values to values of similar connections.
Ø Investigate anyvalues that deviate from similar bolted connections by more than 50 percent of the
lowestvalue.
Ø Bolt-torque levels should be in accordance with manufacturers published data. In the absenceof
manufacturers published data, use Table 100.12 (see below)
Ø Results of thermographic survey to be analyzed.
Ø Air-gap spacing and machine alignment shall be in accordance with manufacturer’s publisheddata.
8.3.2. Electrical Test Values
Ø Compare bolted connection resistance values tovalues of similar connections. Investigate

anyvalues that deviate from similar bolted connections by more than 50 percent of the lowestvalue.
Ø The dielectric absorption ratio or polarization index shall not be less than 1.0. Therecommended
minimum insulation resistance (IR 1 min) test results in megaohms shall becorrected to 40° C and
read as follows:
· IR 1 min = kV + 1 for most windings made before 1970 (kV is the rated machine terminal-to-
terminal voltage in rms kV)
· IR 1 min = 100 megohms for most dc armatureand ac windings built after 1970 (form-wound
coils).
· IR 1 min = 5 megohms for most machines and random-wound stator coils and form-wound coils
rated below 1 kV.
NOTE: Dielectric withstand voltage and surge comparison tests shall not be performedon machines
having values lower than those indicated above.
voltageapplication during the dielectric withstand test, the test specimen is considered to have
passedthe test.
Ø Investigate phase-to-phase stator resistance values that deviate by more than five percent.
Ø Power-factor or dissipation-factor values shall be compared to manufacturers published data.
In the absence of manufacturers published data these values will be compared with previousvalues of
similar machines.
Ø Tip-up values shall indicate no significant increase in power factor.
Ø If no evidence of distress, insulation failure, orlack of waveform nesting is observed by the endof the
total time of voltage application during the surge comparison test, the test specimen isconsidered to
Ø Insulation resistance of bearings shall be within manufacturers published tolerances. In theabsence
of manufacturers published tolerances, the comparison shall be made to similarmachines.
Ø Test results of surge protection devices shall be in accordance with procedures for testing of LV
surge arresters.
Ø Test results of motor starter equipment shall be in accordance withprocedures for testing of motor
starter equipment.
Ø RTD circuits shall be in accordance with system design intent and machine protection
devicemanufacturers published data.
43
Ø Heaters shall be operational.

Ø Vibration amplitudes of the uncoupled and unloaded machine shall not exceed values shown
inTable 100.10 (see below). If values exceed, perform complete vibration analysis.
Ø The recommended minimum insulation resistance (IR1 min) test results in megaohms shall
becorrected to 40? C and read as follows:
· IR 1 min= kV + 1 for most windings made before 1970, all field windings (kV is the rated
machine terminal-to-terminal voltage in rms kV)
· IR 1 min= 100 megohms for most dc armature and ac windings built after 1970 (form-wound
coils).
· IR 1 min= 5 megohms for most machines and random-wound stator coils and form-wound coils
rated below 1 kV.
NOTE: Dielectric withstand voltage, high-potential, and surge comparison tests shallnot be performed
on machines having values lower than those indicated above.
Ø The pole-pole AC voltage drop shall not exceed 10 percent variance between poles.
voltageapplication during the dielectricwithstand test, the winding is considered to have passed
thetest.
Ø The measured resistance values of motor-field windings, exciter-stator windings, exciter-
rotorwindings, and field-discharge resistors shall be compared to manufacturers published data.
Inthe absence of manufacturerspublished data, the comparison shall be made to similarmachines.
Ø Resistance test results of diodes and gating tests of silicon-controlled rectifiers shall be
inaccordance with industry standards and system design requirements.
Ø Exciter power supply shall allow exciter-field current to be adjusted to nameplate value.
Ø Application timer and enable timer for power-factor relay test results shall comply
withmanufacturers recommended values.
Ø Recorded values shall be in accordance with system design requirements.
Ø Plotted V-curve shall indicate correct exciter operation.
Ø When reduced excitation falls below trip value for the power-factorrelay, the relay shalloperate
9. Testing and Commissioning Procedure for Motors
9.1. Scope of Motor Testing
It should be noted that the scope of motor testing depends upon the motor type and size, this being
indicated on the inspection forms.
Motor vibration shall be measured in a tri-axial direction, i.e.:
Ø Point x axis – side of bearing housing at shaft height

Ø Point y axis – top of bearing housing
Ø Point z axis – axial of bearing housing at shaft height
The measurements shall be carried out with an instrument conforming to ISO 2954 (10-1000 Hz
frequency range). With the motor at normal operating temperature, the vibration velocity shall not
exceed 2.8 mm/s RMS, or 4 mm/s PEAK, in any direction.
For bearings fitted with proximity probes, the unfiltered peak-to-peak value of vibration (including shaft
‘run-out‘) at any load between no load and full load, shall not exceed the following values:
Ø 50 µm for two-pole motors

Ø 60 µm for four-pole motors
Ø 75 µm for six-pole or higher motors
44
Motor bearing
Bearing temperature rise limits following a ‘heat run’ of 3.5 – 4 hours are as follows:
Rolling bearings:
Ø Outer ring measurement max. 90 °C

Ø Temperature rise from ambient max. 50 °C
Sleeve bearings:
Ø Oil temperature max. 90 °C

Ø Bearing temperature rise by RTD max. 50 °C
Ø Lube-oil temperature rise from ambient max. 30 °C (for forced lube-oil systems).
When commissioning or re-commissioning motors, precautions shall be taken to avoid excessive vibration
caused by the phenomenon known as ‘soft foot‘; i.e. feet which do not have solid flat contact with the base
prior to the tightening of the holding-down bolts.
This may be measured and rectified during installation or detected during running by the loosening of each
holding-down bolt in turn while measuring motor vibration.
Motor ‘Soft Foot’ Condition:
‘Soft feet’ are those which do not have solid flat contact with the base prior to the tightening of the holding-
down bolts; one or more feet may be ‘soft’ as shown in Figures 1 to 3.
The profile of the foot contact area may be as shown in Figures 4 to 6.
The profile of the foot contact area (Figures 1, 2 and 3)
45
· Figure 1 - Machine resting on 3 feet, foot 4 is raised or ‘soft’

· Figure 2 - Machine resting on diagonal formed by feet 3 and 4, feet 1 and 4 are ‘soft’
· Figure 3 - Bottoms of all 4 feet are not parallel with base, feet 3 and 4 are ‘soft’
Profile of 'soft foot' contact area
NOTE: Re-machining of rotor feet is required in Figures 4 and 5; temporary use of wedge-shaped shims may
be acceptable (maintenance).
46
Form 14 – Inspection of electric motor – Cage-induction type (incl. control unit)
Inspection of electric motor cage-induction type (including control unit)
47
Form 4 – Inspection of Switching Units – HV Switchgear
Inspection of Switching Units - HV Switchgear
48
Form 11 – Inspection Of Outgoing Unit – LV Switchboard
Inspection of Outgoing Unit - LV Switchboard
49
Electrical machine wired for electrical testing
The Electrical Machines Laboratory
50
Maximum Allowable Vibration Amplitude
Table 100.10 Maximum Allowable Vibration Amplitude
10. Field Inspection and Testing of Medium-Voltage Motor Control Centers (MCCs)
10.1. Equipment and Installation Check Items
Ø Check MCC equipment for: alignment, levelness, and tightness of all bolting.
Ø Check all equipment for: removal of blocking, supports, temporary ties, and temporary wire
jumpers.
Ø Check that all protective barriers are properly installed.
Ø Check door alignment of individual starter units and door interlock operation.
Ø Check operation of external overload protective device reset.
Ø Check those draws out contacts are completely disconnected when drawout handle is operated.
Ø Check CPT and PT fuses for: size, type, and circuit location.
Ø Check PT and CT ratios.
Ø Check CPT size and rating.
Ø Check voltage rating of contactor coil.
Ø Verify that metering or relaying devices using resistance temperature detectors(RTDs) have the
correct rating.
Ø Check fuses and wiring to power factor correction capacitors for size and rating.
Ø Check all components for proper identification according to the drawings and specifications.
10.2. Equipment and Installation Inspection Items
Ø Inspect MCC bus bar connections for tightness by verifying that the torque meets manufacturer’s
specifications. Verify that connection hardware is consistent with the Owner’s project specifications.
Ø Inspect MCC bus bar supports for: cleanliness and tightness.
Ø Inspect ground connections to ground bus. Inspect operation of: mechanical interlocks, position
indicators, draw out or rollout mechanism, and all safety interlock features.
Ø Inspect contactor rating.
Ø Inspect contactor-insulating parts for: cleanliness and dryness.
Ø Inspect contactor electrical contact surfaces for cleanliness and smoothness. Lubricate per
manufacturer’s instructions.
Ø Inspect contactor-seating surfaces of unplated and laminated magnet faces of contactor and relays.
Remove any rust or rust preventative if present.
Ø Inspect contactor power stabs and adjust per manufacturer’s instructions.
Ø Inspect manual operation of contactor and mechanical relay devices to verify that all parts are free
and that they work smoothly. For air contactors, verify adjustment for contact wipe and alignment
per manufacturer’s instructions.
Ø Inspect lubrication of contactor moving parts.
Ø Inspect contactor vacuum bottles for damage.
Ø Inspect size, type, and rating of current-limiting power fuses.
Ø Inspect overload protective device rating and setting.
51
10.3. Testing Requirements
Ø Test insulation resistance of MCC bus with a 1-minute test (phase to phase and phase to ground).
Ø Test insulation resistance of control power and instrument transformers with a 1-minute test at
applicable voltage.
Ø Test insulation resistance of contactor (closed position) with a 1-minute test (phase to phase and
phase to ground).
Ø Test contactor contact resistance with micro-ohmmeter.
Ø Test integrity of each vacuum interrupter on a vacuum contactor in accordance with manufacturer’s
instructions.
Ø Calibrate and test each protective relay with settings on devices being in accordance with approved
relay settings summary or coordination study.
Ø Test contactor drop-out time if power disturbance ride-through is specified.
Ø Test operation of all space heaters including switching and indicating devices.
Ø Test CT circuit by applying current to the CT primary circuit and verifying operation of all applicable
relays and metering devices.
Ø When primary current injection is not practicable because of size of current requirements, test CT
secondary circuit by applying current to CT secondary circuit with CT disconnected, and verify
operation of all applicable relays and metering devices.
Ø Test window-type ground CTs and their circuits by applying current to a conductor passed through
the window.
Ø When specified on the Data Sheet, perform a CT ratio-verification test using the voltage or current
method in accordance with ANSI C57.13.1.
Ø Test voltmeter, ammeter, and related selector switches when installed.
Ø Test proper operation of overload protective device. Operate mechanical trip option if present.
10.4. Function Test Items
Ø Function-test each contactor in the test position:

Ø Close and trip contactor with all local and remote control devices. Verify operation of all auxiliary
devices by functional testing.
Ø Trip contactor from each protective device individually. Verify operation of all auxiliary devices.
Ø Verify operation of capacitor discharge resistor system on power factor capacitors using a properly
sized voltmeter.
Example of MV MCC Switchgear
52
11. Commissioning of HV Panel – Operational and Functional Checkup
11.1. Main Objective
The main objective of the test is to check the proper operation function of the circuit breaker; in this
test we do the following:
A. Close Operation Test – Local—Remote
This test is conducted by manual, Local and Remote.
For the manual Operation test, we will charge the spring manual and breaker is also closed my
manual and opening also done. For the Local operation we give Control supply and A.C supply for
spring charge motor.
We close the Circuit Breaker using the TNC (Trip Neutral Control) switch.
We observe for the closing coil function and spring charging of motor operation. For remote operating
is the site is ready (such as plc or BMS) then remote operation is done using the remote system.
If its site is not ready for this, we provide a local signal to the remote terminal and observe the
operation of breaker.
B. Trip Operation Test – Local-Remote
This test is conducted by manual, Local and Remote. For the manual Operation test, The manually
charged breaker is opened using the Trip switch.. For the Local operation we give Control supply and
A.C supply for spring charge motor. We open the Breaker using the TNC switch.
We observe for the tripping coil function. For remote operating is the site is ready (such as PLC or
BMS) then remote operation is done using the remote system.
If its site is not ready for this, we provide a local signal to the remote terminal and observe the
operation of breaker.
C. Protection Trip
For this test the breaker has in closed position at initially. We provide an auxiliary rated voltage to
Master trip relay, and observe the opening of the breaker and the position of the trip coil.
11.2. Functional Check
(i). Emergency Trip
For this test the breaker has to be in charged or ON position, we operate the emergency push button.
We observe the operation of circuit breaker opening.
(ii). Aux. Switch Operation
When the breaker is in open condition we check the Aux. contact of the breaker using continuity tester,
to conform the contact is in NO /NC. Then we close the Circuit Breaker and check the same contact
with continuity tester, to conform the contact is in NC /NO.
(iii). On-Off Indications (Lamp + Flag)
When the breaker is in open condition we check the Lamp + Flag of the relay. Then we close the
Circuit Breaker and check the same Lamp operation.
53
(iv). Trip / Trip circuit healthy Lamp Indication
The relay is operated and we observer the Trip lamp indication.
(v). Limit Switch for spring charge motor
On this test we observe the operation of the limit switch of the spring charging motor.
We give an A.C power to motor and observer the operation of motor and charging of spring, on the
indication of fully charged spring the motor operation has to get stopped.
(vi). Test / Service Limit Switch

This test is conducted to check the Test / Service Limit Switch Operation. During rack out the Breaker
we obverse the indicator to change to test position and during rack in the breaker we obverse the
indicator to change to service.
(vii). Operation Counter
This test is conducted if operational counter provision is available in breaker. We operated the breaker
and look for the change in counter for counting the operation.
(viii). Heater / Heater Switch / Thermostat
The control A.C supply is given for heater and we look for heater operation.
(ix). Function of illumination and socket switch
In this test we look for the panel internal illumination and socket switch operation. We operate the limit
switch manually and observe the operation of illumination circuit.
12. Erection procedure for HV switchgear
66kV/230kV GIS extension work
54
12.1. Important points
Before commencing erection of HV switchgear check that all connectionsare tight on bus-bars and on
main circuits as well as auxiliary circuits.
Examine the insulation very carefully, because there have been reported cases of burned out
connections due to failure to observe this precaution. Obvious faults such as distorted panel work,
broken meter glass and damaged packing cases should be noted and immediate steps taken to rectify
the damage or to return the equipment to the supplier or manufacturer.
After erection, steps must be taken to prevent deterioration of the equipment due to damp. Dust or
casual damage. Substations should be cleared out and locked fast and should not be used as a site
office, store or workshop after the equipment has been installed.
When all erection and jointing work is complete the equipment must be inspected and thoroughly
cleaned to remove cuttings of cable, spare nuts, and washers, accumulations of dust or copper filings
and tools which may have been left behind.
However, it is dangerous to blow out equipment because dust, filings, light metal scraps, rags and
sawdust can be blown into positions where they become inaccessible and may pass unnoticed. It is
better to clean manually and vacuum the plant.
An important point to remember is the removal of all packing materials particularly in moving parts,
and of course makes sure that oil circuit-breakers receive their first filling of water-free oil.
In the erection of the switchgear the following points should be emphasized.
Where steel channels are used as foundations, ensure that they are correctly laid to an accuracy of
about ±1mm in 3 m. Use a masking strip to prevent fouling by the floor materials.
IMPORTANT: Read and apply the manufacturer’s erection instructions and use the correct tools such
as torque spanners to obtain the appropriate tightness of nuts.
GIS Installation
55
Make sure equipment is properly aligned. This means vertically and horizontally in both longitudinal
and lateral directions. Incorrect alignment causes problems during operation of mechanical linkages
and connections, difficulty in removing and replacing circuit-breakers and other withdraw able parts
and puts stress on interpanel connections such as bus-bars and earth bars.
When the floor is being laid and there are no steel inset channels, it should be level both front to back
and should not vary by more than a millimeter or so between cubicle centers.
When the floor is being laid it is common practice to form pockets at the foundation hole positions in
order to avoid having to cut them out of the solid floor at installation time. The floor should be marked
out in accordance with the switchgear assembly drawings usually provided by the manufacturer to
ensure that the switchgear is correctly located with respect to cable trenches, building walls and other
equipment in the room.
A datum line requires to be established usually along the rear foundation bolts, and using normal
geometric methods the switchboard and foundation bolt holes can be located.
The method of positioning the equipment is dependent on a number of factors such as equipment
size, building location, site accessibility and lifting tackle available.
Lifting eyes are often either incorporated into switchboards or can be screwed into pre-machined
holes, but generally slinging is necessary and this should be done strictly in accordance with the
manufacturer’s recommendations. Without the use of cranes, however, the traditional manual methods
utilizing jacks and roller bars are effective.
Care must be taken not to exert pressure on weak parts such as control handles during this
manhandling.
12.2. Positioning of cubicles
Positioning of the cubicles should start near to the center of the switchboard, installing as early as
possible the enclosures associated with any special chambers or trunking.
The first enclosure should be positioned and checked to ensure the side sheets are plumb and that
any runner rails are level in both planes.
When the first enclosure panel is correctly set the remaining enclosures should be positioned
successively on alternate sides of this panel to make the front form an unbroken line.
Adjacent enclosures should be bolted together after they have been correctly aligned using whatever
shimming proves necessary to make sure that the cubicles are vertically and horizontally true. The
fixing bolts should be positioned in the foundation holes andcemented in leaving adequate time for the
cement to set before tightening up.
The equipment may now be connected up and cable joints made.
In particular one must confirm that the earthing of the equipment has been carried out using the
recommended cross-section of material and satisfactory terminations.
The LV system must then be proved for continuity, preferably by using a hand generator or other
portable device and with a current of about 1.5 times the design current. A further examination of all
incoming and outgoing circuit and auxiliary cables, including a test of the correctness of the
connections at the remote ends, should be done; this should include measuring the insulation
resistance and continuity of all cables and wiring including internal and auxiliary connections.
56
Where appropriate, phase rotation checks must be made before three-phase drives are energized.
All moving parts must be inspected to ensure they are all operative.
Dashpots must be filled to the correct level with the right grade of fluid, and the operation and
accuracy of meters and relays by secondary or primary injection tests should be checked. All settings
should be agreed with the client’s engineers.
Gas-insulated switchgear ELK-04 with integrated control cabinets
All cable boxes must be properly topped up and compound filling spouts capped off. All insulators and
spouts must be clean and dry and cover plates securely bolted up with all screws in position and
tightened and breather vents clear of obstruction. Ensure that the top of the equipment is free from all dirt
and rubbish.
A final check on all incoming and outgoing cable connections to terminals ensures that they are tight and
have adequate clearance. High-voltage testing can then be carried out to the test figures laid down in the
appropriate switchgear specification or as specified by the client’s engineers who should witness the
tests and sign the test results.
After testing, precautions must be taken to discharge any static and remove the test connections before
bolting up any covers removed for testing.
Before energizing, the operation of all circuit-breakers and relays should be confirmed manually and
electrically to ensure that no sticking or malfunction is present, particular attention being given to manual
trip and close operations and to the operation of overcurrent relays and residual current devices.
When the equipment is ready to make alive all circuits not in service shall be locked off at each end and
safety operation procedures adopted. All switching operations should be carried out by a competent
person.
The substation’s entry and emergency exit doors must be operative and kept clear and free from
obstruction. All substations should be kept locked when the equipment is live, and access restricted to
authorized personnel only.
Danger, safety, shock cards and any statutory notices must be prominently displayed.
57
Tools required for operating switchgear should be stored adjacent to the equipment in proper racks or
cabinets. Circuit and interlock keys should also be contained in special cabinets under the control of
authorized personnel and no spare keys must be allowed to abort the safety of the system. Batteries
should be examined to ensure that they have received their first charge and the electrolyte is at the
correct level and of appropriate specific gravity.
The fire-fighting requirement should be checked and if it is CO2 it must be confirmed that the safety lock-
off procedure is understood by the personnel authorized to enter the substation.
External warning notices must be fixed to protect any strangers from inadvertently suffocating.
12.3. Prefabricated gas-insulated switchgear (GIS)
Integrated GIS is a prefabricated gas-insulated switchgear (GIS) unit with housing is based on ABB’s
well-proven GIS technology and can be produced at the same speed as a conventional GIS but has a
considerably shorter installation time which is less than 50 percent of typical GIS installations.
13. Testing and Commissioning of MV/HV Cables
13.1. Visual and Mechanical Inspection
Ø Compare cable data with drawings and specifications.

Ø Inspect exposed sections of cables for physical damage.
Ø Inspect bolted electrical connections for high resistance using one or more of the following
methods:
· Use of a low-resistance ohmmeter in accordance with Section 1.2 above.
· Verify tightness of accessible bolted electrical connections by calibrated torque-wrench method
in accordance with manufacturer’s published data or Table 100.12.
· Perform a thermographic survey.
· (NOTE: Remove all necessary covers prior to thermographic inspection. Use appropriate
caution, safety devices, and personal protective equipment.)
· Inspect compression-applied connectors for correct cable match and indentation.
· Inspect shield grounding, cablesupports, and terminations.
· Verify that visible cable bends meet or exceed ICEA and manufacturer’s minimum published
bending radius.
· Inspect fireproofing in common cable areas. (**)
· If cables are terminated through window-type current transformers, inspect to verify that neutral
and ground conductors are correctly placed and that shields are correctly terminated for
operation of protective devices.
· Inspect for correct identification and arrangements.
· Inspect cable jacket and insulation condition.
· ** Optional test
13.2. Electrical Tests

applicable, in accordance with Section 1.1.
Ø Perform an insulation-resistance test individually on each conductor with all other conductors and
shields grounded. Apply voltage in accordance with manufacturer’s published data. In the absence
of manufacturer’s published data, use Table 100.1.
Ø Perform a shield-continuity test on each power cable.
Ø In accordance with ICEA, IEC, IEEE and other power cable consensus standards, testing can be
performed by means of direct current, power frequency alternating current, or very low frequency
alternating current. These sources may be used to perform insulation-withstand tests, and baseline
diagnostic tests suchas partial discharge analysis, and power factor or dissipation factor.
Ø The selection shall be made after an evaluation of the available test methods and a review of the
installed cable system.
58
Ø Some ofthe available test methods are listed below:

· Dielectric Withstand:
· Direct current (DC) dielectric withstand voltage
· Very low frequency (VLF) dielectric withstand voltage
· Power frequency (50/60 Hz) dielectric withstand voltage
· Baseline Diagnostic Tests:
· Power factor/ dissipation factor (tan delta):
· Power frequency (50/60 Hz)
· Very low frequency (VLF)
· DC insulation resistance:
· Off-line partial discharge:
· Power frequency (50/60 Hz)
· Very low frequency (VLF)
13.3. Test Values
13.3.1 .Test Values – Visual and Mechanical
Ø Bolt-torque levels should be in accordance with manufacturer’s published data. In the absence of
manufacturer’s published data, use Table 100.12.
Ø Results of the thermographic survey.
Ø (NOTE: Remove all necessary covers prior to thermographic inspection. Use appropriate caution,
safety devices, and personal protective equipment.)
Ø The minimum bend radius to which insulated cables may be bent for permanent training shall be in
accordance with Table 100.22.
13.3.2. Test Values – Electrical
which deviate from those of similar bolted connections by more than 50 percent of the lowest
value.
Ø Insulation-resistance values shall be in accordance with manufacturer’s published data. In the
absence of manufacturer’s published data, use Table 100.1.Values of insulation resistance less
than this table or manufacturer’s recommendations should be investigated.
Ø Shielding shall exhibit continuity. Investigate resistance values in excess of ten ohms per 1000 feet
of cable.
Ø If no evidence of distress or insulation failure is observed by the end of the total time of voltage
application during the dielectric withstand test, the test specimen is considered to have passed the
test.
Ø Based on the test methodology chosen, refer to applicable standards or manufacturer’s literature
for acceptable values.
59
13.3.3Tables
Table 100.12.1
Bolt-Torque Values for Electrical Connections

US Standard Fasteners (a)
Heat-Treated Steel – Cadmium or Zinc Plated (b)
Table 100.12.1 - Bolt-Torque Values for Electrical Connections
a) Consult manufacturer for equipment supplied with metric fasteners.

b) Table is based on national coarse thread pitch.
Table 100.12.2

Silicon Bronze Fasteners (b, c)
Torque (Pound-Feet)
Torque (Pound-Feet)

c) This table is based on bronze alloy bolts having a minimum tensile strength of 70,000 pounds per
square inch.
60
Table 100.12.3

Aluminum Alloy Fasteners (b, c)
Torque (Pound-Feet)
Torque (Pound-Feet) - Aluminum Alloy Fasteners

c) This table is based on aluminum alloy bolts having a minimum tensile strength of 55,000 pounds per
Square inch.
Table 100.12.4

Stainless Steel Fasteners (b, c)
Torque (Pound-Feet)
Torque (Pound-Feet) - Stainless Steel Fasteners

c) This table is to be used for the following hardware types:
Ø Bolts, cap screws, nuts, flat washers, locknuts (18-8 alloy)

Ø Belleville washers (302 alloy).
Tables in 100.12 are compiled from Penn-Union Catalogue and Square D Company, Anderson Products Division,
General Catalog: Class 3910 Distribution Technical Data, Class 3930 Reference Data Substation Connector
Products.
61
Table 100.1
Insulation Resistance Test Values Electrical Apparatus and Systems
Table 100.1 - Insulation Resistance Test Values Electrical Apparatus and Systems
In the absence of consensus standards dealing with insulation-resistance tests, the Standards Review Council
suggests the above representative values. Test results are dependent on the temperature of the insulating material
and the humidity of the surrounding environment at the time of the test.
Insulation-resistance test data may be used to establish a trending pattern. Deviations from the baseline information
permit evaluation of the insulation.
Table 100.22
Minimum Radius for Power Cable

Single and Multiple Conductor Cables with Interlocked Armor, Smooth or Corrugated Aluminum Sheath or Lead
Sheath
Table 100.22 - Minimum Radii for Power Cable
ANSI/ICEA S-93-639/NEMA WC 74-2000, 5-46 kV Shielded Power Cable for Use in the Transmission and
Distribution of Electric Energy, Appendix I – Recommended Bending Radii for Cables and Table I1 – Minimum
Radii for Power Cable.
a. 12 x individual shielded conductor diameter, or 7 x overall cable diameter, whichever is greater.

Resource: STANDARD FOR ACCEPTANCE TESTING SPECIFICATIONS for Electrical Power Equipment and
Systems (NETA 2009)
62
14. Testing and Commissioning of Substation DC System
14.1. Objective
Power substation DC system consists of battery charger and battery. This is to verify the condition of
battery and battery charger and commissioning of them.
14.2. Test Instruments Required
Following instruments will be used for testing:
Ø Multimeter
Ø Battery loading unit (Torkel-720 (Programmer Make) or equivalent.
The Torkel-720is capable of providing a constant current load to the battery under test.
Torkel 720 Battery Load Capacity Tester Front View
14.3. Commissioning Test Procedure
14.3.1. Battery Charger
Ø The battery charger cleanliness to be verified, proper cable termination of incoming AC cable and
the outgoing DC cable and the cable connection between battery and charger to be ensured. A
stable incoming AC supply to the battery charger is also to be ensured.
Ø Voltage levels in the Float charge mode and the Boost charge mode to be set according to
specifications using potentiometer provided.
Ø Battery low voltage, Mains ‘Off”, charger ‘Off’ etc., conditions are simulated and checked for proper
alarm / indication. Thus functional correctness of the battery charger is ensued.
Ø Charger put in Commissioning mode for duration specified only one time during initialcommissioning
of the batteries. (By means of enabling switch)
Ø Battery charger put in fast charging boost mode and battery set boost charged for the duration
specified by the battery manufacturer.
Ø After the boost charging duration, the battery charger is to be put in float charging (trickle charge
63
Ø mode for continuous operation.
Ø Some chargers automatically switch to float charge mode after the charging current reduces below a
certain value.
Ø Voltage and current values are recorded during the boost charging and float-charging mode
NiCad Batteries being charged
This test establishes the correct operation of the battery charger within the specified voltage and
current levels in various operational modes.
14.3.2. Battery Unit
Ø The battery set should have been properly charged as per the commissioning instructions of the
battery manufacturer for the duration specified.
Ø Cleanliness of battery is checked and the electrolyte level checked as specified on the individual cells.
The tightness of cell connections on individual terminals should be ensured.
Ø The load current, minimum voltage of battery system, ampere-hour, duration etc., is preset in the test
equipment using the keypad.
Ø For (e.g.) a 58 AH battery set, 5 Hr. duration specification 11.6 A and 5 Hr. duration are set. Minimum
voltage setting is = No. of cells x end cell voltage of cells as per manufacturer specification.
Ø It is to be ensured that the set value of the current and duration is within the discharge capacity of the
type of cell used. Also the total power to be dissipated in the load unit should be within the power
rating of the battery load kit.
Ø Individual cell voltages to be recorded before the start of the test.
Ø Battery chargers to be switched off/load MCB in charger to be switched off.
Ø Loading of the battery to be started at the specified current value.
Ø Individual cell voltages of the battery set are to be recorded every half an hour.
Ø It is to be ensured that all the cell voltages are above the end-cell voltage specified by the
manufacturer.
Ø If any of the cell voltages falls below the threshold level specified by the manufacturer, this cell
number is to be noted and the cell needs to be replaced.
Ø Test set automatically stops loading after set duration (or) when minimum voltage reached for the
battery set.
Ø Test to be continued until the battery delivers the total AH capacity it is designed for.
Ø Value of AH and individual cell voltages to be recorded every half an hour.
14.3.3 Acceptance Limits
This test establishes the AH capacity of battery set at required voltage.

The acceptance limit for the test is to ensure the battery set is capable of supplying the required
current at specified DC voltage without breakdown for the required duration.
64

Guidelines For Electrical Testing and Co

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Guidelines For Electrical Testing and Co

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Guidelines for Electrical Testing and Commissioning

1. INSPECTION General external condition. 1Y All

1.2. MV Switchgear (up to 36 kV)

General external condition. 1Y

2.Test on 110kV Power Cable after Installation

2.1. Mechanical Check and visual Inspection

Item Description Remark

1 Check Phasing for Conductor and sheath

if old portion are involved then soaking for

2.3. Phase indication test

Equipment / Instruments Used

2.4. DC Conductor Resistance Measurement

The DC resistance of conductors of the cables, to be measured at ambient temperature before

Schematic layout for measurement of DC resistance for long cable

IEC 60228 – Conductors of insulated cables

Equipment / Instruments used

Ø Any Wheatstone bridge, micro Ohm-Meter.

Formula for Temperature Correction:

For Copper R20 = R/L (1 + 0.00393*(T-20)) Ω/KM

R20 – Conductor resistance at 20ºC *(ohm/km

2.5. Capacitance Test

Schematic layout for capacitance measurement

Omicron – for zero positive sequence test and capacitance measurements

Ø Connections are made as per below schematic.

Formula for Capacitance:

2.6. DC sheath test on outer sheath

Equipment / Instruments used

DC Hipo Tester, BAUR PGK 25

DC Sheath Test diagram

2.7. Insulation resistance measurement

Equipment / instruments used

KYORITSU High Voltage Insulation Resistance Tester

Ø Cable should be free from all system connections.

Insulation resistance test diagram

2.8. Cross bonding check

Equipment / Instruments used

ØScreen is to be grounded at both ends.

Cross bonding check diagram

2.9. Zero sequence and positive sequence impedance test

Instruments / Equipment used

3-phase variable transformer (up to 100 Amps supply capacity).

Measurement of positive/negative sequence impedance:

Figure 1A – Schematic layout for measurement of Positive/Negative Sequence Impedance

Figure 1B – Schematic layout for measurement of Zero Sequence Impedance

2.10. Earth resistance measurement at link boxes

Equipment / Instruments used

Analogue Earth tester Model-04102A, Make-KYORITSU.

Analogue Earth tester Model-04102A, Make-KYORITSU

Earth resistance measurement at link boxes

2.11. Link box contact resistance measurement

Equipment / Instruments used

Megger DLRO-200 for contact resistance and DC resistance measurements

Megger DLRO-200 for contact resistance and dc resistance measurements

Ø All the bolts are to be tightened firmly

Link box contact resistance schematic layout

3. Impulse withstand Voltage test

Figure 1 – Application of the impulse withstand

The test is passed if no discharges are detected.

Table 1 – IEC 61439-1, Impulse withstand voltages

The safety factor 1.5 takes into consideration manufacturing tolerances.

Table 2 – Safety factor (minimum clearance in air)

The minimum clearances shall be verified by measurement or verification of measurements on design