Testing & Commissioning Manual SEC

TRANSMISSION PRE-COMMISSIONING TEST PROCEDURE Index Number:

Title:

Revision Number:

T-PreCom-1000-R0 Prepared By:

PRE-COMMISSIONING TEST PROCEDURES FOR SEC TRANSMISSION ELECTRICAL INSTALLATIONS

00 Original Issue Date:

Pre-Commissioning Committee Revised By:

2003-06-17 Revision Date:

‫ــ‬ Recommended By:

Page Number:

Mohammad S. AL-Rafaa

1 of 124

Approved By:

I.Y. Al-Hamoudi, Vice President CTA

1.0

INTRODUCTION

Proper pre-commissioning of new electrical equipment is important to prove that new equipment has been properly shipped and correctly erected and installed. This Procedure highlights the necessary steps related to proper pre-commissioning of new electrical equipment. As a general practice, all equipment is tested in the factory before delivery to the site. Pre-commissioning testing at site is done to prove that: • • • • • •

No equipment was subjected to any damage during transportation. All equipment has been installed correctly. All equipment is working in coordination with other equipment, as specified. All the protection and control schemes are working in accordance with relevant specifications and protection requirements. All equipment has been adjusted properly in accordance with approved settings. The installation is safe for putting into service. 1.1

Purpose

The main purpose of this procedure is 1.1.1 1.1.2 1.2

To provide guidelines to the witnessing engineer or technician to organize work at site during the pre-commissioning test period. To provide the minimum tests to be performed on the equipment by the contractor, who has to prepare his work according to this Procedure.

Procedure

This Procedure is divided to two parts: the first part describes organizing the work at site before, during and after pre-commissioning tests. The second part concerns the mechanical checks, inspections and electrical tests to be performed on the equipment before commissioning the equipment into service. PART I. ORGANIZATION OF THE WORK SITE FOR PRE-COMMISSIONING PART II. MECHANICAL TESTS, VISUAL INSPECTIONS AND ELECTRICAL TESTS

TRANSMISSION PRE-COMMISSIONING TEST PROCEDURE PART I Title:

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PART I: ORGANIZATION OF THE WORK AT SITE FOR PRE-COMMISSIONING 1.0

T-PreCom-1000-R0 Page Number:

Page 2 of 124

INTRODUCTION

Pre-commissioning tests for a new or reinforcement project are to be checked thoroughly and witnessed by SEC Commissioning engineer or technician. During the course of the commissioning it has been observed that at many stages the contractors are not ready and consequently the Commissioning personnel have to wait with the result that some tests may be missed or ignored. A procedure is required to check the complete readiness of the contractor before the pre-commissioning tests and prepare the commissioning engineer/technician for applying commissioning tests as per SEC commissioning Procedure. This document briefly outline the necessary steps to be followed to ensure that contractors are ready to start the pre -commissioning in order to reduce or maintain the approved project milestones and control the quality of the commissioning test. The main purpose of this procedure is to provide necessary guidelines to ensure the readiness of the contractors to start the pre-commissioning testing of new or reinforcement projects and how to apply and perform the pre-commissioning tests ensuring that: • • •

The project is ready for pre-commissioning tests. The contractor is fully equipped and ready from all aspects to start the pre-commissioning test. The time for witnessing the pre-commissioning tests is at minimum duration with high quality performance.

2.0

PROCEDURES 2.1

Project Management Responsibility

Project Management shall confirm the readiness of the contractor from all aspects. A joint inspection shall be conducted with commissioning personnel and the contractor to ensure the contractor’s readiness to start the project after written confirmation is received from Project Management. 2.1.1 Contents of Confirmation Letter The Confirmation Letter shall, at minimum, contain: • • • • • • • • • •

Equipment is installed and has been inspected and satisfied by the SEC Project Quality section. Availability of contractor’s qualified manpower and testing engineers. Availability of tools and test equipment with one-year valid calibration certificate. Insulation Resistance test and pre check of all wiring. Stable power supply for testing The site is safe for testing. Approved relay settings and drawings. Site office as per SEC requirements. Over-all approved schedule along with approved outages. Substation HVAC system is in service; required for protection/control testing.

2.1.2

Joint Inspection

The contractor, Project Engineer and commissioning personnel shall visit the substation jointly two weeks prior to the start of the pre commissioning testing and the following points shall be confirmed.


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PART I: ORGANIZATION OF THE WORK AT SITE FOR PRE-COMMISSIONING 2.1.2.1


Page 3 of 124

Site Office Facilities

The site office shall be complete with the following facilities: • • • • • • 2.1.2.2

Commissioning Group Room with working table, chairs, telephone, PC and PC table. Conference room with conference table, chairs, white board, telephone and notice board. Drawing/record room with filling cabinets and Operation and Maintenance Manuals. Fax. Proper W.C. facilities are provided with raw water for washing. Kitchen with refrigerator. Site Technical and Equipment Requirements

The following shall be available at site prior to precommissioning: • • • • • • • • • •

3.0

Confirmation Letter for verification of Section 2.1.1. Approved drawings, Scope of Work and one set of approved drawings available for sole use of witnessing personnel. Catalogues, Operation and Maintenance Manuals, all relevant specifications and protection requirements. Factory Test results. Approved site test procedures and format. Proper communication must be ready for SCADA if applicable. SCADA program is ready for implementation if applicable. Proper housekeeping and safety standards. Approved deviations List. Base and Detailed Design Comments.

WITNESSING COMMENCEMENT

After confirmation of all the items of Section 2.1.2, witnessing can begin after two weeks. 3.1 Commissioning File The Commissioning engineer/technician shall have a Commissioning File for each substation; the File shall include at minimum: • Single Line Diagram. • Approved relay settings. • Site Instructions. • Weekly and overall Commissioning Schedule. • Minutes of Meeting. • Technical Specifications. • Copy of approved deviations list and Base Design comments. 3.2 Site Instructions/Records and Project Punch List/Snags Rectifications Commissioning personnel are responsible for witnessing the pre-commissioning tests for reinforcement and new substations. During the course of witnessing, the necessary Site Instructions (S.I.) are issued which indicate the deficiencies in fulfilling SEC relevant Standards, SOW, workmanship, safety and common operation and maintenance problems. Sometimes differences have been noted in the S.I.s issued by different engineers on a particular point. Therefore guidelines are required for issuing S.I.s. This document briefly describes the


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T-PreCom-1000-R0

PART I: ORGANIZATION OF THE WORK AT SITE FOR PRE-COMMISSIONING

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Page 4 of 124 guidelines to be followed by all Commissioning personnel to issue S.I.s in order to achieve uniformity and consistency. It should be kept in mind that this is a guideline only and it will not supercede any SEC relevant Specification in any manner. 3.3

Sequence of Events

Any items contrary to SEC Standards, SOW, workmanship and safety will be reflected in the deficiency section of the Register File, see Attachment No. 1. The Register File has two sections, one section belongs to the activities (Attachment No. 2) along with the single line diagram to help an engineer to visualize the project and the other section for the deficiencies. After one week from the registration of a deficiency in the book, all outstanding items will be sent to the Project Engineer via Site Instructions/Records (Attachment No. 3). Bi-weekly, the status of the punch list has to be issued by the contractor on the SEC format, Attachment No. 4. One month prior to the scheduled energizing of the equipment, the categorized deficiency list shall be issued by the commissioning personnel to identify the items which must be corrected prior to energization (Attachment No. 5). ATTACHMENTS TABLE ATTACHMENT NO. 1. 2.

DESCRIPTION Register Book/Deficiency Record Register Book/Activity Record

3.

Site Instructions

4.

Status of the Punch List Categorization of the Punch List

5. 6. 7. 8.

Pre-Commissioning Time Utilization Statistic Sheet Final PreCommissioning Report Sample Check (Optional Agreement)

9.

Check List

10.

Contractor’s Performance Report

REMARKS The Commissioning engineer/technician shall record all the items contravening safety, SEC Standards, Scope of Work and workmanship on the Deficiency Record. The Commissioning engineer/technician is responsible to daily update site activities to help any engineer to familiarize him with the status of the project. After one week from recording in the Deficiency Record, incomplete items will conveyed to the Project Engineer via the Site Instructions Form. Bi-weekly the status of the punch list shall be updated by the contractor. One month prior to energizing the equipment, the categorized deficiency list shall be issued by the commissioning personnel to identify the items to be done before energization. The commissioning engineer/technician shall fill in this sheet on a daily basis. The Commissioning engineer/technician shall issue a final Precommissioning Report at the end of the project. In order to reduce the pre-Commissioning time the “sample check” procedure may be exercised based on the contractor’s previous performance and the last time utilizations status sheet. This shall be based on agreement between the contractor and SEC Transmission. The check list is intended to provide information to the commissioning engineer/technician who are assigned to inspect the contractor’s work and witness commissioning testing on behalf of SEC. The commissioning engineer/technician shall fill this form at the end of the project to evaluate the performance of the contractor.


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Page 5 of 124

ISSUING SITE INSTRUCTIONS/RECORDS

Site Instructions (SI) shall conform to the following: • • • • • • •

The Site Instruction will be issued on a standard format, see Attachment 3. Every site instruction will be allocated with a number prefix and a letter P (Protection), S (Testing of Substation Equipment), L (Overhead), U (Cable), O (Operations) and FM (HVAC, Building), etc., with date. The S.I. will be issued to the site project engineer who will hand over the same to the contractor. Deficiencies in the drawing/literature, tools and test equipment, etc., shall be conveyed without S.I. Number with one week’s notice and if not corrected within a week the same to be issued with an S.I. Number. This also shall be discussed with the section head for further guidance. While issuing an S.I., necessary reference to the drawing No., sheet No., specification No., P.R. and design approval stage comments, etc., must be indicated. A copy of the S.I. signed by the Project Engineer and Contractor will be kept in the commissioning file. Some of the instructions although necessary, cannot be implemented due to Contractual terms, lack of wording in the Scope of Work, unclear P.R., etc., are to be filed with proper remarks in the respective substation file for implementation at a later stage. Such items shall be communicated to Engineering and Design Department for inclusion in future Projects.

The contents of the S.I. can be categorized under various headings as noted below. The common Snags/Punch list mentioned will be issued once in one S.I. for the whole substation and repetition of the same for different bays shall be avoided. 4.1

Equipment not fit for Service

This consists of the following deficiencies relating to protection, metering and control equipment. • • • • •

Missing equipment. Physical damage to the equipment. Rating is not matching with relevant specifications. Equipment with internal fault causing incorrect test results. The equipment is not on the SEC Approved Manufacturer’s List.

4.2

Deviations from SEC Specifications

Examples are listed as follows: • • • 4.3

Protection or a part of it is not in line with SEC relevant Specifications and/or Protection requirements. Work has not been executed in line with general requirements or has not had approval during the design stage. Design comments have not been implemented for the protection scheme and other equipment. Poor Work Quality

Examples are listed as follows: • •

Segregation of protection CT and VT cables is not maintained and color coded cables are not used. Poor ferrule printing quality which will fade over time.


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PART I: ORGANIZATION OF THE WORK AT SITE FOR PRE-COMMISSIONING


•

Page 6 of 124 Cables are directly terminated on terminal blocks without providing adequate clearances for access during troubleshooting or maintenance. Equipment or terminals are not sufficiently accessible to allow maintenance. Ferruling method does not meet relevant specifications. Apparatus is not properly labeled. Wiring has either wrong ferrules or no ferrules. Improper use of terminal lugs. Control cables do not carry proper number tags. Proper wiring dressing has not been done in panels. Labels with incorrect spelling, uneven engraved letters, improperly aligned, letters too small, badly cut edges, etc. Alarm annunciator labels/text with letters too small to read from a distance, and acknowledge/reset/test push buttons at difficult to reach locations. Congested wiring obstructs other terminals on a terminal block. Very loose plug/socket arrangement. These should always be locking type. Improper locking of panel doors has caused frequent breaking of the panel door locking mechanism. Adequate illumination does not reach all working places, terminals, in the panel, in front of relays, etc. Terminals, auxiliary relays, flag relays mounted at very low level or very high level. Wiring not supported properly causing undue termination tension, which may result eventually slipping of wire/breaking off from crimp. Bad crimping of wires. For CT circuit this is most dangerous as this may lead to open circuiting of energized circuits. Open circuited energized CT circuits may cause fires and serious electrical hazards. Inadequately rated relays used for continuously energized relays in fail safe, scheme, etc.

4.4

Improper Electrical Scheme

• • • • • • • • • • • • • • • • •

A protection scheme may not operate properly in spite of implementation of the relevant specification. Examples are listed as follows: • • • • • • • • • • • • • 4.5

Pole discrepancy in tripping of the required CBs. Alarm is not working, either locally or remotely. Problems with auto re-closing. Problem with the inter trip scheme. Absence of anti pumping operation. This can be dangerous if the anti pumping fails to operate. D.C. supervision scheme is not working. Trip circuit supervision scheme is not working properly. Improper operation of auto switching (ABTS) scheme. Improper operation of distance relay accelerating scheme. Problems with closing selection, interlock wiring, close lockout relay elements. Relay flags not working properly due to mechanical problem or other reasons. Alarm does not operate due to very fast resetting of main protection relay contacts. Auto re-closing scheme does not work correctly due to like failure of synchrocheck relay, inadequate duration of start pulse, etc. Updating of Records

Examples are listed as follows: •

Equipment is missing from the apparatus list.


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PART I: ORGANIZATION OF THE WORK AT SITE FOR PRE-COMMISSIONING • • • • • • • • 4.6


Page 7 of 124

Rating, contact arrangement and ordering number is incomplete. Cross-references are missing or incorrect. Correct catalogues have not been provided. Testing procedures are not available for some relays. Three copies of drawings are required to be updated for modifications and corrections, using red for addition and green for deletion. This has not been done correctly. Proper test record forms are not available to record the test results. Some drawing sheets missing. Factory test results not available at site. Common Punch List/Snags

The following Punch list/ snags are found repeatedly in substation construction. Most of them are clearly mentioned in the SEC Specifications/General Requirements. Irrespective of this fact, they are usually repeatedly discovered. When these types of points are raised at site, the contractor generally tries to avoid implementation. Every effort should be made to have the contractor promptly correct the inadequacies. Some examples are listed as follows: • • • • • • • • • • • • •

• • • •

Color-coded cables shall be used for control and/or alarm functions and black ones shall be used for CT, PT or AC circuits. Quality of printing and the placement of ferrules is poor in many cases. While terminating cables, the contractor does not leave any margin inside/outside the panel for re-terminating the cables in another location in the same panel, in case it is required. While laying cables, segregation is not maintained section-wise, so that in case of fire in one section the other sections will also be affected. Paralleling of alarms is done with software, whereas it is necessary to do this with help of wiring for system reliability. Equipment lists do not correlate with the installed equipment and details such as ordering number and the numbers of NO/NC contacts, etc., are not correct. More than one earth point has been made for the CT’s feeding the unit protection, e.g., Restricted Earth fault, Differential, Breaker Failure and Bus bar protection. From the maintenance point of view the access to relay terminal blocks is very important; some contractors do not pay enough attention to this. Positive (+), Negative (-) and trip marked in red are not provided on the relevant wires. Contractors do not allocate fault recorder channels as per SEC specifications. Site modifications are not properly reflected in the drawings. CT shorting and isolating arrangement is not in line with SEC standard arrangements including shorting/isolating, instruction and caution notices. Lack of proper labeling to the protection and control equipment in different location, e.g., relay panels, control panels, LCC and AVC panels, AC/DC distribution boards, power transformer marshalling kiosks, CB isolators and earth switches, etc. This equipment includes main relays, auxiliary relays, contactors, trip relays, MCB’s terminal blocks, points on the test switch (MMLG or ABB type), trip links and other links used for other specific functions. CT and VT protection cables are not segregated. Terminal block wiring is too low for convenient access, especially CT shorting and isolating switches. These shall be at working height level. Crimping of terminal lugs is not done properly, particularly for CT and VT wires. Length of the metallic part of CT and VT lugs is not enough to provide proper grip when they are tightened in the terminal blocks.


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PART I: ORGANIZATION OF THE WORK AT SITE FOR PRE-COMMISSIONING • • • • • • • • • • • • • • • • • •


Page 8 of 124 Plug in type miniature relays are used in tripping and interlock circuits. After a period of time, these relays do not function properly, due to displacement from their original position. Normal earth switch was used on the line instead of high-speed type. In one substation, the backup main protection was found not working when the DC supply to the first main protection was switched off since the isolator image was controlled by the first main DC supply. Power cables for the fans from the AC distribution board to the transformer marshalling kiosk were found underrated. Protection coordination of MCB’s installed in the DC distribution board was not maintained, so the contacts of an ON/OFF switch were burnt due to a short circuit in the DC wiring. During on-load checks 12 volts were observed across the CT terminals of feeder cable protection. The manual mode status of the Halon was found not annunciated. As per SEC specifications it is necessary to install an independent synchrocheck relay for manual and auto re-closing for each CB rated 110 kV and above. The bus-bar protection trip logic for double bus-bar substations does not conform with SEC specifications. The annunciator output contacts did not follow the initiation when the input was reset as per SEC specifications. Remote end breakers also trip in case the HV E/F relay of transformer operates. It should only trip the local breaker. The A/R did not close the breaker when the D.E.F. tripped the breaker. It was due to the tripping of the breaker in advance before the initiation of the A/R.) The phases R and B were found interchanged for the reactors. Two phases of earth switch were on one side of the CT’s whereas the third one was on the other side of CT’s. CT polarity if it was left reversed on one of the spare feeders and the loading of the spare feeder led to operation of BBP. The anti pumping circuit is not operational for CBs. This deficiency will lead to re-closing of the CB on to fault when a long duration closing pulse is initiated. The pilot wire protection 87PW is commissioned with reverse pilot; this will lead to indiscriminate tripping. The DEF relay for one circuit is commissioned with wrong direction this will lead to indiscriminate tripping of the circuit.

The following items were found missing:

• • • • • • • • • • •

Labeling of spare cores with cable numbers. Provision of 10 % spare terminal blocks in each relay panel, control panel, LCC, etc. Provision of 10 % spare annunciator windows. Provision of cover on emergency trip push button. Availability of proper lighting arrangement in 13.8 kV and 33 kV switchgear panels, relay panels, control panels, AVC panels, AC/DC panels and all marshalling kiosks. Proper test facility for indicating and recording meters. Test facility for indicating lamps. Provision of indicating lamp extractor tool. Labeling of the duty CT cores. Labeling of CT primary polarity, e.g., P1 and P2. CT neutral looping with metallic jumpers.


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PART I: ORGANIZATION OF THE WORK AT SITE FOR PRE-COMMISSIONING • • •


Page 9 of 124

Labeling of relays, pressure relief devices, oil temperature gauges and winding temperature gauges, etc. Blocking of spare plugs. Avoiding use of plug in connections and plug-in type auxiliary relays.

These problems will be updated regularly as needed 4.7

Clearing The Punch List/Snags

It is very important to clear the Punch List/Snag items as soon as possible after confirming their implementation. Sometimes it is very difficult to confirm their implementation once the substation is energized, if they are not cleared during the pre-commissioning stage. It is very useful that the witnessing engineer/technician keeps the site instruction records updated by putting his signature with date without any delay after inspecting and approving the relevant snag.

5.0

TIME AND QUALITY MANAGEMENT

The following sections listed below elaborate the techniques to ensure that all equipment tests are done with optimal use of the time available. 5.1

Check List

The Check List is intended to provide information to commissioning personnel who are assigned to inspect the contractor’s work and witness commissioning testing on behalf of SEC to verify that substation and transmission line equipment and system are acceptable as per SEC- Standards and Specifications. The listing of commissioning checks and tests are based on the SECCommissioning Procedure T-PreCom-1000-01. 5.2

Time Utilization Statistic Sheet

A time utilization statistics sheet is being included in this Procedure. This sheet must be filled in daily. The contents of this sheet will be used for planning future projects by using the total time consumed. Moreover this sheet will also allow corrective measures to be taken to reduce the precommissioning time. The number of hours lost should be filled correctly, see Attachment No. 6. 5.3

Testing Schedule

In order to start witnessing after two weeks from confirmation, the contractor shall submit to SEC the testing schedule, giving details for each test of the time and the commissioning personnel required. Every week, the contractor shall submit a three-week testing program giving details of the previous week’s completed jobs and the current and following week’s proposed jobs. If in the previous week, some job was not completed, a reason for the deferral and its effect on the overall schedule should also be mentioned. 5.4

Marked Up Drawings

The contractor is responsible to provide enough qualified manpower to prepare three sets of markedup drawings during the pre-commissioning testing period in order to expeditiously finalize the as-built drawings without using the substation marked-up drawing. The three copies of the marked up drawing shall be distributed as the following: • • •

Substation copy for emergency usage Contractor copy to prepare the as-built drawing Maintenance Department library copy for as-built drawing verifications


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Page 10 of 124

Sample Check (Optional)

In order to reduce the pre-Commissioning time, “sample checks” could be exercised based on the following criteria, see Attachment No. 8. • •

6.0

If the overall rating of the contractor performance in his immediately previous contract was GOOD. If the hours lost due to the contractor is less than 5% of the work, for the last time utilization statistic sheet.

FINAL PRE COMMISSIONING REPORT AND CONTRACTOR’S EVALUATION

Project completion depends on the pre commissioning report, which has to be issued by the commissioning engineer/technician (Attachment No. 7). In case of separate contractors working on the same substation (lines and substation), the line-commissioning engineer/technician shall provide a copy of the final reports to the substation-commissioning engineer/technician and vise versa. Each commissioning engineer/technician shall evaluate the contractor at the end of the project, see Attachment No. 10. 6.1

Final Pre-Commissioning Report

The commissioning engineer/technician shall issue the Report based on but not limited to the following. • • • • • •

The status of the Punch List (A, B) for which “A” refers to any deficiency requiring an outage to clear it or equipment damage or a safety requirements. “B” is any deficiency other than “A”. Marked up drawing are available at site in good condition. Emergency contact list provided. Operation spare parts are available. Operation and Maintenance Manuals are available. Test results provided.

• • •

All site tests completed. Test completion and energization of station service transformer. Test completion and energization of HVAC.

6.2

Contractor Evaluation

The commissioning engineer/technician shall use SEC format to evaluate the contractor using the following criteria: • • • • • • •

Quality of the work. Availability of qualified manpower. Availability of proper tools and test equipment. Quality of supervision/testing engineer. Safety. Cooperation. Punctuality.


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IMPLEMENTATION

The following steps need to be given special consideration, for implementation of this procedure:

• • • • • •

An appropriate coordination is required with Project Management. The major problems must be reported to the Commissioning Manager/Senior Engineer for guidance. Every effort should be done to ensure that this procedure is implemented. This procedure shall be included in the Scope of Work. The contractor/Project Management Engineer shall return all the dismantled material to SEC store via CTA/DTA Project Department. It is recommended to store a Project Commissioning File, which includes critical Punch List/Snags, contractor evaluation, final commissioning report, single line diagram, Minutes of Meeting and Relay Setting Sheet in the substation.

TRANSMISSION PRE-COMMISSIONING TEST PROCEDURE PART II Title:

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MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 1.0


Page 12 of 124

INTRODUCTION

This Procedure describes the tests and checks to be performed during the pre-commissioning stage of SEC Transmission projects. It deals primarily with the pre-commissioning tests to be followed for protection schemes and main equipment such as cables, transformers and switchgear, etc., keeping in view the SEC standard practices for various types of tests. Further, this listing of tests and checks is based on the requirements and recommendations of international standards such as IEC, ANSI, etc. They are the minimum tests and checks to be performed during pre-commissioning.

2.0

PURPOSE

The main purpose of this Procedure is to present a list of checks and tests to be performed on transmission equipment. They shall be performed by the project contractor and witnessed by SEC Precommissioning personnel.

3.0

PROCEDURE

ITEM NUMBER 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3.27 3.28 3.29 3.30 3.31 3.32 3.33 3.34

EQUIPMENT Oil Filled Power Transformers Shunt Reactors Bushings Inspection and Testing Surge Arrestors Station Service Transformers Neutral Earthing Resistors Current Transformers Potential Transformers Capacitive Voltage Transformers Coupling Capacitor Voltage Transformer s Gas Insulated Switchgear (GIS) Metal Clad Switchgear Metal Enclosed Bus Duct Indoor and Outdoor Bus Structures Indoor Circuit Breakers Outdoor Circuit Breakers Disconnect and Grounding Switches Circuit Switchers LV Switchgear (110/220 V) 230 kV and 380 kV XLPE Cables 230 kV and 380 kV LPOF Cables 110 kV, 115 kV and 132 kV XLPE Cables 110 kV, 115 kV and 132 kV LPOF Cables 69 kV XLPE Cables 13.8 kV and 33 kV XLPE Cables LV Cables Control Cables Pilot Cables Over Head Lines Protection and Control Substation Batteries Battery Chargers AC Distribution Panels DC Distribution Panels


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MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 3.35 3.36 3.37 3.38 3.39 3.40 4.41 4.42

LVAC Auto-Transfer Schemes/Switches Grounding Systems Switchgear Air Compressor Systems HVAC Systems Dry Transformers Fire Detection and Suppression Systems Civil Work Static VAR Compensation Systems


Page 13 of 124


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Page 14 of 124

Oil Filled Power Transformers

(Standard Reference is IEC 60076 and relevant SEC Transmission Specifications)

3.1.1 ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

20. 21.

Mechanical Checks and Visual Inspections

DESCRIPTION Check the impact recorder for any abnormal impact during transit. Check all components are installed. Check for quality of paint, lifting lugs, quality of weld areas, rust spots and wheel stoppers. Check nameplates information (visible location) as per contract specifications. Check tightness of all bolts (torque wrench method). Check that all grounding is securely connected (two grounding connections to main tank are required). Check that the piping to Buchholz relay has proper slope. Check that the tank pressure is positive, if applicable. Check that the valves between the main tank and radiators are open. Check the HV, LV and TV (if applicable) bushings for damage and completeness. Check for correct color and quantity of desiccant (moisture absorbing media) in breathers. Check for correct breather oil levels. Check heaters and humidity meters in local panel are at correct settings. Check that phase marking in cable box matches with GIS and cables. Check all pipes, hoses and fan protection (not rubber or plastic). Check the vertical and horizontal clearances of live parts to adjacent grounded points conform to standard. Check integrity of diaphragm/air bag in the conservator. Perform all of the manufacturer’s specific checks. Check labeling of all auxiliary devices as per approved drawing. Check proper operation of auxiliary devices as follows: a. Cooling fans/pumps (for all settings). b. Tap changer (upper–lower–out of step and interlock). c. Oil level gauges. d. Top oil temperature gauges. e. Buchholz relay by gas injection. f. Winding temperature gauges. g. OLTC oil/gas surge (pressure) relay. h. Ensure correct operation of the Pressure Relief Device microswitch. i. Push buttons and indicators. j. Oil sampling port (main tank and OLTC). k. Upper and lower main tank valves. l. Tap changer diverter switch compartment, oil filtering pumps and filter in good condition (if available). Check oil leakage; if any noted, apply 0.35 kPa over pressure for 24 hrs to make sure. Check that the oil sampling valves for the main tank and OLTC

REMARKS


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MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 22. 23. 24. 26. 27.

3. 4.

5. 6. 7.

8. 9. 10. 11 12. 13. 14. 15.

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are accessible from ground level. Check oil level in main tank, conservator, tap changer tank and bushings, etc. Test the oil level gauges and their alarms. Bleed trapped air at the bushing turrets and radiators. Check flow of oil in flow meter in correct direction and proper rate (if applicable). Check all external wiring for correctness and tightness. Check on-line insulating oil dissolved gas and moisture monitoring system (if installed). 3.1.2

ITEM 1. 2.

T-PreCom-1000-R0

Electrical Tests

DESCRIPTION Core Insulation Resistance Test. Winding Insulation Resistance Test and Polarization Index Test at 5 kV DC. Winding Resistance Test (all taps). Excitation Current measurements from primary side at each tap during ratio test and from secondary side when energized from secondary terminals keeping primary side open or winding excitation current measurement test at 10 kV during power factor testing. Insulation power factor and bushing test at 10 kV AC. Vector Relationship Test. Winding temperature device test by heating the sensor in oil bath and checking against standard thermometer. Also check by current injection. Setting as per approved drawing to be applied and tested. Oil temperature device to be calibrated by heating in oil bath. Setting as per approved drawing to be applied and tested. Percent Impedance test at nominal tap. Turn Ratio (all taps). Check for current and voltage ratings of all motors for tap changer and fans match to SEC standard supply. Check that MCBs for protection are set at proper over load settings. Fan motor currents shall be measured and checked against rating. Check wiring size is adequate to carry the current. Check that the phase sequence of supply voltage to fan motors is correct. Check fan rotation direction and confirm air flow is towards radiator. MCBs in cooler control cubicle to be checked by current injection for alarm and trip. On load Tap Changer tests: a. Check current and voltage ratings of tap changer motor. b. Raise/Lower Control (local–remote) and indication, and perform adjustment as required. c. End of tap travel control. d. End of winding travel control (both ends). e. AVR setting of bandwidth, mid point, time delay, etc., and adjust as per approved setting. f. Master/Slave check out of step blocking alarm. g. Master/Slave control check either transformer as

REMARKS


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MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS

16.

17

18.

19.

master. h. Parallel Operation Disturbed–check alarm. i. Check that the windings are not open circuited during tap changing. This should be done during the winding resistance test. Bushing Current Transformer Tests: a. Polarity. b. Insulation Resistance. c. Secondary Winding Resistance (all windings and all taps). d. Current Ratio (inject current) e. Magnetization Characteristics (minimum five points below and two points above the knee point). f. Verify secondary circuits, terminal to terminal. g. Burden Test. Demagnetize CT cores after all tests. Ensure no open circuit on CT secondary side. Functional Checks for the Following: a. Liquid level (alarm and trip). b. Top Oil Temperature Device: fans/pumps (stop, start alarm and trip). c. Winding Temperature Device. d. Buchholz Relay (alarm and trip). e. Oil / Gas Surge (pressure) relay (alarm and trip). f. Pressure Relief Device (alarm and trip) Insulating Oil Tests: Prior to energization, the contractor shall submit insulating oil test reports tested at an independent laboratory, for the following: a. Dielectric Strength i. ASTM D 877 (2.5 mm gap) for unprocessed oil and for OLTC oil ii. ASTM D 1816 (1.0 mm gap) for oil in main tank b. Neutralization Number (ASTM D 974) c. Interfacial Tension (ASTM D 971) d. Color (ASTM D 1500) e. Moisture Content (ASTM D 1533) f. Power Factor Test (ASTM D 924) g. Dissolved Gas in Oil Analysis (ASTM D3 612) h. (Dielectric Dissipation Factor, Resistivity, Sediment and/or Precipitable Sludge). Another oil sample shall be given to SEC transmission for their own analysis and comparison purposes. A syringe oil sample shall be taken by contractor. A main tank insulation oil sample for dissolved gas analysis shall be taken immediately prior to first energizing a power transformer and another sample three days after continuous energization.


Page 16 of 124


Index Number:



Page 17 of 124

Shunt Reactors


3.2.1 ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

20. 21. 22. 23. 24.

Mechanical Checks and Visual Inspections

DESCRIPTION Check the impact recorder for any abnormal impact during transit. Check all components are installed. Check for quality of paint, lifting lugs, quality of weld areas, rust spots and wheel stoppers. Check nameplates information (visible location) as per contract specifications. Check tightness of all bolts (torque wrench method). Check that all grounding is securely connected (two grounding connections to main tank are required). Check that the piping to Buchholz relay has proper slope. Check that the tank pressure is positive, if applicable. Check that the valves between the main tank and radiators are open. Check the bushings for any damage and completeness. Check for correct color and quantity of desiccant (moisture absorbing media) in breather. Check for correct breather oil level. Check heaters and humidity meters in local panel are at correct settings. Check that phase marking in cable box matches with GIS and cables. Check all pipes, hoses and fan protection (not rubber or plastic). Check the vertical and horizontal clearances of live parts to adjacent grounded points conform to standard. Check integrity of diaphragm/air bag in the conservator. Perform all of the manufacturer’s specific checks. Check labeling of all auxiliary devices as per approved drawing. Check proper operation of auxiliary devices as follows: a. Cooling fans/pumps (for all settings). b. Oil level gauges. c. Top oil temperature gauges. d. Buchholz relay by gas injection. e. Winding temperature gauges. f. Ensure correct operation of the Pressure Relief Device microswitch. g. Push buttons and indicators. h. Oil sampling port (main tank). i. Upper and lower main tank valves. Check oil leakage; if any noted, apply 0.35 kPa over pressure for 24 hrs to make sure. Check that the oil sampling valves for the main tank are accessible from ground level. Check oil level in main tank, conservator and bushings, etc. Test the oil level gauges and their alarms. Bleed trapped air at the bushing turrets and radiators. Check all external wiring for correctness and tightness.

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 3.2.2 ITEM 1. 2. 3. 4. 5. 6.

7. 8. 9.

10.

11.


Page 18 of 124

Electrical Tests

DESCRIPTION Core Insulation Resistance Test Winding Insulation Resistance Measurement Test and Polarization Index (P.I.) Test at 5 kV DC. Winding Resistance Test. Inductance Measurement. Impedance Measurement. Winding temperature device test by heating the sensor in oil bath and checking against standard thermometer. Also check by current injection. Setting as per approved drawing to be applied and tested. Oil temperature device to be calibrated by heating in oil bath. Setting as per approved drawing to be applied and tested. Insulation power factor and bushing test at 10 kV AC. Bushing Current Transformer Tests: a. Polarity. b. Insulation Resistance. c. Secondary Winding Resistance (all windings and all taps). d. Current Ratio (inject current) e. Magnetization Characteristics (minimum five points below and two points above the knee point). f. Verify secondary circuits, terminal to terminal. g. Burden Test. Demagnetize CT cores after all tests. Ensure no open circuit on CT secondary side. Functional Checks for the Following: a. Liquid level (alarm and trip). b. Top Oil Temperature Device: fans/pumps (stop, start alarm and trip). c. Winding Temperature Device. d. Buchholz Relay (alarm and trip). e. Pressure Relief Device (alarm and trip) Insulating Oil Tests: Prior to energization, the contractor should submit insulating oil test reports tested at an independent laboratory, for the following: a. Dielectric Strength i. ASTM D 877 (2.5 mm gap) for unprocessed oil ii. ASTM D 1816 (1.0 mm gap) for oil in main tank b. Neutralization Number (ASTM D 974) c. Interfacial Tension (ASTM D 971) d. Color (ASTM D 1500) e. Moisture Content (ASTM D 1533) f. Power Factor Test (ASTM D 924) g. Dissolved Gas in Oil Analysis (ASTM D3 612) h. (Dielectric Dissipation Factor, Resistivity, Sediment and/or Precipitable Sludge). Another oil sample shall be given to SEC transmission for their own analysis and comparison purposes. A syringe oil sample

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 12.

shall be taken by contractor. Cooling system checks and measure for fan motors and pumps (as applicable), etc., for current, supply voltage and air flow direction.


Page 19 of 124


Index Number:



Page 20 of 124

Bushings Inspection and Testing


ITEM 1. 2. 3. 4. 5. 6. 7.

DESCRIPTION Cleaning the insulator surface. Check for tightness test between transformer and bushing flange and outer terminal. Visually inspect for any damage or cracks. Check for leakage. Check and adjust of oil level. Note that adding insulating oil to a bushing shall be done under vacuum. Measurement of capacitance and tan delta. The bushing shall be tested in a vertical position and the lower portion set into an oil reservoir. Check of through resistance.

REMARKS


Index Number:



Page 21 of 124

Surge Arrestors

(Standard Reference is relevant SEC Transmission Specifications)

3.4.1 ITEM 1. 2. 3. 4. 5. 6.

DESCRIPTION Inspect for physical damage or defects. Check tightness of all bolted connections (torque wrench method). For multi-unit stacks, check that the physical arrangement of the units are erected according to the manufacturer’s specifications. Check that all grounding cables are correctly and secured connected. Check name plate information for correctness as per SEC’s specifications. Check that impulse counter and leakage current meter glasses are not broken or cracked. 3.4.2

ITEM 1. 2. 3.

Mechanical Checks and Visual Inspection: REMARKS

Electrical Tests

DESCRIPTION Check calibration of leakage current meters. Insulation resistance test at 5 kV DC. Power factor test at 10 kV AC.

REMARKS


Index Number:



Page 22 of 124

Station Service Transformers (less than 2 MVA)


3.5.1 ITEM 1. 2. 3. 4. 5. 6.

DESCRIPTION Check the Impact recorder for any abnormal impacts during transit (if applicable). Check earthing, color, painting, external damage, oil leakage, wheel stopper, cable connection and bolt tightness, etc. Check nameplate data against contract specifications. Perform all special checks according to the manufacturer’s instructions. Check oil level in HV side cable box and its oil level indicator or HV fuses. Check all devices are labeled correctly as per drawing. 3.5.2

ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Mechanical Checks and Visual Inspection REMARKS

Electrical Tests

DESCRIPTION Check LV side MCB setting as per transformer current rating Ratio Test (all taps), Insulation resistance measurement test on all windings and polarization index (P.I.) test. Polarity and Vector Group symbols confirmation Test. Check oil level and its indicator alarms. Check oil temperature gauge by oil bath method and its alarms. Check LV and HV side phases match with the LV bus bar phasing in the distribution panels and with the main transformer phases. Check phasing at the automatic transfer switch (as applicable ) Winding resistance measurement (at all taps). Excitation current test (all taps). Back energization test at rated voltage for 15 minutes. Check that the off load tap changer is set at the nominal voltage tap. Perform functional tests of all auxiliary devices (as applicable ) Insulating Oil Tests: Prior to energization, the contractor should submit insulating oil test reports tested at an independent laboratory, for the following: a. Dielectric Strength i. ASTM D 877 (2.5 mm gap) for unprocessed oil ii. ASTM D 1816 (1.0 mm gap) for oil in main tank b. Neutralization Number (ASTM D 974) c. Interfacial Tension (ASTM D 971) d. Color (ASTM D 1500) e. Moisture Content (ASTM D 1533) f. Power Factor Test (ASTM D 924) g. Dissolved Gas in Oil Analysis (ASTM D3 612) h. (Dielectric Dissipation Factor, Resistivity, Sediment and/or Precipitable Sludge).

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS Another oil sample shall be given to SEC transmission for their own analysis and comparison purposes. . A syringe oil sample shall be taken by contractor.


Page 23 of 124


Index Number:



Page 24 of 124

Neutral Earthing Resistors

(Standard Reference is Manufacturer’s Instructions)

ITEM 1. 2. 3. 4. 5. 6. 7. 8.

DESCRIPTION Check the value of resistance and current ratings against specifications. Check that the external earth connection to main earth is copper wire at least 240 mm2 in size. Test NER HV side associated CT and power cable. Visually inspect the interior for broken insulators. Measure the main circuit resistance. Insulation Resistance Test. Ensure that the interior and exterior of the NER is clean prior to energization. Check identification and function of NER isolator (if applicable).

REMARKS

>=1000 megaohms


Index Number:



Page 25 of 124

Current Transformers

(Standard Reference is IEC 60044-1 and relevant SEC Transmission Specifications)

Note that Bushing current transformer tests and inspections are covered in the sections relating to the equipment into which they are installed. 3.7.1 ITEM 1. 2. 3. 4. 5. 6. 7. 8.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness. Check that outdoor secondary wiring terminations are installed in moisture proof enclosures. Check tightness of all bolted connections (torque wrench method). Check that all grounding cables are securely connected. Check secondary wiring is correctly color coded and size of wires is as specified. Check proper lugs have been used on terminations. Check CT locations physically and secondary terminal labeling has been done correctly. 3.7.2

ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12.

Mechanical Checks and Visual Inspections REMARKS

Electrical Tests DESCRIPTION

Insulation resistance test. Winding resistance measurement. Polarity test or flick test with battery. Ratio test by current primary injection. Magnetizing current test (minimum two points above knee point). Loop resistance measurement test (burden test). Phase identification test. Verify secondary circuits, terminals, shorting/isolating links by primary injection of CTs. Insulation power factor test (live tank CTs-110 kV and above if applicable). High voltage test: During normal HV tests on switchgear or GIS the CTs are included in the HV test. CT secondaries shall be shorted to ground and isolated from relays and meters. Test intercore coupling for all bus differential CTs. Demagnetize CT cores after all tests.

REMARKS


Index Number:

T-PreCom-1000-R0


Page Number:

Page 26 of 124

Potential Transformers


3.8.1 ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness. Check tightness of all bolted connection. Check that the HV connection does not transfer stress to the HV terminal. Check that all grounding cables are securely connected. Check mechanical clearances and proper operation of all isolation and grounding devices (as applicable). Check integrity of primary fuses (if applicable). Check insulation liquid level (if applicable). Gas leakage check for GIS VTs. 3.8.2

ITEM 1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11. 12. 13. 14.


Electrical Tests

DESCRIPTION Winding Resistance Test. Insulation resistance tests HV TO G, LV TO G and HV TO LV using a one kV insulation tester. Ratio Test. Polarity Test. Primary and secondary fuses rating checks for 11 kV VTs and above (if applicable). Ensure VT is included in switchgear and GIS high voltage test.

Check VT HV neutral is solidly grounded. Check electrical operation of all isolating and grounding devices (if applicable). Check phase sequence, for the final three-phase assembly. Verify secondary circuits, terminal to terminal for correctness and tightness. Loop resistance test and burden test. Check gaps of protective flashover devices (if applicable). Insulation power factor test, 110 kV and above. Back energization test at rated voltage for 15 minutes.

REMARKS

Test voltage is 1.5Uo (where Uo is φ-N voltage) for 1 minute For electromagnetic VTs, see Table 1.


Index Number:



Page 27 of 124

TABLE 1 SYSTEM RATED VOLTAGE (KV) 11 13.8 33 69 110 115 132 230 380

RATED LOAD FACTOR 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

TEST VOLTAGE (KV) 9.5 12 28 60 95 99.5 114 199 329

FREQUENCY

60 Hz

TIME PERIOD

REMARKS

I Minute

These tests are applicable to electromagnetic VT’s


Index Number:



Page 28 of 124

Capacitive Voltage Transformers


3.9.1 ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness. Check tightness of all bolted connections. Check that all grounding cables are securely connected. Check mechanical clearances and proper operation of all isolation and grounding devices (as applicable). Check oil level (if applicable). Check for oil leakage. Check electromagnetic unit spark gaps for correct setting (if applicable). Check drain coils (if applicable). 3.9.2

ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.


Electrical Tests

DESCRIPTION Winding Resistance Test. Insulation resistance tests HV TO G, LV TO G and HV TO LV using a one kV insulation tester. Ratio Test. Polarity Test. Check HV neutral is solidly grounded. Check electrical operation of all isolating and grounding devices (if applicable). Check phase sequence, for the final three-phase assembly. Loop resistance and burden tests. Capacitance and dissipation factor measurement tests. Insulation power factor test, 110 kV and above. Check on fast damping device (FDD).

REMARKS


Index Number:



Page 29 of 124

Coupling Capacitor Voltage Transformer


3.10.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness. Check tightness of all bolted connections. Check that all grounding cables are securely connected. Check mechanical clearances and proper operation of all isolating, grounding and shorting devices (as applicable). Check electromagnetic unit spark gaps for correct setting (if applicable). Check drain coil unit spark gaps for correct setting (if applicable). Check wave trap mechanical assembly, bird screens, etc.

REMARKS

3.10.2 Electrical Tests ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

DESCRIPTION Winding resistance test Insulation resistance tests HV TO G, LV TO G and HV TO LV using a one kV insulation tester. Ratio test Polarity test Check electrical operation of all isolating and grounding devices (if applicable) Check phase sequence, for the final three-phase assembly. Loop resistance and burden tests. Capacitance and dissipation factor measurement tests. Insulation power factor test, 110 kV and above. Perform all specific tests per manufacturer’s instruction Phase angle check if the equipment is assembled at site.

REMARKS


Index Number:

T-PreCom-1000-R0


Page Number:

Page 30 of 124

Gas Insulated Switchgear (GIS)


3.11.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

21. 22.

23.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness. Inspect enclosures for proper alignment and foundation fixing and grounding. Check quality of paintwork. Ensure that all special tools and equipment are provided as specified and have proper storage. Ensure that gas-handling cart (if provided) operates correctly and that special filling and degassing fittings are provided and have proper storage. Verify that all lifting devices are correctly labeled for lifting capability. Ensure that adequate ladders and walkways are provided for access to meters, filling ports, cranes, lights, etc. Check and verify that all grounding of GIS is as per approved layout drawings and specification and is securely connected. Check that all specified grounding switches are insulated, with removable grounding links. Check operation of all mechanical interlocks. Check tightness of all bolted connections (torque wrench method). Check each gas section filled to correct rated pressure. Check SF6 gas at each gas section for air and moisture content after filling at rated pressure. Gas leak test of all flanges and joints after erection and filling. Calibrate gas pressure (density) gauges. Check the gauges have correct, legible and readable scales. Check the gauges are ambient temperature compensated. Check operation of all gas density switches (alarm trip signals and lockout functions). Confirm correct set points. Check all wiring is correct according to approved drawings or confirm the correctness of all modifications. Verify that all front panel mounted devices (meters, push buttons, switches, indicator lamps, mimic buses, etc.) are installed as per drawings, fixed permanently and are correctly labeled. Verify that all operating devices are correctly labeled. Perform mechanical checks and visual inspections on all component equipment: a. Circuit breakers. b. Current transformers. c. Voltage transformers. d. Disconnect and grounding switches. Check that all phase marking and circuit labeling have been installed as per specifications.

REMARKS

Permissible Dew Point is -35 °C or lower. Wrap all joints with sealed plastic sheeting and test for gas leakage after 24 hours.


Index Number:


25. 27. 28.


Page 31 of 124

Ensure that all disconnect switches are provided with viewing windows or mechanical indicators for verification of contact positions and that all grounding switch positions can be visually verified. Verify that correct Dispatch Numbers have been installed. Check the closed barriers at the ends of each gas zones are externally colored yellow or orange. The zone gas density gauges shall have a zone marking plates fixed over the gauges. Check GIS over pressure relief discs are not cracked or deformed. 3.11.2 Electrical Tests

ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12.

13. 14. 15. 16.

DESCRIPTION Insulation resistance test for all low voltage wiring and cabling. Functional test of all controls and interlocks. Resistance of all ground connection joints at 100 A DC. Resistance of bus joints at 100 amperes DC. Overall resistance of the main circuit. Functional check of all alarms, interlocking and indication circuits from the switchgear through to the local control cubicle. CB Timing Test (open and close) with contact travel and speed analysis. Disconnect switch close and open time tests for the confirmation of early make and late break operation of auxiliary contacts with main contacts for CT switching schemes. Checks on CB hydraulic system or vacuum system for pump start stop trip/close lockout threshold values. GIS PTs to be included during AC HV tests on GIS when test frequency is well above rated frequency, otherwise test at 1.5Un – one minute at rated frequency without secondary load. PT secondary output volts shall be monitored during the high voltage test. All AC/DC MCBS shall be tested by trip test through current injection. Check and confirm GIS PTs primary isolation device with manual operation provided where fitted, along with it’s monitoring system locally as well as on mimic diagram in control room. Check VT HV neutrals externally available especially in case of VTS installed directly on cable feeder. Check and confirm that the three-phase test adaptor and bushing for HV test on GIS has been provided. Verify the alarms being initiated by SF6 density gauges on LCC and up to control room during calibration process. Check that all cubicle space heaters and thermostats are functional and at correct temperature control settings. Perform all electrical tests on following GIS components as per manufacturer’s instructions and SEC approved procedures. Circuit breakers. Current transformers. Voltage transformers.

REMARKS

Not more than 1.2 X Rdesign with components (CBs, disconnects, etc.) in closed position.


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 17. I.


Page 32 of 124

Disconnect and grounding switches. Perform high voltage test at 10 kV AC for 1 minute on all grounding switches’ external insulating bushings. HV Tests on GIS Main Circuits

AC HV tests on main circuit of GIS are performed with all CB’s and disconnect switches in the closed position at 80% of the factory routine test voltage for one minute. Partial discharge measurements (If applicable and possible to be performed) are performed at 1.2 X Un (Un = phase to neutral voltage). II.

Preparation for HV Tests

Check and confirm following points and condition to be met before high voltage tests. i. ii.

iii. iv. v. vi. III.

The Switchgear shall be erected completely and filled with gas at rated pressure. Some part may be disconnected before test, such as: High Voltage cables and overhead lines. Power transformer and most voltage transformers. Surge arrestors and protective spark gaps. Current transformer secondary windings should be shorted and grounded. Every newly erected part of GIS shall be tested with high voltage. The test should be performed at rated frequency (60 Hz.). If such arrangement is not possible, then the frequency should be limited to the range of 30 to 300 Hz. AC voltage tests are sensitive in detecting contamination and abnormal field configuration. Tests with switching impulse voltages are useful especially for high rated voltage to detect the presence of contamination as well as abnormal field configuration

Two Test Procedures are Utilized to Test the GIS

Contractor can adopt one of the two procedures A or B to perform high voltage test on GIS after erection at site i.

Procedure A

Site AC test voltage level shall be equal to the 80% of the factory routine test voltage. This test may be performed through series resonance method Or by a test transformer with sufficient capacity. PD measurements are possible to be measured in this case at test voltage level = 1.2 Un (Un = phase to neutral rated voltage) during the HV Test process. Electrical conditioning at voltage equal to U/√3 for longer period such as 30 minutes may be performed to move and trap the contamination in areas where they become harmless. Partial discharge measurements may be helpful in detecting some kind of faults. ii.

Procedure (B) a.

Through GIS Voltage Transformers

Site AC test voltage level equal to 1.2 Un for 5 minutes followed by Impulse Voltage test at a test level equal to 64% of the rated lightening impulse withstand level specified in IEC-517. Three positive and three negative polarity impulses shall be applied. b.

With Separate Source


Index Number:



Page 33 of 124 In case the GIS VTs are not suitable to be used as test transformer; a special voltage transformer shall be used to perform such tests. GIS VT can only be used as a test transformer if the manufacturer guarantees its safety and capability to perform such tests otherwise it shall not be used as a test source.

IV.

Deviation Due to Practical Needs

Sometime in extension projects due to practical and technical reason of joining new and old GIS together, the test may be performed at reduced voltage level for an extended duration subject to agreement between SEC and supplier. V.

Assessment of Tests i. ii. iii. iv.

VI.

Test is considered passed if no disruptive discharge occurs during the test period. If disruptive discharge occurs in solid insulation, the compartment should be opened and repaired. After fault repair, again, test with full site test voltage. If disruptive discharge occurs in gas, the test may be repeated and if discharge again takes place, then compartment should be opened to clean out the compartment. If the discharge occurs and second time it disappears, it should be considered acceptable after repeating one test more at full site test voltage mentioned in Table 1.

Repetition of test after flash over at site

Test may be repeated several times to listen and locate the location of fault point subject to the agreement between SEC and Contractor. Table-1 on the next page describes the exact test voltage levels, time and kind of tests to be applied after erection of GIS at site. i.

For 132 kV GIS the test voltage shall be 220 kV AC 60 Hz for one minute as per Procedure A clause 7.107.1.5 of IEC 517- 1990

ii.

For 380 kV GIS and GIBs shall be 416 kV AC 60 Hz for one minute as per procedure A clause 7.107.1.5 of IEC 517-1990.

iii.

In case of procedure B as per clause 7.107.1.5 of IEC 517-1990 the test voltage for 132 kV rated GIS shall be 84 kV AC for 5 minutes and followed by 416 kV Impulses of three positive and three negative polarities.

iv.

In case of procedure B to be applied for high voltage tests on 132 kV GIS special VT should be used as Test voltage source. GIS VTs shall not be used as HV test voltage source.


Index Number:

T-PreCom-1000-R0


Page Number:

Page 34 of 124

A

13.8

10 kV for 10 min.

A

33

22 kV for 15 min.

A

B

A

B

A

B

A

B

69

69

110

110

115

115

132

132

44 kV for 30 min.

-

84 kV for 30 min.

-

84 kV for 30 min.

-

84 kV for 30 min.

-

30

60 Hz

1 min.

-

-

-

56

60 Hz

1 min.

-

-

-

128

44

220

84

220

60 Hz. or 10300 Hz.

60 Hz.

60 Hz. or 10300 Hz.

60 Hz.

60 Hz. or 10300 Hz.

84

60 Hz.

220

60 Hz. or 10300 Hz.

84

60 Hz.

1 min.

5 min.

1 min.

5 min.

1 min.

5 min.

1 min.

5 min.

-

-

248 kV

3 positive 3 negative

-

-

416 kV


-

-

416 kV


-

-

416 kV


REMARKS

Partial Discharge Measure

No. Of Impulses

Swing or Switching. Impulse level

Time Of AC Test Voltage

Freq. Of Test Voltage

AC Test Voltage kV

Electrical Conditioning

System Rated Voltage KV

Method No.

Table 1. Test Voltage Levels for Metal-Enclosed Gas Filled Switchgear (GIS)

Leakage current < 1000 mA Leakage current < 0.86 mA

At 48 kV less than 10 pC

Electrical conditioni ng is a cleaning process only.








Index Number:

T-PreCom-1000-R0

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS A

B

A

230

230

380

142 kV for 30 min. -

245 kV for 30 min.

316

142

416

10-300 Hz. Better 60 Hz. 10-300 Hz. Better at 60 Hz. 10-300 Hz. Better at 60 Hz.

1 min.

5 min.

1 min.

Page Number:

Page 35 of 124

-

-

608 kV


840 kV


-

PD or HF detection techniques to be applied

Impulse test is applied in special cases only


Index Number:



Page 36 of 124

Metal Clad Switchgear


3.12.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 27.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness. Inspect enclosures for proper alignment, foundation fixing and grounding and vermin proofing. Inspect all covers, panels section and doors for paint work and proper fit. Check for smooth and proper movement of racking mechanisms for alignment, shutters, rollers, rails and guides. Check for proper alignment of the breaker primary and secondary contacts. Check operation of all mechanical interlocks. Check tightness of all bolted connections (torque wrench method). Check bus and supports for defects such as cracked welds, chipped porcelain, cracked insulation, etc., and free from dust accumulation. Check main and riser buses for correct phasing. Verify that all front panel mounted devices (meters, push buttons, switches, indicator lamps, mimic buses, etc.) are installed as per drawings. Perform mechanical checks and visual inspection on all circuit breakers. Perform mechanical checks and visual inspection on all current transformers. Perform mechanical checks and visual inspection on all voltage transformers. Perform mechanical check and visual inspection on all disconnect and grounding switches. Check for correct breaker position indication. Check for correct spring status indication (spring charged/discharged). For air magnetic breakers check the arc chutes for damage and correct positioning above the interrupter contacts. For minimum oil breakers, check correct oil level in each pole. For SF6 breakers, check the correct gas pressure, quality and leakage where possible. For SF6 breakers, check the operation of the gas density switch (alarm and lockout functions). Perform all specific checks on the breaker and spring operating mechanism according to the manufacture’s instructions. Check that all control wiring is correct according to the approved drawing and terminal connections are secure. Check all wiring is correct according to approved drawings. Check that all phase marking have been installed per specifications. Verify that correct Dispatch Numbers have been installed.

REMARKS


Index Number:



Page 37 of 124

Check that all special tools, devices, etc., as per specification have been provided. 3.12.2 Electrical Tests

ITEM 1. 2. 3. 4.

5. 6. 7.

8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

DESCRIPTION Insulation resistance test of all circuits in the panels. Functional test of all controls and interlocks. Bus continuity and phasing test. Main Circuit Resistance Test with the switchgear erected but not yet connected to the cables. Performed with 10 or 100 Ampere DC by micro-ohmmeter from panel to panel on each phase from cable spouts with all circuit breakers racked in service and in the on position. Check all AC/DC MCBS in the panel for correct ratings and grading. Trip test by current injection for one point on curve. Insulation resistance test at 5 kV DC on all main circuits between phase to phase and phase to ground (before HV test). Perform electrical tests on all component equipment as per SEC approved procedures: a. Circuit breakers. b. Current transformers. c. Voltage transformers. d. Disconnect and grounding switches. Ensure the cable spouts are included in the high voltage tests. Insulation test on all wiring at 500 V DC. Functional test of all electrical interlocks. Functional test of trip free and anti pump circuits. Functional test of local alarm and indications. Functional test of remote alarm and indications. Minimum control voltage trip and close operations. Check and test capacitor trip circuit (if applicable). Check spring charge time and motor currents at rated control voltage. Functional check of thermostat and space heaters, measure heater current. Functional check of breaker operation counter. Timing test open/close using an electronic oscillograph. For SF6 breakers, verify electrically the low gas pressure alarm and lockout functions. For minimum oil breakers, test insulating oil for dielectric strength according to ASTM D 877 (with 2.5 mm gap). Check correct operation of all auxiliary “a” and “b” contacts (for breaker open/closed position).

REMARKS 500 V DC The resistance values from panel to panel should vary no more than 15%. Compare the measured resistance values with factory test results, and shall be within +/- 20% of factory test results.


Index Number:



Page 38 of 124

Guidelines for High Voltage Tests on main circuits including CBs i.

Preparation and precautions before HV Test

ii.

For vacuum breakers, test across open contact and live parts to ground. Precautions shall be taken against emission of X-rays. For all other breakers. Test in conjunction with breaker racked in the switchgear and in the closed position.

iii.

The following shall be observed: • • • • • • • • • • • II.

New switchgear should be tested as a whole unit with all circuit breakers in the closed position and not connected to cables. All back shutters must be closed. Gas circuit breaker interrupters should be checked to be within limits of correct pressure. VTs, cables or any other voltage indication should be disconnected and VTs secondary side fuses should be removed. VTs, cables or any other voltage indication should be in out position and VTS secondary side fuses should be taken out. CTs secondary terminals should be short-circuited and earthed. Test voltage should be applied on each phase to ground with other phases in earthed position. The test should be repeated on other phases similarly. The test period should not be more than one minute at full test level and the test voltage frequency should be kept at 60 Hz. Charging current for each test is noted and recorded. HV Test is considered successful if no breakdown occurs during test period. HV Test levels and time for pre-commissioning testing of switchgear are given in Table 2. AC High Voltage test

The test program shall be: Voltage shall be applied on each phase with all other phases and then frame grounded. • Tests shall be performed with the CB in both the closed and open position • In the open position, the cable contacts are to be grounded. • Test voltage levels are given in Table 2 below. • After the high voltage test on main circuit is finished, rack the voltage transformers in service position and apply a test voltage on the primary side equal to 1.5Un (Un = phase to neutral rated voltage) on each phase consecutively and measure the secondary output voltage same time during the test. • Make sure the VTs secondary side MCBs are switched off and any resistor in open delta winding should have been removed. • Compare the observed ratio with actual ratio. • The HV Test should be repeated with circuit breakers in open position keeping cable spouts in earthed condition in all panels.


Index Number:



Page 39 of 124

TABLE 2. TEST VOLTAGE LEVEL FOR MEDIUM VOLTAGE METALCLAD SWITCHGEAR

SWITCHGEAR RATINGS

AC TEST VOLTAGE

TIME PERIOD

11 kV

25 kV 60 Hz

60 Sec

13.8 kV

30 kV 60 Hz

60 Sec

33 and 34.5 kV

56 kV 60 Hz

60 Sec


Index Number:



Page 40 of 124

Metal Enclosed Bus Duct


3.13.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

DESCRIPTION Inspect for physical damage or defects. Check bus arrangement for conformance with approved drawings. Check tightness of all bolted connections (torque wrench method). Check that all enclosure grounding is securely connected. Inspect internal compartments for cleanliness (free from dust and moisture). Check for watertight seals at joints including expanding interface points. Check bus conductor support insulators for cracked insulation, chipped porcelain, etc. Check quality of paint work (inside and outside). Check that ventilation opening are not blocked, and meet specified Degree of Protection. Moisture drain holes available at bottom of enclosure. Check anti-condensation heaters mounted at the correct locations (bottom)

REMARKS

3.13.2 Electrical Tests ITEM 1. 2. 3. 4. 5. 6.

DESCRIPTION Perform phasing checks. Ensure correct phase identification. Perform continuity check. Bus joint resistance test. Insulation resistance test HV test (to ground and between phases). Heaters and thermostats functional test. Measure the heater currents.

REMARKS

Ductor at 100 A DC


Index Number:



Page 41 of 124

Indoor and Outdoor Bus Structures


3.14.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6.

DESCRIPTION Inspect bus and support insulators for physical damage or defects. Check bus physical arrangement for conformance with approved drawings. Check bus connections for correct phasing and marking of phases. Check tightness of all bolted connections (torque wrench method). Check for proper phase to phase and phase to ground clearances. Ensure that PT, etc., connections are flexible, to prevent transferring expansion stress from the bus

REMARKS

3.14.2 Electrical Tests ITEM 1. 2. 3.

DESCRIPTION Measure resistance of bus section joints. Insulation resistance test at 5 kV DC. HV test (indoor bus work including PTs where applicable, 69 kV and below).

REMARKS Ductor at t 100 A DC.


Index Number:



Page 42 of 124

Indoor Circuit Breakers



12.

13.

DESCRIPTION Inspect bus for physical damage or defects. Check nameplate information for correctness. Check tightness of all bolted connections (torque wrench method). Check all wiring is correct according to approved drawings and that terminal connections are secure. Check quality of paintwork. Check that all grounding cables are securely connected. Check breaker truck, rails, for proper alignment and smooth movement. Check operation of all mechanical interlocks with associated disconnects, grounding switches, racking truck mechanism, cubicle doors, etc. Check for correct breaker position indication (breaker open/closed). For minimum oil circuit breakers, check for correct oil level in each pole. For SF6 breakers: a. Check for correct SF6 pressure in each pole. b. Check for gas leakage. c. Calibrate SF6 pressure gauge. d. Check operation of gas density switch (alarm and lockout functions). e. Verify that all special filling adapters have been provided. For motor/spring operation mechanisms: a. Check manual spring charge operation. b. Verify correct spring status indication (spring charged/discharged). c. Perform all specific checks on the mechanism according to the manufacture’s instructions. For pneumatic operating mechanisms(69KV and above): a. Check the compressor, air piping, valves, pressure gauges, air filter, water trap and switches for damage, defects or blockage. b. Calibrate the air pressure gauges. c. Check the setting of air pressure switches (compressor start/stop, alarm, lockout). d. Perform all specific checks on the compressed air system according to the manufacturer’s instructions. e. Check for correct direction of compressor rotation. f. Check air-charging time. g. Check safety relief valve operating pressure and resetting pressure. h. Measure air consumption for C, O, CO and OCO operations. Air storage test, perform as specified, the following i.

REMARKS


Index Number:


14.

15.


Page 43 of 124

without replenishment: 5X CO, or O + CO + 3min. + CO j. Air leakage test (pressure drop method over 24 hours, CB closed and open). For hydraulic operating mechanisms: a. Check, the pump, piping, valves, gauges and switches for damage/defects/blockage. b. Bleed air from hydraulic system. c. Calibrate the fluid pressure gauges. d. Check the Nitrogen pre-charge pressure in accumulators. e. Check for correct hydraulic fluid level in the reservoir. f. Check the setting of air pressure switches (pump start/stop, alarm, lockout). g. Perform all specific checks on the hydraulic system according to the manufacturer’s instructions. h. Check for oil leaks i. Check pump-up time. j. Check safety relief valve operating and resetting pressure. k. Measure pressure drop for C, O, CO and OCO operations. l. Stored energy test – perform O + CO + 3min + CO without replenishment. m. Oil leakage test (pressure drop method over 24 hours, CB closed and open). n. Check operation of the nitrogen low pressure switch. Verify that correct Dispatch Numbers have been installed. 3.15.2 Electrical Tests

ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

DESCRIPTION Measure resistance of main conducting circuits at 100 A DC. Insulation resistance test of each breaker pole at 5 kV DC. Insulation resistance test of all low voltage wiring and cabling. Functional test of all electrical interlocks. Functional check of trip free and anti pump circuits. Functional check of phase disagreement protection circuit (applicable to breakers whose poles are not mechanically gang operated). Functional check of local control, alarm and indications. Functional check of remote control, alarm and indications. Minimum control voltage trip and close operation. Functional check of breaker operation counter. Functional check of thermostat and space heaters, and measurement of heater current. Check correct operation of all auxiliary “a” and “b” contacts (for breaker open/closed positions). Timing test using an electronic oscillograph. For SF6 breakers, verify electrically the low gas pressure alarm and lockout functions. For minimum oil circuit breakers, test insulating oil for dielectric strength.

REMARKS

ASTM D 877(with 2.5 mm gap)


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 16. 17.

18.

For motor/spring operating mechanisms, measure spring charge time and motor current. For pneumatic or hydraulic mechanisms: a. Measure compressor/pump motor starting and running currents. b. Verify electrically the low stored energy (fluid pressure) alarm and lockout functions. c. Functional check of the motor excessive running alarm circuit. Verify the electrical operation of the breaker racking truck. Check the correct functioning of interlocks and limit switches.


Page 44 of 124


Index Number:



Page 45 of 124

Outdoor Circuit Breakers


3.16.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8.

9.

10.

11.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness. Check tightness of all bolted connections (torque wrench method). Check all wiring is correct according to approved drawings and that terminal connections are secure. Check quality of paintwork. Check that all grounding cables are securely connected. Check for correct breaker position indication (breaker open/closed). For SF6 breakers: a. Check for correct SF6 pressure in each pole. b. Check for gas leakage. c. Calibrate SF6 pressure gauge. d. Check operation of gas density switch (alarm and lockout functions). e. Check air and moisture content of SF6 gas in breaker. For motor/spring operation mechanisms: a. Check manual spring charge operation. b. Verify correct spring status indication (spring charged/discharged). c. Perform all specific checks on the mechanism according to the manufacture’s instructions. For pneumatic operating mechanisms: a. Check the compressor, air piping, valves, pressure gauges, air filter, water trap and switches for damage or defects. b. Calibrate the air pressure gauges. c. Check the setting of air pressure switches (compressor start/stop, alarm, lockout). d. Perform all specific checks on the compressed air system according to the manufacturer’s instructions. e. Check for correct direction of compressor rotation. f. Check air-charging time. g. Check safety relief valve operating pressure and resetting pressure. h. Measure air consumption for C, O, CO and OCO operations. i. Air storage test, perform as specified, the following without replenishment: 5X CO, or O + CO + 3min. + CO j. Air leakage test (pressure drop method over 24 hours, CB closed and open). For hydraulic operating mechanisms: a. Check, the pump, piping, valves, gauges and switches for damage/defects. b. Calibrate the fluid pressure gauges.

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS c. d. e. f. g. h. i. j. k. l.


Page 46 of 124

Check for correct hydraulic fluid level in the reservoir. Check the setting of air pressure switches (pump start/stop, alarm, lockout). Perform all specific checks on the hydraulic system according to the manufacturer’s instructions. Check for oil leaks Check pump-up time. Check safety relief valve operating and resetting pressure. Measure pressure drop for C, O, CO and OCO operations. Stored energy test – perform O + CO + 3min + CO without replenishment. Oil leakage test (pressure drop method over 24 hours, CB closed and open). Check operation of the nitrogen low pressure switch. 3.16.2 Electrical Tests

ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

17.

DESCRIPTION Measure resistance of main conducting circuits at 100 A DC. Insulation resistance test of each breakers pole at 5 kV DC. Insulation resistance test of all low voltage wiring and cabling. Functional test of all electrical interlocks. Functional check of trip free and anti pump circuits. Functional check of phase disagreement protection circuit (applicable to breakers whose poles are not mechanically gang operated). Functional check of local control, alarm and indications. Functional check of remote control, alarm and indications. Minimum control voltage trip and close operation. Functional check of breaker operation counter. Functional check of thermostat and space heaters, and measurement of heater current. Check correct operation of all auxiliary “a” and “b” contacts (for breaker open/closed positions). Timing test using an electronic oscillograph. For SF6 breakers, verify electrically the low gas pressure alarm and lockout functions. For minimum oil circuit breakers, test insulating oil for dielectric strength. For bulk oil breakers: a. Test insulating oil for dielectric strength and water content. i. ASTM D 877 (with 2.5 mm gap) – for dielectric breakdown ii. ASTM D 1533A – for water content. b. Timing test using a time travel analyzer, measuring: i. Contact stroke, wipe and simultaneity. ii. Over travel and damping oscillations during closing. iii. Close and opening speeds. iv. O, C, CO and OCO times. For motor/spring operating mechanisms, measure spring

REMARKS

ASTM D 877 (with 2.5 mm gap)


Index Number:


19. 20. 21.

charge time and motor current. For pneumatic or hydraulic mechanisms: a. Measure compressor/pump motor starting and running currents. b. Ensure that all air is bled from the hydraulic system. c. Verify electrically the low stored energy (fluid pressure) alarm and lockout functions. d. Functional check of the motor excessive running time alarm circuit. AC HV test (applicable to SF6 breakers, if the tank is opened at site, e.g., to install bushings. Bushing current transformer test (applicable to dead tank breakers) Insulation and bushing power factor tests.


Page 47 of 124


Index Number:



Page 48 of 124

Disconnect and Grounding Switches


3.17.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness. Check quality of galvanizing (if applicable). Check tightness of all bolted connections (torque wrench method). Check smoothness and ease of operation (both closing and opening). Check simultaneity and synchronism of all 3 poles during closing. Check for proper contact, fingers spread and contact pressure in fully closed position. Check that end of travel stops are correctly adjusted, set and locked in position. Check open gap and minimum clearance between phases and to ground Check switch opens more than 90° (for horizontally mounted vertical open disconnects). Check switch drive linking toggled in both the closed and opened positions. Check that switch can be pad locked in both the closed and opened positions. Check that all grounding is securely connected. Check that switch-operating handle is grounded properly as specified. Check mechanical interlocks (with grounding switches, CBs, etc.). Check that the operator’s platform is of adequate size and is properly grounded.

REMARKS

3.17.2 Electrical Tests ITEM 1. 2. 3. 4.

DESCRIPTION Measure resistance of main current path (terminal to terminal) at 100 A DC. Functional test of all electrical interlocks. Check position-signaling contacts (if applicable). For motor operated mechanisms: a. Check mechanism cabinet is grounded. b. Check correct setting of motor limit switched (open/close). c. Check correct operation of all auxiliary “a” and “b” contacts. d. Measure switch opening and closing times and motor current at rated voltage (for fast acting disconnects and grounding switches, perform a timing test with an electronic oscillograph).

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS e.

5.

Minimum voltage operation (close and open) at 90 V DC. f. Functional check of thermostat and space heaters. Measure heater current. g. Insulation test all control and power wiring/cables at 500 V DC/ h. Check that in the manual mode, insertion of the operating handle automatically disconnects the motor DC supply. For bus bar isolators, carefully check make and make before brake contact function for auxiliary switch contacts used for CT switching schemes during open close time test on disconnect main contacts.


Page 49 of 124


Index Number:



Page 50 of 124

Circuit Switchers


3.18.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4.

DESCRIPTION Perform mechanical checks and inspection of isolating disconnect, as per Section 3.17.1, above. Perform mechanical checks and adjustments on interrupter unit according to the manufacturer’s instructions. Check the low SF6 target at the interrupter units. Check interrupter position indicator operation.

REMARKS


5. 6. 7. 8.

DESCRIPTION Resistance of main current path (terminal to terminal) at 100 Amps DC. Functional check of all electrical interlocks. Check position-signaling contacts (if applicable). For motor operating mechanisms: a. Check mechanism cabinet properly grounded. b. Check correct setting of motor limit switched (open/close). c. Check correct operation of all auxiliary “a” and “b” contacts. d. Measure switch opening and closing times and motor current at rated voltage (for fast acting disconnects and grounding switches, perform a timing test with an electronic oscillograph). e. Minimum voltage operation (close and open) at 90V DC. f. Functional check of thermostat and space heaters. Measure heater current. g. Insulation test all control and power wiring/cables at 500V DC h. Check that in the manual mode, insertion of the operating handle automatically disconnects the motor DC supply. Check shunt trip device operation. Verify proper operation sequence of interrupters and disconnects. Insulation power factor test of the interrupters. Timing test of the interrupter contacts with electronic oscillograph.

REMARKS


Index Number:



Page 51 of 124

LV Switchgear (110/220 V)


3.19.1 Inspections and Tests ITEM 1. 2. 3. 4. 5. 6. 7. 8.

DESCRIPTION Main circuits Continuity Test for tightness of joints and bolts. Main circuit insulation resistance measurement by 2.5 kV Megger or 2 kV AC HV test for one minute. Phasing check. Check and verify for all MCCBs ratings as per requirement and Trip Test by current injection. All ammeters and volt meters shall be calibrated. Insulation Test on all secondary wiring and cables. Tests on changeover schemes as per approved drawings if applicable. Confirm the neutral cable coming from auxiliary transformer is grounded in the LV distribution board.

REMARKS


Index Number:

T-PreCom-1000-R0


Page Number:

Page 52 of 124

230 kV and 380 kV XLPE Cables


3.20.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

DESCRIPTION Inspect for physical damage or defects. Check tightness of all bolted connections (torque wrench method). Check for proper cable bolted connections. Check for proper cable support, clamping, trays, blocking. Check cable bends to ensure that bending radius is equal to or greater than the minimum bending radius specified. Link box tightness check. Verify that shields are terminated as specified (through link box or directly grounded). Verification of exact route length from termination to termination as per approved drawings. Check that all grounding points are securely connected to ground grid as specified. Check that phases are identified and color coded. Single core cable connected between power transformer and switchgear shall be single point earthed at switchgear side and at floating side SVL (sheath voltage limiter) should be installed. Check single point or both ends, via voltage limiter as per approved design. Check cable entry path trench as ducts are to be properly sealed. For accessories (sealing terminations, instrument panels and link boxes), check the following as applicable: a. Nameplates installed and data is correct. b. Condition of paint work. c. All bolted connections.

REMARKS


DESCRIPTION Phase checking for conductor and sheath bonding in every link box. Conductor resistance, capacitance and inductance measurement test. Sheath DC high voltage test (10 kV for 1 minute) and 5 kV DC insulation tester before and after high voltage test. Anti corrosion sheath test. Measure the ground resistance at all link box positions. Zero and positive sequence impedance measurement. SVL (sheath voltage limiter) test with 2.5 kV DC insulation tester. Insulation resistance test of cable by 5 kV DC. Cross – bonding verification test. Contact resistance test on link boxes (less than 20 µΩ). Metallic sheath continuity test (if applicable).

REMARKS

less than 10 Ω

Sheath Current < 3 %


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 12. 13. 14.

Cable jacket test. Cable profile test. AC High voltage test.


Page 53 of 124

See table 2-1


Index Number:



Page 54 of 124

230 kV and 380 kV LPOF Cables


3.21.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

DESCRIPTION Inspect for physical damage or defects. Check tightness of all bolted connections (torque wrench method). Check for proper cable bolted connections. Check cable bends to ensure that bending radius is equal to or greater than the minimum bending radius specified. Check for proper cable support, clamping, trays and blocking. Verify that shields are terminated as specified (through link box or directly grounded). Verification of exact route length as per approved drawings from termination to termination. Check that all grounding points are securely connected to ground grid as specified. Pressure test of all associated oil piping. Check that phases are identified and color coded. Single core cable connected between power transformer and switchgear shall be single point earthed at switchgear side and at floating side SVL (sheath voltage limiter) should be installed. Availability of oil sampling facility valve arrangement. Check single point or both ends, via voltage limiter as per approved design. Check cable entry path trench as ducts are to be properly sealed. Oil flow test. Impregnation test. RGP test and DGA tests. For accessories (sealing terminations, pressure tank, gauges, instrument panels and link boxes), cheek the following as applicable: a. Nameplates installed and data is correct. b. All valve positions according to design (open/closed). c. Calibrate pressure gauges and pressure switches. d. Oil pressure. e. No oil leaks. f. Condition of paint work. g. All bolted connections.

REMARKS


DESCRIPTION Check Phasing for conductor and sheath bonding in every link box Conductor resistance, capacitance and inductance measurement test. Sheath DC high voltage test (10 kV for 1 minute) and 5 kV DC insulation tester before and after high voltage.

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

SVL (surge voltage limiter)test by 2.5 kV DC insulation tester. Anti corrosion sheath test. Measure the ground resistance at all link box positions (less than 10 Ω). Zero and positive sequence impedance measurement. Insulation resistance test for conductor. Cross – bonding verification test. Contact resistance test on link boxes. Oil pressure gauge function test. Shield continuity test. Cable Jacket test. Cable profile test. Insulation oil dielectric breakdown test and water content test. AC High voltage test.


Page 55 of 124

Sheath current <3% less than 20 µΩ

See table 2-1


Index Number:

T-PreCom-1000-R0


Page Number:

Page 56 of 124

110 kV, 115 kV and 132 kV XLPE Cables


3.22.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

DESCRIPTION Inspect for physical damage or defects. Check tightness of all bolted connections (torque wrench method). Check for proper cable bolted connections. Check cable bends to ensure that bending radius is equal to or greater than the minimum bending radius specified. Check for proper cable support, clamping, trays, blocking. Link box tightness check. Verify that shields are terminated as specified (through link box or directly grounded). Verification of exact route length as per approved drawings from termination to termination. Check that all grounding points are securely connected to ground grid as specified. Check that phases are identified and color coded. Single core cable connected between power transformer and switchgear shall be single point earthed at switchgear side and at floating side SVL (sheath voltage limiter) should be installed. Check single point or both ends, via voltage limiter as per approved design. Inspection of label inside link boxes and water proofing test. Check cable entry path trench as ducts are to be properly sealed. For accessories (sealing terminations, instrument panels and link boxes), cheek the following as applicable: a. Nameplates installed and data is correct. b. Condition of paint work c. All bolted connections

REMARKS

3.22.2 Electrical Tests ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

DESCRIPTION Check phasing for conductor and sheath bonding in every link box. Sheath DC high voltage test and 5 kV DC insulation tester before and after high voltage test. Conductor resistance, capacitance and inductance measurement test. Conductor insulation resistance test. Cross – bonding verification test. Zero and positive sequence impedance measurement. SVL (sheath/surge voltage limiter) test with 2.5 kV DC insulation tester. Measure the ground resistance at all link box positions. Contact resistance test on link boxes. Metallic sheath continuity test (if applicable).

REMARKS

10 kV for 1 minute

Sheath Current < 3 %

less than 10 Ω less than 20 µΩ


Index Number:


Cable Jacket test. Cable profile test. AC high voltage test.


Page 57 of 124

See table 2-1


Index Number:

T-PreCom-1000-R0


Page Number:

Page 58 of 124

110 kV, 115 kV and 132 kV LPOF Cables

(Standard Reference is IEC 60141-1, -2, -3 and relevant SEC Transmission Specifications)

3.23.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

DESCRIPTION Inspect for physical damage or defects. Check tightness of all bolted connections (torque wrench method). Check for proper cable bolted connections. Check for proper cable support, clamping ,trays, blocking. Check cable bends to ensure that bending radius is equal to or greater than the minimum bending radius specified. Verify that shields are terminated as specified (through link box or directly grounded). Verification of exact route length as per approved drawings from termination to termination. Check that all grounding points are securely connected to ground grid as specified. Pressure test of all associated oil piping. Check that phases are identified and color coded. Single core cable connected between power transformer and switchgear shall be single point earthed at switchgear side and at floating side SVL (sheath voltage limiter) should be installed. Availability of oil sampling facility valve arrangement. Check single point or both ends, via voltage limiter as per approved design. Oil flow test. Impregnation test. RGP test and DGA test. Check cable entry path trench as ducts are to be properly sealed. For accessories (sealing terminations, pressure tank, gauges, instrument panels and link boxes), check the following as applicable: a. Nameplates installed and data is correct. b. All valve positions according to design (open/closed). c. Calibrate pressure gauges and pressure switches. d. Oil pressure. e. No oil leaks. f. Condition of paint work. g. All bolted connections.

REMARKS


DESCRIPTION Check phasing for conductor and sheath bonding in every link box Sheath DC high voltage test with 5 kV DC insulation test before and after high voltage test. Conductor resistance, capacitance and inductance measurement.

REMARKS

10 kV for 1 minute


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Conductor insulation resistance test. Cross – bonding verification test. Link box tightness check. SVL (sheath voltage limiter) test with 2.5 kV DC insulation tester. Inspection of label inside link boxes and water proofing test. Measure the ground resistance at all link box positions. Contact resistance test on link boxes. Oil pressure gauge function test. Shield continuity test. Cable Jacket test. Cable profile test. Insulation oil dielectric breakdown test and water content test. AC high voltage test.


Page 59 of 124 Sheath Current < 3 %

less than 10 Ω

See table 2-1


Index Number:

T-PreCom-1000-R0


Page Number:

Page 60 of 124

69 kV XLPE Power Cables


3.24.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

DESCRIPTION Inspect for physical damage or defects. Check tightness of all bolted connections (torque wrench method). Check for proper cable bolted connections. Check cable bends to ensure that bending radius is equal to or greater than the minimum bending radius specified. Check for proper cable support, clamping, trays, blocking. Link box tightness check. Verify that shields are terminated as specified (through link box or directly grounded). Verification of exact route length as per approved drawings from termination to termination. Check that all grounding points are securely connected to ground grid as specified. Check that phases are identified and color coded. Single core cable connected between power transformer and switchgear shall be single point earthed at switchgear side and at floating side SVL (sheath voltage limiter) should be installed. Check single point or both ends, via voltage limiter as per approved design. Check cable entry path trench as ducts are to be properly sealed. For accessories (sealing terminations, instrument panels and link boxes), cheek the following as applicable: a. Nameplates installed and data is correct. b. Condition of paint work. c. All bolted connections.

REMARKS


DESCRIPTION Check phasing for conductor and sheath bonding in every link box. Conductor resistance, capacitance and inductance measurement test. SVL (sheath voltage limiter) test with 2.5 kV DC insulation tester. Anti corrosion sheath test. Measure the ground resistance at all link box positions. Zero and positive sequence impedance measurement. Insulation resistance test for conductor. Sheath DC high voltage test (10 kV for 1 minute) and 5 kV DC insulation tester before and after high voltage test. Cross – bonding verification test Contact resistance test on link boxes. Metallic sheath continuity test (if applicable).

REMARKS

less than 10 Ω

Sheath current < 3 % less than 20 µΩ


Index Number:


Cable Jacket test. Cable profile test. AC High voltage test.


Page 61 of 124

See table 2-1


Index Number:

T-PreCom-1000-R0


Page Number:

Page 62 of 124

13.8 kV and 33 kV XLPE Power Cables



DESCRIPTION Inspect for physical damage or defects. Check irregularities of outer jacket caused by non-uniform shield wire distribution. Verify all cable connections as per drawing. Check for proper cable support, clamping, trays, blocking. Check cable bends to ensure that the bending radius is equal to or greater than the minimum bending radius specified. Verify shield grounding as per design (single point, both ends, via voltage limiters, etc. Check tightness of all bolted connections (torque wrench method). Single core cable connected between power transformer and switchgear shall be single point earthed at switchgear side and at floating side SVL (sheath voltage limiter) should be installed. Check that phases are identified and color coded. Check cable entry path trench as ducts are to be properly sealed. Verification of exact route length as per approved drawings from termination to termination. Check for proper cable arrangement in the path (RYB) in order to prevent circulating current.

REMARKS

3.25.2 Electrical Tests ITEM 1. 2. 3. 4. 5.

DESCRIPTION Sheath armor continuity test. Sheath insulation resistance test. Main conductors insulation resistance test (5KV DC insulation tester) before and after HV Test. Phasing and continuity test of main conductor AC- high voltage test a. For new XLPE power cables, AC HV test voltages should be applied up to 2 Uo for one hour or by VLF at 0.1 Hz at test voltage level of 3 Uo for one hour can be performed. b. For mixed new and old cables, the test voltage shall depend upon the service life of the old cable. c. At least It should be tested at normal working voltage phase to neutral (Uo). d. Mixed new and old cables should not be tested by DC test voltage at any condition except by AC or VLF methods. e. Where cables are connected to switchgear, the AC HV test time should be reduced to 5 minutes. One hour test applies if the cables are fully isolated. f. Uo for all the applied tests is equal to phase to neutral voltage.

REMARKS IR for sheath > 10 megohms


Index Number:

T-PreCom-1000-R0


Page Number:

Page 63 of 124

3.26 LV Cables (Standard Reference is IEC 60227-2 and relevant SEC Transmission Specifications)

3.26.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9.

DESCRIPTION Inspect for physical damage or defects. Check for proper cable support, clamping, trays, blocking. Verify all cable connections as per approved drawing. Verify that all cables and cores are labeled correctly. Check tightness of terminals and confirm the cables are secured. Check that all cable trays are secure and correctly grounded. Check cable entry path trench as ducts are to be properly sealed. Visual Insulation, size and rating confirmation. Check cable size against rating required.

REMARKS


DESCRIPTION Phasing and continuity check. AC HV Test at 2 kV 60 Hz for 1 minute between core to core and core to grounded armor. Insulation Resistance Test with 2.5 kV DC insulation tester.

REMARKS

>=100 MΏ


Index Number:



Page 64 of 124

Control Cable


3.27.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9.

DESCRIPTION Inspect for physical damage/defects. Verify all cable connections as per approved drawing. Verify that all cables and cores are labeled correctly. Check for proper cable duct, support, clamping, trays, blocking. Check tightness of terminals, ferrule numbering and confirm the cables are secured. Check that all cable trays are secure and correctly grounded. Check all cables are securely supported throughout. Visual inspection, size and rating confirmation. Size checking against rating required.

REMARKS

3.27.2 Electrical Tests ITEM 1. 2.

DESCRIPTION Phasing and continuity check. Insulation Resistance Test with 1 kV DC insulation tester.

REMARKS IR > 100 Megohms


Index Number:



Page 65 of 124

Pilot Cables


3.28.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

DESCRIPTION Inspect for physical damage or defects. Verify all cable connections as per approved drawing. Verify that all cables and cores are labeled correctly. Check for proper cable support, clamping, trays, blocking, etc. Check tightness of terminals, ferrules, wiring identification and confirm the cables are secured. Check that all cable trays are secure and correctly grounded. Check all cables are securely supported throughout. Visual inspection, size and rating confirmation. Size checking against rating required. Verification of exact route length as per approved drawings from termination to termination.

REMARKS


DESCRIPTION Conductor loop resistance test for all pairs. Core Identification for each core between two ends. Insulation Resistance for sheath armor to ground by 500V DC insulation tester for each section before jointing. Insulation Resistance for sheath armor to ground with a 500 V DC insulation tester after all joints are completed and before termination in the pilot boxes (if applicable). Capacitance measurement for all cores. Insulation resistance test between core to core and core to ground with a 5 kV DC insulation tester. Frequency response test. End to end terminal and pair matching. Noise Level Measurement. Cross-talk and coupling test between pairs. High voltage test for protection and control core by 15 kV DC for 1 minute.

REMARKS

IR > 10 megohms IR > 10 megohms

IR > 1000 megohms


Index Number:



Page 66 of 124

(TABLE2-1)TEST VOLTAGE LEVELS FOR HIGH VOLTAGE POWER CABLES SYSTEM RATED VOLTAGE (KV) 13.8 kV XLPE POWER CABLES 33 kV XLPE POWER CABLES 69 kV XLPE POWER CABLES 110/115 kV XLPE/LPOF POWER CABLES 132 kV XLPE/LPOF POWER CABLES

PRE-COMMISSIONING SITE TEST LEVEL

TIME PERIOD (MINUTES)

2Uo = 16 kV AC or VLF test level = 3Uo = 24 kV 2Uo = 38 kV AC or VLF test level = 3Uo = 57 kV 2Uo = 80 kV AC or VLF test level = 3Uo = 120 kV

60 60 60 60 60 60

2Uo = 128 kV AC

60

2Uo = 152 kV AC

60

230 kV XLPE/LPOF POWER CABLES

2Uo = 265 kV AC

60

380 kV XLPE/LPOF POWER CABLE

2Uo = 438 kV AC

60

REFERENCES AC HV Test: Recommendation by KEMA Research Laboratory (Netherlands). VLF Test: Recommendation by High Voltage Corporation (USA) and Seba-Dynatronic (GERMANY) as a Manufacturer of VLF Test Sets. Test Voltage levels for LV Cables, Control Cable and Pilot Cables SYSTEM RATED VOLTAGE (KV)

PRE-COMMISSIONING SITE TEST LEVEL

TIME PERIOD (MINUTES)

LV Cables

2.5 kV DC Insulation Tester

1

Pilot Cable Core to Core and Cores to Sheath Test Protection and Control Core

Pilot Cable Core to Core and Cores to Sheath Test Protection and Control Core

- Insulation Resistance Test by 5 KV DC Insulation Tester

1

IR > 1000 megohms If IR < 1000 megohms, perform the following test : 10 kV DC between core to core of the pairs and 15 kV DC between all cores to grounded armor

1


Index Number:



Page 67 of 124

Overhead Lines


3.29.1 Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5.

6. 7.

8. 9. 10. 11. 12. 13. 14. 15. 16.

17.

18. 19.

DESCRIPTION Inspect that the access roads and structure pads are to specification (locations, widths, depth of base, cover material properly compacted, etc.). Check that sand stabilization has been done per specification (if applicable). Check the right of way to ensure that there is no construction or agricultural encroachment. Check that the ground profile allows water run-off from the structures. Check that grounding connection is made properly with steel structure and protective coating is applied on the concrete cap (if specified). There shall be no cracks, and the concrete cap shall slope away from the stub angle. Check that crash barrier and/or flood protection are being done as per specification (if applicable). For wooden pole structures, ensure that pole types and sizes are the correct specification and have been installed correctly (depth and plumb). Ensure that the depth indication tags are on each pole. For wooden pole structures, check structure guy wire, cross braces, and other framing work have been done correctly. Check that all wood structures have been identified correctly and that the identification plates are to specification. For double circuit structures, ensure that each circuit is correctly identified. For steel structures, ensure that type is as per specification / drawings. Check galvanizing quality and thickness (rust is not acceptable). Check bolt types and tightness (torque wrench method). Ensure anti-climbing guards are correctly installed (if applicable). Check step bolt tightness. For porcelain insulators, check insulators for chips, cracks, etc. Ensure correct number of insulators have been installed in each string. Ensure that cotter keys have been properly installed. For composite insulators, perform close elevated inspection on each structure to check that the insulator sheaths and sheds are not cracked, damaged or torn. The inner fiberglass rod should not be exposed at any location. Check that all line hardware (insulators, corona rings, vibration dampers, spacers, conductor clamps, warning spheres, warning lights, armor rods, counter weights, flag socket/keys, etc.) is installed correctly and in correct locations as per specification and drawings. Make sure that the insulators are clean and line is safe to be energized. Check that all splices are correct and installed in correct span locations.

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 20. 21. 22. 23. 24. 25. 26. 27. 28.

29.


Page 68 of 124

Check that all jumpers are installed correctly. Ensure correct clearances between jumper and structure as well as with other phases. Check that overhead shield wire/OGW(Optical Ground Wire) and associated joint box are grounded to towers as specified. Ensure that sags for phase and overhead ground conductors are even and to specification. Check that ground clearances meet company standards. Check circuit/phase identification plates, structure numbers, danger sign plate, etc., have been correctly installed at each structure. Check line/phase correctly transposed at the specified locations (if applicable). Check that washing platform and pumping system has been installed as per specification (if applicable). Check solar unit for tower lighting (if applicable). For terminal compound, check the following, if available, as per contract: a. Outdoor equipment such as surge arresters, CVTs, etc. b. Equipment structure. c. Foundation. d. Bonding of equipment / structures. e. Gravelling inside terminal compound. f. Circuit identification. g. Conductor dropper and connectors. h. Fence and gate are complete and grounded. Ensure that the site has been properly cleaned up and all earthwork profiles are correct before acceptance. 3.29.2 Electrical Tests

ITEM 1. 2. 3. 4. 5.

DESCRIPTION Perform phase sequence/rotation check. Perform sequence impedance and susceptance tests and mutual impedances (both zero and positive sequence for double circuit lines. Check tower foot earth resistance as per company standard. Check the aircraft warning lights are properly functioning (if applicable). Perform continuity and conductivity test.

REMARKS


Index Number:



Page 69 of 124

Protection and Control

(Standard Reference is SEC Transmission Standard Procedures and relevant Manufacturer’s Recommendations)

3.30.1 Protection and Control Panels-Mechanical Checks and Visual Inspections ITEM 1. 2. 3. 4. 5.

6. 7. 8. 9.

10.

DESCRIPTION Inspect for defects and physical damage from shipping and handling. Prior to opening any case or panel, confirm that the equipment will not be contaminated by dust, excessive humidity or other pollutants. Ensure that there is no foreign material, moisture, dust, etc., inside panels and device cases. Check all installed equipment nameplate information for compliance to approved drawings and equipment/material lists. Ensure that all relays, relay covers, meters, controls and test facilities are properly identified as per the approved drawings and relevant SEC standards and that the identification does not obscure information displays. Ensure the mimic bus provides an accurate representation and that all switchgear identification is accurate and as assigned by Systems Operations Department. Confirm that each panel has been properly secured to the floor in its final service location. Confirm that panels are constructed and wired as per SEC relevant specification. For all internal and external panel wiring, confirm that all screw terminations are tight and that crimp connectors are firmly secured to the wire and to the termination point. Ensure that no part of the wire is bent at the termination point. Check that panel equipment is mounted securely and protected against mal operation due to vibration, shock, etc.

REMARKS

3.30.2 Internal Panel Wiring Tests ITEM 1.

DESCRIPTION Wiring Test / Confirmation a. The equipment is safe to work on and free of construction activities. b. Ensure that the approved drawings, relevant specification, protection requirement, manufacturer’s manuals, factory test results, site test procedures, etc., are available at site. c. All necessary tools and equipment with their valid calibration certificates are available. d. Stable auxiliary power supplies at the rated voltages are available. e. Prior to conducting panel checks, open all supply breakers, remove all fuses and ensure that all DC (including alarm, SOE, SCADA, etc.), AC, VT and CT circuits are properly isolated. f. Confirm all DC circuits are ungrounded. g. Check CT and VT circuits to confirm the presence of a

REMARKS


Index Number:


2.

3.

ground. Temporarily isolate the ground point on each circuit individually and retest to confirm that each CT and VT circuit is grounded at a single point. h. Check the burden of each DC circuit with an ohmmeter to confirm absence of short circuits. i. Check auxiliary power supply polarity and magnitude at the supply side of all circuit breakers/fuses to be correct as per schematics and relay/meter ratings. j. All wiring including CT, VT, AC, control, alarm and earthing shall be confirmed terminal to terminal and wire by wire using an ohmmeter. k. Operate all switches and relay contacts confirming connection terminal numbers and contact status using an ohmmeter. l. Confirmed wiring is to be highlighted in yellow on the schematic diagram. Corrections/changes in the schematics shall be marked up using red pencil for additions and green for deletions. m. For all MCBs, confirm ratings as per approved drawings; operate several times by hand. Inject 150% of rated current and record the timing for trip operation. n. Confirm that each internal and external wire is properly ferruled at termination points. CT Circuit Confirmation a. Inject AC current at about 50% of the rated current into one phase to neutral of the current circuit at the incoming CT cable connection using a suitable meter and isolated current source (for each phase of each current circuit). b. At each current test facility, confirm current flow and polarity in the subject phase and neutral as appropriate and according to the approved schematics. Confirm no current in the other two phases. c. Withdraw each relay in the current circuit one at a time and confirm that the case shorting facility is working and that at no time during its withdraw is the current circuit opened. Check test facility shorting and isolating devices for proper operation. d. Confirm current flow in the relay by opening the case shorting manually and confirming the meter to read zero. e. Confirm that any phase selector switch for metering is connected in the correct phase being tested. (for each phase of each current circuit). VT Circuit Confirmation a. Connect a fused or current limited adjustable three phase, four wire voltage source to the VT circuit and slowly increase the voltage to the rated value. b. Using a voltmeter and phase angle meter, confirm the phase angle and magnitude at each terminal in the voltage circuit according to the approved schematics. c. Check total burden per phase to conform to expected loading as per connected relay/metering specifications. d. Confirm that any phase selector switch for metering is connected in the correct phase being tested for each


Page 70 of 124


Index Number:



Page 71 of 124

phase of each current circuit. DC Circuit Confirmation a. Withdraw all removable relays and meters from the panel. b. Apply normal DC supply (insert fuses/close breaker) to the circuit and use a DC voltmeter to confirm all direct connections to the positive and negative supply between the fuse/breaker and the device terminals are made correctly. Confirm power supply at each relay/meter case terminals is correct. c. Disable the DC supply and reinstall the relays and meters in the panel. Restore the DC supply. d. Test the panel by operating (or simulating operation for external devices) each switch/coil/contact separately while monitoring correct circuit operation. Use a voltmeter to confirm DC voltages at progressive locations in the panel wiring. Proceed in such a way as to confirm that each contact operates only the intended devices in the panel. Confirm all contacts of control switches/relays including spares. 3.30.3 External Panel Wiring and Cable Tests Cable testing requires at least two personnel with a means of communication between the cable/wiring ends. Spare cores shall be clearly identified and of sufficient length to be terminated at the farthest terminal in the panel. CAUTION: Before conducting any external wiring or cable tests, ensure that all sources of supply to the circuits involved have been de-energized or disconnected.

ITEM 1.

2.

3.

DESCRIPTION Continuity Checks Cables and external wiring insulation shall be tested as for panel internal wiring, Section 3.30.2. All control cables shall be tested using a low ohms reading ohmmeter to check each wire separately to ground (CT and VT circuits must have their normal grounding point isolated during this test). The technician at one end shall ground one core at a time in communication with the technician at the other end who shall use an ohmmeter to monitor the cores. CT Cable Checks A final check of each CT circuit shall be conducted by current injection at the source end while measuring magnitude and phase angle in the downstream circuit test facilities. VT Cable Checks A final check of each VT circuit shall be conducted by voltage injection at the source end while measuring magnitude and phase angle in the downstream circuit test facilities.

REMARKS

3.30.4 Panel Device Tests ITEM 1.

DESCRIPTION Each panel device shall be mechanically inspected prior to

REMARKS


Index Number:


2.

3.

testing. CAUTION: When working with electronic devices, never remove modules with the DC supply energized. Use precautions to prevent static discharge damage to the modules. Grounded wrist strap, anti-static work surface and electrically conductive storage bags should be used. a. Check condition of internal wiring and solder joints. b. Case cover and gasket for proper seal against dust. c. Condition of any connectors, contacts, alignment and travel. d. Operation of moving parts, mechanical target operation and reset. Relay Tests Relay tests shall be conducted in accordance with the approved site test procedure. Additional tests may be required as recommended by the manufacturer, by Company Standard or as deemed necessary by the Company from operational experience. a. 500 V insulation tests shall be conducted between the AC circuits and from AC circuits to the relay frame. All outputs/indications shall be tested. b. For electromechanical relays, the DC circuits shall be insulation tested to AC circuits and to the frame of the relay. c. Initial tests of new protective relays shall include operating characteristics checks for a representative range of available settings with Company approved computer operated test equipment running routines developed for the specific relay and test set involved. d. Relay auxiliary devices such as external resistors, metrosils, etc., to be tested to conform to required ratings and manufacturer’s information. e. Proper electrical operation of targets/indicators shall be confirmed. f. Final calibration test of all protective relays must be carried out on approved settings with the relays mounted in their cases, by secondary injection at the front panel mounted test facilities. g. Auxiliary and tripping relay testing shall include: i. Insulation testing as above. ii. Pickup and dropout voltage, verification of all contacts. iii. Operation timing at 80% and 100% nominal voltage. iv. Time delay relays shall be tested at 0%, set point and 100% delay. h. Use of red and green tags for tested relays, meters, etc. i. All the relays and meters which have been tested and found acceptable shall have green tags. j. The relays and meters found defective during tests shall be tagged red. Metering Tests Panel metering calibration shall be tested via front panel mounted test facilities. The following represent the minimum


Page 72 of 124


Index Number:


4.

5.

test points required. a. Maximum demand indicator (MDI) meters shall be tested at 10% and 100% of full scale. b. Current and voltage metering and transducers calibration shall be tested at 0, 25, 50 and 100% of scale. c. Watt and VAR metering and transducer calibration shall be tested at (+/- when bi-directional) 0, 25, 50 and 100% of rated load and with rated voltage and current at angles of 0, 45,180, 2270 and 315 degrees. d. KWH and KVARH metering calibration shall be tested at 10% and 100% of rated current at angles of 0, 45, 90, 180, 225, 270 and 315 degrees. e. Frequency metering and transducers calibration shall be tested at minimum, nominal, and maximum rated scale. f. Power Factor metering and transducer calibration shall be tested at rated voltage and at 50% lead, unity, 50% lag power factors at 10, 50 and 100% of rated current. g. Tap position indicators shall be checked and confirmed for the entire range of transformer tap positions. Annunciator Tests a. Confirm dual supply operation by disabling primary and backup supplies one at a time. b. Confirm operation of Acknowledge, Reset and Lamp Test push buttons. i. Alarm indication lamp flashes on receipt of alarm. ii. Pressing Acknowledge does not reset the alarm points. iii. Alarm does not reset until Reset is pressed. c. Confirm Annunciator Failure alarm to SCADA. d. Check operation of each alarm point one at a time by simulating input at the marshalling panel. e. Confirm individual alarm identification for each point during functional testing of remote panels’ output contacts. Digital Disturbance (DDR) Tests a. DDR shall be inspected and calibrated as recommended by the manufacturer. b. Calibration of voltage and current channels shall be confirmed by secondary injection. c. Each digital input shall be confirmed by operation of the associated auxiliary contact in the remote panel. d. Program and electrically confirm trigger levels and initiating contacts. e. All alarm/SOE/SCADA outputs shall be tested and confirmed. f. Verify accuracy of all channel descriptions. g. Verify operation to the local printer if available. h. Verify proper communication and software i. Update/installation at all concerned locations by establishing communications with each unit and downloading event data.


Page 73 of 124


Index Number:



Page 74 of 124

3.30.5 Functional Checks ITEM 1.

2.

3.

4.

5.

6.

DESCRIPTION Test to Local Auxiliaries With all tripping isolating switches opened, operate the protective relays by secondary injection to test all functions to the panel auxiliaries. Check and confirm correct operation of all trip, alarm, SOE and SCADA auxiliaries in the panel as well as initiation outputs to DFR, breaker failure, etc. End To End Tests Communications with the test crew at the remote end are essential to this test. Where protection signaling equipment (PSE) is used in the scheme, end to end tests shall be conducted to confirm operation of each channel individually to the correct remote tripping/protection inputs in coordination with personnel at the remote end. Round trip channel delay should be checked and recorded. Pilot Differential Protection shall be end to end tested as recommended by the manufacturer. Test to Remote Functions Individually operate each control switch, protection output trip, initiation and alarm function with the associated isolating switch (if available) first in the open position and then in the closed position to prove the switch connection. Take care to limit tripping when testing to transfer tripping or breaker failure protection prior to initiating. Where no physical or visual indication of the signal is available, use a multimeter to monitor the received signal at the appropriate terminals of the remote panel or equipment. Interlocks such as close blocking from lockouts shall also be proven. Testing shall include all reclosing, initiation, trip, SCADA, SOE, annunciator and fault recorder outputs from the panel to actuate the associated remote devices. Primary Injection Phase and ratio connection of CT and VT circuits shall be confirmed by primary injection and checked to the panel test facilities. Stability Tests Stability of bus bar, transformer differential protection and restricted E/F protection circuits shall be confirmed by injecting current on the primary bus and simulating first internal and then external fault conditions while monitoring spill current at the protective relay. Remote Tap Change Control (RTCC) a. Selection of Independent, Master/Follower, Auto, Manual from RTCC local pushbuttons and from SCADA. b. Raise and lower operation of the tap changer in Independent/Manual from both the RTCC control pushbuttons and from SCADA. c. Raise and lower operation of the tap changer in Master-Follower for each possible combination of paralleled transformers, in Manual mode from both the RTCC control pushbuttons and from SCADA.

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS d.

7.

8.

9.

10.

11.

Raise and lower operation of the tap changer from the AVR relay in Independent/Auto and Master/Auto both when the RTCC is in Local and in SCADA control modes. e. Check of blocking and reset of operating modes when breakers are opened or paralleling is disturbed. f. Operation of all alarm, SCADA and SOE outputs from the panel and control panel. Automatic control switching equipment panel a. Check the proper scheme for automatic closing of third transformer 13.8 kV incomer circuit breaker in case of tripping of any transformer in service. b. Check all alarms, command and back indication of the system with SCADA. Trip On Parallel scheme a. Check the manual tripping of one circuit breaker and selection of the circuit breaker to be closed and in time of tripping of that selected circuit breaker the fifth circuit breaker will closed accordingly (13.8 kV three transformers and two bus section circuit breakers). b. Check all alarms, command and back indication of the scheme to SCADA. Automatic Bus Transfer Scheme (ABTS) Panel a. Operation in service for tripping of each transformer individually when paralleled with a second transformer to demonstrate automatic paralleling of the third transformer. If possible, offload one bus at a time so that it is possible to prove operation for loss of the independent transformer without loss of customer load. b. Prove that protection blocking interlocks (bus differential, transformer high side time overcurrent etc.) prevent operation of the ABTS. c. Prove scheme for opening of bus section breaker to break parallel of three transformers is functioning. d. Test blocking and forced operation of the RTCC by the ABTS. e. Operation of all alarm, SCADA and SOE outputs from the panel. Automatic Transfer Schemes (ATS) a. Confirm proper operation of station service (AC and DC) automatic transfer schemes by simulating incomer failures. b. Confirm operation of interlocks to prevent/limit paralleling of incomer sources as per approved scheme. c. Test automatic and manual controls for all possible operating conditions. Switchgear Control Panel Functional Tests a. Checks of all interlocking and blocking functions (synch check, lockout block closing, ground switch, etc.) b. Tests of open and close operation and indication of the associated switchgear. c. Operation of all alarms, SCADA and SOE outputs from the panel.


Page 75 of 124


Index Number:



Page 76 of 124

3.30.6 Energization ITEM 1.

2.

3.

DESCRIPTION First Time Energization Testing-Checks Prior to Energization a. All in service CT circuit shorting is removed. b. All VT circuits MCBs closed, fuses in place. c. All supplies to protection, control, switchgear, etc., are normal. d. No abnormal relay targets, alarms, SCADA SOE indications. e. All relays have approved settings applied and have been fully tested and are in service. f. All switchgear and other power equipment testing is completed. g. All protection equipment is properly labeled. h. All fire/smoke alarm systems are fully tested and in service. i. All necessary fire fighting equipment is on site and accessible without obstruction. j. Confirm all men and tools are clear of equipment to be energized and that all personnel are aware of the pending energization. Phasing Checks Before paralleling two sources, phasing shall be absolutely proven by selectively energizing a common three phase VT set from the two sources one at a time and checking the phasing (voltage and phase angle) of the VT set to a reference potential whose source shall remain unchanged for the duration of the test. For example, if one new incoming line to an existing station is to be energized, use the existing incoming line ‘A’ phase to neutral potential as a reference and measure and record the new line VT secondary three phase voltage and phase angles when energized from the remote end only. Then after opening the remote end of the new line, energize the new line from the local station only and repeat the voltage and phase angle measurements, the results of the two tests should be identical (within a few degrees) if phasing is correct. Where possible, phasing sticks can be used. In Service Checks a. Immediately after energization, in-service/on-load checks should be taken and recorded by measuring the magnitude and phase of all voltage and current circuits to a common reference at all of the test points available to prove VT and CT connection, ratio and polarity. b. Check and record all panel meter readings to compare with CT/VT measurements in the control circuits. c. As soon as sufficient load is available, all directional and distance type relays shall have their operating direction proven using in service voltages and currents. d. Directional earth fault relays shall be proven by selectively isolating in service voltages and currents to

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS e.

f.

g.

h. i.

provide a range of simulated fault conditions. For REF and bus differential relays, check to ensure minimal spill currents in service. Test the differential circuit by isolating one service current from the summation to force operation and prove the summation circuit is not shorted. For transformer differential circuits, check spill currents and minimum, center and maximum transformer taps. Spill current at minimum and maximum taps should be similar with near zero spill current on the center tap position if the auxiliary CTs are selected to the correct tap. Check transformer AVR operation in independent and parallel modes as applicable. Manually raise (lower) the transformer(s) two taps and place them back in AUTO to observe the automatic return to the correct voltage tap. Confirm operation from SCADA and in all possible operating modes. Functionally test the ABTS scheme by operating transformer protection to trip the breakers and initiate the system. Check in service reclosing for OHTL circuits by operating the protection to initiate trip and reclose.


Page 77 of 124


Index Number:

T-PreCom-1000-R0


Page Number:

Page 78 of 124

Station Batteries

(Standard Reference is IEC 60623, clause 4 and relevant SEC Transmission Specifications)

3.31.1 Mechanical Checks and Visual Inspection ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9.

10. 11. 12. 13. 14. 15.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness as per standards. Check tightness of all external wiring and cabling connections. Verify all panel mounted devices (meters, switches, push buttons, indicator lamps, etc.) are supplied and installed according to approved drawings. Make sure all battery connections are clean and free from corrosion. Verify system configuration and capacity with contract specification. Check that all cells are properly numbered. Check protective covers installed. Check that all battery maintenance tools and accessories (hydrometer, wall mounted thermometer, insulated torque wrench, rubber gloves, apron, face shield) have been provided per specifications. Ensure that all maintenance equipment is stored in a wall mounted lockable cabinet. Check that the room ventilation, exhaust fan, etc., are to specification. Check installation of safety equipment (eyewash, showers, ”No smoking “and “Warning Caustic/Acid” signs). For flooded lead acid batteries, check for correct specific gravity and liquid level. Check that all battery racks are correctly and securely grounded. Check that the battery bank is provided with an isolating disconnect switch. Check that the Valve Regulated Lead Acid (VRLA) battery bank has an ammeter provided for monitoring the float charge current.

REMARKS


DESCRIPTION For valve Regulated lead Acid Batteries, check the open circuit voltage of each cell. Perform initial charging of the battery (equalize voltage, charging rate and charging time according to the manufacturer’s instructions). Record individual cell voltage electrolyte specific gravity and cell temperatures at the end of charge cycle. Battery discharge test: a. The battery must not have been discharged within last 7 days before test is performed. b. While battery on float, read and record the voltage of each cell or unit and battery terminals float voltage.

REMARKS

Room temperature shall be between 25 and 30 °C.


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS c.

5.

Disconnect the battery charger and any other load on the battery. d. Record the initial voltage of each unit and battery terminals. e. Select the discharge rate based upon the battery capacity (ampere-hour) and the time period the test shall be carried out for 10 hours. f. With the variable load bank (dummy load) with an ammeter in series and a voltmeter across the battery terminals, connect the load while simultaneously starting the timing device. g. Maintain the correct current while periodically reading and recording total battery voltage. After 10 hours record the final unit voltage and compare the test result with the manufacturer’s recommended voltage chart to confirm the battery end voltage. Fully recharge the battery according to the manufacturer’s instructions.


Page 79 of 124


Index Number:



Page 80 of 124

Battery Chargers

(Standard Reference is IEC 60623, clause 4 and relevant SEC Transmission Specifications)

3.32.1 Mechanical Checks and Visual Inspection ITEM 1. 2. 3. 4.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness as per standards. Check tightness of all external wiring and cabling connections, labeling, drawing pocket shall be checked. Verify all panel mounted devices (meters, switches, push buttons, indicator lamps, fuses, etc.) are supplied and installed according to approved drawings.

REMARKS


5. 6. 7. 8. 9.

10. 11.

DESCRIPTION Insulation test for all external wiring. Battery charger test by simulation of variable load to check for correct charger current output response to different values of load. Check the adjustment range of output float and equalize voltage. Note that the adjustment of float and equalize voltage should be independent of each other. Functional check of the following: a. High and low output voltages alarm/shutdown. b. Ground monitoring/ground detector for +ve and –ve alarms. c. All other protective alarm/shutdown. d. All devices (switches, push buttons, timers, indicating lamps, etc.). e. Current limits. f. Soft start. g. Impedance monitors (if applicable). h. Silicon droppers (if applicable). Check output voltage ripple content (battery disconnected). Check regulation at 0%, 50% and 100% of full load. Measure AC input and DC output voltages and currents and calculate efficiency at 50% and 100% of rated output current. Calibrate voltmeters and ammeters. If applicable measure the following and verify that they are compatible with and meet the requirements of the communications equipment: a. Voice band noise voltage. b. Wideband noise voltage. Check load sharing operation for parallel chargers. Ensure that the settings of adjusted control, shutdown, alarm voltage, etc., have been reset to the final operational values as specified by SEC.

REMARKS


Index Number:



Page 81 of 124

AC Distribution Panels


3.33.1 Mechanical Checks and Visual Inspection ITEM 1. 2. 3. 4. 5. 6.

DESCRIPTION Inspect for physical damage or defects including of quality of paint work. Verify circuit layout for conformance with breaker directory drawing. Verify correct rating of each circuit breaker per design drawings. Check tightness of all bolted connections. Verify that all front panel mounted devices (meters, selector switches, push buttons, timers, indication lamps, etc.) are installed per layout drawing and are correctly labeled. Check for proper grounding connection (torque wrench method).

REMARKS


DESCRIPTION Insulation test of all buses and wiring. Phasing check. Functional check of main power contactor (or breaker). Functional check of each branch breaker. Calibrate voltmeters, ammeters and wattmeters. Functional check of meters and phase selector switches. Functional check of all auxiliary devices including individual, group and main circuit breaker alarms. Functional check of under voltage protection/alarm circuits. Functional check of ground fault circuit interrupter (if applicable). Check all MCBs for their ratings and alarms.

REMARKS 2.5 kV for one minute


Index Number:



Page 82 of 124

DC Distribution Panels



DESCRIPTION Inspect for physical damage or defects including of quality of paint work. Verify circuit layouts for conformance with breaker directory drawing. Verify correct rating of each circuit breaker per design drawings. Check tightness of all bolted connections. Verify that all front panel mounted devices (meters, selector switches, push buttons, timers, indication lamps, etc.) are installed per layout drawing and are correctly labeled. Check for proper grounding connection (torque wrench method).

REMARKS


DESCRIPTION Insulation test for all buses and wiring. Polarity check. Functional check of main breaker. Functional check of each branch breaker. Calibrate voltmeters, ammeters and wattcmeters. Functional check of meters. Functional check of all auxiliary devices including individual, group and main circuit breaker alarms. Functional check of under voltage protection and alarm circuits. Functional check of DC transfer switches and interlocks. Functional check of positive and/or negative ground alarm (calibrate resistors for proper detection sensitivity earth fault relay setting shall be checked). Check all MCBs for their ratings and alarms.

REMARKS 2.5 kV for one minute


Index Number:



Page 83 of 124

LV AC Auto-Transfer Schemes/Switches



DESCRIPTION Inspect for physical damage or defects. Check that all front panel mounted devices are supplied and arranged according to approved drawings. Check that all devices and cables are properly identified and labeled. Check tightness of all bolted connections (torque wrench method). Check that all grounding is correct and securely connected (including neutral bus). Check mechanical/electrical interlocks.

REMARKS


DESCRIPTION Phasing check of incomers and transfer switch connections. Calibrate under voltage relays and time delays. Calibrate voltmeter and ammeters. Functional check of meters and selector switches. Functional check of electrical and mechanical interlocks. Functional check of preferred source selector switch. Check transfer motor fuses. Functional check of transfer operation (simulate loss of one source) and retransfer on re-establishment of preferred source voltage. Check with each source as the preferred source. Ensure the sources are from two separate buses. Set under voltage relay and time delay per manufacturer’s instructions.

REMARKS


Index Number:



Page 84 of 124

Grounding Systems

(Standard Reference is IEEE 81 and relevant SEC Transmission Specifications)

3.36.1 Mechanical Checks and Visual Inspection ITEM 1. 2. 3. 4.

DESCRIPTION Inspect the grounding system(s) for conformance with approved design drawings and specification. Inspect the mechanical integrity and quality of all bolted and/or thermite welded grounding joints and connection. Inspect and verify the size and type of conductors conform to standard requirements. Check that all metal parts in the substation are grounded.

REMARKS

3.36.2 Electrical Tests ITEM 1. 2.

3.

DESCRIPTION Measure the ground grid system resistance by the “fall of potential” method. Measure the contact resistance at 100 A DC of all bolted and/or thermite-welded joints at the grounding conductor between the equipment to be grounded and the grounding mesh. Note that bolted below grade connections are not permitted. Measure the electrical resistance between each major electrical equipment grounding point, grounded neutral points and the substation main grounding system by the “millivolt drop” method.

REMARKS


Index Number:



Page 85 of 124

Switchgear Air Compressor Systems


3.37.1 Mechanical Checks and Visual Inspection ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

13.

DESCRIPTION Inspect for physical damage or defects. Check labeling and marking according to the approved drawings. Check tightness of bolts on direct drive and base-mounted equipment. Check oil level and leakage and air compressor main components, air receiver tank design and specification. Check hour meter, safety relief valve, pressure switch and gauges. Check air lines piping according to the approved materials. Check that the exposed airlines protected against rupture damage. Check that all piping runs parallel to flooring or walls and is clamped properly by u-bolts or metal clamps supported on at least 6 foot intervals or less. Check that all piping has sufficient spacing so that each line can be accessed without disturbing the rest of the piping. Check that all pipes are supported on steel benches on the floor of the trench. Check that all piping fitting connections to be used shall be flare cup type nuts with sleeve. Check that air compressors are fitted with: a. Automatic drain valve. b. Manual drain valve. c. Pressure relief valve. d. Oil level sight glass. Check that the receiver tank provided with inlet and outlet stop valves, manual drain valve, pressure relief valve and pressure gauge.

REMARKS


5.

DESCRIPTION Check that the motor for air compressor designed for operation on 220 V, 3 phase 60 Hz including magnetic contactors, relays and accessories. Check that circuit breaker, isolating switch wires and conduit sizes are suitable for load requirement of the system. Check that all wiring shall be in rigid steel conduit, wire ducts or flexible conduit; wires shall be standard type THW and color coded. Check that all wiring splices shall be made with wire connector or terminal bed connectors of approved type and insulated with two layers of rubber, covered with friction tape to protect the rubber. Check that main control panel is equipped with indication lamps,

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 6. 7.

change over switch, hour meter. Check interlock against overload operation, single phasing of power supply, continuous operation not attended for 1-hour. Check low pressure alarm, high pressure alarm, compressor faulty alarm.


Page 86 of 124


Index Number:



Page 87 of 124

HVAC Systems

(Standard Reference is manufacturer’s recommendations and relevant SEC Transmission Specifications)

3.38.1 Mechanical Checks and Visual Inspection ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

12. 13. 14.

DESCRIPTION Inspect for physical damage or defects. Check labeling and marking is according to the drawings. Check tightness of bolts on direct drive and base-mounted equipment. Check for adequate access to the equipment. Check that ducts exposed to weather are properly insulated and wrapped with weather proofing materials, e.g., wrapped with aluminum sheet. Check that the space clearance around the duct shall be properly sealed to prevent the passage of rain water or any other foreign matter. Check that all panels such as control panel, compressor panel, motor blower panels shall be provided with left and right handles. Check that air conditioning essential components, electrical controls, breaker, etc., is properly labeled or marked. Check that all exposed refrigerant suction lines are properly insulated and wrapped with aluminum sheet and suitably protected from rupture damage. Check that the exposed refrigerant liquid line is painted with liquid refrigerant gas color code paint and fitted with liquid sight glass, solenoid valves expansion valves and strainer if required. If semi-hermetic reciprocating compressor with nominal cap of 20 tons and above is used, check that the size of receiver tank is able to contain all refrigerant charged into the system plus 20% excess volume for gas expansion. Check that receiver is provided with inlet and outlet shut off valves, relief valves, purge cock, liquid level sight glass and oil drain. Check that the refrigerant compressor is a sealed hermetic type or semi-hermetic reciprocating type. Check that the compressor is provided with the following: For sealed type hermetic compressors: a. Suction and discharge service valves with charge plug fitting connection. b. Crank case heater. c. High and low pressure cut-out manual reset. For semi-hermetic reciprocating compressors: a. Suction and discharge service valves with charge plug fitting connection. b. Oil level sight glass. c. Suction, discharge and oil pressure gauges. d. Crank case heater. e. Oil pressure protective switch to stop compressor operation in case of lubrication failure. f. High and low pressure cut-out manual reset. g. Suction line strainer with service valves.

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 15. 16. 17. 18. 19.


Page 88 of 124

Check that thermostat control with temperature indicator is provided and suitable to operate the system automatically. Check that the thermostat is equipped with independent switch to operate the air supply fan continuously if required. Check that the thermostat control is protected by a clear plastic transparent guard cover with standard lock and key. Check that the belt driven blower and fan motors are protected by a belt guard cover. Check that the air filters are easily removable from unit and washable type and check that the frame is 18 gauge galvanized iron with welded or screw type corners. 3.38.2 Electrical Tests

ITEM

DESCRIPTION

1.

Check rating of all motors, magnetic contactors, relays and accessories is 220 V, 3-phase, 60 Hz. Check all wiring is in rigid steel conduit, is standard type THW and color coded. Check that the size of all wires and circuit breakers are suitable for requirement of the system. Check that all wires splices are made with wire connectors of approval type or soldered and insulated with two layers of rubber and friction tape. Check interlock to stop the compressor when: a. Condenser blower motor fails. b. Air handling unit (AHU) blower motor fails. c. Suction and discharge operating pressure exceeds predetermined level. d. Overload operation of compressor. e. Low and high voltage in the power supply. f. Single phase of power supply. g. Compressor lubrication fails. h. When desired room temperature required is attained. Contractor shall perform the following tests prior to start commissioning of the system: a. Preliminary test. b. Pressure test. c. Leak test. d. Control test. e. Operation test. Measure compressor continuous line current and power supply voltage. Note compressor’s discharge and suction pressure (PSIG). Check indoor fan and heater current. Functional check of the system.

2. 3. 4. 5.

6.

7. 8. 9.

REMARKS


Index Number:



Page 89 of 124

Dry Type Transformers



DESCRIPTION Inspect for physical damage/defects (cracks, chips, etc., of the cast resin). Check nameplate for correctness. Check tightness of all bolted connections (torque wrench method. Check that all grounding is securely connected, including star point neutral. Perform all specific checks per manufacturer instructions. Check proper operation of all auxiliary devices (as applicable).

REMARKS

3.39.2 Electrical Tests ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9.

DESCRIPTION Insulation resistance and Polarization Index (PI) test. Turns ratio all (taps) test. Polarity and vector relationship test. Winding resistance measurement (all taps). Excitation current test (at nominal tap). Back energization test (at rated voltage for 15 minutes). Check the off load tap changer is set at the rated voltage tap. Functional test of all auxiliary devices (if applicable). Control and protective circuit functional tests.

REMARKS


Index Number:



Page 90 of 124

Fire Detection and Protection Systems

Internal Security Department/Fire &Loss Prevention division(ISD/F&LPD) is responsible for fire detection and suppression systems, but transmission witnessing personnel shall check the alarms and trip signals (if applicable) which affect the main equipment such as power transformer, GIS, etc.


Index Number:



Page 91 of 124

Civil Work

Witnessing of civil work is the responsibility of the CTA/DTA Support Facility Project Division to witness the work of the civil contractor. Transmission witnessing personnel shall check the accesses and ventilation that affects the main equipment.


Index Number:



Page 92 of 124

Static VAR Compensation System


3.42.1 Pre-Commissioning Tests and Safety Measures ITEM 1. 2. 3. 4. 5. 6. 7.

DESCRIPTION Get the sanction for test document. Check the safety documents for entering the capacitor bank area. Check the safety documents for entering the TCR area. Check the safety document for touching the capacitor banks and TCRs. Check the anti-static instruction prior to handling the electronic devices. Never touch the components of electronic cards without antistatic wrist strap. Check your safety shoes, helmet, goggles and industrial uniform.

REMARKS

3.42.2 SVC Transformer Tests See Oil Filled Power Transformers, Section 3.1. 3.42.3 Harmonic Filters: Capacitors and Associated Inductors (Standard Reference is IEEE 1303-1994, IEEE Guide for Static VAR Compensator Field Tests and relevant SEC Transmission Specifications)

3.42.3.1 ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness. Check leakage. Check deformation. Check tightness of the bolts according to specifications. Check that all grounding cables are securely connected. Check for any damaged paint. Check earthing switch. Capacitor bushing tightness check. Check for bushing cracks. Check for proper termination. Check CT locations physically. 3.42.3.2

ITEM 1. 2. 3. 4. 5. 6.


Electrical Tests

DESCRIPTION Check of test and measuring instruments calibration certificates. Check of condition of battery cells of the T&M instruments. Check individual insulation resistances. Measure each individual capacitance. Capacitance bank insulation test. Capacitance bank measurement test.

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 7. 8. 9. 10. 11. 12.


Page 93 of 124

Capacitance and Dissipation factor measurement test. Insulation power factor (Doble) test –115 kV and above. Perform all specific tests per manufacturer’s instructions. Megger test phase to phase. Capacitance bank neutral unbalance measurement. Test the inductance of the harmonic filter inductors. 3.42.4 Thyristor Controlled Reactor (Standard Reference is IEEE 1303-1994, IEEE Guide for Static VAR Compensator Field Tests and relevant SEC Transmission Specifications)

3.42.4.1 ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness. Check for overall body deformation. Check tightness of the bolts according to specifications. Check that all grounding cables are securely connected. Check for any damaged paint. Check of foreign particles between the layers of the reactor coils. Check of any insulation cracks. Check for proper termination. Check CT locations physically. 3.42.4.2

ITEM 1. 2. 3. 4. 5.


Electrical Tests

DESCRIPTION Check of condition of battery cells of the T&M instruments Check main current path connection contact resistance. Temperature measurement at different joints after energization. Check the insulation resistance. Inductance measurement between different cores.

REMARKS

3.42.5 Cooling System Component Tests (Standard Reference is IEEE 1303-1994, IEEE Guide for Static VAR Compensator Field Tests and relevant SEC Transmission Specifications)

3.42.5.1 ITEM 1. 2. 3. 4. 5. 6. 7.

Mechanical Checks and Visual Inspection

DESCRIPTION Inspect for physical damage or defects for entire system. Check nameplate information for correctness and installation of the cooling network according to the drawings. Check for the redundancy of the fluid circulating pumps in the cooling system. Check pressure holding test on the expansion vessel/reservoir. Check the pressure release valve and its operation on the expansion vessel/reservoir. Check the availability of nitrogen regulating system on the expansion tank and ensure no leakage. Check the Motor and pump for leveling and alignment.

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

Page Number:

Page 94 of 124

Check tightness of all joints and couplings of the coolant circuit (torque wrench method). Check all pipe network and cooling system to stand test pressure and operating pressure. Check the unobstructed coolant circuits in all parallel paths. Check the provision of control valve for inlet and outlet for all parallel paths. Check the provision of control valve for all equipment in the cooling system for replacing or repairing without any interruption to the cooling system. Check the availability of pressure regulating valves at the outlet of the pumps. Check the availability of shut off valve at the inlet and outlet of the pumps. Check provision of replacing the pump while system is on line. Check the provision of air bleeding valve at the top of all parallel paths and at the ion exchanger/ deionizer. Check the provision of leak-water collection (drainage) on the floors. Check the provision to replace the resin while system is on line. Check the provision to replace filters/strainer while system is on line. Check the availability of the filters at the inlet and out let of the deionizer. Check the availability of the strainers at the outlet of the deionizer and at the inlet of the valves with bypass circuit. Check the availability of the control valves at the inlet and outlet of each heat exchanger. Ensure the outdoor piping network is stainless steel. Ensure unobstructed ventilation for all heat exchangers. Ensure the availability of vibration shocks for the all heat exchangers. Check, calibrate and functional test of the all temperature gauges. Check and calibrate all pressure gauges, flow switches, differential pressure gauges and liquid level switches. All the cooling system should be flushed over several hours, including all branches, heat exchangers, deionizers, etc. Verify no leakage in the cooling system. Test the coolant for purity, proper percentage of anti freezing and anti algae before filling the cooling system. Check the rotation of pumps and cooling fans. Run the pumps on and off repeatedly, until no more particles accumulate in the filters. Vibration check of cooling network. Sound level check. Check the auto operation of ion exchanger/bypass valves with the conductivity meter (if applicable). 3.42.5.2

ITEM 1.

T-PreCom-1000-R0

Electrical Tests

DESCRIPTION Check of condition of battery of the T&M instruments.

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

Visual check of electrical panel. Insulation resistance test of motors. Winding resistance measurement of motors. Check the proper rating of the motor protection breakers and perform the functional trip test by current injection, under voltage, and phase reversal. Verification of current, overload, thermal, under voltage, and phase reversal settings of motor protection. Check the operation of the pumps from local pump station PLC, and SCADA. Ensure the alarm signal when pump is on local mode. Record the power supply input voltage and phase rotation. Record starting and running motor current. Check the redundancy of auxiliary power supply and operate the pumps one by one by both power sources. Check the alarm and status by simulating the breaker open/ loss of auxiliary power sources. Verify overload trip time of all motors by artificial single phasing of all three-phase motors. Simulate the operation of pumps by loss of power, pump failure, differential pressure and running hours completion cycle and ensure automatic changeover. Ensure automatic changeover time is coordinated with loss of cooling alarm time. Verify start-up of standby pump on loss of supply to running pump and record the time. Check PLC of cooling system for measurement of pressure, temperatures, Levels, resistively and status of pumps, heat exchanger fans and valves. Check to see that monitoring signals show correct values or correctly indicate alarms. Check the alarm/trip signal on loss of input voltage, pump failure, low coolant level, high and low resistivity, pressure, fellow, and temperature from all gauges, sensors and meters. Check the cooling fans auto-changeover and auto operation by temperature. Check the cooling fans operation from Manual and Auto from PLC control panel. Check the cooling fan’s minimum run time, and on-off hysteresis. Check the simulated operation of all electrical operated valves. Ensure the full cooling capacity is available with one cooler failed or out of service. Display messages check for alarms and trips. PLC internal battery check if present and note the date of replacement. Check Automatic operation of de-ionizer by resistivity. Check the conductivity measurement of the coolant to see that it drops below alarm level when new water is circulated, if applicable. Check the deionizer time for recovering the resistivity, if applicable. Check the minimum activation time of deionizer, if applicable. Ensure that liquid coolant is electrically grounded.


Page 95 of 124


Index Number:



Page 96 of 124

3.42.6 SVC System Controller Computer (Standard Reference is IEEE 1303-1994, IEEE Guide for Static VAR Compensator Field Tests and relevant SEC Transmission Specifications)

3.42.6.1 ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness. Check tightness of all bolted connections. Check that the connection does not transfer stress to the connection terminal. Check operation of the cooling fan. Check that the filters for the cooling fan are not dirty.. All input and output cables are secure. Fiber optics cables are secure without squeezing and without severe bends. All modules are properly labeled. Check the panels are well ventilated with dust filter. Check that the connection ports which are under use have dust covers and all other unused ports should be sealed off. Check that the connections ports are clearly and correctly identified. Check that the ferrules are properly marked. Card locations are clearly numbered. Sequence event recorder panel check. Annunciator panel check. Check the labeling on thyristor towers. Check of proper extractor tool. Panel lighting is operating properly. Check that the panel heaters are not installed. Check that the terminals are furnished with isolator links. Check that the wire terminals have banana sockets for the testing purposes. Check that all grounding cables are securely connected. Verification against drawings and contract specification. 3.42.6.2

ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.


Electrical Tests

DESCRIPTION Check of Test and Measuring instruments calibration certificates. Check of condition of battery cells of the T&M instruments. Check of hardware. Check of software. Hardware jumpers check. Micro console and PC with software check. Check of user program loading. Input and output operation check. Test of light guides passing from controller to TCR towers. Firing pulses tests to thyristors simulation. Snubber circuit testing. DC functional tests.

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44.


Page 97 of 124

Complete wiring checking. Cooling system alarm checks from controller. All alarms and trips initiation checks. Trouble shooting guide verification with initiation of alarms. Check of disconnects and low voltage switchgear by control panel operation. Check of print-out on the printer and alarm on the annunciator. Check of alarms and trips to controller, annunciator and to even recorder. Check of cooling system ready. Check of temperature normal. Check of SVC ready. Check of alarms at controller due to alarms of the transformer. Check of all controller cards. Low voltage tests for SVC with different firing angles, i.e., B=0 to B=90 (LIMAX=0 TO –1.0. Stability test of differential protection thyristor bypass switch closed. Emergency trip operation check. SCADA point list testing. Check of thyristor monitoring software operation. Check of CB fail to close and fail to open alarm. Controller over current protection level-1 tests, if applicable. Controller over current protection level-2 tests, if applicable. Secondary under voltage level –70% protection for immediate trip, if applicable. Primary under voltage –30% protection for 100 msec and no trip, if more the system to trip, if applicable. Primary under voltage 0.6 p.u. for more than 1 sec. CB trips. Secondary under voltage 0.6 p.u., TCR blocks if more than 1 sec. then CB trips. UPS operation time to be checked if ac is off to the UPS. UPS alarm and trip level tests. Controller cards battery replacement date check. Check of Remote communication with modem to SER. Final trip tests. Annunciator AC and DC supply MCB operation check. Watch dog of SER check. Operational check of thyristor bypass switch. 3.42.7 Protective Relay Tests and Check of Protection Schemes (Standard Reference is manufacturer’s relay documents)

3.42.7.1 ITEM 1. 2. 3. 4.

Mechanical Checks and Visual Inspection

DESCRIPTION Inspect for physical damage or defects. Check nameplate information for correctness. Check tightness of all bolted connections. Check that the connection does not transfer stress to the connection terminal

REMARKS


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 3.42.7.2 ITEM 1. 2. 3. 4. 5. 6. 7.


Page 98 of 124

Electrical Tests

DESCRIPTION Check of Test and Measuring instruments calibration certificates. Check of condition of battery cells of the T&M instruments. Test the protection relays related to transformer. Test the protection relays related to HV CB. Test the protections related to TCR and Harmonic Filters. Check and test the modified schemes. Check of alarms from the SVC local panel, and remote alarm in the control panel and corresponding alarm to the Control Center.

REMARKS

3.42.8 SVC Energization: Sequence of Events and On-Load Tests 3.42.8.1

Electrical Tests

(Standard References are manufacturer’s instruction manual and SEC relevant Transmission Standard))

ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14. 15. 16. 17. 18. 19. 20. 21.

DESCRIPTION SVC pre-energization check list. Check the SVC energization list. Confirm the final settings. Operation division shall issue caution for energization process. Check and follow the switching program. Check that the operating division has issued a warning to the contractor for the Energization, copy to the Control Center. Final NPS settings shall be issued to the Control Center, Protection and Test and to 132/380 kV Projects Division. Re-check and confirm final settings, except the settings of TCR temperature, pressure, flow and VarMach. Check, clean and lock transformer area. Check, clean and lock disconnect room. Check, clean and lock filter area. Check, clean and lock TCR area. Remove the firing optical fibers connected to the thyristor valves, so that the thyristor valves are tested without conduction. Red fibers only (16x3=48). Check HV CB grounding switch opened from GIS. Check bus isolator closed from control room. Send close command to HV CB. Check the indication on SER for CB closed. Verify the synchronism by indication pulses generated from the TCU (thyristor control unit). Open the CB and close with H5h harmonic filter. Check the bus voltage before and after the CB close and calculate short circuit power of the network. Record measurements on the mimic panel, and MVAR meter should read –20 MVAR to confirm that the filter H5 is rated for -

REMARKS

This is to avoid damage to the thyristors in case of mis synchronism between the firing pulses and voltage across the thyristor


Index Number:

MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51.

20 MVAR (-ve for capacitance). Close the CB with filter H7 and take the similar measured above, but this time the load is –10 MVAR. Open the CB. Return the firing optical connections back to thyristors. Open CB and close with TCR and Vref to =401 KV so that no current flows in TCR. Check the cooling starting on close command of CB from SVC room or control room or from the Control Center. Check the alarm with thyristor address on removing of indication pulses fibers in PC and alarm on annunciator. Check that on removing more than two fibers the SVC trips. After CB open and all disconnect switches are closed. Give close command to CB for TCR, H5, and H7 in service with manual mode. Make all the measurements with different loads, such as HV, MVAR, LV, SVC I, synch pulses graphs. On cooling system PLC panel check all the pressures and temperatures, running of pumps and running of cooling fans, etc. Keep running for one day in auto mode. Vary the voltage reference from mimic panel and check the MVAR and alarm svc reached max capacity. Check and record all the currents in protection relay panels. Check current limitation/protection in SVC controller. Check of regulation with full load to no load and with different slopes. Check of step response with Vref settings for 1% voltage difference and gain of 0.2,1,1.5, 3, etc. Check auto recloser operation. Check joint SVC operation with different bus bar configuration. Check thyristor by-pass configuration mode. Check of strip-chart recorder operation. Check Event recorder alarms having responsibilities added. Check the start inter-lock sequence. Check stop sequence. Record temperature measurements of TCRs at different joints with temperature sensor stickers. Auto/manual change over test. Harmonic content tests. Pump change over test by simulating fault in one pump. Check cooling fans change over. Check LV incomers change over


Page 99 of 124


Index Number:



Page 100 of 124

3.42.9 Air-Conditioning Systems The reliability of air-conditioning is very important for the SVC controller, so this part of the equipment should be tested thoroughly. For details of its pre-commissioning please refer to Section 3.38, HVAC Systems. 3.42.10 Fire Detection and Suppression Systems The reliability of fire detection and suppression systems is very important for the SVC System, like any other substation component. This equipment should be thoroughly tested. For details of its precommissioning please refer to Section 3.40, Fire Detection and Suppression Systems

TRANSMISSION Pre-commissioning test procedure PART II Title:

Index Number:

T-PreCom-1000-R0

Mechanical Check & Visual Inspection and Electrical Test

Page Number:

Page 101 of 124 The following is an example of a Test Record Form submitted by the contractor for the Substation 9009 SVC pre-energization checks: 1.

General

The following units are covered by this energization tests. TCR No. ____________________________________________ Filter No. _____________________________________________ 2.

Pre-Energization Checklist

Checks and Final Trip Test performed according to RQTR-710-D ------------------- □ 3.

Energization of Substation Bus Bar

With bus bar energized voltage response to VAR Control was checked. Primary voltage according to existing metering: ________ kV Input to Data Acquisition Computer measured: Phase: R-Y: ________V

Y-B: ________V

B-R: ________V

Value on software variable

VRESP: _______________

Final parameter setting: (Voltage Response)

VRESPNOM: _______________

Voltage selection checked: ---------------------------------------------------------------- □ All energized VT circuits measured: ------------------------------------------------------ □ 4.

Energization of Main Transformer

Recording of inrush current to transformer, see appendix: __________ Voltage input to Synchronizing Board YPQ 107 measured: Phase on ∆ - side:

R-Y: ________V

Phase on Y – side: R-Y: ________V

Y-B: ________V Y-B: ________V

B-R: ________V B-R: ________V

Phase relation & sequence checked: ------------------------------------------------------- □ Synchronizing signals out from the synchronizing board checked: For each phase it was checked that the signals were as below: ----------------------- □ Visual check of transformer and bus bars done: ------------------------------------------- □ All VT circuits of protection and metering checked: -------------------------------------- □


Index Number:

T-PreCom-1000-R0


Page 102 of 124

Energization of Filters

Test result in 2000 852-192-D: No. of Units: _________ 6.

Page Number:

Performed: ----------- □

Energization of TCR

Test Results in RQTR 703-D: No. of Units: _________ Performed: ------------ □ 7.

Total Rating Test

Measurements of current and voltages taken from: __________________________________ ------------------------------------------------------------------------------------------------------------VT ratio: _____________________

CT ration: _____________________

Measurements at SVC maximum inductive: Voltage Phase

R-Y

Current Y-B

B-R

R

Y

B

Y

B

Sec Prim

Average measured values: Um = ___________ kV

Im = ___________ A

Measurement at SVC maximum capacitive: Voltage Phase

R-Y

Current Y-B

B-R

R

Sec Prim Average measured values: Um = ___________ kV

Im = ___________ A

Unit Reactive Power capacity is calculated according to the formula. Q = √3 * Um * Im * (Un / Um)2 this gives ____________ Max inductive is: ___________ MVAR 8.

Max capacitive is: ______________ MVAR

Heat Run Test

Test with Max load on transformer, SVC operated at __________ MVAR. Ambient temp: __________


Index Number:

T-PreCom-1000-R0


Page Number:

Page 103 of 124

Time

Time

Test with Max load on cooling system, SVC operated at __________ MVAR. Ambient temp: __________

Valve temp: ____________

Time

9.

Check of TCR Controls

Increase and decrease ramp of control signals for all phases checked: ------------------- □ TCR No.: _____________ _____________

See appendix: _____________ ______________


Index Number:

T-PreCom-1000-R0


Page Number:

Page 104 of 124

Measurement of load-sharing: TCR ________________ Load

10.

Ph. R

Ph. Y

TCR ________________ Ph. B

Ph. R

Ph. Y

Ph. B

Check and Setting of Current Limit

Current limit for each TCR checked ------------------------------------------------------------- □ TCR No.: _____________

See appendix: ________________

_____________ Final parameter setting:

________________

ILIMLEV: ____________

Current limit ILIMGAIN: ____________ Parameters corresponds to _______ A primary TCR current and __________ sec time constant for the current limit operation.


Index Number:

T-PreCom-1000-R0


Page Number:

Page 105 of 124

Reactive Symmetry

Prim. Values Q-tot Ph.

Prim. Values Q-tot Ph.

Bus Voltage (kV) a-b

b-c

c-a

Bus Voltage (kV) a-b

b-c

c-a

Delta Current (A) a-b

b-c

c-a

Impedance (Ω) a-b

Delta Current (A) a-b

b-c

c-a

b-c

c-a

Impedance (Ω) a-b

b-c

c-a


Index Number:



Page 106 of 124

Static Characteristic

Rated values on SVC used for calculation, are: Un: ________kV

In: ________A

Bn: ________mS

Measurement of susceptance and setting calculation in switching points: Parameter

SwitchPoint

U (kV)

SwitchPoint

U (kV)

I (A)

B (mS)

B (p. u.) Name

Value

Parameter I (A)

B (ms)

B (p. u.) Name

Name


Index Number:



Page 107 of 124

Measurement of B-prim versus BREF, after parameter setting: BREF

U (kV)

I (A)

B (ms)

B (p.u.)

Graph of B-prim (p.u.) versus BREF, see appendix: _____________ Adjusted parameters to improve linearity:

Name

Value

____________ _____________ ____________ _____________ ____________ _____________


Index Number:

T-PreCom-1000-R0


Page Number:

Page 108 of 124

Final measurement of B-prim versus BREF:

BREF

U (kV)

I (A)

B (ms)

B (p.u.)

Graph of B-prim (p.u.) versus BREF After final adjustment: Final parameter setting:

see appendix: __________ Name

Value

Name

Value

_______

_______

________

________

_______

_______

________

________

_______

_______

________

________

_______

_______

________

________


Index Number:

T-PreCom-1000-R0


Page Number:

Page 109 of 124

Switching Control MAN-AUTO-MAN Switching from MAN to AUTO and from AUTO to MAN works correctly See appendix: ______________ Final parameter setting: (Follow function) 13.

TFOL: ______________

Operating Characteristic and Slope Setting

Final parameter setting: (op. Char. and slope)

BREFNOM: ____________ SLOPE: ____________

Measurement of slope:

Slope (%)

Uprim (kV)

Iprim (A)

Slope (%)

Uprim (kV)

Iprim (A)

Uprim - Uref

Uref (value)

(kV)

Uref (value)

(kV)

Uprim - Uref (kV)

(value)


Index Number:


Graph of slope at ___________%,

see appendix: ________

Graph of slope at ___________%,

see appendix: ________

Calculation of actual slope gives…

set __________%


Page 110 of 124

Measured ____________%

set __________%

Measured ____________%


Index Number:

T-PreCom-1000-R0


Page Number:

Page 111 of 124

Step Response Test for Gain Optimization Network short circuit power Sk at point of common coupling as follows: During test: _______ MVA

System minimum: ________ MVA

Steps in VREF was done to give responses of approx. __________ MVAR Readings, see appendix: ________ Final parameter setting: (SVC gain)

VREGKI: _________ VREGNI: _________

1.

Control Logics etc.

Start: Complete sequences checked:

□ see appendix: _________

Stop: Complete sequences checked:


Trip: Complete sequences checked:


Rampspeed: Check and final settings

□

Final parameter setting: (rampspeeds)

Minloss function:

Name

Value

Corresponds to

_________

__________

______________

_________

__________

______________

_________

__________

______________

_________

__________

______________

_________

__________

______________

Operation checked in all hysteresis area:

Final parameter setting: (minloss function)

□

MLOSSLEV: ___________ MLOSST: ____________

Final parameter setting:

Name

Corresponds to ___________ seconds delay Value Corresponds to

__________

__________

______________

__________

__________

______________

__________

__________

______________

__________

__________

______________

__________

__________

______________


Index Number:

T-PreCom-1000-R0


Page Number:

Page 112 of 124

Remote Control Functions: All applicable functions checked:

□

Final parameter setting: (remote control)

14.

Name

Value

Corresponds to

__________

__________

_______________

__________

__________

_______________

__________

__________

_______________

__________

__________

_______________

__________

__________

_______________

__________

__________

_______________

Redundancy Systems

It was checked that the SVC operates correct during the following change-overs to redundant functions. Checked To standby pump in cooling system: -----------------

□

To standby incoming AC supply:

□

___________________________:

-------------------------------------

________________________: --------------------- □ ___________________________: ------------------

□


Index Number:

REGISTER BOOK/FILE DEFICIENCY FILE ATTACHMENT No. 1


Page 113 of 124

Project Title: Sr.#

Substation Name/Number: Deficiency

*Required to be filled if the deficiency is not cleared in week time. To be filled by Commissioning engineer/technician.

Issued by

Issued Date

Status

* Assigned Punch list/ Snag No.

* Date of assigning Punch list/ Snag

* S.I #


Index Number:

REGISTER BOOK ACTIVITY RECORD ATTACHMENT NO. 2

Project Title: Sr.#

Date

Brief of the Activities

To be filled by Commissioning engineer/technician.


Page 114 of 124

Substation Name/Number : Contractor Witnessed Engineer by Name

Remarks


Index Number:

T-PreCom-1000-R0

SITE INSTRUCTION ATTACHMENT No. 3

Page Number:

Page 115 of 124

Site Instructions / Records No. ______ Substation

Circuit

Contract No Project Title Contractor Name Attention Mr..

‫اﻟﻤﻘﺎول‬ contractor

‫رﻗﻢ اﻟﻤﺸﺮوع‬ ‫اﺳﻢ اﻟﻤﺸﺮوع‬ ‫اﺳﻢ اﻟﻤﻘﺎول‬ ‫ﻟﻌﻨﻠﻴﺔ اﻟﺴﻴﺪ‬

‫اﻟﺸﺮآﺔ اﻟﺴﻌﻮدیﺔ ﻟﻠﻜﻬﺮﺑﺎء‬ ‫إﺻﺪار‬

Issued by

SEC ‫إﻋﺪاد‬

Prepared by Name Sign Job Title


Index Number:

T-PreCom-1000-R0

STATUS OF PUNCH LIST ATTACHMENT No. 4

Page Number:

Page 116 of 124

CONTRACT #: S/S NAME/NUMBER : S.I. #

Snag/ Punch list No.

PROJECT TITLE: DATE:

Description of the Deficiency

Issued Date

Issued By

Expected Time of Completion by

Confirmed By Commissioning Personnel

Commissioning Eng.

Project Management Eng.

Contractor

Name:

Name:

Name:

Signature:

Signature:

Signature:

Date:

Date:

Date: To be filled by the Contractor

Remark

TRANSMISSION Pre-commissioning test procedure PART I Title:

Index Number:

T-PreCom-1000-R0

Categorization of Punch List Attachment# 5

Page Number:

Page 117 of 124 CONTRACT #:

PROJECT TITLE: DATE: S/S NAME/NUMBER :

S.I. #

Snag/ Punch list No.

Type of Deficiency

Description of the Deficiency

“A” or ”B”

Issued Date

Issued By

Date to be Completed by the Contractor

Remarks

“A” means item to be cleared by contractor prior to Project Energization. “B” means Expected Time of Completion (ETC) to be provided by Contractor/ Project Management Department (PMD); It does not affect Energization. Commissioning Eng.

Project Management Eng.

Contractor

Name:

Name:

Name:

Signature:

Signature:

Signature:

Date: Date: To be filled by Commissioning engineer/technician prior one month from the Energization.

Date:


Index Number:

T-PreCom-1000-R0

PRE-COMMISSIINING TIME UTILIZATION STATISTICS SHEET ATTACHMENT No. 6 Contract No.: Substation Name/Number:

Sr#

Initial By

Date

Time Spent by Comm. Personnel Hrs From To .

Page Number:

Page 118 of 124 Project Title: Date:

Description of the Job

Time Lost Hrs.

Time Lost SEC □ CSD

PMD

SOD

Others

* To be filled by SEC Commissioning engineer/technician. Legend: CSD: Comm. Services Department

Test Equip

Contractors □ Staff Staff Others Exper. NA

PMD: Project Management

Remarks

SOD: System Operation


Index Number:

T-PreCom-1000-R0

FINAL PRE COMMISSINING REPORT ATTACHMENT No. 7

Page Number:

Page 119 of 124

The following items have to be confirmed at the end of the pre commissioning tests: ITEMS

YES

NO

N/A

Categorization of the punch list (A, B) Site Tests Completion. Complete Site Test of HVAC and Energized. Complete Site test of Station Service Transformer and Energized. Marked up drawings are available at site in good condition Operational Spare Parts are provided Tests Results are available Emergency contact list is provided

Further Remarks:

Issued by Commissioning engineer/technician Signature: Name:

Contract No. Contractor Name. Project Title. Substation Name/Number:

‫رﻗﻢ‬ ‫اﻟﻌﻘﺪ‬ ‫اﺳﻢ‬ ‫اﻟﻤﻘﺎول‬ ‫اﺳﻢ‬ ‫اﻟﻤﺸﺮو‬ ‫ع‬ ‫أﺳﻢ‬ ‫اﻟﻤﺤﻄ‬ ‫ة‬


Index Number:

COMMISSIONING TIME REDUCTION AGREEMENT ATTACHMENT NO. 8


Page 120 of 124

AGREEMENT TO REDUCE TIME OF PRE-COMMISSIONING (OPTIONAL) AGREEMENT BETWEEN SEC AND CONTRACTOR TO REDUCE PRECOMMISSIONING TIME FOR _____________PROJECT UNDER CONTRACT NO. ________________

Date & Place: _________________ In order to reduce pre-commissioning time for __________Project, the following agreement is being made between SEC and the contractor. 1.

Site Conditions

The following shall be ensured at site before start of SEC witnessing: a. b. c. d. e. 2.

Testing area is free from all construction activities. There is no safety hazard in the testing area and its vicinity. Stable auxiliary supply is available for testing purposes. Adequate cooling/heating arrangement as the case may be, is available in the control room. Adequate lighting is provided to safely carry out the testing activities.

Tools and Equipment

All the tools and equipment with valid calibration certificate shall be available at site. 3.

Documents

The following documents shall be available at site before start of SEC witnessing: a. b. c. d. e. 4.

Approved drawings bearing very clear name and signature of the approving authority with approval stamp on each sheet along with complete approval correspondence. The manuals giving detailed test procedure of each equipment, technical data of all electrical equipment, factory test records of all equipment, cable schedules, equipment interconnection wiring schedule and wiring tables/diagrams. SEC approved test procedure and test formats carrying approval stamp with name and signature of the approving authority. The project specifications and protection requirements. List of deviations from SEC specs and SEC approval letters for the same.

Relay Settings a. b. c. d.

The contractor shall submit his proposed relay settings for all settable relays one month before starting of pre-commissioning witnessing. SEC-Engineering Protection Division shall provide final approved settings before precommissioning witnessing is started. Pre-commissioning witnessing will not be started in the absence of approved relay settings, in order to avoid re-setting. Commissioning Program.


Index Number:

COMMISSIONING TIME REDUCTION AGREEMENT ATTACHMENT NO. 8

5.


Page 121 of 124

e.

Overall testing commissioning program indicating requirements of Protection, Testing, Operation, Maintenance and SCADA witness engineers with duration shall be furnished to SEC for approval.

f.

A three-week testing program based on the approved overall program shall be submitted every Tuesday indicating the proposed activities for the following two weeks and this program will indicate activities completed in the current week and the reasons for not completing any planned activity and its impact on the overall program with proposed remedial measures.

Pre-commissioning Procedures

Pre-commissioning of all equipment shall be carried out in line with SEC Pre-commissioning Procedure and in line with this agreement. 6.

Testing and Commissioning Engineers a. b.

7.

Availability of qualified commissioning personnel to perform pre-commissioning tests. One Commissioning Engineer from the contractor shall control the site activities and doing all required coordination.

Tests to be Done by the Contractor

The contractor shall demonstrate a sample test for each equipment mentioned under (I-V) according to the approved test procedure in presence of SEC-Commissioning Personnel and record the results on the approved test format. If the SEC Commissioning personnel are satisfied with test procedures and results, the contractor can complete the tests of the remaining equipment under (I-V) accordingly without SEC present. I. II. III. IV. V.

Secondary injection of all the aux. Relays, MCBs, Timers and O/C or E/F relay. CT’s magnetic curves. AC/DC Distribution boards. All VTs. The contractor shall prepare the detailed test procedure and format to perform the functional tests.

The contractor shall carry out on his own 100% functional tests for all relay panels, control panels, LCCs, AVC panels and transformer-marshalling kiosk etc. The tests shall ensure the following: a. b. c. d. e. f. g. h. i. j.

Healthiness of all wiring. Each wire has correct ferrules as per SEC Standard. All wires are correctly terminated. The required number of spare terminals has been provided for each terminal block. Required number of spare annunciator windows is available on the control and LCC panels. The accessibility to every equipment terminal is maintained. Complete DC isolation for both protection schemes. Every abnormality in the substation is indicated in the form of annunciator, relay flag, LED or lamp, etc. Voltage rating of all indicating lamps is 25% higher than substation DC supply. All wires are properly identified.


Index Number:

COMMISSIONING TIME REDUCTION AGREEMENT ATTACHMENT NO. 8 k.


Page 122 of 124

All DC functional checks and the test results for the same shall be tabulated in special formats and this format shall include the following items: i. ii. iii. iv. v. vi. vii.

The name of relay/equipment under operation. The flag or LED appeared on any main or auxiliary relay. Circuit breakers tripped. Auto-re-closing and auto-reclose blocking functions, etc. The annunciator on the control panel. Alarm in interface marshaling kiosk. Inter trip send to the remote end.

viii. ix. VI. VII. VIII. IX. X. XI. XII.

Inter trip received at the remote end. All the above-mentioned functions shall be added as per scheme expectation and the checking shall be indicated by a tick (3) mark. The contractor will use yellow color to indicate the schemes, which have been checked, red color for addition and green color for deletion. The contractor shall prepare detailed test record for all the equipment mentioned under (I –IV) and submit to SEC. The contractor shall prepare detailed test record for all the functional tests mentioned under V. and submit to SEC. The contractor will be fully responsible for all the above-mentioned tests under (I-V) in all respects. If the contractor fails to carry out these tests properly, he will re-test all these under 100% SEC witnessing. The defective equipment if any will be promptly replaced. The protection scheme and control problems shall be cleared from problems to present them for witness Three sets of marked up drawings with all the modifications incorporated in red color for addition, green color for deletion and yellow color to indicate the checked scheme will be made available before starting witnessing.

Sample Witnessing by SEC a. b.

8.

The SEC witnessing personnel will select 20% of the equipment covered under I-IV and the contractor will test all this equipment under SEC witnessing. SEC commissioning personnel will sign only those test results which will be done under his presence. SEC witnessing engineer/technician will do sample test by 20% of each type of panels with minimum of 1 of each type. The contractor will carry out all the functional tests as mentioned under V for these sample-selected panels under witnessing of SEC commissioning personnel. SEC engineer will sign only those test results, which will be done under his presence. SEC engineer has the right to witness complete bay in respect of all panels, i.e., LCC, relay and control panels, etc.

100% Witnessing by SEC

The following tests shall be 100% witnessed by SEC: a. b. c. d. e. f.

Secondary injection of all main protection relays except O/C and E/F relays. All indicating and recording meters. All transducers. Primary injection and stability and sensitivity test of all unit protections, i.e., BBP, transformer differential and REF protection and underground cable protection, etc. Final trip tests, closing tests, SCADA alarm tests. End to end tests, operation and interlock checks and on-load tests, etc. All tests relating to the fault recorder.


Index Number:

COMMISSIONING TIME REDUCTION AGREEMENT ATTACHMENT NO. 8 g. h. i. j. k. l. 9.

Page Number:

Page 123 of 124

RCT, CT insulation, Lead resistance, CT polarity and Single Point Grounding. VT polarity, VT ratio and VT circuit. All tests relating to GIS, switchgear, auxiliary transformers, power transformers, underground cables and battery and battery chargers. AC/DC changeover and supervision scheme tests. All tests relating to signaling equipment. High voltage tests relating to GIS, transformer and underground cable, etc. as applicable.

Snag Rectification, Drawing Updating and Test Record: a. b. c. d.

10.

T-PreCom-1000-R0

The contractor will promptly attend to all of the snags. Every effort will be done to achieve the goal of “Snag Free Energization”. Three sets of the drawings shall be regularly updated with all the modifications effected from time to time during pre-commissioning. These modifications will be done in red color for addition and green color for deletion. Three sets of marked up drawings; O & M manuals and test records shall be available just before energization of the substation. One set will be kept in a pad-lockable cupboard at the substation, the 2nd one will be handed over to Transmission Department for the office and the 3rd one will be taken by the contractor to prepare the final as built drawing.

Signing of Testing Record/Snag Clearance a. b.

The test record formats will be duly signed by the contractor’s testing engineer and SEC Commissioning personnel simultaneously at the completion of formats for any test. No formats shall be left unsigned for signing next day for quite obvious reasons. SEC Commissioning personnel shall clear the snags after confirming satisfactory completion and such clearance shall not be deferred to a later date in any case.

11.

The contractor will submit complete test record to SEC. This test record will include all the tests conducted by the contractor on his own and all those tests conducted by him under SEC witnessing.

12.

This agreement can also be applied by the contractor to other substations under the same contract.

13.

This agreement will be considered null and void at the end of Contract No. _________ and the contractor will have to make a fresh agreement for any other contract/substation in the future.

For SEC Names PMD CSD

Contract No. Project Title. Date: S/S NAME/NUMBER

For Contractor Signature

Names

Signature


Index Number:

CONTRACTOR’S PERFORMANCE REPORT ‫اداء اﻟﻤﻘﺎول ﺗﻘﺮﻳﺮ‬ ATTACHMENT No. 10


Page 124 of 124

‫ﺗﻘﻴﻴﻢ أداء اﻟﻤﻘﺎول ﺑﻮﺿﻊ داﺋﺮة ﺡﻮل اﻟﺮﻗﻢ اﻟﻤﻨﺎﺳﺐ‬ EVALUTE THE CONTRACTOR’S PERFORMANCE NY CIRCLING APPROPRIATE NUMBER ‫یﺤﺘﺎج‬ ‫ﻏﻴﺮ ﻡﺮﺿﻲ‬ ‫ﺟﻴﺪ ﺟﺪا‬ ‫ﻟﺘﺤﺴﻴﻦ‬ ‫ﺟﻴﺪ‬ ‫ﻡﻘﺒﻮل‬ UNSATISFAC ‫اﻟﻔﺌﺔ‬ CATEGORY VERY GOOD SATISFACTORY NEEDS TORY GOOD IMPROV. QUALITY OF THE ‫ﺟﻮدة اﻟﻌﻤﻞ‬ 25 21 19 15 11 WORK AVAILBILTY Of ‫ﺗﻮاﺟﺪ آﻔﺎءة‬ QUALIFIED 22 19 16 13 10 ‫اﻟﻤﻬﻨﺪﺳﻴﻦ‬ TESTING ENG. ‫اﻟﺘﺰام‬ PUNCTUALITY 20 17 15 12 9 ‫ﺑﺎﻟﺤﻀﻮر‬ SAFTEY ‫اﻟﺴﻼﻡﺔ‬ 15 13 11 9 7 COOPERATION ‫اﻟﺘﻌﺎون‬ 10 9 7 6 5 AVAILABILITY OF ‫ﺗﻮﻓﺮ اﻷدوات‬ PROPER TOOLS 8 7 6 5 4 ‫واﺟﻬﺰة‬ AND TEST ‫اﻻﺧﺘﺒﺎرات‬ EQUIPMENT 1009279-68 6753-46 TOTAL POINTS ‫ﻡﺠﻤﻮع اﻟﻨﻘﺎط‬ 93 80 54 OVER ALL RATING

‫اﻟﺘﻘﺪیﺮ اﻟﻌﺎم‬

FURTHER REMARKS

‫ﻡﻼﺡﻈﺎت‬

(‫ﻗﺎم ﺑﺎﻟﺘﻘﻴﻴﻢ )ﻡﻬﻨﺪس اﺧﺘﺒﺎرات ﻡﺎ ﻗﺒﻞ اﻟﺘﺸﻐﻴﻞ‬ Evaluated By (Comm. Eng) :‫اﻟﺘﻮﻗﻴﻊ‬ SIGNATURE: NAME

:

:‫اﻻﺳﻢ‬

DATE

:

:‫اﻟﺘﺎریﺦ‬

Testing & Commissioning Manual SEC

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