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INSTALLATION TEST PLAN HV & LV SWITCHGEAR

Prepared by: SMS/ R Dhawad

Group Manufacturing Services

Electrical

Page 1 of 12
Date: 14.07.2007

Approved by: GS Vishnumurthy

Doc. No: GMS/ELE/ITP/001

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Inspection and Test Plan for HV & LV Switchgear

1. Objective
a. Proper installation, testing and commissioning of switchgear will ensure plant
reliability and integrity.
b. The objective of the document is to establish the standard practice for Inspection
and Testing of LV & HV switchgear.
2. Scope
a. Scope of this document is to prepare systematic check sheet for installation,
testing and commissioning audit of HV & LV switchgear
3. Mandatory Safety considerations
a. All local statutory requirements
b. Existing permit system
c. Risk assessment for the job
4. Inspection, testing & commissioning plan for HV & LV Switchgear Breaker
The detailed inspection, testing & commissioning plan for HV & LV Switchgear is given in
Annexure - A, referring to manufacturers recommendation, national and international
codes/standards and RIL practices.
5. Resources for HV & LV Switchgear Installation, testing & commissioning
For safe & reliable installation & commissioning of HV & LV Switchgear following preparatory
activities, documentation, material, testing & measuring instruments, tools & tackles are required.

The list given below is for guidance purpose. However based on the actual site requirements, the
resources may vary. Hence site survey is necessary to assess the exact requirement of
resources for installation, testing & commissioning.

Prepared by: SMS/R Dhawad

Group Manufacturing Services

Electrical

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5.1

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Documentation prior to starting the job

a. OEM installation & commissioning manual.
b. Switchboard SLD and BOM.
c.

Substation equipment layout

d. Certification of completion of civil foundation.

e. Earthing layout.
f.

Cable schedule for Inter panel, Breaker control and power cables.

g. Power and control wiring drawings of the panel.

h. AC/DC control supply system commissioning report
5.2

Material prior to starting the job

a. HV/LV Switchgear with all accessories.

5.3

Test / Inspection certificates

a. Switchboard test report / Acceptance report.
b. Cable laying and termination installation completion report.
c. Test certificate of all bought out items
d. HV CT & PT test reports
e. Breaker test report

5.4

Special Tools & Tackles

a. Crane / jacks of adequate capacity.
b. Breaker handles and panel keys
c.

Rigging tools & tackles as required.

d. Torque wrech
5.5

Testing and measuring instrument

a. Megger of appropriate voltage rating.
b. Multi meter.
c.

Contact resistance measurement kit.

d. Breaker test kit

e. HV test kit
f.

Earth test meter

Prepared by: SMS/R Dhawad

Group Manufacturing Services

Electrical

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5.6

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Skilled Manpower
a. Riggers
b. Electricians
c. Testing Engineer with experience in HV & LV Switchboard testing.

Annexure
Annexure-A: ITP HV & LV Switchgear
Annexure-B: ITP HV & LV Switchgear Hi Pot Test Records
Annexure-C: ITP HV & LV Switchgear CT Primary Injection
Annexure-D: ITP HV & LV Switchgear: - Testing & Measuring Instruments

Prepared by: SMS/R Dhawad

Group Manufacturing Services

Electrical

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Annexure - A
HV & LV SWITCHGEAR - PRECOMMISSIONING CHECK SHEET

Plant :

Date of
Commissioning :

Area / Unit :

Year of
Manufacturing :

No. of Panels

Make :

Voltage Rating :

Current Rating :

Short Circuit Rating :

SN

Activity

Observation / Action taken

/ Remarks

Receipt and Preservation

1
Ensure certified tools, lifting equipment are used
for unloading of Switchgears by trained and
competent personals. Avoid any sudden jerks
when moving.
2
Ensure completeness of supply and specification as
per packing list, BOQ, OEM manual & PO.
3
Check name plate data against data sheet.
4
Inspect all items of equipments as soon as possible
upon arrival at site to ascertain whether they have
been damaged in transit or whether any items are
missing. Particular attention should be paid to
bushings, meter and relays which are the items
most liable to damage.
5
If the Switchgear is to be stored for long duration,
it should be stored in the clean, dry, and airy
place.
6
Packing material such as wood, wool or straw
packed around insulation other than porcelain,
should be removed as they may absorb moisture.
Periodic inspection and vermin proofing is carried
out of such places.
Panel Foundation
Ensure foundation is ready and released by concerned
1
department.

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Group Manufacturing Services

Electrical

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SN

Activity

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Observation / Action taken

/ Remarks

2
3

Check dimensions of floor cut outs w.r.t. drawings

Check the panel base frame dimensions w.r.t cut
out/Frame.
4
Check layout and leveling of base frame and
foundation bolts /holes before installation of
switchgear panel.
Panel Checks
1
Check name plate & tag Number on front & rear
sides as per Drawing.
2
Check orientation, vertical & horizontal alignment
of panels and clearance.
3
Check all inter-panel coupling bolts are properly
leveled and tightened.
4
Check the gaskets provided on panel doors/ inter
panel location are ok.
5
Check for panel grouting / bolting and proper
fastening of panel body with base frames.
6
Check for provision of Anti-condensation heaters
7
Check for correct component and internal control
wiring, correct ferrule numbering as per drawing.
Check for no loose control wiring, proper dressing
of control cables.
8
Check that no live parts are exposed.
9
Check for provision of future expansions.
10
Check for condition of limit switches, alignment of
male & female contact.
11
Check for vermin proofing of panels.
12
Check for panel door interlocks & padlocking
arrangement.
13
Check for availabilty of explosion vents /
ventilationand helthyness of the same wherever
applicable.
14

Check whether any loose items are left inside the

panel and ensure general cleanliness of panels
15
Check for provision of rubber mats in front of the
panels
16
Check Thermography survey window is available
Bus Bar Checks
1
Check for correct size, rating and alignment of bus
bars.
2
Check bus bar connections are correct, properly

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Group Manufacturing Services

Electrical

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SN

Activity

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Observation / Action taken

/ Remarks

aligned and tighten with torque wrench. Also

ensure proper size and quality of Bolts, nuts and
washers are provided.
3
Check for phase separators & their position.
4
Check for condition of bus bar support insulators /
bushings / shrouds.
5
Check for correct phase color marking on bus bars.
7
Check Cable/ bus duct entry properly sealed.
Metering and Protection Checks
1
Check for rating, correct positioning, termination &
polarity of CTs. earthing through removable link
2
Check for rating, correct positioning, termination &
polarity of PTs. earthing through removable link
3
Check for shutter operations for withdrawable
PTs.
4
Check for correct rating of fuses control & power
both as per drawing.
5
Check protective relays are available as per
drawings.
6
Check the relays are tested and set as per
recommended relay settings.
7
Check for appropriate range & size of meters.
Earthing
1
Check for provision of double and distinct earthing
of panels
2
Check for provision of Earth bus, panel earthing &
earth marking.
3
Check Inter panel continuous earth bus properly
tighten.
4
Check for CT / PT earthing through removable link.
5
Check CT base earthing.
6
Check for earthing bond between panel & door.
7
Check for shutter earthing & earthing of bus duct
enclosure.
8
Check for body earthing of protective relays,
wherever applicable.
9
Measure the earth resistance
Checks on Circuit breaker
1
Check for correct current and short circuit rating &
type of Circuit breaker for corresponding feeder.
2
Check interlocks with upstream or downstream
breakers of feeders if any

Prepared by: SMS/R Dhawad

Group Manufacturing Services

Electrical

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SN

Activity

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Observation / Action taken

/ Remarks

3
4

Check interchangeability of the breakers.

Check all breakers and associated switchgear
thoroughly. (Refer HV & LV Breaker ITP)
Power cable Termination
1
Check cable termination ITP completed.
2
Check for adequate phase to phase & phase to
earth clearances.
3
Check that all additional / spare openings at the
gland plate are sealed.
Control Supply
1
Check for AC / DC control bus bars are properly
installed with all hardware.
2
Check for correctness and tightness of control
wiring.
3
Check for correct component & ferrule numbering
as per approved drawings.
4
Check for proper dressing of control cables
Electrical checks
1
Check IR value of control wiring, bus bar, breaker,
PTs are satisfactory and data recorded
2
Check Contact resistance of bus bar joints,
isolating contacts are satisfactory and data
recorded
3
Check Hi-Pot test results of Bus and breakers are
satisfactory and data recorded
4
Check ratio, polarity of CTs, PTs and Knee point
voltage (wherever applicable) for Protection class
CTs are tested and data recorded
5
Check all relays are tested and data recorded.
6
Check simulations of all control, Under voltage &
auto commutation scheme, interlock protection,
annunciation and indicator circuits done and data
recorded.
Miscellaneous Checking
1
Check that no loose items are left inside the
panel.
2
Check space heater supply made available
3
Check for general cleanliness of the panels.
4
Check that fire-fighting equipments are provided.
5
Check Stage wise inspection clearance / test
reports.
6
Check DC Control supply of rated voltage made

Prepared by: SMS/R Dhawad

Group Manufacturing Services

Electrical

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SN

Observation / Action taken

/ Remarks

Activity

available with correct polarity

Check proper precautions taken to prevent water
falling on the roof of the board or any part of it
Check sufficient lighting arrangement made and is
in service.
Check Switchboard room properly cleaned.
Switch Fuse Unit (For LV Switchboard)
1
Check for correct rating and size of power fuses.
Check rating and size of fuses match to that of
fuse carrier/base/switch.
2
Check for proper operation of switch fuse unit & its
interlocks.
3
Check for correct rating & setting of overload
relays as per recommended relay setting wherever
applicable.
7

Checked and witnessed by

[RIL Engineer ]

[Contractor Engineer]

Name / Signature & Date

Name Signature & Date

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Group Manufacturing Services

Electrical

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Annexure B
HV & LV Switchgear TEST RECORD
Plant :

Unit :

Equipment no.:

Substation no.:

Switchboard No.

Panel no.

Operating voltage

Manufacturer:

Front:

Short Circuit capacity

Rear:
Drawings No.

a) G.A. Drawing

B) Control Drawing

c) Operation and
Maintenance Manual

1.

Bus IR Value before Hipot:

Megger Voltage :
RE =
YE =
BE =

Megger Sr. No.

RY =
YB =
BR =

2. Hipot Testing:
Voltage Applied
Between

Applied
Voltage

Duration

Leakage Current
Start

Finish

Remarks

R&Y+B+E
Y&B+R+E
B&R+Y+E
3.

4.

Bus IR Value after Hipot:

RE =
YE =
BE =
PI value:
RE =

RY =
YB =
BR =
RY =

YE =
BE =

YB =
BR =

Checked and witnessed by

[RIL Engineer ]

[Contractor Engineer]

Name / Signature & Date

Name Signature & Date

Prepared by: SMS/R Dhawad

Group Manufacturing Services

Electrical

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Annexure - C
CT Testing

Make:

Switchboard No.

Equipment no.:

Substation no.:

Sr. No.

Type

VA

CT Ratio

R:
Y:

Ith

B:
BIL

Class

Hz

Instrument Safety factor

Primary Injection Test

Phase

Injection primary

Secondary

Metering

Reading of

current

Protection

Current

panel

R
Y
B

Checked and witnessed by

[RIL Engineer ]

[Contractor Engineer]

Name / Signature & Date

Name Signature & Date

Prepared by: SMS/R Dhawad

Group Manufacturing Services

Electrical

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Annexure - D
TESTING & MEASURING INSTRUMENTS

TESTING & MEASURING INSTRUMENTS USED

SR no. of

Instrument Name

Instrument used

Instrument

& Details

for which tests

Tested at

Calibration
Validity

Checked and witnessed by

[RIL Engineer ]

[Contractor Engineer]

Name / Signature & Date

Name Signature & Date

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Group Manufacturing Services

Electrical

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