Pre Commissioning & Commissioning - Procedure & Test Reports - MV Switchgear

PROJECT: 2X35 MW PEAT FIRED POWER PLANT
AT
SOUTH AKANYARU, RWANDA.
COMMISSIONING PROCEDURE
FOR
11KV SWITCHGEAR
DOCUMENT No: SPEPC.RWANDA.11KV.CP01

Preparation date Nov 2019 Rev number: 0 Next rev due on
Prepared by Checked by Reviewed by Approved by

2 X 35 MW PEAT FIRED POWER PLANT - 11KV SWITCHGEAR
COMMISSIONING PROCEDURE AND TEST REPORT
DOC.NO: SPEPC.RWANDA.11KV.CP01
REVISION CONTROL SHEET
Revision Changed
sheets Prepared by Checked by
No. Date Total Sheet Reviewed by Approved by
e N No.
e o
.
Page 2 of 123
TABLE OF CONTENT
Page
Content number Description
Number
(i) Cover page 1
(ii) Revision control sheet 2
(iii) Table of content 3
1.0 Introduction 6
2.0 Purpose 6
3.0 Pre-requisites & Initial conditions 6
3.1 Requirement of other systems 6
3.2 System requirements 7
3.3 Manpower requirements 7
3.4 Test instruments and other materials 8
requirement
3.5 Requirement of outside agencies 8
3.6 Hazards and special precautions 8
4.0 General methods 9
4.1 Installation checks 9
4.2 Checks on bus ducts 11
4.3 Cabling and connection checks 11
4.4 Interfacing Checks 12
4.5 Pre-commissioning checks on 11KV 13
switchgear (excluding working supply
incomers, VT cubicle & outgoing feeders)
4.6 Pre-commissioning checks on working 15
supply incomers
A Visual inspection of the cubicle 15
B Internal wiring checks 16
C Testing of circuit breaker 16
D Testing of current transformer 19
E Testing of potential transformer 21
F Testing of electromagnetic locks, limit 21
switches, circuit breakers, fuses,
resistances, heaters & indication lamps
G Testing of relays 22
H Testing of meters 22
I Logics and interlocks checks 22
4.7 Pre-commissioning checks on main and 23
supplementary VT cubicles
C VT checks 24
D Testing of electromagnetic locks, limit 25
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switches, miniature circuit breakers, fuses,

E Testing of relays 26
F Testing of meters 26
4.8 Pre-commissioning checks on outgoing 26
feeders
C Circuit breaker checks 27
D Testing of current transformers 30
E Testing of potential transformers 32
F Testing of electromagnetic locks, limit 32
switches, miniature circuit breakers, fuses,
G Testing of relays 33
H Testing of meters 33
I Logics and interlocks checks 33
5.0 Energization of switchgear 34
6.0 Design intents 35
7.0 Test report formats 36
8.0 References 36
9.0 List of annexures 36
Annexure -1 List of 11KV switchgears 38
Annexure -2 Checklist for installation checks 40
Annexure -3 Checklist for bus duct checks 44
Annexure -4 Checklist for cabling and connection checks 46
Annexure -5 Checklist for interfacing checks 50
Annexure -6 Checklist for pre-commissioning checks on 54
11KV switchgear (excluding working supply
incomers, VT cubicle & outgoing feeder)
Annexure -7 Checklist for bus bar clearance checks 57
Annexure -8 Checklist for joint tightness and contact 60
resistance checks of bus bars
Annexure -9 Checklist for pre-commissioning checks on 63
working supply incomers
Annexure-10 Checklist for circuit breaker checks 65
Annexure-11 Checklist for current transformer checks 72
Annexure-12 Checklist for potential transformer checks 78
Annexure-13 Checklist for Electromagnetic locks, Limit 82
switches, Circuit breakers, Fuses,
Page 4 of 123
Resistances & Indication lamps checks

Annexure-14 Checklist for ABB IED relay checks 84
Annexure-15 Checklist for IED relay checks for incomer, 88
VFD Transformer panel, Bus coupler.
Annexure-16 & Checklist for IED relay checks for bus PT 92 & 95
16A and BRPT panel
Annexure-17 Checklist for IED relay checks for 98 & 102
&17A Transformer feeder panel
Annexure-18 Checklist for voltmeter checks 104
Annexure-19 Checklist for ammeter checks 106
Annexure –20 Checklist for logics and interlocks checks on 108
working incomer, Outgoing feeder, PT
cubicle.
Annexure – 21 Checklist for pre-commissioning checks on 111
Incomer and VT cubicle
Annexure – 22 Checklist for VT checks 113
Annexure – 23 Checklist for pre-commissioning checks on 116
outgoing feeders
Annexure – 24 Checklist for energization of switchgear 118
Annexure – 25 Checklist for relay settings checks 121
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1.0 Introduction:
11KV switchgears are intended for reception and distribution of a three phase,
50Hz AC power to Power Plant auxiliary loads. 11KV switchgear includes
normal operation power supply system switchgears and common station
auxiliary power supply system switchgears. The 11KV switch gears have
been designed based on IEC 62271-200 standards for station smooth
operation by providing ABB 11KV HT Switchgear Type UniGear ZS1 (ABB
Ref no: 4201539208-01) with all relevant protections for electrical system
healthiness.
2.0 Purpose:
This procedure is prepared for carrying out the pre-commissioning checks,
energization and post energization checks on 11KV switchgears of 2 X 35MW
of Rwanda power plant. This procedure is applicable for ABB 11KV HT
Switchgear listed in annexure-1. Switchgears to be tested in order to ensure
that it has not been damaged during transport & erection and to ensure its
trouble free operation.
3.0 Pre-requisites & initial conditions:

3.1 Requirement of other systems:
1. The UAT power transformer feeding to the 11KV switchgears are
commissioned and available for energized.
2. Panels associated with 11KV switchgear is installed, tested and
commissioned.
3. Control room panel and associated annunciation which are meant for
11KV switchgear is installed, tested and commissioned in switchyard
control room or main control room.
4. Bus duct from transformers to 11KV switchgear is erected and tested.
5. Lighting system of 11KV switchgear rooms is functional and sufficient
illumination is available.
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6. 110 V DC power supply for control & protection of 11KV switchgears is

commissioned and is available.
7. 220 V AC power supply for control & protection of 11KV switchgears is
commissioned and is available.
8. Fire fighting equipment’s are installed in 11KV switchgear room.
9. Ventilation system in 11KV switchgear room is installed and
commissioned.
10. Telephone system is ready and available in 11KV switchgear room.
11. All civil works in and around 11KV switchgear room is completed, room
floor painting is completed and room is in lockable condition.
12. 415 Volt, 3 phase power supply is available for testing.
3.2 System requirements:

1. Erection of 11KV switchgear is completed as per WD (Working Draft) is
received from electrical construction group.
2. Nomenclature is written on switch gear panels and all incomer, standby
and outgoing feeders.
3. Power and control cabling of switchgear is completed.
4. 11KV danger stickers are pasted at front and back of 11KV switchgear.
5. 11KV switchgear earthing is completed as per WD.
6. Manufacturer’s instructions, WDs, and approved settings of relays to be
available.
7. Insulation mats of 11KV grade are provided in front and back of
switchgear panels.
3.3 Manpower requirements:
1. Engineer -2
2. Supervisor – 1
3. Tradesman – 5
Page 7 of 123
3.4 Test instruments and other materials requirement

1. 100V, 250V, 500V & 5 KV megger.
2. Earth tester.
3. Millimeter.
4. Tong tester.
5. Primary injection test kit.
6. Secondary injection test kit
7. Single phase & three phase auto transformers.
8. Polarity tester.
9. CB timing kit/ CB Analyzer
10. Micro – Ohmmeter.
11. Electrician Tool kit.
12. HV test kit.
13. Infra red type thermo meter.
14. Vacuum measurement kit.
15. Cleaning agent.
16. Gada cloth.
17. Extension Board.
18. Lubricating grease.
3.5 Requirement of outside agencies:

1. Electrical construction group/erection contractor for attending deficiencies.
2. 11KV switchgear and relay manufacturer’s representative (if applicable).
3.6 Hazards and special precautions:

1. Post “ENTRY RESTRICTED” board near switchgear under test to restrict
personnel entry to switchgear area.
2. Proper electrical isolation shall be ensured before taking up any work and
“DO NOT OPERATE” tags should be provided at isolation points as per
work permit system.
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3. 11KV switchgear shall be connected to station grounding grid at two

points.
4. 11KV grade insulation mats shall be provided at the front and back side of
the 11KV switchgear.
5. Insulated hand gloves for 11KV rating shall be used for any on line job.
6. “11KV” danger stickers shall be pasted at front and back of 11KV
switchgear panels.
7. Adequate illumination shall be maintained in 11KV switchgear room.
8. Proper housekeeping shall be ensured in switchgear room.
9. No CT secondary shall be left open circuited during testing. Spare CT if
any shall be shorted.
10. No temporary earthing or discharge rod shall be left connected at the time
of charging.
11. Ventilation system in switchgear area shall be functional.
12. Phase sequence of Incomer -1 and Incomer-2 supply shall be matched.
4.0 General Methods:

4.1 Installation checks:
1. Installation checklist enclosed as annexure-2 shall be filled.
2. Check the designation of 11KV switchgear is as per WDs and indicate
same in checklist.
3. Check that name plate details and ratings of incomer-1, incomer-2,
outgoing feeder, PT etc. are as per WD.
4. Check and ensure that the 11KV switchgear is installed completely as per
the WD, note down pending points relating to installation if any.
5. Check and ensure that the MS base frame is welded as per WD.
6. Check and ensure that inter-cubicle bolts are tightened.
7. Check and ensure that bus bars are installed as per WDs in bus bar
chamber and all flexible connections are installed.
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8. Check and ensure that bus duct erection and connections from
transformer to the switchgear is completed.
9. Check and ensure that phase sequence of feeding transformer to the
11KV switchgear, 11KV bus duct and 11KV switchgear are matching.
10. Check and ensure that all cubicles are bolted to earthing bus bar at rear
side and the earthing bus bar is connected to station grounding grid at two
points.
11. Check the contact resistance between switch gear grounding point and
station grounding. Resistance shall not be more than 0.1 ohm.
12. Check that control and power cabling is completed as per design/ drawing.
13. Check and ensure that switchgear and surrounding area is clean and free
from debris.
14. Check and ensure that free access is available to all points of installed
components and especially to points requiring frequent operations,
maintenance and control.
15. Check and ensure that the bonding / blocking material for relays,
contactors etc is removed.
16. Check and ensure that all unused holes and openings are properly
plugged.
17. Check and ensure that “11KV” grade insulation mat is provided in front
and back of switchgear.
18. Check and ensure that “11KV” danger sticker is pasted at front and back
side of switchgear.
19. Check and ensure that no unwanted tools, tackles, equipment’s etc are
left nearby.
20. Check and ensure that adequate illumination is available in switchgear
room.
21. Check and ensure that all WDs relay settings etc are available.
22. Check and ensure that cubicle illumination lamps are provided with lamps.
Page 10 of 123
23. Check and ensure that all trench openings and unused floor openings are
closed.
24. Check and ensure that all civil works in and around 11KV switchgears are
completed, room floor painting is completed and room is in lockable
condition.
4.2 Checks on bus ducts:
1. Checklist for bus duct checks enclosed as annexure-3 shall be filled.
2. Check and ensure that the bus ducts are installed as per the WD and note
down pending points related to installation if any.
3. Check and ensure the continuity of bus bars of bus duct from transformer
end to switchgears.
4. Check and ensure that phase sequence at transformer end is matching
with phase sequence at 11KV switchgear end.
5. Check and ensure bus ducts are earthed at transformer end as well as at
11KV switchgear end.
6. Check the insulation resistance of bus duct with 5KV megger before HV
test.
7. Carry out HV test of the bus duct at __ KV AC voltage for 1 minute.
8. Check the insulation resistance of bus duct with 5KV megger after HV test
4.3 Cabling and connection checks
1. Cabling and connections checklist attached as annexure-4 shall be filled.
2. Check and ensure that external power and control cables are laid and
terminated as per the WDs and record all details in the data sheet
available in annexure-4.
3. Check and ensure all external cables (control, signal, power, indication)
connected at individual switchgear panels are dressed, glanded,
supported, clamped and provided by aluminium identification tags at both
ends as well as at intermediate points at a regular interval of 15 meters.
Cable number shall be punched in aluminium tags.
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4. Check and ensure spare cores of control cable shall be neatly dressed
and placed in its location. Also ensure that spare cores are tagged as
spare cores.
5. Check and ensure that armour of cable is earthed at switchgear end only
(applicable if armoured cables are laid).
6. Check and ensure that single core cables are laid in trefoil formation and
trefoil clamps are provided through out its length.
7. Check for continuity, IR value, correct ferruling, lugging, connection
tightness, IR value of all external cables connected to switchgear and also
that they are connected as per WDs.
4.4 Interfacing checks:

1. Interfacing checklist enclosed as annexure-5 shall be filled.
2. Check interfacing cabling between individual cubicles of 11KV switchgear
and ensure that continuity, correct ferruling, lugging, connection tightness,
IR value, tagging, proper dressing and supporting have been checked as
per annexure-4.
3. Check interfacing cabling between IED relay and connector of 11KV
switchgear cabinet and ensure that continuity, correct ferruling, lugging,
connection tightness, IR value, tagging, proper dressing and supporting
have been checked as per annexure-4.
4. Check interfacing cabling between 11KV switchgear and FBT panel/DCS
per annexure-4
5. Check interfacing cabling between 11KV switchgear and
GRP/UATRP/GMSP/GTRP/ and ensure that continuity, correct ferruling,
lugging, connection tightness, IR value, tagging, proper dressing and
supporting have been checked as per annexure-4.
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6. Check interfacing cabling between 11KV switchgear and other Inter panel
contacts and ensure that continuity, correct ferruling, lugging, connection
tightness, IR value, tagging, proper dressing and supporting have been
checked as per annexure-4.
7. Check interfacing cabling between 11KV switchgear and transformer
protection scheme and ensure that continuity, correct ferruling, lugging,
8. Check interfacing cabling between 11KV switchgear and 110V DCDB and
ensure that continuity, correct ferruling, lugging, connection tightness, IR
value, tagging, proper dressing and supporting have been checked as per
annexure-4.
9. Check interfacing cabling between 11KV switchgear and 220V AC panel
per annexure-4.
10. Check interfacing cabling between 11KV switchgear and control room and
ensure that continuity, correct ferruling, lugging, connection tightness, IR
value, tagging, proper dressing and supporting have been checked as per
annexure-4 (if applicable).
11. Check interfacing cabling between 11KV switchgear panel and its standby
switchgear feeder and ensure that continuity, correct ferruling, lugging,
12. Check and ensure the interfacing bus duct between 11KV switchgear and
feeding transformer.
4.5 Pre-commissioning checks on 11KV switchgear (excluding working
supply incomers, VT cubicle & outgoing feeders):
1. Checklist for pre-commissioning checks on 11KV switchgear enclosed as
annexure-6 shall be filled.
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2. Check that bus bars are installed as per WDs. Check that bus ducts are
correctly connected to the switchgear buses with respect to phase
sequence.
3. Check and ensure switchgears for proper phase sequence.
4. Check all bus bars are properly painted with red, yellow & blue colors.
5. Check and clean the bus bars and support insulators properly. Check that
there is no physical damage to any insulator or bus bars.
6. Check and ensure that no foreign materials are left inside the bus bar
chamber.
7. Check the clearance of bus bars between phases and between phases
and earth and record the results in annexure-7.
8. Check all joint tightness and record the result in annexure-8. Torque value
of various size nut and bolt are as follows,
Nominal bolt thread Tightening torque N-m

M6 10.5
M8 26
M10 50
M12 86
M16 200
9. Check the contact resistance of all joints i.e. carryout milli volt drop test for
each joint and record the results in annexure-8. Contact resistance of
various joints based on current carrying capacity are as follows,
Sl. No. Nominal current rating of contact in Contact resistance in
Ampere micro-ohm
1 400 As recommended by
2 630 Manufacturer
3 1000
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4 1600
5 ≥2000
10. Box up bus bar chamber.

11. Rack in & close all the circuit breakers and rack out VT.
12. Carryout insulation resistance test of bus bar with 5KV megger before HV
test.
13. Carry out HV test at __KV AC voltage for 1 minute.
14. Carryout insulation resistance test of bus bar with 5KV megger after HV
test.
15. Randomly interchange the CB trucks between different CB cubicles.
Ensure free movement of CB trucks in any of the CB cubicles. Similarly
check for PT trucks.
16. Insert the CB and PT trucks inside their cubicles, check for their free
movement and check that the safety shutters over the cluster contacts in
the cubicle are operating satisfactorily.
17. Check and ensure that 110V DC bus is wired as per WDs.
18. Carry out insulation resistance test of 110V DC bus wiring with 250V
megger.
19. Check and ensure that 220V AC bus is wired as per WDs.
20. Carry out insulation resistance test of 220V AC bus wiring with 0.5KV
megger.
21. Check and ensure that all the rear doors of switchgear cubicles are closed
with nuts and bolts and handle knob is existing.
4.6 Pre-commissioning checks on working supply incomers:

A. Visual inspection of the cubicle:
a) Checklist for pre-commissioning checks on working supply incomers
enclosed as annexure-9 shall be filled.
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b) Check and clean the breaker compartment completely and ensure that
no foreign materials are left inside.
c) Check bill of material and ensure that all the components are existing
as per WDs.
B. Internal wiring checks:
Check and ensure that the internal wiring and control circuit are as per
WDs and tighten all wires and TBs.
i. Control & protection circuit checks:
a) Check the control & protection circuit is wired as per drawing and
check the continuity of each wire.
b) Check IR of control & protection circuit at 250V.
ii. Monitoring and indication circuit checks:
a) Check the monitoring and indication circuit is wired as per drawing.
b) Check the continuity of each wire.
C. Circuit breaker checks:
Checklist for checks on CB enclosed as annexure-10 shall be filled.
i. Physical inspection and mechanical interlocks checks
a. Inspect the CB for any physical damage & missing of parts.
b. Clean of all the insulators & interrupter surface with dry cloth.
c. Check and ensure lubrication of all the linkages, moving / sliding parts
as per manufacturer’s instructions.
d. Check blue matching of the female cluster contact with male bus bar
contact and ensure that blue matching is successful.
e. Check and ensure manual spring charging is functional and check the
local operation of circuit breaker.
f. Check vacuum in the breaker interrupter chamber.
g. Carryout a closing-opening cycle and an opening-closing-opening
cycle of operation manually and check that CB is functional and no
abnormality is noticed. Check that CB open/close status indicator and
spring charged/uncharged status indicator is functional.
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h. Check and ensure that auxiliary contacts for CB status

(closing/opening) indication (52a & 52b) are functional.
i. Check and ensure the functioning of mechanical interlocks.
1. Check and ensure electromagnetic locks of CB truck and earthing
switch are functional.
2. Check and ensure that CB cannot be racked into service position if
it is closed.
3. Check and ensure that CB cannot be taken out of service position if
it is closed.
4. Check and ensure that CB cannot be closed if it is in intermediate
position i.e. between service position and test position.
5. Check and ensure that earthing switch cannot be closed if CB is in
service position.
6. Check and ensure that if CB is moved from test position to service
position when it is closed, CB trips immediately.
7. Check and ensure that if CB is moved from service position to test
8. Check and ensure that earthing switch driving rod can be inserted
into the drive slot only after releasing of electromagnetic lock.
9. Check and ensure that earthing switch drive blocking casing cannot
be opened if circuit breaker is in service position.
10. Check and ensure that when earthing switch is closed then earthing
switch drive blocking casing cannot be closed.
11. Check and ensure that breaker can be rolled out of service position
only after releasing electromagnetic lock.
12. Check and ensure that circuit breaker cannot be racked into service
position if earthing switch is closed.
j. Check contact changeover of test position limit switch, service position
limit switch & earthing switch operation limit switch.
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k. Insert the plug into the socket for control circuit connection between
fixed portion of cubicle and the CB truck; check that the plug can be
inserted in only one position i.e. correct position.
ii. Contact resistance check:
a) Close the circuit breaker and measure the contact resistance between
upper pole and lower pole for each phase. Acceptable contact
resistance of various capacity circuit breakers are as follows,
Sl. No. Circuit breaker type Nominal current Contact resistance

rating in Ampere in micro-ohm
1 VD4 1250 As recommended
by manufacturer
b) Rack in the circuit breaker into service position and check the contact
resistance of upper and lower cluster contacts respectively with bus
bars for each phase separately. Also measure the contact resistance
from upper bus to lower bus with circuit breaker in closed position.
c) Check contact resistance between circuit breaker body (foot paddle)
and switchgear base frame. Contact resistance shall be less than 0.1
ohm.
iii. Insulation resistance checks:
a) Measure the insulation resistance between upper and lower contacts
with CB in open condition for each phase with 5KV megger.
b) Measure the insulation resistance between phase to phase and phase
to earth respectively with CB in close condition with 5KV megger.
iv. CB coils & spring charging motor checks:
a) Measure the insulation resistance of spring charge motor, closing coil
& tripping coil with respect to earth at 250V.
b) Measure the winding resistance of spring charging motor, coil
resistance of closing coil & coil resistance of tripping coil respectively.
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v. Spring charging time & CB timing checks:

a) Measure the spring charging time at 70%, 100% & 110% of 110V DC
respectively across spring charging motor.
b) Measure the closing time of CB using CB timing kit at 70%, 100% &
110% of 110V DC respectively across closing coil. Note down closing
time of each pole.
c) Measure the CB opening time using CB timing kit at 70%, 100% &
110% of 110V DC respectively across trip coil-1. Note down opening
time of each pole.
d) Measure the CB opening time using CB timing kit at 70%, 100% &
time of each pole.
vi. Anti pumping & trip free feature checks:
a) Insert the CB trucks into the cubicle and check for anti pumping and
trip free feature. Press the close PB and keep it pressed, the CB
closes. Now press the trip PB, the CB trips, but does not close again
even though a persistent close command is present. Now release the
close PB and then again press it, the CB closes now. Hence it is
checked that the anti- pumping feature is operating.
b) Check the trip free feature of the CB. Press the trip PB and keep it
pressed, breaker opens. Now press the close PB and check that
mechanism operates to close the CB but CB do not close. This
indicates that trip command over-ride close command and trip free
feature is functional.
D. Testing of current transformers:
a. Checklist for current transformer checks enclosed as annexure-11
shall be filled.
b. Check that CTs are as per WDs. Note down name plate details of CTs.
c. Inspect the CT for any breakages, damages, improper mounting /
clamping
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d. Verify the wiring as per drawing of the CT secondary and earthing with
respect to the scheme.
e. Check for earthing of CTs as per scheme.
f. Interchanging of CTs among protection CTs and measuring CTs shall
not be done even if VA rating is same.
g. Measure secondary winding resistance.
h. Carryout IR measurement at 5KV of CT for secondary to earth &
primary to secondary.
i. Using a battery operated polarity tester, check that positive emf is
induced between S-1 to S-2 terminal when a positive current pulse is
applied between P-1 to P-2
j. Using a primary injection test kit, inject rated primary currents into the
P1 & P2 terminals. Measure these currents and those flowing out of
CT secondary terminals. Tabulate the readings. Calculate the ratio and
compare with these name plate ratio.
k. For protection class of CT carry out saturation test as follows,
Using a 1 phase variac; apply increasing voltages across the CT
secondary winding. Increase the voltage up to Vk/2 mentioned on CT
name plate. Note the voltage applied and the current flowing into the
CT secondary at each step of increase in the voltage. Draw a graph
with voltage and current as the x and y-axis respectively and
incorporate the tabulated readings into the graph. When an increase in
the current by 50% is observed for an increase in the voltage by 10%,
V knee is said to have been reached. The magnetizing current Im at
voltage Vk/2 shall be within the limit as mentioned on CT name plate.
l. CBCTs (core balance current transformers) shall be tested for ratio as
follows,
Pass the known current to primary and measure the current in the
secondary of CBCT.
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m. Measurement CTs shall be tested for primary injection with burden

connected into secondary.
n. Spare secondary terminals (if any) shall be shorted and earthed.
E. Testing of potential transformers:

a) Checklist for checks on potential transformer enclosed as annexure-12
shall be filled.
b) Check that PTs are provided as per WDs and note down the name
plate details of PTs.
c) Inspect PTs for any breakages, damages, improper mounting /
clamping.
d) Check that the fuses at the primary and the secondary are as per WD
and check that fuse is OK.
e) Take the IR value of the PT secondary winding using a 500V megger.
f) Conduct ratio test by applying 11KV across the primary with
11KV/240V step up transformer. Note voltage at secondary. Tabulate
and compare the values with the nameplate values & manufacturers
documents.
g) Using a battery operated polarity tester, check that positive emf is
induced between S1 to S2 terminal when a positive current pulse is
applied between P1 to P2.
F. Testing of electromagnetic locks, limit switches, miniature circuit
breakers, fuses, resistances, heaters & indication lamps:
a) Checklist for checks on electromagnetic locks, limit switches, miniature
circuit breaker, fuses, resistances, heaters & indication lamps enclosed
as annexure-13 shall be filled.
b) Note down the make, type, ratings & model number of electromagnetic
locks, limit switches, circuit breaker, fuses, resistances, heaters &
indication lamps.
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c) Check the operation of electromagnetic lock manually and also by

supply DC voltage.
d) Check the operation of limit switches manually.
e) Check the operation of miniature circuit breaker manually.
f) Check the operation of indication lamps.
g) Check the resistance values of resistances.
h) Check the resistance value and IR value of heaters.
G. Testing of relays:
a. Check the REF615-D IED relays as per annexure-14, 15, 17, 17A.
H. Testing of meters:
a. Check voltmeters as per annexure-18
b. Check ammeters as per annexure-19
I. Logics and interlocks checks:
a) Checklist for logics and interlocks checks on incomers enclosed as
annexure- 20 shall be filled.
b) Ensure bus duct checks are completed as per annexure-3 and no
deficiency exists.
c) Ensure that cabling and connections checks are completed as per
annexure-4 and no deficiency exist.
d) Ensure that internal wiring checks are done as per WDs and no
deficiency exists.
e) Ensure that circuit breaker is checked as per annexure-10 and no
deficiency exists.
f) Ensure that relays are tested as per their testing procedure attached in
annexure 14, 15, 16, 16A, 17 & 17A and no deficiency exist.
g) Ensure that meters and transducers are checked as per their testing
procedure attached in annexure 18, 19, and no deficiency exists.
h) Ensure that current transformers are tested as per annexure-11 and no
deficiency exists.
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i) Ensure that potential transformers are tested as per annexure-12 and

no deficiency exists.
j) Ensure that electromagnetic locks, limit switches, circuit breakers,
resistances, heaters and indication lamps are tested as per annexure-
13 and no deficiency exists.
k) Check that 110V DC is available in switchgear as per WDs.
l) Check that 220V AC is available in switchgear as per WDs.
m) Check local & remote closing of circuit breaker in both test position and
service position.
n) Check the local and remote tripping of circuit breaker in both service
position and test position with 110V DC supply connected to only trip
coil-1.
o) Check the local and remote tripping of circuit breaker in both service
coil-2.
p) Check protection trips of circuit breaker by simulating faults with only
trip coil-1 energized.
q) Check protection trips of circuit breaker by simulating faults with only
r) Check protection trips of circuit breaker by simulating faults with both
trip coil-1 & trip coil-2 energized.
s) Check that indication/annunciation/alarm circuit is functional as per
WDs.
t) Check the interlock related to electromagnetic locks as per WDs.
u) Check various contact changeovers as per WDs with respect to circuit
breaker positions.
4.7 Pre-commissioning checks on main and bus VT cubicles:
a. Checklist for pre-commissioning checks on VT cubicles enclosed as
annexure-21 shall be filled.
Page 23 of 123
b. Clean the VT compartment completely and ensure that no foreign

materials are left inside.
c. Check bill of material and ensure that all the components are existing
as per WDs.
d. Check and note down details of VT fuse e.g. type, make etc.
WDs and ensure tightness of wires.
a. Check and ensure that control & protection circuit is wired as per
drawing and check the continuity of each wire. Remove all extra /
unwanted wires.
b. Check IR of control & protection circuit at 250V.
ii. Monitoring and indication circuit checks:
a. Check that monitoring and indication circuit is wired as per drawing.
Check the continuity of each wire.
b. Check the IR value of circuit at 50V.
C. VT checks:
Checklist for checks on VT enclosed as annexure-22 shall be filled.
a. Inspect the VT for any physical damage & missing of parts.
b. Clean of all the insulator surface with dry cloth.
c. Check and ensure for lubrication of all the linkages, moving / sliding
parts as per manufacturer’s instructions.
e. Check and ensure functionality of MCB of VT secondary.
f. Check and ensure the functioning of mechanical interlocks.
1. Check and ensure that earthing switch cannot be closed if VT is in
service position.
Page 24 of 123
be opened if VT is in service position.
5. Check and ensure that VT cannot be racked into service position if
earthing switch is closed.
g. Check and ensure contact changeover of test position limit switch,
service position limit switch & earthing switch operation limit switch.
ii. Winding resistance checks:
a. Measure the primary and secondary winding resistance of VT.
b. Check contact resistance between VT body (foot paddle) and
switchgear base frame.
a. Measure the insulation resistance between phase to earth of primary
and secondary respectively with 5KV megger.
b. Measure the insulation resistance between primary and secondary with
5KV megger.
iv. Ratio checks:
Conduct ratio test by applying 11KV across the primary with 11KV/240V
step up transformer. Note voltage at secondary. Tabulate and compare
the values with the nameplate values & manufacturers documents.
D. Testing of electromagnetic locks, limit switches, miniature circuit
breakers, fuses, resistances, heaters & indication lamps:
a. Checklist for checks on electromagnetic locks, limit switches, miniature
circuit breaker, fuses, resistances, heaters & indication lamps enclosed
as annexure-13 shall be filled.
Page 25 of 123
b. Note down the make, type, ratings & model number of electromagnetic
locks, limit switches, circuit breaker, fuses, resistances, heaters &
indication lamps.
c. Check the operation of electromagnetic lock manually and also by
supply DC voltage.
d. Check the operation of limit switches manually.
e. Check the operation of miniature circuit breaker manually.
f. Check the operation of indication lamps.
g. Check the resistance values of resistances.
h. Check the resistance value and IR value of heaters.
E. Testing of relays:
a. Check the ABB IED relays as per annexure-14,16,16A.
F. Testing of meters and transducers:
4.8 Pre-commissioning checks of outgoing feeders:
a. Checklist for pre-commissioning checks on outgoing feeders
enclosed as annexure-23 shall be filled.
b. Clean the breaker compartment completely and ensure that no
foreign materials are left inside.
c. Check bill of material and ensure that all the components are existing
as per WDs.
WDs.
a. Check and ensure that control & protection circuit is wired as per
drawing and check the continuity of each wire.
b. Check IR of control & protection circuit at 250V.
Page 26 of 123
ii. Monitoring and indication circuit checks

a. Check and ensure that monitoring and indication circuit is wired as per
drawing. Check the continuity of each wire.
C. Circuit breaker checks
Checklist for checks on CB enclosed as annexure-10 shall be filled.
a. Inspect the CB for any physical damage & missing of parts.
b. Clean all the insulators & interrupter surface with dry cloth.
c. Check and ensure for lubrication of all the linkages, moving / sliding
parts as per manufacturer’s instructions.
e. Check and ensure manual spring charging is functional and check the
local operation of circuit breaker.
f. Carryout a closing-opening cycle and an opening-closing-opening
cycle of operation manually and check that CB is functional and no
abnormality is noticed. Check that CB open/close status indicator and
spring charged/uncharged status indicator is functional.
g. Check and ensure that auxiliary contacts for CB status
(closing/opening) indication (52a & 52b) are functional.
h. Check and ensure the functioning of mechanical interlocks.
1. Check and ensure that electromagnetic locks of CB truck and
earthing switch are functional.
2. Check and ensure that CB cannot be racked into service position if
it is closed.
3. Check and ensure that CB cannot be taken out of service position if
it is closed.
4. Check and ensure that CB cannot be closed if it is in intermediate
position i.e. between service position and test position.
Page 27 of 123
5. Check and ensure that earthing switch cannot be closed if CB is in

service position.
6. Check and ensure that if CB is moved from test position to service
7. Check and ensure that if CB is moved from service position to test
be opened if circuit breaker is in service position.
11. Check and ensure that breaker can be rolled out of service position
only after releasing electromagnetic lock.
12. Check and ensure that circuit breaker cannot be racked into service
position if earthing switch is closed.
i. Check and ensure contact changeover of test position limit switch,
service position limit switch & earthing switch operation limit switch.
j. Insert the plug into the socket for control circuit connection between
fixed portion of cubicle and the CB truck; check that the plug can be
inserted in only one position i.e. correct position.
ii. Contact resistance check:

a. Close the circuit breaker and measure the contact resistance between
upper fixed contact and lower moving contact for each phase.
Accepted contact resistance of various capacity circuit breakers are as
follows,
Sl. No. Circuit breaker type Nominal current Contact resistance

rating in Ampere in micro-ohm
Page 28 of 123
1 VD4 1250 As recommended

by manufacturer
b. Rack in the circuit breaker into service position and check the contact
resistance of upper and lower cluster contacts respectively with bus
bars for each phase separately. Also measure the contact resistance
from upper bus to lower bus with circuit breaker in closed position.
c. Check contact resistance between circuit breaker body and switchgear
base frame.
a. Measure the insulation resistance between upper and lower contacts
with CB in open condition for each phase with 2.5KV megger.
b. Measure the insulation resistance between phase to phase and phase
to earth respectively with CB in close condition with 2.5KV megger.
iv. CB coils & spring charging motor checks:

a. Measure the insulation resistance of spring charge motor, closing coil
& tripping coil with respect to earth at 250V.
b. Measure the winding resistance of spring charging motor, coil
resistance of closing coil & coil resistance of tripping coil respectively.
v. Spring charging time & CB timing checks:

a. Measure the spring charging time at 70%, 100% & 110% of 110V DC
respectively across spring charging motor.
Page 29 of 123
b. Measure the closing time of CB using CB timing kit at 70%, 100% &
110% of 110V DC respectively across closing coil. Note down closing
time of each pole.
c. Measure the CB opening time using CB timing kit at 70%, 100% &
time of each pole.
d. Measure the CB opening time using CB timing kit at 70%, 100% &
time of each pole.
vi. Anti pumping & trip free feature checks:
a. Insert the CB trucks into the cubicle and check for anti pumping and
trip free feature. Press the close PB and keep it pressed, the CB
closes. Now press the trip PB, the CB trips, but does not close again
even though a persistent close command is present. Now release the
close PB and then again press it, the CB closes now. Hence it is
checked that the anti- pumping feature is operating.
b. Check the trip free feature of the CB. Press the trip PB and keep it
pressed, breaker opens. Now press the close PB and check that
mechanism operates to close the CB but CB do not close. This
indicates that trip command over-ride close command and trip free
feature is functional.
D. Testing of current transformers:
a. Checklist for current transformer checks enclosed as annexure-11
shall be filled.
b. Check that CTs are as per WDs. Note down name plate details of CTs.
c. Inspect the CT for any breakages, damages, improper mounting /
clamping
d. Verify the wiring as per drawing of the CT secondary and earthing with
respect to the scheme.
e. Check for earthing of CTs as per scheme.
Page 30 of 123
f. Interchanging of CTs among protection CTs and measuring CTs shall

not be done even if VA rating is same.
g. Measure secondary winding resistance.
h. Carryout IR measurement at 2500V of CT for secondary to earth &
primary to secondary.
i. Using a battery operated polarity tester, check that positive emf is
induced between S-1 to S-2 terminal when a positive current pulse is
applied between P-1 to P-2
j. Using a primary injection test kit, inject rated primary currents into the
P1 & P2 terminals. Measure these currents and those flowing out of
CT secondary terminals. Tabulate the readings. Calculate the ratio and
compare with these name plate ratio.
k. For protection class of CT carry out saturation test as follows,
Using a 1 phase variac; apply increasing voltages across the CT
secondary winding. Increase the voltage up to Vk/2 mentioned on CT
name plate. Note the voltage applied and the current flowing into the
CT secondary at each step of increase in the voltage. Draw a graph
with voltage and current as the x and y-axis respectively and
incorporate the tabulated readings into the graph. When an increase in
the current by 50% is observed for an increase in the voltage by 10%,
V knee is said to have been reached. The magnetizing current Im at
voltage Vk/2 shall be within the limit as mentioned on CT name plate.
l. CBCTs (core balance current transformers) shall be tested for ratio as
follows,
Pass the known current to primary and measure the current in the
secondary of CBCT.
m. Measurement CTs shall be tested for primary injection with burden
connected into secondary.
n. Spare secondary terminals (if any) shall be shorted and earthed.
E. Testing of potential transformers:
Page 31 of 123
a. Checklist for checks on potential transformer enclosed as annexure-12

shall be filled.
b. Check that PTs are provided as per WDs and note down the name
plate details of PTs.
c. Inspect PTs for any breakages, damages, improper mounting /
clamping.
d. Check that the fuses at the primary and the secondary are as per WD
and check that fuse is OK.
e. Take the IR value of the PT secondary winding using a 250V megger.
f. Conduct ratio test by applying 11KV across the primary with
11KV/240V step up transformer. Note voltage at secondary. Tabulate
and compare the values with the nameplate values & manufacturers
documents.
g. Using a battery operated polarity tester, check that positive emf is
induced between S1 to S2 terminal when a positive current pulse is
applied between P1 to P2.
F. Testing of Electromagnetic locks, Limit switches, miniature circuit
breakers, Fuses, Resistances, Heaters & Indication lamps:
a. Checklist for checks on Electromagnetic locks, Limit switches,
miniature circuit breaker, fuses, resistances, heaters & indication
lamps enclosed as annexure-13 shall be filled.
b. Note down the make, type, ratings & model number of
electromagnetic locks, limit switches, circuit breaker, fuses,
resistances, heaters & indication lamps.
c. Check the operation of electromagnetic lock manually and also by
supply DC voltage.
d. Check the operation of limit switches manually.
e. Check the operation of miniature circuit breaker manually.
f. Check the operation of indication lamps.
g. Check the resistance values of resistances.
Page 32 of 123
h. Check the resistance value and IR value of heaters

G. Testing of relays:
a. Check the ABB IED relays as per annexure-14,15,16,16A
H. Testing of meters and transducers:
I. Logics and interlocks checks:
a. Checklist for logics and interlocks checks on outgoing feeder enclosed
as annexure- 20 shall be filled.
b. Ensure that installation checks are completed as per annexure-2 and
c. Ensure bus duct checks are completed as per annexure-3 and no
deficiency exists.
d. Ensure that cabling and connections checks are completed as per
annexure-4 and no deficiency exist.
e. Ensure that internal wiring checks are done as per WDs and no
deficiency exists.
f. Ensure that circuit breaker is checked as per annexure-10 and no
deficiency exists.
g. Ensure that relays are tested as per their testing procedure attached in
annexure 14, 15, 16,16A and no deficiency exists.
h. Ensure that current transformers are tested as per annexure-11 and no
deficiency exists.
i. Ensure that potential transformers are tested as per annexure-12 and
j. Ensure that electromagnetic locks, limit switches, circuit breakers,
resistances, heaters and indication lamps are tested as per annexure-
13 and no deficiency exists
k. Check local & remote closing of circuit breaker in both test position and
service position.
Page 33 of 123
l. Check the local and remote tripping of circuit breaker in both service
coil-1.
m. Check the local and remote tripping of circuit breaker in both service
coil-2.
n. Check protection trips of circuit breaker by simulating faults with only
o. Check protection trips of circuit breaker by simulating faults with only
p. Check protection trips of circuit breaker by simulating faults with both
trip coil-1 & trip coil-2 energized.
q. Check that indication/annunciation/alarm circuit is functional as per
WDs.
r. Check the interlock related to electromagnetic locks as per WDs.
s. Check various contact changeovers as per WDs with respect to circuit
breaker positions.
t. Check other logics as per relay logic diagram
5.0 Energisation of switchgear:

1. Checklist for charging of switchgear enclosed as annexure-24 shall be filled.
2. Check and ensure that installation checks as per 4.1 are completed and no
deficiency exits.
3. Check and ensure that checks on bus duct as per 4.2 is completed and no
deficiency exits.
4. Check and ensure that cabling and connection checks as per 4.3 are
completed and no deficiency exits.
5. Check and ensure that interfacing checks as per 4.4 is completed and no
deficiency exits.
6. Check and ensure that pre-commissioning checks on 11KV switchgear
(excluding working incomers, PT cubicle & outgoing feeders) are completed
as per 4.5 and no deficiency exists.
7. Check and ensure that pre-commissioning checks on main and
supplementary VT is completed as per 4.7 and no deficiency exists.
Page 34 of 123
8. Check and ensure that pre-commissioning checks on outgoing feeders are

completed as per 4.8 and no deficiency exists.
9. Rack in Incomer 1&2 circuit breakers into service position and keep it
“OFF”.
10. Rack in main and bus voltage transformers into service position.
11. Rack out all the outgoing feeders & Bus couplers into draw out position and
keep it “OFF”. Put “DO NOT OPERATE TAG” to all the outgoing feeders.
12. Reset all the relays and note the position of LEDs indication of relays is as
per scheme.
13. Charge the transformer feeding the 11KV switchgear. Ensure 11KV is
available up to the PTs in the switchgear and 11KV voltage is indicated in
the incomer cubicle relay/voltmeter.
14. Switch ON main incomer and check the availability of all three phase
voltage in voltmeter.
15. Record various parameters on hourly basis for 2 hours.
6.0 Design intents:

1. Contact resistance between switch gear grounding point and station
grounding shall not be more than 0.1 ohm.
2. Bus bar minimum clearance shall be as indicated below,
a. Between phases –As recommended by manufacturer.
b. Between phase –As recommended by manufacturer.
3. Contact joint tightness for various size nut and bolt shall be as indicated
bellow
Sl. No. Nominal bolt thread Tightening torque N-m
1 M8 As recommended by Manufacturer
2 M10
3 M12
4 M16
4. Contact joint resistance for various joints shall be as indicated bellow
Sl. No. Nominal current rating of Contact resistance in micro-
contact in Ampere ohm
1 As recommended by
manufacturer
Page 35 of 123
7.0 Test report formats:

Test formats are enclosed in annexure-1 to annexure-25 .
8.0 References:
1. 11KV switch gear O&M manual
2. Set of switchgear documents supplied by manufacturers
9.0 List of annexures:
Annexure -1 List of 11KV switchgears

Annexure -2 Checklist for installation checks
Annexure -3 Checklist for bus duct checks
Annexure -4 Checklist for cabling and connection checks
Annexure -5 Checklist for interfacing checks
Annexure -6 Checklist for pre-commissioning checks on 11KV switchgear
(excluding working supply incomers, VT cubicle & outgoing
feeder)
Annexure -7 Checklist for bus bar clearance checks
Annexure -8 Checklist for joint tightness and contact resistance checks of bus
bars
Annexure -9 Checklist for pre-commissioning checks on working supply
incomers
Annexure-10 Checklist for circuit breaker checks
Annexure-11 Checklist for current transformer checks
Annexure-12 Checklist for potential transformer checks
Annexure-13 Checklist for Electromagnetic locks, Limit switches, Circuit
breakers, Fuses, Resistances & Indication lamps checks
Annexure-14 Checklist for ABB IED relay checks
Annexure-15 Checklist for IED relay checks for incomer, VFD Transformer
panel, Bus coupler.
Annexure-16 & Checklist for IED relay checks for bus PT and BRPT panel
16A
Annexure-17 Checklist for IED relay checks for Transformer feeder panel
&17A
Page 36 of 123
Annexure-18 Checklist for voltmeter checks

Annexure-19 Checklist for ammeter checks
Annexure –20 Checklist for logics and interlocks checks on working incomer,
Outgoing feeder, PT cubicle.
Annexure – 21 Checklist for pre-commissioning checks on Incomer and VT
cubicle
Annexure – 22 Checklist for VT checks
Annexure – 23 Checklist for pre-commissioning checks on outgoing feeders
Annexure -1 List of 11KV switchgears
Annexure -2 Checklist for installation checks
Annexure -3 Checklist for bus duct checks
Annexure – 24 Checklist for energization of switchgear
Annexure – 25 Checklist for relay settings checks
ANNEXURE-1
Page 37 of 123
LIST OF 11KV SWITCHGEARS
S.NO PANEL NUMBER PANEL IDENTIFICATION ABB DOC. NO.

YN1V300013-LA-
1 PNL.NO.1 INCOMER-1 SLD
BAG FILTER TRANSFORMER YN1V300013-LA-
2 PNL.NO.2 FEEDER SLD
YN1V300013-LA-
3 PNL.NO.3 VFD TRANSFORMER-3 SLD
UNIT SERVICE TRANSFORMER YN1V300013-LA-
CW SERVICE TRANSFORMER YN1V300013-LA-
STATION SERVICE TRANSFORMER YN1V300013-LA-
YN1V300013-LA-
YN1V300013-LA-
9 PNL.NO.9 SPARE TRANSFORMER FEEDER SLD
YN1V300013-LA-
10 PNL.NO.10 BUS RISER CUM BUS PT SLD
YN1V300013-LA-
11 PNL.NO.11 BUS COUPLER SLD
UNIT SERVICE TRANSFORMER YN1V300013-LA-
STATION SERVICE TRANSFORMER YN1V300013-LA-
Page 38 of 123
YN1V300013-LA-
YN1V300013-LA-
16 PNL.NO.16 SPARE TRANSFORMER FEEDER SLD
BAG FILTER TRANSFORMER YN1V300013-LA-
YN1V300013-LA-
YN1V300013-LA-
19 PNL.NO.19 BUS PT-2 SLD
YN1V300013-LA-
20 PNL.NO.20 INCOMER-2 SLD
ANNEXURE – 2
Page 39 of 123
CHECKLIST FOR INSTALLATION CHECKS

1. Switchgear code:
2. Make of switchgear:
3. Location:
4. Date of check:
5. Details of checks:
Sl. Description of checks Observation

No.
1 Check the designation of 11KV switchgear as per WDs
and indicate same in checklist
2 Check that name plate details and ratings of incomer,
standby incomers, outgoing feeder, PT etc. are as per WD
3 Check and ensure that the 11KV switchgear is installed
completely as per the WD, note down pending points
relating to installation if any.
a. Check feeder designation, rating (KW/KVA/A)
b. Check cubicle number and load designation
c. Check CB name plate details
d. Check and ensure CB test position limit switch
installation
e. Check and ensure CB service position limit switch
installation
f. Check and ensure earthing disconnector limit switch
installation
g. Check and ensure bus bar chamber over pressure
switch installation
h. Check and ensure circuit breaker chamber
overpressure switch
Page 40 of 123
i. Check and ensure electromagnetic lock of earthing

switch
j. Check and ensure electromagnetic lock of CB position
k. Check and ensure that plug, socket, various switches,
diodes, light holders and bulbs etc are installed as per
WDs.
l. Check and ensure electric heater installation
m. Check and ensure current transformer installations as
per WD
n. Check and ensure potential transformer installations as
per WD
o. Check and ensure numerical relay installation
p. Check and ensure electromagnetic relay installation
q. Check and ensure power transducer installation
r. Check and ensure current and voltage transducer
installations
4 Check that the MS base frame is welded to EP as per WD

5 Check and ensure that inter-cubicle bolts are tightened
6 Check and ensure that bus bars are installed as per WDs
in bus bar chamber and all flexible connections are
installed
7 Check and ensure that bus duct erection and connections
from transformer to the switchgear is completed
8 Check and ensure that phase sequence of feeding
transformer to the 11KV switchgear, 11KV bus duct and
11KV switchgear are matching
9 Check and ensure that all cubicles are bolted to earthing
bus bar at rear side and the earthing bus bar is connected
Page 41 of 123
to station grounding grid at two points

10 Check the contact resistance between switch gear
grounding point and station grounding. Resistance shall
not be more than 0.1 ohm
11 Check that control and power cabling is completed as per
design/ drawing
12 Check and ensure that switchgear and surrounding area is
clean and free from debris
13 Check and ensure that free access is available to all points
of installed components and especially to points requiring
frequent operations, maintenance and control
14 Check and ensure that the bonding / blocking material for
relays, contactors etc is removed
15 Check and ensure that all unused holes and openings are
properly plugged
16 Check and ensure that “11KV” grade insulation mat is
provided in front and back of switchgear
17 Check and ensure that “11KV” danger sticker is pasted at
front and back side of switchgear
18 Check and ensure that no unwanted tools, tackles,
equipment’s etc are left nearby
19 Check and ensure that adequate illumination is available in
switchgear room
20 Check and ensure that all WDs, relay settings etc are
available
21 Check and ensure that cubicle illumination lamps are
provided with lamps
22 Check and ensure that all trench openings and unused
floor openings are closed
Page 42 of 123
23 Check and ensure that all civil works in and around 11KV
switchgears are completed, room floor painting is
completed and room is in lockable condition
6. Remarks:
ANNEXURE – 3
CHECKLIST FOR BUS DUCT CHECKS
Page 43 of 123
1. Switchgear code:
2. Bus duct code:
3. Location:
4. Date of check:
5. Ambient temperature:
6. Test instruments details:
Sl. Instrument Make & Serial Calibration valid up to
No. number

No.
1 Check and ensure that the bus ducts are installed as per
the WD and note down pending points related to
installation if any
2 Check and ensure the continuity of bus bars of bus duct
from transformer end to switchgears
3 Check and ensure that phase sequence at transformer
end is matching with phase sequence at 11KV switchgear
end
4 Check and ensure bus ducts are earthed at transformer
end as well as at 11KV switchgear end
5. IR TEST 5KV DC for 60sec
Page 44 of 123
IR value Before HiVolt Test IR value After HiVolt Test in

Condition
in ohms ohms
R-(Y+B+E)
Y-(B+R+E)
B-(R+Y+E)
6. HIGH VOLT TEST
Condition Applied KVAC f0r 60sec Measured mA
R-(Y+B+E)
Y-(B+R+E)
B-(R+Y+E)
7. Remarks:
Page 45 of 123
ANNEXURE –4
CHECKLIST FOR CABLING AND CONNECTION
1. Switchgear code:
2. Location:
3. Date of check:
4. Test instrument details:

No. number
5. Details of check:
Sl. Description of checks Observations

No.
1 Check and ensure that external power and
control cables are laid and terminated as per the
WDs and record all details in the data sheet
available in annexure-4
2 Check and ensure all external cables (control,
signal, power, indication) connected at individual
switchgear panels are dressed, glanded,
supported, clamped and provided by aluminium
identification tags at both ends as well as at
intermediate points at a regular interval of 15
meters. Cable number shall be punched in
aluminium tags
Page 46 of 123
3 Check and ensure spare cores of control cable

shall be neatly dressed and placed in its location.
Also ensure that spare cores are tagged as spare
cores.
4 Check and ensure that armour of cable is
earthed at switchgear end only (applicable if
armoured cables are laid)
5 Check and ensure that single core cables are laid
in trefoil formation and trefoil clamps are provided
through out its length
6 Check for continuity, IR value, correct ferruling,
lugging, connection tightness, IR value of all
external cables connected to switchgear and also
that they are connected as per WDs
7 Perform continuity checks of all wiring and
cabling and ensure it is as per drawing
Glanding & Type and size IR
Sl. Cable Cable terminations of lugs Continuity value at
No. number size & Source Load Source Load 5KV
type end end end end
1
2
3
4
5
6
7
8
9
Page 47 of 123
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
36
37
38
Page 48 of 123
39
40
41
6. Remarks:
Page 49 of 123
ANNEXURE – 5
CHECKLIST FOR INTERFACING CHECKS
1. Switchgear code:
2. Location:
3. Date of check:
No. number

No.
1 Check interfacing cabling between individual cubicles of
11KV switchgear and ensure that continuity, correct
ferruling, lugging, connection tightness, IR value, tagging,
proper dressing and supporting have been checked as per
annexure-4
2 Check interfacing cabling between IED relay and
connector of 11KV switchgear cabinet and ensure that
continuity, correct ferruling, lugging, connection tightness,
IR value, tagging, proper dressing and supporting have
been checked as per annexure-4
3 Check interfacing cabling between 11KV switchgear and
Page 50 of 123
FBT panel/DCS and ensure that continuity, correct

annexure-4
GRP/UATRP/GMSP/GTRP/ and ensure that continuity,
correct ferruling, lugging, connection tightness, IR value,
tagging, proper dressing and supporting have been
checked as per annexure-4
other Inter panel contacts and ensure that continuity,
transformer protection scheme and ensure that continuity,
110V DCDB and ensure that continuity, correct ferruling,
lugging, connection tightness, IR value, tagging, proper
dressing and supporting have been checked as per
annexure-4
220V AC panel and ensure that continuity, correct
annexure-4
Page 51 of 123

Upstream To and Fro contacts and ensure that continuity,
Check interfacing cabling between 11KV switchgear and
Remote To and Fro contacts and ensure that continuity,
10 Check interfacing cabling between 11KV switchgear
MODBUS TCP/IP Converter and ensure that continuity,
checked as per annexure-4 (if applicable)
Remote contacts and ensure that continuity, correct
annexure-4 (if applicable)
control room and ensure that continuity, correct ferruling,
annexure-4
Inter panel and ensure that continuity, correct ferruling,
Page 52 of 123
annexure-4
contacts of FBT and ensure that continuity, correct
annexure-4
contacts of Up stream/Down stream and ensure that
continuity, correct ferruling, lugging, connection tightness,
IR value, tagging, proper dressing and supporting have
been checked as per annexure-4
billing and metering panel and ensure that continuity,
7. Remarks:
Page 53 of 123
ANNEXURE –6
CHECKLIST FOR PRE-COMMISSIONING CHECKS ON 11KV SWITCHGEAR
(EXCLUDING WORKING SUPPLY INCOMERS, VT CUBICLE & OUTGOING
FEEDERS)
1. Switchgear code:
2. Location:
3. Date of check:
5. Testing instrument details:
No. number
No.
1 Check that bus bars are installed as per WDs. Check that
bus ducts are correctly connected to the switchgear buses
with respect to phase sequence
2 Check all bus bars are properly painted with red, yellow &
blue colors.
3 Check and clean the bus bars and support insulators
properly. Check that there is no physical damage to any
insulator or bus bars
4 Check and ensure that no foreign materials are left inside
the bus bar chamber
5 Check the clearance of bus bars between phases and
Page 54 of 123
between phases and earth and record the results in

annexure-7
6 Check all joint tightness and record the result in annexure-
8
7 Check the contact resistance of all joints i.e. carryout milli
volt drop test for each joint. Record the results in
annexure-8
8 Box up bus bar chamber
9 Rack in & close all the circuit breakers and rack out VT
10 Randomly interchange the CB trucks between different CB
cubicles. Ensure free movement of CB trucks in any of the
CB cubicles.
11 Randomly interchange the PT trucks between different PT
cubicles. Ensure free movement of PT trucks in any of the
PT cubicles.
12 Randomly interchange the disconnector trucks between
different disconnector cubicles. Ensure free movement of
disconnector trucks in any of the disconnector cubicles
13 Insert the CB trucks inside their cubicles, check for their
free movement and check that the safety shutters over the
cluster contacts in the cubicle are operating satisfactorily
14 Insert the PT trucks inside their cubicles, check for their
free movement and check that the safety shutters over the
cluster contacts in the cubicle are operating satisfactorily
15 Check and ensure that 110V DC bus is wired as per WDs
16 Carry out insulation resistance test of 110V DC bus wiring
with 500V megger
17 Check and ensure that 220V AC bus is wired as per WDs
18 Carry out insulation resistance test of 220V AC bus wiring
Page 55 of 123
with 250V megger

19 Check and ensure that all the rear doors of switchgear
cubicles are closed with nuts and bolts and handle knob is
existing.
20. IR TEST 5KV DC for 60sec
IR value Before HiVolt Test IR value After HiVolt Test in

Condition
in ohms ohms
R-(Y+B+E)
Y-(B+R+E)
B-(R+Y+E)
21. HIGH VOLT TEST
Condition Applied KVAC f0r 60sec Measured mA
R-(Y+B+E)
Y-(B+R+E)
B-(R+Y+E)
22. Remarks:
ANNEXURE – 7
Page 56 of 123
CHECKLIST FOR BUS BAR CLEARANCE CHECKS

1. Switchgear code:
3. Location:
4. Date of check:
No. number
Acceptance Measured
Cubicle
Clearance between value/Factory value in mm Remarks
No.
value in mm (minimum)
R---Y
Y---B
R---N
R---Body
Y---Body
B---Body
R---Y
Y---B
R---N
R---Body
Y---Body
Page 57 of 123
B---Body
R---Y
Y---B
R---N
R---Body
Y---Body
B---Body
R---Y
Y---B
R---N
R---Body
Y---Body
B---Body
R---Y
Y---B
R---N
R---Body
Y---Body
B---Body
R---Y
Y---B
R---N
R---Body
Y---Body
B---Body
R---Y
Y---B
R---N
R---Body
Page 58 of 123
Y---Body
B---Body
8. Remarks:
Page 59 of 123
ANNEXURE – 8
CHECKLIST FOR JOINT TIGHTNESS AND CONTACT RESISTANCE CHECKS
OF BUS BARS
1. Switchgear code:
3. Location:
4. Date of check:
No. number
Contact resistance check

Tightness check
Sl. Joint Torque Torque value Factory Measured
No. number or Bolt value at at which value/Acce value (micro
description size which tightness ptance ohm)
of joint tightness to checked value
be checked (micro
ohm)
1.
2.
3.
Page 60 of 123
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.
30.
a) Torque value of various size nut and bolt are as follows,
Page 61 of 123
Nominal bolt thread Tightening torque N-m

M6 10.5
M8 26
M10 50
M12 86
M16 200
b) Contact resistance of various joints based on current carrying capacity is

as follows,
Sl. No. Nominal current rating of contact in Contact

Ampere resistance in
micro-ohm
1 400
2 630
3 1000
4 1600
5 ≥2000
8. Remarks:
Page 62 of 123
ANNEXURE –9
CHECKLIST FOR PRE-COMMISSIONING CHECKS ON WORKING SUPPLY
INCOMERS
1. Switchgear code:
3. Location:
4. Date of check:
6. Testing instruments details:
No. number
No.
2 Check and clean the breaker compartment completely
and ensure that no foreign materials are left inside
3 Check bill of material and ensure that all the
components are existing as per WDs
4 Check and ensure that the internal wiring and control
circuit are as per WDs and tighten all the wires and TBs.
5 Check that control & protection circuit is wired as per
drawing and check the continuity of each wire and
tighten all the wires.
6 Check IR of control & protection circuit at 250V
7 Check that monitoring and indication circuit is wired as
Page 63 of 123
per drawing. Check the continuity of each wire and

tighten all the wires
8 Check IR of monitoring and indication circuit at 50V
9 Check circuit breaker as per annexure-10
10 Check current transformer as per annexure-11
11 Check potential transformer as per annexure-12
12 Check electromagnetic locks, limit switches, miniature
circuit breakers, fuses, resistances, heaters & indication
lamps as per annexure-13
13 Check the IED relays as per annexure-14
20 Check voltmeters as per annexure-18
21 Check ammeters as per annexure-19
22 Check logics and interlocks as per annexure-20
8. Remarks:
Page 64 of 123
ANNEXURE –10
CHECKLIST FOR CIRCUIT BREAKER CHECKS
1. Switchgear code:
2. Cubicle code:
3. CB Serial number:
4. CB model number:
5. Make of circuit breaker:
6. Location:
7. Date of check:

No. number

No.
1 Physical inspection and mechanical interlocks
checks
a Inspect the CB for any physical damage &
missing of parts
Page 65 of 123
b Clean all the insulators & interrupter surface with

dry cloth
c Check and ensure lubrication of all the linkages,
moving / sliding parts as per manufacturer’s
instructions
d Check blue matching of the female cluster
contact with male bus bar contact and ensure that
blue matching is successful
e Check manual spring charging is functional and
check the local operation of circuit breaker
f Carryout a closing-opening cycle and an opening-
closing-opening cycle of operation manually and
check that CB is functional and no abnormality is
noticed. Check that CB open/close status
indicator and spring charged/uncharged status
indicator is functional
g Check and ensure that auxiliary contacts for CB
status (closing/opening) indication (KFA1 &
KFA5) are functional
h Check and ensure the functioning of mechanical
interlocks
1 Check electromagnetic locks of CB truck and
earthing switch are functional
2 Check that CB cannot be racked into service
position if it is closed
3 Check that CB cannot be taken out of service
position if it is closed
4 Check that CB cannot be closed if it is in
intermediate position i.e. between service position
Page 66 of 123
and test position

5 Check that earthing switch cannot be closed if CB
is in service position
6 Check that if CB is moved from test position to
service position when it is closed, CB trips
immediately
7 Check that if CB is moved from service position to
test position when it is closed, CB trips
immediately
8 Check that earthing switch driving rod can be
inserted into the drive slot only after releasing of
electromagnetic lock
9 Check that earthing switch drive blocking casing
cannot be opened if circuit breaker is in service
position
10 Check that when earthing switch is closed then
earthing switch drive blocking casing cannot be
closed
11 Check that breaker can be rolled out of service
position only after releasing electromagnetic lock
12 Check that circuit breaker cannot be racked into
service position if earthing switch is closed
k Check contact changeover of test position limit
switch, service position limit switch & earthing
switch operation limit switch
l Insert the plug into the socket for control circuit
connection between fixed portion of cubicle and
the CB truck; check that the plug can be inserted
in only one position i.e. correct position
Page 67 of 123
2 Contact resistance check

a Close the circuit breaker and measure the contact
resistance between upper pole and lower pole for
each phase
i) R-R’
ii) Y-Y’
iii) B-B’
b Rack in the circuit breaker into service position
and check the contact resistance of upper and
lower cluster contacts respectively with bus bars
for each phase separately. Also measure the
contact resistance from upper bus to lower bus
with circuit breaker in closed position
a) Upper R – Lower R
b) Upper Y – Lower Y
c) Upper B – Lower B
c Check contact resistance between circuit breaker
body (foot paddle) and switchgear base frame.
Contact resistance should be less than 0.1 ohm.
3 Insulation resistance checks
a Measure the insulation resistance between upper
and lower contacts with CB in open condition for
each phase with 5000V megger
i) R phase to R phase
ii) Y phase to Y phase
iii) B phase to B phase
b Measure the insulation resistance between phase
to earth for each phase with circuit breaker in
close condition with 5000V megger.
Page 68 of 123
i) R to earth
ii) Y to earth
iii) B to earth
c Measure the insulation resistance between phase
to phase with CB in close condition with 5000V
megger.
i) R phase to Y phase
ii) Y phase to B phase
iii) B phase to R phase
4 CB coils & spring charging motor checks

a Measure the insulation resistance of spring
charge motor at 250V
b Measure the insulation resistance of closing coil
at 250V
c Measure the insulation resistance of tripping coil-
1 at 250V
d Measure the insulation resistance of tripping coil-
2 at 250V
e Measure the winding resistance of spring
charging motor
f Measure coil resistance of closing coil
g Measure coil resistance of trip coil-1
h Measure coil resistance of trip coil-2
5 Spring charging time & CB timing checks

a Measure the spring charging time at 70%, 100% 70%
& 110% of 110V DC respectively across spring 100%
charging motor in seconds 110%
Page 69 of 123
b Measure the closing time of CB using CB timing R Y B

kit at 70%, 100% & 110% of 110V DC 70%
respectively across closing coil. Note down 100%
closing time of each pole in mill seconds 110%
c Measure the CB opening time using CB timing kit R Y B
at 70%, 100% & 110% of 110V DC respectively 70%
across trip coil-1. Note down opening time of 100%
each pole in mill seconds 110%
d Measure the CB opening time using CB timing kit R Y B
at 70%, 100% & 110% of 110V DC respectively 70%
across trip coil-2. Note down opening time of 100%
each pole in mill seconds 110%
6 Anti pumping & trip free feature checks
a Insert the CB trucks into the cubicle. Press the
close PB and keep it pressed, the CB closes.
Now press the trip PB, the CB trips, but does not
close again. Now release the close PB and then
again press it, the CB closes now.
b Check the trip free feature of the CB. Press the
trip PB and keep it pressed, breaker opens. Now
press the close PB and check that mechanism
operates to close the CB but CB do not close.
Acceptance criteria:
a) Accepted contact resistance of various capacity circuit breakers are as
follows,
Sl. No. Circuit breaker type Nominal current Contact
rating in Ampere resistance in
micro-ohm
1 VD4 1250
Page 70 of 123
b) Coil resistance of close coil, trip coil 1 & 2 should be 1.1K ohms.
c) Spring charging time for 70% to 110% of 110V DC should be between
6 to 7 sec.
d) Circuit breaker closing time for 100% of 110V DC should be between
60 to 70 msec.
e) Circuit breaker tripping time for 100% of DC should be between 40 to
50 msec.
11. Remarks:
Page 71 of 123
ANNEXURE –11
CHECKLIST FOR CURRENT TRANSFORMER CHECKS
1. Switchgear code:
2. Cubicle code:
3. Make of current transformer:
4. Location:
5. Date of check:
7. Testing of instrument details:

No. number
Sl. No. Description of checks Observations

1 CT make
2 CT model
3 Note down CT name plate in the below table
Phase Ratio Burden V Knee ( V) I Magn (MN) Accuracy

( VA ) class
Core Core Core Core Core Core Core 1 Core 2
1 2 1 2 1 2
Page 72 of 123
RØ
T11/12
YØ
T21/22
BØ
T31/32
4 Inspect the CT for any breakages, damages, improper
mounting / clamping
5 Verify the wiring as per drawing of the CT secondary and
earthing with respect to the scheme
6 Check for earthing as per scheme
7 Interchanging of CTs among protection CTs and measuring

CTs shall not be done even if VA rating is same
8 Measure secondary winding resistance
Core RØ YØ BØ
Core1
In m Ω
Core 2
In m Ω
9 Carryout IR measurement at __V of CT for secondary to earth & primary to
secondary respectively
Core R-phase Y-phase B-phase
Core-1
prim to
sec
Core-1
sec to
earth
Page 73 of 123
Core-2
prim to
sec
Core-2
sec to
earth
10 Using a battery operated polarity tester, check that positive
emf is induced between S-1 to S-2 terminal when a
positive current pulse is applied between P-1 to P-2
11 Using a primary injection test kit, inject rated primary currents into the P1 & P2
terminals. Measure these currents and those flowing out of CT secondary
terminals. Tabulate the readings. Calculate the ratio and compare with these name
plate ratio (Ratio error should not be more than 2% at specified temperature)
Current applied Current measured Ratio %error
In primary In secondary
Core-1 Core-1 Core-1 Core-1
R Y B R Y B R Y B R Y B
Current applied Current measured Ratio Core-2 % error Core-2

In primary Core-2 In secondary Core-
Page 74 of 123
2
R Y B R Y B R Y B R Y B
12 For protection class of CT carry out saturation test as follows,

Using a 1 phase variac; apply increasing voltages across the CT secondary
winding. Increase the voltage up to Vk/2 mentioned on CT name plate. Note the
voltage applied and the current flowing into the CT secondary at each step of
increase in the voltage. Voltage increase may be up to 10% higher than the rated
Knee point voltage at the output of step up transformer. Draw a graph with voltage
and current as the x and y-axis respectively and incorporate the tabulated readings
into the graph. When an increase in the current by 50% is observed for an
increase in the voltage by 10%, V knee is said to have been reached. The
magnetizing current Im at voltage Vk/2 shall be within the limit as mentioned on CT
name plate.
Voltage
Core 1 secondary current at Core 1 secondary current at
applied at
increasing decreasing
secondar
secondary voltage secondary voltage
y
R Y B R Y B
Page 75 of 123
Voltage Core 2 secondary current at Core 2 secondary current at

applied at increasing decreasing
secondar secondary voltage Secondary voltage
y
R Y B R Y B
13 Measure winding resistance of CBCT

14 Check the polarity of secondary winding of CBCT
15 Measure IR value from sec to earth at 1000V
16 Test the CBCTs (core balance current transformers) for ratio as follows, Pass the
known current to any one phase of primary and measure the current in the
secondary of CBCT
Current applied in Current measured Ratio % Error
primary in secondary
Page 76 of 123
17 Test the measurement CTs for primary injection with burden connected into
secondary
Current applied in Current measured Expected current % Error
primary in meter
18 Ensure that spare secondary terminals (if any) is shorted

and earthed
9. Remarks:
Page 77 of 123
ANNEXURE –12
CHECKLIST FOR POTENTIAL TRANSFORMER CHECKS
1. Switchgear code:
2. Cubicle code:
3. Make of potential transformer:
4. Location:
5. Date of check:

No. number

No.
1 Make of PT
2 Model number of PT
3 Note down the name plate details of PTs
R-phase Y-phase B-phase
Sl. No.
Accuracy
class
Page 78 of 123
V.A
4 Inspect PTs for any breakages, damages, improper

mounting / clamping
5 Check that the fuses at the primary and the
secondary are as per WD and check that fuse is OK
6 Check the primary fuse resistance value
7 Check winding resistance of primary winding

a) R phase
b) Y phase
c) B phase
8 Check winding resistance of primary winding
Core 1
a) R phase
b) Y phase
c) B phase
Core 2
a) R phase
b) Y phase
c) B phase
Core 3
a) R phase
b) Y phase
c) B phase
9 Take the IR value of the PT secondary winding RØ YØ BØ
using a 500V megger (IR should be more than 1000
M ohms)
Page 79 of 123
Core 1 – Earth
Core 2 – Earth
Core 3 – Earth
Core 1 – Core 2
Core 2 – Core 3
Core 3 – Core 1
10 Take IR value of primary at __V (IR should be more RØ YØ BØ
than 1000 M ohms)
Primary –Earth
Primary – Core 1
Primary – Core 2
Primary – Core 3
11 Using a battery operated polarity tester, check that

positive emf is induced between S1 to S2 terminal
when a positive current pulse is applied between P1
to P2
12 Conduct ratio test by applying 11KV across the

Primary with 11KV/240V step up transformer. Note voltage at secondary.
Tabulate and compare the values with the nameplate values & manufacturers
documents
Page 80 of 123
Sl. Primary Secondary core1 Ratio % error

No. voltage voltage
R Y B R Y B R Y B
Sl. Primary Secondary core2 Ratio

No. voltage voltage % error
R Y B R Y B R Y B
Sl. Primary Secondary core3 Ratio % error

No. voltage voltage
9. Remarks:
Page 81 of 123
ANNEXURE –13
CHECKLIST FOR ELECTROMAGNETIC LOCKS, LIMIT SWITCHES, CIRCUIT
BREAKERS, FUSES, RESISTANCES & INDICATION LAMPS CHECKS
1. Switchgear code:
2. Cubicle code:
3. Location:
4. Date of temperature:
No. number
No.
2 Check the electromagnetic lock for earthing switch
interlocks
3 Check the electromagnetic lock for circuit breaker
position interlocks
4 Check the limit switch of test position
5 Check the limit switch of service position
6 Check the limit switch of earthing switch
7 Check the circuit breakers/Contactors in control
circuits
8 Check the fuses in control circuit/ lighting/heating
circuit
Page 82 of 123
9 Check the resistances in control circuit

10 Check the heater functions
11 Check the indication lamps
12 Check the operation of electromagnetic lock
manually and also by supply DC voltage
13 Check the operation of test position limit switch
manually and check the contact changeover
14 Check the operation of service position limit switch
15 Check the operation of earth switch limit switch
16 Check the operation of switches/circuit breakers
manually and check contact changeover
17 Check the resistance value and insulation resistance
of heaters
8. Remarks:
Page 83 of 123
ANNEXURE –14
CHECKLIST FOR ABB IED RELAY CHECKS
1. Switchgear code:
2. Cubicle code:
3. Make of relay:
4. Location:
5. Date of check:
7. Testing instrument details

No. number

No.
1 Check the relay for visual inspection for any physical
damage
2 Note down the model no. of the relay
3 Note down the serial no. of the relay
4 Note down the relay bar code
Page 84 of 123
5 Check the external wiring of relay as per WD
6 Measure IR value of control circuit by 250V
7 Switch on the auxiliary power supply and measure the

voltage at the relay terminals
8 Check the date, time and correct if deviated from the
local time
9 Check time maintained when auxiliary supply is Yes/No
removed
10 Check relay healthy LED glowing or not
11 Check for all LED’S functionality located on the front
panel
12 Check all binary inputs status by simulating and
resetting the inputs as per WD.
13 Check all output relay contact changeover by forcing
through keypad OR giving corresponding input as per
WD.
14 Ensure CT,PT details fed to the relay are correct
15 Check measurement function of relay:-
Inject gradually up to the rated current/voltage of each phase inputs and
compare the displayed value with the applied one
Applied Displayed current Applied Displayed
current voltage voltage
Page 85 of 123
16 Check whether specific function settings applied or

not. Enter the settings if deviated from the setting
sheet. Setting sheet enclosed as annexure- 29 shall
be filled.
17 Check that only those protection settings are enabled
which are applicable to the particular feeder. All other
protections are disabled.
18 Inject current, voltage at analog input terminals or initiate binary inputs as per the
setting values and check the actuation of output relays, indicating LED’S
configured to the corresponding protections
Protection Rated Output relay Confirm Resetted
parameter Actuated LED Yes/No
Yes/No Indication
And LED No.
50
50N
51
51N
27A
27B
59A
59N
51B
50BF
51B
30
95
Page 86 of 123
9. Remarks:
Page 87 of 123
ANNEXURE –15
CHECKLIST FOR IED RELAY TEST FOR INCOMER, VFD TRANSFORMER &
BUS COUPLER PANEL
1. Switchgear code:
2. Cubicle code:-
3. Make of relay:
4. Location:
5. Date of checks:

No. number

No.
A Relay make
B Relay model
C Relay serial number
d Check the relay by visual inspection for any
Page 88 of 123
physical damage
E Check the external wiring as per WDs
F Check the contact status as per WDs
G Set the parameter as per relay setting sheet
H Switch ON the auxiliary power supply and find relay

healthiness
I Measure the terminal voltage of auxiliary supply
J Note down the final setting
9.Current Measurement Checks

Measured current by relay in Amps
Current
Phase Ref Protection core
Applied Remarks
Ia Ib Ic
Ia
Ib
Ic
10. Voltage Measurement checks: (63.5V is applied to all phases with

respect to neutral)
Measured voltage by relay in volts
R-N Y-N B-N R-Y Y-B R-B
11. Overcurrent Protection

11.1 Instantaneous Overcurrent Protection (50)
Page 89 of 123
Set Current Injected Operated

Phases Pickup(A) Set time (s)
(A) Current(A) Time(mS)
RYB
11.2 IDMT Overcurrent Protection (51) ; Curve:

Set Current Current Inj Actual Operated
Curve Tp (TMS)
(A) (A) Time(s) Time(mS)
12.Earth fault Protection

12.1 Instantaneous Earth fault Protection (50N)
RYB
12.2 IDMT Earth fault Protection (51N)

RYB
13.CB Failure Protection (50BF)

RYB
13.2 Instantaneous Earth fault Protection (50N)
Page 90 of 123

RYB
14. Remarks:
Page 91 of 123
ANNEXURE –16
CHECKLIST FOR IED RELAY TEST FOR BUS PT AND BRBPT PANEL
1. Switchgear code:
2. Cubicle code:
3. Make of relay:
4. Location:
5. Date of check:

No. number
No.
A Relay make
B Relay model
D Check the relay by visual inspection for any physical

damage
e Check the external wiring as per WDs
Page 92 of 123

healthiness
9.Measurement Checks
Phase Voltage Voltage measured in relay
Ref Applied Ua-b Ub-c Uc-a Ua Ub Uc
Ua-b
Ub-c
Uc-a
10.Undervoltage Protection (27A)

Stage 1:
Pick
Volt up Applied Time Trip
R/Y/B
set(V) Volt Volt set(S) time(ms)
(V)
10.1Undervoltage Protection (27B)

Stage 2:
R/Y/B Volt Pick up Appli Time Trip
Page 93 of 123
set(V) Volt (V) ed set(S) time(ms)

Volt
11.Over voltage Protection (59A)

Stage 1:
Trip
Volt Pick up Applied Time
R/Y/B time(
set(V) Volt (V) Volt set(S)
ms)
11.1Over voltage Protection (59B)

Stage 2:
Trip
R/Y/B time(
ms)
12.Residual Over voltage Protection (59N)

Trip
R/Y/B time(
ms)
13. Remarks:
Page 94 of 123
ANNEXURE –16A
CHECKLIST FOR IED RELAY TEST FOR BUS PT AND BRBPT PANEL
1. Switchgear code:
2. Cubicle code:
3. Make of relay:
4. Location:
5. Date of check:

No. number

No.
A Relay make
B Relay model
d Check the relay by visual inspection for any physical
Page 95 of 123
damage
E Check the external wiring as per WDs

healthiness

Phase Current
Protection core
Ref Applied Remarks
Ia Ib Ic
Ia
Ib
Ic
10.Busbar Differential Protection (51B)

Set Set
Injected Operated
Phases Current Pickup(A) time
Current(A) Time(mS)
(A) (s)
R
Y
B
Page 96 of 123
11. Remarks:
Page 97 of 123
ANNEXURE – 17
CHECKLIST FOR IED RELAY TEST FOR TRANSFORMER FEEDER PANEL
1. Switchgear code :
2. Cubicle code :
3. Make of the relay :
4. Location :
5. Date of check :
6. Ambient temperature :
7. Testing instrument details :

No. number

No.
a Relay make
b Relay model
c Relay serial number
d Check the relay by visual inspection for any physical

damage
Page 98 of 123
f Check the contact status as per WDs
g Set the parameter as per relay setting sheet
h Switch ON the auxiliary power supply and find relay

healthiness
i Measure the terminal voltage of auxiliary supply
j Note down the final setting

Phase Current
Protection core
Ref Applied Remarks
Ia Ib Ic
Ia
Ib
Ic
10. Voltage Measurement checks: (63.5V is applied to all phases with respect to
neutral)
Measured voltage by relay in volts
R-N Y-N B-N R-Y Y-B R-B
11. Overcurrent Protection

RYB
Page 99 of 123
11.2 IDMT Overcurrent Protection (51) ; Curve:

Set Current Actual Operated
Curve Current Inj (A) Tp (TMS)
(A) Time(s) Time(mS)
12.Earth fault Protection

12.1 Instantaneous Earthfault Protection (50N)
RYB
12.2 IDMT Earthfault Protection (51N)

RYB
13.CB Failure Protection (50BF)

RYB
13.2 Instantaneous Earthfault Protection (50N)

RYB
Page 100 of 123

14.Trip Circuit Supervision Relay (95)

TCSR Operated
Set time (ms) Remarks
(On/Off) Time(mS)
9. Remarks:
Page 101 of 123

ANNEXURE – 17A
CHECKLIST FOR IED RELAY TEST FOR TRANSFORMER FEEDER PANEL
1. Switchgear code :
2. Cubicle code :
3. Make of the relay :
4. Location :
5. Date of check :
6. Ambient temperature :
7. Testing instrument details :

No. number

No.
A Relay make
B Relay model
D Check the relay by visual inspection for any physical

damage
Page 102 of 123


healthiness
9. Standby Earth Fault Protection.

Set
Operate Operated
Current Set time (ms) Remarks
Current (A) Time(mS)
(A)
Page 103 of 123

ANNEXURE – 18
CHECKLIST FOR VOLTMETER CHECKS
1. Switchgear code:
2. Cubicle code:
3. Make of voltmeter:
4. Location:
5. Date of check:

No. number

No.
1 Make
2 Model
3 Range of operating voltage/current
4 Range of measurement
5 Accuracy class
Page 104 of 123

6 Check there is no physical damage
7 Check insulation resistance of terminals
8 Applied input Expected output Measured output % Error

Parameter voltage voltage
0%
25%
50%
75%
100%
Acceptance criteria: Maximum admissible error is ±1.5%
9. Remarks:
Page 105 of 123

ANNEXURE – 19
CHECKLIST FOR AMMETER CHECKS
1. Switchgear code:
2. Cubicle code:
3. Make of ammeter:
4. Location:
5. Date of check:

No. number

No.
1 Make
2 Model
3 Range of operating voltage/current
4 Range of measurement
5 Accuracy class
Page 106 of 123

6 Check there is no physical damage
7 Check insulation resistance of terminals
8 Applied current Expected output Measured output % Error

current current
Acceptance criteria: Maximum admissible error is ±1.5%
9. Remarks:
Page 107 of 123

ANNEXURE –20
CHECKLIST FOR LOGICS & INTERLOCKS CHECKS
ON WORKING SUPPLY INCOMER,BUS PT CUBICLE,OUTGOING FEEDER
1. Switchgear code:
2. Cubicle code:
3. Feeder description:
4. Location:
5. Date of check:

No. number

No.
1 Ensure that installation checks are completed as per
annexure-2 and no deficiency exists
2 Ensure bus duct checks are completed as per
3 Ensure that cabling and connections checks are
completed as per annexure-4 and no deficiency
exist
Page 108 of 123

4 Ensure that internal wiring checks are done as per

WDs and no deficiency exists
5 Ensure that circuit breaker is checked as per
6 Ensure that relays are tested as per their testing
procedure attached in annexure 14, 15, 16, 16A,
17,17A and no deficiency exists
7 Ensure that meters are checked as per their testing
procedure attached in annexure 18, 19, and no
deficiency exists
8 Ensure that current transformers are tested as per
9 Ensure that potential transformers are tested as per
10 Ensure that electromagnetic locks, limit switches,
circuit breakers, resistances, heaters and indication
lamps are tested as per annexure-13 and no
deficiency exists
14 Interlocks check
(a)
(b)
c)
d)
e)
Page 109 of 123

9. Remarks:
Page 110 of 123

ANNEXURE –21
CHECKLIST FOR PRE-COMMISSIONING CHECKS ON INCOMER AND BUS VT
CUBICLES
1. Switchgear code:
2. Cubicle code:
3. Make of VT:
4. Location:
5. Date of check:
No. number

No.
1 Note down WD number of the main/standby VT feeder
2 Clean the VT compartment completely and ensure that no
foreign materials are left inside
3 Check bill of material and ensure that all the components
are existing as per WDs
4 Check and note down details of VT fuse e.g. type, make etc
5 Check and ensure that the internal wiring and control circuit
are as per WDs and ensure tightness of wires
Page 111 of 123


drawing and check the continuity of each wire. Remove all
extra / unwanted wires and ensure tightness of wires.
8 Check that monitoring and indication circuit is wired as per
drawing. Check the continuity of each wire
9 Check the IR value of circuit at 50V
10 Check the VT as per annexure-25
11 Test the ABB IED digital relays as per annexure-
14,15,16,16A,17,17A
12 Test voltmeters as per annexure-18
13 Test ammeters as per annexure-19
14 Test CT as per annexure-11
15 Test PT as per annexure-12
16 Test of electromagnetic locks, limit switches, miniature
circuit breakers, fuses, resistances, heaters & indication
lamps as per annexure-13
9. Remarks:
Page 112 of 123

ANNEXURE –22
CHECKLIST FOR VT CHECKS
1. Switchgear code:
2. Cubicle code:
3. Make of VT:
4. Location:
5. Date of check:

No. number

No.
1 Inspect the VT for any physical damage &
missing of parts
2 Cleanliness of all the insulators surface with dry
cloth
3 Check and ensure lubrication of all the linkages,
moving / sliding parts as per manufacturer’s
instructions
4 Check blue matching of the female cluster
contact with male bus bar contact and ensure that
Page 113 of 123

blue matching is successful

5 Check and ensure functionality of MCB of VT
secondary
6 Check and ensure the functioning of mechanical
interlocks
Check and ensure that earthing switch cannot be
closed if VT is in service position
Check and ensure that earthing switch driving rod
can be inserted into the drive slot only after
releasing of electromagnetic lock
Check and ensure that earthing switch drive
blocking casing cannot be opened if VT is in
service position
Check and ensure that when earthing switch is
closed then earthing switch drive blocking casing
cannot be closed
Check and ensure that VT cannot be racked into
service position if earthing switch is closed
7 Check contact changeover of test position limit
switch, service position limit switch & earthing
switch operation limit switch
8 Winding resistance checks
1. Measure the prim winding resistance
2. Measure the secondary winding resistance
9 Insulation resistance checks at 2.5KV
1. IR value between primary to earth
2. IR value between secondary to earth
3. IR value between primary and secondary
10 Conduct ratio test by applying 11KV across the
Page 114 of 123

primary with 11KV/240V step up transformer.

Note voltage at secondary. Tabulate and
compare the values with the nameplate values &
manufacturers documents
11 Check and note down details of fuse of VT
12 Check contact resistance between VT body (foot

paddle) and switchgear base frame (should be
less than 0.1 ohm)
9. Remarks:
Page 115 of 123

ANNEXURE –23
CHECKLIST FOR PRE-COMMISSIONING CHECKS ON OUTGOING FEEDERS
1. Switchgear code:
2. Cubicle code:
3. Load code:
4. Load description:
5. Date of check:
7. Testing instruments details:
No. number
No.
1 Note down WD number of the outgoing feeder
2 Check and clean the breaker compartment
completely and ensure that no foreign materials are
left inside
3 Check bill of material and ensure that all the
components are existing as per WDs
4 Check and ensure that the internal wiring and
control circuit are as per WDs and ensure tightness
of the wires.
Page 116 of 123

drawing and check the continuity of each wire and

check tightness of wires. Remove all extra /
unwanted wires
7 Check that monitoring and indication circuit is wired
as per drawing and check tightness of the wires.
Check the continuity of each wire
8 Check the IR value of circuit at 50V
9 Check circuit breaker as per annexure-10
10 Test the ABB IED digital relays as per annexure-14
11 Test electromagnetic differential relays as per
annexure-15
12 Test electromagnetic current/voltage/frequency/timer
relays as per annexure-16
13 Test electromagnetic auxiliary relays as per
annexure-17
17 Test voltmeters as per annexure-18
18 Test ammeters as per annexure-19
19 Test current transformers as per annexure-11
20 Test potential transformers as per annexure-12
21 Checks Electromagnetic locks, Limit switches,

circuit breaker, fuses, resistances, heaters &
indication lamps as per annexure-13
9. Remarks:
Page 117 of 123

ANNEXURE –24
CHECKLIST FOR ENERGISATION OF SWITCHGEAR
1. Switchgear code:
3. Location:
4. Date of check:

No. number

No.
1 Check and ensure that installation checks as per 4.1 are
completed and no deficiency exits
2 Check and ensure that checks on bus duct as per 4.2 is
3 Check and ensure that cabling and connection checks as
per 4.3 are completed and no deficiency exits
4 Check and ensure that interfacing checks as per 4.4 is
5 Check and ensure that pre-commissioning checks on
11KV switchgear (excluding working supply and standby
Page 118 of 123

supply incomers, PT cubicle & outgoing feeders) are

completed as per 4.5 and no deficiency exists
main and supplementary VT is completed as per 4.7 and
no deficiency exists
outgoing feeders are completed as per 4.8 and no
deficiency exists
8 Rack in main or standby incomer circuit breakers into
service position and keep it “OFF”
9 Rack in main and supplementary voltage transformers
into service position
10 Rack out standby incomer or main incomer and all the
outgoing feeders into service position and keep it “OFF”.
Put “DO NOT OPERATE TAG” to standby incomer or
main incomer and all the outgoing feeders
11 Reset all the relays and note the position of flag or LEDs
indication of relays is as per scheme
12 Charge the transformer feeding the 11KV switchgear.
Ensure 11KV is available up to the PTs in the switchgear
and 11KV voltage is indicated in the incomer cubicle
relay/voltmeter
13 Switch ON main incomer and check the availability of all
three phase voltage in voltmeter
14 Monitor the following parameters
Sl. Type of check Values achieved

No
Initial ½ hr 1 hr 1½ hrs 2 hrs
Page 119 of 123

(i) Bus voltage
(iii) Any abnormality
(iv) Any
annunciation/ala
rm
(v) Any tripping
8. Remarks:
Page 120 of 123

ANNEXURE –25
CHECKLIST FOR RELAY SETTINGS CHECKS
1. Switchgear code:
2. Cubicle code:
3. Load description:
4. Date of check:
Cubicle No: Relay designation:

Recomme
Sl. As found
Address/Group Parameter nded Comments
No. setting
setting
Page 121 of 123

Page 122 of 123

6. Remarks:
Page 123 of 123

Pre Commissioning & Commissioning - Procedure & Test Reports - MV Switchgear

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PROJECT: 2X35 MW PEAT FIRED POWER PLANT

DOCUMENT No: SPEPC.RWANDA.11KV.CP01

Prepared by Checked by Reviewed by Approved by

REVISION CONTROL SHEET

switches, miniature circuit breakers, fuses,

Resistances & Indication lamps checks

3.0 Pre-requisites & initial conditions:

6. 110 V DC power supply for control & protection of 11KV switchgears is

3.2 System requirements:

3.4 Test instruments and other materials requirement

3.5 Requirement of outside agencies:

3.6 Hazards and special precautions:

3. 11KV switchgear shall be connected to station grounding grid at two

4.0 General Methods:

4.4 Interfacing checks:

Nominal bolt thread Tightening torque N-m

10. Box up bus bar chamber.

4.6 Pre-commissioning checks on working supply incomers:

h. Check and ensure that auxiliary contacts for CB status

Sl. No. Circuit breaker type Nominal current Contact resistance

v. Spring charging time & CB timing checks:

m. Measurement CTs shall be tested for primary injection with burden

E. Testing of potential transformers:

c) Check the operation of electromagnetic lock manually and also by

i) Ensure that potential transformers are tested as per annexure-12 and

b. Clean the VT compartment completely and ensure that no foreign

ii. Monitoring and indication circuit checks

5. Check and ensure that earthing switch cannot be closed if CB is in

ii. Contact resistance check:

Sl. No. Circuit breaker type Nominal current Contact resistance

1 VD4 1250 As recommended

iv. CB coils & spring charging motor checks:

v. Spring charging time & CB timing checks:

f. Interchanging of CTs among protection CTs and measuring CTs shall

a. Checklist for checks on potential transformer enclosed as annexure-12

h. Check the resistance value and IR value of heaters

5.0 Energisation of switchgear:

8. Check and ensure that pre-commissioning checks on outgoing feeders are

6.0 Design intents:

7.0 Test report formats:

9.0 List of annexures:

Annexure -1 List of 11KV switchgears

Annexure-18 Checklist for voltmeter checks

LIST OF 11KV SWITCHGEARS

S.NO PANEL NUMBER PANEL IDENTIFICATION ABB DOC. NO.

CHECKLIST FOR INSTALLATION CHECKS

Sl. Description of checks Observation

i. Check and ensure electromagnetic lock of earthing

4 Check that the MS base frame is welded to EP as per WD

to station grounding grid at two points

Sl. Description of checks Observation

5. IR TEST 5KV DC for 60sec

IR value Before HiVolt Test IR value After HiVolt Test in

6. HIGH VOLT TEST

Condition Applied KVAC f0r 60sec Measured mA

Sl. Instrument Make & Serial Calibration valid up to

Sl. Description of checks Observations

3 Check and ensure spare cores of control cable

Sl. Description of checks Observation

FBT panel/DCS and ensure that continuity, correct

9 Check interfacing cabling between 11KV switchgear and

between phases and earth and record the results in

with 250V megger