PRE COMMISSIONING TEST PROCEDURE FOR SWITCH GEAR

1.0 SCOPE
This procedure covers the Pre commissioning Test for Switchgears

2.0 PURPOSE
 This procedure is prepared to carry out various pre- commissioning tests to be conducted in
systematic manner for Switchgears to ensure the healthiness and performance of the Switchgear.

3.0 PRE-REQUISITES
3.1 SYSTEM REQUIREMENTS
1. Relevant Drawings and layouts.
2. 415 V AC, 3 Ph power supply is available for Testing.
3. All Cables pertaining to switch gear were laid & terminated.
4. Make sure that the Switchgear erected is as per approved drawings & Layouts.
5. Check the Name Plate & Rating Plate Of the Switchgear.

4.0 REQUIREMENTS OF TESTING KITS

S.No Testing Kit Range
1 Contact resistance kit with test leads 0 – 2000milliohm
2 Secondary injection kit with test leads 0 – 100A
3 Three pole timer with test leads 0 – 99sec
4 Primary injection test kit with test leads 0 – 2000A
5 High voltage transformer with test kit 0 – 5kV

5.0 REQUIREMENT OF TESTING INSTRUMENTS

1. Digital Multi meter.
2. 500 V, 1000 V Insulation Tester
3. Milli amp meter
4. 3 Ph- A.C Supply Extension Board with MCB Protection.

1.0 HAZARDS AND PRECAUTIONS

1. Unauthorized persons should not be allowed to enter Testing Area.
2. Barricade the Testing Area With Warning Tape
3. There should not be any temporary (hooking of supply) arrangement for Testing. Proper A.C
Supply extension board should be used
4. Ensure protection MCB is provided in the circuit of AC supply used for testing
5. Ensure Proper Tools & Tackles are Available for carrying out Tests.
6. Ensure Proper PPE ( Personal Protective Switchgears) are used
7. Ensure the Healthiness of the test leads (Check for any insulation Damages).
8. Competent Authority to maintain shutdown & Work permit system in existing Live Bay works.
 9. Any conducting element should be carried horizontally at waist level in the area used for pre-
commissioning tests.

7.0 POST INSTALLATION CHECKS

Post installation checks should be done according to the annexure enclosed.

8.0 TESTS TO BE CONDUCTED

1. Insulation Resistance Measurement Test.
2. Trip Coil/Close Coil Resistance Measurement of CB.
3. Opening/Closing Time Measurement Testof CB.
4. Main Circuit Contact Resistance Measurement Test for CB.
5. Pre commissioning Tests for Switchgear CT
6. Pre commissioning Tests for Switchgear PT.
7. Insulation resistance test for bus bar.
8. Contact resistance test for bus bar.
9. High voltage test for bus bar.

8.1 IR VALUE TEST

Aim:
To find the insulation resistance value of the equipments and ensure the performance of the
equipments based on the values obtained.
Equipments Required:
o Insulation tester.
o Test leads.
Test Procedure:
The above test is to be conducted at following points.
a) Control Circuit of switchgear Breakers
b) Main Circuit of Switchgear Breakers (pole)

a) Control Circuit of Breakers

i) Connect The Meggar across the various points on the control circuit after removing control coils
from circuit.
ii) Switch ‘ON’ the Meggar
iii) Take down the readings
Test Format For the above test are enclosed in Annexure-III
 b) Main Circuit of Breakers (pole)
i) Connect the Meggar across the Pole & Earth while Breaker on ‘Close’ Condition
ii) Switch ‘ON’ the Meggar
iii) Take down the readings

8.2 TRIP COIL / CLOSE COIL RESISTANCE MEASUREMENT TEST

Aim:
To find the value of trip and coil resistance across the respective coils and compare with the
factory approved values.
Equipments Required:
Multimeter.
Test Leads.
Test Procedure:
a) Select the Multi meter in Resistance Mode.
b) Connect the Multi meter across the Trip/Close coils.
c) Note down the readings
Test Format For the above test are enclosed in Annexure-III

8.3 OPENING / CLOSING TIME MEASUREMENT TEST

Aim:
To calculate the timing of the opening and closing of the breaker contacts and ensure that the
values are within acceptable limits.
Equipments Required:
o Single / three pole timer.
o Test leads.
Test Procedure:
a) Connect the Timer across the Breaks for the Opening Time
b) Connect the Timer across the Pole for the Closing Time/ “Close-Open” Time
 Test Format For The above Test In Enclosed in Annexure-III

8.4 CONTACT RESISTANCE MEASUREMENT TEST

Aim:
To calculate the value of the contact resistance and compare the value with the factory reports
and approve the equipment for further use.
Equipments Required:
o Contact resistance meter.
o Test leads.
Test Procedure:
a. Connect the CRM kit across the contact while Breaker in Close Condition.
i. Switch ON the test kit.

Fig 1 : Contact Resistance measurement

Test Format For The above Test In Enclosed in Annexure-III

8.5 TESTS FOR SWITCHGEAR CT

 1. Test Procedure for the above test can be obtained from CT testing procedures.(Whichever
applicable)
Test Format For The above Test In Enclosed in Annexure-IV

8.6 TESTS FOR SWITCHGEAR PT

1. Test Procedure for the above test can be obtained from PT testing procedures. (Whichever
applicable)
Test Format For The above Test In Enclosed in Annexure-V

8.7 INSULATION RESISTANCE TEST FOR BUS BAR

Aim:
To find the insulation resistance value of the equipments and ensure the performance of the
equipments based on the values obtained.
Equipments Required:
o Insulation tester.
o Test leads.
Test Procedure:
The above test is conducted at the following points,
a) Each phase and earth.
b) Between phase and phase.
a)Each phase and earth:
i. Connect the positive terminal of the meggar(5000V) to one phase.
ii. Connect the earth terminal of the meggar to the common earth terminal.
iii. Switch ON the meggar .
iv. Note down the reading in the annexure-VI
v. Similarly note down the reading for all phases and earth.
b)Between one phase to other:
i. Connect the positive terminal of the meggar(5000V) to one phase.
ii. Connect the earth terminal of the meggar to the other phase.
iii. Switch ON the meggar .
iv. Note down the reading in the annexure-VI
v. Similarly note down the reading for all phases.

8.8 CONTACT RESISTANCE MEASUREMENT OF BUS BAR

Aim:
 To calculate the value of the contact resistance and compare the value with the factory reports
and approve the equipment for further use.
Equipments Required:
o Contact resistance meter.
o Test leads.
Test Procedure:
The contact resistance measurement of each of the busbar is measured by the following method.
1) Ensure the required tightness of each bus.
2) Short one end of any two phases.
3) Now connect the CRM kit across the other end of the shorted phases.
4) Note down the reading in annexure –VII.
5) Repeat the test for other phases and ensure that the value is found similar in all the cases.

8.9 HIGH VOLTAGE TEST FOR BUS BAR

Aim:
To ensure that the bus bar withstands high voltage and to spot out minute defects in the busbar
and approve the bus for usage.
Equipments Required:
High voltage test kit.
Test leads.
Test Procedure:
The test is done by the following way.
i. Connect the positive terminal of the test kit to one phase.
ii. Short the other two phases to earth.
iii. Connect the earth terminal of the kit to the same earth point.
iv. Supply the rated high voltage to the bus.
v. Note down the reading in annexure – VIII.

ANNEXURE – I

Details of Switchgear

LOA No. :
 Make :

Type: :

Sl. No. :

Year of manufacture:

Operating Voltage:

Feeder details :

Control Voltage:

ANNEXURE – II
Post Installation check list

S. Description Status Remarks, Record

No. Yes No discrepancies, if any
1. Switchgear is cleaned and free from dust /
dirt, foreign materials etc.
2. Switchgearf is free from all visible defects
on physical inspection
3. Switchgear Panel has been provided with
double earth
4. All nuts and bolts are tightened correctly as
per specified torque
5. Switchgear erection is complete in all
respect
6. Permanent labelling and identification is
done
7. Levelling and alignment of switchgear and
base frame checked
8. Tightness of nuts bolts of Bus Bar are
checked
9. Auxiliary contacts and relays have been
cleaned and free from rust / damage
10 All spare wires terminated at the terminal
blocks
11. Erection completion certificate along with
list of outstanding activities reviewed

ANNEXURE – III

Circuit Breaker Test Report

Board Name Feeder

Description/No:
Rated Voltage Rated Current
 Sl. No. Year of mfg.
Make Closing Coil
Rating
Trip Coil Rating

i) Insulation Resistance Test –

Instrument Details Make

Calibration valid Instrument Sl. No.
upto

Phase Measured Between Insulation Resistance in Ms

R–E
R R`– E
R – R`
Y–E
Y Y`– E
Y – Y`
B–E
B B`– E
B – B`

ii) CB Operation Time Measurement –

Operation Pole
R Y B
Closing Time (msec)
Opening Time (msec)
Close-open Time (msec)

iii) Coil Resistance Measurement –

Instrument Details Make

Calibration valid Instrument Sl. No.
upto

Description Resistance in s
Closing Coil
Trip Coil
iv) Contact Resistance Measurement –

Instrument Details Make

Calibration valid Instrument Sl. No.
upto

Description Resistance in Milli s

R Pole
Y Pole
 B Pole

v) Mechanical Checks –

Description Remarks
CB rack in / out operation
CB rack in / out indications
Manual spring charging operation
Spring charged Indication
Manual ON / OFF operation
CB ON / OFF indication
Emergency Trip operation
Power contact alignment with panel contacts

vi) Electrical Checks -

Description Remarks
Spring Charging operation time (Secs)
Test / Service position switch
ON / OFF operation in Local / Remote
Spring charged Indication
CB ON / OFF indication
Lamp Indications

ANNEXURE – IV
Metering / Protection CT Test Report

Board Name Feeder Description

CT Details Make / Class
Core-1 Details Core-2 Details

CT Serial No.
R Ph Y Ph B Ph

i) CT Insulation Resistance Test –

Instrument Details Make

Calibration valid upto Instrument Sl. No.

(In Ms)
Description R Ph Y Ph B Ph
Primary to Earth
Primary to Secondary Core-1
Primary to Secondary Core-2
Secondary Core-1 to Earth
Secondary Core-2 to Earth
Secondary Core-1 to Core-2

ii) CT Secondary Winding Resistance Measurement –

Instrument Details - Make -

Calibration valid upto - Instrument Sl. No. -

(In s)
Description Terminal Nos. R Ph Y Ph B Ph
Secondary Core-1 1S1-1S2
Secondary Core-2 2S1-2S2

iii) CT Polarity Check –

Description Terminal Nos. R Ph Y Ph B Ph

Secondary Core-1 1S1-1S2
Secondary Core-2 2S1-2S2

iv) CT Ratio Test –

Description Ratio Primary Current Measured Secondary Current

Injected R Ph Y Ph B Ph
Secondary Core-1

Secondary Core-2

CT Check List

Sl. Check Point Remarks

No.
1 All CT quantity, rating, type & make are as per approved drawings.
2 No physical damage to any of the CT.
3 Inter-panel wiring from CTs to disconnector Terminal blocks in panel is as per
approved drawing.
4 CT secondary star point terminals are properly earthed at disconnector terminal
 blocks.
5 CT wiring ferrules are as per drawing.
6 All CT connections are properly tightened.

ANNEXURE – V

PT Test Report

Board Name Feeder Description/No:

PT Details Make / Class
Core-1 Details Core-2 Details

PT Serial No.
R Ph Y Ph B Ph

i) PT Insulation Resistance Test –

Instrument Details Make

Calibration valid upto Instrument Sl. No.

(In Ms)
Description R Ph Y Ph B Ph
Primary to Earth
Primary to Secondary Core-1
Primary to Secondary Core-2
Secondary Core-1 to Earth
Secondary Core-2 to Earth
Secondary Core-1 to Core-2

ii) PT Polarity Check –

Description Terminal Nos. R Ph Y Ph B Ph

Secondary Core-1
Secondary Core-2

iii) PT Ratio Test –

Description Ratio Primary Voltage Measured Secondary Voltage

Applied R Ph Y Ph B Ph
Secondary
Core-1

Secondary
Core-2
 PT Check List

Sl. Check Point Remarks

No.
1 All PT quantity, rating, type & make are as per approved drawings.
2 No physical damage to any of the PT.
3 Inter-panel wiring from PTs to disconnector Terminal blocks in panel is as per
approved drawing.
4 PT primary neutral terminals are properly earthed.
5 PT wiring ferrules are as per drawing.
6 All PT connections are properly tightened.
7 Primary Fuse rating is as per the drawing and fuses are healthy.

ANNEXURE – VI
INSULATION RESISTANCE TEST FOR BUSBAR

a)Phase to earth:

Connection R–E Y–E B–E

Resistance

b)Phase to Phase:

Connection R – Y Phase Y – B Phase R – B Phase

Resistance

ANNEXURE – VII
CONTACT RESISTANCE MEASUREMENT

Resistance of the lead used for shorting =__________

Connection R & Y Phase Y & B Phase R & B Phase

Resistance

ANNEXURE – VIII
HIGH VOLTAGE TEST

Rated voltage Test Voltage Test Voltage Duration in

KV Between Conductor Between Minutes
& Earth Conductor &
KV Conductor
KV
 0.6/1.1 3 3 15
1.9/3.3 5 9 15
3.3/3.3 9 9 15
3.8/6.6 10.5 18 15
6.6/6.6 18 18 15
6.35/11 18 30 15
11/11 30 30 15
12.7/22 37.5 - 15
19/33 60 - 15

Sl No Between Leakage Current Remarks

Y & B Phases &
1 R Phase & Earth
Earthed
R & B Phases &
2 Y Phase & Earth
Earthed
R & Y Phases &
3 B Phase & Earth
Earthed

Circuitry/Operational Checks

S. No. Circuit reference Circuitary checks Operational checks

Local Remote Local Remote
A Tripping of CB
B Closing of CB
C Breaker position indication
D Heater in switchgear
E Illumination in switchgear
F Incomer & Bus coupler
Interlock

Calibration Status Table

TEST INSTRUMENT DETAILS:
Sr Instrument description Range Calibration status
no