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Pre-Commissioning tests for SEC Transmission Electrical

equipments AECC

The Installation guide has been made according to SEC and IEC international Standards.

The Presentation guides the Electrical Engineers who have to inspect or maintain the electrical installations according to SEC standards on the Site.

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Installation guide

As a general practice, all equipments must be tested in the factory before delivery to the site.

Why we have to do pre-commissioning tests? Actually the pre-commissioning testing at site

is done to prove that: No equipment was subjected to any damage

during transportation. All equipment have been installed correctly. All equipment is working in coordination with the

other equipment. All protection schemes are working according to

specifications. AECC

All equipments have been installed properly according to SEC standards.

The installation is safe to put into service.

Purpose: To provide guide lines to the witnessing engineer

to organize work at site during pre-commissioning tests.

To provide minimum tests on the equipment by the Contractor.

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Procedure:

The procedure for the installation is divided into two parts

Organizing the work at site, during and after pre-commissioning tests.

Mechanical checks, inspections and electrical tests to be performed on the equipment before commissioning the equipment into service.

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The main purpose of this procedure is to make sure for the contractor how to apply and perform the pre-commissioning tests ensuring that

The project is ready for the test. The contractor is fully equipped from all aspects

to start the pre-commissioning tests on site. The time for witnessing the pre-commissioning

tests is at minimum duration with high quality performance.

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Organization of the work site for pre-commissioning

Project management shall confirm the readiness of Contractor in all aspects and a Joint Inspection shall be conducted with commissioning personnel and Contractor after written confirmation is received from the Project Management.

There are some points to be conducted by the Project management, given below

Confirmation letter Joint inspection (Contractor’s personnel) AECC

Project Management Responsibility

After confirmation, the witnessing can begin in two weeks with the following points.

Commissioning File Site instructions/record and project punch

list/Snag rectifications Sequence of Events (Includes every sheet

regarding to work for SEC)

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Witnessing Commencement

Commissioning Services Department Contract No. Project Title / Substation Number

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Joint Site Visit Checklist

S.N Requirements before starting of SEC witnessing Yes No N/A

1 Site Conditions

a. Testing area is free from all construction activitiesb. Adequate cleanliness and housekeeping.

c. There is no safety hazard in the testing area and its vicinity.d. Stable power supply is available for testing purpose.

e. Adequate cooling/heating arrangement as the case may be, isavailable in the control roomf. Required facilities for commissioning

g. Completion of major civil works including grounding

h. Completion testing grounding network.

I. Availability for emergency equipment's

j. All main equipments and devices

k. Minuets of meeting

Documents

Issuing Site Instructions: The site instructions contains following points

Equipment not fit for service Deviations from SEC specifications Poor work Quality Improper electrical scheme Updating of records Common punch list/Snags Clearing the Punch list

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Safety and Coordination meeting: Safety and coordination meeting contains

following points.

Definition Scope Purpose Policy

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Technical Problem Report: Technical problem report contains followings

Common manufacturer defect Common misunderstanding of SEC standard Common malpractice by the witness engineer Safety and protection problem

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Time and Quality Management: Time and Quality Management contains the

following points;

Check List Time Utilization Statistic Sheet Testing schedule Marked up Drawings Sample check (Optional)

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Uncontrollable Project Delay Form: Any delay which is out of CSD control and cause a

significant delay in the project commissioning planned completion date is called UPD.

UPD has the followings points: Scope Purpose Policy

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Readiness of Energization Report: Readiness of energization report to be filled by

the PCE (project commissioning Engineer) and he is responsible to send it to SEC commissioning Division Manager.

The official three signatures shall be included: Commissioning Head Engineer SEC project department engineer Contractor project manager

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FINAL PRE COMMISSIONING REPORT AND CONTRACTOR’S EVALUATION:

The final pre-commissioning report and contractor’s evaluation contains the following points (with brief description)

Final pre-commissioning report by commissioning engineer

Contractor’s evaluation by commissioning engineer using SEC format having quality and safety plan.

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IMPLEMENTATION & IMPROVEMENT :

For Commissioning process, the following steps should be given special consideration for implementation

An appropriate coordination is required with Project Management.

The major problems must be reported to the Commissioning Manager/Senior Engineer for further guidance.

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Commissioning Services Dep.

Contract No.

Contract Name

Project Title

Substation Name/No.

Contractor's performance Report

Category Very good Good Satisfactory

Needs Improv.

Unsatisfactory

Quality of work

25 21 19 15 11

Qualified Engineers

22 19 16 13 10

Punctuality 20 17 15 12 09Safety 15 13 11 09 07Cooperation 10 09 07 06 05

Proper tools & equipment

08 07 06 05 04

Total 100-93 92-80 79-68 67-54 53-46

Contractor’s Performance Sheet

The previous all slides were about the documentation for the pre-commissioning tests for the Electrical Equipments but in the coming slides we will discuss the SEC standards for the main equipments to be used for the S/S which contains Mechanical checks, Visual inspections and Electrical tests. AECC

INTRODUCTION: This Procedure describes the minimum tests and checks to

be performed during the pre-commissioning stage of SEC Transmission projects. It deals primarily with the pre-commissioning tests to be followed for protection schemes and main equipment such as cables, transformers and switchgear, etc., keeping in view the SEC standard practices.

PURPOSE: The main purpose of this Procedure is to present a list of

checks and tests to be performed on transmission equipment. They shall be performed by the contractor and witnessed by SEC Pre-commissioning personnel.

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MECHANICAL CHECKS, VISUAL INSPECTIONS AND ELECTRICAL TESTS

Here is the procedure for testing the main equipments according to SEC and IEC standards which will be followed by the given Points.

Name of the Equipment SEC and IEC standards Mechanical check and visual inspection Electrical tests with SEC and IEC standards

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PROCEDURE FOR TESTING OF MAIN EQUIPMENTS

(Standard Reference is: IEC 60076, SEC Transmission Relevant Specifications 53-TMSS)

Mechanical check and Visual Inspection1. Check the impact Recorder for any abnormal impact during Transportation. 2. Check all components are installed.3. Check nameplates information ( visible place )as per contract specifications.4. Check tightness of all bolts.5. Check the valves between the tank and radiator.6. Check the color and quantity of silica gel in breather and oil pot level. 7. Perform all of the manufacturer specific checks. Electrical Tests 1. Core Insulation Resistance at 1 kV DC.2. Winding Insulation Resistance and Polarization Index test at 5 kV DC. 3. Insulation power factor test for oil and bushing at 10 kV ac.4. Insulation resistance of control wires (1000 VDC for one minute).5. Magnetic balance test

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Oil Field Power Transformer

(Standard Reference is IEC 60076-6 and relevant SEC Transmission Specifications58-TMSS-0)

Mechanical check and Visual Inspection1. Check the impact Recorder for any abnormal impact during Transportation. 2. Check all components are installed.3. Check nameplates information (visible location) as per contract Specifications.4. Check tightness of all bolts.5. Check that the valves between the main tank and radiators are open.6. Check that all grounding is securely connected (two grounding connections to main tank are

required).7. Check that phase marking in cable box matches with GIS and cables. Electrical Tests1. Core Insulation Resistance Test at 1 kV DC2. Winding Insulation Resistance Measurement Test and Polarization Index (P.I.) Test at 5 kV DC.3. Winding Resistance Test. (winding temperature shall be recorded; winding resistance shall be

referred to 75°C).4. Inductance Measurement & Impedance measurement.5. Insulation power factor test for oil and bushing at 10 kV AC.

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Shunt Reactors

(Standard Reference is IEC 60044-1 and relevant SEC Transmission Specifications 50-TMSS-01, TES-P-119.28) Mechanical check and Visual Inspection1. Inspect for physical damage or defects.2. Check nameplate information for correctness.3. Check that outdoor secondary wiring terminations are installed in moisture proof enclosures.4. Check tightness of all bolted connections.5. Check that all grounding cables are securely connected.6. Check CT locations physically and secondary terminal labeling has been done correctly.

Electrical Tests1. Magnetizing current test.2. Winding resistance measurement. (Ambient temperature shall be recorded; winding resistance shall be

referred to 75°C).3. Phase identification test4. It is necessary to demagnetize the cores before each test5. Polarity test or flick test with battery. a. Primary to ground 5kV DC for one minute. b. Primary to secondary 2.5kV DC for one minute. c. Secondary to ground and core to core 1kV DC for one minute.

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Current Transformers

(Standard Reference is IEC 60044-2 and relevant SEC Transmission Specifications 50-TMSS-03, TES-P-119.28)

Mechanical check and Visual Inspection1. Inspect for physical damage or defects.2. Check nameplate information for correctness.3. Check that the HV connection does not transfer stress to the HV terminal.4. Check that all grounding cables are securely connected.5. Check integrity of primary fuses (if applicable).6. Gas leakage check for GIS VTs compartment

Electrical Tests1. Winding Resistance Test. (Ambient temperature shall be recorded; winding resistance shall be

referred to 75°C).2. Ratio Test & polarity test.3. Check VT HV neutral is solidly grounded.4. Insulation test as following: Primary to ground 5kV DC for one minute. Primary to secondary 2.5kV DC for one minute. Secondary to ground and core to core 1kV DC for one minute.

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Potential Transformers

(Standard Reference is ANSI/IEEE std 32 and relevant SEC Transmission Specifications 57-TMSS-01)

Mechanical check and Visual Inspection1. Check nameplate data against contract specifications.2. Check the value of resistance and current ratings against the specifications. 3. Test on NER HV side associated CT & power cable.4. Main circuits Resistance measurement test.5. Insulation resistance measurement test. at 5kV DC. >=1000 mega ohms6. Check the grounding resistance of the earth terminal and resistor earth terminal. <2 Ohms

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Neutral Earthing Resistors

(Standard Reference is IEC 62271-203 and IEC 62271-205 and relevant SEC Transmission. Specifications 32-TMSS-02 and

32TMSS-04) Mechanical check and Visual Inspection1. Inspect for physical damage or defects.2. Check nameplate information for correctness.3. Check quality of paintwork.4. Verify that all lifting devices are correctly labeled for lifting capability.5. Check SF6 gas at each gas section for air and moisture content after filling at rated pressure.6. Verify that correct Dispatch Numbers have been installed. 7. Ensure that all special tools and equipment are provided as specified and have proper storage. Electrical Tests1. Insulation resistance test for all low voltage wiring and cabling.2. Resistance of all ground connection joints at 100 A DC.3. Resistance of bus joints at 100 amperes DC.4. Overall resistance of the main circuit.5. All AC/DC MCBS shall be tested by trip test through current injection in each pole.6. Check Minimum control voltage trip (60%) and close (80%) operations.7. Every newly installed part of a GIS shall be subjected to HV test on site.

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Hybrid/Gas Insulated Switchgear

No. Rated Voltage for GIS Ur (kV)

On-Site Uds test 1 min. kV

On Site Ups test kV

1 72.5 120 2602 100 165 3603 123 200 4404 145 235 5205 170 270 6006 245 380 8407 300 380 8408 362 425 9409 420 515 114010 550 560 1240

On site test voltage (IEC 62271-203 @ 2003-11) for GIS

(Standard Reference is IEC 62271-100 and relevant SEC Transmission specifications 32-TMSS-01)

Mechanical check and Visual Inspection1. Inspect for physical damage or defects.2. Check nameplate information for correctness.3. Inspect all covers, panels section and doors for paint work and proper fit.4. Check operation of all mechanical interlocks.5. Check main and riser buses for correct phasing connections.6. Perform mechanical check and visual inspection on all circuit breakers, current transformer,

voltage transformer.7. For SF6 breakers, check the correct gas pressure. Quality and leakage. Electrical Tests1. Insulation resistance test of all wiring, cabling and auxiliary circuit in the panel.2. Functional test of all controls and interlocks.3. Bus continuity and phasing test.4. Insulation resistance test at 5 kV DC on all main circuit between phase to phase and phase to

ground (before HV test).5. Insulation test on all wiring at 500 V DC.6. Functional test of all electrical interlocks, anti pump circuits, alarm and indications.

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Metal Clad Switchgear

(Standard Reference is IEC 60623, clause Specifications 46-TMSS, TES-P-103)TCS-P-105, Rev. 014 and relevant SEC Transmission)

Mechanical check and Visual Inspection1. Inspect for physical damage or defects.2. Check nameplate information for correctness.3. Check that all cells are properly numbered.4. Check protective covers installed.5. Check that all battery maintenance tools and accessories have been provided.6. Check installation of safety equipment like eye washer, shower, No smoking signs. Electrical Tests1. For valve Regulated lead Acid Batteries, check the open circuit voltage of each cell.2. Perform initial charging of the battery.3. Fully recharge the battery according to the manufacturer’s instructions.4. Battery discharge test:a. The battery must not have been discharged within last 7 days before test is performed.b. While battery on float, read and record the voltage of each cell or unit and battery terminals float voltage.c. Disconnect the battery charger and any other load on the battery.d. Record the initial voltage of each unit and battery terminals.e. Select the discharge rate based upon the battery capacity.

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Station Batteries

(Standard Reference Is IEC 60623, Clause 4, and Relevant SEC

Transmission Specifications 46-TMSS, TES-P-103) Mechanical check and Visual Inspection1. Inspect for physical damage or defects.2. Check nameplate information for correctness as per standards.3. Check that all Alarm relays shall be auto-reset.4. Check tightness of all external wiring and cabling connections, labeling, drawing pocket shall be

checked. Electrical Tests1. Insulation test for all external wiring.2. Check output voltage ripple content (battery disconnected).3. Check regulation at 0%, 50 % and 100 % of full load.4. Calibrate voltmeters and ammeters.5. Check load sharing operation for parallel chargers.

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Battery Charger

(Standard Reference is relevant SEC Transmission Specifications 31-TMSS-02, TES-P-119.30)

Mechanical check and Visual Inspection1. Inspect for physical damage or defects including of quality of paint work.2. Verify circuits layout for conformance with breaker directory drawings.3. Verify correct rating of each circuit breaker per design.4. Check for proper grounding connection. Electrical Test1. Insulation test of all buses and wirings.2. Phasing check and functional check of main power contractor.3. Calibrate voltmeters, ammeters and watt-meters.4. Check all MCBs for their ratings and alarms.5. Apply trip test for all MCCBs by pole- pole current injection method.

AC Distribution Panels

(Standard Reference is relevant SEC Transmission Specifications 31-TMSS-02, TES-P-119.30) Mechanical check and Visual Inspection1. Inspect for physical damage or defects including of quality of paint work .2. Verify circuits layout for conformance with breaker directory drawing.3. Verify correct rating of each circuit breaker per design.4. Check for proper grounding connection. Electrical Test1. Insulation test for all busses and wirings.2. Polarity check and functional check of main breaker.3. Calibrate voltmeters, ammeters and watt-meters.4. Check all MCBs for their ratings and alarms.

DC Distribution Panels

This was the presentation regarding to the Pre-commissioning for SEC transmission Electrical Installation equipment.

If any one has any suggestion to modify this presentation, will be highly appreciated. AECC

Thank YouAdvance Energy Contracting Company (AECC)