PRE-COMMISSIONING TESTS AND CHECKS

1- Visual Check and Inspection of all Electrical Equipment

A visual check will be carried out on all electrical equipment, internally and externally,
to determine that no transit/erection damage has occurred (or where this has happened
that satisfactory rectification work has been done). All control and relay panels, local
control panels, Switchgear and electrical devices will be internally checked for
compliance with the approved drawings and approved connection wiring diagrams.

The tests carried out in order to satisfy the above will be: -

1. Internal Panel Wiring Compliance Visual Check

2. Internal Panel Wiring/Devices Insulation Check
3. D.C. Supply Checks
4. A.C. Supply Checks
5. Scheme Checks (Positive and Negative Rail Principle)

All relays will be visually checked to see that there is no packing, dirt, metal swarf, etc.,
present in the magnet gaps or on the contacts. All connections will be checked for
tightness on the relays and at all other wiring terminations including the terminal blocks.

All devices shall be checked to see that they are clearly numbered/identified in
accordance with the general arrangement drawings and that the phases are marked
where appropriate.

2- Earthing
An earth survey is carried out for each substation at the beginning of the contract in
order to obtain a value for the site earth resistivity which is required as part of the
Earthing design brief. This should be witnessed and signed by Owner.
Standard earthing tests are carried out during the erection stage by the erection staff.
On completion of these tests, a copy of the results obtained must be submitted to the
PCE for his approval and retention.

These tests will be repeated during the acceptance testing stage by the erection staff in
liaison with a commissioning team member, when they will be witnessed by the client..

3- Bus Wiring

All inter-panel bus wiring will be tested and checked in accordance with the appropriate
termination diagrams.
Insulation checks will be made using a 500V Megger on each bus wire to earth and
from each bus wire to all others. These checks should be carried out with all individual
fuses, links, miniature Circuit Breakers, etc., open or removed at a) the source of supply
and b) all incoming and outgoing circuit panels and Switchgear. .

4- Multi-Core Cables

All multi-core cables will be tested and checked in accordance with

the appropriate termination diagrams.
The insulation resistance will be measured using a 1000V megger after all the
multi-core cables have been connected to the erected equipment. (These tests
on the multi-core cables although done at the pre-commissioning stage to sort
out any obvious problems will be repeated during the acceptance testing
stage).

5 - Batteries and Chargers

The batteries and chargers will be checked to see that they have been
erected / assembled correctly in accordance with the manufacturers recom-
mended procedures.
The tests that are carried out at this stage will be to determine that the
batteries and chargers are functioning correctly, within the recommended
tolerances, so that their performance can be relied upon during the
commissioning of the rest of the substation equipment.
The responsibility for carrying out the above will be taken by a SCE. The
actual acceptance tests, including the time-consuming discharge tests, to be
witnessed by the client, are carried out towards the end of the commissioning
programme.
.

6- 132kV GIS Site Tests

These tests are carried out in accordance with the format of the Works Site
Test Report. The tests conducted are:
1. Bus-Bar and Connections - Conductivity Tests
2. Circuit Breaker - Contact Resistance Checks
3. Circuit Breaker - Contact Timing Tests
4. Mechanical and Local Electrical Operational Checks
5. Air and Gas Leakage Tests
6. SF6 Gas Pressure Switch Setting Check
7. Compressed Air System Sequence Checks

7- 132/11.5kV 30 MVA Transformer Site Tests

The Transformers are inspected and tested in accordance with the

factory check sheets for Transformer installation. As well as detailed
inspection this also includes oil testing.
8- Shunt Reactor

These tests are carried out in accordance with the format of the Works Site Test
Report. The tests conducted are:-

(1) Visual Checks. .

(2) Winding Insulation Level.
(3) Oil Tests. .
(4) Oil / Winding Temperature Gauge Calibration Fan Control
Sequence Test. .

COMMISSIONING AND ACCEPTANCE TESTS

1- 275, 220,132 and 66kV VT Tests

The tests carried out will be:

1. Insulation test

2. Flick Test

The polarity of the VT will be checked by carrying out the flick

test. 2.2

2- 275, 220,132 and 66kV CT Tests

The tests carried out will be:

1. Insulation Test

2. Flick Test

3. Resistance Test

4. Saturation Test

Where more than one CT is in each phase of a circuit, tests where

practical will be carried out to prove the CT's are positioned
correctly so that arranged overlap of zones of protection is correct
This may be carried out by a) a visual inspection b) a continuity
test.

Flick tests will be done on all CT's in a group to prove that they
are connected to the protection in the same polarity. These tests
will also be done on CT's mounted in Transformer bushings. The
flick test results should be compared with those expected from
the schematic diagrams.

All CT's will have the dc secondary loop resistance and individual
secondary winding resistances measured.

The saturation tests will be carried out to prove there are no

shorted turns associated with the CT and to establish the knee
point voltage of the CT's The magnetization curve will be plotted
for each CT or superimposed on the factory curves in order to
determine that the correct CT is installed.

3- 275, 220,132 and 66kV Primary Injection

Tests these tests carried out will be:

1. CT Ratio and Polarity Test

2. Busbar Inter-Group CT Ratio and Polarity Tests-

3. Relay Operation Tests

4. Busbar Protection Operation and Stability Tests

5. Unit Protection Operation and Stability Tests

6. Directional Over current Operation and Stability Tests

Primary current shall be passed through each CT to prove its ratio

and polarity with reference to other CTs in its group. All relays and
instruments will be proved to be wired in the correct phases.

All current "test terminals" will be checked for correct phasing,

CT shorting Switches will be proved and any withdrawable relays
should have their shorting contacts checked.

Inverse time relays shall be made to "creep' on minimum setting.

Earth fault relays shall be checked for spill Current when

injecting phase to phase and minimum operation.

Transformer biased differential protection. The two groups of CTs,

(one on the 132 kV side and one on the 11kV side of the
Transformer) should each be proved for ratio and polarity, and the
differential relay proved to operate for phase-phase, and phase-
earth fault injection on each side of the Transformer. When the
Transformer is energies, on load tests will be used to prove
stability.

Bus zone protection. The group of CT's of each circuit shall be

checked for correct ratio and polarity. Each group of CT's should
then be checked against the bus section/coupler CT's of the same
zone of protection for out of zone stability by measuring spill
currents.

Directional Over current Protection Operation of the protection

will be tested by primary injection of current and voltage
simulating the fault direction. Reversal of the current polarity
proves the stability of the protection.

4 - Secondary Injection Tests

The secondary injection tests will be made to prove the relays,

transducers and meters are operating and measuring correctly.

Secondary injection tests will consist of 'a.c.' injection into the

relay coils to prove that the relay calibration is correct

A record of the relay type, serial number, and its setting range
shall be recorded.

The secondary current injection shall take place from the point at
which the primary injection checks were made on the CT's.

For inverse time relays, the minimum starting current for which
the relay will close its contacts with a maximum time dial setting
shall be recorded. The resetting time of the disc shall be recorded,
and the time of operation for a current injection of twice, five times
and ten times setting current. These results should be carried out
on the relays service setting (or nominal setting if service not
known). The results should be compared with the relay curve
supplied by the manufacturer. Also the time setting multiplier
characteristics will be checked at 2 points (setting point + 1 other
point).

For instantaneous relays the operating current or voltage and the

drop off value shall be recorded.

For all relays fitted with a mechanical flag, the flag should
operate just before the contacts make and the flag mechanism
should not interfere with the operation of the relay.

Differential Relays (e.g. Transformer biased differential or pilot

wire relays will require "on-load" checks to prove their stability) in
addition to secondary injection tests.

Distance protection relays will require current and voltage of

varying magnitude injected into them to simulate different values
of fault impedance and "on-load" checks will be required to. prove
the directional feature of the relay.

Directional elements of inverse time O / C and E / F relays will

require secondary injection of current and voltage of varying
phase angle between them to determine the operation and
stability zone.

The calibration of all instruments and transducers will be checked

at i scale and full scale by current and/or voltage injection with
varying phase angle as required.

5- 275, 220,132 and 66kV GIS Operational Tests

The tests carried out will be: -

1. Local and Remote Operations of all Isolators, Earth Switches

and Circuit Breakers

2. Local and Remote Indications of above

3. Electrical Interlocks of above

4. Synchronizing Sequence Tests (including secondary

injection of voltage selection scheme)

(iv)
5. Gas Monitoring Sequence Tests

6. Alarm Sequence Tests

7. Tripping Tests

Sequence tests will be carried out to prove all electrical circuits

are operating correctly as shown in the schematic diagrams.

The control circuits will be tested by the manual operation of all

close-trip Switches from all positions, for all Circuit Breakers,
disconnecting Switches (line Switches), ground Switches (earth
Switches), and other devices in accordance with the schematic
diagrams.

The operation of all protection circuits will be proved to be in

accordance with the protective gear schematic diagrams.

The tests will be conducted by manually making every main relay

contact or initiating device at source and observing Circuit
Breaker tripping, auxiliary relay operation, lock-out relay operation
and any others. Tripping initiated by each relay in a protection
scheme will be tested with the appropriate trip link in and out to
prove that the link is connected and labeled correctly.

The annunciator circuits will be proved to be in accordance with

the schematic diagrams including alarm buzzer and/or bell, lights
and any other means of alerting staff.

Operation tests of the alarm circuit will be by operating, at

source, each alarm initiating relay, where possible, or
otherwise by simulation.

Operation of each Circuit Breaker, isolator, earthing Switch or

other piece of equipment will be proved to be free or locked
according to the interlock condition shown on the schematic
diagrams.

Synchronizing Sequence Tests will be made by secondary

injection of voltage at the "VT test terminals" on the, appropriate
panels. Care must be taken to ensure that the VT secondary are
isolated from the VT voltage circuits so that no high Voltage is
developed at the VT primary circuits.

6. 132/11.5kV 30 MVA Operational Tests and Measurement of

Audible Noise Level

The following checks will be carried out.

1. Winding Insulation Level

2. Ratio Test

3. Vector Group Test

4. Cooling System Control Sequence Test

5. Local/Remote Tap Change Operations (Mech. and Elec.)

6. Operation of Protective Devices

Load drop compensation and winding temperature CTs mounted

in the trans-former should be proved to be in the correct phase
and have the correct ratio where practicable.

Buchholz relays: the alarm and trip initiation shall be proved by

means of the test button, if provided, or by shorting the
appropriate terminals at the relay.

Winding temperature tripping and alarms shall be proved by

operating the appropriate initiating Switches. The cooler control
ON and OFF shall be proved when three phase 'A.C.'supplies are
available by operating the ON/OFF Switch and the appropriate
temperature indicating initiating Switches. The direction of the fan
rotation must be checked in accordance with the mark.

Tap-changer position indicator should be proved to indicate the

correct tap position. The limit Switch must function properly to
prevent the tap-changer from further movement beyond the two
extreme tap positions. Tap-changing shall be tested for every step
ensuring stepping relay
functions correctly.

Measurement of audible noise level on site will be carried out

under
the following conditions using a sound level meter
(IEC Pub 551 type 1 or equivalent):

1. The background noise level at all measuring points shall

not exceed 45dBA
in accordance with ANSI standard.

2. Only the Transformer under test shall be energized and shall

have been
on soak for at least 24 hours prior to measurement. The tests
shall be carried
out at rated voltage with all normal fans running at no load
conditions.

3. The audible sound level of each Transformer in turn will be

measured

at a number of points 30 meters from the substation.

4. The average value of the noise measurements for each

Transformer
shall be taken and this value checked to ensure it does not
exceed 50dBA.

7- 11/0.433kV 250kVA Transformer Tests

These tests are carried out in accordance with the format of the
Works Site Test Report. The tests conducted are:-

a) Winding Insulation Level

b) Ratio Test .

c) Vector Group

8- HV Pressure Tests (132kV Equipment)

These tests will be carried out in accordance with the Works Site
Test Reports.

The magnitude and duration of the test voltage is given in Table

below. An opportunity to check VT calibration will be taken during
these tests.

Test
Equipment Test Voltage KV
Duration
 132 GIS 115 10 min.
11 KV 24 1 min

9- Supervisory Interface Test

The tests carried out will be:

a) Initiation of the appropriate alarms or indications at source

and checking that the correct logic signals are received at the tele-
metry terminal (TTB) cabinet.

b) Apply a 50V DC voltage to the (TTB) cabinet terminals and

check that the correct Circuit Breaker or tap changer command is
received and executed.

10 - 11kV VT Tests. .

The tests carried out will be:

a) Insulation Test. .

b) Flick Test. .

The polarity of the VT will be checked by carrying out the flick

test.

11 - 11kV CT Tests

The tests carried out will be:

a) Insulation Test. .

b) Flick Test. .

c) Resistance Test

d) Saturation Test

Where more than one CT is in each phase of a circuit, tests where

practical will be carried out to prove the CT's are positioned
correctly so that arranged overlap of zones of protection is correct
This may be carried out by a) a visual inspection b) a continuity
test.

Flick tests will be done on all CT's in a group to prove that they
are connected to the protection in the same polarity. These tests
will also be done on CT's mounted in Transformer bushings. The
flick test results should be compared with those expected from
the schematic diagrams.

All CT's will have the dc secondary loop resistance and individual
secondary winding resistances measured. .

The saturation tests will be carried out to prove there are no

shorted turns associated with the CT and to establish the knee
point voltage of the CT's The magnetization curve will be plotted
for each CT or superimposed on the factory curves in order to
determine that the correct CT is installed.

12- 11kV Primary Injection

Tests the tests carried out will be:

a) CT Ratio and Polarity Test

b) Relay Operation Tests

c) Unit Protection Operation and Stability Tests

Primary current shall be passed through each CT to prove its

ratio and polarity with reference to other CTs in its group. All
relays and instruments will be proved to be wired in the correct
phases..

All current "test terminals" will be checked for correct phasing, CT

shorting Switches will be proved and any withdrawable relays
should have their shorting contacts checked.

Inverse time relays shall be made to "creep' on minimum setting.

Transformer biased differential protection. The group of CTs

should be proved for ratio and polarity, and the differential relay
proved to operate for phase-phase, and phase-earth fault
injection.

Transformer Restricted Earth Fault Protections. The groups of CTs

shall be proved for ratio and polarity and stability by measuring
spill currents.

13- 11kV Secondary Injection Tests

The secondary injection tests will be made to prove the relays,

transducers and meters are operating and measuring correctly.

Secondary injection tests will consist of 'a.c.' injection into the

relay coils to prove that the relay calibration is correct

A record of the relay type, serial number, and its setting range
shall be recorded. -

The secondary current injection shall take place from the point at
which the primary injection checks were made on the CTs.

For inverse time relays, the minimum starting current for which
the relay will close its contacts with a maximum time dial setting
shall be recorded. The resetting time of the disc shall b_ recorded,
and the time of operation for a current injection of twice, five times
and ten times setting current. These results should be carried out
on the relays service setting (or nominal setting if service not
known). The results should be compared with the relay curve
supplied by the manufacturer. Also the time setting multiplier
characteristics will be checked at 2 points (setting point +1 other
point).

For all relays fitted with a mechanical flag, the flag should
operate just before the contacts make and the flag mechanism
should not interfere with the operation of the relay.

The calibration of all instruments and transducers will be checked

at scale and full scale by current and/or voltage injection as
appropriate.

14. 11kV Switchgear Contact Resistance Checks

The contact resistance of all primary contacts will be checked by

current injection and voltage drop measurement.

15. 11kV Switchgear Operational

Tests The tests carried out will be:

a) Local and Remote Operations of all Circuit Breakers

b) Local and Remote Indications of above

c) Electrical Interlocks of above

d) Gas Monitoring Sequence Tests

e) Alarm Sequence Tests

f) Tripping Tests including Arc Fault Tripping scheme

.

Sequence tests will be carried out to prove all electrical circuits

are operating correctly as shown in the schematic diagrams.

The control circuits will be tested by the manual operation of all

close-trip Switches from all positions, for all Circuit Breakers and
other devices in accordance with the schematic diagrams.

The operation of all protection circuits will be proved to be in

accordance with the protective gear schematic diagrams.

The tests will be conducted by manually making every main relay

contact and observing Circuit Breaker tripping, auxiliary relay
operation, lock-out relay operation and any others. Tripping
initiated by each relay in a protection scheme will be tested with
the appropriate trip link in and out to prove that the link is
connected and labeled correctly.

The annunciator circuits will be proved to be in accordance with

the schematic diagrams including alarm buzzer and/or bell, lights
and any other means of alerting staff.

Operation tests of the alarm circuit will be by operating, at

source, each alarm initiating relay contact, where possible,-or
otherwise by simulation.

Operation of each Circuit Breaker disconnect Switch and earthing

Switch will be proved to be free or locked according to the
interlock condition shown on the schematic diagrams.

16.HV Pressure Tests (11kV Equipment)

These tests will be carried out in accordance with the Marugame

Works Test Sheets. The magnitude and duration of the test
voltages are given in Table 1

17. Battery and Charger Tests

The batteries and chargers will have already been assembled,

checked and put into service during the pre-commissioning stage
by members of the commissioning team.

However certain further tests are now done and others repeated
during the acceptance testing stage to be witnessed by the client.
These tests will be carried out in accordance with the
manufacturers recommended testing procedures and will include
the battery discharge tests.

.
18. Multi-Core Cable Tests

All the multi-core cables will have already been checked to be in

accordance with the appropriate termination diagrams during the
pre-commissioning stage.

The insulation resistance tests will be repeated during the

acceptance testing stage when they will be witnessed by the
client.

19. Earthing Tests

The erection staff will have originally conducted earthing tests

but these will be repeated during the acceptance testing stage
when they will be witnessed by the client.

20. Fire Fighting Equipment Tests

The Subcontractor will have already carried out limited post

erection checks, i.e. mechanical checks including a pressure test
on the main tank and air leakage tests on the air receiver.

The commissioning tests for water spray system will be:-

a) Compressor Sequence Tests

b) Alarm Sequence Tests

c) Indication Sequence Tests

d) Deluge Valve Sequence Tests

e) Discharge and Water Spray Tests

f) Inter-tripping Tests
The commissioning for the other systems will be:

a) Detector Operation Tests

b) Detector Line Supervision Tests

c) Pushbutton Function Tests

d) Tripping Tests

e) Halon Discharge Test

f) Dry Powder Discharge Test