1 PROCEDURE T&C.......................................................................................................

1.1 COMMISSIONING OF BATTERY CHARGER...............................................................4

1.2 DISCHARGE TEST OF BATTERY...................................................................................5

1.3 CIRCUIT BREAKER/CONTACTOR TIMING TEST.....................................................6

1.4 Magnetization Curve of Current Transformer...................................................................7

1.5 SPECIFIC GRAVITY.........................................................................................................10

1.6 RESISTANCE MEASUREMENTS...................................................................................11

1.6.1 CONTROL TRANSFORMER......................................................................................11
1.6.2 POWER TRANSFORMER / OLTC..............................................................................11
1.6.3 CONTACT RESISTANCE............................................................................................11
1.6.4 NER & Relays................................................................................................................12

1.7 INSULATION RESISTANCE TESTING.........................................................................13

1.7.1 POWER CABLE:...........................................................................................................13
1.7.2 POWER / CONTROL TRANSFORMER.....................................................................13

1.8 HIGH VOLTAGE TEST.....................................................................................................15

1.8.1 SWITCH GEAR / DISTRIBUTION PANEL...............................................................15
1.8.2 POWER CABLE............................................................................................................16
1.8.3 DC Voltage Test.............................................................................................................16

1.9 PRIMARY INJECTION TEST..........................................................................................18

1.10 Ratio Test - Current Transformer......................................................................................19

1.11 Ratio Test - Voltage Transformer......................................................................................21

1.12 Procedure for Sampling of Transformer Oil for Testing:................................................23

1.12.1 Procedure for Breakdown Voltage test for Transformer Oil.........................................23

1.13 Relays testing / instrument calibration..............................................................................24

1.14 OPERATION / INTERLOCK VERIFICATION.............................................................25

1.15 ON LOAD TESTS................................................................................................................26

1.16 ENERGISATION CHECKS...............................................................................................27

1.17 RESISTANCE MEASUREMENTS...................................................................................28

1.18 CONTACT RESISTANCE :...............................................................................................29

1.19 SCHEME VERIFICATION TEST....................................................................................30

1.20 SCHEME COORDINATION.............................................................................................31

1.21 SCADA VERIFICATION TEST...........................................................................................32

1 PROCEDURE T&C
1.1 COMMISSIONING OF BATTERY CHARGER
OBJECTIVE
To establish the correct operation of the battery charger at specified voltage and current levels.

PROCEDURE
Visual Inspection: The battery charger cleanliness to be verified. Proper cable termination of
incoming AC cable and the outgoing DC cable and the cable connection between battery and
charger to be ensured. A stable incoming AC supply to the battery charger is also to be ensured.
Voltage levels in the Float charge mode and the Boost charge mode to be set according to
specifications using potentiometer provided.
Battery low voltage, Mains ‘Off”, charger ‘Off’ etc., conditions are simulated and checked
for proper alarm / indication. Thus functional correctness of the battery charger is ensued.
Charger put in Commissioning mode for duration specified only one time during initial
commissioning of the batteries. (By means of enabling switch.)
Battery charger put in fast charging boost mode and battery set boost charged for the
duration specified by the battery manufacturer.
After the boost charging duration, the battery charger is to be put in float charging (trickle
charge) mode for continuous operation. Some chargers automatically switch to float charge
mode after the charging current reduces below a certain value.
Voltage and current values are recorded during the boost charging and float-charging mode.

RESULT
This test establishes the correct operation of the battery charger within the specified voltage
and current levels in various operational modes.
1.2 DISCHARGE TEST OF BATTERY
OBJECTIVE
To establish the current discharge capacity of the battery at the rated voltage level.

TEST INSTRUMENT REQUIREMENT

The equipment to be used for discharge test of battery is Torkel-720 (Programma Make) or
equivalent. The Torkel-720 is capable of providing a constant current load to the battery under test.

PROCEDURE
Mandatory Condition: The battery set should have been properly charged as per the
commissioning instructions of the battery manufacturer for the duration specified.
Visual Inspection: Cleanliness of battery is checked and the electrolyte level checked as
specified on the individual cells. The tightness of cell connections on individual terminals
should be ensured.
The load current, minimum voltage of battery system, ampere-hour, duration etc., is preset
in the test equipment using the keypad. For (e.g.) a 58 AH battery set, 5 Hr. duration
specification 11.6 A and 5 Hr. duration are set. Minimum voltage setting is = No. of cells x end
cell voltage of cells as per manufacturer specification.
It is to be ensured that the set value of the current and duration is within the discharge
capacity of the type of cell used. Also the total power to be dissipated in the load unit should be
within the power rating of the battery load kit.
Individual cell voltages to be recorded before the start of the test.
Battery charger to be switched off/load MCB in charger to be switched off.
Loading of the battery to be started at the specified current value. Individual cell voltages of
the battery set are to be recorded every half an hour.
It is to be ensured that all the cell voltages are above the end-cell voltage specified by the
manufacturer. If any of the cell voltages falls below the threshold level specified by the
manufacturer, this cell number is to be noted and the cell needs to be replaced.
Test set automatically stops loading after set duration (or) when minimum voltage reached
for the battery set.
Test to be continued until the battery delivers the total AH capacity it is designed for. Value
of AH and individual cell voltages to be recorded every half an hour.

ACCEPTANCE LIMITS
This test establishes the AH capacity of battery set at required voltage. The acceptance limit
for the test is to ensure the battery set is capable of supplying the required current at specified
DC voltage without breakdown for the required duration.
1.3 CIRCUIT BREAKER/CONTACTOR TIMING TEST
OBJECTIVE
To determine that circuit breaker/contactor opening & closing times are within specified
limits and there is no significant difference of time between all three poles opening and closing of
main contacts i.e. pole slipping.

TEST INSTRUMENT REQUIREMENT:

“State Sequencer” module in OMICRON test instrument

PROCEDURE
Following precautions should be taken before starting the testing.
Breaker energy for open/close operation should be available before each test.
Breaker should be in isolated position from the live parts of the system and control wiring
should be isolated to use for test only.
Operating mechanism of breaker should be checked manual & electrical mode before
starting the test.
For checking open/close time stable voltage source matching with ratings of tripping &
closing coils should be available.
Check that breaker is in open (off) position. Route the auxiliary voltage to the closing coil of
breaker as well as start input of digital timer. Connect R-phase main contacts of breaker to the
stop input of timer. Switch on the MCB and breaker shall close. Note the closing time on the
timer. Switch off the MCB and route the auxiliary voltage to the tripping coil of the breaker.
Breaker will open on application of auxiliary voltage. Note the opening time of the breaker.
Repeat the test for Y & B phases.

TIMING LIMITS
Test results shall be compared with the manufacturer’s specified limits. Inter-pole timing difference
should not exceed 2ms.
1.4 Magnetization Curve of Current Transformer
OBJECTIVE
To test the magnetization property of the core of current transformer.

TEST EQUIPMENT
The test is carried out with a variable voltage applied to the secondary of the current transformer.
The test voltage can be obtained from a variable voltage source or through a variable auto-
transformer. Voltmeter and Ammeter are required to measure the voltage and current respectively
in the secondary circuit.

PRINCIPLE OF OPERATION
The core of the current transformer gets magnetized due the primary current flowing in the circuit
and this helps in faithful reproduction of the quantity in the secondary circuit. However, it is a
property of the magnetic core to get saturated, due to high value of currents.

In case of core saturation, the CT will not faithfully reproduce the primary current into secondary
current. In some application where primary protection relays are connected, the CT has to remain
unsaturated up to a desired value of primary current. This property of the CT is designated with a
parameter called as ‘Knee-point voltage’.

Knee-point voltage of the current transformer is defined as the voltage at which 10% increase in
secondary voltage results in 50% increase in the magnetization current.

The objective of this test is to plot the magnetization curve of the CT there by, locating the knee-
point voltage, Vk. This value of Vk is compared with the manufacturer’s design value.
Test Procedure

VISUAL CHECK
Ensure that the surface of the transformer is clean and the wires properly terminated.
The secondary circuit earthing lead is temporarily isolated from the ground.
Ensure that the primary circuit is open ie., the circuit breaker in the primary circuit is
kept open.
All the other secondary cores of the CT, which are not used for the test are kept
shorted.
A typical test connection for a magnetization curve of current transformer is shown
below in fig.1:
 Fig. 1: Typical test connection for CT Mag. Curve test.

Voltage is applied in the secondary core of the CT under test. The voltage is slowly
increased and the current (mA) in the secondary is noted.
This process is repeated until the core saturates. The core saturation in indicated by steep
increase in the secondary current for a marginal increase in the secondary voltage.
The values are plotted in a log scale and the knee-point voltage obtained. The obtained
value of Vk should be equal to or greater than the design value specified on the CT nameplate.
Ensure a gradual increase or decrease of the secondary voltage during the test, as a sudden
variation in the voltage may produce dangerous flux variation which may damage the secondary
insulation.
A typical CT mag curve and Vk are shown in fig. 2 below.
The same procedure is repeated for the other phase CTs.
After completion of the test, ensure that all the CT secondary connections are restored back.
RESULT
This test establishes the actual value of Vk of the CT core. Also this test establishes that correct core
is used for the required application and also ensures that there is no mix-up of cores.
1.5 SPECIFIC GRAVITY
OBJECTIVE
To ensure the electrolyte of battery is in the normal chemical composition so that charge/discharge
operation of battery occurs normally.

PROCEDURE
Specific gravity of each cell in the battery system is measured by means of a hydrometer, which
operates on the viscosity of measured fluid.
The hydrometer is inserted into the cells by means of opening the cover of vent. Specific gravity is
a ratio and thus not represented in units.

LIMITS
For lead acid cells 1.24 is the normal specific gravity value of sulphuric acid.
Allowed limits are 1.19 – 2.22. Increase in specific gravity indicates decrease in water content and
thus distilled water to be added to bring the specific gravity to required level. For NiCd cells 1.20 is
the normal value.
1.6 RESISTANCE MEASUREMENTS
OBJECTIVE
To determine the equipment is in healthy status for the service for which it was designed & to give
some basis for predicting whether or not that a healthy condition is suitable to energize / load that
equipment.

TEST INSTRUMENT REQUIREMENT

WEAT STONE BRIDGE for control transformers.
WINDING RESISTANCE TESTER for Power T/F & OLTC.
CONTACT RESISTANCE TESTER for CB’s, E/S’s & Bus bar.
MULTIMETER for NER & Relays.

PROCEDURE
The following precautions should be taken care, before starting the testing.
Ensure that the unit & it’s switch gear cubicle are not under energized status.
A visual inspection shall be made to ensure that the unit is installed properly & it’s control
wiring is made as per the schematics.
Ensure that the component is isolated from other connected system, which may feed back to
other components or circuits not under test.

1.6.1 CONTROL TRANSFORMER

It includes Current & Potential transformer. On testing for resistance measurement after taking
above precautions, test setup shall be made as mentioned in the WEAT STONE Bridge instrument
with each core wise. Results will be recorded in the appropriate test forms.

1.6.2 POWER TRANSFORMER / OLTC

After conforming the above precautions, connect the instrument across the winding, which phase to
be measured. On applying voltage by pressing test push button, the reading can be noted & results
will be recorded. The same test shall be repeated for other two phases. If there is tap changer
available, test required to carry out for all tap positions.

1.6.3 CONTACT RESISTANCE

This test will be carried out for Bus bar and switches like circuit breakers, Earth switches &
contactors. Above mentioned precautions shall be made for this also. Before starting the electrical
starting better to complete the torque verification for the whole of bus bar . DC current injection
shall be done for the complete section of bus bar to measure the conductivity of bus bar at different
connection points on that section.
For switches, to make contact resistance, close the switches & across that contact inject the
DC current of 100A & measure the resistance values. The same test will be done for other two
phases. The value of contact resistance in micro ohm should be similar to all three phases.

1.6.4 NER & Relays

After conforming the above precautions, do the checks as mentioned below……
For NER, disconnect the both end connection and measure the resistor value across the unit &
record.
For relay contacts & coil resistance, measure as required & record the values.

ACCEPTANCE LIMITS
FOR CONTROL TRANSFORMERS
FOR POWER T/F & OLTC
FOR CB’S, E/S’S & BUS BAR
FOR NER & RELAYS
1.7 INSULATION RESISTANCE TESTING
OBJECTIVE
To determine the equipment is in proper condition for the service for which it was designed & to
give some basis for predicting whether or not that a healthy condition will remain or if deterioration
is underway which can result in abnormally short life.

TEST INSTRUMENT REQUIREMENT

Insulation resistance tester up to 5000 V DC

PROCEDURE

SWITCHGEAR / DISTRIBUTION PANEL

It includes panel enclosure, busbar & breaker. The following precautions should be taken care,
before starting the testing.
A visual inspection will be made to ensure the surface dust and moisture has been removed
from the component under test.
Ensure the component is isolated from other connected system, which may feed back to
other components or circuits not under test.
A check shall be made to verify the ground for the component under test and test equipment
being connected to system ground.
On testing, voltage shall be applied between one phase and other phases connected with ground,
testing shall be repeated for other phases as mentioned above. Test voltage limits mentioned below.

1.7.1 POWER CABLE:

Following precautions shall be made before conducting test.
Cable under test should be disconnected at both ends. This will assure that the cable under
test will not feed back to circuits / components not under test.
Personnel should be stationed at both ends and / or the end opposite where the test is
performed should be barricaded with warning tapes & signboards.
On testing voltage shall be applied between one phase and other phases connected with ground,
testing shall be repeated for other phases as mentioned above. Test voltage limits mentioned below.

1.7.2 POWER / CONTROL TRANSFORMER

Above mentioned precautions (switchgear) shall be made for this also. The voltage shall be applied
between
1. Primary plus secondary to ground
2. Secondary to primary plus ground
3. Primary to secondary plus ground
For control transformer if additional cores available, then between the cores, each phase wise with
respect to other phases connected with ground. Test voltage limits mentioned below.

TEST VOLTAGE LIMITS

Voltage shall be applied for one minute. Voltage limits given below

Rated voltage AC / DC volts Test voltage – DC volts

100 – 1000 V AC / DC 1000 V DC
>1000 to < 5000 V AC 2500 V DC
> 5000 V AC 5000 V DC

ACCEPTANCE LIMITS
Value of insulation resistance should meet the manufacturer minimum. If this value is not available,
the component tested should have at least one Meg Ohm for every 1000 volts of rated voltage plus
an additional one Meg ohm.
1.8 HIGH VOLTAGE TEST
OBJECTIVE
To determine the equipment is in proper condition for the service, after installation, for
which it was designed & to give some basis for predicting whether or not that a healthy condition
will remain or if deterioration is underway which can result in abnormally short life.

TEST INSTRUMENT
Calibrated AC hi-pot test set for switchgear with leakage current (micro A) indicator and
with over load protection.
Calibrated DC hi-pot test set for cables with leakage current (micro A) indicator and with
over load protection.

PROCEDURE

1.8.1 SWITCH GEAR / DISTRIBUTION PANEL

It includes panel enclosure, bus bar, CT & breaker / contactor. The following precautions should be
taken care, before starting the test:
A visual inspection will be made to ensure the surface dust and moisture has been removed
from the component under test.
Ensure the component is isolated from other connected system, which may feed back to
other components or circuits not under test.
A check shall be made to verify the ground for the component under test and test equipment
being connected to system ground.
CTs secondary terminals shall be shorted.
VTs & Surge arresters shall be isolated from the equipment under test.
Mark out test area and assure nobody can enter during test.
Circuit breakers/contactors should be inserted and closed.
Busbars should be fully mounted tightened and shields between phases & between phases
and earth should be in place. Moreover, busbar covers should be in place.
All earthing switches related to equipment under test should be open.
Busbar conductivity test shall be performed.
Insulation resistance test should be performed before commencing the test.
Instructions of test equipment being used should be followed.
After each test subject under test should be solid grounded before touching.

Required test voltage shall be raised slowly and maintained for one minute between one phase and
other phases connected to ground and than reduced slowly to zero, testing shall be repeated for
other phases as mentioned above. During each test leakage current shall be recorded. After this, test
shall be repeated after opening all circuit breakers / contactors and applying test voltage across
opening distance between poles with three poles shorted on both sides and grounded on one side
only. Test voltage limits are mentioned below:
Rated Voltage, Rated 1 minute power Actually applied voltage at
 r.m.s(kV) frequency withstand field = 80%
voltage(kV)r.m.s KV, r.m.s
I.E.C 694 I.E.C 298
3.6 10 8
7.2 20 16
12 28 22.4
17.5 38 30.4
24 50 40
36 70 56
52 95 76

1.8.2 POWER CABLE

Following precautions shall be made before conducting test.
Cable under test should be clean and free of dust especially at insulators and stress cones.
Shields of all cables should be grounded and tied together at the near end of the cable and at
far end bare conductor should be taped with some insulation.
Cable under test should be disconnected at both ends. This will assure that the cable under
test will not feed back to circuits / components not under test.
Personnel should be stationed at both ends and / or the end opposite where the test is
performed should be barricaded with warning tapes & signboards.
Instructions of test equipment being used should be followed.

1.8.3 DC Voltage Test

Dc voltage shall be raised slowly up to 4 x Uo (rated power frequency voltage between conductor
and earth or metallic screen) and maintained for 15 minutes between one phase and other phases
and metallic screen of all phases connected with ground. After elapse of test time, voltage shall be
reduced slowly to zero and the cable shall be discharged through resistive grounding. Testing shall
be repeated for other phases as mentioned above. Test voltage limits are mentioned below as per
IEC 60502-2(1997-04):
Rated Cable Voltage(kV), Uo Rated 15minute withstand DC
(Phase to earth) voltage(kV)
3.6 14.4
6.0 24
8.7 34.8
12 48
18 72

1.8.3.1 AC Voltage Test(Alternate method):

As per IEC 60502-2(1997-04), as an alternate method after agreement between the contractor and
purchaser , an a.c. voltage may be applied as a) or b) below:
test for 5min with phase to phase voltage of the system applied between the conductor and
the metallic screen
test for 24 hours with the normal operating voltage Uo of the system
Note: Normally cables has three voltages specified: i.e. Uo\U\Um
Where Uo=rated Phse to eath/screen voltage
 U= rated Phase to phase voltage
Um=rated maximum Phase to phase voltage
-For cables used for solidly earthed system screen current for the earth fault will be high but cable
Uo rating is low i.e. Uo=U/1.732
-For cables used for resistance earthed system screen current will be low for earh fault but cable Uo
rating is high i.e. Uo=U

ACCEPTANCE LIMITS
For Switchgear
No flashover or disruptive discharge should occur during test. Corona discharge noise
may be heard during this test. Insulation test should be performed after the test also.
For Powercables
No flashover or disruptive discharge should occur during test. Insulation test should be performed
after the test also.
1.9 PRIMARY INJECTION TEST
OBJECTIVE
To check whether the current loop / voltage circuit is free of any leakage, discontinuity, shorts and
to ensure there is no mix up of phases within the loop/circuit.

PROCEDURE

CURRENT TRANSFORMERS
Generally 50% to 100 % of nominal current is applied in the primary of C.T. by means of primary
injection kit with the C.T. links closed, shorting links removed.
The secondary current is checked in the C.T. secondary terminals, each component of the current
loop by means of an A.C. clamp meter. The value should be the same and no current flow in other
two phases to be verified.
The above test is repeated for all phases separately and in between two phases.

VOLTAGE TRANSFORMERS
Generally rated voltage of V.T. is applied at the primary by means of hipot tester.
The secondary V.T. voltage is measured at VT secondary MCB and all voltage terminals in the
V.T. secondary circuit. The phase rotation is also verified in all points.

PRECAUTION
For C.T. before applying current in primary, ensure that C.T.links are closed, screwed tightly, no
wires are loose connected (or) open in the current loops.

For voltage transformer, before applying voltage in primary ensure primary terminals are not
earthed, secondary terminals are not earthed anywhere in the V.T. secondary circuit.

INSTRUMENTS REQUIRED
Foster primary injection kit (or) Sverker –750.
Hipot tester.

REMARKS
In case of CT since the primary current, secondary current are normally measured by a.c.
clamp meters an error is introduced in the measurement.
All current operated relays may be set to higher value temporarily in order to avoid any
relay operation.
1.10 Ratio Test - Current Transformer
OBJECTIVE
To establish the correctness of transformation ratio of the current transformer as per the system
requirement.

TEST EQUIPMENT:
This test can be conducted using a primary current injection kit and ammeters at the secondary
circuit to measure the current.

PRINCIPLE OF OPERATION
The current transformer is an equipment which transforms the high value of primary current into
measurable secondary current. The current is stepped down as per the transformation ratio of the
Current Transformer. This test is conducted by injecting certain value of current in the primary
circuit and measuring the magnitude of current flowing in the secondary circuit.

TEST PROCEDURE
Visual Check: Ensure that the surface of the transformer is clean and the wires properly
terminated.
The secondary circuit earthing lead is temporarily isolated from the ground.
All the cores of CT, which are not used for the test are kept shorted.
A typical test connection for a ratio test of current transformer is shown below in fig.1.
The three phases of the primary circuit are temporarily short-circuited. Current is injected
into any of the two phases using a primary current injection kit. The magnitudes of the current
flowing in the respective phases of the secondary circuit are noted. The third phase is also
connected with an either ammeter or short-circuited. Observe that no current flows in the third
phase.
The test is repeated for other phase.
Ammeter A3 is used to measure any leakage currents in the circuit.
The ratio of the CT under test is calculated by finding the ratio of currents measured with
Ammeter A1 with respect to Ammeter A2.
This value is compared with the ratio specified by the manufacturer. Ideally the error should
be less than 1%.
After completing the test, restore the CT connection and the secondary earth connection
properly in the CT secondary terminal block.
Fig.1: Typical Connection diagram for Ratio test of Current Transformer
1.11 Ratio Test - Voltage Transformer
OBJECTIVE
To establish the correctness of voltage transformer transformation ratio as per the system
requirement.

TEST EQUIPMENT:
This test can be conducted using a single-phase voltage source with AC voltmeters for measuring
the primary and secondary voltage.

PRINCIPLE OF OPERATION
The voltage transformer as the case of other transformers operates on the principle of Electro-
magnetic induction. The voltage transformer steps down the higher input voltage into lower
secondary voltage, which can be measured using a voltmeter. Every voltage transformer has a
designed transformation ratio based on its design and construction. The test is conducted by
applying single-phase ac voltage of less than 500V across the primary and measuring the output
voltage at the secondary.

TEST PROCEDURE:
Visual Check: Ensure that the surface of the transformer is clean and the wires properly
terminated.
The secondary circuit earthing lead is temporarily isolated from the ground.
A typical test connection for a ratio test of voltage transformer is shown below in fig.2.
Single phase voltage of magnitude less than 500V is applied across the primary winding and
the secondary output voltage is measured by using a voltmeter.
This procedure is repeated for VTs of other two phases.
The ratio of the VT under test is calculated by finding the ratio of primary and secondary
voltages.
This value is compared with the ratio specified by the manufacturer. Ideally the error should
be less than 1%.
After completing the test, restore the VT primary connection and the secondary earth
connection properly in the VT secondary terminal block.
 Fig.2: Typical Connection for Ratio test of Voltage Transformer

TEST RESULT ANALYSIS

The standards allow an error margin of 1% of the calculated
measure. The error in % will be calculated with of the
following formula.
E (%) = Measured ratio
- calculated ratio x 100

Calculated ratio

CONCLUSION
This test establishes the correctness of ratio of the current transformer or voltage
transformer as per the system requirement.
Also, this test establishes that the transformer is free from any shorted winding, open
winding or any misconnection during assembly.
1.12 Procedure for Sampling of Transformer Oil for Testing:
SAMPLING METHOD:
A clean, dry GLASS container is to be used. The size of the container should be atleast three
times the size of the test cell. (A container of approximately 1 litre is sufficient)
During sampling, rinse the glass container with little quantity of oil and drain.
Fill the container with oil until the container over flows.
Do not allow free air space inside the container.
Do not allow air bubbles inside the container.
Sampled Container should be closed air-tight with cork or any other non-reactive material.
(0ptional). In case the oil is to be transported to a larger distances, ensure that oil is stored in
a clean and dry place and transported with utmost care.
Before filling the oil in the test cell, gently agitate the container without creating air bubbles.
Rinse the walls of the test cells with little of oil and drain it.
Ensure that the electrodes of the test cell are clean.
Fill the oil sample until overflow, into the test cell without formation of air bubbles.
Do Not start the test for atleast for 5 min. after filling the test sample (oil).

1.12.1Procedure for Breakdown Voltage test for Transformer Oil

(It is recommended that the BDV test of transformer oil is performed at site itself)

TESTING METHOD:
The oil sampling to be carried out as per the procedure explained in the sampling
instructions.
The BDV test to be started after atleast 5 minutes from the filling of the sample oil in the
test cell.
Ensure that the gap between the electrodes is maintained at 2.5mm.
Ensure that the electrodes are clean
The rate of rise of the test voltage to be adjusted at 2kV per second.
Conduct the BDV test for 5 to 6 times for the same sample with a time interval of atleast 3 -
4 minutes between tests.
Ensure that between tests, stirring of the test sample is carried out.
Record the test results and obtain the average of the test results to obtain the Break-down
voltage of the test sample. (Ignore the odd values)
1.13 Relays testing / instrument calibration
OBJECTIVE
To determine the healthiness of protection, monitoring & control units.

TEST INSTRUMENT REQUIREMENT

Calibrated single phase injection set
Calibrated three phase injection set
Multimeter

PROCEDURE
The following precautions should be taken care, before starting the testing.
Ensure that the unit & it’s switch gear cubicle are not under energized status. If it is
energized state take necessary other precautions mentioned by manufacturers.
A visual inspection shall be made to ensure that the unit is installed properly & it’s control
wiring is made as per the schematics.
Test set up should be made as recommended by manufacturers for each case, care should be
taken to avoid other problems like CT opening, tripping, false alarm & etc.
Ensure that the component is isolated from other connected system, which may feed back /
disturbance to other components or circuits not under test.
After considering above precautions, test shall be carried out for each checks as manufacturer
recommended steps.

ACCEPTANCE LIMITS
Manufacturer specification limits should not exceed.
1.14 OPERATION / INTERLOCK VERIFICATION
OBJECTIVE
To ensure that the system & equipment are fully operational for their assigned duties and
electrical & mechanical interlocks between various components and devices are correct as
indicated in the related schematics and specifications.

PROCEDURE
Following precautions should be taken before starting the testing.
Ensure that items and installation conform to the specified requirements and applicable
drawings.
Items are free from damage and have been tested and adjusted as per manufacturer
instructions individually.
Available drawings are the as-manufactured status.
All labels and markings are correct.
Ensure free movement of mobile parts.
Correct polarities and continuities of electric circuits.
Auxiliary control voltages are available in correct magnitude and polarities.
Following shall be verified:
Operation of each circuit breaker, contactor, earthing switch both electrically as well as
mechanically whichever applicable.
Operation of power transformer tap changer mechanism.
Draw-in and draw-out operation of circuit breakers/contactors and voltage transformers.
Electrical as well as mechanical interlock between various switching devices
Door interlocks
Sequence interlock verification
Operation of switching devices from protection devices operating from primary
injection/simulation.

ACCEPTANCE LIMITS
Functionality of each unit match / with in the customer stipulated specifications / procedures.
1.15 ON LOAD TESTS
OBJECTIVE:
To ensure that the required systems are commissioned as per it’s required application. In terms of
cross verifying it’s direction / rotation.

TEST INSTRUMENT REQUIREMENT:

Phase angle meter
Phase rotation meter
Multimeter
Remote communication equipment like communication software, remote pocket terminal &
etc.

PROCEDURAL METHOD:
Ensure to take necessary precautions for isolating trip / alarm & making the CT and PT
circuit through for that particular application before proceeding for the ON LOAD TEST of the
same.
Also ensure that second protection is available to protect the system, when the first one is
taken out for on load check.
After conforming the above precautions, the system required to put load at least 25% of its
capacity.
After the successful loading, conform the correct system parameters reaching up to final
terminals of each application by measurement of magnitude & phase displacement.
Follow the manufacturer recommended procedure to carry out the load test of each systems
like Directional / Differential spill / rotational test of the particular application.
Record all the values / results for the reference.
After the verification of each application, ensure that the system is put back in normal.

IMPORTANT NOTE
Doubly ensure to isolate the Tripping / Alarm signals by test plug during “On Load Check” for the
particular application alone.

ACCEPTANCE LIMITS
On load check result should be satisfactory as per the requirement of the system in terms of
Direction / Rotation / Differential spill of each application.
1.16 ENERGISATION CHECKS
OBJECTIVE
To ensure that the required system is energised as per the requirement of it’s application and
obtaining the green signal for the next step of commissioning the system.

TEST INSTRUMENT REQUIREMENT

Phase angle meter
Phase rotation meter
Multi Meter
Remote communication equipment like communication software, remote pocket terminal &
etc.

PROCEDURE
Follow the approved energisation or switching programme. In each step required defined
checks / conformation to be carried out for validating the same & before loading the system.
These checks include measurement of possible secondary electrical signals magnitude at it’s
required terminals, phasing of VT secondary circuits, ensuring that the secondary electrical
signal is reached up to the terminals of required elements & etc.
Record the possible readings for future reference.

ACCEPTANCE LIMITS
Energisation programme should be satisfactorily completed as per the approved sequence.
1.17 RESISTANCE MEASUREMENTS
OBJECTIVE
To determine the equipment is in healthy status for the service for which it was designed &
to give some basis for predicting whether or not that a healthy condition is suitable to energize /
load that equipment.

TEST INSTRUMENT REQUIREMENT

WEAT STONE BRIDGE for control transformers.
WINDING RESISTANCE TESTER for Power T/F & OLTC.
CONTACT RESISTANCE TESTER for CB’s, E/S’s & Bus bar.
MULTIMETER for NER & Relays.

PROCEDURE
The following precautions should be taken care, before starting the testing.
Ensure that the unit & it’s switch gear cubicle are not under energized status.
A visual inspection shall be made to ensure that the unit is installed properly & it’s control
wiring is made as per the schematics.
Ensure that the component is isolated from other connected system, which may feed back to
other components or circuits not under test.

CONTROL TRANSFORMER
It includes Current & Potential transformer. On testing for resistance measurement after taking
above precautions, test setup shall be made as mentioned in the WEAT STONE Bridge instrument
with each core wise. Results will be recorded in the appropriate test forms.

POWER TRANSFORMER / OLTC

After conforming the above precautions, connect the instrument across the winding, which phase to
be measured. On applying voltage by pressing test push button, the reading can be noted & results
will be recorded. The same test shall be repeated for other two phases. If there is tap changer
available, test required to carry out for all tap positions.
1.18 CONTACT RESISTANCE :
This test will be carried out for Bus bar and switches like circuit breakers, Earth switches &
contactors. Above mentioned precautions shall be made for this also. Before starting the electrical
starting better to complete the torque verification for the whole of bus bar . DC current injection
shall be done for the complete section of bus bar to measure the conductivity of bus bar at different
connection points on that section.
For switches, to make contact resistance, close the switches & across that contact inject the DC
current of 100A & measure the resistance values. The same test will be done for other two phases.
The value of contact resistance in micro ohm should be similar to all three phases.

NER & RELAYS

After conforming the above precautions, do the checks as mentioned below……
For NER, disconnect the both end connection and measure the resistor value across the unit &
record.
For relay contacts & coil resistance, measure as required & record the values.

ACCEPTANCE LIMITS
FOR CONTROL TRANSFORMERS
FOR POWER T/F & OLTC
FOR CB’S, E/S’S & BUS BAR
FOR NER & RELAYS
1.19 SCHEME VERIFICATION TEST
OBJECTIVE
To ensure that overall operation of the system & equipment is correct as indicated in the related
schematics and specifications.

PROCEDURE
Following precautions / status conformation should be taken before starting the testing.
Ensure that items and installation conform to the specified requirements and applicable
drawings.
Items are free from damage, have been tested and adjusted as per manufacturer instructions
individually.
Available drawings are the as-manufactured status.
All labels and markings are correct.
Ensure free movement of mobile parts.
Correct polarities and continuities of electric circuits.
Auxiliary control voltages are available in correct magnitude and polarities.
Ensure the unit under test is not functionally connected with other live system (i.e.) isolation
of trip links, CT isolation of Bus bar protection & etc

Start checking the scheme of each assembly/unit as per schematic diagrams. During this test each
device shall be tested for its function verification as a part of overall scheme. Any non-conformity
found shall be rectified and recorded.

AT LEAST FOLLOWING SHALL BE VERIFIED:

Operation sequence and interlock verification
Opening and closing operations of switching devices from local and remote.
Tripping of switching devices from protection.
Status of switching devices to local and remote.
Alarms/indications availability to local and remote.

ACCEPTANCE LIMITS
Functionality of each unit match / with in the customer stipulated specifications / procedures.
1.20 SCHEME COORDINATION
OBJECTIVE
To ensure the availability of proper interconnection / inter relation between the different field
equipment as per the requirement of specific application.

TEST INSTRUMENT REQUIREMENT:

Multi Meter
Remote communication equipment like communication software, remote pocket terminal &
etc.

PROCDURE
Verify the availability of correct field equipment as per the specification in the schematic
drawing as well as at the field. This includes the verification of matching the Meters & Relays
specification with the primary equipment rating like CT, PT, Aux. source, etc.
Check for the available equipment is interconnected / interrelated in the schematic drawing
as well as at the field with reference to it’s application.
It is important to ensure correct reference is made between the equipments in the schematic
drawing as well as at the field. These references can be like labelling, ferruling, colouring, etc.
Make a cross check as per the specification for the interconnection, in the schematic / field,
before making the final verification.
Check for the correct required function as per the required application after interconnection
is verified. This includes the verification of interlocks with different system.
It also important to co-ordinate with the available remote end system like SCADA & etc.
At final stage ensure that the drawing is updated as per the system commissioned at field.

ACCEPTANCE LIMITS:
Availability of all units should match / with in the customer stipulated specifications / procedures.
1.21 SCADA VERIFICATION TEST
OBJECTIVE
To ensure that the various protection and other annunciation signals are correctly routed and
indicated in SCADA system.

PROCEDURE

RELAYS
Protection relays are made to operate by secondary injection and the corresponding signals to
SCADA to be verified.

LEVEL/ TEMP. INDICATION :

Overlevel (or) overtemp. Simulated and corresponding signal observed in scada terminals.

TRANSDUCER :
Rated P.T. secondary voltage and rated C.T. secondary current are applied to transducer, transducer
output checked.
Corresponding indicating meter in scada checked to be in relation to transducer output.
Above test to be repeated at 2 or 3 output values.

RELAY AND CONTROL PANEL :

Breaker on/off control, earth switch on/off control, various protection and control signals from
scada to be verified.Care to be taken to ensure that the same bay only is responding.
Indication from relay panel for selection switch position such as auto reclose on/off verified from
scada.

OLTC MECHANISM AND CONTROL :

Tap position indication in scada and local panel in transformer verified. Increase and decrease of
taps are done manually and again tap position in local and scada verified. OLTC mechanism failure
indication in scada also verified.

BATTERY AND BATTERY CHARGER :

Battery charger on/off, fault relay indications simulated in the charger and verified in scada.

ACCEPTANCE LIMITS
All SCADA points should be satisfactorily meet it’s functional requirement of Signaling / Alarm /
Commands.