Gms Ele Itp 001 Hv & Lv Switchgear

For internal circulation only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

of 12 Prepared by: SMS/ R Dhawad Group Manufacturing Services

Electrical Date: 14.07.2007 Approved by: GS Vishnumurthy Doc. No: GMS/ELE/ITP/001 Revision no.: 0.0

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INSTALLATION TEST PLAN -

HV & LV SWITCHGEAR




of 12 Prepared by: SMS/R Dhawad Group Manufacturing Services


Inspection and Test Plan for HV & LV Switchgear

1. Objective

a. Proper installation, testing and commissioning of switchgear will ensure plant

reliability and integrity.

b. The objective of the document is to establish the standard practice for Inspection

and Testing of LV & HV switchgear.

2. Scope

a. Scope of this document is to prepare systematic check sheet for installation,

testing and commissioning audit of HV & LV switchgear

3. Mandatory Safety considerations

a. All local statutory requirements

b. Existing permit system

c. Risk assessment for the job

4. Inspection, testing & commissioning plan for HV & LV Switchgear Breaker

The detailed inspection, testing & commissioning plan for HV & LV Switchgear is given in

Annexure - A, referring to manufacturer’s recommendation, national and international

codes/standards and RIL practices.

5. Resources for HV & LV Switchgear Installation, testing & commissioning

For safe & reliable installation & commissioning of HV & LV Switchgear following preparatory

activities, documentation, material, testing & measuring instruments, tools & tackles are required.

The list given below is for guidance purpose. However based on the actual site requirements, the

resources may vary. Hence site survey is necessary to assess the exact requirement of

resources for installation, testing & commissioning.






5.1 Documentation prior to starting the job

a. OEM installation & commissioning manual.

b. Switchboard SLD and BOM.

c. Substation equipment layout

d. Certification of completion of civil foundation.

e. Earthing layout.

f. Cable schedule for Inter panel, Breaker control and power cables.

g. Power and control wiring drawings of the panel.

h. AC/DC control supply system commissioning report

5.2 Material prior to starting the job

a. HV/LV Switchgear with all accessories.

5.3 Test / Inspection certificates

a. Switchboard test report / Acceptance report.

b. Cable laying and termination installation completion report.

c. Test certificate of all bought out items d. HV CT & PT test reports e. Breaker test report

5.4 Special Tools & Tackles

a. Crane / jacks of adequate capacity.

b. Breaker handles and panel keys

c. Rigging tools & tackles as required.

d. Torque wrech

5.5 Testing and measuring instrument

a. Megger of appropriate voltage rating.

b. Multi meter.

c. Contact resistance measurement kit.

d. Breaker test kit

e. HV test kit

f. Earth test meter






5.6 Skilled Manpower

a. Riggers

b. Electricians

c. Testing Engineer with experience in HV & LV Switchboard testing.

Annexure

Annexure-A: ITP HV & LV Switchgear

Annexure-B: ITP HV & LV Switchgear Hi Pot Test Records

Annexure-C: ITP HV & LV Switchgear CT Primary Injection

Annexure-D: ITP HV & LV Switchgear: - Testing & Measuring Instruments






Annexure - A HV & LV SWITCHGEAR - PRECOMMISSIONING CHECK SHEET

Plant : Date of

Commissioning :

Area / Unit : Year of

Manufacturing :

No. of Panels Make :

Voltage Rating : Current Rating :

Short Circuit Rating :

SN Activity Observation / Action taken

/ Remarks Receipt and Preservation

1 Ensure certified tools, lifting equipment are used for unloading of Switchgears by trained and competent personals. Avoid any sudden jerks when moving.

2 Ensure completeness of supply and specification as per packing list, BOQ, OEM manual & PO.

3 Check name plate data against data sheet. 4 Inspect all items of equipments as soon as possible

upon arrival at site to ascertain whether they have been damaged in transit or whether any items are missing. Particular attention should be paid to bushings, meter and relays which are the items most liable to damage.

5 If the Switchgear is to be stored for long duration, it should be stored in the clean, dry, and airy place.

6 Packing material such as wood, wool or straw packed around insulation other than porcelain, should be removed as they may absorb moisture. Periodic inspection and vermin proofing is carried out of such places.

Panel Foundation 1 Ensure foundation is ready and released by concerned

department.







/ Remarks 2 Check dimensions of floor cut outs w.r.t. drawings 3 Check the panel base frame dimensions w.r.t cut

out/Frame.

4 Check layout and leveling of base frame and foundation bolts /holes before installation of switchgear panel.

Panel Checks 1 Check name plate & tag Number on front & rear

sides as per Drawing.

2 Check orientation, vertical & horizontal alignment of panels and clearance.

3 Check all inter-panel coupling bolts are properly leveled and tightened.

4 Check the gaskets provided on panel doors/ inter panel location are ok.

5 Check for panel grouting / bolting and proper fastening of panel body with base frames.

6 Check for provision of Anti-condensation heaters 7 Check for correct component and internal control

wiring, correct ferrule numbering as per drawing. Check for no loose control wiring, proper dressing of control cables.

8 Check that no live parts are exposed. 9 Check for provision of future expansions. 10 Check for condition of limit switches, alignment of

male & female contact.

11 Check for vermin proofing of panels. 12 Check for panel door interlocks & padlocking

arrangement.

13 Check for availabilty of explosion vents / ventilationand helthyness of the same wherever applicable.

14 Check whether any loose items are left inside the panel and ensure general cleanliness of panels

15 Check for provision of rubber mats in front of the panels

16 Check Thermography survey window is available Bus Bar Checks 1 Check for correct size, rating and alignment of bus

bars.

2 Check bus bar connections are correct, properly







/ Remarks aligned and tighten with torque wrench. Also ensure proper size and quality of Bolts, nuts and washers are provided.

3 Check for phase separators & their position. 4 Check for condition of bus bar support insulators /

bushings / shrouds.

5 Check for correct phase color marking on bus bars. 7 Check Cable/ bus duct entry properly sealed.

Metering and Protection Checks 1 Check for rating, correct positioning, termination &

polarity of CTs. earthing through removable link

2 Check for rating, correct positioning, termination & polarity of PTs. earthing through removable link

3 Check for shutter operations for withdrawable PTs.

4 Check for correct rating of fuses – control & power both as per drawing.

5 Check protective relays are available as per drawings.

6 Check the relays are tested and set as per recommended relay settings.

7 Check for appropriate range & size of meters. Earthing 1 Check for provision of double and distinct earthing

of panels

2 Check for provision of Earth bus, panel earthing & earth marking.

3 Check Inter panel continuous earth bus properly tighten.

4 Check for CT / PT earthing through removable link. 5 Check CT base earthing. 6 Check for earthing bond between panel & door. 7 Check for shutter earthing & earthing of bus duct

enclosure.

8 Check for body earthing of protective relays, wherever applicable.

9 Measure the earth resistance Checks on Circuit breaker 1 Check for correct current and short circuit rating &

type of Circuit breaker for corresponding feeder.

2 Check interlocks with upstream or downstream breakers of feeders if any







/ Remarks 3 Check interchangeability of the breakers. 4 Check all breakers and associated switchgear

thoroughly. (Refer “HV & LV Breaker ITP”)

Power cable Termination 1 Check cable termination ITP completed. 2 Check for adequate phase to phase & phase to

earth clearances.

3 Check that all additional / spare openings at the gland plate are sealed.

Control Supply 1 Check for AC / DC control bus bars are properly

installed with all hardware.

2 Check for correctness and tightness of control wiring.

3 Check for correct component & ferrule numbering as per approved drawings.

4 Check for proper dressing of control cables Electrical checks 1 Check IR value of control wiring, bus bar, breaker,

PTs are satisfactory and data recorded

2 Check Contact resistance of bus bar joints, isolating contacts are satisfactory and data recorded

3 Check Hi-Pot test results of Bus and breakers are satisfactory and data recorded

4 Check ratio, polarity of CTs, PTs and Knee point voltage (wherever applicable) for Protection class CTs are tested and data recorded

5 Check all relays are tested and data recorded. 6 Check simulations of all control, Under voltage &

auto commutation scheme, interlock protection, annunciation and indicator circuits done and data recorded.

Miscellaneous Checking 1 Check that no loose items are left inside the

panel.

2 Check space heater supply made available 3 Check for general cleanliness of the panels. 4 Check that fire-fighting equipments are provided. 5 Check Stage wise inspection clearance / test

reports.

6 Check DC Control supply of rated voltage made







/ Remarks available with correct polarity

7 Check proper precautions taken to prevent water falling on the roof of the board or any part of it

Check sufficient lighting arrangement made and is in service.

Check Switchboard room properly cleaned. Switch Fuse Unit (For LV Switchboard) 1 Check for correct rating and size of power fuses.

Check rating and size of fuses match to that of fuse carrier/base/switch.

2 Check for proper operation of switch fuse unit & its interlocks.

3 Check for correct rating & setting of overload relays as per recommended relay setting wherever applicable.

Checked and witnessed by [RIL Engineer ] [Contractor Engineer] Name / Signature & Date Name Signature & Date






Annexure – B HV & LV Switchgear – TEST RECORD

Plant : Unit : Equipment no.: Substation no.:

Switchboard No. Panel no.

Front:

Rear:

Operating voltage

Short Circuit capacity

Manufacturer:

Drawings No. a) G.A. Drawing B) Control Drawing c) Operation and

Maintenance Manual

1. Bus IR Value before Hipot: Megger Voltage : Megger Sr. No. RE = RY = YE = YB = BE = BR = 2. Hipot Testing:

Leakage Current Voltage Applied Between

Applied Voltage Duration

Start Finish Remarks

R & Y + B + E

Y & B + R + E

B & R + Y + E

3. Bus IR Value after Hipot: RE = RY = YE = YB = BE = BR = 4. PI value: RE = RY =

YE = YB = BE = BR = Checked and witnessed by [RIL Engineer ] [Contractor Engineer] Name / Signature & Date Name Signature & Date






Annexure - C CT Testing

Make: Switchboard No.

Equipment no.: Substation no.:

Sr. No.

R:

Y:

B:

Type VA

Ith

CT Ratio

BIL Class Hz Instrument Safety factor

Primary Injection Test

Phase Injection primary current

Secondary Protection

Metering Current

Reading of panel

R

Y

B







Annexure - D TESTING & MEASURING INSTRUMENTS

TESTING & MEASURING INSTRUMENTS USED

SR no. of Instrument

Instrument Name & Details

Instrument used for which tests

Tested at Calibration

Validity


Gms Ele Itp 001 Hv & Lv Switchgear

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