Site Tests
The tests to be carried
out on the equipment at pre‑commissioning stage shall include:
1.EHV Circuit breaker
1.IR test on each pole
by Megger (Between poles and lower poles to ground).
2.IR tests on control
circuits.
3.Functional check
of breaker operation on minimum and maximum specified control voltages
4.Checking of interlocks
with isolators & earthing switches.
5. Checking of remote
operation and tripping from protection relays and from other devices as
per approved scheme.
6. Measurement of
contact resistance
7. Testing for leakage
of compressor and hydraulic oil system.
8. Checking tightness of
termination connectors.
9. Checking tightness of
earthing connections.
10. Checking of insulators
for cracks etc.
11. Checking the
settings of pressure switches.
12 Check level of
pressure of air, oil and gas as per the manufacturer's manual.
13. Check direction of
compressor motor and oil pump.
14. Check operation of
breaker at minimum specified pressure.
15. Check for air
leakage in air reservoir.
16. Check for closing
and opening time and simultaneous closing of all poles through oscillograph.
17. Tripping of circuit
breaker at reduced or over voltage i.e. at 60% & 110% .
18. Checking of
hydraulic system and oil leakage in oil pump.
2.EHV
Isolator/Disconnecting switches
1.IR test by HV Meggar
on main poles.
2.IR test on control
circuits.
3.Measurement of contact
resitance for all three phases.
4.Functional checking
for electrial and manual operation.
5.Checking of
interlockings with earth switch and as per write up and
checking of earth switch operation.
6.Checking operation of
earth switch.
7.Setting and checking
of auto trip operation of motor on complete close / open position of
isolator (close/open operation are to be repeated ten times to observe).
8.Testing of overload
relay of motor.
9.Checking for remote
operation.
10.Checking of operation
on minimum and maximum specified voltages (local as well as remote).
11.Checking tightness of
earthing connections.
12.Checking of
insulators for cracks.
3.Lightning Arrestor
1.Continuity check (for
metal oxide type only)
2. Check for connection
to ground.
3.Check insulators for
cracks.
4.Check reading of
leakage current.
5.HT and IR test of each
element.
4.Current Transformer
1.IR test on each
winding, winding to earth and between windings.
2.Checking of winding
ratios by primary injection set.
3.Polarity check on each
winding.
4.Continuity check for
all windings.
5.Check for connections
to correct taps.
6.Measurement of knee
point voltage and secondary winding resitance for the
CTs used for differential protection.
7.Checking of oil level.
8.Checking of continuity
and IR values for cables from CT to Marsh Box.
9.Checking tightness of
earthing connections
10.Checking of insulator
for cracks.
11.Check output after
loading of the main circuit.
5.Potential Transformer
1.IR test of primary
winding by HV megger between windings and earth
2.IR test of secondary
winding by LV megger between windings and winding
to earth
3.Checking of voltage
ratio
4.Verification of
terminal markings and polarity
5.Checking of oil level
6.Checking of continuity
and IR values for cables from PT to Marsh Box
7.Checking tightness of
earthing connections
8.Checking of insulator
for cracks
9.Check output on
charging of the system with connected meters/relays
6.INSULATORS
1.Checking of tightness
of connection.
2.Check for minor
damage/cracks after cleaning.
3.Verification of number
of disks as per drawing.
4.Check for creepage
distance on one type of each set.
5.Check heating at
termination point during shut down.
7.ACSR/ALUMINIUM TUBES
1.Check for continuity
2.Check for tightness of
connections for all the termination points.
3.Check for phase
sequence marking and for their correctness.
8.HT Switchgear
1.IR test
2.HV one minute P.F test
for bushbar and CTs.
3.Checking of SF6 gas
pressure on each unit
4.Measurement of contact
resistance for HT breakers
5.Test to prove inter
changeability of similar parts (including breaker module)
6.Testing of relays as
per bidder's commissioning manual
7.Testing and calibration
of all meters
8.Operation of all
relays by secondary injection
9.Testing of CT
polarities and CT ratio by primary injection test and
CT
characteristics
10.Measurement of knee
point voltage and secondary resistance for CTs used for differential protection
11.IR and voltage ratio
test for PTs
12.Functional test of
all circuit components for each panel/feeder
13.Test to prove closing
/tripping operation at minimum and maximum specified voltage in test and
service position and also measurement of time for above operation
9.LT Switchgear/MCC
1.IR test before and
after HV test.
2.HV test with 2.5 kV
megger
3.Functional test for
all feeders
4.Testing and
calibration of all
meters
5.Checking and
calibration of overload relays and protective relays as per bidder's
commissioning manuals.
6.Check operation of
contactors from local and remote points
7.Checking of
interlockings between incomers/bus coupler and other feeders.
8.Test to prove
interchangeability of similar parts
9.Tests to prove correct
operation of breakers at minimum and maximum specified control voltages.
10.Checking operation of
RC circuit (if there) for tripping of circuit breaker after disappearance of
control voltage
11.Checking of earthing
connection for neutral‑earth bus, cable armour location of E/F CT etc. as per
the scheme
12.Check test, service
and drawout position of all the breakers and operations of mechanical flag
indicator and electrical indication lamps.
13.Check functioning of
various elect. schemes like autochangeover signalling etc.
14.Contact pressure test
15.Testing of CT as per
CT testing details mentioned under sl.no. 4.
16.Breaker : IR value checking
with breaker ON Phase to phase & phase to earth and between phases in
off position
10. HT Busduct
1.IR measurement before
and after HV test
2.HV test
3.Checking tightness of
bolts with torque wrench
4.Checking for phase
sequence marking
5.Check for clearances
between phase to phase and phase to earth
6.Check for minor
damages and cracks in supporting insulators and bushings after cleaning.
7.Checking of busbar
cracks by DP method and rectification of same.
8.Checking for inspection
openings and accessibility for replacement of insulator etc
9.Check tightness of
earthing connections on enclosure
10.Checking of silica
gel breather (if there)
11.Checking of working
of space heater
12.Hot air blowing to
remove moisture if required.
11.ACDB/DCDB/MLDB etc.
1.IR test before and
after HT test
2.HV test by HV megger
(2.5 kV)
3.Checking for functions
of components for each module
4.Checking for
interchangeability of similar components
5.Checking of tightness
of earth connection.
6.Testing and
calibration of all indicating
meters
7.Check output of each
feeder after
energisation.
12.AC Motors (including
slip rings motor)
1.IR test of stator and
rotor windings.
2.Heating of both
windings upto the permissible temp. limit from heating curve. (only for HT
motors).
3.Ensure that
checking/testing of associated switchboard , cables,relays/meter
interlockings as mentioned in relevant chapters are completed.
4.Check tightness of
cable connection
5.Winding resistance
measurement of stator and rotor.
6.Checking continuity of
winding.
7.Check tightness of
earth connections.
8.Check space heaters
and carryout heating of winding (if required)
9.Check direction of
rotation indecoupledcondition during kick start
10.Measure no load
current for all
phases.
11.Measurement of
temperature of body during no load and load conditions.
12.Check for tripping of
motor from local/remote switches and from electrical/technological protection
including differential protection.
13.Checking of vibration
(if required)
14.Checking of noise
level (if required).
15.During load running ,
measurement of stator and bearing temperatures (if applicable) for every half
an hour interval till saturation comes.
16.Checking tightness of
foundation bolts
17.Check operation of
speed switch (if there)
18.Check continuity of
temp. detectors.
19.Check alignment,paralleling
of shafts, level of lubricating oil etc. as per manufacturer's manual
20.Check contact of slip
ring brush and measure brush pressure (150‑200 gm/sq. cm)
21.For CACW drive check
cooling water and system/piping, availability of pressure, cleaning and
pressure testing of pipelines etc.
22.Check for
polarisation index of stator winding, R60/R15 by motorised megger (The value
should not be less than 1.5).
23.Dielectric test (only
for HT motors)
24.Measurement of open
circuit rotor winding voltage for slip ring motor.
25.For actuator drives
following shall be checked/tested :
· Visual and
dimensional
· Hydraulic
pressure for valves
· IR and
operation of limit switches
· Winding
resistance
13.Battery
1.Checking for
completion of civil/ventilation requirement of battery room.
2.Checking of adequacy
of charger output/requirement wrt current required for battery charging as per
the manual
3.Check availability of
safety devices, water and first aid box.
4.Check polarity of
connections between battery and charger.
5.Visual inspection test
for level and leakages.
6.Checking of layout as
per approved drawing
7.Checking of IR value
from positive to earth and negative to earth.
8.Checking of voltage
per cell and total voltage between positive negative and earth to
positive/negative and also tap call voltage (as applicable).
9.Checking of tightness
of connectors on each cell.
10.Checking of capacity
test and hourly measurement of specific gravity and voltage for each cell
14.Battery Charger
1.IR test
2.HV test
3.Checking voltage ratio
of boost and float mode transformers
4.Checking for charging
mode of batteries, constant current and constant voltage mode.
5.Load test on chargers
by running of DC drives and by liquid resistance system.
6.Checking of tightness
of earthing connections.
7.Check for all alarm
conditions.
8.Checking and
calibration of all indicating meters.
9.Check functional
operation of charger, auto/manual change over from float to boost and boost to
float etc.
10.Checking and setting
of all relays
11.Check AC ripple in
boost and float mode after charging.
12.Check polarity of
cables connected to battery.
15.Cables &
Cables Supporting Structures
1.Checking of
continuity/phasing and IR values for all the cables before and after HV test.
2.HV test and
measurement of leakage current after termination of cable kits (for HT cables).
3.Checking of earth
continuity for armour and fourth core (if applicable).
4.Check for mechanical
protection of cables.
5.Check for
identification ( tag numbr system) distance placement of cable marker, cable
joint etc. as per the cable layout drawing.
6.Check earthing of
cable structures.
7.Check safe head room
in gallery area.
8.Check clearances from
ventilation duct and light fittings for cable structures.
9.Check proper fixing of
cable structures.
10.Check for proper
drainage and removal of water (if any).
16.Indoor Lighting
1.Check dressing of
cable
2.Measurement of lux
level at various places
3.Check accessibility
for replacement of lamps
4.Checking for black
spots or poor visibility near operating and indicating equipments
5.Check for mechanical
protection of cables
6.Checking for adequacy
of emergency DC
light
7.Checking for starting
system of periphery lighting
8.Check for auto
switching of battery supply on failure of AC
9.Checking of earthing
of light panel, socket boards, light fittings
10.Checking of type of fittings
wrt specification at various locations
11.Check adequacy of
support of fittings
12.Check water tightness
of outdoor located panels
17.Outdoor Lighting
System
1.Check lux level of
general lighting.
2.Check for visibility
of insulators, bushings and indicating instruments of transformers, breaker and
isolator cabinets etc. during night.
3.Check for adequacy of
escape light during night after failure of general light.
4.Check for proper
painting of lighting supporting structures
5.Check for automatic
switching of light (if applicable)
6.Check for earthing
connections on light fittings, and other control accessories.
7.Check for mechanical
protection of
cables.
8.IR measurement of
lighting cables.
18.Earthing
1.Check tightness of all
earth connections
2.Check earthing of all
metallic equipments, cable trays, busbar supporting structures, yard fencing
steel structures of yard, rails, gates, building column (if steel) all elect.
equipments, gas/oil/water pipe lines etc. as per the drawing /specification
3.Measurement of earth
resistance for each electrode.
4.Measurement of total
earth resistance.
5.Measurement of earth
loop resistance for E/F path of biggest LT drive.
19.Lightning Protection
1.Check continuity of
all the earth strips/shield wire
2.Check tightness of all
connections.
3.Measure earth
resistance of each electrode and combined system
20.Programmable Logic
Controllers (PLCs)
1.Assembly inspection
2.Hardware components
inspection
3.Measurement of
insulation resistance
4.Standard function test
5.Integrated functional
check including sequential interlocks for start/stop of various drives.
21.Control, Relay &
Metering Panels
1.IR value test by
megger
2.Checking of control
cable connection.
3.Operational test of
all components mounted on control panel.
4.Testing and
calibration of indicating meters
5.Testing of all relays
including aux. relays for their pick up drop up values, operation at all taps
(current, voltage and time) etc. as per the manufacturer's commissioning
manuals with the help of relay testing kits.
6.Setting of relays as
per approved setting table and checking its operation for one below and one
upper settings, in the scheme.
7.Measurement of current
and voltage in relay operating coils by secondary injection in CT and PT
circuit at switchboard.
8.Measurement of current
and voltage in relay and meter circuits during loading of the primary
circuit/system
9.Testing of all schemes
for their functions as per approved drawings
10.Checking stability of
differential protection
schemes
11.Checking inter
changeability of similar equipments
12.Verification of
accessibility of all operating points including resetting knob of relays
13.Check operation of
each annunciation facias, operation of bell/hooter etc. and sequence of the
system
14.Check operation of
relays at minimum/maximum control voltage as per the specification
15.Integrated testing of
protective relays for operation of master trip relays and tripping of breakers
from operatin of master trip relay
16.Check dressing of
cables, sealing of openings in gland plate and for provision of double
compression glands
17.Check earthing
connection of panels, fixing of panels and openings from side and bottom.
18.Testing of energy/TVM
meters and operation of recorders
19.Test working of
recorders on failure of AC supply (if applicable)
20.Checking and
adjustment in trivector meters as per the manufacturer's instructions.
22.Ventilation system
1.Check tightness of all
foundation bolts, coupling bolts
2.Check for cable
dressing
3.Check level of fan
4.Check for lubrication
of bearing and tightness of bearing
5.Check for belt
alignment
6.Checking of all duct
support
7.Checking for
close/open operation of all dampers
8.Check for key in motor
and fan
pulley
9.Check no foreign
material inside fan casing
10.Check freeness of fan
and impeller by hand rotation
11.Check tightness of
belt
12.Check for safety
guard for all rotating drives.
13.Flexible machinery
connection at fan inlet and outlet
14.Fan air washing
system, spary nozzle, supply and return pipe re circulating pipe line, make up
water pipeline, float valve, water line gate valve, pump operation should be
checked for proper functioning.
15.Dry panel filter to
be cleaned at regular interval and check whether the PD is within allowable
limit if manometer is provided.
16.For viscous oil
filter, rotation of filter mat, sludge removal, gear motor functioning to be
checked at regular interval. Filter should rotate/move freely.
17.Check the
completeness of the system and layout wrt approved drawings.
18.Check whether
vibration is excessive.
19.Operation
(closing/opening) of damper can be done freely.
20.For electric drives :
· IR
measurement
· Measurement
of no load current
· Calibration
and operation of overload relays
· Measurement
of vibration without and with belt
· Measurement
of vibration
· Checking
for earthing connection
· Check for
all inter lockings
· Check temp.
rise of body
21.Performance
· Air flow
measurement at various entry points of switchgear room basement etc. and total
as per approved drawings
· Velocity of
air at various grill points to be measured
· Noise
measurement
· Measurement
of dust contain and filtration efficiency
· Measurement
of inside and outside temperatures and humidity
· Static
press at fan outlet
· Pressure
difference between inside and ambient in case of plenum system.
22.Air Conditioning System
1.Checking of foundation
bolts and nuts for all the drives
2.Checking of belt
alignment for AHU
motor
3.Check key fixing in
motor and fan pulleys
4.Check operation of all
dampers
5.Check support
arrangement for ducts
6.Check connection and
dressing of cables
7.Check earthing of
panels and all metallic structures
8.Checking and
calibration of all gauges and instruments
9.Checking and
calibration of all indicating meters
10.IR of elect. panel
(MCC) and control panel
11.Check functional
checking of all components
12.Test and calibration
of over load
relays
13.Measurement of no
load current for all motors
14.Measurement of
vibration (with and without belt for AHV motor)
15.Check temp. rise of
motor body
16.Checking of all inter
lockings.
17.Pressure testing of
all pipes
18.Vacuum testing of
refrigeration lines
19.Expansion valve
should not be frosted and to be set properly
20.Air filter cleanness
to be checked.
21.Compressor head temp
should not be too high.
22.Return line to the
compressor should not be frosted.
23.Safety valves at
condenser should be set properly
24.In case of water
cooled condenser water flow switch should be interlocked with compressor
25.Pipe routing of
refrigerated line shall must be done as per the approved drawing.
26.For welding/soldering
of pipe gasket (if any) in the near by pipeline shall be removed before
starting the welding/ soldering.
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