Testing & Comm Procedure-rev 10-Enppi

Projects & Services Execution Division

Field Operations Services

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Procedure For Pre-Commissioning, Commissioning & Startup of Electrical Equipment

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations – Rev.10

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Index

Table Of Contents

Page

1

1. INTRODUCTION

5

2

2. SAFETY

6

3

3. Medium Voltage Equipment

7

4

3.1.1. Pre-Commissioning visual & mechanical inspection

7

5

3.1.2. Commissioning

7

6

3.1.3. Pre-Energization Checks

9

7

3.1.4. Energization Precautions and procedures

9

8

3.1.4.1. Precautions

9

9

3.1.4.2 .Procedures for Energization

9

10

3.2 MV Circuit Breakers

11

14

3.2.2. Vacuum C.B

11

15

3.2.2.1 Pre-Commissioning visual & mechanical inspection

11

16

3.2.2.2. Commissioning

11

17

3.3 Protective Relays

12

18


12

19


12

20

3.4 Current Transformers

13

21


13

22


13

23

3.5 Voltage Transformers

14

24


14

25


14

26

3.6 Power Transformers

15

27

3.6.1. Liquid Filled Transformers

15

28


15

29


15

30

3.6.1.3. Pre-Energization Checks

16

31

3.6.2. On Load Tap Changer (OLTC)

17

32


17

33


17


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3.7 Capacitors (Power factor Correction)

19

35


19

36


19

37


20

38

3.8 MV Motor Starters & Power Feeders

21

39


21

40


21

41


23

42

4. Low Voltage Equipment

24

43

4.1 LV Switchgear (Metal Enclosed)

24

44


24

45


24

46


25

47

4.2 LV Circuit Breakers

26

48

4.2.1. Insulated Case / Molded Case

26

49


26

50


26

51

4.2.2. LV Power (Air C.B)

52


27

53


27

54

4.3 LV Motor Starter& Power Feeders

28

55


28

56


28

57


29

58

4.4 Interposing Relay Panel

30

59


30

60


30

61

4.5 Active Harmonic Filter (AHF)

31

62


31

63


31

54

4.6 Neutral Earthing Resistor (NER)

32


27

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__________________________________________________________________________________ 65


32

66


32

67

4.7 AC/DC power Distribution Boards.

33

68


33

69


33

70

5. Safe Energization Precautions

34

71

6. Appendix A: List of tables

35

72

7. Appendix B: Norms

40

73

8. Appendix C: List of used equipment in Pre-commissioning Commissioning Phase

41


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1. INTRODUCTION The purpose of these specifications is to assure that all tested electrical equipment and systems supplied by SEE (SCHNEIDER ELECTRIC EGYPT & NEA) are operational and within applicable standards and tolerances And that equipment and systems are installed in accordance with design specifications. The need for acceptance testing of electrical power systems is very clear to those with extensive start-up and/or operating experience. Shipping and installation damage, field and factory wiring errors, manufacturing defects, And systems and components not in accordance with drawings and specifications are some of the many problems that can be detected by appropriate testing. When these defects are found before start-up they can be corrected under warranty and without the safety hazards and possible equipment and consequential damages of loss of use/production that can occur if discovered after startup or energizing. In addition, test results obtained during acceptance testing are invaluable as base reference data for the periodic testing that is an essential element of an effective maintenance program. This document lists a majority of the field test available for assessing the suitability for service and reliability of the power distribution system. As a further note, it is important to follow the recommendations contained in the manufacturer’s instruction manuals. Many of the details of a complete and effective acceptance testing procedure can only be obtained from that source. This document details the Field inspection, testing and commissioning procedures that must be followed during commissioning and startup of electrical equipment. These inspections and tests are performed on new Equipment, after installation and prior to energizing, in order to confirm that: 1. The equipment has not been damaged during shipment or installation. 2. The equipment is in compliance with the purchase specification and design intent. 3. Documented test records that can serve as benchmarks for future tests.


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2. SAFETY Proper safety procedures shall be reviewed and followed before each activity listed in this procedure. Job Safety Analysis followed by a toolbox/pre-job meeting shall be conducted prior to any activity listed in this procedure. Services Employees are NOT authorized to work on live equipment. There may be occasions in which you are taking measurements or checking voltages within an energized enclosure, but you are NOT authorized to “do Hands on Live” repairs. Company representative does not typically perform shutdown and/or switching operations, because these operations may result in damage to property or persons downstream of the equipment as a result of conduct, errors, or omissions made by others. If a customer requests Company representative to perform such services, technicians must contact their Manager for approval and proper procedures.


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3. Medium Voltage Equipment 3.1 MV Switchgear (Metal enclosed): from 1 up to and include 40.5 KV 3.1.1. Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plates are according to the corresponding drawings. 2. Inspect physical and mechanical condition of the equipments and all components for clear damage. 3. Verify appropriate anchorage, required area clearances, physical damage, and correct alignment and cleanliness. 4. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware. 5. Verify that the barriers and shutters are installed and operating correctly. 6. Inspect insulators for evidence of physical damage or contaminated surfaces. 7. Verify that filters are in place and all ventilation openings are clear from any kind of obstacles. 8. Verify that main bus bar is connected between the cells. 9. Verify that the earth bars is connected between the cells and connected to the earth. 10. Verify the tightness of accessible bolted electrical connections using the calibrated torque-wrench method in accordance Table 1 11. Using conductivity test, check the bolted electrical connections for high resistance. 12. Confirm that lubricants have been correctly applied at the recommended locations. 13. Inspect all mechanical indicating devices for correct operation. 14. Attempt closure on locked-open devices. Attempt to open locked-closed devices. 15. Verify key exchange with devices operated in off- normal position. 16. Verify that draw out disconnecting contacts, grounding contacts and interlocks are functioning correctly. 17. Verify that fuse and/or circuit breaker size and type correspond to drawings. 18. Verify that current and potential transformer ratios correspond to drawings. 19. Verify that all the interconnection control wires between the cells have been made correctly reference to the control drawings. 20. Verify that customer connections to remote power, operators, interlocks, and indicators have been made.

3.1.2. Commissioning: 1. Check the availability of the required auxiliary supply for control operation.

2. Make sure that cables (Inc/Out) are centered inside the toroide (if found) and the toroide direction and connection are according to the catalogue. 3. Check the phase sequence of the incoming cables using phase sequence device on the secondary connection of the potential transformer.


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__________________________________________________________________________________ 4. Perform a control wiring performance test by applying control voltage and verify that the equipment operates as intended. 5. Test individual circuit breakers or switches in accordance “Section 3.2—MV C.B”. 6. Test protective relays in accordance with “Section 3.3—Protective Relays” 7. Tests instrument transformers in accordance with “Section 3.4: Current Transformers “and “Section 3.5: Voltage Transformers” 8. Perform function operation test to prove correct interaction of all sensing, processing and protecting devices also proves that the control/auxiliary supply is connected properly and alarms and indications are appearing correctly. 9. Perform functional interlock test to prove the proper operation and indications of interlock scheme (electrical / mechanical) 10. Test the anti-condensation heaters by connecting the power supply and measure the consumed current using clamp meter and check the settings of the thermostat. 11. Check ventilation fans operation. 12. Perform insulation-resistance tests (Megger Test) on each bus section, phase-to-phase and phase-toground, at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the recommended values in Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal the causes, clean the equipment well, then re- measure. If cleaning does not reveal the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure. 13. Perform insulation-resistance tests (Megger Test) at the DC test voltage appropriate for control wiring in accordance with Table 2. 14. Perform a dielectric test (Hi-Pot) on each bus section; each phase to ground with phases not under test grounded .Test voltage shall be 80% of the values indicated in table 4. When performing dielectric tests, all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment shall be isolated before the test and put back in place after completing the test.

Important Notes regarding Megger& Hi-Pot tests: 1. Megger test and HI-POT test will be performed on the switchgear including main B.B, C.B, Current transformers, bushings and insulators. 2. Megger Test and HI-POT test to be performed directly (with in the same day/max 24 hours) before startup (Energization). If the startup phase will not follow the comm. Phase (there will be time gap in between), these tests will be delayed to be performed directly before Energization. 3. Insulation-resistance tests (Megger Test) to be performed BEFORE and AFTER the HI-POT test.


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__________________________________________________________________________________ 3.1.3. Pre-Energization Checks: 1. Check that Panels has been appropriately cleaned (including C.B, insulators, B.B compartment, and cable compartments). 2. Check that lubricants have been applied to the recommended places. 3. Check that Barriers, covers and shutters are installed in its place. 4. Check that P.T fuses are installed correctly. 5. Incoming cables to the switchgear are connected with the right phase sequence. 6. Megger test has been performed successfully 7. Hi-pot test has been performed successfully.

3.1.4. Energization precautions & procedures: 3.1.4.1 Precautions: 1. Safety fence and fire extinguisher or fire fighting system must be present around the switchgear. 2. Area around the switchgear must be cleared from any kind of obstacles. 3. Any unnecessary crowd around the switchgear during initial Energization must be cleared. 4. All openings and cut outs must be sealed. 5. All doors and windows in the substation must be installed and closed to protect the switchgear from unnecessary access.

3.1.4.2: Procedure for Energization: 1. All Incoming C.B’s must be in TEST position. 2. All earthing switches must be OFF. 3. All motor charging MCB must be switched OFF. 4. Discharge the C.B manually to make sure it is not charged. 5. Protection relay settings must be set to MINIMUM values for (Over current, short Circuit and earth fault). 6. After rack in the C.B, switch ON the motor charging MCB. 7. After energizing the C.B and everything is stable, re-adjust the protection relay settings to be according to customer/ study values.

For outgoing C.B: 1. All outgoing C.B’s must be in TEST position. 2. All earthing switches must be OFF. 3. All motor charging MCB must be switched OFF. 4. Discharge the C.B manually to make sure it is not charged.


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__________________________________________________________________________________ 5. After rack in the C.B, switch ON the motor charging MCB. 6. Adjust protection relay settings to be according to customer/study values.

7. If the outgoing will energize transformer, make sure that LV side C.B is in TEST position.


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3.2 MV Circuit Breakers: 3.2.1. Vacuum C.B: 3.2.1.1 Pre-Commissioning visual & mechanical inspection: 1. Verify that circuit breakers name plates are according to the corresponding drawings. 2. Inspect the physical and mechanical condition of the breaker. 3. Inspect anchorage and grounding. 4. Inspect and verify adjustment of the mechanism and alignment. 5. Inspect the mechanical operation of the breaker. 6. Confirm that lubricants have been correctly applied at the recommended locations.

3.2.1.2. Commissioning: 1. Verify trip, close, trip-free, and ant pump functions. 2. Trip the circuit breaker by operating each protective device. 3. Perform insulation-resistance tests on each bus section, phase-to-phase and phase-to-ground, at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the recommended values in Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal the causes, clean the equipment well, then re- measure. If cleaning does not reveal the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure.


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3.3 Protective Relays: 3.3.1. Pre-Commissioning visual & mechanical inspection: 1. Inspect the physical, electrical, and mechanical condition of the equipment for any damage. 2. Verify that protection relay type matches the drawings. 3. Tighten accessible wires and verify correct connection as per the drawings.

3.3.2. Commissioning: 1. Inspect Outputs and indicators for correct operation according to protection relay control matrix included in the drawings or in the relay coordination study. 2. Control Verification: Verify that each of the relay contacts performs its intended function in the control scheme, including breaker trip tests; close inhibit tests, 86 lockout tests, and alarm functions using secondary injection test kit. 3. Verify that all pickup/dropout parameters are on each operating element.


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3.4 Current Transformers: 3.4.1. Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plates are according to the corresponding drawings. 2. Inspect the physical and mechanical condition of the equipment for any visual damage. 3. Verify correct connection of transformers with system requirements. 4. Verify that all required grounding and shorting connections provide contact. 5. Verify that all shorting blocks are in the correct position, either grounding or open, as required

3.4.2. Commissioning: 1. Perform insulation-resistance tests (Megger Test) on each bus section, phase-to-phase and phase-toground, at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the recommended values in Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal the causes, clean the equipment well, then re- measure. If cleaning does not reveal the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure. 2. Perform a dielectric test (Hi-Pot) on each bus section; each phase to ground with phases not under test grounded .Test voltage shall be 80% of the values indicated in table 4. When performing dielectric tests, all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment shall be isolated before the test and put back in place after completing the test. Important Notes regarding Megger& Hi-Pot tests: 1. Megger test and HI-POT test will be performed along with the switchgear (As a part of the switchgear at the same time unless the C.T’s are supplied separately or as spare) 2. Megger Test and HI-POT test to be performed directly (with in the same day/max 24 hours) before startup (Energization). If the startup phase will not follow the comm. Phase (there will be time gap in between), these tests will be delayed to be performed directly before Energization. 3. Insulation-resistance tests (Megger Test) to be performed BEFORE and AFTER the HI-POT test.


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3.5 Voltage Transformers: 3.5.1. Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plates are according to the corresponding drawings. 2. Inspect the physical and mechanical condition of the equipment for any visual damage. 3. Verify correct connection of transformers with system requirements. 4. Verify correct operation of transformer draw out mechanism and grounding operation. 5. Verify correct primary and secondary fuse size.

3.5.2. Commissioning: 1. Perform turns ratio verification test.


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3.6 Power Transformers: 3.6.1. Liquid Filled Transformers: 3.6.1.1 Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plates are according to the corresponding drawings. 2. Make a close examination for shipping brackets or fixtures that may not have been removed during installation. 3. Verify appropriate anchorage, fixation, required area clearances, physical damage, and cleanliness. 4. Inspect the physical and mechanical condition of the equipment for any visual damage. 5. Verify correct equipment grounding. 6. Verify the tightness of accessible bolted electrical connections using the calibrated torque-wrench method in accordance Table 1 7. Verify the presence of transformer surge arrestors. 8. Verify correct liquid level and oil level indicators. 9. Inspect for any oil leaks. 10. Check Silica Gel installation, level and color. 11. Verify that fixed tap connections are as per the drawings. 12. Check C.T’s ratings and polarity (Visual). 13. Check Buckolz relay physical condition and assembly. 14. Check oil sampling facility physical condition and assembly. 15. Verify connection of all alarm, control, and trip circuits for temperature indicators, level indicators, pressure relief device, pressure fault relay and any other if found. 16. Verify that the control and alarm settings for temperature indicators are as specified. 17. Verify that customer connections to remote power, operators, interlocks, and indicators have been made.

3.6.1.2. Commissioning: 1. Check the availability of the required auxiliary supply for control operation. 2. Verify that cooling fans operate correctly and check temperature module settings (If found). 3. Verify the operation of tap changer (On load/ off load) if any. 4. Perform function operation test to prove correct interaction of all sensing, processing and protecting devices also proves that the control/auxiliary supply is connected properly and alarms and indications are appearing correctly. 5. Perform insulation-resistance tests on each bus section, phase-to-phase and phase-to-ground, at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance with Table 3. Record the resistances. If the resistance is lower than the recommended values from the vendor


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__________________________________________________________________________________ documents (if available) or If not, refer to the formula in page 37; visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal the causes, clean the equipment well, then re- measure. If cleaning does not reveal the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure. 6. Perform a transformer turns-ratio test. Verify that winding polarities are in accordance with nameplate.

7. Remove a sample of the insulating oil to perform insulating oil testing (Breakdown test). 8. Perform phase sequence check.

3.6.1.3. Pre-Energization Checks: 1. Check that transformer is cleaned. 2. Check that barriers and covers are installed in its place (if found). 3. Megger test has been performed successfully


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__________________________________________________________________________________ 3.6.2. On Load Tap Changer (O.L.T.C): 3.6.2.1 Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plates are according to the corresponding drawings. 2. Make a close examination for shipping brackets or fixtures that may not have been removed during installation. 3. Verify appropriate anchorage, fixation, required area clearances, physical damage, and cleanliness. 4. Inspect the physical and mechanical condition of the equipment for any visual damage. 5. Verify correct equipment grounding. 6. Verify the tightness of accessible bolted electrical connections using the calibrated torque-wrench method in accordance Table 1 7. Verify correct liquid level and oil level indicators. 8. Inspect for any oil leaks. 9. Verify that customer connections to remote power, operators, and indicators have been made

10. Control panel check: •

Check for padlock able incoming supply switch.

•

Check for manual operating facility.

•

Check for local/remote selector switch facility.

•

Check for local mechanical tap changer position indicator.

•

Check for tap status indication.

•

Check for space heater.

3.6.2.2. Commissioning: 1. Check the availability of the required auxiliary supply for control operation. 2. Test the anti-condensation heaters by connecting the power supply and measure the consumed current using clamp meter and check the settings of the thermostat.

3. Make sure that applied voltage to the motor connection terminals has a Clock wise phase sequence. 4. Test tap change operations to check the mechanical function of the OLTC and the motor drive. Operations must be done over the entire operating range. Make sure that the position indicators of the motor-drive and the OLTC have the same reading in every operating position. 5. Test manual operation of the OLTC. Make sure that all mechanical indicators are matching the position of the tap. 6. Check that automatic switch off is working in both ends positions. Schneider Electric Egypt-Projects & Services Execution Division-Field Operations – Rev.10

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__________________________________________________________________________________ 7. Make sure that the OLTC completes the tap change operation before the motor drive stops. 8. Check that the motor drive switches off automatically after performing one operation and the pointer of the tap change indicator stops within the gray field. 9. Operate the motor drive using hand crank while the motor protective switch is activated. Check that the motor protective switch trips after a max of 4 sections. 10. Initiate the OFF push button (test tripping) of the OLTC protective relay. Make sure that the C.B is tripped. 11. Initiate the IN SERVICE (reset) push button of the OLTC protective relay. Make sure that the C.B can be switched on again. 12. Make sure that flap valve (flag indication) is changing with the two positions. 13. Trigger any other protection functions from the transformer side and verify that MV cell is responding as indicated and vice versa. 14. Perform turns-ratio test on all tap positions.

15. Perform insulation resistance test. 16. Remove a sample of the insulating oil to perform insulating oil testing (Breakdown test).


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3.7 Capacitors ( Power Factor Correction): 3.7.1. Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plates are according to the corresponding drawings. 2. Inspect the physical and mechanical condition of the equipment 3. Verify appropriate anchorage, fixation, required area clearances, physical damage, and correct alignment and cleanliness. 4. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware. 5. Verify that bus bar connections are connected properly. 6. Verify that earth bars connects between the cells if any. 7. Inspect insulators for evidence of physical damage or contaminated surfaces. 8. Verify that filters are in place and all ventilation openings are clear from any kind of obstacles. 9. Verify the tightness of accessible bolted electrical connections using the calibrated torque-wrench method in accordance Table 1 10. Inspect all mechanical indicating devices for correct operation. 11. Verify that all protection and measuring devices are corresponding to drawings. 12. Verify that fuse and/or circuit breaker or contactor size and type are corresponding to drawings. 13. Verify that current and potential transformer ratios are corresponding to drawings. 14. Verify regulator connection (current, voltage and earthing) as per drawings. 15. Verify that all the interconnection control wires between the cells have been made correctly referred to the control drawings (If any). 16. Verify that capacitors are electrically connected in their specified configuration as per the drawings. 17. Verify that customer connections to remote power, operators, interlocks, and indicators have been made.

3.7.2. Commissioning: 1. Check the availability of the required auxiliary supply for control operation. 2. Test the anti-condensation heaters by connecting the power supply and measure the consumed current using clamp meter and check the settings of the thermostat. 3. Check ventilation fans operation.

4. Perform insulation-resistance tests on each bus section, phase-to-phase and phase-to-ground, at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the recommended values in Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure


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__________________________________________________________________________________ 5. Measure the capacitance of each capacitor unit. 6. Test the unbalance relay using secondary injection test kit and make sure that tripping accurse. 7. Apply the settings of the regulator as per the drawings (steps). 8. Perform function operation test for C.B/Contactors, Remote operation, protection, alarms and tripping indications. 9. Check the phase sequence of the incoming cables using phase sequence device on the secondary connection of the potential transformer. 10. Perform a dielectric test (Hi-Pot) on main B.B connection.

3.7.3. Pre-Energization Checks: 1. Check that Panels has been appropriately cleaned. 2. Check that lubricants have been applied to the recommended places. 3. Check that Barriers, covers and shutters are installed in its place. 4. Check that P.T fuses are installed correctly. 5. Incoming cables to the panels are connected with the right phase sequence. 6. Megger test has been performed successfully 7. Hi-pot test has been performed successfully.


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3.8 MV Motor Starters & Power Feeders: 3.8.1. Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plates are according to the corresponding drawings. 2. Inspect physical and mechanical condition of the equipments and all components for clear damage. 3. Verify appropriate anchorage, required area clearances, physical damage, and correct alignment and cleanliness. 4. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware. 5. Verify that the barriers and shutters are installed and operating correctly. 6. Inspect insulators for evidence of physical damage or contaminated surfaces. 7. Verify that filters are in place and all ventilation openings are clear from any kind of obstacles. 8. Verify that main bus bar is connected between the cells. 9. Verify that the earth bars is connected between the cells and connected to the earth electrode. 10. Verify the tightness of accessible bolted electrical connections using the calibrated torque-wrench method in accordance Table 1 11. Confirm that lubricants have been correctly applied at the recommended locations. 12. Inspect all mechanical indicating devices for correct operation. 13. Attempt closure on locked-open devices. Attempt to open locked-closed devices. 14. Verify key exchange with devices operated in off- normal position. 15. Verify that draw out disconnecting contacts, grounding contacts and interlocks are functioning correctly. 16. Verify that fuse and/or circuit breaker size and type correspond to drawings. 17. Verify that current and potential transformer ratios correspond to drawings. 18. Verify that all the interconnection control wires between the cells have been made correctly reference to the control drawings. 19. Verify that customer connections to remote power, operators, interlocks, and indicators have been made.

3.8.2. Commissioning: 1. Check the availability of the required auxiliary supply for control operation.

2. Make sure that cables are centered inside the toroide (if found) and the toroide direction and connection are according to the catalogue. 3. Perform a control wiring performance test by applying control voltage and Verify that the equipment operates as intended. 4. Test individual circuit breakers or switches in accordance “Section 3.2—MV C.B”. 5. Test protective relays in accordance with “Section 3.3—Protective Relays”.


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6. Tests instrument transformers in accordance with “Section 3.4: Current Transformers “and “Section 3.5: Voltage Transformers” 7. Perform function operation test to prove correct interaction of all sensing, processing and protecting devices also proves that the control/auxiliary supply is connected properly and alarms and indications are appearing correctly. 8. Perform functional interlock test to prove the proper operation and indications of interlock scheme (electrical / mechanical) 9. Test the anti-condensation heaters by connecting the power supply and measure the consumed current using clamp meter and check the settings of the thermostat. 10. Check ventilation fans operation. 11. Perform insulation-resistance tests (Megger Test) on each bus section, phase-to-phase and phase-toground, at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the recommended values in Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal the causes, clean the equipment well, then re- measure. If cleaning does not reveal the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure. 12. Perform insulation-resistance tests (Megger Test) at the DC test voltage appropriate for control wiring in accordance with Table 2. 13. Perform a dielectric test (Hi-Pot) on each bus section; each phase to ground with phases not under test grounded .Test voltage shall be 80% of the values indicated in table 4. When performing dielectric tests, all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment shall be isolated before the test and put back in place after completing the test.

Important Notes regarding Megger& Hi-Pot tests: 1. Megger test and HI-POT test will be performed along with the switchgear (As a part of the switchgear at the same time unless the feeder is supplied separately) 2. Megger Test and HI-POT test to be performed directly (with in the same day/max 24 hours) before startup (Energization). If the startup phase will not follow the comm. Phase (there will be time gap in between), these tests will be delayed to be performed directly before Energization. 3. Insulation-resistance tests (Megger Test) to be performed BEFORE and AFTER the HI-POT test.


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3.8.3. Pre-Energization Checks: 1. Check that Panels has been appropriately cleaned. 2. Check that lubricants have been applied to the recommended places. 3. Check that barriers and covers are installed in its place. 4. Megger test has been performed successfully 5. Hi-pot test has been performed successfully.


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4. Low Voltage Equipment 4.1 LV Switchgear (Metal enclosed): 4.1.1. Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plates are according to the corresponding drawings. 2. Inspect physical and mechanical condition of the equipments and all components for clear damage. 3. Verify appropriate anchorage, required area clearances, physical damage, and correct alignment and cleanliness. 4. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware. 5. Verify that the barriers and covers are installed correctly. 6. Verify that filters are in place and all ventilation openings are clear from any kind of obstacles. 7. Verify that main bus bar is connected between the cells. 8. Verify that the earth bars is connected between the cells and connected to the earth. 9. Verify the tightness of accessible bolted electrical connections using the calibrated torque-wrench method in accordance Table 1 10. Confirm that lubricants have been correctly applied at the recommended locations. 11. Inspect all mechanical indicating devices for correct operation. 12. Verify that draw out disconnecting contacts and interlocks function correctly. 13. Verify that fuse and/or circuit breaker size and type correspond to drawings. 14. Verify that current and potential transformer ratios correspond to drawings. 15. Verify that all the interconnection control wires between the cells have been made correctly reference to the control drawings 16. Verify that customer connections to remote power, operators, interlocks, and indicators have been made.

4.1.2. Commissioning: 1. Check the availability of the required auxiliary supply for control operation. 2. Check the phase sequence of the incoming cables using phase sequence device on the secondary connection of the potential transformer. 3. Perform a control wiring performance test by applying control voltage and Verify that the equipment operates as intended. 4. Test protective relays in accordance with “Section 3.3—Protective Relays” if found.


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__________________________________________________________________________________ 5. Perform function operation test to prove correct interaction of all sensing, processing and protecting devices also proves that the control/auxiliary supply is connected properly and alarms and indications are appearing correctly. 6. Perform functional interlock test to prove the proper operation and indications of interlock scheme (electrical / mechanical) 7. Test the anti-condensation heaters by connecting the power supply and measure the consumed current using clamp meter and check the settings of the thermostat. 8. Check ventilation fans operation. 9. Perform insulation-resistance tests (Megger Test) on each bus section, phase-to-phase and phase-toground, at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the recommended values in Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal the causes, clean the equipment well, then re- measure. If cleaning does not reveal the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure. 10. Perform contact resistance test (conductivity test) through all main busbar joints as per project specs. 11. Perform secondary injection test on LV protection relays (Tsys-T). test the thermal over load and earth fault of each device and monitor trip time.

4.1.3. Pre-Energization Checks: 1. Check that Panels has been appropriately cleaned 2. Check that lubricants have been applied to the recommended places. 3. Check that barriers and covers are installed in its place. 4. Check that fuses are installed correctly. 5. Incoming cables to the switchgear are connected with the right phase sequence. 6. Megger test has been performed successfully


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__________________________________________________________________________________

4.2 LV Circuit Breakers: 4.2.1. Insulated Case / Molded Case C.B: 4.2.1.1 Pre-Commissioning visual & mechanical inspection: 1. Inspect circuit breaker for correct mounting. 2. Operate circuit breaker to insure smooth operation. 3. Inspect case for cracks or other defects. 4. Verify tightness of accessible bolted connections and/or cable Connections by calibrated torque-wrench method in accordance with Table 1. 5. Verify that trip units, shunt trip coils, auxiliary contacts and all other accessories are in accordance with the drawings. 6. Exercise the push to trip button to verify trip and reset. 7. If the circuit breaker contains a MICROLOGIC™ trip unit, perform the following inspections: ♦ Verify that the breaker is equipped with the correct rating plugs and current sensors. ♦ Verify that the breaker has the specified trip unit, LI, LS, LSI, and LSIG. ♦ Verify that the breaker has the specified accessories, such as Auxiliary Contacts, Cell Switches, Shunt Trip Devices, and under voltage Release. 8. If it is a withdrawable ( MASTERPACT®) circuit breaker, perform the following inspections: ♦ Confirm that lubricants have been correctly applied at the recommended locations. ♦ Inspect anchorage, alignment, and grounding. ♦ Inspect moving and stationary contacts for condition and alignment. ♦ Check the racking mechanism.

4.2.1.2 Commissioning: 1. Verify trip and close functions.

2. Trip the circuit breaker by operating protective device (if found). 3. Make adjustments for the final settings in accordance with the customer requirements. 4. Perform insulation-resistance tests on each bus section, phase-to-phase and phase-to-ground, at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the recommended values in Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure.(that is done as part of switchgear Megger test) Note: Megger test will be performed along with the switchgear (As a part of the switchgear at the same time unless the C.B is supplied separately or as spare)


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__________________________________________________________________________________ 4.2.2. Low Voltage Power (Air C.B): 4.2.2.1 Pre-Commissioning visual & mechanical inspection: 1. Inspect circuit breaker for correct mounting. 2. Operate circuit breaker to insure smooth operation. 3. Verify that trip units, shunt trip coils, auxiliary contacts and all other accessories are in accordance with the job specifications. 4. If the circuit breaker contains a MICROLOGIC™ trip unit, perform the following inspections: ♦ Verify that the breaker is equipped with the correct rating plugs and current sensors. ♦ Verify that the breaker has the specified trip unit, LI, LS, LSI, and LSIG. ♦ Verify that the breaker has the specified accessories, such as Auxiliary Contacts, Cell Switches, Shunt Trip Devices, and under voltage Release. 5. If it is a withdrawable MASTERPACT® circuit breaker, perform the following inspections: ♦ Confirm that lubricants have been correctly applied at the recommended locations. ♦ Inspect anchorage, alignment, and grounding. Inspect arc chutes. ♦ Inspect moving and stationary contacts for condition and alignment. ♦ Check the racking mechanism.

4.2.2.2 Commissioning: 1. Perform insulation-resistance tests on each bus section, phase-to-phase and phase-to-ground, at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the recommended values in Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure. 2. Verify trip, close, trip-free, and anti pump functions.

3. Trip the circuit breaker by operating protective device. 4. Make adjustments for the final settings in accordance with the customer requirements. Note: Megger test will be performed along with the switchgear (As a part of the switchgear at the same time unless the C.B is supplied separately or as spare)


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__________________________________________________________________________________

4.3 LV Motor Starter & Power feeders: 4.3.1. Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plates are according to the corresponding drawings. 2. Inspect physical and mechanical condition of the equipments and all components for clear damage. 3. Verify appropriate anchorage, required area clearances, physical damage, and correct alignment and cleanliness. 4. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware. 5. Verify that the barriers and covers are installed correctly. 6. Verify that filters are in place and all ventilation openings are clear from any kind of obstacles. 7. Verify that main bus bar is connected between the cells. 8. Verify that the earth bar is connected between the cells and connected to the earth. 9. Verify the tightness of accessible bolted electrical connections using the calibrated torque-wrench method in accordance Table 1 10. Confirm that lubricants have been correctly applied at the recommended locations. 11. Inspect all mechanical indicating devices for correct operation. 12. Verify that draw out disconnecting contacts and interlocks function correctly. 13. Verify that fuse and/or circuit breaker sizes and types correspond to drawings. 14. Verify that current and potential transformer ratios correspond to drawings. 15. Verify that all the interconnection control wires between the cells have been made correctly reference to the control drawings 16. Verify that customer connections to remote power, operators, interlocks, and indicators have been made.

4.3.2. Commissioning: 1. Check the availability of the required auxiliary supply for control operation. 2. Check the phase sequence of the incoming cables using phase sequence device on the secondary connection of the potential transformer. 3. Perform a control wiring performance test by applying control voltage and Verify that the equipment operates as intended. 4. Test protective relays in accordance with “Section 3.3—Protective Relays” if found. 5. Perform function operation test to prove correct interaction of all sensing, processing and protecting devices also proves that the control/auxiliary supply is connected properly and alarms and indications are appearing correctly. 6. Perform functional interlock test to prove the proper operation and indications of interlock scheme (electrical / mechanical)


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__________________________________________________________________________________ 7. Test the anti-condensation heaters by connecting the power supply and measure the consumed current using clamp meter and check the settings of the thermostat. 8. Check ventilation fans operation. 9. Perform insulation-resistance tests (Megger Test) on each bus section, phase-to-phase and phase-toground, at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the recommended values in Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal the causes, clean the equipment well, then re- measure. If cleaning does not reveal the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure.

4.3.3. Pre-Energization Checks: 1. Check that Panels has been appropriately cleaned 2. Check that lubricants have been applied to the recommended places. 3. Check that barriers and covers are installed in its place. 4. Check that fuses are installed correctly. 5. Incoming cables to the switchgear are connected with the right phase sequence. 6. Megger test has been performed successfully


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__________________________________________________________________________________

4.4 Interposing Relay Panel: 4.4.1. Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plates are according to the corresponding drawings. 2. Inspect physical and mechanical condition of the equipments and all components for clear damage. 3. Verify appropriate anchorage, required area clearances, physical damage, and correct alignment and cleanliness. 4. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware. 5. Verify that the earth bar is connected between the cells and connected to the earth (if found). 6. Verify that all the interconnection control wires between the cells have been made correctly reference to the control drawings (If any) 7. Verify that customer connections to remote power, operators, and indicators have been made.

4.4.2. Commissioning: 1. Check the availability of the required auxiliary supply for control operation. 2. Test the anti-condensation heaters by connecting the power supply and measure the consumed current using clamp meter and check the settings of the thermostat. 3. Check that ventilation Fans are working properly. 4. Perform insulation-resistance tests (Megger Test) at the DC test voltage appropriate for control wiring in accordance with Table 2.


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__________________________________________________________________________________

4.5 Active Harmonic Filter (AHF): 4.5.1. Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plates are according to the corresponding drawings. 2. Inspect physical and mechanical condition of the equipments and all components for clear damage. 3. Verify appropriate anchorage, required area clearances, physical damage, and correct alignment and cleanliness. 4. Inspect all doors and sections for paint, dents, scratches, fit, and missing hardware. 5. Verify that the earth bar is connected to the earth (if found). 6. Verify that all the interconnection control wires between the cells have been made correctly reference to the control drawings (If any). 7. Verify that customer connections to remote power, operators, and indicators have been made.

4.5.2. Commissioning: 1. Check the availability of the required auxiliary supply for control operation. 2. Test the anti-condensation heaters by connecting the power supply and measure the consumed current using clamp meter and check the settings of the thermostat. 3. Check that ventilation Fans are working properly. 4. Perform function operation test to prove correct interaction of all sensing, processing and protecting devices also proves that the control/auxiliary supply is connected properly and alarms and indications are appearing correctly. 5. Apply the required settings/ratings for the AHF.


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__________________________________________________________________________________

4.6 Neutral Earthing Resistor (NER): 4.6.1. Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plate is according to the corresponding drawings. 2. Inspect physical and mechanical condition of the equipments and all components for clear damage. 3. Verify appropriate anchorage, required area clearances, physical damage, and correct alignment and cleanliness. 4. Verify that the connection of the resistor is as per the attached drawings. 5. Verify that customer connections to voltage terminal blocks are as per the attached drawings.

4.6.2. Commissioning: 1. Check the availability of the required auxiliary supply for heater. 2. Test the anti-condensation heater by connecting the power supply and measure the consumed current using clamp meter and check the settings of the thermostat. 3. Perform insulation-resistance tests at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the recommended values in Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal the causes, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure.


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__________________________________________________________________________________

4.7 AC/DC Power distribution boards: 4.7.1. Pre-Commissioning visual & mechanical inspection: 1. Verify that equipments name plate is according to the corresponding drawings. 2. Verify that ratings and arrangement of inside components is according to the corresponding drawings. 3. Inspect physical and mechanical condition of the equipments and all components for clear damage. 4. Verify appropriate anchorage, required area clearances, physical damage, and correct alignment and cleanliness.

4.7.2. Commissioning: 1. Make sure that incoming cables are connected correctly. 2. Make sure that covers are installed again after all cable works has been finished. 3. Make sure that setting for the MCCB has been applied if applicable. 4. Perform insulation resistance teat.


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__________________________________________________________________________________

5. Safe Energization precautions: 1. Safety fence and fire extinguisher or fire fighting system must be present around the switchgear. 2. Area around the switchgear must be cleared from any kind of obstacles. 3. Any unnecessary crowd around the switchgear during initial Energization must be cleared. 4. All openings and cut outs must be sealed. 5. All doors and windows in the substation must be installed and closed to protect the switchgear from unnecessary access.


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P Projects & Services Execcution Divission

Field Operations O Seervices

__________ _ ___________ __________ __________________________________________ _________________

6. 6 APPENDIX A: A List of o tabless: ndard Bolt Torques T forr Bus and C Cable Conneections Table 1: Stan

Bo olt Siize

(‫ آﻬﻬﺮﺑﺎء‬/ ‫اﻟﻌﺎم )ﻣﻴﻜﺎﻧﻴﻜﺎ‬ ‫اﻟﺮﺑﺎط م‬ Geneeral mechaniical & electrrical assembly ( N.m) Nylsstop lock nutt + Hex.n nut + contacct Flanged nut Hex.nnut + Flat or picot washer conntact or picott or split washer with teeeth used wiith washers steel

‫ﺻﺎﻣﻮﻟﺔ ﻣﺴﺪﺳﺔ ﻋﺎدﻳﺔ‬ ‫ﺻ‬ ‫آﻮﻧﺘﺎآﺖ او‬ ‫ﺖ‬ ‫ وردة‬+ ‫ﺷﻮآﺔ‬

‫ﺻﺎﻣﻣﻮﻟﺔ ﺑﻮردة‬ ‫ﻣﺮووﺣﻴﺔ ﺗﺮﺑﻂ‬ ‫ﻋﻠﻰ اﻟﺼﻠﺐ‬ ‫ﻰ‬

‫ﺻ‬ ‫ وردة‬+ ‫ﺻﺎﻣﻮﻟﺔ آﻮﻧﺘﺮ‬ ‫آﻮﻧﺘﺎآﺖ او ﺷﻮﻮآﺔ‬

‫ﻣﺴﺪﺳﺔ‬ ‫ﺻﺎﻣﻮﻟﺔ ﻣﺴ‬ ‫ ورددة ﻣﺴﺢ‬+ ‫ﻋﺎدﻳﺔ‬ ‫او ﻖ‬ ‫ﺷﻖ‬

M5

7

8

7.5

5

M6

13

13.5

14.5

8.5

M8

28

25

31

19

M 10

50

50

54

37.5 3

M 12

75

79

83

62

M 14

120

125

132

98

M 16

185

180

200

155

M 18

260

270

280

2 210

M 20

370

390

410

2 290

‫ﻣﻘﺎس‬ ‫س‬ ‫ﺴﻤﺎر‬ ‫اﻟﻤﺴ‬

Schneider S Ellectric Egyptt-Projects & Services Exxecution Divvision-Field Operations – Rev.10

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__________________________________________________________________________________ Table 1: Standard Bolt Torques for Bus and Cable Connections (Cont’d) ‫اﻟﺮﺑﺎط ﻋﻠﻰ ﻣﻜﻮﻧﺎت اﻟﺨﻠﻴﺔ اﻟﻤﺨﺘﻠﻔﺔ‬ Component Assembly (N.m) Bolt Size

‫ﻣﻘﺎس‬ ‫اﻟﻤﺴﻤﺎر‬

MV insulators

Current / Voltage Trans. Surge Arrestors (AREVA)

‫اﻟﻌﻮازل‬ ‫ اﻟﺠﻬﺪ‬/ ‫ﻣﺤﻮﻻت اﻟﺘﻴﺎر‬ =S= or ALCE MAGRINI INSULA INSULA or ALCE

M5 M6

‫ﻣﻮاﻧﻊ اﻟﺼﻮاﻋﻖ‬

2 - 2.5 13

M8

6.4

15

15

20 30 - 40

M 10

50

32

M 12

75

45

185

110

40

70

20

M 14 M 16 M 18 M 20


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__________________________________________________________________________________ Table 2: Insulation-Resistance Test Voltage for Electrical Apparatus and Systems

Voltage Rating

Minimum DC Test Voltage

Recommended Minimum Insulation Resistance In Megohms

Duration

0 - 250 251 - 600 601 - 5,000 5,001 - 8,000 8,001 - 15,000 15,001 - 25,000 25,001 - 69,000

500 1000 2500 2500 2500 5000 15000

50 100 1000 2000 5000 20000 100000

60 SEC 60 SEC 60 SEC 60 SEC 60 SEC 60 SEC 60 SEC

Actual test results are dependent on the length of the conductor being tested, the temperature of the insulating material, and the humidity of the surrounding environment at the time of the test. In addition, insulation resistance tests are performed to establish a trending pattern and a deviation from the baseline information obtained during maintenance testing enabling the evaluation of the insulation for confined use. Table 3: Transformer Insulation-Res. Acceptance Test Voltage and

Transformer Winding Rated Voltage 0- 600 601-5000 >5000

Minimum DC Test Voltage 1000 2500 5000

Duration 60 SEC 60 SEC 60 SEC

Min. Result: Recommended Minimum Transformer Insulation Resistance Results: In the absence of consensus standards for minimum acceptable transformer insulation resistance, the NETA Standards Review Council recommends the use of the following formula. Although the origin of this formula is not identified, NETA recognizes its wide use in the electrical testing industry. IR = CE/√KVA IR = Minimum recommended one minute insulation resistance C = Constant E = Phase-to-phase voltage for delta connected windings; phase-to-neutral voltage for star connected windings. Schneider Electric Egypt-Projects & Services Execution Division-Field Operations – Rev.10

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__________________________________________________________________________________ kVA = Rated kVA of transformer Values of C @ 20°C: Oil-filled C = 1.5 Dry-type C = 30 Insulation Resistance Conversion Factors For Conversion of Test Temperature to 20°C Temperature

Multiplier

°C

°F

20 25 30 35 40 45 50 55 60 65 70 75 80

68 77 86 95 104 113 122 131 140 149 158 167 176

Apparatus Containing Immersed Oil Insulation 1.00 1.40 1.98 2.80 3.95 5.60 7.85 11.20 15.85 22.40 31.75 44.70 63.50

Apparatus Containing Solid Insulation 1.00 1.30 1.60 2.05 2.50 3.25 4.00 5.20 6.40 8.70 10.00 13.00 16.00


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__________________________________________________________________________________ Table 4: Rated insulation levels for rated voltages:

Rated Voltage

Rated short-duration power-frequency withstand voltage

Ur

Ud

KV( r.m.s. value)

KV( r.m.s. value)

3.6 7.2 12 17.5 24 36 52

10 20 28 38 50 70 95

Duration

60 SEC 60 SEC 60 SEC 60 SEC 60 SEC 60 SEC 60 SEC


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__________________________________________________________________________________

7. APPENDIX B: NORMS IEC 56 High voltage alternating current circuit breaker (frequencies ≤ 60 Hz) IEC 70 Power capacitors IEC 71 Insulation co-ordination IEC 76 Power transformers IEC 99 Surge arresters IEC 157 Low voltage switchgear and control gear (= IEC 947.2) IEC 185 Current transformers IEC 186 Voltage transformers IEC 254 Lead-acid traction batteries IEC 255 Electrical relays. Contact performance of electrical relays. IEC 298 AC metal enclosed switchgear and control gear for rated voltages between 1 KV and up to and Including 52 kV. IEC 364 Electrical installation of buildings IEC 408 Low voltage switches IEC 439 Low voltage switchgear and control gear assemblies. IEC 694 Common specifications for high-voltage switchgear and control gear standards •

Acceptance Testing Specifications for Electrical Power Distribution Equipment and Systems (NETA ATS 1999).

•

Dielectric tests ANSI/IEEE C37.20.2 & C37.20.3 Metal-Clad, Station-Type Cubical and Metal Enclosed MV Switchgear, C37.23 Bus, Outdoor Circuit Breakers, and ANSI C37.32 Air Switches


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__________________________________________________________________________________

8. APPENDIX C: List of used equipment in Pre-commissioning & Commissioning Phase 123456789-

Secondary Injection test kit. Hi-pot test kit Insulation resistance test kit (Megger) Contact resistance test kit (Conductivity test kit) Phase sequence check kit. Torque wrench. Avo meters. 110 AC power supply 110 DC power supply


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Testing & Comm Procedure-rev 10-Enppi

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