PP10 startup manual (Unofficial as Requested)

STARTUP MANUAL
VOLUME-2
Riyadh Power Plant # 10

Page 1

STARTUP MANUAL
VOLUME-2

Client
Consultant
Contractor

: SEC-COA
:
: BEMCO

Doc. No.: PP10-BS-SU-001

Riyadh Power plant # 10
“10621166/00”
STARTUP MANUAL

Date:13
Feb,09

Revision:
0

Annex B
1. Electrical Test Procedures
1.1. Over all Testing List (Excel Sheet)………………………………………......6
1.2. TP-HP01 High Voltage AC/DC Testing……………………………………….23
1.3. TP-CM01 MV Cable Testing.......................................................................32
1.4. TP-CM02 LV Cable Testing........................................................................44
1.5. TP-AT01 Auxiliary Transformers.................................................................51
1.6. TP-BD01 MV Bus Duct................................................................................70
1.7. TP-BD02 LV Bus Duct.................................................................................83
1.8. TP-CL01 Current limiting Reactor................................................................95
1.9. TP-CT01 Current Transformer....................................................................104
1.10. TP-PT01 Generator Transformer................................................................121
1.11. TP-AM01 Ammeter ....................................................................................160
1.12. TP-EM01 Energy Meter .............................................................................166
1.13. TP-FM01 Frequency Meter.........................................................................181
1.14. TP-PFM01 Power Factor Meter..................................................................187
1.15. TP-PM01 Power Meter...............................................................................193
1.16. TP-VM01 Voltmeter....................................................................................197
1.17. TP-BB01 MV Bus Bar.................................................................................203
1.18. TP-BB02 LV Bus Bar..................................................................................218
1.19. TP-MB01 MV Switchgear Breaker Feeder.................................................234
1.20. TP-DS01 MV Disconnect Switch................................................................282
1.21. TP-LB 01 LV Switch Gear Breaker Feeder................................................282
1.22. TP-AR01 Over current Relay.....................................................................304
1.23. TP-CR01 Trip Circuit Supervision Relay....................................................378
1.24. TP-DR01 Differential Relay........................................................................386
1.25. TP-HR01 Timing Relay..............................................................................496
1.26. TP-LR01 Tripping Relay.............................................................................503
1.27. TP-SR01 Synchronous Check Relay.........................................................510
1.28. TP-VR01 Voltage Relay.............................................................................523
1.29. TP-AX01 Current Transducer....................................................................538
1.30. TP-VX01 Voltage Transducer....................................................................545
1.31. TP-PX01 Power Transducer......................................................................552
1.32. TP-VT01 Voltage Transformer...................................................................559
1.33. TP-BT01 Battery testing and discharge test..............................................575
1.34. TP-BT02 Charger Testing (Later)..............................................................592
1.35. TP-BT03 UPS Testing (Later)....................................................................593
1.36. TP-MT01 Motors........................................................................................594
1.37. TP-GT01 Generators.................................................................................607
1.38. TP-MM01 Low Voltage Motor Control Center……………………………....618
1.39. TP-DB01 DC Switch Board …………………………………………………..635
1.40. TP-BE01 Procedure for Back Energization (Later)
1.41. TP-OS01 Procedure for Electrical Over Speed (Later)
1.42. TP-SY01 Procedure for Synchronization (Later)
1.43. TP-LG01 Procedure for Load Rejection (Later)
1.44. TP-IL01 Procedure for System Interlock Checks (later)

Author: Asif Haneef

Client
Consultant
Contractor

: SEC-COA
:
: BEMCO


“10621166/00”
STARTUP MANUAL

Date:13
Feb,09

Revision:
0

1.45. TP-IT01 Procedure for System Inter trip Checks (later)
1.46. TP-IN01 Initial Energization of the Plant (Later)
1.47. TP-SS01 Procedure for System Stability (Later)
2. Attachment for Section–12 Testing and commissioning-Instrumentation
(Later) .................................................................................................................651
2.1. CI-01 Calibration of Pressure Switches
2.2. CI-02 Calibration of Temperature gauges
2.3. CI-03 Calibration of Pressure gauges
2.4. CI-04 Exhaust over temperature alarm & trip
2.5. CI-05 Exhaust duct over pressure protection
2.6. CI-06 Compressor bleed Valves
2.7. CI 07 Emergency oil pump test & low lube oil pressure trip
2.8. CI-08 Exhaust frame blower (lead / lag test)
2.9. CI-09 Firing checks
2.10. CI-10 Flame detection test and loss of flame trip
2.11. CI-11 Cooling water lead lag test & cooling water fans vibration alarm trip
2.12. CI-12 Hydraulic oil System
2.13. CI-13 Compartment cooling Fans
2.14. CI-14 Hydraulic ratchet System
2.15. CI-15 Trip oil system checks
2.16. CI-16 Vibration protection system
2.17. CI-17 Vanadium inhibitor pip trip, lead lag and change
over distillate
2.18. CI-18 Manual emergency shutdown
2.19. CI-19 High lube oil header temperature alarm & trip
2.20. CI-20 Low and high lube oil alarm
2.21. CI-21 IGV position calibration
2.22. CI-22 Mark VI processor hard
2.23. CI-23 Inlet air-filter
2.24. Instrumentation Test Sheets(Attached)
2.24.1. Orifice Plate Verification Report ......................................................653
2.24.2. Thermo well Verification. .................................................................654
2.24.3. Instrument Calibration Report For Temperature Element
Transmitters……………………………………………………………...655
2.24.4. Instrument Calibration Report(Transmitters)....................................656
2.24.5. Switch Calibration Report (PS/TS/LS-DPS) ...................................657
2.24.6. Local Instrument Calibration Report (PG/TG/LG)............................658
2.24.7. Instrument Loop Test Sheet-Pressure/Level/Flow/Temperature
Transmitter/Other Transmitters........................................................659
2.24.8. Instrument Loop Test Sheet-RTD....................................................660
2.24.9. Instrument Loop Test Sheet-DCS Digital Input Signal(Switches) ...661
2.24.10. Instrument Loop Test Sheet- Motor Operated Valve. ………………662
2.24.11. Instrument Loop Test Sheet- Pneumatic Valves..............................663
2.24.12. Instrument Loop Test -Solenoid valve .............................................664
2.24.13. Switch Calibration report (PS/TS/LS-DPS)…………………………...665
2.24.14. Instrument Control Cable -Megger/Continuity………………………..666

Author: Asif Haneef

Client
Consultant
Contractor

: SEC-COA
:
: BEMCO


“10621166/00”
STARTUP MANUAL

Date:13
Feb,09

Revision:
0

3. Attachment for Section –13 Testing and commissioning-Mechanical
(Later)....................................................................................................................667
3.1. CM-01 Commissioning of Fuel Oil System
3.2. CM-02 Commissioning of Fuel Treatment Plant (Vendor)
3.3. CM-01 Commissioning of Fuel Oil System
3.4. CM-04 Commissioning of Oily Water Drainage System
3.5. CM-05 Commissioning of GT Wash Water Supply System
3.6. CM-06 Commissioning of GT Wash Water Drain System
3.7. CM-07 Commissioning of Raw Water Transfer Pumps
3.8. CM-08 Commissioning of Water Treatment Plant (Vendor)
3.9. CM-09 Commissioning of Dimin Water Plant (Vendor)
3.10. CM-10 Commissioning of Dimin Water Supply Pumps
3.11.
3.12.
3.13.
3.14.
3.15.
3.16.
3.17.
3.18.
3.19.
3.20.
3.21.
3.22.
3.23.

CM-11 Commissioning of Service Water Distribution Pumps
CM-12 Commissioning of Drinking Water Distribution Pumps
CM-13 Commissioning of Instrument Air Compressors and Air Dryers
CM-14 Commissioning of Service Air Compressors
CM-15 Commissioning of Fire Water System Pumps
CM-16 Commissioning of Foam System Equipments
CM-17 Commissioning of Fire Water and Fire Foam Deluge System
CM-18 Commissioning of HVAC Equipments
CM-19 Commissioning of Sewage Treatment Plant (Vendor)
CM-20 Commissioning of Irrigation System Pumps and Equipments
CM-21 Commissioning and Load Testing of Overhead Cranes and Hoists
CM-22 Commissioning of Black Start Diesel Generator (Vendor)
Gas Turbine and Associated Auxiliaries (By GE)

4. Attachment for Section –14 Velocity Flushing...............................................668
4.1. Lube Oil Flushing

Author: Asif Haneef

ent
Clie
Con
nsultant
Con
ntractor

: SEC-C
COA
:
O
: BEMCO

Doc No.: PP1
c.
10-BS-SU-001

Riyadh Po
R
ower plant # 10
t
“1062
21166/00”
STARTU MANUA
UP
AL

Date:13
D
Feb,09
F

Revision
n:
0

LIST OF TEST
F
TING O
OVER ALL (E
EXCEL SHE
L
EET)

Page 6

Testing and commissioning (Electrical)
Testing List
SL
No.

1

2

3

System
Name

380KV
SYSTEM

MV/LV
SYSTEM

Equipment

Project :
Testing Activities

COMMISSIONING OF GENERATOR STEP UP TRANSFORMER
1.General inspection and Name plate details
2.Winding Ratio Test
3.Winding Resistance Test
4.Magnetism Current Measurement
5.Vector Group Test
6.Magnetic Balance Test
7.Insulation and Polarization test
8.Core Insulation test
9.Tan delta Measurement
10.Frequency Response Analysis (if vendor recommended)
11.Winding Temperature Indicator Calibration
12.Oil Temperature Indicator Calibration
GSU
13.Single Phase Impedance Measurement
Transformer
14.Zero Sequence Impedance Measurement
15.Testing of protection devices and auxiliary circuits
16.Testing and commissioning of cooler control system
17.Testing and commissioning of OLTC
18.Testing and commissioning of remote OLTC panel
19.Current transformer test
Ratio test
Polarity Test
Winding Resistance Test
Winding Insulation test
Mag Curve test
COMMISSIONING OF AUXILIARY TRANSFORMER
4.Magnetism Current Measurment
5.Vector Group Test
6.Insulation and Polarization test
7.Winding Temperature Indicator Caliberation
Auxiliary
8.Oil Temperature Indicator Caliberation
Transformer 9.Testing of protection devices and auxilari circuits
10.Current transformer test
Ratio test
Polarity Test
Winding Resistance Test
Winding Insulation test
Mag Curve test

COMMISSIONING OF MV XLPE CABLE
2.Conductor continuity and phasing test
MV XLPE
MV SYSTEM
3.Cable Insulation Test befror hipot
Cable
4.High Voltage Test
5. Insulation resistance test after hipot

Test Proc.
No

Test sheet No

Commissioning Activities

Proc. No

Test sheet
No

CE-01

TP-PT01

TS-PT01

TP-PT02

TS-PT03
TS-PT04
TS-PT04
TS-PT06
TS-PT06
TS-SS01
TS-IL01
TS-1T01
TS-PT07
TS-PT08
TS-PT09

TS-PT02

TP-CT01

Commissioning Test.
1.Internal wiring and control power measurement
2.Trips fromTranformer Protection Device to protection panel
3. Alarms and trips indication to Remote checks
4.CT Loops , Burden , and Single point Grounding test
5.Secondary Injection to Verify Close circuit of the Cuts
6.Stability and sensitivity test for the Transformer and system
7. interlock test for the system
8. inter trip test for the system
9.Pre Energisation Tests
Meggering
Post Enegisation test
Measurement of In rush current
Measurement of noise level (if Vendor Recommends)
10. Load Service Checks

TS-CT01

CE-02

TP-AT01

TS-AT01

TP-CT01

TS-CT01

TP-HC01

TS-HC01

Commissioning Test.
1. Internal wiring and control power measurement
2.Trips fromTranformer Protection Device to protection panel
3. Alrams and trips indication to Remote checks
4. CT Loops , Burden , and Single point Grounding test
5. Secondary Injection to Verify Close circuit of the CTs
6. Stability and sensitivity test for the Transformer
7. Pre Energisation Tests
Meggering

TS-AT02
TS-AT02
TS-AT02
TS-AT02
TS-AT02
TS-AT02
TS-AT03

Testing List
SL
No.

4

5

6

7

System
Name

Equipment

Project :
Testing Activities

COMMISSIONING OF GROUNDING ZIG ZAG TRANSFORMER
Neutral
Grounding
2. Impedance and resistance test
ZIG ZAG
Transformer 3.Insulation Resistance test
COMMISSIONING OF CURRENT LIMITING REACTOR
Current
2.Impedance test
Limiting
3.Insulation Resistance test before hipot
4.High Volatge test
Reactor
5.Insulation resistance test after hipot
COMMISSIONING OF NEUTRAL GROUNDING RESISTOR
Neutral
2.Winding Resitance Test
Grounding 3.Insulation test before hipot
4.High Voltage Test
Resistor
5.Insulation test after hipot
COMMISSIONING OF MV BUS DUCT
1. General inspection and Name plate details
2. Bus continuity and phasing test
3. Torque test
4.
Contact Resitance test
MV bus duct 5.
Main Circuit Contact Resitance test
6.
Insulation resistance test before hipot
7.
High Voltage test
MV SYSTEM
8.
Insulation resistance test after hipot
9. Protective earthing check
COMMISSIONING OF MV SWITCHGEAR
1.
Test on Disconnect switch
a.
Contact Resitance test.
b.
Insulation resistance test before hipot.
c.
High Voltage test.
d.
e.
Switch operating time /motor current measurment
f.
Minimum voltage operation (open/close) at 90V dc.

8

MV Dis
connect
Switch

2.
Discoonect switch operation
a.
Disconect Switch operation at rated Voltage.
b.
Functional test of local controls, alarm and indication.
c.
Functional test of Remote controls, alarm and
indication.
d.
Correct settings of motor limit switches.
e.
Check correct operation of auxiliary switches.
f.
Automatic disconnection of supply to the motor on
insertion of handle
3.
Operation of Earth Switch.
4.
Correct Functioning of Interlocks
5.
Electrical control and protection/Measuring Devices


Test Proc.
No

Test sheet No

TP-NT01

TS-NT01

TP-RT01

TS-RT01

TP-NT02

TS-NT02


Proc. No

Test sheet
No

CE-03

TP-BD01

TS-BD01

Commssioning Test.
1. Heater Circuit Commissioning
2. Dry Air Supply commissioning
Meggering

TS-BD03

CE-04
Commssioning Test.
1. Internal wiring and control power measurment
2. functional checks of feeders and ATS
3. Protection checks
3.1 CT Loops , Burden , and Single point Grounding test
3.2 Tripping of relays by secondary injection at final setting
3.3 Primary Injection test
3.4 Stability and sensitivity test for bus bar
3.5 VT Functional Check
3.5 Arc Protection Checks
3.6 Tripping and itertripping checks
4. Interlock checks
6. Alarms and indication checks
7. Remote opertion and Alarm Checks (DCS)
Meggering of the bus bar

Testing List
SL
No.

System
Name

Project :

Equipment

Testing Activities
a.

MV Dis
connect
Switch

9

MV SYSTEM

MV Switch
Gear

Test Proc.
No

Test sheet No

Insulation resistance measurment for control circuit
Measurment of Voltages
Phase sequence check
Phasing between the line and bus

b.
Control power and current measurment.
6.
Commissioning of Heater Circuit
a.
Visual Checks
b.
Measurment of insulation resistance of heater and
lamp circuit
c.
Functional checks of thermostat , Heaters,
d.
Measurment of Current and voltage
7.
Protective earthing check.

Testing of bus bar
2.
Bus continuity and phasing test
3.
Torque test
4.
5.
6.
7.
High Voltage test
8.
9.
Protective earthing check
Testing of Feeder Breaker
1.
Operation and alignment Checks of breaker
liftingTrolley
2.
Tests on the CB
a.
Breaker Manual closing/opening, and manual
spring charging
b.
Contact gap Measurment for main contact of the
VCB
c.
d.
e.
Vacuum Integrity test on VCB
f.
High Voltage test.
g.
Insulation resistance test after hipot.
h.
Minimum operating voltage for close and trip coil.
i.
j.
k.
l.h
3.


Breaker operating time.
Spring charging motor current and time
t
Stored energy and spring charge mechanism
k Functional check of C.B Operation counter

Breaker operation
a.
CB Racking IN and OUT Checks
b.
CB operation in service position mechanical and
electrical
c.
CB operation in test position electrical
Anti pumping functional check
d.
e.
Functional test of local controls, alarm and
Indication

TP-BB01

TS-BB01

TP-MB01

TS-MB01

Proc. No

Test sheet
No

Testing List
SL
No.

9

System
Name

MV SYSTEM

Project :

Equipment

Testing Activities

MV Switch
Gear

f.
Functional Test of Remote control, alarm, and
indication
4.
Checks for operation of Auxiliary switches ,limit
switches for test, service and
5.
Operation of Earth Switch
6.
Functional check of interlock and limit switches.
7.
Check for interchangeable of CB of same rating for
Interference interlock
8.
a.
Visual Checks
b.
Measurment of insulation resistance of heater and lam
c.
d.
Testing of MV Contactor
General Visual Inspection
Contactor operational checks
Contact Resistance test
insulation Resistance test
Timing Test
Minimum pickup/drop out voltage for the coil
Vacuum Integrity test for vacuum contactors
Testing of current transformer
2.
CT Winding insulation Resistance test
3.
CT Ratio test by primary injection
4.
CT Winding Resitance Measurment
5.
CT Loop Resistance Measurment
6.
CT Polarity Test
7.
CT Burden test
8.
CT Magnetizing Current Test (Knee Voltage test)
9.
Demagnetizing CT cores after above all test
10.
Inter Core Coupling Test for bus differential test
11. High voltage test
12. Verifying secondary circuits, terminals, shorting/isolating l
13. single point earthing check
14. phase identification
Testing of Voltage Transformers
2.
Winding insulation Resistance test
3.
Voltage Ratio test by primary injection
4.
Phase Angle Error
5.
Winding Resitance Measurment
6.
Polarity Test
7.
Loop Resistance Measurment
8.
Burden test
9.
Phase Sequence test
10.
Fuse Failure checks
11. Protective earthing
12. Back Energization Test at rated Voltage for 15 minutes


Test Proc.
No

Test sheet No

TP-MB01

TS-MB01

TP-MC01

TS-MC01

TP-CT01

TS-CT01

TP-VT01

TS-VT01


Proc. No

Test sheet
No

Testing List
SL
No.

System
Name

Equipment

Project :
Testing Activities

Test Proc.
No

Test sheet No

Testing of Components
Phase Over current Relay

1. Electrical Function test
1. Functional check of Test Plug
2. Shorting of links on relay case when relay
is withdrawn
2. Secondary Injection
1. Relay Power measurment
2. Configuration of the relay
3. Testing of LEDs
4. Testing of out put relays
5. Testing of input Devices
6. Metering function
7. Over current Pickup/Dropout test
8. Time current characteristics
i. IEC-Normal inverse

TP-AR01

ii. IEC-Very inverse
iii. IEC- Extremely Inverse
9

MV SYSTEM

MV Switch
Gear

iv. Long time Inverse
v. Definite Time
9.
Testing of Instantaneous element
10. Reduced voltage (at 90 Volts ) trip test for all
output relays
11. Testing at final setting
3.Checking the protective Earthing
GE Relay ------MFII
ABB Relay-----SPAJ
SEL Relay------551
Ground Over Current Relay

is withdrawn
3. Testing of LEDs

TS-AR01(MFII)
TS-AR01(SPAJ)
TS-AR01(SEL551)

TP-AR01


Proc. No

Test sheet
No

Testing List
SL
No.

System
Name

Project :

Equipment

Testing Activities
5.
6.
7.
8.

Test Proc.
No

Test sheet No

Testing of input Devices
Metering function
Over current Pickup/Dropout test
Time current characteristics

TP-AR01

v. Definite Time

9

MV SYSTEM

MV Switch
Gear

9.
output relays
GE Relay ------MFII
ABB Relay-----SPAJ
Voltage Relay
2.
Electrical Function test
1.
Functional check of Test Plug
2.
Secondary Injection
1.
Relay Power measurment
2.
Testing of LEDs
3.
Testing of out put relays
4.
5.
Metering function
6.
Under Voltage Function
i.
Pickup/dropout test
ii.
Timing test
7.
Over voltage test
i.
Pickup/dropout
ii.
Timing test
GE Relay--MVII
ABB Relay-----610
Differential Relay
2.
i.
ii.
Shorting of links on relay case when relay is with
3.
Secondary Injection
i.
ii.
Testing of LEDs
iii.

TS-AR01(MFI)
TS-AR01(SPAJ)

TP-VR01

TS-VR01(MVII)
TS-VR01(MVII)

TP-DR01


Proc. No

Test sheet
No

Testing List
SL
No.

System
Name

Project :

Equipment

Testing Activities
Metering function
Differential Function
1.
Differential current Function
2.
Differential restraint characteristic
3.
Harmonic Function
4.
Instantaneous Differential current function
5.
Timing Test
vii.
Backup over current
1.
current Pickup/Dropout test
2.
Time current characteristics
a.
IEC-Very inverse
b.
IEC- Extremely Inverse
c.
Long time Inverse
d.
Definite Time
3.Testing of Instantaneous elem
GE Relay ------G60
GE Relay-------T6O
GE Relay -------DTP
AREVA-------MCAG
Motor Management Relay

Test Proc.
No

Test sheet No

iv.
v.
vi.

9

MV SYSTEM

MV Switch
Gear

3. Testing of LEDs
7. Group elements checks
1.Thermal over load checks
2. Ground current checks
3. unbalance current checks
4. short circuit current checks
5 RTD 'S Function checks
GE Relay-------369
Synchronous Relay
1.General Inspection
2.
1.
2.
Secondary Injection
1.
2.
Testing of LEDs

TP-DR01

TS-DR01(G60)
TS-DR02(T60)
TS-DR02(DTP)
TS-DR03(MCAG

TP-MR01

TS-AR02(369)

TP-SR01


Proc. No

Test sheet
No

Testing List
SL
No.

System
Name

Project :

Equipment

Testing Activities

Test sheet No

3.
4.
5.
6.

9

MV SYSTEM

MV Switch
Gear

Metering function
Live line- Live bus (synchronous ) test
i.
Difference in voltage test
ii.
Difference in frequency
iii.
Difference in phase angle
iv.
Under voltage blocking test
7.
Dead line –Dead bus test
8.
Dead Bus-Live line test
9.
Dead Line – Dead Bus
ARGUS 8----VATECH
SPUA --ABB
CT Supervision Relay
2.
1.
2.
Secondary Injection
1.
Voltage Pick-Up Verification
2.
Voltage Drop-Out Verification
3.
Function Check
i.
The CB Is In Open Position
ii.
The CB In Close Position
Timing Relay
1.
Secondary Injection
1.
Minimum Voltage Pick-Up Verification
2.
Operating time Measurment
Ammeter
1.
2.
Secondary Injection
Voltmeter
1.
2.
Secondary Injection
power Meter
1.
2.
Secondary Injection
Power Factor Meter
1.
2.
Secondary Injection
VAR meter
1.
2.
Secondary Injection
Energy Meter
1.
2.
Secondary Injection
Multi function meter
1.
2.
Secondary Injection
Current Transducer

Test Proc.
No


TP-CR01

TS-SR01(ARGUS
TS-SR01(SPUA
TS-CR01

TP-CR03

TS-CR03

TP-AM01

TS-AM01

TP-VM01

TS-VM01

TP-PM01

TS-PM01

TP-PM01

TS-PM01

TP-PM01

TS-PM01

TP-EM01

TS-EM01

TP-PM01

TS-PM01

TP-AX01

TS-AX01


Proc. No

Test sheet
No

Testing List
SL
No.

System
Name

Project :

Equipment

Testing Activities

Test sheet No


Proc. No

Test sheet
No

1.
2.

9

10

11

12

13

14

Secondary Injection
Voltage Transducer
MV Switch 1.
MV SYSTEM
2.
Secondary Injection
Gear
Power Transducer
1.
2.
Secondary Injection
COMMISSIONING OF MV /LV MOTORS
2. winding Resistance
MV/LV
3. Winding Insulation
SYSTEM
MV /LV Motors 4. Di-electric absorption Ratio for Motor Less then 200HP
5. Polarization index for motor above 200HP

Test Proc.
No


COMMISSIONING OF DRY TYPE TRANSFORMER
Dry Type
Transformer 4.Insulation Resistance Test
5.Magnetising current Measurment
6.Phase Relation Checks
COMMISSIONING OF LV XLPE CABLE
2.Conductor continuity and phasing test
LV Cable
3.Cable Insulation Test
COMMISSIONING OF LV BUS DUCT
2.
3.
Torque test
4.
LV SYSTEM
LV bus duct 5.
6.
7.
High Voltage test @ 1.6KV AC
8.
9. Protective earthing check
COMMISSIONING OF LV SWITCHGEAR
Testing of bus bar

LV Switch
Gear

2.
3.
4.
5.
6.
7.
8.
9.

Torque test
High Voltage test
Protective earthing check

TP-VX01

TS-VX01

TP-PX01

TS-PX01

TP-MM01

TS-MM01

TP-AT01

TS-AT01

TP-HC02

Commssioning Test.
1.No load current measurment
2.Vibration measurment
3. Bearing temperature measurment
4. Full load current and voltage drop measurment
6. Vibration measurment after coupled
7. Bearing temperature measurment after couple

CE-05
CP-MM01
TS-MM02

Commssioning Test.
Meggering
Post Enegisation test-Measrument of voltages

TS-DT02

TS-HC01
CE-06

TP-BD02

TS-BD02

Commssioning Test.
Meggering

TP-BB01

TS-BB01

Commssioning Test.

CE-07

TP-MB01

TS-MB01

3.1 CT Loops , Burden , and Single point Grounding test
3.4 Stability and sensitivity test for bus bar
3.5 VT Functional Check
3.5 Arc Protection Checks

CP-MS01

CP-MS02

CP-MS03

Testing List
SL
No.

System
Name

Project :

Equipment

Testing Activities

Test Proc.
No

Test sheet No

Testing of Feeder Breaker
1
2.
Tests on the CB
a.
Breaker Manual closing/opening, and manual
spring charging
c.
d.
f.
g.
h.

14

LV SYSTEM

LV Switch
Gear

3.6 Tripping and itertripping checks
4. Interlock checks

High Voltage test.
Insulation resistance test after hipot.
Minimum operating voltage for close and trip coil.


i.
Breaker operating time.
j.
Spring charging motor current and time
measurment.
k.
Stored energy and spring charge mechanism
checks
l.
Functional check of C.B Operation counter
3.
Breaker operation
a.
CB Racking IN and OUT Checks
b.
CB operation in service position mechanical and
electrical
c.
CB operation in test position electrical
Anti pumping functional check
d.
e.
Functional test of local controls, alarm and
Indication
f.
Functional Test of Remote control, alarm, and
indication
4.
Checks for operation of Auxiliary switches ,limit
switches for test, service and
6.
Functional check of interlock and limit switches.
8.
a.
Visual Checks
b.
Measurment of insulation resistance of heater and lamp circuit
c.
d.
Testing of current transformer
TP-CT01
2.
CT Winding insulation Resistance test
3.
CT Ratio test by primary injection
4.
CT Winding Resitance Measurment
5.
CT Loop Resistance Measurment
6.
CT Polarity Test
7.
CT Burden test
TP-CT01
8.
CT Magnetizing Current Test (Knee Voltage test)
9.
Demagnetizing CT cores after above all test
11. Verifying secondary circuits, terminals, shorting/isolating
links by primary injection



TS-CT01

TS-CT01

Proc. No

Test sheet
No

Testing List
SL
No.

System
Name

Equipment

Project :
Testing Activities

12. single point earthing check
13. phase identification
Testing of Voltage Transformers
2.
Winding insulation Resistance test
3.
Voltage Ratio test by primary injection
4.
Phase Angle Error
5.
Winding Resitance Measurment
6.
Polarity Test
7.
Loop Resistance Measurment
8.
Burden test
9.
Phase Sequence test
10.
Fuse Failure checks
11. Protective earthing
12. Back Energization Test at rated Voltage for 15 minutes
Phase Over current Relay

14

LV SYSTEM

LV Switch
Gear

is withdrawn
3. Testing of LEDs
v. Definite Time
9.
output relays

Test Proc.
No

TP-VT01

TP-AR01

Test sheet No

TS-VT01


Proc. No

Test sheet
No

Testing List
SL
No.

System
Name

Equipment

Project :
Testing Activities
GE Relay ------MFII
ABB Relay-----SPAJ
Ground Over Current Relay

Test Proc.
No

Test sheet No
TS-AR01(MFI)
TS-AR01(SPAJ)

TP-AR01

is withdrawn
3. Testing of LEDs
14

LV SYSTEM

LV Switch
Gear

v. Definite Time
9.
output relays
GE Relay ------MFII
ABB Relay-----SPAJ
Voltage Relay
2.
1.
2.
Secondary Injection
1.
2.
Testing of LEDs
3.
4.
5.
Metering function
6.
Under Voltage Function
i.
Pickup/dropout test
ii.
Timing test

TS-AR02(MFI)
TS-AR02(SPAJ)
TP-VR01


Proc. No

Test sheet
No

Testing List
SL
No.

System
Name

Project :

Equipment

Testing Activities
7.

14

LV SYSTEM

LV Switch
Gear

Test Proc.
No

Test sheet No

Over voltage test
i.
Pickup/dropout
ii.
Timing test

GE Relay--MVII
ABB Relay-----610
Synchronous Relay
2.
1.
2.
Secondary Injection
1.
2.
Testing of LEDs
3.
4.
5.
Metering function
6.
Live line- Live bus (synchronous ) test
i.
Difference in voltage test
ii.
Difference in frequency
iii.
Difference in phase angle
iv.
Under voltage blocking test
7.
Dead line –Dead bus test
8.
Dead Bus-Live line test
9.
Dead Line – Dead Bus
ARGUS 8----VATECH
SPUA --ABB
Timing Relay
1.
Secondary Injection
1.
Minimum Voltage Pick-Up Verification
2.
Operating time Measurment
Ammeter
1.
2.
Secondary Injection
Voltmeter
1.
2.
Secondary Injection
power Meter
1.
2.
Secondary Injection
Power Factor Meter
1.
2.
Secondary Injection
VAR meter
1.
2.
Secondary Injection
Energy Meter
1.
2.
Secondary Injection
Multi function meter

TS-VR01(MVII)
TS-VR01(MVII)

TP-CR03

TS-SR01(ARGUS
TS-SR01(SPUA
TS-CR03

TP-AM01

TS-AM01

TP-VM01

TS-VM01

TP-PM01

TS-PM01

TP-PM01

TS-PM01

TP-PM01

TS-PM01

TP-EM01

TS-EM01

TP-PM01

TS-PM01


Proc. No

Test sheet
No

Testing List
SL
No.

System
Name

Project :

Equipment

Testing Activities

Test sheet No


Proc. No

Test sheet
No

1.
2.

14

Secondary Injection
Current Transducer
1.
2.
Secondary Injection
LV Switch
LV SYSTEM
Voltage Transducer
Gear
1.
2.
Secondary Injection
Power Transducer
1.
2.
Secondary Injection
COMMISSIONING OF BATTERY CHARGERS
General Inspection
Battery
Componenet test (Metering Facitlities )

Test Proc.
No


TP-AX01

TS-AX01

TP-VX01

TS-VX01

TP-PX01

TS-PX01

CE-08
TP-BC01
pre energization checks
post energization checks
Operational Check
Alarms Ckecks
Load Test

15

16

COMMISSIONING OF BATTERIES
Torque test
Refersher Charging
Batteries
Battery discharge test

COMMISSIONING OF DC SWITCHBOARD
Testing of bus bar
General Visual inspection
Torque test
Contact Resistance test for the joints
DC SYSTEM
Total conductor resistance test
Insulation Resistance test
Testing of Circuit Breaker
General Visual Inspection
Breaker operational checks
Contact Resistance test
17

DC Switch
board

insulation Resistance test
Voltage Relay
General Inspection
Power Consumption
Digital input/out put checks
Metering function checks
Pickup /dropout checks
Time -Voltage characteristics checks
Lockout or Trip Relay
General Inspection
Pickup/drop out checks

TP-BA01

TP-DB01

TS-DB01

TP-VR02

TS-VR02

TP-CR02

TP-CR02

Commssioning Test.
4. Interlock checks

CE-09
CP-FC03
CP-EN03

Testing List
SL
No.

18

19

System
Name

Equipment

Project :
Testing Activities

Timing test
Timing Relay
General Inspection
Pickup/drop out checks
Timing test
Ammeter
General Inspection
Caliberation of the Meter
DC Switch
Voltmeter
board
General Inspection
Current Transducer
DC SYSTEM
General Inspection
Voltage Transducer
General Inspection
COMMISSIONING OF UPS
General Inspection
Componenet test (Metering Facitlities )

22

Test sheet No

TP-CR03

TP-AM02

TS-AX02

TP-VX02

Test sheet
No

TS-VM02

TP-AX02

Proc. No

TS-AM02

TP-VM02


TS-CR03

TS-VX02

CE-10
TP-UC01
pre energization checks
post energization checks
Operational Check
Alarms Ckecks
Load Test

UPS

COMMISSIONING OF GENERATOR PROTECTION PANEL
Generator differential Relay
G60- GE
Breaker Failure Relay
Gerator
GENERATOR
C60-GE
20
PROTECTION Protection
Transformer Differetial Relay
T60- GE
Panel
Lockout Relays
Multifunction Meter DMM

21

Test Proc.
No


TS-DR01)

TS-DR01(G60)

TS-AR01(C60)

TS-AR01(C60)

TS-DR01

TS-DR01(T60)

COMMISSIONING OF GENERATOR
TP-MM01
2. Polarization index of stator @ 5kv dc
3. Polarization index of Rotor @
MV SYSTEM
4.Insulation Resistance Test of exciter stator
Gerator
5. Commissioning of Heaters
1. Insulation resistance measurement test for heaters and cable
2. Measurement of Current
3. measurement of voltages
COMMISSIONING OF MCC and Distrubution Board
Bus Bar
MCC &
LV SYSTEM
DISTRIBUTION
TP-MM01
2. Torque check
BAORD
3. conatct resistance test for joint

TS-MM01

CE-11
TS-MM01

3. Primary Injection test
4. Interlock checks

Testing List
SL
No.

22

System
Name

Equipment

Project :
Testing Activities

4. Total circuit contact resistance test
5. Insulation resistance test
For Breakers
MCC &
1. Primary injection test for MCCB above 100 Amps
LV SYSTEM DISTRIBUTION 2. Trip test for over load above 100 amps
3. Functional Check of Starter
BAORD
4. Ratio and insulation resistance test for CTs above 100 Amp

Test Proc.
No

TP-MM01

Test sheet No

TP-MM01


Proc. No

Test sheet
No

ent
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nsultant
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ntractor

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Doc No.: PP1
c.
10-BS-SU-001

Riyadh Po
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ower plant # 10
t
“1062
21166/00”
STARTU MANUA
UP
AL

Date:13
D
Feb,09
F

Revision
n:
0

GENERA INST
AL
TRUCTION
FO AC
OR C/DC
VOLTA
V
AGE T
TESTIN
NG

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SEC-COA

Subject

:

High Voltage AC/DC Testing

Doc. No: TP-HP01,

MV Cable and Switch Gear

8 of 1Page
Date:13 Feb,09

Equipment :

BEMCO

“10621166/00”

Revision: 0

TABLE OF CONTENTS
Page
1

1.

PURPOSE

2.

SCOPE

1

3.

REFERENCES

1

4.

NOTES .AND PRECAUTIONS

1

5.

PROCEDURE

2

6.

ACCEPTANCE CRITERIA

4
APPENDICES

A

TEST TABLES

B

HIGH POTENTIAL DATA RECORD

1

The above contents may not be reproduced, transmitted, or
distributed to any form or by any means with out prior permission of
the originator

Originator: BEMCO Services
Prepared by : AH

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Doc. No: TP-HP01,


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Equipment :

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“10621166/00”

Revision: 0

1.

PURPOSE
The purpose of this procedure is to test and document the integrity of cables, metal enclosed
bus duct, and switchgear assemblies of both 4.16kV and 13.8 kV levels using an ac/dc
source.

2.

SCOPE
This procedure applies to both ac and dc high-potential testing. DC high-potential testing is
preferred for testing on a periodic basis since it is more than a "go" or "no-go" test, as is the
ac test. The dc test can indicate that the tested object is all right at the present time but may
fail in the future. The ac high-potential test is more accepted standard in practice.

3.

REFERENCES

3.1.

IEEE Standard 62-1958, IEEE Recommended Guide for Making Dielectric Measurements in
the field.

3.2.

The ac high-potentla1 test levels recommended by the national standards ANSI for
switchgear assemblies and rigid bus.

3.3.

The ac/dc high-potentla1 test levels recommended by IEC 60502 standards for 1kv to 15 kv
cables

4.

NOTES AND PRECAUTIONS

4.1.

Due to high voltage being used, adequate safety precautions should be taken to avoid injury
to personnel and damage to property.

4.2.

Always use approved and tested safety rubber gloves when connecting and disconnecting test
leads to and from the apparatus, and while operating the test equipment.

4.3.

Test equipment operation shall be in accordance with the manufacturer's instructions.

4.4.

In the case of unshielded cable, the non-uniform electric field between conductor and the
metal enclosure (ground) may introduce excessive stresses in the insulation. In the case of
unshielded cable it is therefore recommended that a dc test only be carried out.

4.5.

Shielded power cables require electrical stress control when they are terminated. Cables shall
be made up with either stress cones or with heat-shrinkable stress control material.

4.6.

The cable route or the equipment should be walked down to establish safety boundaries as
necessary for personnel and equipment protection.

4.7.

Ensure that all voltage transformers are disconnected for the duration of the test and that all
current transformers are short-circuited.

4.8.

Continuity and phasing of all cables and switchgear bus-work should be checked, where

2

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Equipment :

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“10621166/00”

Revision: 0

practical.
4.9.

Provision should be made to ground equipment through a resistance by means of a hot stick
after megger or high-potential testing.

4.10.

Ensure that all cable shields and switchgear grounds have been made per the installation
instructions.

4.11.

Conductors of each like phase may be tested together, provided the source has adequate
capacity to maintain the specified test voltage for the required period of time. Conductors not
being tested shall be tied together, using a soft wire and grounded at the test end.

4.12.

Phases should be properly identified and labeled

4.13.

This test should be performed only by personnel who are properly trained on the test
equipment. Safety rules, testing procedures and interpretation of the results.

5.

PROCEDURE

5.1

Determine the test voltage, kVA and times and voltage steps to be used (refer to Appendix
A).

5.2

De-energize, discharge and safety) tag the cable/equipment to be tested, as necessary. Record
the scheme/cable/equipment number on the High-Potential Data Record form.

5.3

Disconnect the cable/equipment from the equipment/cables at each end and position it with
maximum possible clearance from objects. The minimum clearance recommended to
preclude flashover is 10 cm. Ensure that open cable ends are insulated.

5.4

Ground all equipment, cables and conductors not under test that are in contact with the cable
under test or that can become energized by a flashover.
NOTE
Where high-potential testing of shielded cables with grounded shields is to be performed, the
existing cables/equipment need not be grounded.

5.5

As a precautionary measure a 2,500 V megger reading shall be made between the test
terminals to ensure that the equipment/cable is free from gross defects as a result of damage
during installation and that no inadvertent grounds have been left. The megger readings
should be recorded on the High-Potential Data Record form.
NOTE
Megger resistance values will vary over a wide range depending on the type of equipment
being tested and the test environment. As a result it is difficult to state precisely what
constitutes an acceptable megger resistance value. However, as a general rule, tests should be
terminated if the insulation resistance is less than 5 Mohms for 5 kV class equipment and 15
Mohms for 15 kV class equipment. Abnormally low values of insulation resistance should be

3

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Equipment :

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Revision: 0

investigated before proceeding further with any test
5.6

Position the test instrument inside the test area keeping the high voltage lead between the test
instrument and the cable/equipment being tested.

5.7

Connect the test set in accordance with the manufacturer's instructions.

5.8

Set the ammeter to its highest range.

5.9

Set the voltage to its lowest range.
CAUTION
Avoid overshooting the voltage. The initially applied direct-current voltage shall not be
greater than three times the rated alternating-current voltage of the cable for high-potential dc
testing.

5.10

Gradually increase the test voltage until the desired test level is reached. During the voltage
buildup, the rate of increase of the applied voltage shall be approximately uniform so that
the required time shall be no less than 10 seconds and no more than 60 seconds for dc highpotential testing and shall not exceed 10 seconds for ac high-potential testing.
NOTE
If cable/equipment insulation failure should occur as indicated by the high ammeter reading,
secure the test voltage immediately.

5.11

Measure leakage current at the end of each step, record data on the High-Potential Data
Record form.

5.12

Repeat steps 5.10 and 5.1 1 correcting any abnormalities, until the maximum test voltage is
reached.

5.13

Maintain maximum test voltage as indicated in Table 3 of Appendix A. Measure leakage
current every minute and record data on the High-Potential Data Record form.

5.14

Reduce test voltage continuously, but not abruptly

5.15

Turn off the test instrument and allow the voltage to decay for the minimum time in
accordance with the test instrument instruction.
CAUTION
A dangerous charge may be stored by the apparatus unless it is grounded after the test.

5.16

Ground the cable/equipment (use a discharge rod) and allow the ground to remain in place
for a period of at least 3 to 5 minutes.

5.17

Remove the test connections.

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5.18

Restore the cable to its as-found condition.

5.19

Remove all grounds installed in Step 5.4.

6.

Revision: 0

ACCEPTANCE CRITERIA
The equipment tested shall withstand the imposed potentials for the prescribed periods of
time without distress or failure.
NOTE
If the leakage current versus voltage are plotted as a curve, as long as this plotted curve is
linear for each step. The insulation system is in good condition. At some value of step
voltage if the leakage current begins to increase noticeably an increase in the slope of the
curve will be noticed. as shown in the figure below. If the test is continued beyond this test
voltage, the leakage current will increase even more rapidly and immediate breakdown may
occur in the cable insulation.

When the final test voltage of leakage current versus voltage test is reached, it can be left on
for the required time and the leakage current versus time can be plotted for fixed intervals of
time as the leakage current during this step reduces from an initial high value to a steadystate value. A curve for good cables will generally indicate a continuous decrease in leakage
current with respect to time or steady-state value without any increase of current during the
test. This is shown in the figure below.

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APPENDIX A
TEST TABLES
Table I
Test Set kVA Required for High-Potential Testing of 5 kV Class Shielded
Cable (100 m length at 10kV)

Cable Size,
MCM
250

EPR Cable,
kVA
2.5

XLPE Cable.
kVA
2.0

350

2.9

2.3

500

3.4

2.6

750

4.3

3.3

1,000

5.0

4.0

Table 2
Test Set kVA Required for High-Potential Testing of 15 kV Class
Shielded Cable (100 m length at 20 kV)
Cable Size,
MCM
250

EPR Cable,
kVA
5.7

XLPE Cable.
kVA
4.5

350

6.6

5.2

500

7.5

5.9

750

9.5

7.4

1,000

10.8

8.4

NOTES:
1.

The tables show' the values for both cross-linked polyethylene (XLPE) and ethylenepropylene rubber (EPR) type cables.

2.
The values have been calculated based on standard cable dimensions and using a dielectric
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constant of 3.7 for EPR and 2.5 for XLPE. as supplied by cable manufacturers.
APPENDIX A (Continued)
Table 3
Recommended Field Test Levels
AC Testing
Equipment

Power Cable:
Unshielded
Shielded
(including
Cable Bus)

High-potential
VLF @0.1HZ
Rated
Partial Discharge Test
Test(PF)
Voltage,
Test
Pulse
Test
kV
Time, Extinction
Time,
Time,
Level,
Magnitude,
level,
Min Level, kV
Min
Min
kV
pC
kV
3XUo
4.16
N/A
N/A
N/A
N/A
N/A
60
4.16
9(13)
5
4.5(4.5)
3(3)
2
7.2
60
13.85 60
8
13(18)
5
7.5(7.5)
3(3)
2
13.8

Switchgear

19(27)

5

13(13)

3(3)

2

25

45(60)

1

19

100

2

13.8

27(36)

1

10.5(10.5)

100(100)

14(19)
27(36)

1
1

3.5(3.5)
10.5(10.5)

100(100)
100(100)

2
2

Test
Time,
level,
Min
kV
4XU0
9.6
5
9.6
15

23.9

60

N/A

N/A

N/A

19

15

32

15

64

1

37(50)

2

4.16
13.8

Bus Duct :
Isolated phase
Bus (IPB)
MetalEnclosed
Rigid Bus

DC Testing

1

N/A
N/A

N/A
N/A

N/A

N/A
N/A

N/A
N/A

NOTES:
1.
2.
3.
4.
5.

Factory tests are shown in brackets.
The values recommended for field ac high-potential tests are at 75 percent of the factory
levels, for switchgear assemblies 70 percent of factory levels.
The values recommended for field dc high-potential testing of cable as per IEC-60502 is
4times U0 Where as Uo is U/1.732.
The value recommended for field AC VLF testing is 3Uo for 60 minutes
above values to be used in case Vendor recommended values are not available

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Doc No.: PP1
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10-BS-SU-001

Riyadh Po
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ower plant # 10
t
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21166/00”
STARTU MANUA
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Date:13
D
Feb,09
F

Revision
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TES
STING PROC
CEDUR FO ME
RE OR EDIUM
VOLT
TAGE CABLE

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Testing procedure

Form No: TP-CM01,

MV Cable Up to 33kv

Page 1 of 7
Date:13 Feb,09

Equipment :

BEMCO

“10621166/00”

Revision: 0

TABLE OF CONTENT
1.

Task
a. Work Status-----------------------------------------------------------------------------------------------------------------2
b. Documentation-------------------------------------------------------------------------------------------------------------2
c. Personnel--------------------------------------------------------------------------------------------------------------------2
d. Measuring Instrumentation----------------------------------------------------------------------------------------------2

2.
3.
4.
5.

Preconditions--------------------------------------------------------------------------------------------------------------2
Precautions-----------------------------------------------------------------------------------------------------------------2
Scope-------------------------------------------------------------------------------------------------------------------------3
Execution--------------------------------------------------------------------------------------------------------------------3
a. Visual Inspection--------------------------------------------------------------------------------------------------------3
b. Testing of Motor
1. Cable Sheath Testing--------------------------------------------------------------------------------------------3
2. Conductor continuity and phasing test.----------------------------------------------------------------------3
3. Insulation Resistance test Before Hipot.--------------------------------------------------------------------4
4. High voltage AC test for XLPE cable.------------------------------------------------------------------------5
5. Insulation Resistance test After Hipot-----------------------------------------------------------------------7

6.
7.
8.

Documents-----------------------------------------------------------------------------------------------------------------7
Reference-------------------------------------------------------------------------------------------------------------------7
Attachment-----------------------------------------------------------------------------------------------------------------7

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Testing procedure

Form No: TP-CM01,

MV Cable Up to 33kv

Page 2 of 7
Date:13 Feb,09

Equipment :

BEMCO

“10621166/00”

Revision: 0

1.0 Task
All newly installed power cable (1-33kV) in the electrical system requires field
testing.

2.0 Preconditions
2.1 Work Status

• Erection has been completed.
• Labelling of the equipment is complete

2.2 Documentation

• Test Sheet TS-CM01

2.3 Personnel

• 1 Testing engineer: Engineer or technician with experience in high voltage
testing of electrical equipment.
• 1 Helper: skilled worker with adequate on-the-job training.

2.4 Measuring Instruments and Tools

• Fluke
• High Voltage Tester Up to 100KV AC/DC or VLF
• Insulation Tester 5KV

3.0 Precautions
• The work will only proceed when a Permit to Work (PTW) in work permit
area has been obtained. The PTW will be kept on site for consultation
during the testing works.
• Closing of the work permit after completion of the work (if the test area is to
be considered in work permit area) is necessary.
• The test site shall have sufficient protective barriers and warning signs to
conduct the tests.
• All cable section ends under test shall be grounded from accidental contact.
Also the minimum separation from all ends or elements not being subject to
test shall be 25.4mm/10kV of test voltage.
• Before cable test operation started, conductor under test and all cable
accessories shall be checked as being de-energized using reliable voltage
indicator. The voltage indicator should be tested for proper operation with
an independent voltage source prior to operation.
• While the voltage indicator is still in contact with each component and is
showing de-energized, a hot line grounded device for the purpose shall be
continuously attached to all conductors under examination except while test
equipment is ready for energization.
• All adjacent conductors in cable circuit not on test should be de-energized
and left grounded while testing the other conductor.

the originator

Prepared by :M AH

Page 34

Client
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SEC-COA

Subject

:

Testing procedure

Form No: TP-CM01,

MV Cable Up to 33kv

Page 3 of 7
Date:13 Feb,09

Equipment :

“10621166/00”

BEMCO

Revision: 0

4.0 Scope

• Checking termination,
• Checking shield
• Checking of correct earthing,

5.0 Execution
5.1 Visual Checks
•
•
•
•

Checking of the cables for any damage
Inspection for termination.
Inspection for correct tightness for connection
Checking labels

5.2 Testing of Cable
Enter the rating plate data in check list TS-CM01. The following test shall be
carried out
1.
2.
3.
4.
5.

5.2.1

Cable Sheath Testing
Conductor continuity and phasing test.
Insulation Resistance test Before Hipot.
High voltage AC test for XLPE cable.
Insulation Resistance test After Hipot
Cable Sheath Testing
Cable sheath testing is carried out in order to detect damage to
cable sheath. To do this DC test is carried out.
Test voltage 3kv is applied between PVC sheath and ground
provided shield is grounded and insulation resistance or leakage
current is measured.

5.2.2

Conductor Continuity and Phasing Test
To ensure the continuity and phasing of the cable conductor from
terminal to terminal, the cable conductor shall be tested by using a
minimum 500VDC megger as per figure below; tests results shall be
noted down in the test sheet.

M

Conductor continuity test

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Testing procedure

Form No: TP-CM01,

MV Cable Up to 33kv

Page 4 of 7
Date:13 Feb,09

Equipment :

“10621166/00”

BEMCO

Revision: 0

M

Phase verification
FIGURE-5-1

5.2.3

Insulation Resistance test Before High Voltage Test
Prior to performing the high voltage test on the cable, insulation
resistance test by mega ohmmeter at 5000VDC shall be performed
for one minute on each cable, between the conductor and the
metallic shield with the adjacent cable conductors and shield
grounded as per figure below.

M

Grounding sheet
Insulation Resistance Test
FIGURE: 5-2
Minimum insulation resistance of conductor for new cables shall be
determined by the following.

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SEC-COA

Subject

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Testing procedure

Form No: TP-CM01,

MV Cable Up to 33kv

Page 5 of 7
Date:13 Feb,09

Equipment :

“10621166/00”

BEMCO

5.2.4

Revision: 0

High Voltage Test
High Voltage test for medium voltage cable can be accomplished
either of the following method in agreement with the SEC/Consultant

5.2.4.1

AC High Voltage Testing
The AC power frequency voltage shall be applied through the
test set as per figure 5-3. While test, all cable conductors and
shield not on test shall be grounded. The test voltage shall be
pure sinusoidal wave shape. As per IEC 60840 the test voltages
are as follows
The maximum phase to phase voltage of the system shall be
maintained for line to ground for five minutes,
OR
2 X U0 for 60 Minutes
OR
A. C. test volts = .75(2 X equipment maximum voltage + 1kV) for
one minute (as per ARMCO)

In all cases voltage at the rate of 1 kV per second shall be increased until
the maximum recommended test voltage is reached and maintained for
required time duration.
The AC high potential test results are evaluated on a go, no-go basis by
slowly raising the test voltage to the required value of final test voltage and
maintaining for required durat
HV tester

Grounding sheet
AC High voltage Test
FIGURE: 5-3
AC test set shall have adequate volt-ampere capacity to supply the required
cable charging current. The KVA capacity of the test set shall be
determined by the following
KVA= 2πfCE2X10-3
C= Cable capacitance in μf/km
f= Supply frequency
E=Test voltage

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SEC-COA

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Testing procedure

Form No: TP-CM01,

MV Cable Up to 33kv

Page 6 of 7
Date:13 Feb,09

Equipment :

BEMCO

5.2.4.2

“10621166/00”

Revision: 0

DC High Voltage Testing
The high voltage DC shall be applied to each individual cable of
a 3-phase circuit. All cable conductors and shield not on test
shall be grounded.
High voltage DC test shall be as per IEC 60502 that is 4XU0 for
15 minutes.
OR
1.7[.75(2 X equipment maximum voltage + 1kV)] for 15
Minutes (ARMCO)
The test connections are as shown in figure 5-3.
A DC high potential test (controlled over voltage test) is one in
which the increase of applied direct voltage is controlled. The
measured current is continuously observed for abnormalities
with the intention of stopping the test before breakdown occurs
The initially applied voltage shall not exceed 1.8 times the rated
AC phase to phase voltage of the cable. After that the rate of
increase of the test voltage shall be approximately uniform and
shall not more than the maximum test voltage in 10 seconds or
less than the maximum test voltage in 60 seconds.
The maximum test voltage shall be maintained for 15 minutes,
leakage current shall be recorded in TS-CMO2. No breakdown
of the insulation shall occur.
Maximum allowable leakage current for new cables shall be
determined by the following
IL=E/RX10-3 Amps
Where

IL= Leakage current in Amps
E= DC test voltage in Kv
R= Insulation resistance in MΩ

OR

5.2.4.3

VLF High Voltage Testing
VLF is used for the cable testing where power requirement for
the test is high; VLF uses very low frequency (0.01 to 0.1 HZ)
that’s why power requirement for the cable under test is less.
Test voltage equal to 3U0 is applied through the test set as
shown in figure 5.3. While test, all cable conductors and shield
not on test shall be grounded.
Test voltage is applied at the rate 1KV/second till the maximum
test voltage is reached and maintain for 60 Minutes. Leakage
current is recorded.

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Testing procedure

Form No: TP-CM01,

MV Cable Up to 33kv

Page 7 of 7
Date:13 Feb,09

Equipment :

“10621166/00”

BEMCO

5.2.5

Revision: 0

Insulation Resistance Test After High Voltage Test
Insulation resistance test by mega ohmmeter at 5000VDC shall be
performed for one minute on each cable, between the conductor
and the metallic shield with the adjacent cable conductors and
shield grounded after the high voltage test.

Recommended Field Test Levels
AC Testing

Equipment

Power
Cable:
Unshielded
Shielded
(including
Cable Bus)

DC Testing
High-potential
VLF @0.1HZ
Rated
Partial Discharge Test
Test(PF)
Voltage,
Test
Pulse
Test
Test
kV
Time, Extinction
Time,
Time,
Time,
Level,
Magnitude,
level,
level,
Min Level, kV
Min
Min
Min
kV
pC
kV
kV
3XUo
4XU0
4.16
4.16
8
13.8

N/A
9(13)
13(18)
19(27)

N/A
5
5
5

N/A
4.5(4.5)
7.5(7.5)
13(13)

N/A
3(3)
3(3)
3(3)

N/A
2
2
2

7.2
13.85
23.9

60
60
60
60

9.6
9.6
19
32

5
15
15
15

NOTES:
1.
2.
3.
4.
5.

Factory tests are shown in brackets.
The values recommended for field ac high-potential tests are at 75 percent of the factory
levels, for switchgear assemblies 70 percent of factory levels.
The values recommended for field dc high-potential testing of cable as per IEC-60502 is
4times U0 Where as Uo is U/1.732.
The value recommended for field AC VLF testing is 3Uo for 60 minutes
above values shall be used in case Vendor recommended values are not available
otherwise

5.2.6 Checking the protective Earthing
Check the earthing for the armour and shield is properly connected

6.0

Documents
Test sheet TS-CM01 shall be completed.

7.0

References:

8.0

Attachment:

8.1

Test Sheet of Cable TS-CM01
*** End of the procedure ***

the originator

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ent
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Con
nsultant
Con
ntractor

: SEC-C
COA
:
O
: BEMCO

Doc No.: PP1
c.
10-BS-SU-001

Riyadh Po
R
ower plant # 10
t
“1062
21166/00”
STARTU MANUA
UP
AL

Date:13
D
Feb,09
F

Revision
n:
0

TES SHEETS
ST

Page 40

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Contractor

:
:
:

SEC-EOA

“10621166/00”

BEMCO
Form No: TS-CM01
Testing of Medium Voltage Cable

Cable Tag No :
Length :

Type of cable:
From Equipment:

Page 1 of 3
Date:13/02/09,Revision: 0

Location :
To equipment:

ACTIVITIES/CHECKS (All activities are part of field commissioning)

No

1.

Confirms

Remarks

Technical data
Manufacturer:...............................................................................................
Size:.........................................................................................
Rated voltage:..............................................................................................

2.

Visual check

i. Check for Physical damage/Defects and also check for any irregular form
of outer jackets caused by non-uniform shield wire distribution
ii. Check for proper cable support, clamping and blocking etc
iii. Verify Shields are grounded as specified
iv. Check that phases are identified and colour coded
4.
4.1

Electrical test on Cable
Cable Continuity and phasing test
Phases
Continuity

Phasing

Phase A
Phase B
Phase C
4.2

Cable Sheath Test.
Phase
R-G
G-ohms

Test Voltage--------------- KV DC
Y-G
B-G

Test
Voltage
4.3

Insulation Resistance Measurment. Before Hipot Test.
Phase
R-G+Y+B
B-G+Y+R
Insulation Resistance in MΩ

Y-G+B+R

Test Voltage

Subcontract/Tested by

Arabian BEMCO

SEC-COA

Name:
Signature:
Date:
Page 41

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:
:
:

SEC-EOA

“10621166/00”

BEMCO
Form No: TS-CM01

Cable Tag No :
Length :
No

4.4

4.5

Type of cable:
From Equipment:

Page 2 of 3

Location :
To equipment:
Confirms

Remarks

AC High Pot test
Hipot Test at ------------ KV AC for 60minute. VLF @ 0.1 HZ
Phase
R-Y+B+G
Y-R+B+G
B-R+Y+G
Leakage current
Test Voltage
OR
DC Hipot testing Hipot Test at ------------ KVDC for 15minute.
Test voltage
Leakage current
/Time
R-Y+B+G
Y-R+B+G
B-R+Y+G
----KV
-----KV
-----KV
-----KV
-----KV
15 Sec
30 sec
45 sec
1 minutes
2 minutes
3 minutes
4 minutes
5 minutes
6 minutes
7 minutes
8 minutes
9 minutes
10 minutes
11 minutes
12 minutes
13 minutes
14 minutes
15 minutes


Arabian BEMCO

SEC-COA

Name:
Signature:
Date:
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SEC-EOA

“10621166/00”

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Form No: TS-CM01

Cable Tag No :
Length :

No

4.6

Type of cable:
From Equipment:

Page 3 of 3

Location :
To equipment:

Insulation Resistance Measurment.
After Hipot Test.
Phase
R-G+Y+B

B-G+Y+R

Confirms

Remarks

Y-G+B+R

Test Voltage

5

Remarks

Test Equipment

Model

Cal due date


Test Equipment

Arabian BEMCO

Model

Cal due date

SEC-COA

Name:
Signature:
Date:
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nsultant
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ntractor

: SEC-C
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:
O
: BEMCO

Doc No.: PP1
c.
10-BS-SU-001

Riyadh Po
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“1062
21166/00”
STARTU MANUA
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Date:13
D
Feb,09
F

Revision
n:
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TE
ESTIN PRO DURE F
NG
OCED
FOR L
LOW
VOLT
TAGE CABL
LE

Page 44

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SEC-COA

Subject

:

Testing procedure

Form No: TP-CM02,

LV Cable Up to 1kv

Page 1 of 4
Date:13 Feb,09

Equipment :

BEMCO

“10621166/00”

Revision: 0

TABLE OF CONTENT
1.

Task
a. Work Status-----------------------------------------------------------------------------------------------------------------2
b. Documentation-------------------------------------------------------------------------------------------------------------2
c. Personnel--------------------------------------------------------------------------------------------------------------------2
d. Measuring Instrumentation----------------------------------------------------------------------------------------------2

2.
3.
4.
5.

Preconditions--------------------------------------------------------------------------------------------------------------2
Precautions-----------------------------------------------------------------------------------------------------------------2
Scope-------------------------------------------------------------------------------------------------------------------------3
Execution--------------------------------------------------------------------------------------------------------------------3
a. Visual Inspection--------------------------------------------------------------------------------------------------------3
b. Testing of Motor
1. Cable Sheath Testing--------------------------------------------------------------------------------------------3
2. Conductor continuity and phasing test.----------------------------------------------------------------------3
3. Insulation Resistance test Before Hipot.--------------------------------------------------------------------4
4. High voltage AC test for XLPE cable.------------------------------------------------------------------------5
5. Insulation Resistance test After Hipot-----------------------------------------------------------------------7

6.
7.
8.

Documents-----------------------------------------------------------------------------------------------------------------7
Reference-------------------------------------------------------------------------------------------------------------------7
Attachment-----------------------------------------------------------------------------------------------------------------7

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Testing procedure

Form No: TP-CM02,

LV Cable Up to 1kv

Page 2 of 4
Date:13 Feb,09

Equipment :

BEMCO

“10621166/00”

Revision: 0

1.0 Task
All newly installed power and control cable (1KV) in the electrical system
requires field testing.

2.0 Preconditions
2.1 Work Status

• Labelling of the equipment is complete

2.2 Documentation

• Test Sheet TS-CM01

2.3 Personnel

• 1 Testing engineer: Engineer or technician with experience in high voltage
testing of electrical equipment.
• 1 Helper: skilled worker with adequate on-the-job training.

2.4 Measuring Instruments and Tools
• Fluke
• Insulation Tester 5KV

3.0 Precautions
• The work will only proceed when a Permit to Work (PTW) in work permit
area has been obtained. The PTW will be kept on site for consultation
during the testing works.
• Closing of the work permit after completion of the work (if the test area is to
be considered in work permit area) is necessary.
• The test site shall have sufficient protective barriers and warning signs to
conduct the tests.
• All cable section ends under test shall be grounded from accidental contact.
Also the minimum separation from all ends or elements not being subject to
test shall be 25.4mm/10kV of test voltage.
• Before cable test operation started, conductor under test and all cable
accessories shall be checked as being de-energized using reliable voltage
indicator. The voltage indicator should be tested for proper operation with
an independent voltage source prior to operation.
• While the voltage indicator is still in contact with each component and is
showing de-energized, a hot line grounded device for the purpose shall be
continuously attached to all conductors under examination except while test
equipment is ready for energization.
• All adjacent conductors in cable circuit not on test should be de-energized
and left grounded while testing the other conductor.

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SEC-COA

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Testing procedure

Form No: TP-CM02,

LV Cable Up to 1kv

Page 3 of 4
Date:13 Feb,09

Equipment :

“10621166/00”

BEMCO

Revision: 0

4.0 Scope

• Checking termination,
• Checking shield
• Checking of correct earthing,

5.0 Execution
5.1 Visual Checks
•
•
•
•

Checking of the cables for any damage
Inspection for termination.
Inspection for correct tightness for connection
Checking labels

5.2 Testing of Cable
Enter the rating plate data in check list TS-CM01. The following test shall be
carried out
1.
2.

5.2.1

Conductor continuity and phasing test.
Insulation Resistance test Before Hipot.
Conductor Continuity and Phasing Test
To ensure the continuity and phasing of the cable conductor from
terminal to terminal, the cable conductor shall be tested by using a
500VDC meeger or a fluke as per figure below; tests results shall
be noted down.

M

Conductor continuity test

M

Phase verification
FIGURE-5-1
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Testing procedure

Form No: TP-CM02,

LV Cable Up to 1kv

Page 4 of 4
Date:13 Feb,09

Equipment :

“10621166/00”

BEMCO

5.2.2

Revision: 0

Insulation Resistance test
Insulation resistance test by mega ohmmeter at 500VDC shall be
performed for one minute on each cable, between the conductor
and the metallic shield with the adjacent cable conductors and
shield grounded as per figure below.

M

Grounding sheet
Insulation Resistance Test
FIGURE: 5-2
Minimum insulation resistance of conductor for new cables shall be
determined by the following.

5.2.3 Checking the protective Earthing
Check the earthing for the armour and shield is properly connected

6.0

Documents
Test sheet TS-CM02 shall be completed.

7.0

References:

8.0

Attachment:

8.1

Test Sheet of Cable TS-CM02
*** End of the procedure ***

the originator

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nsultant
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ntractor

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: BEMCO

Doc No.: PP1
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10-BS-SU-001

Riyadh Po
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ower plant # 10
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21166/00”
STARTU MANUA
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Date:13
D
Feb,09
F

Revision
n:
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TES SHEETS
ST

Page 49

Customer
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Contractor

:
:
:

SEC-EOA

“10621166/00”

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Form No: TS-CM02
Testing of Low Voltage Cable

Cable Tag No :
Length :

Type of cable:
From Equipment:

Page 1 of 1

Location :
To equipment:


No

1.

Confirms

Remarks

Technical data
Manufacturer:...............................................................................................
Size:.........................................................................................
Rated voltage:..............................................................................................

2.

Visual check

i. Check for Physical damage/Defects and also check for any irregular form
of outer jackets caused by non-uniform shield wire distribution
ii. Check for proper cable support, clamping and blocking etc
iii. Verify Shields are grounded as specified
iv. Check that phases are identified and colour coded
4.
4.1

Electrical test on Cable
Cable Continuity and phasing test
Phases
Continuity

Phasing

Phase A
Phase B
Phase C
4.2

Insulation Resistance Measurment.
Phase

R-G+Y+B

B-G+Y+R

Y-G+B+R

Test Voltage

Test Equipment

Model

Cal due date


Test Equipment

Arabian BEMCO

Model

Cal due date

SEC-COA

Name:
Signature:
Date:
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nsultant
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ntractor

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:
O
: BEMCO

Doc No.: PP1
c.
10-BS-SU-001

Riyadh Po
R
ower plant # 10
t
“1062
21166/00”
STARTU MANUA
UP
AL

Date:13
D
Feb,09
F

Revision
n:
0

TEST
TING PROCE RE FOR AUX
P
EDUR
R
XILIARY
Y
TRA
ANSFO
ORMER
R

Page 51

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SEC-COA

Subject

:

Testing procedure

Doc. No: TP-AT01,

Auxiliary Transformer(<10MVA)

Page 1 of 8
Date:13 Feb,09

Equipment :

BEMCO

“10621166/00”

Revision: 0

TABLE OF CONTENT
1.

Task
a. Work Status----------------------------------------------------------------------------------------------------------2
b. Documentation------------------------------------------------------------------------------------------------------2
c. Personnel-------------------------------------------------------------------------------------------------------------2
d. Measuring Instrumentation---------------------------------------------------------------------------------------2

2.
3.
4.
5.

Preconditions-----------------------------------------------------------------------------------------------------------2
Precautions--------------------------------------------------------------------------------------------------------------2
Scope----------------------------------------------------------------------------------------------------------------------3
Execution-----------------------------------------------------------------------------------------------------------------3
a. Visual Checks------------------------------------------------------------------------------------------------------3
b. Testing of Transformer
1. insulation resistance / Polarization index test----------------------------------------------------------3
2. Voltage Ratio Measurement--------------------------------------------------------------------------------4
3. Vector Group/Phase Displacement-----------------------------------------------------------------------4
4. Winding Resistance Test------------------------------------------------------------------------------------5
5. Excitation current Measurement---------------------------------------------------------------------------6
6. Temperature indicator and sensor Calibration--------------------------------------------------------7
7. Bushing Current Transformer------------------------------------------------------------------------------7
8. Testing and commissioning of cooler control cabinet------------------------------------------------7
9. Transformer protection devices functional check-----------------------------------------------------7
10. Protective Earthing Checks---------------------------------------------------------------------------------7

6.
7.
8.

Documents---------------------------------------------------------------------------------------------------------------8
Reference-----------------------------------------------------------------------------------------------------------------8
Attachment---------------------------------------------------------------------------------------------------------------8

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Testing procedure

Doc. No: TP-AT01,


Page 2 of 8
Date:13 Feb,09

Equipment :

BEMCO

“10621166/00”

Revision: 0

1. Task
This instruction comprises a complete description of the testing of oil and dry type
distribution or auxiliary transformers.
2. Preconditions
2.1. Work status
• Labelling of the equipment and designation of live enclosed plant sections has
been carried out.
2.2. Documentation
• The circuit diagram of Electrical equipment ,cabinets, etc are available
• Test Sheet TS-AT01 is available
• Product manual of the transformer is Available
• Factory Test Results of the transformer is available
2.3. personnel
• Commissioning engineer: - (1) engineer with experience in commissioning of
transformer and switch gear.
• Technician or helper:- (2) skilled worker with adequate on -the-job training
• Witness from the client‘s concern department
2.4. Measuring instrument
• Ratio meter (calibrated)---1
• Multi Meter (calibrated)—2
• Insulation resistance meter –megger(calibrated)—1
• CT tester-CPC100( calibrated)-1
• DC shunt 100 amps( calibrated)--1
• Mini clamp(calibrated)—2
• Tan delta measurement test equipment—1
• Current injection set(calibrated)—1
• 3 phase relay tester(calibrated)—1
3. Precautions
The work will only proceed when a Permit to Work (PTW) in work permit area has been
obtained. The PTW will be kept on site for consultation during the testing works.
• Observe the rules for handling electronic components sensitive to electrostatic
discharge (ESD measures).
• Special safety arrangements shall be made for all areas which are not explicitly
designated as” electrical operating areas” when performing tests at voltages in
excess of 50V.
• Closing of the work permit after completion of the work (if the test area is to be
considered in work permit area) is necessary.
• Before test voltages are applied a check shall be carried out to ensure that no
unauthorized persons are working at the corresponding load-where ever necessary
barriers should be provided.
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Testing procedure

Doc. No: TP-AT01,


Page 3 of 8
Date:13 Feb,09

Equipment :

4.

BEMCO

“10621166/00”

Revision: 0

Scope
• Testing of Transformer
• Checking Auxiliaries and cooling system
• Checking that the mounting position is correct,
• Testing of bushing CT
• Checking of correct Earthing,

5. Execution
5.1. Visual Inspection.
Prior to carrying out electrical tests, a visual check of the transformer should be
carried out paying particular attention to the following points
• Correct labeling of devices and cables
• Equipment and cables are undamaged
• Correct execution of the cable gland/sealing end
• Name plate data, match with drawing and ambient condition
• Firm cable termination/terminal connection and ferruling
5.2. Testing of Transformer
Following tests to be carried out
1. insulation resistance / Polarization index test
2. Voltage Ratio Measurement
3. Vector Group/Phase Displacement
4. Winding Resistance Test
5. Excitation current Mesurment
6. Temperature indicator and sensor Caliberation
a. Winding Temperature
b. Oil Temperature
7. Bushing Current Transformer
8. Testing and commissioning of cooler control cabinet
9. Transformer protection devices functional check
10. Protective Earthing Checks
5.2.1. Insulation resistance/polarization index test
Checking of the insulation resistance and polarization index should be carried
out as under
Apply the test voltage on following Connection and note down the readings
Two Winding Transformers
HV – LV + Earth
LV – HV + Earth
The insulation resistance Measurement is done from 15 seconds to 1 minute
with 15 seconds interval and then for every minute up to ten minutes. Value
obtained at 10 minute divided by value at 1 minute gives polarization index
Please refer below for connection and test arrangement

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Testing procedure

Doc. No: TP-AT01,


Page 4 of 8
Date:13 Feb,09

Equipment :

BEMCO

“10621166/00”

Revision: 0

5.2.2. Voltage Ratio Measurement
The voltage ratio measurement for two or three winding power transformer
can be done either by conventional method by using Voltmeters or by using
Turns ratio Meter
The test shall be done for each and every phase at all tap position as follows.

For Two winding Transformer
• Apply 3 phase Voltage more then 220V on HV Winding and measured
the corresponding voltages at the LV winding
• Note down both HV and LV winding side voltages on all the three
phases and all tap positions.
5.2.3. Vector group check
The vector group or phase relationship can be checked by injecting three
phase supply and measuring the voltages as per the figure below.
One of the phase say 1U and 2U between HV and LV should be shorted
together and three phase low voltage is applied on HV terminals.
Then the voltage between various pairs of line terminal should be measured
and compared
the originator

Prepared by :M AH

Page 55

Client
Consultant
Contractor

:
:
:

SEC-COA

Subject

:

Testing procedure

Doc. No: TP-AT01,


Page 5 of 8
Date:13 Feb,09

Equipment :

BEMCO

“10621166/00”

Revision: 0

Example: condition for Dyn11 is, the voltage between
1W-2V> 1W-2W=1V-2W=1V-2V

5.2.4. Winding Resistance Measurement
The Winding resistance measurement can be done by either conventional
method using 2V DC battery with voltmeter and Ammeter or by Transformer
resistance meter.
The winding resistance will be measured by a drop of potential method on all
windings by injecting direct current through the phase winding as shown
below.

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:

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Subject

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Testing procedure

Doc. No: TP-AT01,


Page 6 of 8
Date:13 Feb,09

Equipment :

BEMCO

“10621166/00”

Revision: 0

For the Y connected transformer the measurement should be made between
each line bushing and single phase value is half of the measured value. For
the delta connection, the measurement should be made between each pair of
bushing and then single phase value is three half of the measured value.
The measured values should be compared with factory value, for that, a
conversion for the temperature correction should be done by following
formula.
R75 = Ra x 234.5+75
234.5+Ra
Where as R75 = Corrected Resitance in ohms
Ra = Measured Resistance at ambient temperature in ohms
Ta = Ambient temperature in 0 C
5.2.5. Magnetization Current Measurement.
The test connection is done as shown in the following drawing. Apply 200 V to
the transformer HV terminals and measure the current and corresponding
voltage for all the tap position.

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Testing procedure

Doc. No: TP-AT01,


Page 7 of 8
Date:13 Feb,09

Equipment :

BEMCO

“10621166/00”

Revision: 0

5.2.6. Oil Testing
Oil sample should be taken from bottom, top of the main tank, OLTC chamber
and also from the conservator tank,
De-electric test for the oil should be performed as per IEC 156 using deelectric test machine
5.2.7. Temperature indicator and sensor.
5.2.7.1.

Oil Temperature
The oil and winding temperature indicators shall be calibrated by heat
sink with thermometer.

5.2.7.2.

Winding Temperature
The winding temperature indicator shall be checked by current injection
at the heater element.

5.2.8. Bushing current transformer
Following tests should be done on all the bushing transformers
• Ratio test
• Magnetization curve
• Polarity test
• Insulation test
• Winding resistance test
• Loop resistance test
All the test results shall be entered in the test form No.TS-CT01of the
transformer. Refer TP-CT01 for the test procedure
5.2.9. Testing and commissioning of cooler control cabinet
Prior to power up cooler control cabinet with auxiliary 3 phase/single
phase/dc voltage, following check up shall be carried out.
Winding insulation resistance and winding resistance for the fan motors
should be carried out.
Insulation resistance test for the control circuit should be carried out.
After obtaining all the results and found satisfactory auxiliary power can be
switched on and voltage/phase sequence measurement should be carried
out.
Manual/auto operation of the fans should be checked
Heater and lighting circuit should be checked and made functional.
5.2.10. Transformer protection devices functional check
Trip and alarm should be simulated from buchholz relay. tripping of protection
relay and breakers should be observed, alarms on local and remote
annunciation shall be observed
Trip and alarm should be simulated from pressure relay. tripping of protection
relay and breakers should be observed, alarms on local and remote
annunciation shall be observed
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:
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Subject

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Testing procedure

Doc. No: TP-AT01,


Page 8 of 8
Date:13 Feb,09

Equipment :

BEMCO

“10621166/00”

Revision: 0

Trip and alarm should be simulated from pressure relief relay. tripping of
protection relay and breakers should be observed, alarms on local and
remote annunciation shall be observed
Trip and alarm should be simulated from oil and winding temperature
indicator. tripping of protection relay and breakers should be observed,
alarms on local and remote annunciation shall be observed
Results for above tests shall be entered in the test form No.TS-AT01 of the
power transformer.
5.2.11. Protective Earthing Check
Transformer protective earthing bond must be earthed in order to afford
protection to human beings.
6. Documents
Test sheet TS-AT01 shall be completed.
7. References

8. Attachment
8.1. Test Sheet for oil filled transformer 13.8/4.16KV: TS-AT01A
8.2. Test Sheet for oil filled transformer 13.8/0.480KV: TS-AT01B
8.3. Test Sheet for oil filled transformer 4.16/48KV: TS-AT01C
8.4. Test for Dry Type transformer: TS-AT01/D

***End of the procedure***

the originator

Prepared by :M AH

Page 59

ent
Clie
Con
nsultant
Con
ntractor

: SEC-C
COA
:
O
: BEMCO

Doc No.: PP1
c.
10-BS-SU-001

Riyadh Po
R
ower plant # 10
t
“1062
21166/00”
STARTU MANUA
UP
AL

Date:13
D
Feb,09
F

Revision
n:
0

TES SHEETS
ST

Page 60

10721026/00'

Client : SEC-COA
Contradtor: BEMCO

"

Auxilairy TransformerTest 13.8/4.16kv

Form No: TS-AT01A

EQUIPMENT LOCATION
TRNASFORMER NAME

TAG No.

FED FROM (BREAKER N
FEEDING TO (BREAKER NO.)

UNIT NO (BELONGS TO) VENDOR DRAWING NO.

SYSTEM NO.

SINGLE LINE DIAGRAM NO.

EQUIPMENT NAMEPLATE DATA
MANUFACTURER:

TYPE:

MODEL:

STYLE:

SERIAL NO.:

INS. CLASS:

FREQUENCY:

AMB. TEMP.:

60 HZ

55

RATINGS
KVA:
NO. OF TAPS

HV BIL

LV BIL

5

50KV

VECTOR GROUP:
Dyn11

28 KV

TYPE OF TAP CHANGER: TYPE OF COOLING:

% IMPEDENCE

SHORT CKT CURRENT

TEMP RISE OF OIL TEMP. RISE OF WINDINGOIL TYPE:
45

NYNAS NYTRO 10GBN

50

HIGH VOLTAGE SIDE VOLTAGE:
TAP #1:14490

TAP #2 :14145

LOW VOLT SIDE VOLTAG
TAP #3 :13800

TAP #4 :13455

TAP #5: 13110
LOW VOLT SIDE CURRE

HIGH VOLTAGE SIDE CURRENT:
TAP #1:

TAP #2 :

TAP #3 :

TAP #4:

TAP #5:

STARTUP DATA
A. TRANSFORMER RATIO TEST (TTR)
PHASE A
WINDING

TAP VOLTS

14490.00
14145.00
13800.00
13455.00
13110.00

TAP #1
TAP #2
TAP #3
TAP #4
TAP #5

ACT.RATIO

MR

PHASE B
%ERROR

MR

PHASE C
%ERROR

6.03

MR

%ERROR

5.89
5.75
5.60
5.46

B. VECTOR GROUP TEST(CHECK OF VOLTAGE RELATIONSHIP)
VOLTAGE APPLIED

PHASE

H1 X1

VOLTAGE MEASUR

PHASE

VOLTAGE

H1-H2

VOLTAGE

X2

H3-X3

H2-H3

H3-X2

H3-H1

X3

H2-X3

H3

H2

H2-X2
CONDITION FOR DYN11

H3-X2>H3-X3=H2-X3=H2-X2

C. MEASURMENT OF WINDING RESISTANCE :
PRIMARY WINDING @ TAP 3
PHASE

VOLTAGE

CURRENT

RESISTANCE IN OHMS

CURRENT

RESISTANCE IN OHMS

H1-H2
H2-H3
H3-H1
SECONDARY WINDING :
PHASE

VOLTAGE

X1-X0
X2-X0
X3-X0

TS-AT01A13.8-4.16

Page 61

Client

: SEC-COA

10721026/00'

Contradtor: BEMCO

Auxilairy TransformerTest

"

Form No: TS-AT01A

D. MAGNETISING CUURENT MEASURMENT :
VOLTAGE

TAP POSITION

MAGNETISATION CURRENT IN MILLI AMPS

FREQ

PHASE A

PHASE B

PHASE C

TAP-1
TAP-2
TAP-3
TAP-4
TAP-5
D. INSULATION RESISTANCE TEST
LV -- GND+HV

HV ---GND+ LV

HV -- LV

TEST VOLT OHMS G

TEST VOLT OHMS G

TEST VOLT OHMS G

2500V

5000V

5000V

E.OIL DIELECTRIC TEST.
BREAK
DOWN
VOLTAGE
TEST NO.
1
2
3
4
5
6
AVERAGE
F. TRANSFORMER PROTECTIVE DEVICES FUNCTIONAL TEST
1)

WINDING TEMPERATURE INDICATOR
ALARM

TRIP

FAN OPERATION

TRIP

FAN OPERATION

SET VALUE
OPERATED VALUE
2)

OIL TEMPERATURE INDICATOR
ALARM
SET VALUE
OPERATED VALUE

2)

BUCCHOLZ RELAY
TRIP CONTACTS

3)

OK

ALARM COTACTS

OK

RAPID RISE RELAY
TRIP CONTACTS

OK

ALARM CONTACTS

OK

TEST EQUIPMENT USED

MODEL

CAL.DUE

TEST EQUIPMENT USED

MODEL

CAL.DUE

DTR
MULTI METER FLUK
MEGGER
SIGNATURE

NAME

COMPANY

DATE

TEST PERFORMED BY:
WITNESSED BY:
WITNESSED BY:

TS-AT01A13.8-4.16

Page 62

Client : SEC-COA
Contradtor: BEMCO

10721026/00'

"

Auxilairy TransformerTest

Form No: TS-AT01A
G.CALIBERATION OF WINDING AND OIL TEMPERATURE GAUGE
OIL TEMPERATUE GAUGE
THERMO METER

WINDING TEMPERATURE GAUGE

GAUGE

THERMO METER

GAUGE

400C
500C
600C
700C
800C
900C
1000C
1100C
H.CALIBERATION OF WINDING GAUGE BY CURRENT INJECTION
WINDIN TEMPERATURE CT RATIO
INJECTION CURRENT =
TIME IN MINUTES

OIL TEMP GAUGE

WIND TEMP GAUGE

DIFF IN TEMP

0
5
10
15
20
25
30
35
40
45

TEST EQUIPMENT USED

MODEL

CAL.DUE

TEST EQUIPMENT USED

MODEL

CAL.DUE

DTR
MULTI METER FLUK
MEGGER
SIGNATURE

NAME

COMPANY

DATE

TEST PERFORMED BY:
WITNESSED BY:
WITNESSED BY:

TS-AT01A13.8-4.16

Page 63

10721026/00'

Client : SEC-COA
Contradtor: BEMCO

"

Auxilairy TransformerTest 13.8/.48kv

Form No: TS-AT01B

EQUIPMENT LOCATION
TRNASFORMER NAME

TAG No.

FED FROM (BREAKER N
FEEDING TO (BREAKER NO.)

UNIT NO (BELONGS TO) VENDOR DRAWING NO.

SYSTEM NO.

SINGLE LINE DIAGRAM NO.

EQUIPMENT NAMEPLATE DATA
MANUFACTURER:

TYPE:

MODEL:

STYLE:

SERIAL NO.:

INS. CLASS:

FREQUENCY:

AMB. TEMP.:

60 HZ

55

RATINGS
KVA:
NO. OF TAPS

HV BIL

LV BIL

5

50KV

28 KV

TYPE OF TAP CHANGER: TYPE OF COOLING:
OFF LOAD

VECTOR GROUP:
Dyn11

% IMPEDENCE

SHORT CKT CURRENT

9.36

TEMP RISE OF OIL TEMP. RISE OF WINDINGOIL TYPE:

ONAN

45

NYNAS NYTRO 10GBN

50

HIGH VOLTAGE SIDE VOLTAGE:
TAP #1:14490

TAP #2 :14145

LOW VOLT SIDE VOLTAG
TAP #3 :13800

TAP #4 :13455

TAP #5: 13110
LOW VOLT SIDE CURRE

HIGH VOLTAGE SIDE CURRENT:
TAP #1:

TAP #2 :

TAP #3 :

TAP #4:

TAP #5:

STARTUP DATA
A. TRANSFORMER RATIO TEST (TTR)
PHASE A
WINDING

TAP VOLTS

14490.00
14145.00
13800.00
13455.00
13110.00

TAP #1
TAP #2
TAP #3
TAP #4
TAP #5

ACT.RATIO

MR

PHASE B
%ERROR

MR

PHASE C
%ERROR

52.28

MR

%ERROR

51.04
49.80
48.55
47.31

B. VECTOR GROUP TEST(CHECK OF VOLTAGE RELATIONSHIP)
VOLTAGE APPLIED

PHASE

H1 X1

VOLTAGE MEASUR

PHASE

VOLTAGE

H1-H2

VOLTAGE

X2

H3-X3

H2-H3

H3-X2

H3-H1

X3

H2-X3

H3

H2

H2-X2
CONDITION FOR DYN11

H3-X2>H3-X3=H2-X3=H2-X2

C. MEASURMENT OF WINDING RESISTANCE :
PRIMARY WINDING @ TAP 3
PHASE

VOLTAGE

CURRENT

RESISTANCE IN OHMS

CURRENT

RESISTANCE IN OHMS

H1-H2
H2-H3
H3-H1
SECONDARY WINDING :
PHASE

VOLTAGE

X1-X0
X2-X0
X3-X0

TS-AT01B13.8-480

Page 64

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