OISD –STD -137

FOR RESTRICTED CIRCULATION

INSPECTION OF ELECTRICAL EQUIPMENT

OISD STANDARD - 137

First Edition, January 1990
Reaffirmed, August, 1999
Amended Edition, October, 2010

Oil Industry Safety Directorate

Government of India
Ministry of Petroleum and Natural Gas

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 OISD STANDARD - 137
First Edition, January 1990
Reaffirmed, August, 1999
Amended Edition, October, 2010

FOR RESTRICTED
CIRCULATION

INSPECTION OF ELECTRICAL EQUIPMENT

Prepared by

COMMITTEE ON
INSPECTION AND MAINTENANCE OF ELECTRICAL EQUIPMENT

OIL INDUSTRY SAFETY DIRECTORATE

7TH FLOOR, NEW DELHI HOUSE
27, BARAKHAMBA ROAD
NEW DELHI – 110 001
 NOTES

OISD publications are prepared for use in the Oil

and gas industry under Ministry of Petroleum and Natural
Gas. These are the property of Ministry of Petroleum and
Natural Gas and shall not be reproduced or copied and
loaned or exhibited to others without written consent from
OISD.

Though every effort has been made to assure the

accuracy and reliability of data contained in these
documents, OISD hereby expressly disclaims any liability or
responsibility for loss or damage resulting from their use.

These documents are intended only to supplement

and not replace the prevailing statutory requirements.
 FOREWORD

The Oil Industry in India is 100 years old. As such

variety of practices have been in vogue because of
collaboration / association with different foreign companies
and governments. Standardisation in design philosophies
and operating and maintenance practices at a national level
was hardly in existence. This, coupled with feed back from
some serious accidents that occurred in the recent past in
India and abroad, emphasized the need for the industry to
review the existing state of art in designing, operating and
maintaining oil and gas installations.

With this in view, the Ministry of Petroleum & Natural

Gas, in 1986, constituted a Safety Council assisted by Oil
Industry Safety Directorate (OISD), staffed from within the
industry, in formulating and implementing a series of self
regulatory measures aimed at removing obsolescence,
standardising and upgrading the existing standards to
ensure safe operations. Accordingly, OISD constituted a
number of Functional Committees of experts nominated from
the industry to draw up standards and guidelines on various
subjects.

The present document on “Inspection of Electrical

Equipment” was prepared by the Functional Committee on
“Inspection and Maintenance of Electrical Equipment. This
document is based on the accumulated knowledge and
experience of Industry members and the various national
and international codes and practices. It is hoped that
provisions of this standard if implemented objectively, may
go a long way to improve the safety and reduce accidents in
Oil and Gas Industry. Users of this document are cautioned
that no standard can be a substitute for the judgement of
responsible and experienced engineer.

Suggestions for amendments, if any, to this standard

should be addressed to:

The Co-ordinator,
Committee on
“Inspection & Maintenance of Electrical Equipment”
OIL INDUSTRY SAFETY DIRECTORATE
7th Floor, ‘New Delhi House’
27, Barakhamba Road
New Delhi – 110 001

.
 COMMITTEE ON PROCESS INSPECTION AND
MAINTENANCE OF ELECTRICAL EQUIPMENT.

LIST OF MEMBERS

----------------------------------------------------------------------------------------------------------------------------
Name Designation / Organisation Position in
Committee
----------------------------------------------------------------------------------------------------------------------------

S/Shri

1. R.K. Ghosh Chief Power and Utility Leader

Manager - IOC (R &P)

2. G.A. Patrachari Chief Tech.Services Manager

HPC(R) Member

3. B.M. Jayaraman Chief Engineer (Safety) Member

OIL

4. A.P. Kant Maint. Manager (Elect.) Member

BRPL

5. G.P. Paret Manager (Project - Electrical) Member

CRL

6. N.V. Mani Joint Director (OISD) Member

Co-ordinator
----------------------------------------------------------------------------------------------------------------------------
In addition to the above several experts from industry contributed in the preparation, review
and finalisation of the document.
 INSPECTION OF ELECTRICAL EQUIPMENT
CONTENTS

SECTION

1.0 Introduction

2.0 Scope

3.0 Definitions

4.0 Permit-to-work(Electrical)

5.0 Basis and types of inspection

6.0 Frequency of inspection

6.1 Rotating machinery
6.1.1 Generator
6.1.2 Motor
6.2 Stationary equipment
6.2.1 Switchboard & Panel
6.2.2 Transformer & Bus duct
6.2.3 Battery
6.2.4 Charger & D.C. board
6.2.5 UPS/Inverter
6.2.6 Reactor/Capacitor
6.2.7 Switchyard equipment
6.2.8 Lighting fixture & junction box
6.2.9 Test instruments for inspection
6.3 Protective Systems
6.3.1 Relay & meter
6.3.2 Earthing & bonding
6.3.3 Lightning protection
6.3.4 Flameproof/weather protection
6.3.5 Fire alarm system
6.3.6 Cathodic protection
6.3.7 Electric heat tracing
6.3.8 Protective & Safety appliances
6.4 Distribution network
6.4.1 Cable/conduit wiring
6.4.2 Cable duct/trench/tray support
6.4.3 Overhead line
6.5 Outdoor switchyard
6.6 Switchroom/substation building
6.7 Safe procedures & systems

7.0 Inspection procedures

8.0 Documentation

9.0 Precommissioning checks

10.0 References

ANNEXURES
I Protective relay inspection & test record
II Maintenance card of transformer & breaker
SECTION

III Cable maintenance card

IV Maintenance card of motor & breaker
V Failure analysis report
VI Details of authorised personnel (Format)
VII Cable fault detection
 INSPECTION OF ELECTRICAL EQUIPMENT

1.0 INTRODUCTION Authorised person is a responsible

person of the Electrical Section in the
Electricity constitutes one of the owner organisation, authorised by
major sources of ignition for fire accidents Electrical-in-charge to carry out Electrical
and explosions in petroleum installations Isolation/Energisation. He is also
where classified hazardous atmosphere is authorised under the provisions of Rule
normally encountered. In so far fire losses No.3 in the Indian Electricity Rules
due to electricity are concerned, it is specifically referred in I.E. Rules 36(2),
estimated to account for approximately 51(1) (a), 64(1)(a). 64(2) (e) & (f), 110(2),
30% of all fire losses, as per the accident 121(1), 121(4), 124 and 124 (8).
statistics. Besides equipment damage Annexures VI of this standard gives
and property loss, electrical hazards also suggestive format for exhibiting the details
include injuries and fatalities to personnel of authorised personnel.
due to electric shock.
ii) TESTING ENGINEER
Timely inspection and preventive
maintenance of electrical equipment and Testing Engineer is a competent
its connected systems will go a long way person in the electrical discipline, for
in ensuring safer operations, for a longer carrying out field tests as stipulated in the
period of time, of the electrical installations approved standards/codes, covering all
in the Oil Industry. the installed electrical systems. He shall
possess the competence required for
2.0 SCOPE “Officer” generally as per Rule No.4B of
the Indian Electricity Rules.
This standard specifies the
minimum inspection requirements on the iii) ENGINEER-IN-CHARGE (EIC)
installed electrical systems in the Oil
Industry, during their operation and EIC is competent person of the
maintenance with special reference to the owner organisation, in charge of the work,
safety aspects. to whom work permit shall be issued by
Unit-in-charge. In case the work involves
Items to be inspected, procedure electrical jobs, EIC shall be an electrical
and scheduling of inspection are dealt engineer.
with. Also included are:
EIC shall be responsible for
i) Permit-to-work(Electrical). or Electrical continuous supervision of the work and for
Line Clearances covering special arranging safe Isolation/Energisation of
safety requirements for jobs requiring the electrical equipment through
Electrical Isolation/.Lockout. Authorised Person as detailed in Section
4.0 to ensure safety while working on the
ii) Pre-commissioning check items for new equipment and associated systems. He
installations as well as for repaired shall also ensure the implementation of
equipment. effective safety measures by personnel/
agencies working under his supervision,
This standard in no way throughout the duration of work.
supersedes the statutory regulations of the
Chief Electrical Inspectorate, Factory iv) UNIT-IN-CHARGE (UIC)
Inspectorate, Chief Controller of
Explosives, Director General Mines UIC is Owner-in-charge as defined
Safety, or other government bodies, which in OISD-STD-105 (Work Permit System)
shall be followed as applicable. authorised to issue Work Permit to work in
the respective Unit under his jurisdiction
3.0 DEFINITIONS (e.g. Chief Chemist shall be UIC for
Laboratory).
i) AUTHORISED PERSON
v) ELECTRICAL-IN-CHARGE
 Electrical-in-charge is a competent 4.1 SCOPE
person in charge of the Electrical
Department/Section of the owner This section shall be read in
organisation responsible for safe operation conjunction with the OISD STD-105 (Work
and maintenance of all electrical systems Permit System). The scope in this section
The system of issuing Electrical Line covers the special requirements for any
Clearances as detailed in Section 4.0 and job on electrical system where Electrical
conformity of installations with statutory Isolation-Lockout/Energisation or Earth
requirements from time to time, shall also Excavation Clearances are also needed.
be ensured by him. In the event of any in-consistency with the
provisions under OISD-STD-105, for jobs
vi) INSPECTOR connected with electrical system, the
special requirements specified in this
Inspector is a competent person in section shall prevail
the Electrical discipline of the owner
organisation who shall ensure carrying out For definitions of terms and
of periodical inspections of the electrical responsibilities of various categories of
systems as per the requirements of this staff involved in Permit System, Section
standard. He shall arrange to conduct 3.0 shall be referred.
required tests, through a Testing Engineer
as defined in Section 3 ii), recommend 4.2 APPLICATION
corrective actions through periodical
reports, and follow up for their timely For any construction, repair,
compliance. He shall possess the testing, maintenance or inspection jobs on
competence required for Inspector an electrical system or for any work in
generally as per Rule No.4 of the Indian close proximity to energised electrical
Electricity Rules. circuits, or for that matter any job in
general where an Electrical Isolation is
vii) PERMIT-ISSUING AUTHORITY needed, the requirements detailed in this
(ELECTRICAL) section shall apply.

Permit-Issuing Authority Compliance to these requirements

(Electrical) is a competent person in the is necessary to prevent:
Electrical Department/Section of the
Owner organisation, authorised by i) The equipment/line becoming
Electrical in-charge to issue Permits accidentally or inadvertently
(Electrical Line Clearances) and related electrically charged when persons are
safety instructions. He shall issue Permit working on them, (as cautioned in
only after ensuring that required Rule No.36 of the Indian Electricity
competent electrical staff, depending upon Rules)
the specific nature of work, are actually
engaged in the work. ii) Induction effect from the nearby
energised electrical systems.
viii) ELECTRICAL LINE CLEARANCES:
iii) Accidental contact by the personnel
These Clearances are electrical with any live part of electrical circuit.
safety requirements related to jobs
covered under Permit-to work(Electrical) The requirements detailed in Section
as described in Section 4.0 4.6 shall apply for obtaining clearances
during earth excavation.
Both the terms “Permit-to work
(Electrical)” and “Electrical Line 4.3 TYPES OF CLEARANCES
Clearance” (briefly “ Permit or “Clearance”)
referred in this Standard covey the same Following Electrical Line
meaning and are interchangeable. Clearances, through a written Permit-to-
work system, shall be obtained by EIC
4.0 PERMIT-TO-WORK from Permit-Issuing Authority (Electrical),
(ELECTRICAL) OR ELECTRICAL for any work covered under Permit system
LINE CLEARANCES as detailed in Section 4.3, in addition to
Work Permit from UIC.
 Procedure identical to 4.4.1
i) Electrical Isolation-Lockout (or briefly except in I) which shall be substituted as:
Isolation) Line Clearance (before
commencement of work). “Electrical-in-charge requests and
obtains Work Permit from UIC for carrying
ii) Electrical Energisation Line Clearance out the specific work”.
(before energisation of isolated
equipment and circuits, after 4.4.3 Another Department requiring
completion of work). completion of a job on an
electrical system (e.g.
iii) Earth Excavation Line Clearance. Revamping work or a design
improvement etc.)
4.4 PROCEDURE FOR ELECTRICAL
ISOLATION - LOCKOUT / i) Work Request by concerned EIC is
ENERGISATION LINE issued to UIC.
CLEARANCES
ii) UIC requests Electrical-in-charge
Whenever the jobs covered under in writing for positive Electrical
Permit system fall into any of the following Isolation.
four categories, the procedure detailed
below (applicable to the respective iii) Authorised Person does Electrical
category) and Special Instructions as per Isolation, arranges to obtain
section 4.5 shall be followed. Electrical Electrical Isolation Line Clearance
Isolation and Energisation shall be carried and submits it to UIC.
out only by Authorised Person.
iv) UIC issues Work Permit and
4.4.1 UIC requiring an electrical Electrical Isolation Line clearance
system to get checked through to EIC for carrying out the
Electrical-in-charge (e.g. An specific work.
electric motor trips repeatedly
interrupting plant operation). v) EIC on completion of the work
returns Work Permit and
i) UIC issues Work Request along with Clearance to UIC, alongwith
Work Permit to Electrical in charge to document showing the
carry out the work. modification carried out, after
ensuring that the circuits are kept
ii) Authorised Person after receiving ready for safe re-energisation.
Work Permit does the positive
Electrical Isolation, completes all the vi) UIC thereafter requests Electrical-
work, keeps the circuits ready for in-charge for safe re-energisation
energisation, reports to Electrical-in- of circuits and hands over to him
charge, and returns Permit. the document showing the
modification carried out.
iii) Electrical-in-charge verifies the
completion of all work, and returns vii) Authorised Person energises
Work Permit to UIC, after ensuring circuits as directed by electrical-in-
that the circuits are kept ready for charge, arranges to obtain
safe re-energisation. Electrical Energisation Line
Clearance and submits it to UIC.
iv) UIC decides when to start the
equipment for operation and vii) UIC decides when to start the
arranges for safe charging of the equipment for operation and
equipment, after obtaining Electrical arranges for safe charging of the
Energisation Line Clearance. equipment.

4.4..2 Electrical-in-charge requiring to 4.4.4 Another Department requiring

complete departmental job of completion of a job on a non-
checks/repair/test on an electrical equipment (e.g. Pump,
electrical system. compressor, fan, etc.) having
electric drive.
 and circuit breakers controlling the
Procedure identical to section 4.4.3 shall supply to the equipment or line, shall
be followed. be kept tagged with caution boards
stating MEN WORKING ON LINE to
4.5 SPECIAL INSTRUCTIONS caution against anyone inadvertently
closing them. if possible, the control
i) The system of issuing Work Request, switches/breakers should be locked
Electrical Line clearances (for also. The area of work shall be strictly
Isolation- Lockout/Energisation) and cordoned off from unauthorised entry.
Work Permit, shall be implemented
through a written Permit-work, system vi) While carrying out Electrical
in the prescribed format which shall be Isolation/Energisation work, the
developed by individual organisation persons connected with the work shall
depending on the type of installation use only approved and tested
and administrative set up, taking care protective equipment (Rubber gloves,
that the provisions of IE Rules shoes, insulating mats, safety
(No.3,29 and 36), IS:5216 and the appliances, etc.,) taking all the safety
Owner-in-charge concept, as defined precautions described in IS:5216.
in OISD-STD-105 (Work Permit
System) are incorporated in this vii) Electrical Line Clearances shall be
format. taken even while working in proximity
of bare energized electrical conductor.
ii) Authorised Person while carrying out
the work covered under Permit system
shall physically posses Permit duly 4.6 PROCEDURE FOR EARTH
authorised by Permit-Issuing Authority EXCAVATION LINE
(Electrical). CLEARANCE

iii) At times, different agencies area called i) This Clearance shall be taken by
upon to work on same equipment. UIC EIC, from Permit Issuing Authority
shall ensure that Work Permits of all (Electrical), wherever earth
the agencies are closed before excavation is to be carried out.
recharging the equipment. Similarly, Without such clearance, if excavation
the equipment may have more than is carried out, especially over
the one source of electric supply. energised underground electrical
Before issuing any Permit to EIC, UIC facilities it may cause fatal accidents
shall arrange through Electrical-in- to the personnel, besides adversely
charge for: affecting the plant operation due to
possible damage of such
(a) Positive Electrical Isolation (by underground facilities (e.g. piercing
disconnection of all sources of the insulation of live cable through
electric power supply) and sharp tool like pickaxe).
obtaining Electrical Isolation Line
Clearance. ii) After first obtaining permission from
UIC for the work, Earth Excavation
(b) Effective earthing of line/ Line Clearance shall be taken by EIC
equipment (Isolated section) from Permit-Issuing Authority
(Electrical) in an approved format to
iv) After completion of the work, EIC shall be developed by individual
arrange to deenergise and remove all organisations depending on the type
temporary installations, construction of installations and administrative set
materials, debris and withdraw up. While designing the format, the
personnel from site, and returns Work need of owner-in-charge concept
Permit/Clearances to UIC. UIC shall shall also be taken care of, as
arrange for safe charging of the defined in OISD-STD-105 (Work
equipment after obtaining Electrical Permit System).
Energisation Line Clearances.
iii) Permit-Issuing Authority (Electrical)
v) Throughout the work, Authorised shall spell out the precautions to be
Person shall ensure that the switches taken, while carrying out such earth
 excavation, in the Clearance itself. Failures of electrical equipment gives rise
Prior to issue of Clearance, he shall to any or all the following hazards:
ensure that the proposed excavation
does not interfere with existing i) Fatal accidents due to electric shock.
underground electrical facilities such
as power (H.T & L.T), telephone, fire ii) Fire accidents and burn injuries due to
alarm, lighting, and control cables, electric arcs/sparks/hot surfaces
earthing, and cathodic protection
installations etc., iii) Abrupt interruption in plant operation..

iv) EIC shall ensure compliance of all the The failures of electrical equipment can be
safety measures including those attributed to:
stipulated in the Clearance and
provide supervision throughout the i) Imposed external conditions such as
work for safe excavation and deterioration of enclosure, insulation
protection of the underground facilities and operating mechanism by
from any damage due to excavation. environment conditions like heat,
He shall promptly report to Permit- moisture, dust, chemical attack and dirt.
Issuing Authority (Electrical) any
damage to underground facilities even ii) Quality of power supply (like
if it be of minor nature, and shall undervoltage, powerdips, unbalanced
proceed with the excavation work only voltage, frequently failures of power
after complying with further supply etc.)
instructions, as endorsed in Permit, if
any. iii) Overloading due to any reason.

v) Irrespective whether mentioned or not iv) Internal faults in the equipment itself
in the Clearance, whenever mainly due to manufacturing defects,
bricklayer, tiles or cables sleeves are or those crept in during installation,
encountered during the excavation maintenance and repairs.
work (which confirm electrical
facilities below), EIC, after stopping v) Inferior quality of work due to factors
excavation work, shall inform of the like poor workmanship by
same to Permit-issuing Authority unqualified/unskilled and untrained
(Electrical) and obtain further workers, inadequate or incompetent
instructions to proceed. supervision, non-compliance of
safety and statutory requirements,
vi) The Earth Excavation Line Clearance adoption of incorrect procedures, and
shall be issued only after EIC first usage of poor quality of tools and
obtains Work Permit from UIC for his tackles.
work in the particular location of the
unit. vi) Usage of substandard materials and
equipment not in conformity with
vii) UIC shall ensure that EIC closes main original design specifications.
Work Permit only after his first
closing Earth Excavation Line vii) Design deficiencies in the technical
Clearance, and obtaining Clearance specifications, improper sizing and
from Permit-Issuing Authority layout of installations and lack of total
(Electrical) which shall confirm that system concept.
the excavation was carried out safely,
trenches backfilled, the construction viii) Bypassing of protective and
materials and debris cleared, and interlocking devices/circuits during
personnel withdrawn from the site. operation though originally designed
for the system.
5.0 BASIS AND TYPES OF
INSPECTION ix) Inability for carrying out shutdown
inspection/tests on the equipment in
time, as required by maintenance
5.1 BASIS OF INSPECTION inspection schedules, due to
 difficulties in taking the equipment out without any downtime of unit operation.
of service. The standby rotary equipment shall
additionally be checked at least once
Inspection programmed on electrical every two months for-
equipment and associated circuits shall be
devised on the basis that the inspection a) Free rotation of shaft
results will be able to pinpoint the trouble b) Proper functioning of space heater
spots in the installations, well in advance, circuit
allowing ample time for the maintenance c) Weather protection.
personnel to take remedial measures, so d) Insulation resistance of motor with
as to prevent failure of equipment leading cable.
to unsafe conditions and hazards as
mentioned above. No equipment shall be If, however, standby equipment was not
operated beyond its safe life period energised earlier, all applicable
assessed on the basis of inspections from Precommissioning checks, as detailed in
time to time and optimum replacement Section 9.0 shall be carried out before
schedule shall be followed. Manufacturer’s taking it into service.
recommendation shall prevail wherever
available. The spare parts shall be inspected to
ensure compliance with original
5.2 TYPES OF INSPECTION specifications as per manufacturers’
catalogue number.
The field inspection of electrical equipment
in an operating unit is classified into 6.0 FREQUENCY OF
following three types: INSPECTION
i) ONSTREAM INSPECTION The inspection scheme given in the
following tabular format shall be followed
This covers audio visual inspection items as minimum requirement for the items to
(instrument aided or otherwise) for be inspected. Frequencies of inspection in
checking of general equipment conditions, this format have been arrived at,
while the equipment is in operation. (e.g. considering a typical installation and
an abnormal nose or vibration of motor, therefore shall be treated as guidelines.
leakage of transformer oil or overheating Depending on specific requirements of the
of equipment etc., can be assessed installation, considering severity of usage,
through such inspections). criticality of equipment, environmental
conditions and such other factors,
ii) SHUTDOWN INSPECTION individual organisations shall review and
develop own inspection frequency
This covers those inspection items for standards which shall be strictly followed.
checking conditions of equipment and
systems which cannot be revealed through The frequency of inspection for new or
Onstream Inspection (such as internal special equipment, where previous
condition of equipment). This inspection experience is not available, shall be
shall be carried out after taking the reviewed by the concerned organisation,
shutdown of the related equipment after after one or two inspections and
obtaining the Electrical Line Clearance, reconsidered whether the interval could be
and Work Permit, requirements of which lengthened safely or should be shortened.
are detailed in Section 4.0 and in OISD- care shall be taken against the bad effects
STD-105 (Work Permit System) of over maintenance especially for
flameproof and such critical installations.
iii) INSPECTION OF STANDBY No attempt should be made to replace or
EQUIPMENT AND SPARE repair a glass in a flameproof enclosure
PARTS (e.g. in lighting fixture or the parts) except
with the complete assembly or part
The standby electrical equipment electrical obtainable from the manufacturer for
equipment shall be inspected on the same which the flameproof certificate from the
basis and schedule applicable under item competent authority shall be obtained to
(ii) above, so that changeover from normal confirm its flame proofness.
to standby equipment shall be possible
For inspection procedures, Section 7.0 vii) Surface overheating F
shall be referred. The safety Electrical viii) Ventilation F
Line Clearances as required in Section 4.0 ix) Abnormal noise F
shall be obtained for work where Electrical x) Functioning of meters F
Isolation is needed or when any work is to xi) Corrosion effects (external M
be carried out in close proximity to bare xii) Provision of Guards to M
energised electrical circuits. moving parts
xiii) any other inspection
Insulation resistance, earth resistance and recommended by the
continuity tests, when required to be manufacturer
carried out in an hazardous area, shall be Note:
carried out only with certified intrinsically
safe insulation/earth tester suitable for use For critical generators such as for Captive
in classified hazardous area, after taking plants, the frequency of inspection shall be
the shutdown of the related equipment Daily (D) basis for all items, except for
through permit system. items (XIII) and (XIV).

However, if such hazardous area is The following shall be Shutdown

rendered non hazardous and certified by Inspection items:
competent authority to be a safe area, i) Insulation resistance
usage of standard testing equipment shall ii) Earthing connections(checks
be permissible till such time the are shall include earth resistance
continues to remain non-hazardous. measurements, tightness of
connections, and continuity of
Additionally, the applicable provisions in conductors HY
the API Guide Chapter XIV (electrical iii) DC resistance of stator/ rotor
systems) Table 5 to 13 (methods of / exciter HY
Inspection) and the recommendations of iv) Air gap between stator and
the manufacturer shall be followed, while rotor HY
devising inspection schedules. v) Manual and automatic
synchornising and change-
LEGEND: over systems. HY
vi) Alignment of coupled
D : Daily HY : Half yearly machine HY
W: Weekly nY : Once in n years
F : Fortnightly TA : Turn around
M: Monthly ASCO: After specified
cycles of
operation
Q: Quarterly

6.1 ROTATING MACHINERY

-----------------------------------------------
Items to be inspected Frequency
-----------------------------------------------
6.1.1 Generator (including Exciter)

The following shall be Onstream

Inspection items:

i) Condition o commutator (for

sparking), brushes, and
collector rings W
ii) Bearing
condition(lubrication, noise, W
and temperature)
iii) Cooling system condition. W
iv) Housekeeping W
v) External damages W
vi) Leakage of OIl/Water F
vii) Operation of circuits
especially related to space
heater,temperature detector,
trippingdevices, annun-ciators
and interlocks. HY

viii) Availability of all protective

devices, and circuits in line as
per design, and all in
operating condition HY
ix) * Moisture absorption
(Dieelectric Absorption Test) Y

x) * Insulation deterioration
(Polarisation Index Test) Y

xi) Internal damages,

discolouration, open or short
circuits, and loose
connections. Y

xii) Condition of commutators,

brushes, and collector rings Y

xiii) Condition of foundation and

tightness of foundation bolts Y
xiv) Any other inspection
recommended by the
manufacturer Y

Note :

* Items (ix) and (x) are needed for critical

high voltage equipment only.

6.1.2 Motor (H.T and L.T)

The following shall be Onstream

Inspection items:
i) General Cleanliness M

ii) Corrosion effect (external) M

iii) Surface Overheating/sparking M
iv) Ventilation M
v) Vibration M
vi) Abnormal noise M
vii External damages M
viii Load (Amperes) M
ix) Lubrication M
x) Cooling System M
xi) Effect of supply system
disturbances such as voltage
drop, power dip etc. (as
given in the log entries at
substation) M
 xii Provision of Guards to
moving parts M
xiii Condition of commutator,
brushes, and collector rings
for slipring and
synchronous motors M
xiv any other inspection
recommended by the
manufacturer M

Note:

For critical motors, the frequency of

inspection shall be weekly (W) basis in
case of all items (I) to (xiv).

The following shall be Shutdown

Inspection items:

i) Mechanical freeness of rotor

shaft
ii) Insulation resistance
iii) Winding resistance
(Measurement)
iv) Earth resistance and
continuity
v) Operation of

--Space heater
--Temperature detector
--Interlocks,/trips
--Annunciation circuits
vi) Availability of all protective
devices and circuits in line
as per design, and all in
operating condition.
vii) Condition of remote tripping
devices & limit switches
viii) Limit & torque switches (in
the case of motor operated
valves) for proper
functioning.
ix) Oil level in lubricating
gearcase.
x) “Moisture absorption ( Di-
electric Absorption Test)
xi) Insulation deterioration
(Polarisation Index Test)

xii) Internal damage, discoloura-

tion and loose connections
xiii) Stator to rotor airgap
measurement
 v) Control supply availability W

xiv Condition of commutator, vi) Ventilation system W

carbon brushes, (for correct
brush pressure) and collector vii) Corrosion effect (external) W
rings
xv Condition of supporting legs, viii) Accessibility for
pedestal and base plate maintenance /operation M
xvi Condition of the foundation
and tightness of foundation ix) Functioning of meters, and
bolts. lamp indicators M
xvi Any carryover of oil or grease
inside the windings x) Oil level and leakage M
xvii Any carryover of oil or grease
inside the windings xi) Correctness of relay settings
xix Signature analysis (optional (for critical services) M
xx Tan delta test (optional)
xxi Any other inspection xii) Any other inspection
recommended by the recommended by the
manufacturer manufacturer
Note:

“ Items (x) and (xi) are needed for critical The following shall be Shutdown
high voltage equipment only. Inspection items:

in the case of synchronous/Slipring i) Dielectric strength of oil ( in

motors, following additional Shutdown breakers) and Oil HY/
Inspection items shall be carried out: Contamination ASC0

i) Tightness of the DC Poles ii) Condition of earthing Q/

fitted on the outer- connection ASCO
Periphery of the rotor HY
iii) Insulation and earth HY/
ii) Condition of end rings HY resistance ASCO

iii) Continuity of the leads iv) Electrical resistance of HY/

connecting the poles and the breaker ASCO
slip rings via brushes HY
v) Internal damages
iv) Any other inspection (breakage of barriers, are
recommended by the chute cracks,
manufacturer jamming solenoid, dirt/dust
accumulation in any part HY/
etc.) ASCO
6.2 STATIONARY EQUIPMENT vi) Operation of
--------------------------------------------------------
Items to be inspected Frequency --Protection, control and
-------------------------------------------------------- interlock circuits
6.2.1 Switchboard and Panel --Circuit breaker (rack-in-
out mechanism,
The following shall be Onstream springs of driver)
Inspection items: --Simultaneous
i) General Cleanliness W closing/opening of all the
three phases.
ii) Weather protection W --Contactor operation
--Space heater operation
iii) Dust and vermin-proofness W --Safety shutters HY

iv) External damages W vii) Tightness of all bolts, cable Y

connections, and terminals
 foundation and yard HY
viii) Condition of contacts,
contact alignment, and xvi) Dielectric strength and
clearances with live parts Y acidity tests of oil samples Y

ix) Breaker closing and xvii) Completeness with all

opening time & total relay accessories Y
operating time Y
xviii) Any other inspection
x) Checking and calibration of recommended by the
relays Y manufacturer

xi) Any other inspection The following shall be Shutdown

recommended by the Inspection items:
manufacturer Y
i) Terminal connection in
primary & secondary Y
6.2.2 Transformer & Bus duct ii) Operation of protection
and annunciation circuits Y
The following shall be Onstream iii) Internal damages, condition
Inspection items: of supports, busduct
i) Oil leakage D flexibles and insulators Y
iv) Insulation resistance of
ii) Oil level (in transformer & in primary and secondary
bushing) windings Y
v) Earth resistance and earth
iii) Condition of silicajel D continuity Y
vi) Earth resistance and earth
iv) Oil temperature /Winding continuity
temperature D vii) Any other inspection
recommended by the
v) Load (Amperes) D manufacturer Y

vi) Cleanliness D 6.2.3 Battery

vii) External damages W The following shall be Onstream

Inspection items:
viii) Operation of cooling fans & i) General cleanliness of
surface temperature W battery room W
ii) Functioning of ventilation
ix) Annunciation (for abnormal system W
conditions) W iii) Formation of acid vapours in
room W
x) Condition of cable end iv) Spillage of electrolyte W
sealing and terminal boxes W v) Level of electrolyte W
vi) Cell voltage and proper
xi) Insulators and bushing connections for correct
(check for any cracks) for polarity W
outdoor transformers M vii) Specific gravity of cell W
viii) Availability & condition of
xii) Corrosion effect (external) M safety equipment (such as
rubber apron, goggle, and
xiii) Condition of oil soak pit and acid proof hand gloves) M
oil drainage arrangement M ix) Caution boards (“No
smoking”) etc., M
xiv) Sealing of bus duct entry on x) Condition of acid-proof
both sides of wall (for flooring M
vapour /dust/water tightness HY xi) Any other inspection
recommended by the
xv) Condition of transformer manufacturer
 with annunciation W
Note:
ix) Insulation resistance HY
For critical/emergency and switchgear
power plant applications, the frequency of
inspection shall be Daily (D) basis, in case
of items (I) to (vii) and weekly (W) basis, in
case of items (viii) to (x).

The following shall be Shutdown

Inspection items:

i) Joints, terminal and bolted

connections for tightness
(for full electrical contact) M

ii) Blockage of vent plugs M

iii) Corrosion effects on

terminals and connectors M

iv) Condition of supports (racks)

M

v) Damages such as cracks in

containers M

vi) Capacity test M

vii) Any other inspection

recommended by the
manufacturer

Note:

For critical/emergency switchgear, and

power plant applications, the frequency of
inspection shall be Weekly (W) basis, in
case of items (I) to (v)

6.2.4 Charger & D.C. Board

i) General cleanliness W

ii) Ventilation system W

iii)
Float voltage & charging W
current

iv) Overheating W

v) External damages W

vi) Tightness of connections W

vii) Condition of contactors and

switches W

viii) Operation of charger circuit

x) Changeover circuits HY
(emergency backup)

xi) Insulation from earth (both +

ve and -ve of DC System

xii) Any other inspection

recommended by the
manufacturer

Notes:

1. For critical/emergency, switchgear, and

power plant applications the
frequency of inspection shall be Daily
(D) basis for items I) to v) Weekly (W)
basis for items 9vi) to (viii)

2. (vi) to (viii) shall be Shutdown

Inspection items.

6.2.5. U.P.S/Invertor

The following shall be Onstream

Inspection items:

i) General cleanliness,
(accumulation of dust, and
dirt on contactors, diodes,
thristors, transformers and
other components) and
external damages W

ii) Condition of ventilation and

detection of any
overheating W

iii) Any other inspection

recommended by the
manufacturer

The following shall be Shutdown

Inspection items:

i) Internal damages HY

ii) Pitting of contacts HY

iii) Voltage and wave forms on

all as specified by the HY
manufacturer

iv) Tightness of wiring

connections HY
 manufacturer HY
v) Operation of protective
devices and changeover
circuits HY 6.2.7 Switchyard Equipment (Circuit
breaker, Disconnect switch,
vi) Functional checks for all C.T, P.T, L.A)
circuits, and annunciation Y
The following shall be Onstream
vii) Any other inspection Inspection items:
recommended by the
manufacturer i) Overheating, and sparking D
( of contacts)

6.2.6 Reactor and Capacitor ii) Oil level and oil leakage D

The following shall be Onstream iii) Earthing connections, and

Inspection items: overhead earth mesh
condition D
i) General cleanliness W
iv) Cleanliness Housekeeping) W
ii) Structural support W
v) Damages W
iii) Damages (external) W
vi) Corrosion effect (external) M
iv) Condition of ventilation W
vii) Functioning of lamps and
v) Oil level W meters M

vi) Oil leakage W viii) Any other inspection

recommended by the
vii) Grounding connections W manufacturer

viii) Any other inspection

recommended by the The following shall be Shutdown
manufacturer W Inspection items:

i) Operation of switchyard
The following shall be Shutdown equipment with control,
Inspection items: trip, and annunciation
circuits HY
i) Insulation resistance Q
ii) Internal damages HY
ii) Discolouration on cable
connector clamps Q iii) Condition of insulators
HY
iii) Earth resistance Q iv) Alignment between
contacts HY
iv) Operation of protective
devices Q v) Insulation resistance HY

v) Dielectric strength and vi) Earth resistance HY

acidity of oil HY

vi) Tightness of wiring

connections HY

vii) Corrosion effects

viii) Any other inspection

recommended by the
 The following inspection items (common
vii) Dielectric strength and Y/ for all the instruments listed) shall be
acidity of oil ASCO carried out:

--Cleanliness
viii) Any other inspection
recommend by the --Breakages (of glass cover etc.)
manufacturer
-- Calibration test, and other safety checks
6.2.8 Lighting Fixture & Junction-box before use as per manufacturer’s
(installed for plant/yard/street and recommendation
building lighting.)
--Zero setting, errors
The following shall be Onstream
Inspection items; --Bent pointers, sticky or jerky movement

i) Cleanliness & external List of instruments (with the frequency of

damages W inspection marked against each item) is
given below:
ii) Fixture support W
i) H.V. discharge rod M
iii) Illumination in critical areas M
ii) Voltage & current detector M
iv) Condition of conduits,
Junction boxes M iii) Megger (for measuring
insulation resistance) M
v) Any other inspection
recommended by the iv) Megger (for measuring
manufacturer earth resistance) M

v) Cable fault locator HY

The following shall be Shutdown
Inspection items: vi) Avometer HY

i) Condition of gaskets Q vii) Tong tester HY

ii) Operation switches & viii) Relay test bench Y

circuits Q
ix) Motor test bench Y
iii) Insulation resistance HY
x) Oil filtering equipment Y
iv) Grounding connections HY
xi) Dielectric test equipment Y
v) Loose connections HY
xii) Phase sequency meter Y
vi) Changeover circuits
(emergency lights) HY xiii) Portable voltmeter,
ammeter, frequency meter,
vii) Corrosion effect, condition hydrometer, thermometer Y
of paint (lighting fixtures,
junction boxes, conduits, xiv) H.V. testing unit Y
poles and switches) HY

viii)Any other inspection recommended by 6.3 PROTECTIVE SYSTEMS

the manufacturer --------------------------------------------------------
Items to be inspected Frequency
6.2.9 Test Instruments for Inspection --------------------------------------------------------
6.3.1 Relay & Meter
The following shall be Onstream 6.3.2 Earthing & Bonding
Inspection items:
The following shall be General Inspection
i) Cleanliness W items:

ii) Brea kage’s of glass & i) Visual checks for external

cover M damages to earth
conductors, earth electrodes M
iii) Erratic operation (obser- and earthing connections.
vation from log book
entries) Q ii) Operation of earth leakage
annunciation and trip circuits
iv) Correctness of relay (Simulation Tests) HY
settings (for critical
services) Q iii) Corrosion effects and
tightness of connections HY

v) Any other inspection iv) Identification of earth

recommended by the electrodes in the field with
manufacturer permanent markers HY

v) Earth resistance on
The following shall be Shutdown individual electrodes once
Inspection items: in dry and one in wet HY
weather
i) Trip circuit operation
(simulation test) TA vi) Continuity of earthing
conductors Y
ii) Relay operation under fault
conditions simulated vii) Bonding and earthing of
(primary injection) TA all metallic structures, pipe
racks, armour of cables,
iii) Changeover circuit and electrical equipment
operation HY enclosures Y

iv) Contacts(for pressure, viii) Whether buried earthing

alignment, free operation, conductors are exposed at
freedom from corrosion any location
and burning effects) HY
ix) Earth loop impedance TA
v) Target operation HY (measurement)

vi) Condition of leather The following shall be the Special items

bellows, oil dashpot, timing Inspection applicable to different
devices and check for categories of installation:
missing nuts and screws
HY i) Neutral earthing of the
vii) Current, potential and electrical system HY
power at pick up, drop out
and intermediate point of ii) Body earthing of the
each relay element HY electrical equipment HY

viii) Checking and calibration of iii) Tankage (bonding of floating

all relays and meters roof, ladder rollers, rails of
(KWA/KVA demand, staricase and lubrication on
ammeter, volt meter) Y rollers) HY
iv) LPG bottling plants, loading
ix) Any other inspection recommended by gantries /tank truck loading HY
the manufacturer
• Check for:
 a) Earthing continuity of the enclosures have IP:55
loading arms, flexible weather protection) HY
hoses, and piping
vii) Corrosive effects Y
b) Earthing & bonding of
rail tracks within the
gantry premises viii)Any other inspection as recommended
by the manufacturer/designer of the
c) Earth connections in system.
carousal /tanks
6.3.5 Fire alarm system (Electrical
v) Process equipment in the circuits)
plant area (such as heat
exchanger, vessel, column, i) Operation of siren circuits
piping etc.) whether (simulation test) W
grounded Y
ii) Operation of breakglass field
station)actuation circuits W
6.3.3 Lightning Protection
iii) Checks to confirm no blown
i) Visual check for external fuses, and no fused lamps W
damages to earth electrodes
down conductors, lightning iv) Emergency supply system W
arrestors, supporting availability, and its auto
structures and insulators Y change over circuit
operation, condition of battery
ii) Cleanliness of insulators (as detailed in 6.2)

iii) Earth resistance and v) Visual check for

continuity damages/missing parts M

vi) Insulation resistance for cables

iv) Any other inspection items required and panels M
as per IS:2309 or BS 6651 as
applicable vii) Continuity of cables M
6.3.4 Flameproof/weather protection
viii) Any other inspection recommended
i) Visual checks for external by the manufacturer or system
damages ( to glasses, designer
casting etc.) M
6.3.6 Cathodic protection (Electrical
ii) Accumulation of dust & dirt M circuits)

iii) Effectiveness of earthing For tankages, underground piping,

connections Q ubmerged structures and cross-country
pipelines)
iv) Condition of gasket (water
tightness) Q i) Performance of transformer /
effective earthing connections W
v) Unauthorised odifications
(conformity with original ii) Pipe/structure to soil potential
specifications) in the measurements for impressed
flameproof equipment HY current and sacrificial anode
systems HY
vi) Completeness of bolts,
glands, stoppers and their iii) Anode current and all
tightness(In case of outdoor connections to anode /
newly installed equipment, structures (conformity to HY
check through manu- design requirements)
acturer’s test certificates that
iv)Any other inspection recommended by 6.3.8. Protective and Safety Appliances
system designer
The condition of following appliances shall
Note: be checked as per the requirements of IS:
4770 or as recommended by the
The frequency of inspection is to be manufacturer. The frequency of
increased if abnormal external corrosion inspection shall be ‘HY” or everytime
and breakdowns are encountered in the before being put to use, whichever is
cathodically protected system. earlier.

6.3.7 Electric Heat Tracing. I) Gloves

II) Rubber shoes, insulating mats
i) Visual checks for functioning III) Safety belts
of all panel indication lamps iv) Ladders
(indicating tracer circuit v) Earthing devices
healthily condition) W vi) Helmets
vii) Current testers/voltage detectors
ii) Temperature measurements at viii) Goggles & face shields
inspection points W ix) Earth leakage circuit breakers.

iii) Check to confirm no buried 6.4 DISTRIBUTION NETWORK

power cable is exposed at any --------------------------------------------------------
location W Items to be inspected Frequency
--------------------------------------------------------
iv) Current reading of each circuit 6.4.1. Cable and conduit wiring
and check for any blown out
fuse W i) Availability of permanent cable
route markers and joint
v) External damages to piping, location markers in the field HY
insulation and tracers W
ii) Condition of cable termination
vi) Weathre proofness for /joints and clamping arrange-
outdoorpanels and junction ments HY
boxes especially whether
doors / covers kept closed. M iii) Provision of identification tags

vii) Voltage drop at the farthest end iv) Mechanical protection to under
of tracer M ground and overhead cables
(especially for energised
viii) Tightness of connections M cables) HY

ix) Sealing and termination M v) Insulation resistance HY

x) Insulation resistance of cables, vi) Insulation deterioration (Polari-

panel boards and tracers HY sation Index Test) HY

xi) Continuity checks HY vii) Continuity HY

xii) Any other inspection viii) Damages to cables, conduits,

recommended by the wires including clamps/cable
manufacturer or system supports HY
designer.
ix) Water tightness of conduit
system Y
Note:
x) Corrosive effects on conduits Y
Items (viii), (x) and (xi) shall be Shutdown & junction boxes.
Inspection items

Notes:
1. It shall be checked (through random viii) Infringement and growth
trial pits) that the underground cables of vegetation M
are protected with sand and bricks
thoughout and ensure that the cables ix) Any damages to
are not exposed at any location. Also insulators and other
armouring, pipe sleeves and such other devices M
mechanical protection requirements
shall be inspected. x) Earthing of staywire M

2. Item vi) shall be applicable only for xi) Safe mechanical

critical high voltage cables. condition (of both normal
and standby O.H. lines) M
3. Items (v) to (vii) shall be Shutdown
Inspection items.

6.4.2 Cable Duct/Trench/Tray support 6.5 OUTDOOR SWITCHBOARD

--------------------------------------------------------
i) Congestion of cable in Items to be inspected Frequency
the duct (conformity for --------------------------------------------------------
pipe fill 50%) HY i) Earthing of fencing, gage,
insulator supports and
ii) Damages to cable trench other metallic structures HY
including covers, duct
and tray support HY ii) Condition of fencing & all
metallic structures from
iii) Sealing cable trenches corrosion effects HY
/ducts (prevention of
entry of foreign materials- iii) Checking of pipe from
vermin, water, chemicals, transformer to soakpit for
dirt, reptiles, etc into any leakage HY
trenches, ducts) Y
iv) Provision of locking
iv) Corrosion on the metallic arrangement for gate and
tray supports Y isolators (especially
when the transformers &
O.H. line are energised) HY
6.4.3 Overhead line (Uninsulated)
v) Provision of metal jelli oil
i) Cleanliness of insulators soakpit and fire partition
and bushings M walls (as applicable) HY

ii) Condition of hardware, vi) Condition of trenches

supporting structure and cover slabs and earth
conductors M electrodes in the yard HY

iii) Abnormal sagging and vii) Condition of transformer

clearances M plinth and other concrete
foundations
iv) Joints in the O.H. lines M
viii) Accessibility for maint-
v) Continuity of earth enance and operation
conductors M of switchyard equipment
with component parts HY
vi) Provision of guards,
anticlimbing devices, ix) General illumination HY
danger boards, and
phase markings M 6.6 SWITCH ROOM/SUBSTATION
BUILDING
vii) Corrosion effects M --------------------------------------------------------
Items to be inspected Frequency or permanent) HY
--------------------------------------------------------
i) General illumination HY iv) Adherence to safety and
fire fighting requirements
ii) Emergency lighting provision as per standards HY
and its auto-changeover circuit
operation HY v) Compliance of items
pointed out by Electrical
iii) Ventilation HY Inspectorduring periodical
statutory inspection(IE Rule
iv) Roof leakage HY No.46) Y

v) Sealing of cable and bus duct vi) Electrical equipment and

entries (to make them water connected installations
and vapour tight) HY whether conform to
Hazardous area classif-
vi) Housekeeping HY ication from time to
time.(including pressurised
vii) Water drainage arrangement HY enclosures and press-
urisation facilities) Y
viii) Provision of insulating mats
conforming to IS:15652:2006 vii) Availability of updated
having ISI mark, shock documentation operating
treatment chart, fire and maintenance manuals Y
extinguisher (suitable for
electrical fires), sand filled viii) Safety audit systems
buckets, break-glass fire (internal & external) Y
alarm station and telephone HY
(for internal and external ix) Training programs of
communication) electrical staff. Y

ix) Condition of trench, cover x) Availability of adequate

slabs, and chequered plates HY illumi nation (Decide on the
basis of joint inspection
x) Marking on the switchboard, with UIC in all operational
for the identification of areas) Y
circuits and provision of
danger, caution boards HY xi) Preservation of idle
equipment, cables, and
xi) Damages and corrosion spare parts Y
effects if any HY
xii) Procedure for allowing
temporary electrical
6.7 SAFE PROCEDURES AND facilities Y
SYSTEMS
-------------------------------------------------------- xiii) Adherence to logging system
Checks for compliance: of hourly reading of current,
-------------------------------------------------------- voltage, frequency, P.F.
i) Compliance of Work Permit KW/KWH, tap positions of
System (Electrical Line transformers etc., and also
Clearances as detailed in registering of power
Section 4.0) HY failures,system distur-
bances, break-downs and
ii) Procedures adopted for other details on 24 hour
safety in jobs by external basis at the main
agencies HY substation Y

iii) Unauthorised additions or xiv) Accessibility for operation

modifications of install- and maintenance of electrical
ations (whether temporary facilities Y
xv) Fireproof construction (for ---For medium voltage
enclosures housing elec- circuits - 500 Volts (d.c)
trical equipment / compo-
nents) Y ---For high voltage
circuits - 1000 Volts (d.c)

7.0 INSPECTION PROCEDURES If the insulation resistance values

obtained are less than required value, the
Before initiating the inspection of approved method of drying out shall be
electrical equipment and associated carried out until the required steady
circuits, Inspector should familiarise insulation resistance value is obtained.
himself with the complete previous history
of the equipment/circuits, design ii) MEASUREMENT OF EARTH-
parameters, service, likely areas of RESISTANCE
concern, manufacturer’s recommendations
and such other pertinent data to arrive at a) Earth resistance can be directly read
the appropriate inspection procedure. through an earth test Megger which
has associated Test, auxiliary Current
Most of the defects/faults in electrical and Potential electrodes. This
system can be discovered only through instrument which is a combination of
tests and not by external inspection alone. ohmmeter and generator works on ‘fall
of potential’ principle. Test voltage is
For the basis on the type of derived from the generator of the
inspection, Section 5.0 shall be referred. Megger.
For competence of the person conducting
the tests, Section 3-ii) shall be referred. b) Allowable earth-Resistance Values
Unless otherwise mentioned, the
acceptable test values shall be the The resistance value of an
compliance of I.E. Rule 29 and the related earthing system to general mass of the
standards published by Bureau of Indian earth should not exceed.
Standards.
-- 4 Ohms for electrical systems and
I) INSULATION RESISTANCE TEST: metallic structures

Insulation resistance is measured -- 7 Ohms for storage tanks

to ensure absence of leakage current and
humidity. For a given insulation condition, -- 1 Ohm for main earth grid, and bonding
the acceptable value of resistance connections between joints in
depends on the size and type of the pipelines and
equipment, and voltage rating. associated facilities.

The insulation resistance is directly -- 2 Ohms for each electrode to the

measured with the help of megger which general mass of the earth.
applies constant test voltage (d.c) on the
insulation. This test voltage has to be iii) EARTH CONTINUITY TEST
applied for the time required for the
absorption current to die down, (normally 1 A separate test of every earth
minute). Electrical installations shall be continuity conductor should be made
tested for insulation resistance between all (Ref:E.3 of Institution of Electrical
conductors and earth and between the Engineers - IEE’s regulation)
conductors themselves.
Since the values of impedance
General 1 megaohm per KV and resistance of earth continuity
should be acceptable value of insulation conductors are subject to the requirements
resistance. However, in case of 0.415 KV for earth loop impedance should also be
circuits 1 megaohm should be minimum tested. (Ref.:D22 of IEE regulation).
acceptable value.
All the earth leakage sensing
Recommended test voltages: devices along with their wiring connections
shall be periodically tested for their proper Periodic testing of cathodic
functioning at set values of leakage protection system such as structure to soil
current. voltage, anode current, soil resistivity,
performance of transformer and rectifier
iv) POLARISATION INDEX TEST shall be carried out to ensure continued
protection.
This test is used to determine the
insulation resistance level of cable, Current output and voltages shall
transformers’ motors’ and similar electrical be adjusted to maintain the degree of
equipment. Using a power driven cathodic protection.
insulation tester, the test voltage is applied
to the equipment for a period of 10 Cathodic protection circuits shall
minutes. The insulation resistance values be ON all the hours of the day all the year
at the end of 1 minute and 10 minutes round.
period are recorded. The ration of the final
resistance to initial resistance is called the Allowable values of structure to
Polarisation index. soil voltage shall be -0.85 volts as
measured with a special meter with
A good to excellent index is 2.5, a respect to copper to copper sulphate half
poor to questionable index is 1 to 2. When cell. Current density requirement depends
index level starts at 2.5 to 4 base level and on the condition of coating and soil
begins to fall one or two years later to 1.5 resistivity. Better the quality of coating,
or 2 it is apparent that either the cable has lower will be the requirement of current.
become dirty or wet, or the insulation has
become weakened to an unsafe condition. vii) CABLE FAULT DETECTION

These values shall be considered Annexure VII describes one of the

only relative and are used to know the procedures for detection of cable fault
trend of insulation deterioration over a location, which shall be used as a
period of time. guideline if specific instruction from the
cable manufacturer is not available.
v) MOISTURE ABSORPTION TEST
viii) TESTS ON LIGHTNING
Moisture absorption is usually PROTECTION SYSTEM
evaluated from the ration of two values of
insulation resistance measured with The ohmic resistance of lightning
Megohmeter after 60 seconds and 15 protective system complete with air
seconds respectively. This ratio is called terminations but excluding earth electrode
the Coefficient of moisture (dielectric) connections should not exceed 1 ohm.
absorption, denoted by ‘K’. The continuity of lightning conductors and
bonding connections of structures shall be
R60 tested to ensure that there are no open
K= ----- circuits. Also, checks shall be made to
R15 ensure that the clearances from other
Damp installation will have a structures are maintained to prevent
coefficient value close to 1. As the flashover to the structure during lightning.
insulation dries out, the coefficient rises
and when it becomes 1.3 or greater the 8.0 DOCUMENTATION
insulation is considered to be dry.
Documentation and record
vi) CATHODIC PROTECTION keeping form an integral part of total
(ELECTRICAL TEST) inspection management system. The
various records, which shall be maintained
The underground or submerged in any unit, are summarised below:
structures such as pipelines shall be
protected against electrolytic corrosion by 8.1 FAILURE ANALYSIS REPORTS
cathodic protection, either by the
“impressed current” or the “sacrificial Failure analysis shall be conducted on
anode” methods.
I) High Voltage equipment
 a) Tanks, gantry structures & process
ii) Repetitive failures of any kind area

iii)Power system failure affecting plant b) Vessels/exchangers/columns

operation
c) Motors/generators
iv) Failure due to arcing or sparking, which
caused unsafe condition/accidents. d) Earthing pits.

v) Failure to newly installed or repaired e) Bonding and grounding of loading

systems arms and piping

vi) Critical equipment and systems. f) Substations/switchyards

For this, various data and records g) Lightning protection system

shall be regularly maintained through
Failure analysis reports (in the formats ii) Insulation resistance tests of all power
suggested for few, as per Annexure V), and control cables, motors, transformers
and monitored by Electrical in-charge. and other critical electrical equipment.

8.2 HISTORY CARDS iii) Cathodic protection tests (potentials at

identified locations of tank bottoms,
History cards for following structures/ pipelines etc.)
equipment shall be maintained by each
Unit-in-charge or Maintenance Planning iv) Transformer oil tests
Cell, which should be the basis for
carrying out failure analysis and enabling v) Calibration tests of meters /
replacement with identical equipment or instruments /relays
components during emergencies:
vi) Simulation test on protective relay
i) Motors/Generators with circuits.
associated switchgear
ii) Transformers with associated vii) Test records on battery
switchgear
iii) Cables viii)Other data
iv) Relays
v) Battery a) Compliance reports of previous audit
vi) Other critical electrical equipment reports and Electrical Inspector’s
and systems observations during periodical
statutory inspections under I.E. Rule
Formats for few of the above have 46 (for the last 5 years)
been suggested in the Annexures I to IV.
The entries also should include the data: b) Manufacturer’s shop test certificates &
field test records of critical equipment
First date of commissioning................... before energisation and after
subsequent repairs.
Last Capital maintenance carried out
on............. c) Updated equipment list (load summary)

8.3 TEST RECORDS AND OTHER d) Updated single line drawing,

DATA incorporating details of electrical
power communication and fire alarm
Records for the following tests and other system incorporating all changes.
data listed shall be available with each
Unit-in-Charge or Maintenance Planning f) Permit to-work (Electrical) or Line
Cell: clearance formats.

I) Earth resistance tests g) Schematic control circuit diagrams with

explanatory notes.
h) Authorisation register (Annexure VI) 9.1.1 Generators

I) Reports on investigation of accidents The following items shall be

(for the last 5 years), if any checked/tested, before start up:

j) Specifications for spare parts (for I) Cable connections

ordering purposes) with original ii) Loose contacts in field circuit
Manufacturer’s catalogues and iii) Open circuits in exciter/field coils
descriptive technical data. iv) Short circuits in the coils
(exciter/stator/field)
k) Operation and maintenance instruction v) Blockage of ventilator openings
manuals (system wise) vi) Condition of bearings
vii) Turning of Oil rings
l) Reference documents (International and viii)Oil lubrication (adequacy & Oil quality)
Indian Standards, Codes, I.E. Rules, ix) Alignment of coupled machines
and other latest statutory regulations) x) Grounding of coils (especially exciter)
xi) Brush spring pressure
Relay co-ordination drawings and table of xii) Earthing connections (body & neutral)
relay settings. xiii)Protection circuits (simulation tests)
xiv) Auto/manual starting and changeover
n) Substation log register with updated system
entries and observations.
The following items shall be
9.0 PRECOMMISSIONING CHECKS checked after start up:

Before commissioning electrical I) Exciter voltage (whether low)

equipment after repairs and maintenance, ii) Load on the generator
the following minimum Precommissioning iii) Overheating of
checks shall be carried out. Wherever alternator/exciter/bearings
manufacturer’s recommendations are iv) Speed whether steady or hunting
available, the same shall prevail. (growling)
v) Sparking of brushes
In the case of newly installed vi) Commutator surface for uniformity
facilities also, the same Precommissioning (projection, if any)
checks shall be applicable but additionally vii) Carbon dust collection (whether
the following shall be ensured: consolidated between the commutator
segments)
I) The statutory clearances from the viii) Audio visual annunciation
State Electrical Inspectorate/Director ix) Noise
General, Mines Safety, (as the case x) Brush spring pressure.
may be) shall be obtained for the
schemes and installations. 9.1.2 Motors and Controlgear

II) Manufacturer’s test certificates shall The items listed below shall be
be obtained(for the successful checked/tested before start up:
passing of shop tests.
I) Mechanical and electrical checks as per
III) Installations conform to acceptable IS: 900
engineering standards and are
appropriate to the respective ii)Cleanliness (free from dirt, dust and
hazardous area classifications (as moisture)
per ISI-NEC-1985). Installations
with all individual Isolating devices iii)Insulation resistance (before and after
(for safe disconnection of electrical connection of the power cables)
circuits) shall be easily accessible
for regular and emergency operation iv)D.C. resistance of stator and rotor
and maintenance. windings(This should not differ from
manufacturers’ data by more than 2%)
9.1 ROTATING MACHINERY
v) Polarisation Index and Dielectric e) Vibration
Absorption tests (for critical equipment f) No load current
only) g) Speed

vi) Sliprings, brushgear polish and Note:

cleanliness of machine winding.
Run the uncoupled motor for a
vii)Brushes in holders (check for clearance minimum period of 4 hours for LT Motors
and pressure and 8 hours for HT Motors and ensure
trouble free operation.
viii)Connection and operation of space
heater where provided. (ensure its 9.2STATIONARY EQUIPMENT
automatic switching off when motor is /SYSTEMS
started and switching on when motor is
stopped) 9.2.1 Switchboards & Panels

ix) Provision of emergency stop switches The following shall be checked/tested:

and coupling guard
I) Cleanliness (free from dirt, dust,
x) External damages, and missing moisture etc.)
components
ii) Any tool or foreign material inside the
xi)Functional checks of motor control and equipment
protective circuits with interlocks and all
audio visual annunciation (through iii)All circuit wiring and terminations in tact
simulation test)
iv) Tightness of connections/clamping of
xii)Freeness of rotation of motor shaft, and wires
lubrication.
v) Vermin proofness (whether unused
xiii)Cable termination (check also for openings closed)
proper size and type of cable)
vi)Protection and annunciation circuits
xiv)Ratings of fuses, thermal, short circuit including checking of relay settings,
& earth fault settings (protective and fuse ratings.
system)
vii) Relay and meter calibrations
xv) Earthing connections/earth resistance (simulation)

xvi)Flameproofness, corrosion and viii) Operation of interlocks and safety

weather protection. devices

xii)Voltage drop ix) Provision of caution notices, tags, and

danger boards
xviii)Alignment with coupled machine.
x) Provision of insulating mats conforming
The items listed below shall be checked to IS:15652:2006 having ISI mark
after start up:
xi) Continuity of wires
I) Mechanical and electrical checks as per
IS: 900 xii) Insulation resistance

ii)Cooling system xiii)Conformity with updated schematic

and single line diagrams
iii)No load run of motors with observations (ratings/settings)
for
a) Supply voltage and frequency xiv) Timer checks
b) Direction of rotation.
c) Abnormal sound xv) Short in CTs,, blockage in relays
d) Temperature
xvi) External damage and dents iii)Body and neutral earthing/earth
resistance
xvii) Cable bends within the switchboard
(whether required bending radius is iv) Dielectric strength, & acidity tests of the
maintained) oil (Conforming to IS:335)

xviii) Contact alignment of draw out type v) Oil leakage

switchgear
vi) Oil level in the conservator, bushings
xix) Oil level, and oil condition for the oil- and thermometer pockets
immersed gear
vii) Condition of silicagel
xx) Anticondensation heater circuit
operation. viii) Blockage, if any, in the breather pipe

xxi) Control supply availability ix) Explosion vent diaphragm not having
any dents, accumulation of any
xxii) Provision of fire fighting equipment oil/air(whether released)
suitable for electrical fires.
x) Buchholz relay (frinctionless movement
xxiii) Electrical & manual closing and and floats)
tripping of all circuit breakers (remote
and local) xi)Protective checks on tips and alarms
(simulation)
xxiv) Provision of phase barriers and
partitions (to avoid inadvertent xii) Polarity and ration tests
contact with live parts.
xiii) Arcing gaps for the bushings
xxv) Corrosion effects (whether to be
painted) xiv) Earthing connections for the surge
divertor
xxvi) Condition of supporting structure
xiv) Operation of the tap changer circuits
xxvii)Earthing connections/resistance on all the tap positions (simulation)

9.2.2 Instrument Transformers (CT’s xvi) Identical indication of tap position on

and PT’s) transformer and on control panel

The following checks/tests shall be carried xvii) Operation of tap changer limit switch
out: on the maximum tap positions.

I) Polarity xviii)Oil condition and oil level in tap

ii) Continuity changer tank
iii) Ratio error
iv) Tightness of wiring connections xix) Insulation resistance of all control
v) Wiring (continuity and completeness) circuits and transformer windings.
vi) Other field checks as pr IS:2705 (for
CT) and per IS:3156 (for PT) xx) Cooling system (automatic starting and
stopping of fans)
9.2.3 Transformer & Busduct
xxi) Cleanliness of transformer surface
The following checks/tests shall be carried
out: xxii) Space heater operation (marshalling
box)
I) Provision of all the accessories
xxiii) Parallel operation (auto/manual
ii)External damages (especially on modes) with protection and interlock
bushings) circuits (simulation tests)
xxiv) Neutral grounding resistor especially iv) Cell voltage, proper cell connections to
for earthing connection and earth maintain correct polarity.
resistance.
v) Normal operation of battery charging
xxv) Phase sequence (when transformers equipment
have to be paralleled)
vi) Corrosion problems (especially to
xxvi) Sealing of busduct entries through terminals), if any
walls (for vapour, dust, water
tightness) vii) Damages, if any

xxvii) Vermin & dust proofness and earth viii) Spillage of electrolyte
connections of bus ducts
ix) Tightness of wiring connections
xxviii) Busduct supports
x) provision of required protective devices
xxix) Expansion joints and flexible and annunciations.
connection of busduct
9.2.5 Lighting System
xxx) Cable terminations
The following shall be checked/tested:
xxxi) Provision of caution boards
I) Installation and components meet the
After commissioning the requirements set by environmental
transformer, the following pints shall be conditions and conform to approved
observed, and recorded: drawings/specifications

I) Oil leakage, if any ii) Ensure no fuses blown and no lamps

fused
ii) The no-load current
iii) Circuit loading and balancing of loads
iii) Alarm, if any, or any relay flag has between phases
operated
iv) Provision of safety features such as:
iv) Voltage and current on all three phases a) Separation sheets
b) Fuse base screening
v) Transformer hum or abnormal noise, if c) Door switches & padlocks
any
v) Continuity and completeness of wiring
vi) Circulation of oil connections

vii) Current, voltage, and temperature vi) Tightness of wiring connections at the
readings (hourly for 24 hours when terminals
transformer is loaded)
vii) Cable terminals
viii) Cables end boxes for any overheating
viii) Ratings of fuses, MCBS and switches
9.2.4 Battery & Charger
ix) Insulation resistance between phases
The items listed below shall be and between phases & earth.
checked/ensured:
x) Weatherproofing and vermin proofness
I) Battery not affected by sunlight.
xi)Earthing connection/earth resistance
ii) Proper ventilation and provision of acid values
proof flooring in the battery room.
xii) Size and type of cables, wires and
iii)Conformity of electrolyte to IS:266 & its conduits used
level
xiii)Painting (corrosion effect
xiv) Functional checks of lighting circuits ix) Continuity of core to confirm no open
for operation circuit.

xv) Operation of emergency lighting 10.0 REFERENCES

circuits and its automatic starting
when normal use supply fails The following codes, standards and
(simulation) publications have either been referred to
or used in the preparation of this standard,
xvi) Condition of lighting fixtures, panels & and the same shall be read in conjunction
distribution boards with this standard:

xvii) Available illumination levels areawise I) Indian Electricity (i.E) Rules 1956/Act-
to confirm operation and safety 1910
requirements through field ii) Bureau of Indian Standards-ISI:s
inspection with UIC) publication: IS:2705, IS:3156, IS:3043,
IS:1554, IS:2309, IS:5216, IS:335,
xviii) Circuit identifications and markings in IS:266, IS:900, IS:3156, IS:10029,
the field. IS:1255, IS:732, IS:5572, IS:2148,
IS:7389, IS:3072, IS:4770, IS:10118,
9.2.6 CABLES IS:1866, IS:2516, IS:5124,

The items listed below shall be iii) ISI-national Electrical Code, 1985
checked/ensured:
iv) Model code of safe practice Electrical-
I) Identification of the cable with equipment Part 1, 1974 (Institute of Petroleum
tag no., circuit inscription, provision of publication)
cable route markers and joint
location markers. v) Guide for Inspection of Refinery
Equipment-Chapter XIV-Electrical
ii) Depth of laying and spacing between System-(API-Publication) 1976
cables of different voltage grades
(random checks on trial pit basis). vi) OISD-STD-105 (Work Permit system),
1988
iii) Voltage rating, size and type of the
cable (to ensure correct specifications) vii) British Standard Code of Practice BS-
6651, CP-1013
iv) Cable support/clamping arrangement
viii) Regulations for the electrical
v) Cable terminals (especially for equipment of buildings. Fifteenth
flameproof, watertight terminaitions) eidtion 1976 (Institution of Electrical
Engineers - IEE’s publication)
vi) Armour earthing and bonding
ix) Oil Mine Regulation 1984
vii) Cable sleeves (whenever crossing the
roads, walls etc.,) x) Petroleum Rules 1976

viii) Insulation resistance of every circuit xi) Asian Electricity Journal, Oct 96.
(phase to phase, phase to ground and
armour)
 ANNEXURE I

PROTECTIVE RELAY INSPECTION AND TEST RECORD

CIRCUIT LOCATION________________CIRCUIT DESIGNATION_____________________

RELAY______________________PHASE OR LOCATION IN PANEL__________________

MANUFACTURER___________TYPE__________STYLE NO._________FUNCTION______

C.T. RATIO_____________________________P.T. RATIO___________________________

TAP RANGE_____________________________INSTANTANEOUS RANGE____________

TIME OPERATIONS INDICATOR_______AND INSTANTANEOUS

INDICATOR_______AMP

RELAY INSPECTION
DATE
COVER
GLASS TIGHT
GLASS CLEAN
GASKET TIGHT
RELAY CONDITION
DUST
RUST
IRON FILINGS
BEARINGS STICKY
SHORTCOMING
BARS IN PLACE
CONNECTIONS
TIGHT
CONTACTS
DIRTY
PITTED
OPERATIONS
INDICATOR
ARMATURE FREE
TARGET FREE
INSTANTANEOUS
ATTACHMENT
ARMATURE FREE
TARGET FREE
DISC.RUBBING
INSPECTION
 ANNEXURE III

________________

CABLE MAINTENANCE CARD

_______________________________

CARD NO.

MAKE TYPE YEAR OF TAG NO. SIZE

INSTALLATION

VOLTAGE CURRENT LENGTH INITIAL NO. CABLE ROUTE

OF JOINTS LINE MARKER

DATE TYPE OF FAULT DISTANCE JOBS EXECUTED

FAULT LOCATION FROM LENGTH CARRIED BY
DETAILS (MTS) OUT
 ANNEXURE V

FAILURE ANALYSIS REPORT

INSTALLATION.......................................................
UNIT _________________________ EQUIPMENT TAG NO.:___________
DATE______________
------------------------------------------------------------------------------------------------------------------------------------------
1. Present Failure/Abnormality Last Failure/Abnormality
Date: Date:
Nature: Nature:

2. Component Damage/Abnormality Cause of Damage.

3. Principal Cause of Failure

4. Repair/Replacement Carried out

5. Steps taken to prevent repetition

------------------------------------------------------------------------------------------------------------------------------------------

Signature/name/Designation
(of the Officer preparing the
Report)
 ANNEXURE VI

DETAILS OF AUTHORISED PERSONNEL

(Requirement under I.E. Rules, 1956)

INSTALLATION .................................................................... DATE:.........................

___________________________________________________________________________________
Sl.No. Name Designation Technical No.of IE The work Signature of
Competency Rules 1956 for responsibility person in
which authorised entrusted to token of
authorised of
person authorisation
------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------

Signature/name/Designation
(of the Officer preparing the
Report)
 ANNEXURE VII
CABLE FAULT DETECTION
(Ref.Asian Electricity Journal Oct. ‘86)

GENERAL
Fault locating procedure:
The use of particular fault finding equipment • Through diagnosis
depends on the factors such as type of fault, • Accurate route measurement
length of cable, location of cable, cable • Trustworthy pre-location (i.e correct
construction and, very important, funds instrument)
available for procurement.
(a) Contact fault:
Broad guidelines for methods and
equipment necessary Pulse Echo Set if fault resistance is
suitable. If not, H.V. Or High Resistance bridge
The methods and equipment necessary are: or Impulse current set can be used.

Diagnosis -Ohm meter (b) Flashing Fault:

- Insulation Tester
Impulse Current Set
Pre-location - High voltage
Bridge or High • Pin-pointing
Resistance fault
locator Surge Generator-occasionally Audio
- Impulse current Frequency Sets for low resistance core to core
Equipment faults.

Fault Choice of instruments

Conditioning - Burn down set
(Sometimes necessary before pre-location) - For XLPE Insulated cable, a full set of
equipment incorporating Impulse current
Pin-pointing - Surge Generator equipment will be required, because it is
- Audio Frequency impossible to burn down faults on this
Set type of cable and pulse echo is, therefore,
Route tracing - Audio Frequency not possible for contact faults.
Set
Fault Confirmation - Acoustic Detector - For long cables, say up to 15 Km
- Audio Frequency presents few problems in pre-location but
set Pin-pointing equipment is essential
occasionally. because even a low-pre-location error
All above - Combination Sets results in a wide search area.
of
functions portable - For short route lengths a rough “one
equipment for Instrument” approach may be successful.
full fault location For Instance, assuming pre-location is
capability. possible, the application of modern-
powerful Surge generator to jest a few
Type of fault: hundred meters of cable and careful
patrolling of the route often gives a “spot-
In general, faults can be said to be on” location within a short time.
open or short circuits, However, in practice,
many conditions can arise i.e. a break may not Minimum essential equipment required
be “clean”-it may have resistance across it or,
more usually, to the sheath or earth. A contact - A High Impedance Fault locator.
fault may be “hard down” or exhibit hundred of - A Pulse Echo Set.
ohms, kiloohms or even megohms. - A Shock wave Generator.

Also faults occur on one or more of

the cores of conductors.
NOTES

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