Method Of Statement

FOR 22KVSwitchgear

CONTRACT NO:

CLIENT:

CONSULTANT:

MAIN CONTRACTOR:

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

Contents:

1) Purpose

2) Reference Document

3) Responsible Personnel

4) Preparation for Testing

5) Details of Tests

6) Quality Control

7) Safety

8) Attachment

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

1.0 PURPOSE

1.1 The purpose of this document is to explain briefly the method and procedure that
will be used to ensure proper testing of the 22KV MV SWGR.

All works relating to the above item will be carried out in accordance with the
approved site test procedures and in compliance with the specifications.

1.2 This method statement to be read in conjunction with relevant approved site test
formats.

2.0 REFERENCE DOCUMENT

2.1 Technical Specification

2.2
2.3 Approved Shop Drawings / Manufacturer’s Drawing/Schematic Drawings
2.4 Approved Site Test Formats

3.0 RESPONSIBLE PERSONNEL

3.1 Project Manager Electrical

3.2 Electrical Engineer – Testing & Commissioning

3.3 Electrical Supervisor

4.0 PREPARATION FOR TESTING

4.1 Prior to the commencement of any permanent works, areas and access will be
inspected to confirm that they are in a condition for permanent works to
commence ensuring the environment is clean and dry. Testing will commence
only after the equipment is completely installed and released for testing and
commissioning

4.2 All materials and documentation relevant to this testing works shall be checked
by the responsible personnel prior to the commencement of testing activities.

4.3 Before any item of equipment is accepted for testing a visual inspection will be
carried out on that equipment. Where defective equipment is found, it will be
reported to the Client/Consultant for further action.
SUB CONTRACTOR CONTRACTOR
COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

4.4 The Testing Engineer/Supervisor should confirm the availability of necessary 3

Phase AC Power Supply of testing activities.

4.5 The Testing Engineer/Supervisor should confirm the availability of proper access
to the site area in which the equipment are to be tested.

4.6 When a satisfactory pre-testing inspection has been carried out, the testing
works will commence.

4.7 The Testing Engineer will instruct the supervisor regarding the testing works and
will arrange for all necessary schematic drawings, data sheets and test formats
to be available at testing area.

4.8 The supervisor will check that all necessary tools and equipment to be used for
testing are available at the testing area.

4.9 After the testing work is completed the supervisor checks all the testing
equipment and returns to the storage cabin.

4.10 While carrying out the testing work the Testing Engineer will fill all the necessary
test formats. After completion of testing work the Testing Engineer will obtain the
signature of relevant officials: Client/Consultant

5.0 DETAILS OF TEST:

SUB CONTRACTOR CONTRACTOR
COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

5.1 Visual Inspection

5.2 Switchgear Functional Tests
5.3 Circuit Breaker Tests
5.4 Bus Bar Contact Resistance Test
5.5 Current Transformer Tests
5.6 Voltage Transformer Tests
5.7 Auxiliary Relays Tests
5.8 Over Current and Earth Fault Relay Tests
5.9 Switchgear HV Test

5.1 VISUAL INSPECTION CHECKS

 Check for complete installation of Switchgear

 Check the Cleanliness of switchgear and Surroundings.
 Inspect for physical damage/ defects on switchgear during Installation &
Mobilization.
 Verify all components nameplate ratings in accordance with customer
drawings & specifications
 Check that all grounding is securely connected.

5.2 SWITCHGEAR FUNCTIONAL TEST:

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

During the functional test the overall operation of the switchgear is checked in
accordance to the approved and as manufactured schematic drawings.

The Following checks will be carried out for the functional checks.
 Electrical/Manual close/open operation of the circuit breaker
 Electrical/Manual close/open operation of the disconnector
 Manual close/open operation of the earth switch
 Position indicator operation of the circuit breaker
 Position indicator position of the disconnector
 Position indicator operation of the earth switch
 ON/OFF/TRIP indication of the circuit breaker
 Interlock checks between disconnector& earth switch
 Interlock checks between disconnector& circuit breaker
 Interlock checks between circuit breaker and cable compartment cover
 Manual/Electrical operation of the spring charger
 Circuit breaker operation counter verification check
 Circuit breaker protection tripping check
 Lock-out relay functionality checks
 Trip Circuit Supervision Relay functionality checks
 Panel lighting & Heater function checks
 Signals to Remote Monitoring (DMS System) checks
 Spare contacts or signals checks
 Earth continuity to the Main Earth checks

5.3 CIRCUIT BREAKER TESTS:

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

5.3.1 INSULATION RESISTANCE TEST (IR TEST):

The Purpose of insulation resistance (IR) measurement is to determine the

insulation conditions of the CB Contacts to earth and between them. Test will be
carried out as follow.

Pole to Pole - 5kV @ 1 Min.

 Close the circuit breaker.
 Connect IR tester (Megger) between R Pole to Y Pole as shown in fig1.
 Set and inject the 5000V DC for 1 Min and record the value in the attached test
format.
 Repeat the same steps for other poles (R-B, Y-R, Y-B, B-R, B-Y) and record the
results in the attached test forms.

Pole to Earth - 5kV @ 1 Min.

 Close the circuit breaker
 Connect IR tester (Megger) between R Pole to Ground.
 Set and inject the 5000V DC for 1 Min and record the value in the attached test
format.
 Repeat the same steps for other poles (Y-E, B-E) and record the results in the
attached test forms.

5.3.2 CONTACT RESISTANCE TEST:

The Purpose of test is to check the contact resistance of the CB. This test will be
done by injecting small DC current to the CB contacts and measuring Resistance
of the same. Test will be carried out as follow.

 Close the circuit breaker.

 Connect Low resistance ohm meter (Micro Ohm Meter) between R Pole as shown
in fig 2.

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

 Set and inject the 100A DC and Resistance will be appeared in the test set after
internally computing the voltage.
 Repeat the same steps for other poles (Y and B) and record the results in the
attached test forms.

Fig.1 Insulation Resistance test setup Fig.2 Contact Resistance test setup

5.3.3 TIMING TEST

The Purpose of test is to check CB opening and closing time as per
recommended value. This test will be done by using CB analyzer kit which will
record the CB timings and provide the results with graphical form. Test will be
carried out as follow

CB Opening & Closing Time Measurement.

 Connect the timing measurement leads (test leads) between CB R Poles as
shown in fig 3.
 Connect the test set opening and closing pulse leads to the CB closing and
tripping coil.

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

 Initiate opening and closing pluses and record the results in the attached test
forms.

Fig.3 Timing test setup

5.4 BUS BAR CONTACT RESISTANCE TEST :

The contact resistance of the bus bar is measured between test panel 1&2,
keeping the circuit breakers, isolators in close condition.
This test will be done by injecting small DC current to the Bus bar and
measuring Resistance of the same. Test will be carried out as follow.

 Close the circuit breaker.

 Connect the test leads to R phase between test panels (Panel1 to Panel 2) as
shown in fig 4.
 Set and inject the 100A DC and Resistance will be appeared in the test set after
internally computing the voltage.
 Repeat the same steps for other phases (Y and B) and other panels.
 Record the results in the attached test forms.

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

Fig.4 Bus bar Contact Resistance test setup

5.5 CURRENT TRANSFORMER TEST

Following test will be carried for CT
5.5.1 Insulation Resistance test
5.5.2 Winding Resistance test
5.5.3 Polarity Test
5.5.4 Knee Point Voltage Test
5.5.5 Ratio Test

5.5.1 Insulation Resistance test (IR Test):

Primary to Earth - 5kV @ 1 Min.

 Connect IR tester (Megger) between CT primary to earth as shown in fig. 5.
 Set and inject the 5000V DC for 1 Min and record the value in the attached
test format.

Primary to Secondary - 5kV @ 1 Min.

 Connect IR tester (Megger) between CT Primary to secondary
 Set and inject the 5000V DC for 1 Min and record the value in the attached
test format.

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

Secondary to earth - 1kV @ 1 Min.

 Connect IR tester (Megger) between CT secondary to earth
 Set and inject the 1000V DC for 1 Min and record the value in the attached
test format.

5.5.2 Winding Resistance Test:

The Purpose of Measurement is to check correctness of windings and terminal

connections. Winding resistance of CT will measured using digital millimeter.
Temperature correction will be made according to reference temperature (75 0C).

Ambient temperature must be measured and resistance values to be calculated

for reference temperature.

 Connect the multimeter across the R- phase CT secondary S1-S2 as shown

in fig 6.
 Measure and Record the resistance value in the test form.
 Repeat the same steps for the other phases (Y and B Phases) and all cores
(S1-S3) and record the values.

Fig.95 Insulation Resistance test setup Fig.6 Winding Resistance test setup

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

Fig.7 Polarity test setup

5.5.3 Polarity Test:

Polarity test for CT is conducted to check the secondary current flow with
respect to Primary.
Polarity test will be carried out by flicker method, using battery with switch. The
test will be conducted as follow.

 Connect the Battery with Switch across the R- phase CT Primary P1-P2 as
shown in fig 7.
 Connect the Analogue Multi meter or Galvano meter across the R- phase CT
secondary S1-S2 as shown in fig 7.
 Inject DC voltage in one pulse in CT primary and check the CT secondary
current flow. If the polarity is normal, then Secondary current will flow in S1-
S2 direction and analogue meter shows positive deflection. If current
direction is reverse i.e, polarity is wrong, and then the meter will show
negative deflection.
 Record the result in the attached test form.
 Repeat the same steps for the other phases (Y and B Phases) and all cores
(S1-S3) and record the values.

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

5.5.4 Knee Point Voltage Measurement:

Knee point voltage test is conducted to check the saturation level of CT.
Knee point voltage
Knee point voltage test shall be carried out using step up transformer. Knee
Point Voltage (Vk) is the voltage at which 10% increase of secondary voltage
will produce 50% increase in excitation current. The test will be done as
follow.

 Connect the test set across the R- phase CT Secondary S1-S2 as shown in fig 8.
 Make Sure CT primary is not connected or open.
 Demagnetize the CT before start the test.
 Apply voltage and increase gradually until the above Vk condition observe.
 Record increasing secondary voltage and secondary current simultaneously.
 Record the result in the attached test form.
 Repeat the same steps for the other phases (Y and B Phases) and all cores (S1-S3)
and record the values.

Fig.8 Knee Point test setup

5.5.5 Ratio Test:

The Ratio is conducting to ensure the ratio of the CT according to the name
plate.
Ratio test is conducted by applying current in primary and measuring the current
in secondary. The test shall be followed as follow.
SUB CONTRACTOR CONTRACTOR
COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

 Connect the test set across the R- phase CT Primary P1-P2 as shown in fig 9.
 Make Sure CT Secondary is connected properly & tightened.
 Apply Current and increase gradually to the specified value.
 Measure the corresponding secondary current (at S1-S2) to the primary injected
current and record result in the attached test form.
 Repeat the same steps for the other phases (Y and B Phases) and all cores (S1-S3)
and record the values.

Fig.9 Ratio test setup

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

5.6 VOLTAGE TRANSFORMER TEST:

Following test will be carried for CT
5.6.1 Insulation Resistance test
5.6.2 Winding Resistance test
5.6.3 Polarity Test
5.6.4 Ratio Test

5.6.1 Insulation Resistance test (IR Test):

Primary to Secondary - 5kV @ 1 Min.

 Connect IR tester (Megger) between VT Primary to secondary as shown in fig 10.
 Set and inject the 5000V DC for 1 Min and record the value in the attached test
format.

Secondary to earth - 1kV @ 1 Min.

 Connect IR tester (Megger) between VT Secondary to Earth
 Set and inject the 1000V DC for 1 Min and record the value in the attached test
format.

Fig.10 Insulation Resistance test setup Fig.11 Winding Resistance test

setup

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

Fig.7 Polarity test setup

5.6.2 Winding Resistance Test:

The Purpose of Measurement is to check correctness of windings and terminal
connections. Winding resistance of VT will measured using digital millimeter.
Temperature correction will be made according to reference temperature (75 0C).

Ambient temperature must be measured and resistance values to be calculated

for reference temperature.
 Connect the multimeter across the R- phase VT secondary a1-n as shown in
fig 11.
 Measure and Record the resistance value in the test form.
 Repeat the same steps for the other phases (Y and B Phases) and all cores
(S1-S3) and record the values.

5.6.3 Polarity Test:

Polarity test for CT is conducted to check the secondary current flow with
respect to Primary.
Polarity test will be carried out by flicker method, using battery with switch. The
test will be conducted as follow.

 Connect the Battery with Switch across the R- phase VT Primary P1-P2 as
shown in fig 12.

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

 Connect the Analogue Multi meter or Galvano meter across the R- phase VT
secondary a1-nas shown in fig 6.
 Inject DC voltage in one pulse in VT primary and check the VT secondary
current flow. If the polarity is normal, then Secondary current will flow in a1-n
direction and analogue meter shows positive deflection. If current direction is
reverse i.e, polarity is wrong, and then the meter will show negative
deflection.
 Record the result in the attached test form.
 Repeat the same steps for the other phases (Y and B Phases).

Ratio Test:
The Ratio is conducting to ensure the ratio of the VT according to the name
plate.
Ratio test is conducted by applying current in primary and measuring the current
in secondary. The test shall be followed as follow.
 Connect the test set across the R- phase VT Primary P1-P2 as shown in fig
13.
 Make Sure VT Secondary is connected properly & tightened.
 Apply Current and increase gradually to the specified value.
 Measure the corresponding secondary current to the primary injected current
and record result in the attached test form.
 Repeat the same steps for the other phases (Y and B Phases)

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

Fig.13 Ratio test setup

5.7 TRIP CIRCUIT SUPERVISION & LOCK OUT RELAY TESTING:-

5.7.1 Visual Inspection:-

 Inspect for physical damage/ defects transport mobilization.

 Verify ratings in accordance with customer drawings and specifications.
 Check that grounding is securely connected.

5.7.2 Pick Up & Drop Off Level:-

 Isolate relay from control circuit and connect the relay to the test set.
 Apply and gradually increase the DC voltage until relay will get pick up.
 Note and record the value.
 Gradually reduce the DC voltage until relay will get drop off and record the
value.

5.8 OVER CURRENT, EARTH FAULT RELAY TESTING:-

5.8.1 Visual Inspection:-

 Inspect for physical damage/ defects transport mobilization.

 Verify ratings in accordance with customer drawings and specifications.
 Check that grounding is securely connected.

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

5.8.2 Pick Up & Drop Off Level:-

 Isolate relay from control circuit by inserting test plug.

 Connect the test set current leads to the Relay CT circuits as per drawing.
 Set ( Specified setting) the Over current and Earth fault setting in the relay
 Apply and gradually increase the current until relay will get pick up.
 Note and record the value.
 Gradually reduce the current until relay will get drop off and record the
value.

The recorded values have to verify in accordance to the tolerance specified by the
manufacturer.

5.8.3 Operating Time Checks:

 Isolate relay from control circuit by inserting test plug.
 Connect the test set current leads to the Relay CT circuits and test set
potential free contact leads to the relay tripping contacts as per drawing.
 Set ( Specified setting pickup current, TMS and IDMT curve) the Over
current and Earth fault setting in the relay
 Apply 2 times of setting current and measure the operating time and record
the value.
 Apply 5 times of setting current and measure the operating time and record
the value.
 Repeat the same steps for other phase (Y and B) and Earth fault and
record the results.

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

Fig.14 Over current / earth fault relay test setup

5.9 HIGH VOLTAGE TEST

HV test is conducting for the switchgear to check and confirm the dielectric strength
of the switchgear. Test duration will be 1 min and test voltage will be 80% of
switchgear short time withstand voltage.

Following pre-cautions shall be made before commence the HV test.

 Approved and trained personnel only shall conduct HV test.

 Safety barricade / warning tapes shall be placed in the testing area to notify the
HV test in progress.
 Any materials around the switchgear will be cleared and walk way shall be
cleared.
 Feeder earthswitch is open and no power cables will be connected to the
switchgear end.
 Ensure Voltage Transformers (VT) are isolated and earthed.
 CTs are to be connected in to the circuits and spare cores of CT is properly
shorted, if applicable.
SUB CONTRACTOR CONTRACTOR
COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

HV test will be conducted as below.

 Close the circuit breaker and disconnector for all feeders.

 Conduct insulation resistance test (IR Test) before and after HV test for all
phases with respect to earth as per attached test format and record the result.
 Connect the test set lead to R phase of the switchgear as shown in fig 15.
 Connect adjacent phases (Y and B) to the earth as shown in fig.15.
 Switch on and inject the Voltage as specified above for 1 min. and record the
leakage current.
 Switch off test set and discharge properly before access the switchgear.
 Repeat the above steps to other phases (Y and B) and record the results.

Fig.15 High Voltage test setup

6.0 On Site Protection

Until the Equipment is permanently energized, Contractor should ensure that a

protective cover will remain over all the equipment that are being tested from ingress of
dust etc.
SUB CONTRACTOR CONTRACTOR
COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE
 Method Of Statement
FOR 22KVSwitchgear

7.0 QUALITY CONTROL

The testing engineer will ensure that all the equipments are tested as per
approved test formats and test results recorded in the same.

8.0 SAFETY

All works will commence as per safety regulations laid down in the contract
specification and project safety plan.

9.0 ATTACHMENTS

Test Format.

SUB CONTRACTOR CONTRACTOR

COMPANY ALPHA POWER AL JABER
NAME Muthuswamy Vn
SIGNATURE