LT PANEL

PRE COMMISSIONING TEST PROCEDURE FOR LT

PANEL
1.0 Purpose
This procedure is prepared to carry out various pre- commissioning tests
to be conducted in systematic manner for LT Panel to ensure the
healthiness and performance of the LT Panel
2.0 Scope
This procedure covers the Pre commissioning test for LT Panel as for the
following
1. CRM Test for Circuit Breaker
2. IR Test for Circuit Breaker
3. Timer Test for Circuit Breaker
4. CRM Test for Bus Bar
5. IR Test for Bus Bar
6. CT Test
7. PT Test
3.0 Responsibility Unit Head / Regional managers:
Unit heads / Regional managers have overall responsibility for health
and safety management and role includes:
1. Planning and scheduling of activities with a view to execute the
project
2. Identify significant health and safety and eliminate or minimize
them
3. Maintaining all legal and statutory requirement
4. Assist the safety team to conduct the safety training and audit at
sites
5. Ensure all safety rules and regulations are followed at work sites
Site Engineers:
Site engineers are responsible for all aspects of health and safety on site
and are accountable to the Unit head / Regional manager. Their roles
include:
1. Report any issue affecting health and safety issues at the work sites to
the regional manager / unit head / safety team
2. Coordinate with end customer / client for the taking work permit and
returning work permit
3. Communicating the work content / hazard involved to working group
through the medium of Toolbox meeting before commencement of work
every day
4. Initiating proactive measures to minimize / eliminate accidents
5. Reporting in detail in the event of incident
6. Ensure effective use of appropriate PPE
7. Ensure the quality of job at all times without any compromise on safety
8. “Stop Work” in the event of any serious safety violation
Safety Manger / Regional Safety Engineers:

Safety manger / Regional safety engineers are responsible for

providing health and safety advice and guidance to their Unit head/
Regional manager, site engineers and their roles include:

1. Ensuring implementation of all instruction and procedures based

on the occupational health and safety
2. Communicating all safety rules, regulations and practices to all
site engineers / regional manager/ unit head
3. Follow up for the closure of audit non conformances and help
regional mangers / unit head to take corrective action and
preventive action
4. Report and investigate all the incidents / Near misses to the top
management
5. Create awareness amongst site engineers / regional managers
and also organize the regular training program.
6. Ensure that Tool box talk meetings are in being conducted daily at
site and the workers are aware of all the hazards at the work site
7. Ensure adequate PPE’s and safety equipment as are required are
available at sites and are being used at site appropriately
8. Reporting of any issues affecting the health and safety at the work
site to the unit head / Regional managers
9. Ensure basic first aid facilities are available at sites
10. Ensure that no unsafe act is performed at any site
11. Ensuring that any unsafe condition observed at site is eradicated
at the earliest
12. Issuing of safety challans in the event of any safety violations.
4.0 Working Activity and descriptions
4.1 Pre-Testing Checks
1. Check out the working condition of ELCB(30 mA)
2. Check the insulation of power cable for equipment
3. Ensure proper earthing and rubber mats available at the work
location.
4. Calibrated Testing equipment should be used and calibration
reports available with engineers for the same
5. Check out the insulates hand tools available with the technician
6. Ensure the Healthiness of the test leads (Check for any insulation
Damages)
7. Ensure appropriate PPE’s available at sites
4.2 Resources – Tools and Equipment Required
For CRM Test:
a. CRM kit
b. Connecting cables
c. Insulated Hand tools
For Insulation Resistance measurement Test (IR Test):
d. Test Leads
e. 500 V, 5000 V Insulation Tester
f. Insulated Hand Tools
For Timing Measurement Test
g. Timer Kit
h. Testing leads
i. Insulated Hand Tools
Winding resistance test
 Multimeter with leads
 Coil Resistance measurement
4.3 Operational Sequence of work(Test Procedure)
4.3.1 Contact Resistance Measurement Test (Pole to
Pole):
1. Take the work permit from the client
2. Ensure zero energy in the Bus Bar
3. Keep the Breaker in closed condition
4. Connect the earth from CRM kit to earth plate or earth pit
5. Connect the CRM kit Current and Voltage leads across the Breaker
contact R & R’
6. Connect the CRM kit in A.C supply extension board with ELCB
rated with 30 mA
7. Inject the rated current to the Circuit Breaker
8. Note down the contact resistance value from the CRM kit
9. Repeat the above test for another phases (Y & Y’) & (B & B’)
10. Switch off the power supply to the CRM Kit and disconnect them
 DO’s DON’TS
1. Breaker should be in closed 1. Don’t change the connection
position. sequence (i.e., V+, C+ should
2. Voltage leads should be be connected to R or Y or B &
connected inside the Current V-, C- should be connected to
leads. R’ or Y’ or B’ ).
3. While doing this test, no 2. Don’t change the supply
external cables should be configuration (i.e., voltage
connected. should be applied outside the
4. Proper grounding should be current leads).
done for the kit. 3. Contacts should not have any
dust during this test.
 IR TEST (BREAKER OPEN CONDITION)
1. Keep the Circuit Breaker in open position
2. Connect the IR kit across the RØ Breaker contact (R
& R’)
3. Select the required voltage range in IR kit
4. Switch ON the IR kit and press the test button take
down the reading
5. Repeat the above steps for the other phases (YØ &
BØ)
6. Discharge the voltage from the Circuit Breaker with
respect to earth.
IR TEST BETWEEN PHASE TO EARTH (BREAKER
CLOSED CONDITION)
1. Keep the Circuit Breaker in closed position
2. Connect the IR kit Positive lead with RØ Breaker
contact
3. Connect the IR kit Negative lead with earth
4. Select the required voltage range in IR kit
5. Switch ON the IR kit and press the test button take
down the reading
6. Repeat the above steps for the other phases (YØ & BØ)
7. Discharge the voltage from the Circuit Breaker with
respect to earth.
 DO’S DON’TS
1. Remove all external wires from 1. Don’t touch any cables and the
the CB contacts. kit when it is in running
2. Check the calibration due of condition.
the test equipment 2. Don’t touch any bushing while
3. Ensure zero resistance when doing the tests
line and earth are shorted and 3. Don’t connect any transmission
switched on to know the zero line cables to the contacts.
value for the proper working of 4. Don’t test with damaged cables
kit. and improper clips
4. Keep some distance while 5. Don’t work in wet (rainy)
doing the test. conditions
5. After Insulation resistance test 6. Don’t lose your concentration
completion, note down the while testing.
values and discharge the CT
terminals and remove the test
cables
6. Ambient temperature must be
noted.
4.3.2 Timing Test for circuit Breaker:
1. Keep the Breaker in closed condition
2. Connect the earth from Timer kit to earth plate or earth pit
3. Connect the Timer kit feedback cables R and R’ leads across the
RØ Breaker contact
4. Connect the Timer kit feedback cables Y and Y’ leads across the
YØ Breaker contact
5. Connect the Timer kit feedback cables B and B’ leads across the
BØ Breaker contact
6. Connect the Timer kit in A.C supply extension board with ELCB
rated with 30 mA
7. Give The open command and note down the value from the
timer kit
8. Give the close command and note the value from the timer Kit
9. Give the close/open command and note the value from the timer
kit
10. Switch off the power supply to the Timer Kit and disconnect
them
 DO’s DON’TS
1. Charge the spring motor 1. Don’t supply improper voltage
manually or electrically to close to the tripping and closing coils
the CB and to measure the (i.e., for 110V coil, 110V should
time. be applied).
2. While doing this test, no 2. Don’t give the supply with
external cables should be fluctuations.
connected. 3. Don’t remove the power pack
3. Proper grounding should be cables without discharging.
done for the kit.
4. Check the three phase contacts’
switching times are in the
specified limit and the same.
4.3.3 Contact Resistance Measurement (CRM) Test – Bus Bar
1. Take the work permit from the client
2. Ensure zero energy in the Bus Bar
3. Disconnect Bus bar from the transformer
4. Connect the earth from CRM kit to earth plate or earth pit
5. Connect the CRM kit voltage leads to across the(R-Phase) Bus Bar
joint
6. Connect the CRM kit current leads to across the(R-Phase) Bus Bar
Joint, at the same time Voltage leads should be connected inside the
current leads
7. Ensure that all the connections are connected properly
8. Connect the CRM kit in A.C supply extension board with ELCB rated
with 30 mA
9. Apply the rated current to the Bus bar
10. Note down the resistance value from the CRM kit
11. Repeat the above procedures for remaining (YØ & BØ)Phases for
CRM Test
12. Switch off the supply to the CRM Kit and disconnect the connections
 DO’s DON’TS

1. Ensure the bus bar is in the 1. Don’t change the connection

zero energy condition sequence (i.e., V+, C+ should
2. Voltage leads should be be connected to R or Y or B &
connected inside the Current V-, C- should be connected to
leads. R’ or Y’ or B’ ).
3. While doing this test, no 2. Don’t change the supply
external cables should be configuration (i.e., voltage
connected in the bus bar. should be applied outside the
4. Proper grounding should be current leads).
done for the kit. 3. Contacts should not have any
5. Check the tightness for the bus dust during this test.
bar joints
4.3.4 IR TEST BETWEEN PHASE TO EARTH (BUS
BAR):
1. Check the Bus Bar tightness and panel earthing
2. Connect the IR kit Positive lead with RØ Bus Bar
3. Then connect the IR kit Negative lead with earth
4. Select the required voltage range in IR kit
5. Switch “ON” the IR kit and press the test button take
down the reading
6. Switch “OFF” the IR kit
7. Discharge the potential from the bus bar with
respect to earth  Repeat the above steps for the
other Bus bar phases (YØ & BØ)
IR TEST BETWEEN PHASE TO PHASE (BUS BAR):
1. Connect the IR Kit across the RØ-YØ Bus Bar \
2. Select the required voltage range in IR kit
3. Switch “ON” the IR kit and press the test button take
down the reading
4. Switch “OFF” the IR kit
5. Discharge the potential from the Bus bar with
respect to earth
6. Repeat the above steps for the other Bus bar phases
(YØ-BØ) &( BØ-RØ)
 Do’s Don’ts

1. Personal Protective equipment 1. Unauthorized persons should

(PPE) should be used while not enter the testing premises.
testing 2. Avoid contact with energized
2. All the testing equipment must electrical circuits
be connected to the proper 3. Do not use the twisted testing
earth line cables
3. Ensure all the connections are 4. Never bypass fuses and circuit
in tight after testing breakers.
4. Ensure the external wires are 5. Don’t use the joint cables while
removed from isolator testing.
5. Before doing testing, discharge 6. Avoid testing during rainy
the Isolator terminals. season.
6. Test equipment's to ensure 7. Do not make connection
zero energy state before changes while testing
beginning the work
7. Discharge the Bus bar after
each test
4.3.5 Insulation Resistance (IR) Test for CT
Primary to Earth:
1. Connect the Earth lead of the IR kit to the earth Terminal
2. Connect HV lead of the IR kit to either P1 or P2 of the current
Transformer
3. Switch “ON” the IR kit and Select the required voltage range in IR
kit
4. press the Test button take down the readings
5. Switch “OFF” the IR kit
Primary to Secondary:
6. Connect HV lead of the IR kit to either P1 or P2 of the current
Transformer
7. Connect Earth lead of the IR kit to either S1 or S2 of the current
Transformer
8. Switch “ON” the IR kit and Select the required voltage range in IR kit
9. press the Test button take down the readings
10. Switch “OFF” the IR kit
Secondary to Earth:
1. Connect Earth lead of the IR kit to the earth terminal
2. Connect HV lead of the IR kit to either S1 or S2 of the current
Transformer
3. Switch “ON” the IR kit and Select the required voltage range in
IR kit
4. press the Test button take down the readings
5. Switch “OFF” the IR kit
Between Secondary Cores:
6. Connect HV lead of the IR kit to either S1 or S2 of the current
Transformer
7. Connect Earth lead of the IR kit to either S1 or S2 of the other
core of the current Transformer
8. Switch “ON” the IR kit and Select the required voltage range in
IR kit
9. press the Test button take down the readings
10. Switch “OFF” the IR kit
11. Discharge the voltage from the CT with respect to earth.
 DO’S DON’TS

1. Check all the CT secondary wires are 1. Don’t touch any cables and the kit
isolated when it is in running condition.
2. Check the calibration due of the test 2. Don’t touch any bushing while
equipment doing the tests
3. Breaker should be in open condition 3. Don’t keep the breaker in service
and in test position. and on position
4. Ensure zero resistance when line 4. Don’t test with damaged cables and
and earth are shorted and switched improper clips
on to know the zero value for the 5. Don’t work in wet (rainy) conditions
proper working of kit. 6. Don’t lose your concentration while
5. Keep some distance while doing the testing.
test.
6. After Insulation resistance test
completion, note down the values
and discharge the CT terminals and
remove the test cables
7. Ambient temperature must be
noted.
 4.3.6 Polarity test for CT:
1. Connect the secondary S1 terminal to galvanometer positive terminal
and S2 to the negative terminal
2. Touch the battery positive terminal to P1 in and negative terminal to
the P2 terminal at the CT primary winding Terminals
3. Check the deflection in the galvanometer
4. It must be in clock-wise direction
DO’S DONT’S
1. Check the connections as per the 1. Don’t use low batteries for testing
diagram. 2. Don’t apply the charge continuously
2. Check the CT secondary cable (apply single pulse).
continuity from CT secondary to CT
terminal block.
3. Check whether the battery is
charged or not
4. Verify the galvanometer in good
condition
4.3.7 Ratio test for CT

1. Connect the variac and loading transformer

2. Connect the loading transformer across the primary
terminals(P1,P2)
3. Connect the variac in A.C supply extension board
With ELCB rated with 30mA

4. Inject the current across the primary terminals.

Short Secondary
5. Note down the corresponding secondary current at
various cores.
6. Switch off the supply to the primary injection kit
 DO’S DONT’S
1. Check the current leakage testers 1. Don’t leave any CT secondary
are calibrated terminals in open condition during
2. Check the input voltage levels for the test.
avoid voltage variation, fluctuations 2. Multiple earthing should not in the
3. Connect the welding cables with full CT secondary circuits
tightness in the loading transformer 3. No loose connections should be in
and CT primary terminals. the CT secondary circuits.
4. 80% of the rated current should be 4. Don’t leave the spare core in open
applied in the CT primary and condition
measure the secondary current
values.
5. Measure the CT secondary current
in meters and relays end points.
6. Single point earthing should be
taken in the CT secondary circuits.
7. Make the variac slowly to Zero
position and remove the cables.
4.3.8 Winding resistance test for CT
1. Connect the multimeter leads to the CT secondary
winding Terminals
2. Note down the winding resistance value
3. Repeat the above procedure for remaining cores
4.3.9 Continuity test for CT
4. Connect the multimeter leads to the CT secondary
winding Terminals
5. Observe the beep sound in multimeter
6. Repeat the above procedure for remaining cores
4.3.10 Knee point test for CT:
1. Connect the variac to the step-up transformer
2. Connect the step-up transformer output to the CT
secondary terminal
3. Inject the rated voltage to the CT
4. Measure the leakage current in that core using
leakage current tester with different voltages
5. Repeat same procedure to all other core if applicable
 DO’S DONT’S
1. Do the Magnetizing curve test 1. Don’t apply the voltage above
for PS class only. the limit Or else the CT will be
2. Keep the CT primary in open saturated.
3. Apply voltage in the CT 2. Don’t apply more voltage in CT
secondary coils only. secondary terminals.
4. Isolate the CT secondary wires. 3. Don’t touch the primary and
5. Do the test for protection cores secondary terminals while
only. doing the test
6. Measure the knee point voltage 4. Don’t take more time to
and exciting current. conduct the test
5. Don’t short the primary and the
secondary terminals during this
test
4.3.11 Insulation Resistance (IR) Test for PT:
1. Connect the IR kit earth lead with earth and
connect Positive lead with CVT primary side
2. Connect the positive lead to primary and earth lead
to secondary each core Connect the positive lead to
core and earth lead to earth
3. Connect the positive lead to any core and earth lead
to another core if applicable
4. Select the required voltage range in IR kit and apply
the voltage to the CVT
5. Note the IR values from IR kit
6. Discharge the voltage from the CVT with respect to
earth.
 DO’S DON’TS
1. Remove the VT primary earth 1. Don’t touch any cables and the kit
2. Check all the VT primary and when it is in running condition.
secondary wires are isolated 2. Don’t remove the cables without
3. Check the calibration due of the test discharging.
equipment 3. Don’t test with damaged cables and
4. Ensure zero resistance when line improper clips
and earth are shorted and 4. Don’t work in wet (rainy) conditions
switched on to know the zero 5. Don’t lose your concentration while
value for the proper working of kit. testing.
5. Keep some distance while doing
the test.
6. After Insulation resistance test
completion, note down the values
and discharge the VT terminals
and remove the test cables
7. Ambient temperature must be
noted.
4.3.12 Polarity test for PT:
1. Connect the primary P1 terminal to galvanometer
positive terminal and P2 to the negative terminal
2. Touch the battery positive terminal to S1 in and
negative terminal to the S2 terminal at the CVT
secondary winding Terminals
3. Check the deflection in the galvanometer
4. It must be in clock-wise direction
 DO’S DONT’S
1. Check the connections as per 1. Don’t use low batteries for
the diagram. testing
2. Check the VT secondary cable 2. Don’t apply the charge
continuity from VT secondary continuously (apply single pulse)
to VT terminal block.
3. Check whether the battery is
charged or not
4. Verify the galvanometer in good
condition
4.3.13 Ratio test for PT:
1. Connect the variac and step-up transformer
2. Connect the step-up transformer across the primary and earth
3. Connect the variac in A.C supply extension board with ELCB rated
with 30 mA
4. Inject the voltage across the primary terminals.
5. Note down the corresponding secondary voltage at various cores.
6. Switch off the supply to the primary injection kit

DO’S DONT’S

1. Apply the voltage in the primary 1. Don’t apply voltage across the
terminals only secondary terminal
2. Secondary side should be kept
open
4.3.14 Winding resistance test for PT:
1. Connect the multimeter leads to the CVT secondary winding
Terminals
2. Note down the winding resistance value
3. Repeat the above procedure for remaining cores

DO’S DON’Ts
1. Measure with calibrated 1. Measure the VT winding resistance
multimeters for individual cores
2. Note the ambient temperature 2. Primary winding resistance should
3. Remove the secondary terminals not be measured (Only the
to isolate the VT secondary)
4. Clean the secondary terminals 3. Loose connections should be
and measure the resistance avoided in the VT secondary
terminals.
4. Don’t measure the terminals with
dust in VT secondary terminals
4.3.15 Continuity test for PT:
1. Connect the multimeter leads to the CVT secondary
winding Terminals
2. Observe the beep sound in multimeter
3. Repeat the above procedure for remaining cores
 Do’s Don’ts
1. Personal Protective equipment 1. Unauthorized persons should not
(PPE) should be used while testing enter the testing premises.
2. Ensure the zero energy condition 2. Don’t change the kit probe in on
3. All the testing equipment must be condition. Switch off the kit after
connected to the proper earth line one each test
4. Ensure the all connections are in 3. Avoid contact with energized
tight after testing electrical circuits
5. Ensure all the supply is dead 4. Do not use the twisted testing
6. Before doing testing, discharge the cables
respective terminals 5. Never bypass fuses and circuit
7. Test equipment's to ensure zero breakers.
energy state before beginning the 6. Don’t use the joint cables while
work testing.
7. Avoid testing during rainy season.
8. Do not make connection changes
while testing
4.4 Control Measures
1. OCP for LT Panel is available with testing engineers
2. Ensure PTW system in place for the particular Panel
3. Ensure all supply to the equipment is dead
4. Unauthorized persons should not be allowed to
enter Testing area
5. Above 2mtr height Use proper plat form or ladder
for height work and wear safety belt
6. Barricade the testing area with warning tape
7. Proper supervision, conduct job specific toolbox
meeting and barricading the entire area
8. Calibrated equipment shall be used
 9. Insulated hand tools shall be used
10. Avoid joints for power cable and supply has to be
taken via ELCB
11. Avoid Lone working
12. Use appropriate insulated hand gloves
5.0 Final Checks & Restoration of work area after
completion of work:
1. Disconnect the temporary supply and remove the
barricading tapes
2. Ensure no loose materials / tools are kept in and
around the area
3. Leave the place by keeping it tidy and clean