Procedure Field Inspection and

Testing Electrical Equipment

Procedure

Field Inspection and Testing

Electrical Equipment

Document

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 Procedure Field Inspection and
Testing Electrical Equipment

Table of Contents

Section Title Page

1.0 PURPOSE 2
2.0 CODE, STANDARD AND SPECIFICATION 2

3.0 SAFETY PROCEDURE 2

3.1 General Procedures 2
3.2 Electrical Equipment 2

4.0 INSPECTION AND TESTS 4

4.1 Purpose 4
4.2 Transformer 4
4.3 Switchgear and MCC 5
4.4 Electric Motors 6
4.5 Cables 7
4.6 Grounding System 7
4.7 Lighting Installation 7
4.8 Electrical Monitoring System 8
4.9 UPS / Battery Charger and Batteries 8
4.10 Diesel Engine Generator 9
4.11 Distribution Panel 9
4.12 Telecommunication System 9
4.13 Cathodic Protection System 10
4.14 Heat Tracing System 10
4.15 Miscellaneous 10
5.0 TEST METHOD 10
5.1 Insulation Resistance Test 10
5.2 High Voltage Test 11
5.3 Grounding Resistance Test 12
5.4 Grounding Continuity Test 12
5.5 Electrical Continuity Test 13
5.6 Contact Resistance Measurement 13
5.7 Power Transformer Polarity Test 13
5.8 Dielectric Strength Test 14
5.9 Current Transformer Test 14
5.10 Voltage Transformer Test 16
5.11 Interlock and Control Test 16
5.12 Protective Relay Test 16
5.13 Dielectric Absorption Test 17
5.14 Lighting Circuit Test 17
5.15 Electrical Distribution System Phase Rotation Check & Polarity Test 17
5.16 Running Test of Motor Uncoupled 18

6.0 ACCEPTANCE CRITERIA 18

1.0 PURPOSE

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 Procedure Field Inspection and
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This specification covers the procedures for field inspection and pre-commissioning of
electrical equipment and installations for Betara Complex Development Project.

2.0 CODE, STANDARD AND SPECIFICATION

The requirements contained in the latest editions of the following publications shall form a part
of this specification in the manner and to the extent specified herein.

- Indonesian Law
- Statutory Regulation
- American National Standard Institute (ANSI)
- American Petroleum Institute (API)
- International Electro Technical Commission (IEC)
- National Electrical Manufacturers Association (NEMA)
- National Electrical Code (NEC) NFPA 70
- PCIs Specification:
- BCD03-01-00-46-CRT-001-1 (Electrical Design Criteria)
- BCD03-01-00-46-SPC-013-1 (Specification Electrical Installation)

3.0 SAFETY PROCEDURE

3.1 General Procedures

1. Whenever inspection and tests are to be performed on electrical facilities, safety

should be the primary consideration at all times. To assure the safety of testing and
construction personnel, assume that:

(1) Any underground circuit is energized until tests show otherwise or until it is
grounded.
(2) Wiring is incorrect.
(3) Motors are connected to run in reverse.
(4) Phases are different across a bus-tie breaker.
(5) Everything needs checking.

2. Safety assurance during the testing of electrical systems cannot be overemphasized.

Wherever possible, all power sources must be isolated by opening and withdrawing
the breakers. Tag all breakers and padlock switches if necessary.

3. Unauthorized personnel must be kept away from test work. Rope off the area if
necessary. Provide warning signs. Plan ahead and think before acting. One good
way to avoid trouble is to write down the sequence before proceeding with a complex
or hazardous inspection or test.

4. Use applicable personal protection equipment (PPE) when working on electrical

equipment at any rated voltage.

3.2 Electrical Equipment

Here are mostly electrical equipments that we should take a concern to the safety since
certain test equipment can cause painful, if not lethal, shocks. However, it does not mean
we are not care to the other electrical equipment. The same safety procedures should be
followed.

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1. Transformers

a. Remember that certain test equipment such as megger and dielectric test sets can
cause painful, if not lethal, shocks. Be careful when working with transformers; low
voltages applied to the secondary windings can produce lethal voltages at the
primary terminals.

b. Remember that open-circuit secondary windings of current transformers can

produce extremely high voltages if their primaries are excited.

c. All secondary of current transformers should be short-circuited whenever their

loads are removed. For example, the current transformer should be short-circuited
when the ammeter is removed.

2. Switchgear and MCC

a. When working on any one circuit, be sure to positively identify the specific source
breaker(s) and then lock it open and tag it. In the case of draw-out type gear,
remove the breaker from its operating position. Make sure that personnel working
on the equipment are familiar with the test procedures. Make sure they observe
that the breaker is locked open.

b. Serious accidents may result due to improper switchgear operation. If switchgear

cannot be mounted in a rack, or switched on, it must not be forced.

c. It should also be remembered that secondary- selective substations allow electrical

power to be maintained at all plant loads, while individual system elements are de-
energized for inspections or tests.

3. Cables

a. Establish that the circuit is dead by testing it with a high voltage detector (glow-
stick), or in the case of low voltage use a voltage tester.

b. Make sure that the glow-stick, voltmeter, or voltage tester is in working order, by
checking it against a live cable or test device both before and after the circuit check.

c. In addition to these tests, the source circuit breaker should be opened and tagged.
Only after these precautions have been taken, the testing and checking of circuits
can be started.

d. When a long cable is impressed with voltage and a megger is used during tests, the
cable can still give a painful kick after the source is removed. Before allowing
personnel to work on the cable, the cable must be discharged by connecting an
insulated wire to earth.

4. Motors

a. Before any work is done on a motor, ensure that the motor controller has been
disconnected and tagged out. If possible, the motor feeder should be connected to
earth.

b. If it is necessary to remove a motor for repair, always remember to reconnect the

earth to the motor frame when reinstalling.

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4.0 INSPECTION AND TESTS

4.1 Purpose

The inspection and tests described in this procedure shall be carried out at the
appropriate time both during and after the installation or erection of the electrical facilities.
At the beginning of the electrical inspection and tests, the check sheets (Appendix l) shall
be filled in by the inspection engineer.

4.2 Transformer

The following general items shall be checked, inspected, and tested. Detail requirements
for inspection and testing should refer to the check sheet, appendix-1. Check & inspection
result, general information of transformers shall be filled in this check sheet.

4.2.1 Two-Winding Transformer (13.8/0.48kV)

Visual and Mechanical Inspection
1. The rating on the nameplate same with drawing and specification
2. The design meets the area classification where the transformer is installed.
3. The bushing seals are satisfactory.
4. The oil level for main tank is correct and there is no leakage.
5. The valves and pipe plugs are correct and tight.
6. The cables and connections are correct and firm.
7. The cable glands are tight.
8. The cable gland mounting plate is suitable for magnetic flux.
9. The terminal box seals are satisfactory.
10. The bolting and gaskets are tight and satisfactory.
11. The dehydrator of the breather is good.
12. The pressure relief devices are correctly adjusted.
13. Check the continuity of the tap setting switch.
14. The bolting, clamping, etc. of the neutral connection is complete and firm.
15. Check the continuity of the equipment grounding connection (tank and
marshalling kiosk should be connected to earth).
16. The polarity of the terminals is correct.

Electrical Inspection Test

1. Measure the insulation resistance of high and low voltage winding
2. Perform a high voltage test of the winding.
3. Measure the dielectric strength of the insulation oil.
4. Perform turns-ratio test at all tap positions.
5. For transformer with OLTC (On Load Tap Changer), perform manual operation
through all tap position, driving motor rotation (Rise and Lower Position, set at
centre axe before energizing), Upper and lower limit switch.
6. Alarm, tripped, control circuit, and auxiliary circuit.

4.2.2 Two-Winding Transformer (480/380-220V)

For two winding transformer 480/380-220V the same procedure as two-winding
transformer 13.8/0.48kV should be performed.

4.2.3 Three-Winding Transformer (13.8/4.16/0.48kV and 13.8/0.48/0.48kV)

For three-winding transformer the same procedure as two winding transformer
should be performed.
4.3 Switchgear and MCC

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The following general items shall be checked, inspected, and tested. Detail requirements
for inspection and testing should refer to the check sheet, appendix-1. Check & inspection
result, general information of switchgear and MCC shall be filled in this check sheet.
1. 13.8kV and 4.16kV Switchgear and MCC

Visual and Mechanical Inspection

1. The rating on the nameplate and the switchboard layout is correct.
2. No unauthorized modifications have been performed.
3. The board assembly, bolting, and levelling are satisfactory.
4. The bus-bar connections and supports, control bus bars, and neutral bar
connections are complete and tight.
5. Contact resistance readings shall be taken for field assembled and complete
bus bar.
6. The grounding bars and connections inside the board and equipment are
complete and tight.
7. The safety features are satisfactory.
8. The type and rating of the fuses in use are correct. The gage ring rating of the
plug cartridge fuse bases are correct.
9. The type and rating of the circuit breakers are correct. The current setting and
tripping are correct.
10. The contacts of the draw-out mechanisms are correctly aligned.
11. The cable end bells (compounded type), glands, clamping, and termination are
in good condition.
12. Test the anti-condensation heaters.
13. The circuit wiring is correct. Including conformity with wiring diagram, correct
and sure connection to instrument and protective relays terminal, and the
identifications of the conductor. The relays and measuring instruments are
checked and tested. The rating and range are checked in accordance with
setting data if the ratings of current and potential transformers are adequate. All
blocking materials are removed. Adjust the relays and devices to the correct
duty point per setting data.
14. The indicating and signalling lamps or devices operate correctly.
15. The phase rotation and polarity of the electrical distribution system are correct.
16. The accessories and special tools are correct.

Electrical Inspection Test

1. Perform insulation resistance test
2. Perform ratio and polarity test on all current and voltage transformer
3. Perform power frequency voltage test on main circuit
4. Dielectric test on aux. and control circuit
5. Perform interlock and control-wiring test consist in checking the proper
operation of all the electrical and electromechanical circuit, simulating the
various working conditions of switchgear as closely as possible.

2. 0.48kV Switchgear and MCC

Visual and Mechanical Inspection

1. The rating on the nameplate and the switchboard layout is correct.

2. No unauthorized modifications have been performed.
3. Holding down arrangement and seat alignment correct.
4. Ground bar and grounding correct and tight
5. Phase identification is correct.
6. Instrument, indication lamps and interlocks correct.
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7. MCCB, Contactor, Fuses, Etc. correctly sized and identified as per Single Line
Diagram.
8. Padlocking facilities correct.
9. Ammeter and current transformer correctly installed.
10. Check internal for cleanliness.
11. Check manual operation of selector switch, MCB, push button, etc.
12. Incoming cables correctly installed, terminated and supported.
13. Unused cable entry sealed.
14. All internal cabling and wiring neat, correct and undamaged.
15. Heater correctly installed.
16. The relays and measuring instruments are checked and tested. The rating and
range are checked in accordance with setting data if the ratings of current and
potential transformers are adequate. All blocking materials are removed. Adjust
the relays and devices to the correct duty point per setting data

Electrical Inspection Test

1. Perform dielectric withstand / dry insulation test.

2. Perform insulation resistance test.
3. Perform test of auxiliary and functionality. These functional tests consist of
checking the proper operation of all the electrical and electromechanical circuit,
simulating the various working conditions of switchgear as closely as possible.

4.4 Electric Motors

The following general items shall be checked, inspected, and tested. Detail requirements
for inspection and testing should refer to the check sheet, appendix-1. Check & inspection
result, general information of electric motor shall be filled in this check sheet.

Visual and Mechanical Inspection

1. The rating on the nameplate is correct.

2. The design meets the area classification.
3. The shaft-blocking device is removed for transport.
4. The coupling alignment and rotor endplay are satisfactory.
5. Rotate the motor by hand.
6. The bearings, grease packing, grade and quality of grease, oil level, and oil rings are in
good condition.
7. The bolting and weatherproofing of the terminal box are complete and tight. The
terminal connections are correct and tight.
8. Test the anti-condensation heater.
9. The cable end bells and glands are completed and tightened.
10. The equipment grounding is completed and tightened.
11. The components of the cooling system are in good condition.
12. The push-button station is correctly installed.
13. The direction of rotation is correct.

Electrical Inspection Test

1. Perform insulation resistance test.

2. Verify that resistance temperature detector (RTD) circuits, if applicable, conform to
drawings.
3. Verify that the motor space heater is functional.
4. Run the motor uncoupled and check the bearings for overheating.
5. Measure the voltage, amperage, and vibration during the uncoupled run.
4.5 Cables

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The following general items shall be checked, inspected, and tested. Detail requirements
for inspection and testing should refer to the check sheet, appendix-1. Check & inspection
result, general information of cables shall be filled in this check sheet.

Visual and Mechanical Inspection

1. The cable trench is clean and free from any foreign objects.
2. The size and installation are in accordance with the approved drawings.
3. The cable tray is correctly and rigidly installed.
4. The circuit indication and terminal numbering are correct and firm.
5. The cable end bells, oil or compound levels are satisfactory and there is no leakage.
6. The cable end seals are complete and tight.
7. The cable glands are complete and tight.
8. The cable is protected against mechanical damage.
9. The underground cable joints are complete and meet the specifications.
10. The grounding connections are completed.
11. The cable terminations and connections are correct and tight.
12. The cable route markers are correct.

Electrical Inspection Test

1. Measure the insulation resistance.

2. High-voltage test on cables (those rated at and above 4.16 kV)
3. Check the electrical continuity and cross connection of the conductors for parallel
feeders.

4.6 Grounding System

The following general items shall be checked, inspected, and tested. Detail requirements
for inspection and testing should refer to the check sheet, appendix-1. Check & inspection
result, general information of grounding system shall be filled in this check sheet.

Visual and Mechanical Inspection

1. The grounding joints are complete and tight. The underground joints should be spot-
checked before they are backfill.
2. The size of the cables and installation comply with the approved drawings.
3. The installation of the electrodes is satisfactory.
4. Check the protective measures that have been taken against mechanical damage to
the system.

Electrical Inspection Test

1. Measure the grounding resistance of each electrode.

2. Check the grounding continuity of the grounding system.
3. Measure the grounding resistance of the grounding system.

4.7 Lighting System

The following general items shall be checked, inspected, and tested. Detail requirements
for inspection and testing should refer to the check sheet, appendix-1. Check & inspection
result, general information of lighting system shall be filled in this check sheet.

Visual and Mechanical Inspection

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1. The enclosure for area classification.

2. The numbers and location of the equipment are correct.
3. The circuit numbers and load of the distribution panel are correct.
4. The switch ratings and the fuse ratings are correct.
5. The weatherproofing of the cable glands is satisfactory.
6. The feeder cable size is correct.
7. The equipment grounding is complete and tight.
8. The operation and setting of the time switches, photoelectric cells, magnetic control
switches, etc. are satisfactory.
9. The lighting circuit connection is correct for circuit numbering and identification.

Electrical Inspection Test

1. Check the insulation resistance of each circuit.

2. Measure the illumination level.
3. Measure the voltage and phase at each socket.

4.8 Electrical Monitoring System (EMS)

The following general items shall be checked, inspected, and tested. Detail requirements
for inspection and testing should refer to the check sheet (Hold), appendix-1. Check &
inspection result, general information of electrical monitoring system shall be filled in this
check sheet.

Visual and Mechanical Inspection

1. Check name plate and there is no damage and loss material / component as per
vendor drawing.
2. Check component of system are correctly installed in the location.
3. Check availability of power supply

Electrical Inspection Test

1. Check system function and performance
2. Detail item to be tested in accordance with vendor document for testing.

4.9 UPS / Battery Charger and Batteries

The following general items shall be checked, inspected, and tested. Detail requirements
for inspection and testing should refer to the check sheet, appendix-1. Check & inspection
result, general information of UPS / Battery Charger and Batteries shall be filled in this
check sheet.

Visual and Mechanical Inspection

1. The rating on the nameplate of the charger is correct.

2. The battery rating, voltage, and ampere-hours are correct.
3. The connected loads agree with the approved drawings.
4. The level of liquid in each cell is within the limit.
5. The protective devices for the battery charger, i.e. fuses, relay etc., are correct.
6. The cable connections are correct and tight.
7. The equipment grounding is complete.
8. The batteries are completely charged or voltage/cell within the limit

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Electrical Inspection Test

1. Verify correct AC input voltage

2. Verify charger output voltage regulation from no load to full load
3. Measure AC input current
4. Verify instrumentation and alarms.

4.10Diesel Engine Generator

The following general items shall be checked, inspected, and tested. Detail requirements
for inspection and testing should refer to the check sheet, appendix-1. Check & inspection
result, general information of Diesel Engine Generator shall be filled in this check sheet.

Visual and Mechanical Inspection

1. The rating on the nameplate is correct.
2. The board assembly, bolting, and levelling are satisfactory.
3. The equipment grounding is complete.
4. The interlock and control are correct.
5. The phase rotation and polarity are correct.
6. Measure the insulation resistance.
7. Operation of the emergency power system equipment is satisfactory according with
manufacturers manuals.

Electrical Inspection Test

1. Measure the insulation resistance
2. Calculate polarization index
3. Test protective relay device
4. Conduct performance test in accordance with the specification. Detail item to be
tested refer to vendor document for testing.

4.11 Distribution Panel (e.g. Lighting panel, Control Panel, etc)

The following general items shall be checked, inspected, and tested. Detail requirements
for inspection and testing should refer to the check sheet, appendix-1. Check & inspection
result, general information of Distribution Panel shall be filled in this check sheet.

Visual and Mechanical Inspection

1. The rating on the nameplate is correct.
2. No damage and loss material / component as per drawing.
3. The equipment grounding is complete.

Electrical Inspection Test

1. Measure the insulation resistance
2. Adjust the relay and devices, if applicable, to the correct duty point per the setting
data.

4.12Telecommunication Systems

The inspection and testing for the communication systems shall be carried out in
accordance with the manufacturers recommended procedures and manuals.

4.13Cathodic Protection System

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The installation of cathodic protection system shall be checked and tested in accordance
with the manufacturers recommended procedures and manuals.

4.14Heat Tracing System

The installation of Heat Tracing System shall be checked and tested in accordance with
the manufacturers recommended procedures and manuals.

4.15Miscellaneous
For the miscellaneous electrical equipment or installation that not specified on the above,
the detail inspection and testing should refer to the check sheet on appendix-1.

5.0 TEST METHODS

5.1 Insulation Resistance Test

1. The Insulation resistance shall be measured using an appropriate insulation tester

as shown in Figures 1 and 2.
Confirm that conductors, windings and metal frame other than tested are securely
grounded i.e. conductor screen, steel armour of cable, transformer frame, motor
frame, etc.

Figure - 1
MEASURING RESISTANCE BETWEEN CONDUCTOR AND EARTH

2. Voltages supplied by megger shall be as:

1. Circuits rated above 600V : 2500V
2. Circuits rated at 600V and below : 500V
3. Telephone system : 250V

3. Voltage shall be applied until the pointer remains steady. Insulation resistance of
HV motor shall be measured after 15 sec., 30 sec., 1 min., 10 min. to calculated the
polarization index.

4. Charged energy shall be discharged after a reading.

5. Complete an insulation resistance test data sheet for every test.

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Figure - 2
MEASURING RESISTANCE BETWEEN CONDUCTORS

5.2 High Voltage Test (This test shall be carried out by Vendor recommendation).

This test shall be applied to switchgear, and cables.

The switchgear shall be tested to disconnect from testing circuit of the inside equipments
i.e. instrument voltage transformer, lightning arrester, surge absorber, and neutral
grounding register.

1. Measure the insulation resistance.

2. DC test equipment can be used in case of cables with big capacitance.
3. When the insulation resistance measured is satisfactory, connect the high-voltage test
equipment as shown in Figure 3.
4. Increase the voltage gradually to the required value.
5. Read the voltage and leakage current when the voltage steadies at the required
voltage.
6. Maintain the voltage for the time.
7. After timing up, decrease the voltage gradually to ZERO, cut off voltage and then
discharge any residual voltage.
8. Measure the insulation resistance as before.
9. Complete a high-voltage test data sheet for every test.

Figure - 3
HIGH VOLTAGE TEST

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5.3 Grounding Resistant Test

1. Grounding resistance shall be measured using an earth resistance tester, as shown in

Figure 4.

2. Grounding resistance shall be measured at each electrode.

3. Complete an grounding resistance test data sheet for every test.

Figure - 4
MEASURING GROUNDING RESISTANCE

5.4 Grounding Continuity Test

Before backfilling the grounding wiring, make a visual check of the underground
connections. Measure the electrical continuity by use of a circuit tester, according to the
following sequence:

1. Apply the circuit tester to all of the grounding electrodes, as shown in Figure 5 (1st
step).
2. Apply the circuit tester between grounding electrode and the nearest connected
equipment, as shown in Figure 5 (2nd step).
3. Apply the circuit tester between adjacent connected equipment, as shown in Figure 5
(3rd step).
4. Using the same procedure, check the resistance between all connected equipment and
grounding electrodes.
5. Complete an grounding continuity test data sheet for every test.

Figure - 5
CHECKING GROUNDING CONTINUITY

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5.5 Electrical Continuity Test

Measure electrical continuity by use of a circuit tester, according to the following

procedure: If metal sheath is not provided, one of core to be used instead of metal sheath.
1. Bond the conductor and metal sheath at one end of the cable with a wire clip, as shown
in Figure 6.
2. Apply the circuit tester between the same conductor and metal sheath, as shown in the
figure.
3. Using the same procedure, check the electrical continuity between all of the
conductors.
4. Complete a cable test data sheet for every test.

Figure - 6
CHECKING ELECTRICAL CONTINUITY

5.6 Contact Resistance Measurement

1. The test shall be applied to all bus bars bolted connection that are assembled at site
and complete bus bar.
2. Resistance of the connected parts shall be measured by low- resistance test set.

5.7 Power Transformer Polarity Test (Vector Test)

The test shall be applied for power transformers in accordance with the following
procedure:

1. Connect primary terminal "C" and secondary terminal "C", as shown in Figure 7.
2. Connect a temporary test power source to the primary side of the transformer and
switch it on.

Figure - 7
TESTING POLARITY OF POWER TRANSFORMER

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3. Measure the voltage between each terminal as follows:

Aa V
Ab V
Ba V
Bb V

5.8 Dielectric Strength Test

This test shall be applied to electrical insulation oil in accordance with applicable standard.
Two samples shall be taken from the insulating oil. Each sample shall be tested
according to the following procedure:

1. Make the connections as shown in Figure 8.

Figure - 8
DIELECTRIC STRENGTH TEST

The testing vessel and electrodes shall be cleaned, dried, and then rinsed with a little
of the insulating oil that is to be tested.

2. Take a sample of the insulating oil from the transformer, etc.

Do not uncork the sample until its temperature equals the ambient temperature of the
test area.
3. Maintain the ambient temperature during the test at 15-35 deg. C.
4. Fill the testing vessel with the sample and wait approximately 3 minutes, until the oil
bubbles have disappeared.
5. Increase the test voltage by 3kV per second until a breakdown occurs.
6. Repeat the procedure five times while the sample is in the testing vessel and record the
results.
7. Complete an insulation oil test data sheet for every test.
The breakdown voltage of the insulating oil shall be determined by calculating the
arithmetical average of the five breakdown voltages recorded (the first breakdown
voltages recorded are not used in the calculation).

5.9 Current Transformer Test

1. Polarity Check (Kick Test)

Each current transformer shall be individually tested to verify that the primary and
secondary polarity markings are correct. A low voltage battery is used, via a single-
pole push-button switch to energize the primary winding.
When polarity are as shown below, on closing the push-button, the d.c. ammeter
should give a positive flick and on opening, a negative flick.

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Figure - 9
TEST CIRCUIT

2. Ratio Test (Primary Injection Test)

a. This check is usually carried out during the primary injection test. The circuit shall
be as shown in figure 10.
b. Current is passed through the primary conductors and is measured on the test set
ammeter (A1).
c. The secondary current is measured on the ammeter (A2) and the ratio of the
reading on A1 to that on A2 should approximate to the ratio marked on the
switchgear to be applied with Primary Injection Test.
d. Connect injection leads on the primary circuit of CT using primary junction device.
e. Check the secondary terminals by a temporary wire.
f. Confirm other CT secondary loop is complete, if not, short the CT secondary
terminals by a temporary wire.
g. Inject the current as same value of CT primary (as possible) and confirm the CT
ratio measuring the CTs secondary current.
h. Record the test results and complete the test report.

Figure 10
MEASURE CT RATIO (PRIMARY INJECTION)

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5.10Voltage Transformer Test

1. Polarity Check (Kick Test)

a. The voltage transformer polarity can be checked with the test described for the
current transformers.
b. Care must be taken to connect the battery supply to the primary winding, with the
polarity ammeter connected to the secondary winding.

5.11 Interlocks and Control Test

With the switchgear control power energized, each circuit breaker position shall be
checked, and then checked again in the operating position, according to the following
procedure:

1. Close the circuit breaker and trip it from the control switch and remote control panel.
2. Mechanically trip each electrically operated circuit breaker.
3. Test the lockout device in the closing circuit for proper operation by simulating
conditions in which a lockout would occur.
4. Complete a sequence test data sheet for every test.

5.12Protective Relay Test

1. Protective relay shall be tested in accordance with relay Manufacturers manual.

2. Input current and/or voltage of the set tap value of protective relay and confirm the
relay to pick-up.
3. Primary injection test shall be applied where necessary i.e. for bus-zone protection.
To understand the test procedure, refer to the following sample of the protective relay
test.

5.12.1 Inverse - Time Relay Calibration and Test

1. Using a relay tester with a third harmonic filter, set the relay in accordance with
the Relay Setting List.
2. Connect one relay unit to the relay tester.
3. The minimum pickup current input to the relay and the calibration of the relay
shall be tested as follows:
a. Rotate the armature disk by hand to the midpoint of its full travel. Mark a
red target line between the disk and a stationary part.
b. Increase the input current to the set tap value and monitor the armature
disk to determine when it starts to rotate.
c. If the disk does not start rotating at the set tap current, increase the current
slightly.
d. Check that when the disk stops, the red lines coincide. If not, adjust the
tension in the spring accordingly.
4. Operational Test.
a. Set the input current at 300% of the set tap value.
b. Set the cycle counter and input the 300% current through the relay coil.
Measure the duration of operation.
c. Repeat the procedure with a 600% tap current.
5. Complete the Relay Setting List for every item of test data.

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5.12.2 Instantaneous Relay Test

1. Set the relay in accordance with the Relay Setting List.

2. Set the input current at the set tap value and confirm that there is current
between the relay and pickup.
3. Complete the Relay Setting List for every item of test data.

5.13Dielectric Absorption Test

1. The procedure for this test shall be the same as that for the insulation resistance test.

2. For motors and generators rated below 1,100 kW, take readings at 30 and 60 second
intervals to determine the dielectric absorption ratio.

3. For motors and generators of l,l00kW and larger, take readings at one minute and 10
minute intervals to determine the polarization index.

4. Calculate the ratios from the following formulas:

1. Dielectric absorption ratio = 60 second reading
30 second reading

2. Polarization index = 10 minute reading

1 minute reading

5. Depending on the type of test, complete a dielectric absorption ratio data sheet or a
polarization index data sheet, for every test.

5.14Lighting Circuit Test

After satisfactory insulation resistance values have been obtained, the lighting circuit shall
be tested according to the following procedure:
1. Turn off all the branch circuit switches in the lighting panel.
2. Energize the distribution circuit up to the lighting panel.

3. Check the voltage between all phases, and between each phase and the neutral
conductor, at the buses to the lighting panel.

4. Turn on one branch circuit switch and check that the illuminated lighting is in
accordance with the lighting drawing.

5. Check all the branch circuits one by one, using the same procedure.

6. Complete a lighting circuit test data sheet and an illumination level data sheet for every
test.

5.15Electrical Distribution System Phase Rotation Check and Polarity Test

1. Before energizing the electrical panel by permanent power, phase rotation and polarity
shall be checked by using the temporary low voltage power.

2. Complete a phase rotation and polarity test data sheet for every test.

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5.16Running Test of Motor Uncoupled

All tests and inspections of the motor, such as visual inspections, insulation resistance
measurements, and sequence checks, shall be completed before making a motor no-
load run test. Other checks to be performed are as follows:
1. Check that the motor can be easily turned over by hand.

2. Ensure that the coupling is correctly aligned and the motor is fixed to its foundation.

3. Using the starter, rotate each motor to check that it rotates in the direction indicated
by the rotation arrow. If not, reverse the connection leads at the starter, or at the
motor if necessary.
Run the motor uncoupled until the motor tempera-ture reaches the saturation point.

4. Check the vibration, noise, and bearing tempera-ture. Use a thermometer to check
and record the bearing temperature. Do not try and determine the temperature by
feeling the bearing housing. Defective bearings will be discovered by their being
noisy or by their overheating.

5. Complete a motor uncoupled run test data sheet for every test.
Note: Motors with special construction or fractional capacity shall be individually
discussed and decided before the test.

6.0 ACCEPTANCE CRITERIA

This section defines the acceptance criteria of site test, which shall be used for evaluation of
measured values. The acceptance value of each test item shall be referred to a list as follows:

No. Description of Test Test Equipment & Tolls Test Voltage & Min Acceptance
Duration Value

1 Grounding Resistance
Measurement

Grounding Rod Ground. Resistance Tester Below 25 Ohm

Lightning Earth Rod Ground. Resistance Tester Below 10 Ohm
Ground. System Network Ground. Resistance Tester Below 1 Ohm
Instrument Grounding Ground. Resistance Tester

2 Power Transformer

2.1 Insulation Resistance Test

a) Control Circuit 500V Megger 1M Ohm
b) LV below 1KV 1000V Megger 5M Ohm
c) HV above 1KV 2500V Megger 50M Ohm

2.2 Insulation Oil Test AC Dielectric Test set 30KV

2.3 Continuity Test

a) Primary Winding Circuit Tester
b) Secondary Winding Circuit Tester
c) Neutral Grounding Circuit Tester
d) Equipment Grounding Circuit Tester

2.4 Polarity Test

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No. Description of Test Test Equipment & Tolls Test Voltage & Min Acceptance
Duration Value

3 Switchgear & Controlgear

and Panelboard

3.1 Insulation Resistance Test

a) Control Circuit 500V Megger 1M Ohm
b) LV below 1KV 500V/1000V Megger 5M Ohm
c) HV above 1KV 2500V Megger 50M Ohm

3.2 Continuity Test

a) Equipment earthing Circuit Tester / Buzzer
b) Power circuit Circuit Tester / Buzzer
c) Control circuit Circuit Tester / Buzzer

3.3 Conductivity Test Contact Resistance

Measurement Tester (Ductor
Tester)

3.4 HV Test (Apply HV above 1 AC Dielectric Test Set 4.16KV x 1.5 (10
KV) mnt)
* 4.16KV Circuit Tester & Battery

3.5 Polarity Test Relay Test Set

supplied by Vendor
3.6 Protective Relay Test
(by Vendor SV)

3.7 Interlocks and Control /

Sequence Check Rotation Meter

3.8 Phase Rotation Check Primary Injection Test Set

Ammeter
3.9 Ratio Test

4 Cables

4.1 Insulation Resistance Test

a) Control Cable 1000V Megger 10M Ohm
b) LV Cable below 1KV 1000V Megger 10M Ohm
c) HV Cable above 1KV 2500V Megger 100M Ohm

4.2 HV Test (Apply HV above 1

KV)
From 1KV up to 15KV

4.3 Continuity Test Circuit Tester / Buzzer

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 Procedure Field Inspection and
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No. Description of Test Test Equipment & Tolls Test Voltage & Min Acceptance
Duration Value

5 Electrical Motor

5.1 Insulation Resistance Test

a) HV Motor 2500V Megger 50M Ohm
b) LV Motor 500V/1000V Megger 5M Ohm
c) Space Heater 500V Megger 1M Ohm

5.2 Vibration Test (Uncoupled) Vibration Meter

5.3 Running Current (Uncoupled) Clamp Multi Meter

5.4 Temperature Rise

a) Bearing Temp. Indicator
b) Frame Temp. Indicator

6 Lighting

6.1 Insulation Resistance Test 500V Megger 1M Ohm

6.2 Circuit Continuity Circuit Tester / Buzzer

6.3 Circuit Voltage Check Circuit Tester

6.4 Function Test

6.5 Illumination Level Check Lux Meter

7 Power & Convenience Outlets

7.1 Insulation Resistance Test 500V Megger 5M Ohm

7.2 Circuit Continuity Circuit Tester / Buzzer

7.3 Polarity Test Circuit Tester

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