MV & LV SWGR, METHOD STATEMENT

Method Statement for
MV & LV SWGR & MCC

SAT
Contract Job No: SC-PGB-ETPC-0024
JIGCC POWER BLOCK PROJECT (PACKAGE 4)
Document No: SES-PGB-ET-MS-0039
Contract No: SEPCO Electric Power Construction Corporation Date:
REV:1 Date: 15-May-2017
6600033163 (IK)
MV & LV SWGR & MCC SAT
OMAR MOHAMMED GUAN

1 15-May-2017 IFA LIU ZHIGANG
ABDELLAH HAMED WENSHENG
Checked by Reviewed by Approved by

Rev. Date Status Written by
（ PCD&HSE） (QA/QCD) （chief Engr.）
SEPCO Electric Power Construction Corporation

MV & LV SWGR & MCC
SAT
6600033163 (IK)
Revision Information
Section
Rev. No. Description of Main Changes
0 ALL ALL
1 ALL ALL

MV & LV SWGR & MCC
SAT
Contract No: SEPCO Electric Power Construction Corporation DATE:
Date:
6600033163 (IK)
TABLE OF CONTENTS
1- PURPOSE
2- SCOPE
3- DEFINITION
4- RESPONSIBILITIES
5- DETAILS OF TEST PROCEDURE & EQUIPMENT
6- HSE REQUIREMENT
7- TEST RESULTS

MV & LV SWGR & MCC
SAT
DATE:
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1- PURPOSE
 The purpose of this Document is to define the MV / LV SWGR & MCC SAT general sequence of
events for the ARAMCO Company.
2- SCOPE
 This Document is to provide a controlled, systematic and standardized approach to 13.8KV
/4.16KV/0.48KV Switchgear and MCCs. This method statement defines the method and process to
be adopted, to ensure that activities regarding the work are done in accordance with Project Quality
Plan, Site Safety Manual, SEPCO & ARAMCO Company standards.
3- DEFINITION
 COMPANY: ARAMCO COMPANY
 Project: JIGCC POWER BLOCK PROJECT (PACKAGE 4)
 Contractor: SEPCO
 Sub-contractor: ALFANAR
4- RESPONSIBILITIES
4-1- Electrical supervisor shall be responsible for the following:

 Ensures that the construction work is carried out as per above project Specifications and Standards.
 Controls of materials and workers at site.
 Notifies to Electrical Manager the completion of the preparation of site for inspection.
 Preparation of site for inspection.
 Initiates RFI for material receiving inspection.
 Checks that construction work is ready for inspection and prepares RFI.
 Assistance of inspection and testing when required at site.
 Checks PPE in accordance with site condition.
 Checks the equipment and materials which are required for work.

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4-2- Electrical manager shall be responsible for the following:

 Preparation, Revision and Implementation of installation Method Statement
 Establishment and execution of termination schedule and sequence.
 Review of work procedure and approval.
 Control of Document and Drawings.
 To check Schedule and Materials.
4-3- QC inspector shall be responsible for the following:

 Conducting surveillance and inspection duties for material receiving, all electrical & instrument works
and ensure efficient recording and reporting of results as required.
 Review all relevant documents and certificates.
 Raise CAR for any discrepancies and shall receive all internal requests for inspection from Electrical
& Instrument Department.
 Facilitate invitation to company representatives that require their presence.
 Control quality of whole work process, arranging the field inspection and reviewing required
inspection documents
 Work shall be controlled in accordance with Saudi Aramco standards and specifications, SAIC and
IFC drawings and accordingly prepare/submit RFI‟s.
4-4- QA/QC manager shall be responsible for the following:
 Informs to company representatives of the official inspection request when their presence is required
to carry out inspection.
 Ensures that inspections are performed in a timely manner and recorded as per specifications and
standard detailed drawings, as per ITP and/or inspection records requirements.
 Submission of inspection and test record to company for approval.

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4-5- Testing and commissioning Project manager shall be responsible for the
following:
 Preparation and Revision of work schedule.
 Checks the availability of testing equipment‟s which are required for work.
 Review all testing documents and certificates.
 Control Al-fanar testing and commissioning team according to site condition.
 Representative of testing in all meetings.
 Preparation of daily activity report and the overall progress for testing.
 Review of work procedure and site test format.
 Submission of test format and drawings at the end of project.
 Submission of NCR for any defect material to Contractor.
4-6- Testing and commissioning engineer shall be responsible for the following:
 Test for the whole device that included in SEPCO contract.
 Deliver daily activity and progress report to Al-fanar project manager.
 Deliver test format after being signed to Al-fanar project manager.
 Write NCR for any defect materials and deliver it to al-fanar project manager.
4-7- Vendor shall be responsible for the following:

 Switchgear & MCC testing shall be carried out under vendor supervision.
 Switchgear & MCC Energization shall be done after vendor confirmation.

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5- DETAILS OF TEST PROCEDURE & EQUIPMENT:
5-1- 13.8KV & 4.16kV MV SWGR:

5-1-1- Current transformer (CT) test procedure:
a- Test objective:
- This test is considered as one of the main test, it‟s aimed to test:
 Current transformer ratio.

 Current transformer polarity.
 Burden of current transformer.
 Knee point of current transformer.
 Current transformer winding resistance.
 Magnetization curve of current transformer.
 Megger test (insulation test).
b- Required Equipment:
 Current transformer (CT) analyzer.

 Megger.
c- Mechanical check and visual inspection:
 Check tightness of all connection.

 Check ferrules.
d- Current transformer analyzer connection:
 CT analyzer has 4 leads, two should be connected to primary side which contains primary side of
CT and other two should be connected to secondary side of CT which you want to check its ratio.
 After connecting CT analyzer through laptop and using CT analyzer software, test can be started
and result can be printed out for CT ratio, CT polarity, CT burden, CT knee point & CT winding
resistance.
 This result should be compared with current transformer factory test and be sure that result within
acceptable tolerance.
 To measure the burden: Inject 1 ampere on secondary side of CT, and using multi-meter you can
measure voltage calculate burden by multiply voltage and current and compare it with CT burden.

MV & LV SWGR & MCC
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 To test insulation: Using megger by 1 kilo volt injection for 1 minute, this test should be done.
between primary to secondary and secondary to secondary But for Primary to ground 5 kilo volt
injection for 1 minute.
 See figure.1 which shows CT analyzer connection for CT TEST.
Figure.1 CT analyzer connection
5-1-2- Voltage transformer (VT) test procedure:
a- Test objective:
- This test also is considered as one of the main test and its purpose is to test:
 Voltage transformer ratio.

 Voltage transformer polarity.
 Voltage transformer winding resistance.
 Megger test (insulation).
b- Required equipment:
 CPC100.
 Multi-meter (Fluke).

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c- Mechanical checked and visual inspection:
 Check tightness of connection.

 Check ferrules.
d- Voltage transformer test connection:
 Connect two leads from CPC device to primary side of voltage transformer and other two lead of
CPC with secondary side of VT, then press start from VT page of CPC.
 Using CPC with same connection but from different page, you can measure winding resistance.
 To check the loop burden: inject the rated secondary voltage and measure the current. Burden will
be the injected voltage * measured current and then compare it with VT burden.
 Insulation test: Using megger to test insulation by 1 kilo volt injection for 1 minute, this test should be
done between primary to secondary and secondary to ground, But for primary to ground 5 kilo volt
injection for 1 minute.
 See figure.2 which shows connection of VT Test.
Figure.2 show CPC100 connection to test

5-1-3- Timing test for Circuit breaker and megger test:
a- Test objective:
 This test aimed to test the closing/opening time for circuit breaker and to make sure that there is no
pole discrepancies between poles (red, yellow and blue) and CB closing/opening time within
acceptable range according to factory test result.
 EGIL breaker analyzer.

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 B10E (used as DC supply and can resist high burden equipment).
 Megger.
 High potential test kit.
c- Timing and megger test connection:
 Connect B10 as external DC supply for closing (in case of measurement of closing time) circuit or
opening (in case of measurement of opening time) circuit, for switching device that should be tested.
 Connect breaker analyzer in the circuit of opening or closing using dry contact from device to give
command of open or close to the switching device and take contact from this device to work as
feedback signal from the device while being closed or opened to measure CB closing/opening time.
 After opening or closing, the breaker analyzer will print the result which should be compared with
factory test result to be sure that result within acceptable range.
 To start megger test: inject 1 KV for 1 minutes, when breaker open inject between the same pole
(red-red, yellow-yellow and blue-blue) and when breaker close inject between pole and ground,
between pole to pole.
d- High potential AC test:
 Applying high potential AC voltage when the breaker in service position line to line and line to ground
(see number 5-1-4 point C).
5-1-4- High potential and contact resistance test for bus bar with circuit breaker:
a- Test objective:
 For contact Resistance, this test is aimed to measure the resistance of bus bar and for circuit
breaker after being installed in the site to avoid high resistance which may be results from welding or
installing in the site.
 For high potential this test is aimed to measure and test the withstand of the insulations and isolators
against the high voltage without break down.
 Check anti pumping relay operation.
 Vacuum bottle integrity test.
 Measurement of moving contact travel.
 For contact resistance test the applied Current shall be 100 amperes.
 High potential test to be perform individual on circuit breaker outside the switchgear cubicle.
 Circuit breaker operation counter must be recorded in the test form before and after starting the test.
 Functional test (Manual charging, Manual opening and closing, Manual rack-in/rack-out and Remote
rack-in/rack-out, limit switches, auxiliary contacts a & b. TOC, MOC, trip coil and close coil)

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 Micro-ohm meter Contact resistance device.

c- High potential AC test:
 Insulation test by megger to test insulation by 5 kilo volt injection for 1 minute 3 phases line to line
and line to ground.
 Applying high potential AC voltage on the bus bar line to line and line to ground and the CB in
service position, protection relays are energized and the VTs are racked out.
 Applying high potential AC (higher voltage level than first applying time) voltage on the bus bar line
to line and line to ground and the CB in test position, protection relays are energized and the VTs are
racked out.
 Take the record of passing current in mille Amperes from the high potential test kit.
 Insulation test by megger to test insulation by 5 kilo volt injection for 1 minute 3 phases line to line
and line to ground.
 Compare the insulation test results to gathers before and after high potential test.
d- Contact resistance test connection
 Contact resistance device has 4 leads, two for current and others for voltage, it depend on current
injection on bus bar or circuit breaker then sense the voltage and calculate resistance by divide
voltage on current (ohm‟s law)
 Check the BB torqueing of all bolted and confirm the torque value as per factory inspection.
 Connect current leads between the device which you want to measure its resistance, connect
voltage leads on the same terminals of current then adjust 100A injection then hold your hand on
contact resistance pushbutton, after few second the result will be displayed.
 See figure.3 which shows connection of Contact Resistance Test.

MV & LV SWGR & MCC
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Figure.3 shows contact resistance equipment connection
5-1-5- High potential test for circuit breaker:
a- Test objective:
 This test aimed to test if bus bar will withstand its withstand voltage after being installed in the site or
it will breakdown and to check the vacuum bottle integrity, also to measure leakage current and
insulation between CB and ground
b- Testing equipment required:
 AC HI-voltage injection machine (100KV, 60HZ).

 Earthing Rod or Ground Discharge stick (coming with high pot tester)
 Megger 5KV DC Supply.
c- Mechanical and visual inspection:
 All safety rules should be taken into consideration

 breaker cleaning and house keeping
 Check all shipping devices removed.
 Inspect ground to switchgear ground bus.
 Ensure the adequate clearance (distance) between circuit test ends and to other Ground object and
other phases (not under the test) and also with other electrical equipment‟s to prevent flash over.
d- Test connection and test procedure

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 Test VCB withstand voltage: VCB should be close , inject voltage as per FAT value.
NOTE:
- When we conduct HIPOT Test for one phase, other remaining phases should be
connected to Ground.
- Use Ground discharge stick with high tension Electrical for discharge the voltage
from the system after each High potential Test.
 Test CB withstand voltage: VCB should be open , inject voltage as per FAT value.
 measure insulation after high voltage test with CBs close and open status then inject 5 KV for 1
minute then record the value and compare it with the value before high voltage test.
NOTE:
Use Ground discharge stick with high tension Electrical for discharge the voltage from the
system after each High potential Test
5-1-6- Miniature Circuit Breaker (MCB):
a- Test objective:
 This test aimed to test the trip time characteristic of MCB if it‟s within limits or no and check MCB
auxiliary contact if it is available.
 Sverker (used as current source).

 Multi-meter.
 Check tightness for all wires.

 Check ferrules.
 Check for physical damage or defect.
d- Test connection and procedure:
 Connect sverker (which used as current source) direct to MCB, check MCB type and its rated current
value.

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 Inject from sverker twice of its rated current and measure the trip time in which MCB will be tripped,
compare the measured trip time with its acceptable limit from MCB manual depending on its type.
 Auxiliary contact should be checked in both condition of MCB (open/close) and check that auxiliary
contact change its status from being open to close or vise, depending on its nature Normally open or
Normally close.
5-1-7- Auxiliary relay test:
a- Test objective:
 This test aimed to test relay‟s output contact, pick-up and drop off voltage, operating and resetting
time.
b- Required equipment :
 Sverker (used as Voltage source and used its voltmeter).

 Multi-meter [used as Ammeter].
 Miniature Circuit Breaker 2Pole (MCB).

 Check ferrules.
d- Test connection:
I. Check output contact:
 Our Auxiliary relay has several points, 2 used for Coil, before injecting any voltage on Auxiliary
relay's Coil, check contacts at its normal condition which mean Normally Open (NO) contact is being
opened and Normally Closed (NC) contact is being closed, Inject the desired control voltage of Aux.
coil (which is normally 125 volt DC), at which Aux. relay will pick up that‟s mean its contact will
change its position i.e NO contact will be closed and NC contact will be opened.
II. Pick-up and drop off current and voltage:
 Pick up voltage can be measured using voltmeter when the coil voltage is increased gradually from 0
volt, the Aux. relay will operate (i.e Contacts change its normal status No will be closed and vice
versa) at a certain voltage. This voltage is called pick-up voltage, Record the reading of voltmeter
and Ammeter which is pick-up voltage and current.

MV & LV SWGR & MCC
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 Drop-off voltage can be measured using voltmeter when the coil voltage on an operate relay is
decreased gradually, the relay will release (i.e its contact will return to its normal status) at a certain
voltage. This voltage is called drop-off voltage, Record the reading of Ammeter which is drop-off
current.
III. Operating and resetting time:
 Adjust voltage source at the coil operation voltage of Aux. relay (in our case 125 v DC), To get
operating time, adjust sverker at (on+time location) and switched MCB ON, To get resetting time,
readjust voltage source at 125 volt DC and switch MCB OFF.
IV. Burden test:
 Adjust voltage source (sverker) at 125 volt DC, select on position and make MCB ON.
 Record reading of Ammeter.
 Calculate burden by multiplying coil operated voltage and reading of Ammeter.
5-1-8- Ammeter and voltmeter test:

a- Test objective:
 This test is aimed to calibrate and adjust the reading of ammeter and voltmeter test.
 FREJA 300.
 Checked tightness of all connections.

 Checked ferrules.
 Inspection for physical damage or defects.
 Set the VT ratio (for voltmeter) and CT ratio (for ammeter).

 Inject different values (min. 3 values) of current (in case of ammeter) and voltage (in case of
voltmeter) and compare the injected values with reading values, calculate error in each reading and
check that its percentage error within the acceptable range.

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5-1-9- Current transformer loop:
a- Test objective:
 This test aimed to check all current transformer loop, starting from first panel and distributed in the
whole switchgear depending on scheme, check shorting facility in terminal block [if exist].
 FREJA (used as current injection).

 Multi-meter.
 Mini-clamp.

 Check ferrules for the whole looping.
 Check the single earth point.
d- Test connection
 Connect three phase current from FREJA to secondary side of current transformer, inject three
phase current by different values and use mini-clamp to measure current in each phase and follow
the loop until the last point
5-1-10- Voltage transformer loop:

a- Test objective:
 This test is aimed to check the whole loop of VT starting from first panel and distributed in the whole
substation depending on scheme (i.e. metering or protection purpose)
 FREJA.
 Multi-meter.
 Check all voltage transformer loops.
d- Test connection:

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 Connect FREJA which considered as voltage source to secondary side of VT, inject three phase
voltage with different values on each phase and then use multi-meter to measure the voltage on the
whole loop starting from first panel to different location depending on the function of each VT.
5-1-11- Lockout relay (86):
a- Test objective:
 This test aimed to test lockout relay which is like muscles of the body and responsible to trip circuit
breaker in case of trip order coming from protective relay
b- Testing Equipment Requirement:

 Fluke [used as Ammeter].
 Miniature Circuit Breaker 2Pole (2MCB).
 Check for physical damage or defects.

 Check tightness of all connections.
 Check ferrules.
d- Test connection and test procedure:
i. All Contacts check:
 Before injecting any voltage on relay's coil, check contacts at it normal condition which mean
normally open (NO) contact is being opened and normally closed (NC) contact is being closed and
check Red flag operation.
 Inject the desired control voltage of coil (which is in our case 125 volt DC), at which aux. relay will
pick up that‟s mean its contact will change its position i.e. NO contact will be closed and NC contact
will be opened check red flag must be not shown.
ii. Pick up and drop off currents and voltages:
volt, the relay will operate (i.e. contacts change its normal status should not be closed and red flag is

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shown and vice versa) at a certain voltage. This voltage is called pick-up voltage, Record the reading
of voltmeter and Ammeter which is pick-up voltage and current.
decreased gradually, the relay will release (i.e. its contact will return to its normal status) at a certain
voltage. This voltage is called drop-off voltage, Record the reading of ammeter which is drop-off
current.
iii. Operating time and resetting time:
 Adjust voltage source at coil operated voltage of relay (in our case 125 v DC).
 To get operating time, adjust sverker at (on+time location) and switch MCB ON.
 To get resetting time, readjust voltage source at 125 volt DC and switch MCB OFF.
iv. Burden test:
 Adjust voltage source (sverker) at 125 volt DC, select on position and make MCB ON
5-1-12- Lockout Supervision (74-86):
a- Test objective:
 This test aimed to test lockout supervision relay which is responsible to supervise DC on lockout is it
healthy or is there any lose or disconnect wires on it.


 Check ferrules.

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check Red flag must be shown.
 Pick up voltage can be measured using voltmeter when the coil voltage increased gradually from 0
of voltmeter and Ammeter which is the pick-up voltage and current.
 Drop-off voltage can be measured using voltmeter when the coil voltage on an operate relay
current.
 Adjust the voltage source at coil operated voltage of relay (in our case 125 v DC).
iv. Burden test:
5-1-13- DC Supervision Relay:
a- Test objective:
 This test aimed to test DC supervision relay which supervises the most important DC loop in the
panel (e.g. DC loop of relay binary input and relay output).

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 Check ferrules.
i. Check all contacts:
 Before injecting any voltage on relay's Coil, check contacts at its normal condition which mean
normally open (NO) contact is being opened and normally closed (NC) contacts is being closed and
check red flag operation.
 Inject the desired control voltage of coil (which is in our case 125 volt DC), at which Aux. relay will
pick up that‟s mean its contact will change its position in no contact will be closed and NC contact
will be opened and check Red flag operation.
volt, the relay will operate (i.e. contacts change its normal status (No) will be closed and red flag
shown and vice versa) at a certain voltage. This voltage is called pick-up voltage; record the reading
of voltmeter and Ammeter which is the pickup voltage and current.
 Drop-off voltage can be measured using voltmeter when the coil voltage on an operated relay is
voltage. This voltage is called drop-off voltage, record the reading of ammeter which is drop-off
current.
 To get operating time, adjust sverker at (on time location) and switched MCB ON.
 To get resetting time, re-adjust voltage source at 125 volt DC and switched MCB OFF.
iv. Burden test:

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5-1-14- Trip Circuit Supervision Relays (TCS):

a- Test objective:
 This test aimed to test trip circuit supervision which supervises the trip circuit and shows if it‟s
healthy or has any lose or disconnected wires in the trip circuit, in each panel there are two trip
circuit supervision, first one to supervise trip circuit one and the other to supervise trip circuit two.


i. Check all Contacts:
Normally Open (NO) contact is being opened and normally closed (NC) contact is being closed.
will be opened.
 Pick up voltage can be measured using voltmeter by increasing voltage gradually from 0 volt up to
the relay will be operated (i.e. Contacts change its normal status, NO contact should be closed and
vice versa) at a certain voltage. This voltage is called pick-up voltage, Record reading of V and A
which is pick-up voltage and current. Drop-off voltage can be measured using voltmeter when the
relay in an operate status and then decrease voltage gradually, the relay will release (i.e. its contact
will return to its normal status) at a certain voltage.

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This voltage is considered drop-off voltage, Record the reading of voltmeter and Ammeter which is
drop-off voltage and current.
iii. Resetting time:
 Adjust voltage source at relay rated voltage (in our case 125 v DC).
 To get resetting time, adjust the voltage source at 125 volt DC and switch MCB OFF.
iv. Burden test:
 Adjust voltage source (sverker) at 125 volt DC, select on position and make MCB ON Record
reading of Ammeter.
 Same pervious procedure for each coil.
 Connection Diagram of Trip Circuit Supervision.
5-1-15- Close Circuit Supervision Relays (CCS):

e- Test objective:
 This test aimed to test close circuit supervision which supervises the close circuit and shows if it‟s
healthy or has any lose or disconnected wires in the close circuit, in each panel there are two close
circuit supervision, first one to supervise close circuit one and the other to supervise close circuit two.
f- Testing Equipment Requirement:

g- Mechanical checked and visual inspection:

h- Test connection and test procedure:

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will be opened.
iv. Burden test:
reading of Ammeter.
 Connection Diagram of Close Circuit Supervision.
-

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5-1-16- Primary injection test:
a- Test objective:
 This test aimed to check that the selected ratio of current transformer is correct and current
transformer relay setting is OK and considered as back-up test of CT loop.
 Primary Injection Tester.

 Multi-meter.
 Mini-clamp.
 Power-clamp meter.
 Check that all current transformer terminal block is tightened and normalized.
d- Test connection:
 Connect Primary Injection Tester to inject current on bus bar including current transformer.
 Start injection of current, using power clamp we can measure the injected current to make sure that
injected current which appear on screen of primary injection tester is same as the actual injected
current, then using of mini-clamp, we can measure the current at each point of the loop and read the
primary current value on each relay.
5-1-17- Bus Bar Stability:
a- Test objective:
 This test aimed to check that the selected ratio of BB current transformer is correct and CT relay
setting is OK and considered as second back-up test of CT loop and polarity of BB CT is correct and
to check at normal condition the summation of current is zero.

 Multi-meter.
 Mini-clamp.

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 Check that all current transformer terminal block is normalize and wires is connected probably.
d- Test connection:
 Start sensitivity test: reverse the CT polarity from one side of CT only.
 Start current injection and use mini-clamp to measure the current at the end of loop, measure the
current after CT summation point it should be summation of the secondary side.
 Start stability test at normal condition.
 Start current injection and use mini-clamp to measure the current at the end point of each loop and
read the primary current value on each relay measure the current after ct summation point it should
be zero.
5-1-18- Medium voltage switchgear Function test:
a- Test objective:
 This test is considered as a major test or combined test for the whole work in switchgear panels and
finalizing phase for switchgear panels.
 No equipment used.
 Inspect for the whole panel if any missing or damage device which can be resulted from installation.
d- Test procedure:
 Segregation of DC loop inside panel, by switching on only one MCB and follow its loop and so on for
other DC MCB.
 Check the circuit of closing command for circuit breaker.
 Check the circuit of opening command for circuit breaker.
 Check Automatic transfer switch (ATS) logic and functionality.
 Check anti parallel scheme.
 Check mechanical interlock.

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 Check interlock of circuit breaker from close switch (CS) and bay control unit between CB and earth
switch.
 Check alarm signal from source up to relay.
 Check inter trip between upper voltage level CB and switchgear CB, between lower voltage levels
CB and switchgear CB.
 Confirm the relay logic.
 Check the CB functional like (travelling contact, manual charging, manual close & open, CB Rack in
& out ,CB counter operation before and after test also check the CB TOC, MOC, Trip coil and close
coil.
5-1-19- Protection relay (Main relay):
a- Test objective:
 This test aimed to test function of main relay according to approved final setting for each one, but
here we generally discussed main function which should be exist in most of approved final setting.
 FREJA 300.
 Multi-meter.
 Wires.

 Check case earth.
 Check indication and LEDs.
 Check test switch for correct operation either shorting CT if exist or isolation of binary inputs/outputs.
d- Burden test
 Adjust voltage source at 125 volt DC.

 Record reading of Ammeter in case of all binary output deactivated and in case of binary output
activation.
 Calculate burden in case of normal operation (all binary output deactivated) and abnormal operation
(in case of binary output activated) by multiplying voltage and reading of ammeter.
 Compare the result with existing burden exist in relay manual.
e- Test connection and test procedure:

MV & LV SWGR & MCC
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DATE:
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i. Binary input/output check:
 To test binary input: Apply rated binary input DC voltage on each input and verify the status of the
input through relay‟s software or from relay‟s LCD [if exist].
 To test binary output: Using relay‟s software you can force binary output to close for certain time and
using multi-meter you can measure binary output contact resistance it should be around zero which
indicates binary output being closed.
ii. Measurements
 Set CT ratio and VT ratio which used to the relay by studying the scheme.
 By using FREJA we inject secondary rated voltage and secondary rated current
 Record the primary value reading at relay‟s screen.
iii. High Impedance Differential Protection for Bus Bar circuit (87B)
 As per final setting of relay set (Numerical relay-Resistor-Metrosil) the resistor must be adjusted to
give the desired operating voltage at which the relay will operate.
 numerical relay setting the value of secondary current and the value of resistor is inserted for relay
then The relay calculate the actual voltage value by multiplying the value of secondary current and
the resistor then compare it with the setting voltage value.
- To test Pick up and drop off test:-
 Adjust the value of the series resistor as per final setting and measure its value.
 Inject current and gradually increase the value till relay operation.
 Measure the pickup current and voltage across the series resistor.
- To test Time:
 Take one normally open contact of the relay, adjust the sverker to (on time) and apply a voltage
more than the setting value.
iv. Transformer differential (87T):
 Transformer differential is a low impedance protection in which the current vector is measured as
amplitude and angle and the measured current from transformer sides summed together to calculate
the differential current, If the current value exceeds the setting value the relay generates a trip
command.

MV & LV SWGR & MCC
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 To test PICK UP & drop off test, Inject current and increase it's value gradually till relay operation,
measure the value of the injected current and calculate the differential and restrain current, Repeat
for each current transformer location, Decrease the current value gradually till relay drop off,
Measure the current and repeat for each current transformer location.
 To test time test: Assign a normally open contact from the relay as a differential protection trip; inject
a current more than the setting value, Measure the tripping time.
v. Instantaneous over-current (50)
 Pickup and drop off test: gradually increase secondary current to each phase separately in steps,
until the LED which you used to indicate instantaneous over-current to operate this is considered
pick-up value. The current must be reduced in the same manner until the LED reset and then this
considered as drop-off value.
 Limits: then calculate the error and compare the error value with acceptable tolerance error that exist
in manual of relay Timing test: set each phase separately to amount of current equal to 2*2Is, then
inject this value of current and measure the time taken to close binary output of the relay which
indicates that ins. Over-current trip.
in manual of relay.
vi. Instantaneous earth fault (50N):
until the LED which you used to indicate inst. Earth fault to operate this is considered pick-up value.
The current must be reduced in the same manner until the LED reset and then this considered as
drop-off value.
 LED reset and then this considered as drop-off value.
 Limits: then calculate the error and compare the error value with acceptable tolerance error that
exists in manual of relay.
 Timing test: set each phase separately to amount of current equal to 2*2Is, then inject this value of
current and measure the time taken to close binary output of the relay which indicates that inst. E.F.
in manual of relay.
vii.Time delayed earth fault (51N):

MV & LV SWGR & MCC
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drop-off value.
current and measure the time taken to close binary output of the relay which indicates that inst. Earth
fault.
 Limits: Limits: then calculate the error and compare the error value with acceptable tolerance error
that exist in manual of relay.
viii. Thermal overload:
 Inject single phase current greater than setting current in the relay for certain time and take binary
output from relay indicate thermal overload trip.
 After a time the binary output will be ON which indicate the thermal overload trip.
5-1-20- ATS and anti-parallel scheme Function Check:

a- Test Objective:
UP Stream
Incomer-1 Incomer-2
Bus Section
BUS-1 BUS-2
 The principle of operation for the ATS (Automatic Transfer Switch) is that Two Incomers are feeding
two busses divided through one Bus Section. In case of one incomer power supply lost (Incomer-1)
hence the corresponding bus bar become dead (Bus Bar under voltage) and the bus section circuit
breaker should close automatically to feed the load for the dead bus. When the incomer feeder be

MV & LV SWGR & MCC
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energized again the operator should block the ATS function by make it Manually and then choose
through one selector switch which circuit breaker should open after he closes the incomer-1 circuit
breaker hence he will give close command to the incomer-1 circuit breaker and after this incomer
becomes closed the selected circuit breaker (Incomer-2 or the Bus Section) will trip automatically.
b- Test Equipment:
 Freja300
c- Test procedure:
 Connect 3phase voltage to the relay to simulate the line and bus VT source and then inject 3phase
healthy voltage for both incomers (Incomer-1 & Incomer-2) through MCBs.
 Close both incomer-1 and incomer-2 and leave the bus section in the open position.
 Close the 4 MCBs that simulate Line-1, Bus-1, Line-2 and Bus-2 voltage to the relay.
 Make the selector switch of the ATS mode on Automatic.
 Open the MCBs that connect the Bus and Line voltage of the Bus-1 to the relay.
 The relay will wait for some time and then it will give open command for incomer-1.
 Then the relay will wait for some time more and give close command to the bus section.
 Now close the MCB of the Line-1 voltage (simulation to energize the incomer-1).
 Now the relay will check the synchronization between line-1 and line-2 voltages.
 Then make the selector switch of the ATS mode on Manual.
 Select either Incomer-2 or Bus Section (through the selector switch) which you need to open after
you close the incomer-1.
 Now give manual close command to the incomer-1 circuit breaker.
 If step no.9 achieved and the relay will enable the close command to incomer-1 circuit breaker.
 Then the relay will give an open command to the selected circuit breaker.
 Do the same steps for Incomer-2.
DESCRIPTION OF OPERATIONS:
The Main-Tie-Main transfer scheme proposed here provides manual, automatic transfer and
automatic retransfer breaker operations. All three breakers must be racked in except operations of
breakers at breaker test position described in Section 14
Automatic Transfer Ready and Automatic Transfer Enable

MV & LV SWGR & MCC
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Automatic transfer will occur, when one of the automatic transfer triggers comes, only when the
automatic transfer function is ready and enabled.
Automatic transfer function can only be enabled after all the following automatic transfer conditions are
met, which can be verified by observation of the TRF READY output of Aux16 of the all three relays are
closed.
The output will be turned on for each relay when the following conditions are all met.
For Incomer 1 main breaker relay,

•The “Incomer 1” setting is selected under the TRANSFER FUNCTION setpoint
•The transfer scheme is not blocked from the “Block Transfer” input
•Tie Breaker is racked-in
•Incomer 1 Breaker is racked-in and closed
•No transformer lockout 86T1 or source trip 86L1 is present
•No undervoltage is detected on any of the two sources
•No faults on the load side of the circuit breaker.
For incomer 2 main breaker relay,

•Bus Tie Breaker is racked-in and open
For tie breaker Relay,

•The “Bus Tie” setting is selected under the TRANSFER FUNCTION setpoint
•The transfer is not blocked from the “Block Transfer” input
•Incomer 1 breaker is racked-in and closed
•Incomer 2 breaker is racked-in and closed.

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Automatic Transfer Initiation
Automatic transfer is initiated when all of the following conditions are true:
• Automatic transfer function is ready and enabled.
• Affected main breaker is closed and racked in at the time when one of the automatic transfer triggers
comes from the associated incoming source.
• The other incoming source has healthy voltage and the main breaker for the other incoming source is
closed and racked in.
• The tie breaker is open and racked in.
And with any one of the automatic transfer triggers comes:
• The voltage on an incoming source, either three-phase voltage loss, or the phase(s) the actual line PT
connected to, on one of the incoming lines falls below the transfer initiate voltage threshold for a period
of time defined by a preset time delay setting and the loss of voltage is not caused by blocking
overcurrent element pick up for incoming line.
• (Optional) 86T or 86L on the main breaker relay trips
In addition to trip the transformer low side breaker, 86T should always trip the transformer high side
breaker also, this can be done by hard wiring or through additional GOOSE message communication to
the transformer high side relay .
Automatic Transfer Execution
When automatic transfer is initiated, the affected main breaker opens first and sends an automatic
transfer initiate signal to the other relays. The automatic transfer signal is sealed-in by the main breaker
logic until the automatic transfer process is finished, an automatic retransfer signal occurs or the
automatic transfer scheme is disabled. This prevents repeated attempts at a transfer process.
Upon receipt of the automatic transfer initiate signal, the tie breaker closes if all of the following is true:
• Incomer-1 is open and the voltage on Bus 1 below the Residual Bus Voltage setting; Or
Incomer-2 is open and the voltage on Bus 2 below the Residual Bus Voltage setting;
• Automatic transfer scheme is enabled.
• A predefined automatic transfer time delay has expired.
If an automatic trigger returns after the affected main breaker opens but before the tie breaker closed,
the tie breaker will not be closed. The result is the other main breaker with the healthy source remains

MV & LV SWGR & MCC
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closed, but the other two breakers are open. If this happens, operator needs to set the scheme back to
manual transfer mode and then close the currently opened tie breaker manually.
Simulation Method :
- Simulation of voltage by using Secondary Injection Kit FREJA300

MV & LV SWGR & MCC
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DATE:
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5-2- 480V LV SWGR:
a- Test objective:


 Megger.

 Check ferrules.
resistance.
measure voltage calculate burden by multiply voltage and current and compare it with CT burden.
 To test insulation: Using megger by 1 kilo volt injection for 1 minute, this test should be done
between primary to secondary, Primary to ground and secondary to secondary.

MV & LV SWGR & MCC
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a- Test objective:

 CPC100.

 Check ferrules.

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done between primary to secondary, primary to ground and secondary to ground.
 The vector group can be done for 3-phase VT only.
5-2-3- Trip Time test for Air Circuit Breaker (ACB) and megger test:
a- Test objective:
 This test aimed to test the trip time for circuit breaker in case of over current or short circuit and to be
sure that tripping time within acceptable range.
 Primary injection tester. (Or special test kit to test the CB)
 Megger.

MV & LV SWGR & MCC
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 To test trip time: there are three setting in each MCCB first setting is (long = „L‟), second is
(Short=‟S‟) and third is (Instantaneous=‟I‟) also (Ground fault=‟G‟).
 To test (L): adjust L on min. setting which is considered percentage from rated current, inject the
setting current using primary injection tester and measure the time to be tripped, compare the value
of tripping time with the value of setting time if its within acceptable tolerance or not.
 To test (S): adjust S on min. setting which is considered percentage from rated current, inject the
 To test (I): adjust I on min. setting which is considered percentage from rated current, inject the
setting current [if the value of injected current can be injected by tester as in some cases the min
value of (I) is equal to 10 and rated current is 500 A, so to test you should inject 5000 ampere which
isn‟t applicable] using primary injection tester and measure the time to be tripped, compare the value
 To test (G): adjust I on min. setting which is considered percentage from rated current, inject the
 To start megger test: this test is applicable for CB which rated current greater than 100 Amp. when
breaker open inject 1KV for 1 minutes, between the same pole (red-red, yellow-yellow and blue-blue)
and when breaker close inject 1 KV for 1 minutes between pole and ground, between pole to pole as
per SA-P-000.
 The secondary injection test can be done by special manufacturer test kit.
5-2-4- Contact resistance test for bus bar and circuit breaker:
a- Test objective:
 For high potential this test is aimed to measure and test withstand of the insulations and isolators
c- Contact resistance test connection

MV & LV SWGR & MCC
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voltage leads on the same terminals of current then adjust 100A injection then hold your hand on
contact resistance pushbutton, after few second the result will be displayed.
a- Test objective:

 Multi-meter.

 Check ferrules.

MV & LV SWGR & MCC
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value.
Normally close.
a- Test objective:
time.


 Check ferrules.
d- Test connection:
i- Check output contact:
coil (which is normally 125 volt DC), at which Aux. relay will pick up that‟s mean its contact will
ii- Pick-up and drop off current and voltage:

MV & LV SWGR & MCC
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Contract No: SEPCO Electric Power Construction Corporation
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current.
iii- Operating and resetting time:
 Adjust voltage source at the coil operation voltage of Aux. relay (in our case 125 v DC), To get
readjust voltage source at 125 volt DC and switch MCB OFF.
V. Burden test:
a- Test objective:
 FREJA 300.


MV & LV SWGR & MCC
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a- Test objective:

 Multi-meter.
 Mini-clamp.

d- Test connection
the loop until the last point.

a- Test objective:
 FREJA.
 Multi-meter.

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d- Test connection:
5-2-10- Lockout relay (86):
a- Test objective:
 This test aimed to test lockout relay which is like muscles of the body and responsible to trip circuit
breaker in case of trip order coming from protective relay


 Check ferrules.
check Red flag operation.

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of voltmeter and Ammeter which is pick-up voltage and current.
current.
iv. Burden test:
 Adjust voltage source (sverker) at 125 volt DC, select on position and make MCB ON
5-2-11- Lockout Supervision (74-86):
a- Test objective:
 This test aimed to test lockout supervision relay which is responsible to supervise DC on lockout is it
healthy or is there any lose or disconnect wires on it.


 Check ferrules.

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check Red flag must be shown.
 Pick up voltage can be measured using voltmeter when the coil voltage increased gradually from 0
of voltmeter and Ammeter which is the pick-up voltage and current.
 Drop-off voltage can be measured using voltmeter when the coil voltage on an operate relay
current.
 Adjust the voltage source at coil operated voltage of relay (in our case 125 v DC).
iv. Burden test:
5-2-12- DC Supervision Relay:

a- Test objective:
 This test aimed to test DC supervision relay which supervises the most important DC loop in the
panel (e.g. DC loop of relay binary input and relay output).

MV & LV SWGR & MCC
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 Check ferrules.
i. Check all contacts:
normally open (NO) contact is being opened and normally closed (NC) contacts is being closed and
check red flag operation.
pick up that‟s mean its contact will change its position i.eno contact will be closed and NC contact
will be opened and check Red flag operation.
volt, the relay will operate (i.e. contacts change its normal status (No) will be closed and red flag
shown and vice versa) at a certain voltage. This voltage is called pick-up voltage; record the reading
of voltmeter and Ammeter which is the pickup voltage and current.
 Drop-off voltage can be measured using voltmeter when the coil voltage on an operated relay is
voltage. This voltage is called drop-off voltage, record the reading of ammeter which is drop-off
current.
 To get operating time, adjust sverker at (on time location) and switched MCB ON.
 To get resetting time, re-adjust voltage source at 125 volt DC and switched MCB OFF.

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iv. Burden test:
5-2-13- Trip Circuit Supervision Relays (TCS):
a- Test objective:
 This test aimed to test trip circuit supervision which supervises the trip circuit and shows if it‟s
healthy or has any lose or disconnected wires in the trip circuit, in each panel there are two trip
circuit supervision, first one to supervise trip circuit one and the other to supervise trip circuit two.


will be opened.

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iv. Burden test:
reading of Ammeter.
 Connection Diagram of Trip Circuit Supervision.
5-2-14- Close Circuit Supervision Relays (CCS):

i- Test objective:
 This test aimed to test close circuit supervision which supervises the close circuit and shows if it‟s
healthy or has any lose or disconnected wires in the close circuit, in each panel there are two close
circuit supervision, first one to supervise close circuit one and the other to supervise close circuit two.
j- Testing Equipment Requirement:

k- Mechanical checked and visual inspection:

l- Test connection and test procedure:

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will be opened.
iv. Burden test:
reading of Ammeter.
 Connection Diagram of Close Circuit Supervision.
-
a- Test objective:

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 Multi-meter.
 Mini-clamp.
d- Test connection:
5-2-16- Low voltage switchgear Function test:
a- Test objective:
 This test is considered as a major test or combined test for the whole work in switchgear panels and
finalizing phase for switchgear panels.
d- Test procedure:
 Segregation of DC loop inside panel, by switching on only one MCB and follow its loop and so on for
other DC MCB.
 Check the circuit of closing command for circuit breaker.

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 Check the circuit of opening command for circuit breaker.
 Check Automatic transfer switch (ATS) logic and functionality.
 Check anti parallel scheme.
 Check anti pumping relay operation.
 Check interlock of circuit breaker from close switch (CS) and bay control unit between CB and earth
switch.
a- Test objective:
 FREJA 300.
 Multi-meter.
 Wires.

 Check bush buttons LEDs and Relay bush button.
d- Burden test
 Adjust voltage source at 125 volt DC.

activation.

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ii. Measurements
iii. Instantaneous earth fault (50N):
drop-off value.
in manual of relay.
iv. Time delayed earth fault (51N):
drop-OFF value.

MV & LV SWGR & MCC
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fault.
5-2-18- ATS and anti-parallel scheme Function Check:

a- Test Objective:
UP Stream
Incomer-1 Incomer-2
Bus Section
BUS-1 BUS-2
 The principle of operation for the ATS (Automatic Transfer Switch) is that Two Incomers are feeding
two busses divided through one Bus Section. In case of one incomer power supply lost (Incomer-1)
hence the corresponding bus bar become dead (Bus Bar under voltage) and the bus section circuit
breaker should close automatically to feed the load for the dead bus. When the incomer feeder be
energized again the operator should block the ATS function by make it Manually and then choose
through one selector switch which circuit breaker should open after he closes the incomer-1 circuit
breaker hence he will give close command to the incomer-1 circuit breaker and after this incomer
becomes closed the selected circuit breaker (Incomer-2 or the Bus Section) will trip automatically.
b- Test Equipment:
 Freja300

MV & LV SWGR & MCC
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6600033163 (IK)
c- Test procedure:
 Connect 3phase voltage to the relay to simulate the line and bus VT source and then inject 3phase
healthy voltage for both incomers (Incomer-1 & Incomer-2) through MCBs.
 Close both incomer-1 and incomer-2 and leave the bus section in the open position.
 Close the 4 MCBs that simulate Line-1, Bus-1, Line-2 and Bus-2 voltage to the relay.
 Make the selector switch of the ATS mode on Automatic.
 Open the MCBs that connect the Bus and Line voltage of the Bus-1 to the relay.
 The relay will wait for some time and then it will give open command for incomer-1.
 Then the relay will wait for some time more and give close command to the bus section.
 Now close the MCB of the Line-1 voltage (simulation to energize the incomer-1).
 Now the relay will check the synchronization between line-1 and line-2 voltages.
 Then make the selector switch of the ATS mode on Manual.
 Select either Incomer-2 or Bus Section (through the selector switch) which you need to open after
you close the incomer-1.
 Now give manual close command to the incomer-1 circuit breaker.
 If step no.9 achieved and the relay will enable the close command to incomer-1 circuit breaker.
 Then the relay will give an open command to the selected circuit breaker.
 Do the same steps for Incomer-2.
DESCRIPTION OF OPERATIONS:
The Main-Tie-Main transfer scheme proposed here provides manual, automatic transfer and
automatic retransfer breaker operations. All three breakers must be racked in except operations of
breakers at breaker test position described in Section 14
Automatic Transfer Ready and Automatic Transfer Enable
Automatic transfer will occur, when one of the automatic transfer triggers comes, only when the
automatic transfer function is ready and enabled.
Automatic transfer function can only be enabled after all the following automatic transfer conditions are
met, which can be verified by observation of the TRF READY output of Aux16 of the all three relays are
closed.
The output will be turned on for each relay when the following conditions are all met.

MV & LV SWGR & MCC
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For Incomer 1 main breaker relay,
•Tie Breaker is racked-in
For incomer 2 main breaker relay,

For tie breaker Relay,

•The “Bus Tie” setting is selected under the TRANSFER FUNCTION setpoint
•The transfer is not blocked from the “Block Transfer” input
•Incomer 1 breaker is racked-in and closed
•Incomer 2 breaker is racked-in and closed.
Automatic Transfer Initiation
Automatic transfer is initiated when all of the following conditions are true:
• Automatic transfer function is ready and enabled.
• Affected main breaker is closed and racked in at the time when one of the automatic transfer triggers
comes from the associated incoming source.
• The other incoming source has healthy voltage and the main breaker for the other incoming source is

MV & LV SWGR & MCC
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closed and racked in.
• The tie breaker is open and racked in.
And with any one of the automatic transfer triggers comes:
• The voltage on an incoming source, either three-phase voltage loss, or the phase(s) the actual line PT
connected to, on one of the incoming lines falls below the transfer initiate voltage threshold for a period
of time defined by a preset time delay setting and the loss of voltage is not caused by blocking
overcurrent element pick up for incoming line.
• (Optional) 86T or 86L on the main breaker relay trips
In addition to trip the transformer low side breaker, 86T should always trip the transformer high side
breaker also, this can be done by hard wiring or through additional GOOSE message communication to
the transformer high side relay .
Automatic Transfer Execution
When automatic transfer is initiated, the affected main breaker opens first and sends an automatic
transfer initiate signal to the other relays. The automatic transfer signal is sealed-in by the main breaker
logic until the automatic transfer process is finished, an automatic retransfer signal occurs or the
automatic transfer scheme is disabled. This prevents repeated attempts at a transfer process.
Upon receipt of the automatic transfer initiate signal, the tie breaker closes if all of the following is true:
• Incomer-1 is open and the voltage on Bus 1 below the Residual Bus Voltage setting; Or
Incomer-2 is open and the voltage on Bus 2 below the Residual Bus Voltage setting;
• Automatic transfer scheme is enabled.
• A predefined automatic transfer time delay has expired.
If an automatic trigger returns after the affected main breaker opens but before the tie breaker closed,
the tie breaker will not be closed. The result is the other main breaker with the healthy source remains
closed, but the other two breakers are open. If this happens, operator needs to set the scheme back to
manual transfer mode and then close the currently opened tie breaker manually.
Simulation Method :
- Simulation of voltage by using Secondary Injection Kit FREJA300

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5-3- LV/MV Motor Control Center (MCC)

a- Test objective:


 Megger.

 Check ferrules.
resistance.
measure voltage calculate burden by multiply voltage and current and compare it with CT Buden.
 To test insulation: Using megger by 1 kilo volt injection for 1 minute, this test should be done
between primary to secondary, Primary to ground and secondary to secondary.

MV & LV SWGR & MCC
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6600033163 (IK)
a- Test objective:

 CPC100.

 Check ferrules.

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done between primary to secondary, primary to ground and secondary to ground.
5-3-3- Trip Time test for Molded Case Circuit Breaker (MCCB) and megger test:
a- Test objective:
 This test aimed to test the trip time for circuit breaker in case of over current or short circuit and to be
sure that tripping time within acceptable range.
 Primary injection tester. (Or special test kit to test the CB)
 Megger.

MV & LV SWGR & MCC
SAT
6600033163 (IK)
 To test trip time: there are three setting in each MCCB first setting is (long = „L‟), second is
(Short=‟S‟) and third is (Instantaneous=‟I‟).
 To test (L): adjust L on min. setting which is considered percentage from rated current, inject the
 To test (S): adjust S on min. setting which is considered percentage from rated current, inject the
 To test (I): adjust I on min. setting which is considered percentage from rated current, inject the
setting current [if the value of injected current can be injected by tester as in some cases the min
value of (I) is equal to 10 and rated current is 500 A, so to test you should inject 5000 ampere which
isn‟t applicable] using primary injection tester and measure the time to be tripped, compare the value
 To start megger test: this test is applicable for CB which rated current greater than 100 Amp. when
breaker open inject 5 KV for 1 minutes, between the same pole (red-red, yellow-yellow and blue-
blue) and when breaker close inject 1 KV for 1 minutes between pole and ground, between pole to
pole.
5-3-4- Contact resistance test for bus bar and circuit breaker:
a- Test objective:
c- Contact resistance test connection
voltage leads on the same terminals of current then hold your hand on contact resistance pushbutton,
after few second the result will be displayed.

MV & LV SWGR & MCC
SAT
6600033163 (IK)
5-3-5- High potential for MV MCC bus bar and contactor:
a- Test objective:
c- High potential AC test:
 Insulation test by megger for 1 minute 3 phases line to line and line to ground.
 Applying high potential AC voltage on the bus bar or contactor line to line and line to ground.
 Take the record of passing current in mille Amperes from the high potential test kit.
 Insulation test by megger for 1 minute 3 phases line to line and line to ground.
 Compare the insulation test results to gathers before and after high potential test.

MV & LV SWGR & MCC
SAT
6600033163 (IK)
a- Test objective:

 Multi-meter.

 Check ferrules.
value.
Normally close.
a- Test objective:
time.


MV & LV SWGR & MCC
SAT
6600033163 (IK)

 Check ferrules.
d- Test connection:
i- Check output contact:
coil (which is normally 120 volt AC), at which Aux. relay will pick up that‟s mean its contact will
ii- Pick-up and drop off current and voltage:
current.
iii- Operating and resetting time:
 Adjust voltage source at the coil operation voltage of Aux. relay (in our case 120 v AC), To get
readjust voltage source at 120 volt AC and switch MCB OFF.
iv- Burden test:
 Adjust voltage source (sverker) at 120 volt AC, select on position and make MCB ON.

MV & LV SWGR & MCC
SAT
6600033163 (IK)
a- Test objective:
 FREJA 300.


a- Test objective:

 Multi-meter.
 Mini-clamp.


MV & LV SWGR & MCC
SAT
6600033163 (IK)
d- Test connection
the loop until the last point.

a- Test objective:
 FREJA.
 Multi-meter.
d- Test connection:
a- Test objective:

 Multi-meter.
 Mini-clamp.

MV & LV SWGR & MCC
SAT
6600033163 (IK)
d- Test connection:
5-3-12- MCC Function test:
a- Test objective:
 This test is considered as a major test or combined test for the whole work in MCC panels and
finalizing phase for MCC panels.
d- Test procedure:
 Check the circuit of closing command for contactor.

 Check the circuit of opening command for contactor.
 Check interlock of closing the contactor.

MV & LV SWGR & MCC
SAT
6600033163 (IK)
a- Test objective:
 FREJA 300.
 Multi-meter.
 Wires.

 Check indication and LEDs.
d- Burden test
 Adjust voltage source at 120 volt AC.

activation.

MV & LV SWGR & MCC
SAT
6600033163 (IK)
ii. Measurements
iii. Instantaneous earth fault (50N):
drop-off value.
in manual of relay.
iv. Time delayed earth fault (51N):
drop-OFF value.
fault.

MV & LV SWGR & MCC
SAT
6600033163 (IK)
5-3-14- Timing test for MV MCC Contactors and megger test:
a- Test objective:
 This test aimed to test the closing/opening time for contactors and to make sure that there is no pole
discrepancies between poles (red, yellow and blue) and contactors closing/opening time within
acceptable range according to factory test result.
b- Required equipment
 SVERKER 670
 Megger
 Miniature Circuit Breaker 2Pole (2MCB)
c- Timing and megger test connection
 Connect the line 120V AC supply Through 1 pole MCB and the neutral direct to Contactor coil for
closing (in case of measurement of closing time) circuit or opening (in case of measurement of
opening time) circuit, for switching device that should be tested.
 To get closing / opening time, the other pole of MCB will make start initiation for the SVERKER to
measure the time and then put sverker at (on+time location) and switch MCB ON and then the main
poles of contactor will make stop.
 The displayed time of contactor closing / opening is time between start and stop initiation.
 To start megger test: when contactors open inject 2.5 KV for 1 minutes between the same pole (red-
red, yellow-yellow and blue-blue) and when breaker/contactors close inject 2.5 KV for 1 minutes
between pole and ground, between pole to pole.
5-3-15- Contact resistance test for contactors:
a- Test objective:
 This test is aimed to measure the resistance of contactor after being installed in the site to avoid high
resistance which may be results from welding or installing in the site.

MV & LV SWGR & MCC
SAT
6600033163 (IK)
c- Contact resistance test connection:
injection on contactors then sense the voltage and calculate resistance by divide voltage on current
(ohm‟s law) .
voltage leads on the same terminals of current then hold your hand on contact resistance pushbutton,
after few second the result will be displayed.
 The contactor shall be removed during test for visual inspection.
5-3-16- RTD Relay Check:

a- Test objective:
 This test is aimed to measure the resistance of temperature of MOTOR.
 Variable Resistance.
c- Test procedure:
 Connect +ve probe of resistor to the end of RTD Relay.

 Connect -ve probe of resistor to the end of RTD Relay.
 Adjust the resistance at certain value.
 As per relay manual check the corresponding temperature value which will meet this resistance.
 Set the trip and alarm setting into relay and check it actual.

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)
5.4. –General Procedures Points:
 5 kV insulation resistance tester (Megger) Will be used for the 13.8 kV & 4.16 kV switchgears.
 1 kV insulation resistance tester (Megger) for the 480 V switchgear and 480 V MCCs.
 Torqueing of all bolted connections will be donefor Bus Bar .
 For contact resistance test, applied current is 100 amperes.
 Contact resistance shall be tested section by section.
 The test voltage of the insulation resistance shall be 5 KV DC for 13.8 KV equipment and 2.5 KV DC
for 4.16 KV equipment.
 The voltage level of the hi-pot test shall be as per the vendor recommendation.
 During hi-pot test, the substation shall be free from scaffolding and only authorized parsons shall be
allowed to enter the substation.
 All the power cables shall be disconnected from the switchgear during high-pot or insulation
resistance test.
 The test location shall be barricaded. also, when performing the test, safety light required and watch
man shall be available at the remote end of the equipment.
 CT terminals shall be return back to the correct one before starting the bus bar or transformer
differential stability test.
 Check all available field signals coming from the motors or other equipment. Check the trip and
alarm signals coming from the power transformers.


MV & LV SWGR & MCC
SAT
6600033163 (IK)
6- HSE REQUIREMENT
 Personal Protective Equipment are mandatory to all.
 Tools and equipment shall be Contractor approved and or certified.
 All waste shall be regularly collected from work area and disposal as per waste management plan,
housekeeping must be observed at all times.
 Safety Officer must be available at worksite.
 The tools used are suitable and safe to use.
 Scaffolding when used is confirmed “Tagged for Use” by authorized person.
 Safety harness shall be used working on high-elevated platform.
 Precautionary warning signs for this type of work place are visibly kept in place.
 Certified work permit receiver shall receive work permit on daily base.
 The test location shall be barricaded. also, when performing the test, safety light required and watch
man shall be available at the remote end of the equipment.
7- TEST RESULTS:
SEE THE ATTACHMENT

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR & MCC
SAT
6600033163 (IK)

MV & LV SWGR, METHOD STATEMENT

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Method Statement for

MV & LV SWGR & MCC

Method Statement for

MV & LV SWGR & MCC SAT

OMAR MOHAMMED GUAN

Checked by Reviewed by Approved by

SEPCO Electric Power Construction Corporation

SEPCO Electric Power Construction Corporation

5- DETAILS OF TEST PROCEDURE & EQUIPMENT

SEPCO Electric Power Construction Corporation

4-1- Electrical supervisor shall be responsible for the following:

SEPCO Electric Power Construction Corporation

4-2- Electrical manager shall be responsible for the following:

4-3- QC inspector shall be responsible for the following:

4-4- QA/QC manager shall be responsible for the following:

SEPCO Electric Power Construction Corporation

4-7- Vendor shall be responsible for the following:

SEPCO Electric Power Construction Corporation

5- DETAILS OF TEST PROCEDURE & EQUIPMENT:

5-1- 13.8KV & 4.16kV MV SWGR:

 Current transformer ratio.

 Current transformer (CT) analyzer.

c- Mechanical check and visual inspection:

 Check tightness of all connection.

d- Current transformer analyzer connection:

SEPCO Electric Power Construction Corporation

Figure.1 CT analyzer connection

5-1-2- Voltage transformer (VT) test procedure:

 Voltage transformer ratio.

SEPCO Electric Power Construction Corporation

 Check tightness of connection.

d- Voltage transformer test connection:

Figure.2 show CPC100 connection to test

 EGIL breaker analyzer.

SEPCO Electric Power Construction Corporation

c- Timing and megger test connection:

d- High potential AC test:

SEPCO Electric Power Construction Corporation

 Micro-ohm meter Contact resistance device.

c- High potential AC test:

d- Contact resistance test connection

SEPCO Electric Power Construction Corporation

Figure.3 shows contact resistance equipment connection

5-1-5- High potential test for circuit breaker:

b- Testing equipment required:

 AC HI-voltage injection machine (100KV, 60HZ).

c- Mechanical and visual inspection:

 All safety rules should be taken into consideration

d- Test connection and test procedure

SEPCO Electric Power Construction Corporation

5-1-6- Miniature Circuit Breaker (MCB):

 Sverker (used as current source).

c- Mechanical checked and visual inspection:

 Check tightness for all wires.