RELIANCE ENERGY LIMITED

KGS – 3&4 Rev No.-00

COMMISSIONING PROCEDURE FOR
220V DCDB – U1,U2 AND V1,V2 Page

INDEX

SL. PAGE
DESCRIPTION
NO. NO.
1.0 PURPOSE 4

2.0 PRE – REQUISITES

2.1 System Requirement 4
2.2 Requirement of Instruments 4
2.3 Manpower Requirement 4
2.4 Requirement of Outside Agencies 4
3.0 PRE - COMMISSIONING CHECKS
3.1 Installation Checks 5
3.2 Cabling/Wiring Checks 5
3.3 DCDB Checks 5
3.4 General Checks 5
4.0 DESIGN INTENT 6

5.0 EXPECTED PROCESS PARAMETERS 6

6.0 WORK PLAN 6

7.0 TEST PROCEDURES AND FORMAT 6

8.0 REFERENCE 6

9.0 ANNEXURES
ANNEXURE – 1: Preliminary Checks 8
ANNEXURE – 2: Insulation Resistance Measurement 12
ANNEXURE – 3: Bus Bar Contact Resistance Measurement 13
10.0 VERIFICATION SHEET 14
11.0 DEFICIENCY REPORT OF K-3&4-CP-52321-E-01 15
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KGS – 3&4 Rev No.-00
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220V DCDB – U1,U2 AND V1,V2 Page

5 - General
2 – Station Service Power System
3 – Standby Power Supply And Distribution
2 – DC System
1 – Switchgear

1.0 PURPOSE:

Procedure for testing and commissioning of DC Distribution Board so as to

ensure its proper commissioning and to verify its design intent.

2.0 PRE-REQUISITIES:

2.1 System Requirement:

1. Completions of erection of DCDBs in all respects with proper earthing

at two points and inter panel connections.
2. Availability of calibrated testing instruments and tools & tackles
3. Relevant Schematic drawings, Factory test reports, Manufacturers
O&M Manual, GA drawings, are available.
4. Availability of 220 V DC supply.
5. Laying of control & Power Cables and their termination are completed.

2.2 Requirement of Instruments:

1. Digital Multimeter - 1 No.

2. 500 V megger - 1 No.
3. Analogue Multimeter - 1 No.
4. Static Contact Resistance Meter – 1 No.
5. Tool kit with all necessary tools and torque wrench – 1 Set

2.3 Manpower Requirement:

Manpower NPCIL BHEL

Engineer 1 1
Supervisor 1 1
Technicians 3 3

2.4 Requirement of Outside Agencies:

1. Electrical construction and QA group for Co-ordination.

2. RELIANCE representative for pre-commissioning and commissioning.
 RELIANCE ENERGY LIMITED
KGS – 3&4 Rev No.-00
COMMISSIONING PROCEDURE FOR
220V DCDB – U1,U2 AND V1,V2 Page

3.0 PRE-COMMISSIONING CHECKS:

3.1 Installation Checks:

1. Check for the Completion of erection of DCDBs in all respects with proper
Earthing and inter panel connections w.r.t. GA Drawings.
2. Ensure no physical damage in any part of DCDB or its associated
auxiliaries.
3. Check earthing of Panels at two different points.
4. Check no foreign particles (like nuts, bolts, loose wires etc) are lying on
the bus-bars/panels.
5. Check label, nomenclature and BOM of each feeder/compartment as per
scheme and GA drawings.

3.2 Cabling/Wiring Checks:

1. Ensure that power and control cables are terminated with proper ferruling.
2. Ensure correct sizes of cable are used and properly tagged.
3. Check for proper ratings of fuses.
4. Check healthiness of fuses, links, MCBS, Switches, indication lamps, push
buttons, space heater & illumination circuit.
5. Check the wires are dressed & routed properly.
6. Check cables are supported properly.

3.3 DCDB Checks:

1. Check the healthiness of DC supply.

2. Check the metering circuit.
3. Measure and record IR value between bus bars and earth using 500V
megger.
4. Measure and record IR value of control circuit with respect to earth using
500 V megger.
5. Measure and record bus bar contact resistance and tightness torque.
6. Check the polarity of shunt, ammeter, voltmeter etc.
7. Check space heater for continuity
8. Check indicating lamps rating and their circuits and ensure their colours
are in order

3.4 General Checks:

1) Check name plate and feeder details

2) Check panel to wall clearance
3) Check door alignment
4) Check door lock facility
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KGS – 3&4 Rev No.-00
COMMISSIONING PROCEDURE FOR
220V DCDB – U1,U2 AND V1,V2 Page

5) Check panel to panel bolting for tightness

6) Check cleanliness of the board.
7) Check function of all switch fuse units
8) Check rating of all fuses

4.0 DESIGN INTENT:

The results of commissioning tests shall be in line with factory test report
results.
Bus Voltage: 220 V DC
Maximum permissibility leakage current: 3.5 mA

5.0 EXPECTED PROCESS PARAMETERS:

The results shall be in line with factory test report results.

6.0 WORK PLAN:

1. Visual Inspection.
2. Wiring/Cabling checks
3. IR measurement of Bus bars and control circuit.
4. Bus Bar Contact Resistance Measurement

Commissioning of each DCDB is expected to take 7 days.

7.0 TEST PROCEDURES AND FORMAT:

Refer to check lists enclosed as Annexure.

8.0 REFERENCE:

1. RELIANCE Testing and commissioning Instructions for DCDB.

2. RELIANCE Checklist and Recording Formats for DCDB.
List of Drawings:

1. Kaiga 3,4 / 52321 / 2531/ GA

2. Kaiga 3,4 / 52321 / 2532 / GA
3. Kaiga 3,4 / 52321 / 2533/ GA
4. Kaiga 3,4 / 52321 / 2534 / GA
5. Kaiga 3,4 / 52321 / 2501 / BM
6. Kaiga 3,4 / 52321 / 2501 / ED
7. Kaiga 3,4 / 52321 / 2502 / ED
8. Kaiga 3,4 / 52321 / 2503 / ED
9. Kaiga 3,4 / 52321 / 2501 / DD
10. Kaiga 3,4 / 52321 / 2501 / TL
 RELIANCE ENERGY LIMITED
KGS – 3&4 Rev No.-00
COMMISSIONING PROCEDURE FOR
220V DCDB – U1,U2 AND V1,V2 Page
 RELIANCE ENERGY LIMITED
KGS – 3&4 Rev No.-00
COMMISSIONING PROCEDURE FOR
220V DCDB – U1,U2 AND V1,V2 Page

ANNEXURE – 1
PRELIMINARY CHECKS

DESIGNATION: DATE:
LOCATION:
NAME PLATE DETAILS:
a) DCDB Panel:
Make :
Serial No. : Type:

1.1 Pre-Requisites checks:

S.NO. Description Observation

1. Ensure erection completion checklist is submitted
and reviewed.
2. Ensure availability of 220V DC control supply.
3. Ensure availability of calibrated testing
instruments and tools & tackles
4. Ensure lying of control & Power Cables and their
termination are completed.
5. Ensure relevant schematic drawings, factory test
reports, O&M manual are available.
6. Ensure required manpower is available from
NPCIL and RELIANCE
7. Ensure Electrical construction and QA groups are
available for co-ordination.
8. Ensure RELIANCE representative is available for
pre-commissioning and commissioning.

1.2 Pre-Commissioning Checks:

Sl.No. Description Observation

1 Ensure installation of DCDB is completed w.r.t. to
GA drawings
2 Ensure Availability of all switches, relays, lamps as
per BOM
3 Ensure door alignment
4 Ensure door lock out facility
5 Ensure panel to panel bolting for tightness
6 Ensure cleanliness of board
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KGS – 3&4 Rev No.-00
COMMISSIONING PROCEDURE FOR
220V DCDB – U1,U2 AND V1,V2 Page

7 Ensure polarity of shunt, ammeter, voltmeter etc

8 Ensure cubicle illumination and auxiliary 240 VAC
circuit for continuity and IR value
9 Ensure indicating lamps ratings and their colours
in order
10 Ensure bus bar cleanliness and clearances
11 Ensure tightness of Bus joints with help of a
Torque wrench
12 Ensure module door alignment, operation and door
interlock arrangements of all switch-Fuse units
13 Ensure tightness of cable termination of all switch-
Fuse units
14 Ensure wirings of all relays and meters
15 Ensure calibration of all relay and meters
16 Ensure annunciation circuits for continuity w.r.t. ED
17 Ensure two point grounding and panel’s ground is
connected to station grounding
18 Ensure Ground-Fault detector/annunciator circuit
for continuity w.r.t. ED
19 Ensure calibration of Ground-Fault indicators
20 Check and record Panel to wall clearances
21 Check and record clearances of Bus bars
22 Check for rating of fuses.
23 Check healthiness of fuses
24 Check for any physical damage.
Ensure that power & control cables are terminated
25
with proper ferruling.
26 Check cables are supported properly.
27 Ensure correct sizes of cables are used.
28 Check all cable lugging & termination.

1.3 Commissioning Checks:

S.NO. Description Observation

Ensure all pre-commissioning checks vide1.2 -- 1 to 28
1)
are completed and results are satisfactory
Ensure supply source i.e. battery charger or battery is
2)
ready to feed.
Ensure that before energisation all the IR values of bus
3) bar and control circuit is measured with 500 v Megger
and results are satisfactory
4)
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KGS – 3&4 Rev No.-00
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220V DCDB – U1,U2 AND V1,V2 Page

Ensure control supply is available and is healthy.

Ensure that after energisation of control and main
5) incomer the ground fault level reading is 0 mA .If not
rectify it and then proceed.

6)
Check DC output terminals by switching it one by one.
After all outgoing feeders are closed note and record all
7)
voltages and ground fault level reading
Ensure simulation of annunciation system by creating
8)
fault condition
Ensure that the system is left as per operational
9)
requirement
Check the healthiness of DC supply by observing
10)
indications on the panel.
Check the metering circuit by doing injection of voltage
11)
& current.
Measure and record IR value between bus bars and
12)
earth as per Annexure – 2.
Measure and record IR value of control circuit with
13)
respect to earth as per Annexure – 2.
Measure and record contact resistance of all the bus bar
14)
joints as per Annexure – 3.

15)
Check control wiring for its correctness & continuity.

16) Ensure C.R.M test is done all bus joints

Clearances Measurement

Bus bar Clearances

17)
OBSERVED EXPECTED
ve
+ and earth >25.4 mm
-ve and earth >25.4 mm
+ve and -ve >25.4 mm
Panel to wall
RELIANCE NPC (Elect) NPC (O&M)
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KGS – 3&4 Rev No.-00
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220V DCDB – U1,U2 AND V1,V2 Page

Name and Signature

Of Technicians with
date
Name and Signature of
Supervisor with date

Name and Signature of

Engineer with date

ANNEXURE – 2
INSULATION RESISTANCE MEASUREMENT
2.1 Bus bars to Earth: Date:
Details of test equipments used:
Equipment used: 1000 V megger
Make : Type :
Serial No : Range :

Note: 1) Remove fuses of illumination/heater circuit, indication and metering circuit.

2) Isolate control AC &DC before IR measurement.
3) Ensure no outgoing cable is connected on MCBS/switches terminal before
measurement

S.NO. Between IR Value (M)

 RELIANCE ENERGY LIMITED
KGS – 3&4 Rev No.-00
COMMISSIONING PROCEDURE FOR
220V DCDB – U1,U2 AND V1,V2 Page

220 V DCDB
Actual Remarks
1
+Ve bus bar and earth

2
- Ve bus bar and earth

3
+Ve bus bar and – ve
bus bar

2.2 Control Circuit:

Details of test equipments used:

Equipment used: 500 V megger

Make : Type :
Serial No : Range :

IR Value (M)
220 V DCDB Remarks
IR value of
control circuit
with respect to
earth
RELIANCE NPC (Elect.) NPC (O&M) NPC (QA)
Name and Signature of
Technicians with Date
Name and Signature of
Supervisor with Date
Name and Signature of
Engineer with Date
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KGS – 3&4 Rev No.-00
COMMISSIONING PROCEDURE FOR
220V DCDB – U1,U2 AND V1,V2 Page

ANNEXURE – 3
BUS-BAR CONTACT RESISTANCE MEASUREMENT
Details of equipment used: a) Torque wrench
Make: Type:
Serial No.: Range:

b) CRM kit
Make: Type:
Serial No. Range:

Ambient Temperature:
Contact
Torque
Sl.No. Designation Joint No. Resistance
Applied
value (Ω)
220V /
48 V
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KGS – 3&4 Rev No.-00
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220V DCDB – U1,U2 AND V1,V2 Page

DCDB

+ VE BUS

- VE BUS 220V /
48 V
DCDB

RELIANCE NPC (Elect.) NPC (O&M) NPC (QA)

Name and Signature of
Technicians with Date
Name and Signature of
Supervisor with Date
Name and Signature of
Engineer with Date

10.0 VERIFICATION SHEET

Certification by verifying agency

Sl. Acceptance Verifying
Activity
No. criteria agency Procedure Inspection Functional Results General
certification witness tests certification remarks
Minimum
1 Insulation
resistance 2 MΩ QA/O&M O&M O&M O&M O&M
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KGS – 3&4 Rev No.-00
COMMISSIONING PROCEDURE FOR
220V DCDB – U1,U2 AND V1,V2 Page

2 Bus Bar Compare

Contact with factory
QA/O&M “ “ “ “
Resistance values
Measurement

11.0 DEFICIENCY REPORT OF K-3&4-CP-51321-E-01

NIL
 RELIANCE ENERGY LIMITED
KGS – 3&4 Rev No.-00
COMMISSIONING PROCEDURE FOR
220V DCDB – U1,U2 AND V1,V2 Page