Overall Method Statement - Substation Tests

METHOD STATEMENT
FOR
TESTING & COMMISSIONING
OF
SUBSTATION EQUIPMENTS

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METHOD STATEMENT FOR
CURRENT TRANSFORMER SITE TESTING
CURRENT
TRANSFORMER

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3. CURRENT TRANSFORMER
SCOPE:
This method statement covers the procedure for doing site tests to be carried out on current
transformer.
OBJECTIVE OF THE TEST:

The objective of the test is to verify the readiness & healthiness of the current transformer.
SAFETY PRECAUTIONS
 Secondary circuit of current Transformer should be open circuited during testing since the
high voltage injected during insulation resistance may damage the insulation and other
components in the circuit.
 Standards rules for working on high voltage equipment will be followed.
 Company’s safety codes will be followed.
STANDARD/SPECIFICATION REFERENCE OF THE TEST:

Current Transformer specification and approved drawings.
PROCEDURE OF TEST:
The tests to be carried out in site for current transformer are Insulation resistance, Polarity,
Winding Resistance, Magnetization curve, Ratio Check, and Burden test.

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 INSULATION RESISTANCE:
 To check and confirm the insulation of current transformers, “Insulation Test” is carried out on
individual core of each current transformer. Insulation test is done between Primary – Secondary,
Secondary to Earth and Secondary to Secondary in case of two or more secondary winding in one CT.
DC VOLTAGE TO BE APPLIED Time

COMBINATION
LV Switchgear MV/HV/EHV SWITCHGEAR Duration
Primary to Secondary 500V 2500/5000V 60 Seconds
Secondary to Earth 500V 500V 60 Seconds
Secondary - Secondary 500V 500V 60 Seconds
 Do the connections as shown in the drawing, select the voltage level as per the combination,
apply the voltage for 60 Seconds and record the values in the test sheet.
 POLARITY
 Each current transformer will be individually tested to verify that the primary and the secondary
polarity markings are correct.
 When primary current enters the P1 terminal, secondary current leaves the S1Terminal (or) when
primary current enters the P2 terminal, secondary current leaves the S2 terminal.
 The primary and secondary terminals of the CT to be connected to the CT Analyzer as shown in
figure - 1 and the test to be started after testing CT Analyzer will give the report as polarity ok or not
ok.
 Care should be taken that from the CT Analyzer red colored terminals are connected to P1, S1
terminals of the CT and the black colored terminals are connected to P2, S2 of the CT. Refer figure-1.
 WINDING RESISTANCE
 The secondary winding of the current transformer has its own resistance, this winding resistance to
be measured and noted for protection calculations.
 This can be measured using milliohm meter or CT Analyzer.
figure-1 and the test to be started after testing CT Analyzer will give winding resistance of the CT
secondary. Refer figure-1.

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 MAGNETIZATION CURVE
 Definition: AC voltage is applied across the secondary winding of the current transformer and the
voltage is increased slowly from zero to saturation point in stepwise, the point where the exciting
current increases by 50% for a 10% increase in secondary voltage is called the saturation point.
figure and the test to be started after testing CT Analyzer will give magnetization curve of the CT.
Refer figure - 1.
 RATIO TEST
 The rated transformation ratio is the ratio between the primary rated current to the secondary rated
current.
 The ratios of the CT are checked by giving the current in the primary and monitor the induced
secondary current and compare the results with the name plate ratio.
figure and the test to be started after testing CT Analyzer will give the CT ratio. Refer figure - 1.

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 BURDEN MEASUREMENT
 Burden measurement is the load connected between the CT secondary terminals, like protection or
metering or monitoring devices.
 It can be measured using CT Analyzer or CPC 100.
 Isolate the CT secondary circuit from CT secondary winding by opening the terminal block link as shown
in the figure.
 Connect the current and voltage leads from the kit to the CT secondary terminals as shown in the
Figure - 3
 Switch on the kit and press the start button, kit will give the circuit burden measurement.
 ONE POINT EARTHING

 Current transformer secondary star point (Neutral) to be earthed in only one point to make the metering
and protection functions accurate.
 Open the neutral earth link of the CT secondary under test and all other earth links to be closed.
 Using 500V insulation tester do IR test between CT Secondary star point terminal to earth, the value of
the insulation should be high (MΩ).
 Close the neutral earth link of the CT secondary under test and then do the same IR test the insulation
should be zero.
 Thus the one point earthing is confirmed.
ACCEPTANCE CRITERIA: Record all the values in the test report and compare the values with factory
test repot and the name plate. All the readings should be within criteria limit.

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VOLTAGE TRANSFORMER SITE TESTING
VOLTAGE
TRANSFORMER

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VOLTAGE TRANSFORMER
SCOPE:
This method statement covers the procedure for doing site tests to be carried out on voltage
transformer.

The objective of the test is to verify the readiness & healthiness of the voltage transformer.
SAFETY PRECAUTIONS
 Secondary circuit of voltage Transformer should be open circuited during testing since the
high voltage injected during insulation resistance may damage the insulation and other
components in the circuit.

Voltage Transformer specification and approved drawings.
PROCEDURE OF TEST:
The tests to be carried out in site for voltage transformer are Insulation resistance, Polarity,
Winding Resistance, Ratio Check,

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 INSULATION RESISTANCE:
 To check and confirm the insulation of voltage transformers, “Insulation Test” is carried out on
individual core of each voltage transformer. Insulation test is done between Primary – Earth, Primary
– Secondary, Secondary to Earth and Secondary to Secondary in case of two or more secondary
winding in one Voltage Transformer.
DC VOLTAGE TO BE APPLIED Time

COMBINATION
LV Switchgear MV/HV/EHV SWITCHGEAR Duration
Primary to Earth 500V 2500/5000V 60 Seconds
Primary to Secondary 500V 2500/5000V 60 Seconds
Secondary to Earth 500V 500V 60 Seconds
Secondary - Secondary 500V 500V 60 Seconds
 Do the connections as shown in figure - 1, select the voltage level as per the combination,
apply the voltage for 60 Seconds and record the values in the test sheet.
 POLARITY
 Each voltage transformer will be individually tested to verify that the primary and the secondary
polarity markings are correct.
 When primary voltage is applied between A-N (i.e.) positive in ‘A’ terminal and negative in ‘N’
terminal, in secondary side flow will be from a to n.
 The primary and secondary terminals of the VT to be connected to the test kit (CPC100) as shown in
figure – 2 then select the polarity mode in the kit and test to be started after testing kit will give the
report as polarity ok or not ok.
 Care should be taken that from the test kit (CPC100) red colored terminals are connected to P1, S1
terminals of the CT and the black colored terminals are connected to P2, S2 of the CT. Refer figure-2.

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 WINDING RESISTANCE
 The primary and secondary winding of the voltage transformer has its own resistance, this winding
resistance to be measured and noted for protection calculations.
 The primary winding resistance can be measured using resistance mode in multimeter
 The secondary winding can be measured using milliohm meter or CPC 100.
 The secondary terminals of the CT to be connected to the CPC100 as shown in figure-3 and the test
to be started after testing CPC100 will give winding resistance of the CT secondary. Refer figure-3.
 RATIO TEST
 The rated transformation ratio is the ratio between the primary rated voltage to the secondary rated
voltage.
 The ratios of the VT is checked by applying voltage in the primary and measure the induced
secondary voltage and compares the results with the name plate ratio.
 The primary and secondary terminals of the VT to be connected to the CPC100 as shown in figure - 4
and the test to be started after testing CPC100 will give the VT ratio. Refer figure - 4.

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LVAC SWITCH BOARD SITE TESTING
LVAC
SWITCHGEAR

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NAME OF TEST: LVAC IR Test.
OBJECTIVE OF THE TEST: To verify the insulation Resistance of LVAC Bus Bars and
Breakers.
PREREQUISITES: LVAC Panel erection shall be completed in all respect, LVAC bus bar
tightness shall be verified by torque checks
PROCEDURE OF TEST: With all ACBs are in service position and closed, the IR value
between phase-to-phase, phase to neutral, phase to earth and neutral to earth is measured
with 1000V IR tester.
ACCEPTANCE CRITERIA: All IR values should be more than 200 Mega ohms.
NAME OF TEST: LVAC Insulation Resistance & HV Test.
OBJECTIVE OF THE TEST : To verify the insulation Resistance of LVAC Bus Bars and
Breakers.
PROCEDURE OF TEST : With all ACBs are in service position and closed :
1. 2kV (AC) is applied for 1 minute to each phase and neutral with other phases and
neutral shorted and earthed. Leakage current shall be recorded.
2. IR to be measured before and after HV test.

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Note: All the out going feeders shall be in closed condition while doing the HV test. Care
must be taken to ensure that the fuses are capable to withstand the 2kV applied voltage.
ACCEPTANCE CRITERIA : All Bus bar should withstand the HV for 1 minute.
NAME OF TEST: LVAC Scheme.
OBJECTIVE OF THE TEST: The function of this test is to verify the operation logic of the
LVAC panel in Auto & Manual mode. The logic is achieved through PLC program.
PROCEDURE OF TEST : The entire LVAC scheme logic is controlled by PLC. The LVAC
panel is provided with three in feeds from earthing transformers. Including two bus couplers
there is total five breakers in LVAC panel. Out of five only 3 are permitted to close at a time.
Paralleling of the transformers should never happen.
The major scheme checks are, (When all incomer and Bus section are in service position)
 All incomers can be closed in without paralleling.
 When any incomer supply fails, that incomer breaker switches OFF, the corresponding
Bus Section closes and maintains the supply to the outgoing feeders.
 When the failed incomer resumes supply, first the corresponding Bus section switches
OFF and after a delay incomer breaker switched ON.
 Standby incomer cannot be switched on when any of the incomer is in service position
and vice versa.
ACCEPTANCE CRITERIA : All operations shall be according to the scheme.
TEST FORMAT : Attached as annexure.

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NAME OF TEST: LVAC Switch / Lamp Indication.
OBJECTIVE OF THE TEST: To verify the various indications and their color.
PROCEDURE OF TEST: Lamps, semaphore indicators etc are provided on the panel to
indicate the status of devices, alarms etc. All these indications shall be verified for the
correct function. This shall be verified by creating the respective conditions. (For Eg.
Bringing the CB in to the test condition can simulate breaker test condition.) . Like that all
conditions shall be simulated and verified.
ACCEPTANCE CRITERIA : All indications shall be as per Test Report.
NAME OF TEST: LVAC Breaker Travel.
OBJECTIVE OF THE TEST: To verify the travel of breakers form Service to Test- Test to
isolated condition with out any tripping of other breakers in service. There should not be
any effect on the breakers under operation when other breakers moved from one position
to another position.
PROCEDURE OF TEST : The test shall be carried out for different combinations. While
doing the testing the operating mode of the PLC shall be selected to manual. As mentioned
in the format different CBs shall be taken for movement & all combinations shall be verified.
ACCEPTANCE CRITERIA : The Service position breakers should not trip , when other
breakers travel from their position.

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NAME OF TEST: LVAC Outgoing feeder identification.
OBJECTIVE OF THE TEST: To verify the outgoing feeder distribution with respect to the
drawing also to ensure the correct termination of the cable at load& Source end.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: Approved Drawing.
PROCEDURE OF TEST : All outgoing feeders from LVAC panel must be switched off
before proceeding the testing. IR value of the cable shall be measured for each out going
feeder. One by one feeders has to be switched ON & the voltage & phase sequence shall
be measured at the load end. Correct tightness, Ferrules if any, insulation shrouds etc shall
be verified during the testing. The sizing of the cable & voltage drop at the load end etc
shall be in line with the design document.
ACCEPTANCE CRITERIA : All outgoing feeders shall be terminated as per the drawing.
Voltage drop at the load end must be within the allowable limits.

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MEDIUM VOLTAGE SWITCH BOARD SITE TESTING
MEDIUM
VOLTAGE
SWITCHGEAR

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NAME OF TEST: CB INSULATION RESISITANCE TEST
OBJECTIVE OF THE TEST: To measure the insulation resistance between phase to Earth
and phase to phase of Circuit Breaker (R, Y & B phases).
PROCEDURE OF TEST:
1. Record the Circuit breaker name plate details and verify the supplied Vacuum bottle
manufacturer.
2. General visual inspection for circuit breaker fixing , cleaning and damage.
3. Circuit breaker shall be rack-out from the switchgear panel and insulator poles to clean.
4. Ambient temperature must be recorded with a calibrated temperature meter.
5. Circuit breaker shall be closed for measure the IR.
6. Apply 5KV between phase and Earth for 60 second and repeat for the other phase’s
record the values.
7. Apply 5KV between phase and Phase for 60 second and repeat for the other
phase’s record the values.
BETWEEN PHASE TOEARTH BETWEEN PHASE TO PHASE
ACCEPTANCE CRITERIA
Measured Insulation resistance shall be obtained in the unit of Giga ohms.

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NAME OF TEST: MV SWGR Circuit Breaker contact resistance measurement
OBJECTIVE OF THE TEST: -This test is carried out to confirm the healthiness of circuit breaker
contact during circuit breaker closed position.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: - IEC 62271-100
PROCEDURE OF TEST:
 Contact resistance of entire C.B shall be measured. It can be measured in different

ways. Between the points of measurement of contact resistance 100 A DC current
is injected & the voltage drop is measured. Micro ohm meter shall be used for this
measurement. Voltage measurement probes shall be kept inside the current
injecting point.
 Contact resistance of each phase is measured separately.
 Record the temperature and humidity during the measuring time.
ACCEPTANCE CRITERIA: Resistance should be ±5 % of the factory value.

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NAME OF TEST: - MV CB Operational Functional Checks (Mechanical).
OBJECTIVE OF THE TEST: -
This test is primarily carried out to verify the operation of the Circuit breaker tripping & closing by
manual commands (pushing manually buttons provided on the circuit breaker). Manual spring
charging shall also be verified during this test. All indications like semaphore & mechanical
indications shall be verified.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: - IEC 60298
PROCEDURE OF TEST: -
Motor spring charging:-
Switch off the supply to the spring charge motor to prevent spring re charging. Operate the
breaker; to make the spring discharged condition. Insert the spring charge handle in to specified
place for manual charge and charge the spring.
CB Operation:-
Check the circuit breaker operations by pushing manual close/open buttons provide on the circuit
breaker.
CB Indication:-
During the closing /opening operation indications like semaphore, indication lamps, mechanical
indications etc shall be checked.
ACCEPTANCE CRITERIA: -
CB manual spring: Operation shall be smooth
CB open / close operations: Operation shall be smooth
CB indication: Indication lamp shall be OK

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NAME OF TEST: - MV CB Operational Functional Checks (Electrical).

This test is primarily carried out to verify the operation of the Circuit breaker through viz. tripping &
closing by electrical commands. Electrical spring charging shall also be verified during the testing.
All indications like semaphore, indication lamps & mechanical indications shall be verified.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: - IEC 60298
Motor spring charging:-
Switch off the supply to the spring charge motor to prevent spring re charging. Operate the
breaker; to make the spring discharged condition. Switch on the supply of the spring charge motor
and stop watch, immediately the spring get charged and the spring charging time shall be
measured by stopwatch. Also record the maximum spring charging current using clamp or
ammeter. Compare the charging time with in limit as compared with FAT reports.
CB Operation:-
1. Check the operation of the close coil/ Trip coil at Rated Voltage
2. Check the anti pumping function by enabling close command continuously for that close
circuit breaker wait for spring charge after C.B spring fully charged give close command
continuously and open circuit breaker. Circuit breaker shall not close after opened.
3. Check open-Close- Open (OCO) by close the circuit breaker wait for C.B spring and switch
off C.B spring charge supply. Give open – close – open command.
Circuit breaker mechanism shall capable for the OCO operation is verified.
CB Indication:-
During the closing /opening operation indications like semaphore, indication lamps, mechanical
indications etc shall be checked.
Motor spring charging time/Current : As specified by the manufacturer
Motor spring charge current: As specified by the manufacturer
CB operation at: Operation shall be smooth
CB indication: Indication lamp shall be OK

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NAME OF TEST: CB Timing Measurement
OBJECTIVE OF THE TEST: To measure the closing and opening time of main contact of Circuit
Breaker (R, Y & B phases) & including the discrepancy among the poles operation timing.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: IEC 62271-100.
PROCEDURE OF TEST:
Timing measurement has to be done for close and trip coils.
At first simulate all the field point of CB (After removing CB control plug) by using a simulator.
Usually a PROGRAMMA kit or any other suitable instrument can be used for measuring
close/open timing of Circuit Breaker. At rated voltage we have to give the close/open pulse from
that kit. The duration of operation will be recorded in the instrument & it shall be displayed in the
form of graph.
Following shall be recorded for open, Close & OCO operation
 Duration of operation of individual poles & discrepancy between operation of poles
 Close Coil/ Trip coil current.
 One set of NO & NC contact operation timing.
Time for CB close /open (individual R, Y & B) can be measured from the graph. Closing and
opening current also we can take along with that graph. Pole discrepancy also we have to check
for close/open time. 1 NO & 1 NC auxiliary contact timing also we can take along with that graph.

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ACCEPTANCE CRITERIA
Acceptance criteria are as per manufacturer standard.

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NAME OF TEST: MV SWGR Circuit Breaker contact resistance measurement
OBJECTIVE OF THE TEST: -This test is carried out to confirm the healthiness of bus bar joints
between panels, feeder tapping’s and circuit breaker fixed and moving contact during circuit
breaker service closed position.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: - IEC 62271-100
PROCEDURE OF TEST:
 Contact resistance of bus bar between 2 panels and 2 circuit breaker service
position measured. It can be measured in different ways. Between the points of
measurement of contact resistance 100 A DC current is injected at 2 panel cable
terminations& the voltage drop is measured. Micro ohm meter shall be used for this
measurement. Care must be taken to avoid wrong measurement by putting leads
wrongly. Voltage measurement probes shall be kept inside the current injecting
point.
 Bus bar Contact resistance of each phase is measured separately.
 Record the temperature and humidity during the measuring time.
Resistance should be ±5 % of the factory value.

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NAME OF TEST:- High voltage test on MV SWG BUSBAR
OBJECTIVE OF THE TEST: - Ensure the power frequency with standing capacity for support
insulator of bus bar.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: - IEC 62271-100.
1. Pre – Requisites:
a) Ensure that all safety signs are put in place and test area is cordoned off. Ensure
that test area is cleaned and free from dust.
b) Ensure that tool box talk is conducted.
c) Ensure that all CT's are shorted and grounded in the LV compartment.
2. HV Test on Bus Bar:
1. Rack in all the circuit breaker in service position. Close all the breakers except Bus –
Section Breaker.
2. Short Y, B Phase of Bus bar of section – 1 and connect to ground.
3. Using 5kV Insulation Tester measure, insulation resistance between R-Phase to
(Y+B+E) and record the values.
4. Insert Incomer and Bus VT of section – 1.
5. Apply AC RMS Voltage across R-Phase to (Y+B+E) and measure secondary output
voltage of all the VT's.
6. Check for correct operation of voltage indicators.
7. Reduce the voltage and remove all the VT's of section – 1.
8. Apply AC High Voltage of 80 % of FAT for 1 minute across R-Phase to (Y+B+E)
and record the leakage current.
9. Repeat point 3 after HV test.
10. Repeat step 2 to 9 for Y- Phase and B – Phase respectively.
11. Repeat the above steps 1 to 9 for Bus – Bars of section – 2 and section – 3
respectively.
12. Normalize all the CT connection.
ACCEPTANCE CRITERIA: - HV test can be considered as passed if high with stood for 60
second.

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NAME OF TEST:- High voltage test on 11 KV Circuit Breaker

OBJECTIVE: - Ensure the power frequency with stand for insulator and Vacuum bottle.
1. Ensure that all safety signs are put in place and test area is cordoned off. Ensure
that test area is cleaned and free from dust.
2. Ensure that tool box talk is conducted.
3. Ensure that all CT's are shorted and grounded in the LV compartment.
4. HV Test on 11kV Circuit Breakers: (Open Condition)
1. Open all Circuit Breakers.

2. Draw out the circuit breaker from switchgear by dedicated CB trolley.
3. Position all CB’s in wooden platform.
4. Short top contacts of R, Y, B Phase of all Circuit Breakers and connected to HV
test kit.
5. Short bottom contacts of R, Y, B Phases of all Circuit Breakers and connected to
Earth.
6. Using 5kV Insulation Tester measure insulation resistance between Top contact to
Bottom contacts and record the values before HV.
7. Apply AC High Voltage for 1 minute across Top contacts to Bottom contacts and
record the leakage current.
8. Repeat point 6 and record the values after HV test.
9. This CB HV Test shall be conducted section by section.
5. HV Test on 11kV CB Bus Section 1 & 2: (Close Condition)
1. Draw out the circuit breaker of bus section 1&2 by dedicated CB trolley.
2. Ensure that both Circuit Breakers are kept closed.
3. Short Y, B Phase of Breakers and connect to Earth.
4. Using 5kV Insulation Tester measure insulation resistance between R - Phase to
(Y+B + ground) and record the value before HV.
5. Apply AC High Voltage for 1 minute across R Phase to (Y+B+ ground) and record
the leakage current.
6. Repeat point 4 and record the value after HV.
7. Repeat steps 3 to 6 for Y – Phase and B – Phase respectively.
ACCEPTANCE CRITERIA: - HV test passed can be considered pass ,if CB’s with stand HV
voltage for 60 second .

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NAME OF TEST:- Electro mechanical interlocks feeder earth switch

Interlocking system against putting the feeder earth switch ON is given below.
Earth switch can be possible to operate when the VCB in test position.
General
 Check the control circuit and control wiring.
 Check the ferrule number on each component and terminal block on the respective circuit
and in capacitor door interlock.
 Check the manufacturing details of the component as per approved drawing.
 Check the functionality of the earthing switch auxiliary contacts (open/close)
 Check that the earth switch cannot be closed when the CB is in service position (should not
try with huge force ut may damage the earth switch mechanism).
 Check that the CB cannot be inserted in to the service position when the earthing switch is
closed.
 Check the status of the position-indicating device (Semaphore and mechanical indication).
Condition for closing the earth switch
 VCB should be in test position.

Negative check also to be checked by changing all the first condition and check the
operation of the feeder earth switch.
ACCEPTANCE CRITERIA: - Interlock shall satisfy all the above requirements

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HIGH VOLTAGE SWITCHGEAR SITE TESTING
HIGH
VOLTAGE
SWITCHGEAR

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NAME OF TEST:
GIS SF6 Gas Purity Check, GIS SF6 Gas Dew Point Measurement.
To verify that the SF6 gas content of all chambers is within the given limit, Using a dew
point meter, confirm that the moisture content in SF6 gas is less than normal value for all
gas zones of the newly assembled GIS.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: IEC 62271, IEC 62271-203,

IEC 60694.
PROCEDURE OF TEST:
Connect the SF6 gas content measuring device to each chamber as per the diagram.
Switch on the device. Open the NC valve slowly to allow the gas from the chamber into the
device, wait for the reading to be stabilized and record the reading
Connect the dew point meter to the different zones as per the following figure. SF6 gas
shall be allowed to pass through the instrument as per the recommended testing
procedure. (Refer the instructions of the instrument manufacturer). Dew point shall be
converted to the PPM as per the standard conversion graph.
ACCEPTANCE CRITERIA:
The SF6 gas content in each chamber shall be more than 95%, The moisture content shall
be less than 1)150ppm for CB chamber 2)500ppm for all other chambers of the GIS

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NAME OF TEST:
GIS SF6 Density Monitor Calibration (Alarm contact setting checks)
OBJECTIVE OF THE TEST: To verify that the SF6 gas density monitors work correctly
and within the given criteria.
IEC 62271-203
PROCEDURE OF TEST:
Density meter shall be calibrated through out its range from 5 bar to the maximum
available. To carry out the test an external standard gauge shall be connected in parallel to
the Density monitor and the reading in the reference gauge & standard gauge shall be
compared through out the range. In particular the pressure readings for the alarm
thresholds shall be verified. As the standard gauge is normally not temperature
compensated the reading shall be corrected for the ambient conditions.
Criteria is Po = Pd +- 0.2barg
Where,
Po = Operating pressure
Pd = Designed operating pressure

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NAME OF THE TEST: SF6 ALARM CHECKS
OBJECTIVE OF THE TEST

Gas Insulated Switchgear (GIS) consists of several bays and each bay contains different gas
compartments separated by gas tight barriers. Gas barriers are indicated by yellow colour paint.
Manufacturer of GIS have specified the recommended value of pressure in their individual gas
compartments/zones. The objective of the test is to check that the density monitor contacts are
switching in relation to the variation of gas pressure/density in the respective gas compartment,
according to the scheme provided.
STANDARD/SPECIFICATION REFERENCE OF THE TEST
For the CB compartments, a lockout feature shall be provided to prevent operation whenever SF6
gas pressure is less than that permitted by the design for satisfactory operation.
Two sets of voltage free electrical changeover contacts will be provided for every alarm for remote
SCADA and repeat alarm facilities in addition to alarm facials incorporated in the LCC/marshalling
kiosk associated with each primary circuit. Contact multiplying relays may be used.
In some type of switchgears if different pressures are maintained in CB & other compartments,
then high pressure (pressure rising) alarm shall be provided in the adjacent gas compartments.
PROCEDURE OF THE TEST

Ensure that control cable wirings are completed from the respective density monitors to the LCC
Panel. Verify that control cable terminations are properly done at both ends. Check that proper
labels and ferrules are provided at both ends as per the schematic drawing. Density monitor
contacts switching can be verified either by varying the gas pressure in the gas compartment by
using gas handling machine or by a separate portable gas cylinder arrangement if non-return
valve assembly is provided in the density monitor block. These alarms need to be verified with the
approved schematic drawing of the LCC Panel.
ACCEPTANCE CRITERIA
Normally density monitors are temperature compensated. Permissible limit of variation in the
operation of density monitor contacts willl be specified by the manufacturer of density monitor.

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NAME OF TEST: DS & ES manual operation
OBJECTIVE OF THE TEST: To ensure proper close/open operation of CB DS ES.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: 62271-102
PROCEDURE OF TEST:
Each device in the 132kV GIS shall be operated manually to ensure the perfect operation of the
device along with the interlocks for mechanical operation. Depending on the manufacturer there
will be different types of interlocks for mechanical operation for the safety of operating personnel.
These interlocks have to be verified during the operation. Mechanical position indication of status&
semaphore indications shall also be checked during this test. Operating handles are usually used for
the mechanical operation of devices. Identification of operating instructions, warnings if any during
mechanical operation etc shall be checked.
Operation shall be smooth & there should not be any abnormal sound from operating mechanism.
Mechanical indication shall also be aligned.
NAME OF TEST: CB local electrical and manual operation
OBJECTIVE OF THE TEST: To ensure proper close/open operation of CB
PROCEDURE OF TEST:
The CB close /Open operation shall be performed first at rated control voltage. After giving
close/open command from LCC the CB wwill be checked whether it is closed/opened
properly or not. If there is a glass window the physical status of the CB contacts shall be
verified. Semaphore and electrical indication for close/open of CB also we have to verify at
LCC. Mechanical indication on the CB poles shall also be verified.
Manual Charging of Closing spring & operation of CB
A discharged spring shall be manually charged using the manual spring charging handle.
After charging the closing spring CB can be closed/opened by mechanical operation push

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button. Semaphore and mechanical indication of close/open shall be verified. CB counter

operation& spring status indication shall also be verified.
ACCEPTANCE CRITERIA: Operation should be smooth & mechanical indications must be

accurate.
NAME OF TEST: CB Timing Measurement
OBJECTIVE OF THE TEST: To measure the closing and opening time of main contact of
Circuit Breaker (R, Y & B phases) & including the discrepancy among the poles operation
timing.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: 62271-100.
PROCEDURE OF TEST:
In each CB there are two nos. of closing coils and two nos. of tripping coils. Timing
measurement has to be done for all these coils.
At first, simulate all the field point of CB (After removing CB control plug) by using a
simulator. Usually a PROGRAMMA kit or any other suitable instrument can be used for
measuring close/open timing of Circuit Breaker. At rated voltage we have to give the
close/open pulse from that kit. The duration of operation will be recorded in the instrument
& it shall be displayed in the form of graph.
Following shall be recorded for open, Close & OCO operation
 Duration of operation of individual poles & discrepancy in operation of poles

 Close Coil/ Trip coil current.
 One set of NO & NC contact operation timing.

Page 6 of 18
Time for CB close /open (individual R, Y & B) can be measured from the graph. Closing and
opening current also we can take along with that graph. Pole discrepancy also we have to
check for close/open time. 1 NO & 1 NC auxiliary contact timing also we can take along with
that graph.
ACCEPTANCE CRITERIA
Acceptance criteria shall be obtained from the respective manufacturer.
For eg: AREVA 132 kv GIS B165:

Closing time: 100 to 115 ms Pole discrepancy:  5 ms (¼ Cycle)
Opening time: 27 to 31 ms Pole discrepancy:  3.33 ms (1/6 Cycle)
NAME OF TEST: CB FUNCTIONAL TEST
OBJECTIVE OF THE TEST: To verify the function of circuit breaker as a whole. For
verification of the CB function the following tests/ measurements are employs.
 CB Operation.
 Verification of 2Co or OCO operation
 Verification of nameplate.
 Lock out function.
 CB spring charging time & motor current measurement.
 Function of anti condensation Heater & its current measurement.
 Checking of anti pumping feature.
 PNT function in case of Single pole mechanism
 Operation of CB counters.
PROCEDURE OF TEST: CB operation shall be performed through all the closing &
opening coils. Care must be taken to see that the second close coil are included in the

Page 7 of 18
circuit as it is normally kept as spare. OCO operation/ 2CO operation (Depending on the
type of Mechanism) shall be verified. OCO /2CO operation are performed after switching off
the spring charging motor/ Hydraulic Motor supply MCB after closing the CB. MCB shall be
switched ON only after performing the entire operation
 Pole not together is applicable in case of single pole mechanism breakers. In case
such cases PNT function shall be verified.
 Antipumping: Prohibits the closing command to CB incase of repeated closing
command.
The close command shall be given continuously by keeping the TNC switch in close
position. Because of the continuous close command the antipumping relay will be
picked up and closing circuit will be electrically isolated. Then give a trip command
through emergency push button. Though closing command is persisting, CB should not
be closed without de-energizing the antipumping relay.
 CB lock out function for SF6 pressure drop/ Spring Discharge/ hydraulic pressure
drop etc shall be checked for close lock out, Trip lock out & General Lock out.
 Measurement of spring charging motor current shall be measured during the
operation of the spring charging motor by using an appropriate clamp meter. Usually
the spring charging motor will be DC motor. Spring charging time shall also be
measured by using a stopwatch.
 Function of anti condensation heater shall be performed by adjusting the thermostat
in the control circuit. Heater current shall be measured during this time using an
appropriate clamp meter.
 CB operational counter verification shall be done during the operation of CB. Care
must be taken to ensure that the counter is increasing once for a close & open
operation. A non-resettable type counter is preferred as CB counter.
ACCEPTANCE CRITERIA: All the above functions should be perfect.

Page 8 of 18
NAME OF TEST: GIS Contact Resistance Measurement of the Main Circuit.
The purpose of the test is to verify that the main circuit resistance of the GIS is within the
factory data. The test shall be carried out for the entire primary connections of the
switchgear including earth switches.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: IEC 62271-203
PROCEDURE OF TEST:
The resistance of the main circuit shall be measured by injecting 100A DC current. The connection
is to be done as per fig.-1. Voltage probes shall be connected inside the current probes. Care has to
be taken to avoid current injection & voltage measurement from the same point as such
measurement can cause errors.
ACCEPTANCE CRITERIA: The measured value of resistance shall be +/- 20 %(µΩ) of the
factory data.

Page 9 of 18
NAME OF THE TEST: SF6 GAS PERIODICAL CHECK FOR LEAKAGE

The objective of the test is to check that there is no SF6 leakage from the GIS and the condition
of the gas barriers and gaskets/o-rings are perfect.
STANDARD/SPECIFICATION REFERENCE OF THE TEST
The Manufacturer should be prepared to guarantee the equipment for a gas loss of not more than
0.5% per annum in any single gas compartment.
PROCEDURE OF THE TEST:

SF6 gas leakage is to be checked by gas leak detector for assembled section covered with plastic
at site after more than 24 hours accumulation.
Gas leak detector
Leak Tester
Field connection point
Wrapping by plastic sheet
ACCEPTANCE CRITERIA: The amount of gas loss shall be not more than 0.5% per annum in
any single compartment.

Page 10 of 18
NAME OF TEST: HVAC Test of 132kV GIS
SCOPE OF TEST:
The high voltage power frequency withstand test on 132kV gas insulated
switchgear to check the dielectric integrity of the switchgear
It is important for GIS to check the dielectric integrity in order to eliminate

fortuitous causes (wrong fastening, damage during handling, transportation,
storage and installation, presence of foreign bodies, etc.) which might in the future
give rise to an internal fault.
The aim of the HVAC test is to check the dielectric integrity of the completed
installation and of detecting irregularities as mentioned above. Normally the
dielectric test shall be made after the GIS has been fully installed and gas-filled at
the rated filling density preferably at the end of all site tests, when newly installed.
Dielectric test will be performed in accordance with clause 3.02 of section 16359 of
the specification and clause 7.107.1.5 procedure A of IEC 60517.
IEC 60298[8] and IEC 60517[9] are applicable for dielectric test on the main circuit
of the GIS.
PROCEDURE OF TEST:
The test will be made on the entire assembled GIS. The test voltage will be applied
between main circuit and grounded enclosure keeping the other two phases
shorted and earthed. The insulation resistance between main circuit and ground
will be measured before and after AC high voltage test by using 5000V megger for 1
minute. The IR value shall be more than 2000 M-Ohm. CT secondaries shall be
isolated from the relays, shorted and grounded at LCC. The GIS earthing system is
to be checked for proper connection to main earth grid.

Page 11 of 18
Voltage Application:
Test voltage : 80% of factory tested voltage

- Duration : 1 minute
- Frequency : 50Hz (Application of variable frequency is under
consideration)
- Gas pressure : Rated gas density
- The test voltage will be applied between each conductor and the earthed
enclosure; other two phases will be earthed.
- Voltage transformer will be excluded under the AC high voltage.
- The test voltage will be applied through the temporary test bushing fitted at the
busbar/Cable side of the GIS.
- VT ratio check will be performed during the AC high voltage test at Rms Voltage
- Voltage rising will be performed as per the following pattern.
PD meas. (1.1x BIL)

HV
Voltage
Rms Voltage
PD measurement
VT ratio check
VT isolator is open
Note: Before applying High Voltage,

VT isolator is closed
conditioning of the switchgear can be done

Page 12 of 18
The following shall be completed before HV test

GIS erection shall be completed in all respect.
Contact Resistance measurement of the entire primary circuit shall be completed
All devices must be operated at least five times either electrically/mechanically.
Earthing of GIS, Safety aspects shall be ensured.
The GIS shall withstand HVAC voltage for 1 minute, while the partial discharges
recorded during HV test at specified voltage shall be less than 10pC.
NAME OF TEST: 132kV GIS PD Coupler Sensitivity Check.
To confirm that the sensitivity of each PD sensor is enough to pick up 5pC or less of
PD at any point in the GIS.
IEC Standards: As per IEC 62271-203 ; CIGRE guide lines.
PROCEDURE OF TEST:
PD couplers (UHF Sensors) are mounted at different places on GIS. PD shall be

measured during HV test of the GIS. Each coupler shall have enough sensitivity to
pick up 5pC or less of PD at any point in the GIS. So before high voltage test & PD
measurement, sensitivity of PD sensor is to be verified.
The sensitivity of each UHF coupler is confirmed by the following method.

1) Inject artificial PD (rectangular pulses with rise time less than 1ns) with voltage
of 20V from one UHF coupler. This level is assigned as (a). The specification of
the artificial pulse according to CIGRE TF 15/33.03.05 is as follows:
- Rise time: less than 1 nano second.
- Magnitude of impulse voltage: N/A (it is dependent on the sensor for
injection and/or injection value).
- Pulse with: more than 500 nano seconds( rectangular pulse)
- Time between consecutive pulses: less than 100kV (e.g. 50/60Hz).

Page 13 of 18
2) Measure PD signal from another UHF coupler. This level is assigned as (b).
3) Attenuation between UHF coupler (a) and (b) is calculated and this is assigned
as (c) = (a) + (b)
4) Take one half of attenuation (simulate PD source at the middle between two UHF
couplers) and this is assigned as (c´) = (c)/2
5) The minimum sensitivity assigned as (d), is calculated by the following formula.
d = 300X10((-85+25+ c´)/20)
Where, +25 is the gain of the amplifier
6) The test result and calculated result is to be shown in a table.
The test circuit of attenuation measurement is shown bellow,
Pulse Portable
Generator PDM
Fig. 1 Test Circuit for Confirmation of Signal Attenuation
ACCEPTANCE CRITERIA: Each PD sensor shall have enough sensitivity to pick up

5pC or less partial discharge at any point of the GIS.

Page 14 of 18
NAME OF THE TEST: VOLTAGE SELECTION SCHEME & SYNCHRO CLOSE CHECKS

Switchgear consists of double busbar arrangement. A separate LV scheme ( voltage Selection
scheme) is utilized for making proper selection of busbar voltage by making use of line VTs
secondary. Selection of a particular line voltage as the respective busbar voltage is accomplished
in accordance with the connection of busbar disconnector& CB to the respective busbar.
Interposing VTs with 1:1 ratio also inserted in VT secondary circuit for electrical isolation of VT
secondary. The scheme is designed to get proper selection of busbar voltage depending upon the
switching to the different busbars.
The objective of the test is to check that proper selection of voltage is made in accordance with
the switching to the respective busbar.
PROCEDURE OF THE TEST

Ensure that control cable wirings and interpanel buswirings are completed as per the approved
scheme in the LCC Panel. Verify that terminations are properly done and ferrules are provided at
both ends as per the schematic drawing. R & Y phases of the VT secondary is used for synchro
selection scheme. Energized condition can be simulated by injecting variable AC voltage in the VT
secondary circuit. Before voltage injection ensure that VTs primary disconnectors and secondary
isolating links are open to avoid back charging of the VT. Voltmeters shall be connected in the bus
coupler panel at the corresponding points to measure busbar I, II, V & VI, running and incoming
voltages in relation to the various switching combinations of the power circuit. Check that proper
voltage is extending to the running and incoming voltage buses by actuating synchro-selecting
relay. Check that any voltage induced in the non-energized buses. Verify that what means
provided to reduce the level of induced voltage in the non-energized buses.
Check the synchro closing condition by varying incoming and running voltage parameters.
Synchronization command will be issued by the synchrocheck relay only when both the incoming&
running voltages are within the specified limits as mentioned below. Create the negative
conditions to check the synchronizing scheme and software program are functioning correctly.

Page 15 of 18
ACCEPTANCE CRITERIA
Parameters for synchro closing
Difference in voltage : ±10%
Difference in frequency : ±0.5 Hz
Difference in phase angle : ±10 degree
NAME OF THE TEST: Operational Interlocks. (LOCAL & REMOTE)
Objective of Test: -
To avoid the human mistakes during the operation of the equipments and devices in
the substations. The interlock will be advisory system to support the operators and
the site engineers with special expert information and knowledge to guaranty safe
operations of the equipments.
The interlock system is not a fixed scheme; it is changed from manufacturer to
manufacturer and depending on operational safety.
There are different control level of the equipments in side the substations and each
level having different inter lock, the control can be as follow:
Mechanical operation ,Local electrical operation, Remote & SCADA operation
Based on the above we can segregate the interlock test as follows:
1. Mechanical interlock test
2. Electromechanical interlock test
3. Local electrical interlocks
4. Remote interlocks.
Note: Prior to any interlock test all electrical &mechanical operation shall be
completed. The interlock test shall be carried out as per the interlock logic sheet ,
Sample attached.

Page 16 of 18
 Sample Inter lock logic diagram

Page 17 of 18

Page 18 of 18
CABLE SITE TESTING
MV & HV
CABLE

Page 1 of 26
CABLE SITE TESTING
A. List of Tests to be carried out in MV Cable
a. Phase Identification Test.

b. Insulation Resistance Test (Before and after HV Test)
c. Sheath Integrity Test.
d. Conductor HV Test
PHASE IDENTIFICATION TESTING
1 Purpose:
 To ensure the continuity and phasing of the cable from terminal to terminal, the
cable sheath shall be tested using a minimum of 250V DC. The phase checking
test shall be done after the complete termination works.
2 Test Equipment Used:
 Discharge Rod
 Connection leads
 Digital Multimeter
 Warning tape, Caution Board etc
 Tools
 All pre-requisite mentioned in page 1 shall be ensured.

 Ensure the completion of cable installation and Termination
 Ensure labelling with Phase Identification is provided.
 Ensure that none of the cable terminations are touching each other.
4. Test Procedure Details:
 Ensure labelling with Phase Identification is Provided.

 Check the continuity with multimeter for individual cables,
 The correct phasing shall give low resistence approx. 0.3Ω (Shorted condition).
 Verify the proper phase markings at test location & remote end.
 Above procedure shall be repeated for the other phases also.
 The test results shall be recorded in test format.

Page 2 of 26
CABLE SITE TESTING
Insulation Resistance Test
1 Purpose:
 To check any damage occurred during cable pulling, To check the insulation
integrity before and after any voltage injection. To ensure conductive parts are
isolated from ground.
2 Test Equipment Used:
 Discharge Rod
 Connection leads
 Insulation Resistance Tester
 Digital Multimeter
 Warning tape, Caution Board etc
 Tools

3. Test Procedure Details:
 All power cables are in final position (Trefoil) with Cable tie fastened
 Ensure that no other party is working near to testing area.
 Connect negative terminal of the Insulation test kit to the conductors of same
phase together ( all will be shorted together) and positive to earth. The other two
phases shall be earthed.
 Before injection make sure that far end is open and isolated from earth
 Apply 1 KV DC for one minute and measure the Insulation Value.
 Connect the discharge rod to the cable after switching off the kit
 The test results shall be recorded in test format.
 Same test procedure shall be done for other phase as well.
 This test will be done before and after the HV test of cable to ensure the
healthiness of the cable

Page 3 of 26
CABLE SITE TESTING
DIAGRAM FOR INSULATION RESISTENCE MEASURMENT TESTING

SHEATH INTEGRITY TEST.
Purpose :
 To determine the healthiness of the sheath of the cable after completion of cable
installation work
Equipment used for the test:

DC high voltage kit.
Temperature & Humidity indicator.

Page 4 of 26
CABLE SITE TESTING
Discharge / Earth Rod.
Connection leads.
Hand Tools.
Warning tape & Caution Board.
Test Procedure Details:

 Sheath test to be carried out after completion of back filling work.
 Earthing connection of the cable will be isolated, to segregate the cable from
earth.
 Connect testing set to the cable as per connection diagram.
 All safety points to be checked before switching on the power supply to
the testing set and communicates with remote end.
 Raise voltage to 10 kv gradually and observe leakage current on Ammeter,
Hold it for 60 sec. And record leakage current on the test format.
 Switch off the power supply of Testing set and wait till the voltage reaches to zero.
 Discharge the cable using by discharge rod. Connect the next phase as per the
above and repeat the process.
DIAGRAM FOR SHEATH TEST

Page 5 of 26
CABLE SITE TESTING
DC HIGH VOLTAGE TEST.
Purpose :
To determine the healthiness of the cable insulation after completion of cable installation
workand before energisation.

DC high voltage kit.
Discharge / Earth Rod.
Connection leads.
Hand Tools.
Warning tape & Caution Board.
Procedure Details:
 Test shall be carried out after completion of cable installation and back filling work,
 All Electrical tests to be completed before HVDC test,
 11KV Cable connections to the Switchgear and Transformer shall be disconnected
 Ensure good grounding connection,
 Measure IR value of the cable before HV Test and record the readings
 Connect testing set to the cable as per connection diagram.
 All safety points to be checked before switching on the power supply to the test set and
communicates with remote end.
 Raise voltage to 25.4 kv gradually and observe leakage current on Ammeter.
 Hold it for 15 Minutes. And record leakage current on the test format.
 Switch off the power supply of Testing set and wait till the voltage reaches to zero.
 Discharge the cable using by discharge rod.
 Connect the next phase as per the above and repeat the process.
DIAGRAM FOR HV DC TEST

Page 6 of 26
CABLE SITE TESTING
HV CABLES
Sheath Integrity Test before Cable laying (Drum test)
Purpose of the test:
To ensure that the cables are free from defect & fault during transportation from factory to site and
to avoid any ambiguity between manufacturer & cable contractor.
 DC high voltage kit.
 Discharge / Earth Rod.
 Connection leads.
 Hand Tools.
 Warning tape & Caution Board.

Safety Requirements:
 All safety measures should be checked & confirmed by safety officer.
 Barricade the cable drum and provide warning tapes.
 All the power tools and hand tools to be properly insulated.
 Unwanted materials to be r removed from the work location.
Test Procedure:
1. Cable drum shall be placed in a leveled ground and suitable stoppers shall be placed on both sides to
prevent the movement of the drum .
2. Cable drum to be kept open and both ends of the cable to be taken out.
3. Removal of graphite coating of outer protection sheath at both ends (<20 cm)
4. Nail to be inserted up to lead sheath at test end Graphite removed area.
5. Earthing to be provided to graphite coating area and the cab le drum itself,
6. Inject voltage gradually up to 10KV, kept injection for 60 sec and note the leakage current.
7. Switch off the power supply of the test kit and allow self discharge.
8. Discharge the cable by discharge rod.
9. Repeat the test for other cable drums. All test results are recorded in test format.

Page 7 of 26
CABLE SITE TESTING
Acceptance criteria:
10kV DC voltage should withstand for a time period of 1 min without any breakdown.
Test Diagram

Page 8 of 26
CABLE SITE TESTING
Insulation Resistance Test
• To check any damage occurred during cable pulling.
• To check the insulation integrity before and after any voltage injection.
• To ensure conductive parts are isolated from ground.

• Insulation Tester (Megger).
• Temperature & Humidity indicator.
• Discharge / Earth Rod.
• Connection leads.
• Hand Tools.
• Warning tape & Caution Board.

• All safety measures should be checked & confirmed by safety officer.
• Barricade the cable drum and provide warning tapes.
• All the power tools and hand tools to be properly insulated.
• Unwanted materials to be r removed from the work location.

Test Procedure:
1 All power cables are in final position (Trefoil) with Cable tie fastened
2 Ensure that no other party is working near to our testing area.
3 Connect negative terminal of the test kit to the test terminal & the positive to earth.
4 Before injection to ensure the far end is open and isolated from earth.
5 Switch on the instrument, apply 1 KV DC for one minute and note the Insulation Value.
6 Switch off the power supply and wait till the residual voltage gets self discharged.
7 Discharge the cable with earth rod.
8 Repeat the process for all the other phases. All test results are recorded in test format.

Page 9 of 26
CABLE SITE TESTING
Insulation resistance of XLPE shall be measured at 1 kV‐‐DC for 1 minute and the measured
value shall not be less than 100 MΩ per 1000m at ambient temperature. The actual
resistance values can be higher or lower, depending upon factors like temperature or
moisture content of the insulation (resistance decreases in temperature or moisture).

Test Diagram

CABLE Phase Verification & Sheath integrity test

Page 10 of 26
CABLE SITE TESTING
• To make sure the correct phasing of the cable before termination and also prior to dockin
• To determine the healthiness of the sheath of the cable after laying & before HVAC test.

• DC high voltage kit.
• 1kV Insulation Tester.
• Hand Tools.


Test Procedure:
• Ensure that no other party is working near to testing area and in the other end of the cable

a) Sectional Phasing
1. Checking of the safety measures for both ends.
2. Each phase shall be tested one by one.
3. Connect negative terminal of the test kit to the conductor & the positive to earth, connect the other end of
the cable to earth by keeping other two phases in open at far end.
4. Injection voltage to be limited to 50‐150V in normal situations.
5. Switch on the IR Tester apply the voltage, now successively ground each phase cable from the far end.
6. The correct phase shall indicate 0ΩΩ (Short condition) while shorted in the far end with all other phase open.

7. This can be further cross checked by removing and connecting the ground of the phase at far end, now the
meter shall read open and 0Ω respectively as per the connection at far end.

Page 11 of 26
CABLE SITE TESTING
8. Provide proper phase markings at test location & remote end.
9. Above procedure shall be repeated for checking the other phases.
10. The test results are recorded in test format.

b) Sectional Sheath test
1 Removal of graphite coating of outer protection sheath a t both ends (15‐20 cm )
2 Nail to be inserted up to lead sheath at test end Graphite removed area.
3 Insulation resistance test (1kV) to be performed for all cables.
4 Inject voltage gradually up to 5KV, for 60 sec and note the leakage current.
5 Switch off the power supply of the test kit and allow self discharge.
6 Discharge thee cable by discharge rod.
7 Repeat the test same for other cables.
8 Repeat Insulation resistance test (1 kV) for all cables.
9 All test results are to be recorded in test format.

Sectional Phasing
Ensuring the tested phase is in short condition while other phases are in open condition,
the test to be considered as passed
Sectional Sheath Test
5kV DC voltage should withstand for a time period of 1 min without any breakdown.

Page 12 of 26
CABLE SITE TESTING
Sheath Voltage Limiter (SVL) Integrity Test
Purpose of test:
To ascertain the withstanding capacity and proper functioning of SVL.
• DC high voltage kit.
• 1kV Insulation Tester.
• Hand Tools.


Test Procedure:
1 Ensure that the link box installation completed & connections made properly.
2 Disconnect all the SVL leads from the bonding links.
3 Clean it properly & handle the housing part carefully.
4 Ensure there is no physical damage in the SVL.
5 Confirm the rating of the SVL
6 Insulation resistance test (1 kV) to be performed for all SVLs.
7 One end of the SVL to be connected as injecting point from the HVDC test kit and other end to ground.
8 Switch on the HVVDC test kit.
9 Record the Leakage current at UC ‐2, UC ‐1, and UC , while Voltage is gradually applied across two
points.
10 Increase voltage until the cut off voltage reaches at 100 µA & 1 mA.
11 Switch OFF the test Kit
12 Discharge the SVL until the voltage comes down to zero.
13 Perform Insulation Resistance test (1KV) on SVL Repeat the above tests for all other SVL’s

Page 13 of 26
CABLE SITE TESTING
Acceptancee Criteria:
SVL shall be in open condition when applying voltage up to Uc voltage. SVL to regain its
open condition after achieving the above mentioned leakage currents.

Test Diagram

Link box Contact Resistance Test
Purpose of test:
To make sure that the links are tightened properly inside the link box

Page 14 of 26
CABLE SITE TESTING
Equipment used for the Test:
• Micro Ohm Meter).

• Barricade the test area with warning tapes.

Test Procedure:
1 Ensure the Completion of all Link box installation
2 Fix the Links & SVL as per approved the schematic diagram.
3 Make required tightness of all links in the Link Box.
4 Coordination with other working team to ensure no other test on it.
5 After setting the instruments connection as per the below test diagram, the contact resistance shall be
measured..
6 If the links are not fixed properly, the measurement shall be high due to the potential drop between the
gaps of two contacts.
7 The test results are recorded in test format.

Acceptance Criteria:
The measured value should be less than 20 µ ΩΩ.
Test Diagram

Page 15 of 26
CABLE SITE TESTING
132KV Cable Phase verification through Sheath
Purpose of test:
To make sure the sheath Bonding System is installed correctly.
• IR Tester (MEGG ER)
• Discharge Rod
• Connection leads
• Tools
• Warning tape, Caution Board etc.


Test Procedure:
1. Ensure the completion of cable installation and back filling off cable route.
2. Ensure all Bonding cables (Inner & Outer core) Labeling completed.
3. Ensure NO other parties working near to thee testing area.
4. Both solid earthing links shall be isolated from the earth.
5. SSVL connections to be isolated in the link box and bonding connections to be maintained as per
bonding scheme.
6. Sufficient manpower to be placed at both ends of testing &each phase shall be tested one by one.
7. Connect negative terminal of the test kit to the conductor & the positive to earth, connect the other
end of the cable to earth by keeping other two phases in open at far end.
8. Injection voltage to be limited to 50‐150V in normal situations.
9. Switch on the IR Tester apply the voltage, now successively ground each phase cable from the far end.
10. The correct phase shall indicate 0ΩΩ (Short condition) while shorted in the far end with all other phase
open.
11. This can be further cross checked by removing and connecting the ground of the phase at far end, now

Page 16 of 26
CABLE SITE TESTING
the meter shall read open and 0Ω respectively as per the connection at far end
12. Provide proper phase markings at test location & remote end.
13. Above procedure shall be repeated for checking the other phases.
14. The test results are recorded in test format.

Sectional Phasing
Ensuring the tested phase is in short condition while other phases are in open condition,
the test to be considered as passed

Page 17 of 26
CABLE SITE TESTING
CABLE CONDUCTOR RESISTANCE TEST

Purpose:
Conductor Resistance values for the cable are measured as part of pre commissioning
tests in order to ensure the integrity of the joints and termination.
Equipment used for the Test:
• Micro Ohm Meter.

• Barricade the test area with warning tapes.

Test Procedure:

 Connecting lead wire will be used for connecting the conductors at far end of the cable.
 DC Resistance of the connecting lead will be measured.
 Two cable cores will be connected to each other at far end of the cable, (Phase R & Y).
 At other end connect the Michro Ohm meter in Phase R & Y.
 The DC resistance of these two cables also will be measured.
 Connect the meter to Phase Y & B and shift the connecting leads at far end to Phase Y&B
aswell
 Measure the DC resistance
 Repeat the same test by connecting between Phase R &B aaswell
 Conductor resistance is calculated by the below formula.
Rt = Rm – RcL
Where Rt = Measured Resistance, RcL = Shorting Lead Resistance, Rf = Final
Resistance
 Measured Resistance shall be converted to 200 C , By using formula
R20 =Rt/L (1+0.00393(T-20)
Where R20 is calculated Resistance at 200C t is measured temperature,

Page 18 of 26
CABLE SITE TESTING
(for 630sq mm copper conductor , Coefficient of resistivity is 0.00393)
The measured resistance value corrected at 20 C must be equal or less than the design
resistance of 630mm2 cable (0.0283 ohm/km)

Page 19 of 26
CABLE SITE TESTING
HVAC Test on CABLE and Terminations
Purpose
The purpose of the test is to ensure that the cable and terminations are fit for service and
safe to energize.
The method used will be to apply a sinusoidal voltage between each cable conductor and
insulation shield (ground) in turn for a period of time.
The cable has to withstand 132KV for 1 hour.
The AC voltage will be generated by LC series resonance whereby the cable under test will
be the capacitor and a high voltage reactor will be the inductor.
An exciter transformer connected between the low voltage terminal of the reactor and
ground will be used to energize the resonant LC pair. The exciter transformer is energized
from a variable frequency inverter via a isolation transformer. The Inverter output
frequency can be varied electronically between 20HZ and 300HZ.
Equipment / Accessories to be used for the Test:
• Resonant frequency High Volt AC test kit
• 5kV insulation tester
• Discharge / Earthing rod
• Hand Tools
• Warning tape & Caution Board

• Safety officer shall be available & safety persons to be kept a t all entrance/ exits.
• Safety measures to be checked by safety officer.
• Take confirmation of site readiness from GIS cable box manufacturers’ at substation and coordinate
with other contractors before starting the test.
• Ensure no other party is working in the GGIS room and basement.
• The testing area to be completely barricaded.
• Provide warning tape on the area where the circuit to be tested.
• Provide warning sign inside substation of circuit of be tested
• Keep sufficient s supervisor far end and testing end during the test.
• Fire extinguisher (C02) shall be available at site.

Page 20 of 26
CABLE SITE TESTING
TEST PROCEDURE
 Site survey will be conducted to determine the appropriate location to assemble the test
equipment and capacitor divider (preferably GIS off-loading platform area).
 HV winding of the IDT will be earthed inside the HV cable boxes.
 Prior to start of test to ensure that the Transformer HV cable side oil treatment completed
and cable box filled with oil tested in lab.
 GIS side to ensure that CB (Q0) is in Open condition and earth switch (Q52) in closed.
 Quality of the gas filled in the cable boxes to be tested and ensured for its purity.
 The terminations remote from the testing location to be barricaded and warning
 signs displayed to indicate testing is likely to be in progress.
 During application of test voltage , access to the IDT / Basement room will be restricted
and a watchman will be stationed near IDT area terminations as a safety precautions.
 The free-air electrical clearance of all grounded energized parts shall be minimum of 25mm
per 10KV ( peak) of applied test voltage to avoid flashover.
 AC resonant test set will be installed adjacent to the GIS into which the HV test adopters
have been installed. If a connection cannot be made between the HV test set and GIS HV
adopter in a single span an intermediate temporary support will be erected to support the
HV test lead.
 Copper wire 6sq.mm test lead will be contained within 100mm diameter aluminum foil
ducting to reduce the corona losses and minimize the generation of external partial
discharges.
 All test equipment grounds will be securely connected to substation ground system.
 Diesel genset will be the source of LV input power for the test equipment.
 Rigid safety barricades, warning signs and flashing warning lights will be erected around
the test site.
 All cable shields and link boxes will be in their service position except for SVL which will be
shorted to avoid being damaged in the event of flash-over during testing.
 HVAC test will commence with the measurement of cable insulation resistance between
conductor and insulation shield one phase at a time using 5KV meggar.
 Measured values will be recorded at the completion of one minute of measurement.
 Each conductor will be connected to ground on completion of IR test.
 Ground will be disconnected from the termination of the first cable to be tested.
 HV output terminal of the test lead will be connected to cable terminal via low corona test
lead.
 Cable HVAC test can be conducted one phase at a time or all three phases together as
agreed by the client and depending on availability of test adopters.
 All test reports should be available at site prior to start of HVAC test
 Following a final check of safety arrangements, equipment connections & grounds, and
after safety clearance from safety officer, the LV power supply to test equipment can be

Page 21 of 26
CABLE SITE TESTING
switched ON from the genset.

 PD measurement to be done prior to HVAC test at U0 and 1.5 U0, HVAC test can
commence if the PD is clear.
 After entering the required details, in the software for testing, the frequency inverter is
energized.
 The test voltages, stages and voltage duration will be given and the software will search
for the resonant frequency automatically.
 After reaching the resonant frequency point the test voltages for required duration can be
started or increased in stages. The AC test voltage for 60 minutes with max phase-phase
voltage of the system applied between conductor and metallic sheath /screen, will be
132KV AC .
 In the event that a failure of the cable / accessories occurs during the HVAC test, the effect
will be that the Q factor of the resonant circuit will be considerably degraded and
consequently the test voltages will immediately fall to reduced value. Damage at the failure
location would be minimal.
 Test eqpt will be immediately shut down and the location and cause of the failure can be
investigated.
 At the end of the specified test duration, the reactor output will be decreased automatically
to minimum and the inverter will shutdown.
 PD measurement is repeated again after the HVAC test at 1.5 U0 and at U0.
 After completing HVAC test , the tested cable will be earthed .
 Test adopters will be shifted to the next circuit and HVAC test to commence as per the
above procedures.
 After completion of HVAC test of all cable circuits IR measurement procedure will be
repeated.
 Test adopters dismantled, links fixed inside the GIS cable boxes, Gas filled and treatment
done, Gas quality checked.
Acceptance Criteria
The test can be deemed passed, if it withstands 132 kV AC voltage per phase (U0 X 1.732) for new
cable, 106 kV AC voltage / phase (U0 X 1. 732 X 0.8) for old cable for a duration of 1 hour at a
frequency range of 200‐300Hz without any breakdown during test.

Page 22 of 26
CABLE SITE TESTING
Test Diagram
PD
Measurement during HVAC Test

Page 23 of 26
CABLE SITE TESTING
Purpose of test:
Determination of the healthiness of cable / Termination after installation ( before energisation )
The presence of PD activity occurring in terminations and joints can be determined and measured.
PD activity occurring within voltage range close to operating voltage of the cable can be a
predictor of early joint/ termination failure.
Equipment / Accessories to be used for the Test:
• Resonant frequency High Volt AC test kit
• PDM Kit
• Discharge / Earthing rod
• Hand Tools
• Warning tape & Caution Board

• Safety officer shall be available & safety persons to be kept a t all entrance/ exits.
• Safety measures to be checked by safety officer.
• Take confirmation of site readiness from GIS cable box manufacturers’ at substation and coordinate
with other contractors before starting the test.
• Ensure no other party is working in the GGIS room and basement.
• The testing area to be completely barricaded.
• Provide warning tape on the area where the circuit to be tested.
• Provide warning sign inside substation of circuit of be tested
• Keep sufficient s supervisor far end and testing end during the test.
• Fire extinguisher (C02) shall be available at site.
TEST PROCEDURE
1. All requirements for HVAC test to be completed
2. Identify and confirm the cable ( Feeder and phase) to be tested
3. Mount the UHF coupler on the stress cone of the cable termination for the individual.
4. Lay the UHF cable and connect one end of UHF cable to the coupler as per drawing attached.
5. Provide an external ground before switch on the portable kit.
6. Switch on PD equipment and Laptop and confirm the system is working properly
7. Confirm the communication between processor unit and laptop is intact.
8. Create substation folder per test and sub folder for the PD measurement voltage
9. Inform the HV test coordinator for the readiness of PD measurement.

Page 24 of 26
CABLE SITE TESTING
10. BG noise level sensitivity 76kV BHV, 106kV BHV, 106 AHV and 76 AHV to be performed
12. Check the background noise level and adjust the threshold level and add hardware filter to achieve better
signal to noise ratio.
13. The above exercise should not affect sensitivity of the PD coupler
14. Perform PD coupler sensitivity test by injecting 20V with CAL 2B PD pulse injector.
15. Confirm the coupler sensitivity for the all cable to be tested and record.
16. In case of any abnormality observed the PD can be measured at different voltage level (below 106kV) to
know the injection on extinction voltage level for PD activity.
17. Procedure 8 to 15 shall be repeated for other phase / Group cables.
18. The test report to be recorded in test format.
During testing at 76kV & 114 kV no PPD shall detected.

Page 25 of 26
CABLE SITE TESTING

Page 26 of 26
CAPACITOR BANK SITE TESTING
CAPACITOR
BANK

Page 1 of 9
3. CAPACITOR BANK
SCOPE:
This method statement covers the procedure for doing site tests to be carried out on Capacitor
Bank.

The objective of the test is to verify the readiness & healthiness of the Capacitor units and Damping
Reactor.
SAFETY PRECAUTIONS
 Never Over tight the Capacitor Units , Follow the installation drawings for tightening torque.
 Confirm magnetic clearances mentioned in the drawing is followed.
Capacitor BANK specification and approved drawings. IEC 60871-1 & 4
List OF TEST:
Below Tests to be Carried out in Capacitor Bank.
1. CAPACITOR INSULATION RESISTANCE TEST

2. CAPACITOR - CAPACITENCE MEASUREMENT
3. DAMPING REACTOR WINDING RESISTANCE
4. DAMPING REACTOR HV TEST
5. DAMPING REACTOR -INDUCTANCE MEASUREMENT
6. CAPACITOR BANK UNBALANCE CURRENT MEASUREMENT

Page 2 of 9
11 KV CAPACITOR INSULATION RESISTANCE TEST
OBJECTIVE OF THE TEST :The purpose of the test is to verify the healthiness of insulation of the
capacitor units.
STANDARD/SPECIFICATION REFERENCE OF THE TEST :IEC 60871-1 & 4
PROCEDURE OF TEST:
1. Keep the terminals of capacitor unit shorted and the IR value between terminals to
container is measured with 2500V IR tester.
2. The above step to be repeated for all capacitor units.
./ IR values must be above 100 MOhms.

Page 3 of 9
11 kV CAPACITOR ‐ CAPACITENCE MEASUREMENT
OBJECTIVE OF THE TEST: The purpose of the test is to verify the capacitance value of the
capacitor units are within the factory data.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: IEC 60871-1 & 4
PROCEDURE OF TEST
1. Connect the LCR tester / Suitable device across the Capacitor Unit and measure the
Capacitance
2. Record the capacitance measured each unit.
3. All capacitence values should be compared with factory test reports.
./ All capacitence values should be comparable with factory value and within tolerance recommended
by the factory.

Page 4 of 9
11 KV DAMPING REACTOR WINDING RESISTANCE
OBJECTIVE OF THE TEST: The purpose of the test is to verify that there is no internal short
circuit in the winding and the winding resistance of the damping reactor units is within the factory
data.
STANDARD/SPECIFICATION REFERENCE OF THE TEST : IEC 60076‐6
PROCEDURE OF TEST
1. Measure and record the ambient temperature and humidity in the test format.
2. Measure the Winding resistance across the terminals using a micro ohm meter.
3. Convert the winding resistance measured to 750 C.
./ All resistance values should be compared with the factory test reports

Page 5 of 9
11 kV DAMPING REACTOR HV TEST
OBJECTIVE OF THE TEST: To verify the dielectric strength of damping reactor
STANDARD/SPECIFICATION REFERENCE OF THE TEST: IEC 60076‐6
PRE-REQUISITES:
1. Isolate the Power Cable before HV Test.
2. The jumper between damping reactor and Capacitor Bank must be removed
before HV Test.
3. Valid calibration certificates for testing instrument must be available.
PROCEDURE OF TEST :
1. Measure Insulation Resistance before and after HV test.
2. Apply 22.4 kV (AC) for 1 minute to each terminal and earth.
3. Leakage current shall be recorded.
./ All reactors should withstand the HV for 1 minute. (Note: There is no criteria for leakage
current. The measured record is a reference for future)

Page 6 of 9

11 kV DAMPING REACTOR ‐INDUCTANCE MEASUREMENT
OBJECTIVE OF THE TEST :The purpose of the test is to verify that the inductance of the damping
reactor units is within the GTP and factory data.
STANDARD/SPECIFICATION REFERENCE OF THE TEST:IEC 60076‐6
PREREQUITE:
1. Isolate the Power Cable before the Test.
2. The jumper between damping reactor and Capacitor Bank must be removed
before the Test.
3. Valid calibration certificates for testing instrument must be available.
PROCEDURE OF TEST
Y Measure the Inductance across the terminals using a inductance measurement meter.
./ All inductance values should be compared with the factory test reports.
./ Allowable tolerances are mentioned in the factory test reports.

Page 7 of 9
11 KV CAPACITOR BANK UNBALANCE CURRENT MEASUREMENT
OBJECTIVE OF THE TEST: Determine the unbalance current in the capacitor bank and ensure that the
unbalance current is within the protection setting.
STANDARD/SPECIFICATION REFERENCE OF THE TEST: NO specific specification. This test

is to ensure that unbalance value is less than 20% of Trip settings.
OBJECTIVE OF THE TEST: Determine the unbalance current in the capacitor bank and ensure that the
unbalance current is within the protection setting.
PRE REQUISITE:
1. Ensure that capacitor unit tests are completed and interconnections between capacitor
units and damping reactor.
2. Ensure valid calibration certificates for test instruments (Digital Multi-meter, Clamp
meter), are available.
PROCEDURE OF TEST:
1. Calculate the total capacitance in each phase of the capacitor bank.

2. Compare the difference in total capacitance across the phases. It must be
within the alarm setting of the unbalance relay. In case the unbalance is more
than the setting, rearrange the capacitor units to balance the capacitance
fairly equal in all phases.
3. Ensure the interconnection between capacitor units and reactor is available.
4. Apply 380V 3 Phase AC Supply to Capacitor Banks.

Page 8 of 9
5. Measure current in each phase and neutral.

6. Compare the measured neutral current with setting of the out of balance
protection relay. No further action required if the neutral current is within the
relay setting.
7. Rearrange capacitor unit if the neutral current is more than the alarm setting of
the out of balance protection relay.
8. Measure the phase and neutral current again after rearranging capacitor unit and
ensure the unbalance current is less than the alarm setting of out of balance
protection relay (OBR).
./ Acceptance criteria: The neutral current should be within the alarm setting of Out of Balance
Protection Relay. It shall not be more than 20% of Trip setting

Page 9 of 9
TRANSFORMER SITE TESTING
TRANSFORMER

Page 1 of 52
01. TRANSFORMER GENARAL DATA
This format contains the general technical data of the transformer.Data shall be filled in the
format shall be filled as per the details from the nameplate, valve schedule plate, factory
acceptance test report, approved drawings etc.
02. FINAL CHECKS
This document contains the items to be checked and reconfirmed prior to energisation of the
transformer. These checks are conducted after completion of all tests as a reconfirmation. All
items specified in this format are verified and comments if any are reported.
03. INTIAL CHECKS
These are the checks that to be verified prior to start of any site acceptance tests. These are for
ensuring the fitness of the transformer to be tested at site. The checks include ensuring that the
transformer was received safely at site on the basis of the safe receipt report and shock recorder
data. With the available details, verification is to be done on perfect completion of site processing
(errection,asembling,oil processing and etc).Also the availability of records including
specifications, approved drawings their catalogues, site note file etc.at site office to be checked.
04. SITE PROCESING DETAILS
These are checks to ensure whether the oil processing at site was completed either as per the
procedure furnished by the manufacturer or based on any relevant documents/standards. The
safe and healthy condition of oil purifier, vacuum pump, pressure gauges etc. used during oil
processing are to be ensured. The record of the insulation resistance values taken at regular
intervals during oil filtration site has to be verified. Also the degree of vacuum maintained during
processing and the condition of the hot oil circulation are verified. The ppm, BDV and tan delta
capacitance values of the oil as per test report are verified.

Page 2 of 52
05. VISUAL INSPECTION
These checks include physical verification of the components and accessories fixed on the
transformer, marshalling kiosk etc.This is general check for compliance of the different parts of
the transformer with approval list and specifications. All the times listed in the parts list and given
in general outline arrangement drawings are verified.
06. INSULATION RESISTANCE TEST OF WINDING, CORE&CLAMP
Standards: IEC60076-2000(Part1), IEEE62

General
Insulation resistance measurements are performed to verify that the state of dryness of the
insulation of the various winding and the core are of acceptable values. Insulation resistance
testing may also reveal important information about concealed damage of bushings.
Insulation resistance is the volume and surface resistivity of the insulation involved. Insulation
resistance of transformers and reactors are measured using insulation tester and the value
expressed in mega ohms. The output voltage from the insulation tester is DC.The value of
insulation resistance (IR value) depends on the design (Voltage class, type etc.).Temperature of
oil, dryness of internal parts, cleanness of parts (especially bushing porcelains, terminals), and
condition of oil atmosphere conditions (humidity) etc.IR value varies with voltage applied for
measurement and hence compression may always be done with measurement carried out at
same voltages.IR value is inversely proportional to the temperature.
Before starting of the measurement, the temperature of the oil must be noted; which shall be
almost the same as the reference ambient temperature. Measurements are made at 15th, 60th
and 600th seconds. Ensure that the measured value at 60th seconds is not less than
2000meg.ohm.Polarization index (PI) value, which is the ratio of 600th to 60th seconds IR value is
determined. PI value gives a rough guide to the condition of the insulation properties; especially
the dryness of the windings and internal parts of the transformer. PI value ≤1.0 indicates
bad/unsatisfactory, ≥1.3 satisfactory, ≥1.5 good and, ≥2.0 very good condition of the
dryness/insulation properties inside the transformer.
The new generation insulation testers have inbuilt provisions for discharging the voltages through
the testing equipment itself, which takes place within a few seconds after switching off. However,
as the voltage generated for measurement is off the tune of 500V-5000V, earthing may be done
externally before removing the connection as a satisfactory precaution.

Page 3 of 52
7.1 Insulation resistance of winding
Aim
a) To determine the insulation resistance of winding to earth and between windings.
b) To evaluate the condition of the transformer insulation.
Test preparation
Insulation tester (Megger) must be off 5KV range having valid calibration. The earthing of the
main body/tank, core/clamp etc. cleanness and dryness of the bushing porcelain/terminals and
tightness of the connections are checked. The temperature of the oil inside the transformer (OTI
reading) is noted. Check the leveling of the megger; if required and access of the supply unit.
Care may be taken to see that test leads do not touch among themselves and with the
transformer body.
Test procedure
Terminals of all HV bushings and HVN bushings are shorted together as shown in the figure.
Similarly all terminals of LV bushings are shorted together. The test voltages is selected as 5000V
in the megger.IR values of individual winding to earth and between windings are measured at
15th, 60th, and 600th seconds. Compare the measured IR values with the factory results. Also
evaluate PI values.
Connection for two winding transformer is as shown in the figure.
1. HV-LV+EARTH

Page 4 of 52
2. LV-HV+EARTH
1. LV-HV

Page 5 of 52
Precautions/Safety
a) Transformer and bushings under test shall be thoroughly cleaned with dry cloth.
b) During the measurement the test area shall be demarked with warning tape.
c) Megger shall be placed at leveled platform.
d) Sagging of the connections and leads shall be avoided.
e) Infinity and zero of the megger shall be checked prior to test.
f) Sufficient time shall be given for discharge of megger before taking the next measurement.
The test circuit must be discharged by short circuiting for a period which shall be at least
four times the voltage application time; if the connection is made by bare hands. However
in practice at least a discharge time equal to the voltage application time shall be given.
g) Measurement at higher voltage shall not be done while the transformer is under vacuum.
Interpretation
a) A high value of polarization index indicates the insulation is very good. PI value <1
indicates immediate corrective action required.
b) There are no specific absolute values of acceptable insulation resistance; however
reference should be made to previous test history to establish a trend.
7.2 Insulation Resistance of Core and Clamp
Aim
To determined the insulation resistance of core, core clamp and between core& clamp.

Page 6 of 52
Test preparation
Identify the core and core clamp bushings, insulation tester (Megger) shall be of 500V range
having valid calibration. Ensure proper earthing of the transformer main body. Disconnect the
earthing from core and core clamp bushings. Check the cleanness & dryness of the core and core
clamp bushing porcelains/terminals and tightness of the connections. Note the temperature of the
oil inside the transformer (OTI reading).Check that the megger is placed on a leveled surface and
access of the supply input. Care has to be taken to see that test leads do not touch among
themselves and with the transformer body.
Test procedure
The test is conducted at 500V.IR values are measured at 60th second for core to earth, clamp to
earth and core to clamp. The measurements are repeated after the application of 2KV.
Interpretation
a) Single point earthing of core is ensured by good IR value between core system and earth.
b) Typical IR value for a new transformer shall be >1000MΩ.
c) For a transformer in service.IR value core to earth >100MΩ indicates normal conditions of
insulation.IR value is between 10&100MΩ indicates core deterioration.IR value <10MΩ
indicates generation of inadvertent destructive circulating currents which shall be
investigated.
08.2KV TEST ON CORE AND CLAMPING STRUCTURE

Standards: IEC60076-2000, Clause-II
Aim
To ensure that the insulation is capable to withstand the specified test voltage.
Test preparation
The test setup consist of a source transformer of sufficient capacity in order to test voltage of 2KV
AC, single phase slide arc, voltage transformer,multimeters etc.Ensure the input supply,
connecting leads, tightness of the connection etc before application of test voltage. Test duration
is 60 seconds.
Test procedure
The voltage is varied from minimum to the specified test voltage of 2KV rms and maintained for
60 seconds. During this period, there should not be any collapse in voltage or sudden increase in
leakage current. The leakage current is also noted with the clamp meter.

Page 7 of 52
2KV test is conducted between core & core clamp together to tank (earth) and between core and
core clamp for one minute each.
A typical circuit is shown below
Test condition
Core to tank (Clamp connected to Tank earth)

Clamp to tank (Core connected to Tank earth)
09. RATIO AND VECTOR GROUP CHECK
Standards: IEC60076-2000, Part1
9.1 Voltage Ratio Measurement
General
The turns ratio of a transformer is the ratio of the number of turns in a higher voltage winding to
that in a lower voltage winding. The voltage ratio of a transformer is the ratio of the rms terminal
voltage of a higher voltage winding to the rms voltage of a lower voltage winding under specified
conditions of load. When the transformer is open circuit, for all practical purpose its voltage and
turns ratio may be considered equal.

Page 8 of 52
Ratio error is the ratio of the difference between ratios of the measured value and the actual
(design/declared) value to the actual ratio. The maximum allowable ratio error for principle tap is
±0.5% or ± 1/10 of the actual percentage impedance; whichever is less. For the other taps the
desired maximum ratio error is ±0.5%; even though it is not purely binding.
Aim
a) To ensure the voltage ratio of the transformer are designed/manufactured as per the
specifications/requirements.
b) To ensure the voltage ratio errors within acceptable limit.
Test preparation.
Ensure proper earthing of main tank, core and clamp, availability of stable variable 3 Phase or
single phase input supply, voltmeters and/or Ratio Bridge meter etc. Also ensure that the neutral
is not connected to earth.
Test Procedure for voltage ratio measurement.
The voltage ratio shall be determined by two methods.

a) Direct measurement of the voltages using voltmeter
b) Measurement using Ratio Bridge
a) Direct measurement of the voltages using voltmeter
The 3 phases or single phase voltage is applied to the high voltage side and induced voltage
across the low voltage side is measured. The result is determined from the two measured
voltmeter readings. In a star windings transformer the applied and measured voltage shall be
checked between line and neutral. Measurements are made for all phases at all taps positions.
Percentage ratio error is determine as [(measured ratio-declared ratio)/Declared ratio] x100
Arrangement for the measurement of ratio error of a two winding Transformer with HV star and
LV delta as shown.

Page 9 of 52
b) Ratio measurement using Ratio Bridge.
The applied and measured voltages are compared in a bridge by the null indication method. This
is a direct measurement of the ratio error and hence do not require any calculation. This can be
done either with 3phase or single phase bridge. Measurements are made for all phase at all taps
positions.
9.2 Polarity /Vector group check
General
The individual winding of poly phase transformer can be connected in star, delta or Zig Zag as per
design requirements. The phase displacement between windings may be 0°-360° according to the
connection methods.
The vector diagram of the high voltage winding is placed on a clock face so that the tip of the
vector 1U is at 12 O’ clock and the vector diagram of the low voltage winding is placed on top
with the same phase orientation; then the direction of vector 2U identifies the clock number of
the vector group.
For a three phase transformer, the phase angle of the intermediate and low voltage winding is
referred to the high voltage winding for the vector group. For zig zag connections the winding half
closet to the terminals determines the terminal markings.
Aim

Page 10 of 52
To ensure the phase displacement or vector group of the transformer is designed/manufactured

as per the specification.
Test Procedure for polarity/Vector group
1) Single phase Transformer
For a single phase transformer, the polarity shall be either additive or subtractive. Polarity shall be
checked either by
a) Voltmeter method or
b) DC kick method
(a) Volt meter method
I. Subtractive polarity
Terminals 1.1(HV) and 2.1(LV) are shorted. The applied voltage across HV (V1), the
induced voltage on LV in the opposite direction (V3) and the voltage between the terminals
1.2(HV) and 2.2(LV) i.e., V3 are measured. If V2 is less than V1, the polarity is subtractive.
II. Additive polarity
The low voltage winding is connected in series with the high voltage winding in series.
Terminals 1.1(HV) and 2.2(LV) are shorted. Also terminals 1.2(HV) and 2.1(LV) are shorted.
The applied voltage across HV (V1), the induced voltage on LV in the opposite direction (V3)
and the voltage between terminals 1.2(HV) and 2.1(LV) ie, V3 are measured. If V2 is greater
than V1 the polarity is additive.
(b) DC Kick method
The positive of the DC source is connected the HV terminal 1.1 through a switch K and
negative is connected to HV terminal 1.2.The LV terminals 2.1 AND 2.2 are connected to positive
and negative of a center of zero galvanometer. While closing the switch K if the galvanometer
gives a clock wise (positive) kick and a clock wise (negative) kick while opening the switch, the
polarity is subtractive. For additive polarity, the direction of kick will be reverse to that of
subtractive under the same conditions.
(2) Three Phase Transformer

Page 11 of 52
For the phase three transformer, the polarity/phase displacement shall be verified by checking
vector group. The vector diagram for a three phase, two winding transformer with HV star
connection (YN) and LV delta 1 O” clock direction (dl) is shown below.
Terminals 1U (HV) and 2U (LV) are shorted. Thus HV U phase and LV U phase are brought
together in phase. A balanced three phase 400V shall be applied across the HV winding and
induced voltages across the terminals for the following combinations are measured.

Page 12 of 52
a) 1U –1V
b) 1V-1W
c) 1U-1W
d) 1W-2u
e) 1W-2v
f) 1U-N
g) 2u-2v
h) 2v-N
The vector is confirmed as Y nd1, if the measured voltages as per the above combinations satisfy
the following.
i. a=b=c
ii. dNe
iii. f=g+h
OLTC Continuity Check
General
On load tap changer is a device for changing the tapping connections of a winding, suitable for
operation while the transformer is energized or on load condition. OLTC is normally connected at
the neutral end of the winding. For large capacity Power Transformers three separate OLTCs are
provided one for each phase: according to the design.
Aim
To ensure that the Transformer windings are not open circuited during OLTC operation.
Test preparation
Ensure availability of 3 phase or single phase variable supply, analog type voltmeter etc. connect
the voltmeters tightly across the line terminals of HV.
Test procedure
The OLTC continuity check shall be done using either 3 phase of single phase voltage supply.
However the 3 phase supply is preferred as the test can be done simultaneously on all the three
phases. Voltage is slowly raised across the low voltage winding of the transformer in order to get
a readable value in the voltmeters connected across the line and neutral of the HV winding. The
OLTC is operated for one complete cycle (minimum tap-maximum-minimum tap). If there is any
winding break/discontinuity through the OLTC, the respective voltmeter will indicate zero reading

Page 13 of 52
during the OLTC operation at that particular tap. For ensuring OLTC continuity, there should not
be any zero indication in the voltmeters during the OLTC operation.
10. MEASUREMENT OF MAGNETISING CURRENT
Standards: IEC60076-2000
General
The exciting current test is very useful in locating problems like the magnetic core structure,
shifting of windings, failure in the turn-to-turn insulation or problems in the tap changer. These
conditions result in a change in the effective reluctance of the magnetic circuit, which affects the
current required to force a flux through the core.
Low voltage exciting current is measured by this test. The pattern and value of the magnetizing
current gives an idea of the magnetic circuit of the built-up core and winding interconnection.
These values are considered as reference for all future measurements and
Said to be the base of transformer diagnostic tool. The measured value at site shall be compared
with the previous test results at factory. As the value varies accordingly to the applied voltage,
comparisons may be done with the same applied voltage. Usually 400V, 3phase balanced supply
is applied on the HV terminals and the corresponding magnetizing currents are noted. For LV, the
voltage is suitably reduced in order to limit the induced voltage on the HV terminals. The
repeatability of magnetizing current readings is an indication of the healthy magnetic circuit in the
transformer.
The magnetic currents will be in the tune of milli ampears.For a star connected winding the
magnetizing currents in the middle phase (V Phase) will be less than the other two phases and
the magnetizing currents on U&W phase will be almost equal and >V phase. For delta connected
transformers the magnetizing current in W phase will be < U&V phases and magnetizing currents
of V phase will be <U phase, but slightly >W phase. For D11 delta connected transformers the
magnetizing currents in the U phase will be <V&W phases and magnetizing currents of V phase
<W phase, but slightly >U phase.
The test results may be none confirming as a result of residual magnetisms in the core due to DC
applied. Hence this test has to be carried out before applying any DC on the transformer.ie,
before the winding resistance measurement. The core will be demagnetized once the high voltage
AC is fed to the transformer.
Aim
a) To ensure that there is no shorting in the core material.

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b) To ensure no inter turn shorting of winding.

c) To ensure no loose contact or loose connection in the winding or core.
1. MAGNETISING CURRENT-HV
2 MAGNETISING CURRENT-LV
Test preparation
Stabilized 3 phase variable input supply, voltmeters and ammeters with valid calibration must be
available. The neutral of the transformer must be open. For comparison of test results, ensure
that the test voltage at factory is same as that the site. Confirm the tightness of all connections
made.

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Test procedure
The 3 phase supply is fed to the transformer with milli ammeters in series to each pahse.With LV
winding open circuited. Voltage on HV is varied from minimum to the applied voltage of 400V and
magnetizing currents are measured at all taps. While Applying on LV, care has to be taken to
restrict the voltage in safe limits; if required as the HV/LV ratio is high and induced voltage on HV
is more. Also the phase sequence of the applied voltage shall be maintained.
A test circuit of two winding transformer (Star/Delta) for measurement of magnetizing current is
shown in below.
Precaution/Safety
a) The test shall be performed at highest possible test voltage without exceeding the voltage
rating of excited winding.
b) The instrumentation shall exclude to the possible extent exclude from the measurement of
the capacitive currents between the excited winding and other windings, the core or the
tank.
c) For the purpose of comparison, the subsequent test shall be performed at the same test
voltage and similar test connections.
Interpretation
a) The residual magnetism results in the measurement of higher than the normal exciting
current.
b) There is no widely accepted field method for distinguishing between the effect of residual
magnetism and effect of a problem present in the transformer.
c) The measured values are compared with previous test results and if the values fall within
+150%, it is usually considered as normal.
11. WINDING RESISTANCE MEASUREMENT
Standards: IEC60076-2000, Part1, Clause-10.2
General
Winding resistance is defined as the DC resistance of the winding and its value is applied voltage
divided by delivered current expressed in ohms. Measurement is made by applying a DC current

Page 16 of 52
to the specified winding. In order to compensate the resistance of the lead wires a four wire
system is established as two wires each for potential and current connections.
Winding resistance provides the base value to establish the load loss. It forms an indirect base
to establish the winding temperature and winding temperature rise from the resistance
measurement made during heat run test on transformer.
For preventing core saturation and raise of temperature in the winding during the measurement,
the test current should be limited to a maximum of 10% of the rated current of the specified
winding. Also this current should be at least 1.2 times of the crest value of the magnetization
current.
Winding resistance is proportional to the temperature and reference is75ºC.Resistance measured

at a temperature t1ºC (R1) may be converted to R@75ºC.Resistance at 75ºC as
R@75º= [(K+75 ºC)/ (K + t1ºC)] X R1
Where K = Temperature co efficient of winding material

(Copper = 235 & Aluminum = 225)
R1 = Measured Resistance & t1 Ambient temperature
Aim
a) To determine the winding resistance of HV winding for all phases at all taps and that of LV winding
for all phases.
b) To confirm the FAT report values are matching with the site tested values within the tolerance
limits.
c) For verifying the electrical continuity in a winding and to ensure absence of loose contact of leads
connection at OLTC, bushing terminals.etc.
Test Preparation
A Constant current DC source, switch and leads with sufficient cross sectional area.DC ammeter, voltmeter
or measuring bridge with suitable current rating and leads with sufficient cross sectional area.
Test procedure
Winding resistance can be measured either as phase to phase or phase to neutral. The winding for which
the resistance is to be measured must be connected in the circuit and other phases and windings shall be
kept open circuited. After switching on the DC voltage source, reading shall be taken only after the current

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reaches a steady state condition as otherwise the switching may cause induced voltage which in turn
influences resistance vaue.Measurement of winding resistance for HV winding at all phases and all tap
positions and that of LV windings for all phases are to be carried out. Also the oil temperature shall be
noted.
Two methods basically used to measure the winding resistances.
a) Voltmeter –Ammeter method
This method is also known as VI method and the measured resistance is determined by ohm’s law
as the voltage drop in the winding (Voltmeter reading) divided by the DC current flowing through
the winding (Ammeter reading). Connections shall be given as shown in the figure.
The voltmeter leads must be independent from the current leads and shall be connected as close as
possible to the winding terminal in order to prevent possible voltage drop. After the applied DC
current reached its steady state, the voltmeter and ammeter readings are simultaneously noted.
The voltmeter has to be disconnected from the circuit before switching on and switching off the DC
supply has the sudden off scale damping may damage it.
b) Bridge or micro-ohm meter
1. HV WINDING RESISTANCE
2. LV WINDING RESISTANCE

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This measurement is based on the comparison of two voltage drops in the bridge, namely the
Voltage drop across the unknown resistance Rx compared to the voltage drop across a known
resistance RN.
DC current is injected through the Rx and RN.Corresponding voltage drops are measured
and compared.Varieing the value of resistances Rdec and Rv the bridge shall be balanced
showing null deflection in the galvanometer will be RN X Rdec.
Rv
Where
Rx = Winding Under test.
RN = Standard resistor
Rdec = Decade resistor
Rv = Variable Resistor
G = DC source
A Wheatstone bridge is preferred for resistance values ≥1Ω and a Kelvin bridge or a micro
ohmmeter for resistance values ≤1Ω
While using a micro ohmmeter only a range selection is to be made and the measured
reading is displayed directly on the measurement.

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The average value of the winding resistance of three phases at each tap is corrected to
75ºC
Precaution/Safety
 The voltage and current leads shall be independent and shall be connected as closely as
possible to the winding terminals in order to avoid lead resistance.
 Readings shall be taken only after the current and voltage values become stable.
 If the current is suddenly switched off, a high voltage is generated in the winding. The
current should be switched off by a suitable isolated switch before any personnel
contact the circuit.
Interpretations
i. A tolerance of ±3% is generally acceptable for the measured values at site over the factory
test report values.
ii. Similarly the measured values between phases of transformers of identical design also may
vary with in ±3%.
.
1. Since the overall measurement accuracy is around 1%, changes of ±2% of the short circuit
impedance with the factory measured value is usually considered significant.
2. Changes of more than ±3% of the short circuit should be considered as a significant and
hence not acceptable.
13. MEASUREMENT OF TAN DELTA AND CAPACITANCE OF WINDING.
Standards: IEC60076-2000, Part1, Clause-10.1.3, IEEE62
General
Tan delta
Dielectric loss is the power dissipated by the insulation when subjected to an alternating voltage,
Tan delta or dissipation factor is the ratio of absorbed active power to the absolute value of the of
the reactive power expressed in percentage. It is ratio of resistive current to capacitive current
flowing through the insulation.
Low value of dielectric loss indicates good condition of insulation, aging of dielectric media,

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Deteriorations/contaminations of insulation, physical damage due to electrical stress/out side

forces etc, results in the increase of dielectric loss and thereby increase dissipation factor.
Dissipation factor varies with environmental conditions like temperature, relative humidity and
precipitation etc at the time of testing. It is also dependent on dryness of the transformer
insulation (Oil and insulation materials), external, and cleanness of the porcelain, applied voltage
and influence of stray parameters during measurement. Tan Delta is reported at a reference
temperature of 20ºC.
Capacitance
Capacitance is defined as charge per unit current, i.e. C=Q/V.It is usually expressed in Pico farad.
It is dependent on the characteristics of dielectric material; conductor configuration etc.It does
not vary considerably with the voltage and temperature.
Tan delta and Capacitance shall be measured simultaneously using tan delta and capacitance
measuring bridge or Volt-ampere watt method bride.
Aim
1. To ensure the condition of transformer insulation.

2. To check any physical damage /shifting of the transformer windings/internal parts during
transportation.
Test preparation
All windings shall be shorted separately with proper shorting leads and tightness checked. Proper
earthing of core/clamp and main tank are checked. Common earthing for the testing equipment
and transformer is ensured. Arrangements for the oil and ambient temperatures and humidity are
made.
Test Procedure
Measurement may be done in the following modes in Megger DELTA, Dobble equipments.
 Ground mode (GND/GST)

Measures the insulation between the HV probe and Ground (earth) as well as between
HV probe and LV leads.

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 Guard mode (GRD)

Measure the insulation between the HV and ground (earth); leakage through the
insulation between HV probe and LV leads by passes the meter.
 Un Grounded specimen(UST)
Measure the insulation between the HV probe and LV leads; leakage through the
insulation between HV probe and ground (earth) lead by pass the meter.
If n is the number of independent windings the number of possible measurement in GST

(Grounded specimen) mode is given by
(n+1)! / 2! *(n-1)!
For n>1, Hence for a two winding transformer, there shall be 3 measurements possible.
Before the test, bushing terminals of the same winding shall be shorted together and connection
given accordingly as per the circuit shown in below. Tan delta and capacitance between the
following combinations shall be measured. Test voltage at site is limited to 10KV for HV and 5KV
for LV windings.
 HV- EARTH
 LV-EARTH
 HV+LV-EARTH

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After verifying the connection and setup supply is switched on. Initially around 20% of the test
voltage is applied and tan delta and capacitance are measured. This is to reduce the time delay
for stabilizing the final test results and to reduce the extent of damage in case of a fault. Then the
actual test voltage is applied and measured repeated for the different combinations. Ambient
temperature, oil temperature and humidity are noted. The conversion factor 20ºC is applied for
tan delta value and compared with factory test results.
Between each pair of winding and each winding to earth constitute discrete capacitances. Atypical
transformer having two independent winding has capacitances. Atypical transformer having two
independent winding has capacitances as shown below
Measurement by shunting CL (Shorting LV and E) gives (CH+ CL).Shorting of HV to E gives (CHL+

CL).By shorting HV to LV gives (CH+ CL).Solving three simultaneous equation CH, CL,
CHL.Corresponding tan delta in combination is also obtained.
Precautions/Safety
1. All bushings terminals and the bushings shall be thoroughly cleaned with dry cloth to avoid
surface leakage current.

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2. During measurement the test area shall be demarked with warning tape.
3. Sagging of the connections shall be avoided.
4. Measurement at higher voltage shall not be done while the transformer is under vacuum.
5. Electrostatic interference; especially due to nearby EHV lines may lead to unreliable results.
Interference suppressor circuits along with shielded cable may be used to avoid this.
6. Ensure the tightness of the test tap in HV winding.
Interpretation
1. Dielectric factor for oil filled transformer in good condition should not exceed 0.5% at 20
ºC.
2. Periodic tests done in service will indicate whether the aging of insulation is normal or
rapid.
3. Diagnostics tests on suspect or failed equipment may be helpful in locating fault or reason
for failure.
4. Test results on new equipment provide a benchmark for failure comparison.
14. MEASUREMENT OF TAN DELTA AND CAPACITANCE BUSHING.
Standards: IEC60076-2000, Part1, Clause-10.1.3, IEEE62
Aim
To ensure the condition of bushing

insulation.
General
Bushing test tap is used to for this

measurement and hence measurement
is possible only in condenser type
bushing having test tap provision.
Test preparation
Same setup for measurement of tan

delta and capacitance measurement of winding shall be used for this measurement with the
measurement lead in test tap of the respective bushing. Test voltage is 10KV.

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Test procedure
The voltage shall be given parallel to all bushing in HV and LV at a time or separately in HV and
LV or one by none. Test voltage shall be applied at the bushing line terminal and measurement
lead from test tap of bushing. Each of the condenser bushing tan delta and capacitance C can be
measured in UST mode.
After verifying the connection and set up is switched on.Initally around 20% of the test voltage is
applied and tan delta and capacitance are measured. This is to reduce the time delay for
stabilizing the final test results and to reduce the extent of damage in case fault.
Then the actual test voltage is applied and measurement repeated for all condenser bushings.
Ambient temperature, oil temperature and humidity are noted. The conversion factor for 20°C is
applied for tan delta value and compared with factory tested values. The site test results must be
comparable with the factory test values.
Precautions.
 The bushing terminals and test tap under test shall be thoroughly cleaned with dry cloth to
avoid surface leakage currents.
 If the bushings are shorted together, the test tap of the bushings that are not under
measurement must be tightly closed.
 During the measurement the test area shall bed demarked with the warning tap.
 Measurement at higher voltage shall not be done while the transformer is under vacuum.
 Electrostatic interference; especially due to near b y EHV lines may lead to unreliable
results. Interference suppressor circuits along with shielded cable may be used to avoid
this.
 After testing/measurement ensure the test tap tightness.
Interpretation
a) Dielectric factor for condenser bushings in good condition should not exceed 0.7% at 20°C.
b) Test results on the new bushings provide a bench mark for future comparison.

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15. CALIBRATION OF TEMPERATURE INDICATORS
Standards: IEC60076-1, 2000
Aim
To ensure that the proper working of temperature indicators according to the actual sensing of
temperature of the transformer oil and winding.
General
The temperature indicators are used to measure the transformer oil and winding temperatures
accurately. The indicator used for measuring oil is called oil temperature indicator (OTI) and for
winding is called winding temperature indictor (WIT).Separate contacts are provided for alarm,
trip and cooler start/off functions. These indicators contribute as protective devices for
transformer giving timely warnings and action against possible faults arising due to rise of
temperature of oil/winding.
Following formula are generally adopted for alarm and trip contact setting, but some
manufacturers are using thereon formulas
OTI
Alarm: Maximum top oil temperature rise during factory test +ambient average +5ºC.
TRIP: Alarm+10ºC.
WTI
Alarm: Maximum top oil temperature rise during factory test + (Winding gradient*1.3)
+ambient average +5ºC.
TRIP: Alarm+10ºC.
Test preparation

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A standard oil bath with valid calibration status and sufficient dimensions for fully immersing the
sensing bulb of OTI/WTI is selected for the test. Transformer oil at ambient temperature is filled
in the bath up to the required level. This test is started with minimum temperature onwards and
reading taken at multiples of 20ºC up to 120 for OTI and 120ºC for WTI.Calibration of indicators
shall be done simultaneously. Do not disturb any factory settings already made in the meters by
the manufacture at factory.
Temperature readings between standard bath and indicators shall be ±2ºC at all calibration steps.
Temperature reading between indicators is given a maximum allowance of 2ºC.
Test procedure
The oil bath is set at the required temperature. Minimum 45minutes shall be given for stabilization
of each set temperature and temperature reading of the indicators and standard bath are noted
down. Close monitoring is required during the test to check whether any indicator needles goes
abnormal fast/slow or is getting struck. Compare the measured and standard temperature reading
and verify that it is acceptable or not as per the tolerance limits. Factory set alarm and trip
contacts shall be checked with the setup. The bath temperature is brought to the required level
and contact operations are checked with the help of multi meter.
Precautions/Safety
1. Ensure the capillary tube of indicators is not damaged while making preparation for test.
2. Ensure the sensing bulb of indicators does not have any contact with the walls of the bath
and is free in oil.
3. Care shall be taken against possible fire while the bath temperature rises up to 120 ºC
4. The bath shall be kept at the same height at which the indicators are located to avoid
effects due to head variations.
Interpretation
1. If the difference in the temperature readings between standard bath and the indicator is
>2 ºC at any of calibration steps, that indicator is rejected.
2. If temperature reading between indicators is more than 2ºC, the indicators are rejected.
16. HOT SPOT GRADIENT CHECK OF WINDING TEMPERATURE INDICATORS
Aim
To ensure the set gradient in WTIs either as per the factory temperature rise test results or as per
the values given in the factory acceptance test report.

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General
Winding gradient is the difference between winding temperature and average oil temperature.
Hot spot winding gradient is the hot spot developed in the winding and is 1.3 times the winding.
Winding temperature is depending upon the load current. Hence that secondary current of WTI
BCT is taken in to account for gradient checking. While passing the BCT secondary current
through the heater coil of WTI, heat and gas will be produced in the capillary tube of the
indicators. This will expand further due to heat conveyed and push the needle to indicate winding
temperature at the particular load current.
Test preparation
The same set up used for calibration of indicators shall be used for this test. Set the hot spot
gradient shall be checked at 80ºC of oil temperature. Hot spot gradient shall be checked first at
ONAF rating, since this is full load continuous rating and there upon extended for other rating like
ONAN, and 1.2 times of ONAF (LTEC).
Calculate the BCT current required for each rating. Put the sensing bulb of local and remote WTI
in the oil bath. Digital multi meter with valid calibration status is used to measure the milli ampere
output of transducer for RWTI.
Test procedure
Switch on the bath and set the reading at 80ºC and is kept for 45minutes for stabilization of the
temperature. Check and note down the readings of oil bath, indicators and milli ampere output of
the remote WTI.The current corresponding to ONAF rating is injected to the heater coil of the
indicator and kept for minimum 45 minutes. The difference of WTI reading after injecting BCT
current and bath temperature gives the hot spot gradient in the local WTI.
Take the indicator reading and milli ampere output of the remote WTI.The difference of measured
milli ampere output of the transducer before and after injecting BCT current and multiplied with
ratio of full scale reading of WTI to maximum output of transducer gives the hot spot gradient.
Compare the measured hot spot gradient with factory test results and set values in the indicators.
The factory set values and measured values must be more or less the same difference should be
less then 2ºC in any case for acceptance of test.
17. RATIO CHECK OF CURRENT TRANSFORMER FOR WTI
Aim

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To ensure that the ratios of BCTs for WTI are correct and manufactured as per the specifications.
General
This test is done to verify the primary to secondary current ratio of WTI BCTs without connecting
a burden and hence this is only a rough ratio check. The principle is that primary ampere turns
and secondary ampere turns in the BCT are same. A separate winding called the test winding
provided in addition to the secondary winding, is used for the measurement and easy checking of
ratio. If test windings are not available, the test can be done during short circuit impedance
measurement.
Test preparation
The test can be done either during short circuit impedance measurement or with the test winding
and the test setup can be decided accordingly. For test with test winding, single phase dimmer
start and it accessories are required. When measured through test winding.HV and LV are kept
open.
Test Procedure
BCT secondary is connected to ammeter. The BCTs secondary current and primary applied current
shall be measured as shown below. Tap positions shall be noted during the measurement.
Data and calculation for checking the BCT ratio as an example is given below.
Design Ratio Voltage Vector Accuracy Class
HV---- 400/5 112.2Kv at tap 19 YN 3.0

LV-----3500/5 12Kv d1 3.0
From the above data, HV/LV ratio is = 9.35A

Applied HV current = 2.80A
Corresponding current in LV =2.8*HV/LV Ratio = 26.18A
HV BCT
If measured HV BCT secondary current when HV current is 2.8A is 35 milli amperes (0.035A),
then the BCT secondary current, when HV is 400A = (400/2.8)*0.035 = 4.99A
Hence the percentage error for HV BCT = (4.999-5.0)/5*100 = -0.02% ok.
Thus the measured ratio is 400/4.999 against design ratio of 400/5A

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HV BCT
If measured LV BCT secondary current when LV current is at 26.18A is 37 milli amperes

(0.037A), then the BCT secondary current, when LV is 3500A= (3500/26.18)*0.037 = 4.946A
Hence the percentage error for HV BCT = (4.946-5.0)/5*100 = 1.08% ok.
Thus the measured ratio is 3500/4.946 against design ratio of 3500/5A
Measurement with Test Winding
Since the transformer lead conductor serves as the primary of BCT, the primary turn of the BCT is
normally designed with a single turn.
Data and calculations to check the BCT ratio as an example is given below.
Let HV BCT design ratio is 400/5 and test winding current is 10A.
Assume HV turns =1, BCT secondary turns =80 and test winding turns =40
Primary ampere turns = Secondary ampere turns

Primary ampere turns = 400 *1=400
Secondary ampere turns=5*80=400
Test winding ampere turns =10*40=400
This means Primary ampere turns=Secondary ampere turns=Test winding ampere turns
If 10A is applied to test winding, the secondary winding will read 5A.Keeping the HV and LV
winding open applied 10A to the test winding and measure the secondary current. If the
measured secondary current is 4.96A, then the BCT measured ratio can be taken as 400/4.96
19. OPERATION CHECK OF ON LOAD TAP CHANGER
Aim
To ensure the proper operation of /performance of On Load Tap Changer and it’s compliance with
the requirements.
General
On Load Tap Changer is device, used for enabling the transformer to serve a constant voltage in
the load dispatch side (Grid) as per the input supply or demand variation by changing the tap

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positions on the transformer on loaded condition. Performance of operation of OLTC can primarily
confirmed by the operation from MDU.
Test Preparation
Earthing of transformer and MDU body is ensured. The supply input and phase sequence to the
MDU is checked.Multimeter and 500V megger is also required.
Test procedure
Insulation resistance of motor and wiring to MDU is checked. Under voltage and over voltage
setting are done the voltage monitoring relay and its performance checked. The handle operation
of OLTC, electrical & hand operation limits at extreme tap, step by step operation, limits of over,
travel, starting & running current of motors, tap position indications in MDU/AVR,rotations of
handle per step of operation, time for tap changing at normal tap setting of MPR&Voltage
monitoring relay etc has to be checked.
20. TAP POSITION INDICATION CHECK
Aim
To check the tap position indications on OLTC, MDU, AVR, DCS and SCDA are same at every tap.
Test preparation
Ensure the availability of MDU input supply and phase sequence.
Test procedure
The OLTC tap shall be operated in raise or lower mode. The tap position indications are
simultaneously checked at OLTC, MDU, AVR, DCS and SCADA to confirm that all tap position
indications are same either in raise or lower mode.
22. FAN MOTOR CHECKS
Aim
To ensure the performance of the fan motor.

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Test preparation
Ensure all wiring is completed at marshalling kiosk. Check the supply input of fan motor and
phase sequence. Availability of digital multimeter, 500V megger, stop watch etc are to be
required.
Test procedure
Switch on individual fans one by one and ensure correct direction of rotation, i.e. it should be in
air intake directions to the radiators. Check the starting and running current of individual motor.
The time taken to trip the over load setting shall be noted after blocking the rotor of each fan.
The over load setting shall be done as per the manufacturer instructions.
23. OPERATION CHECK OF COOLING EQUIPEMENT
Aim
To ensure the performance of cooling equipments.
Test preparation
Ensure all the wiring is completed at marshalling and supply is put and phase sequence of fan
motors. Also check the availability of digital millimeters.
Procedure
Energize the marshalling kiosk. Check the manual and auto control of fans from HV and LV WTI
by selecting respective switches and selection modes. Check the tripping of MCB and fan control
switchs.Check the cooling fan interlock with fire deluge operation. Terminal block numbers
ferrules, grouping of fan etc.shall are checked with respective drawings.
23. b Settings
Aim
To ensure operation of cooling fans are according to the start /stop temperature setting at WTI.
General

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Start /Stop set values of cooling fans are given by the manufacturer according the factory
temperature raise test results and these values are normally set in each of the indicators. Fans
may be group in to two, say group 1 and group 2.
Test preparation
Ensure availability of standard oil bath with accessories, single phase supply and digital oil bath.
Test procedure
HV and LV WTI sensing bulbs are inserted in the oil bath carefully. Transformer oil shall be filled
in the oil bath kit up to the required level. Switch on the oil bath and set required temperature in
the oil bath for start of group 1 fans. Check the start operation of the group 1 fans when the set
value of the temperature is attained in the oil bath. Then set the stop value at oil bath and check
the stopping of cooling fans when the set temperature is attained in the oil bath.
The procedure is repeated to check the operation of the cooling fans in group 2.
24. PROTECTIVE DEVICE WIRING AND OPERATION CHECKS
Aim
1. To ensure correct operation of protective devices at DCS/SCADA before energisation of the

substation.
2. To check the wiring and terminals identification at MK/LCC/RCP/RP/etc are as per the
approved drawings
Test preparation
Check the availability of approved wiring drawing with terminal details and digital multi
meter.
Test procedure
Alarm and trip contacts of each protective device shall be checked at

MK/LCC/RCP/RP/DCS/SCS/SCADA etc by operating the respective devices.Buchhloz relay
shall be checked by applying nitrogen (N2) with pressure.
26.0 CHECK ON AUTOMATIC VOLTAGE REGULATOR (AVR)

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Aim
To ensure the operation and performance of AVR as per the specifications and
documents/requirements.
General
Automatic voltage control shall be initiated by a voltage-regulating relay. The relay shall operate
from the nominal reference voltage stated in requirements, derived from a circuit mounted LV
voltage transformer. The relay shall be insensitive to frequency variation from 47 to 51 Hz. The
relay shall also incorporate an under voltage blocking facility, if the reference voltage falls below
80% of the nominal value and with automatic restoration of control when the reference voltage
raises to 85% of the nominal value. The relay band width shall preferably be adjustable to any
value between1.5 and 2.5 times the transformer tap step%; the nominal setting being twice the
transformer tap step%.
Test Preparation
Ensure the single-phase supply input and earthing for the AVR panel. Check the readiness of the
MDU and DCS &SCADA connections. Availability of digital multi meter technical specifications,
drawings, documents etc. are also ensured.
Operation
a) Put AVR in auto mode and MDU in remote and check the following
1. No operation possible from MDU, AVR DCS and SCADA.

2. Auto operation takes place with variation in VT secondary voltage. When tap raise
command is given, VT secondary voltage reduces and vice versa.
b) Put AVR in manual mode and MDU in remote and check the following.
1. Auto operation not possible

2. Manual operation possible from AVCR, DCS, SCADA.
c) Put MDU in local position and check the following
1. Operation possible for MDU

2. Operation not possible from AVR, DCS and SCADA.
d) Put MDU in remote position and check the following
1. Operation not possible from MDU

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e) Put MDU and AVR in remote and check the following
1. Operation possible from AVR

2. Operation not possible from DCS and SCADA.
f) Put AVR in supervisory and MDU in remote and check the following.
1. Operation not possible from MDU and AVR

2. Operation possible from DCS and SCADA.
g) Under and over voltage blocking of MDU
1. No operation possible from any point.
AVR Display
Ensure that AVR display has parameters like Voltage, Current, Frequency, Tap no.,
Master/Follower/independent mode, paragramer functions (Breaker status).
Detailed test procedures of AVR test with following formats are given below
Formats no: CDT/PT/ST/21 : Check on AVR
CDT/PT/ST/22 : Tap changer and cooler alarm
CDT/PT/ST/23 : AVR parallel operation
CDT/PT/ST/24 : AVR parallel operation
TESTING PROCEDURES OF REMOTE TAP CHANGER CUBICLE (RTCC) CONSISTING OF

AUTOMATIC VOLTAGE REGULATOR RELAY (AVR)
Following are the components of RTCC site testing:-

 Installation and Drawing checks.
 Operation, Indication and Alarm Checks on each AVR relay.
 Parallel Operation, Indication and Alarm checks
 Communication with DCS/SCC
AVR-Modes of operation
 R/L Control (Hand) & AVRs in Independent mode.

 R/L Control (Auto) & AVRs in Independent mode.
 R/L Control (Hand) & AVRs in Parallel Manual mode.

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 R/L Control (Auto) & AVRs in Parallel Manual mode.

 R/L Control (Hand) & AVRs in Parallel Auto mode.
 R/L Control (Auto) & AVRs in Parallel Auto mode.
1. Installation and Drawing checks.
1. a Drawings and document verification
The following are checked and verified.

 Approved drawing and letter of approval
 Engineering comments and their compliance
 Statement/reply of the contractor against the comments.
 Period of warranty.
 O & M manual.
 Inspection report at manufacturer’s site.
 Marked up drawing.
 Suggested modification on the drawing to rectify the problems, if any
1. b Installation inspection
The following checks are carried out on the AVR.

 AVR identification including the serial no, model no. etc. corresponding to all the
transformers. i.e. IDT1, IDT2, IDT3.
 Front Panel arrangement, module disposition of devices and MCBs used, terminal block
marking and arrangement, ferruling, neatness and proper dressing of wiring,
functioning of heater and its controllers, lamp testing, panel earthing etc. are checked
with approved drawing for conformity.
 Also ensure that sources of AC & DC power supply are as per drawing.
2. Operations, Indication and Alarm Checks each AVR Relay.
Following procedures are to be carried out in each AVR. Also take Safety precautions before
starting the test.
2. a R/L Control (Hand) & AVRs in Independent mode.
 Switch on AVR & MDU control supply, DC supply and MDU motor supply, Identify and
verify the Terminals where CB status input are connected.
 All the CB status inputs are temporarily short circuited.

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 Select paragrammer screen of all AVRs and ensure that all CB status are closed in all
AVRs.
 Switch off control supply of AVR1 and observe whether there is any status disturbance
in the paragrammer of other AVRs.
 Keep MDU in Local and ensure that the tap positions are same in MDU, OLTC, and AVR
Display and Bus Bar diagram.
 Keep AVR in “Hand” (manual) and Independent mode and ensure the following
Indications/operations.
o Check that Tap Changer in Local indication lamp glows.

o REMOTE/SUPRY try color LED off and MDU local LED glows.
o LED in the Hand push button glows and Raise/Lower operation not possible. Also
Independent LED glows.
o AVR VT supply absent message in the status line.
o Keeping MDU in Remote ensure that tap operation is not possible from MDU.
o Keeping AVR in “REMOTE” ensure that “REMOTE / SUPRY” try color LED glows in
green and MDU local LED off. Also LED in the “HAND” push button glows.
o Raise/Lower operation possible from AVR and Independent LED glows.
o AVR VT supply absent message in the status line.
o Give Raiser/Lower commands from AVR and ensure simultaneous tap
raising/lowering of the tap positions at MDU, OLTC, AVR display & Paragramer.
 During Raise/Lower operation ensure following indications and status:
o Check that no display of alarm in the status line and alarm LED indication is received
during these operations.
o “Tap change in progress” message will be displayed in the status line as long as the
operation is in progress.
o Independent display in status line and corresponding green LED in the Raise/Lower
push button glows.
 During tap operation ensure that “Tap 0” display is not coming at any point.
 Bring the OLTC in extreme tap positions and observe the message Tap changer in extreme
position in the status line is displayed and tap operations are blocked at extreme positions.
 Check “T.C. Incomplete” alarm in the status line when tap operation is stopped midway.
This can be simulated by switching off the MDU control supply during tap operation in
progress. Reset TC Incomplete alarm by doing further tap operations after switching on the
MDU control supply.
 Ensure “TC motor supply faulty” alarm in the status line by switching off the MCB of TC
motor supply at LVAC panel. Ensure “TC control supply faulty” alarm in the status line by
switching off the MCB of TC control supply at AVR panel

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 Put the AVR in “SUPRY” and ensure the following:
o Put the AVR in “SUPRY” and ensure that Red color LED of REMOTE/SUPRY push
button glows.
o Raise/lower operation not possible from AVR panel.
o Tap Changer in “Local” indication lamp off.
o MDU local LED off
o LED in the “Hand” push button glows
o Independent LED glows.
o AVR VT supply also absent message in the status line.
2.b R/L Control (Auto) & AVRs in Independent mode:-

 Identify the Terminals where VT secondary connections are to be given.
 Disconnect the wires from the terminal after noting the TB. And ferrule Nos.
 Connect the output wires of a variac of suitable rating at these terminals.
 Ensure that TB links are properly inserted.
 Set the output voltage of the variac at 110 V
 Note down the present tap position
 Put the AVR in AUTO mode.
 Ensure that Raise/Lower operation from the AVR panel not possible manually.
 Keep AVR in REMOTE position.
 Also ensure following Indications and display.
o LED in the Hand push button off.
o LED in the “AUTO” push button glows.
o Measuring value display“11KV” in the home screen.
o Voltage deviation display approximately zero.
o Deviation pointer in balanced position.
o Time bar remains unfilled.
o AVAR VT supply absent alarm message vanished
o No alarm display and alarm indication.
o REMOTE/SUPRY try color LED glows in green.
 Gradually raise the voltage output of the variac and observe the voltage deviation in the
home screen display. Also, observe the deviation pointer moves upwards.
 Increase the voltage by 4% of the (band width) the reference level (110 V) and ensure the
following:
o Time bar in the home screen display starts filling and the end of filling, LED in the
“Lower” Command push button starts glowing.
o Tap change in progress message in the status line as long as the operation is in
progress.
o After Green LED of lower command goes off, tap position is seen reduced by one
tap.

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o Tap position in MDU, OLTC, AVR display and programmer are same.
o As soon as the lower tap operation starts, bring the variac out put back to 110V.
o Repeat the above automatic tap lowering for two or three tap operations.
 Decrease the voltage by 4% of the (band width) the reference level (110 V) and ensure
the following:
o Time bar in the home screen display starts filling and at the end of filling. LED in the
“Raise” Command push button starts glowing.
o Tap change in progress message in the status line as long as the operation is in
progress.
o After Green LED of Raise command goes off, tap position is seen increased by one
tap.
o Tap position in MDU, OLTC, AVR display and paragramar are same.
 As soon as the Raise tap operation starts, bring the variac out put back to 110 V.
 Repeat the above automatic tap raising for two or three tap operations.
 Keep the variac out put at 110 V and ensure no alarms.
 Reduce the voltage by 20% of the reference value and ensure the following:
o Red LED glows against “<U”.

o Under voltage message in the status line.
o Automatic tap raising operation is seen blocked from AVAR.
o Ensure that in manual mode both raise and lower operations are blocked when AVR
is in under voltage conditions.
o Put AVR in AUTO mode.
 Bring the variac back to 110 V and increase the output by 20% of the reference value and
observe following:
o Red LED glows against “>U”.

o Over voltage message in the status line.
o High speed automatic taps lowering command issued by the relay.
o Bring the variac out put less than 30% of the reference value and observe that all
alarm indication vanished except “AVAR VT supply absent” message in status line.
o Put the AVR in SUPRY mode and in AUTO.
o Ensure that automatic tap operation and signaling take place in SUPRY mode also as
described above.
3. Parallel Operation, Indication and Alarm checks.

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3. a Parallel Manual R/L control in Manual:-
 Identify and verify the Terminals where CB status inputs are connected.
 All the inputs are temporarily short circuited.
 Select all AVRs in Hand mode.
 Keep all IDTs in the same tap positions.
 Ensure that tap position at MDU, OLTC, AVR display and Programmer is same.
 Select parallel control of all AVRs in manual.
 Select AVRs in REMOTE.
 Select AVR1 in Master and others in Followers. (Ie. M F F).
 Ensure the following:
o MASTER LED of AVR1 glows.

o FOLLOWER LED of AVR 2 & 3 glows.
o LED against parallel symbol glows in all AVRs.
o Master message in the status line display of AVR1.
o Follower message in the status line of AVR 2 & 3.
o No alarm display and alarm indications in any AVRs.
o All circuit breakers are in closed status in programmers of all AVRs.
o Programmer shows the correct indication of the parallel selection.
o Raise/Lower the tap from the master AVR and ensure proper parallel tap operation
in all IDTs. Check taps position at MDU, OLTC, AVR display and Programmer of all
IDTs.
o Ensure that tap operations are not possible from the AVRs selected as Followers.
o Select AVR2 as Master and Others as Followers and do the tap operations as done in
AVR1 and ensure satisfactory operations and indications. ( F M F)
 Then select AVR3 as Master and others as Followers and repeat the procedure as
mentioned above. ( F F M)
 Do tap operations and indication checks on all possible combinations as suggested in the
test format for OLTC Operation Checks-Parallel Manual mode.
 Ensure that operation shall not be possible from followers AVRs.
 Parallel operation shall not be possible from any of the AVRs if more than one master are
selected.
 Parallel operation shall not be possible from any of the AVRs if Followers are selected
without any master.
 Switch off AVRs one by one and observe “Failure Par Control” message in the status line of
other AVRs.
 Operate any of the AVRs in Independent mode and keep one-step tap difference with other
AVRs.

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 Put this AVR again in parallel mode and then observe that Raise/ Lower tap operation takes
place in this AVR to bring it to the same tap position as that of others.
 Again operate the same AVAR in Independent mode and create one step tap difference
and Switch off the MDU control supply.
 Then put this AVR again in parallel mode and then observe that Raise/lower command is
initiated from the AVR but tap operation is not taking place at MDU and OLTC.
 Mean time ensures an “Out of Step” alarm message in the status line of each AVR after a
time delay.
 Repeat this check in other AVRs also.
 Create two-step tap difference and put the AVR in parallel mode and observe an “out of
step” alarm message immediately.
 Select AVRs in SUPRY mode and ensure that operations are not possible from AVR panel.
3. b Parallel Manual – R/L control in Auto:
 Select all AVRs in REMOTE.

 Then connect variac out put to the VT input of all AVRs as done earlier.
 Keep the variac out put at 110V.
 Select all AVRs in AUTO mode.
 Select Parallel control of all AVRs in Manual mode.
 Select M F F mode
 By varying variac out put ensure tap operation as done earlier.
 Ensure proper parallel operation. I.e. Follower AVRs follow the Master.
 Ensure indications and tap position at various locations.
 Ensure no alarm display and alarm messages at this condition.
 Create various alarm conditions as described earlier.
 Ensure Parallel operation blocking on alarm conditions.
 Ensure that VT wiring is done correctly such that a cable coming from IDT1 VT is
connected AVR1, IDT2 VT to AVR2 and IDT3 VT to AVR3 respectively.
3. c Parallel AUTO-R/L control in Manual:
 Disconnect all shorting wires from the TB of CB status.

 Identify the CB open/close status condition input terminals in LCC and 11 KV panel.
 Insert all LV CB in test position and close all the CBs including HV CBs.
 Observe the programmers of all AVRs for correct bus bar status.
 Select AVTRs in REMOTE and in HAND.
 Select all AVRs in Parallel AUTO mode.
 Observe AVR1 automatically selected as Master and others as Followers (MFF).
 Mean time checks all indications and alarms for proper display.

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 Keep the Master IDT out of parallel control by opening respective CBs and then observe
that AVR of another IDT, who’s CAN BUS ADDRESS, is low, is selected automatically as
Master. Men time the AVR of the IDT which is out of parallel control becomes independent.
 Repeat the check as per the test format for Parallel Auto Mode and observe that correct
selection and indications take place automatically.
 Raise/Lower operations at each combination shall be done in HAND mode and tap
positions, indications and display shall be checked for its correctness as described earlier.
 Create various alarm conditions as described earlier.
 Ensure Parallel operation blocking on alarm conditions.
3. d Parallel Auto –R/L control in Auto:
 Keep AVRs in Parallel Auto and Tap control in AUTO mode.

 Keep AVR1 in Master and other in Followers.
 Check Raise/Lower operation by varying the variac output by +/- 4% of the reference
voltage.
 Ensure that Parallel control is satisfactory in this mode also.
 Ensure tap positions, indications and display for its correctness as described earlier.
 Ensure that in this mode Raise/Lower operation is not possible by HAND.
 Create alarm conditions in AVRs and ensure blocking of parallel operation.
28.0 OLTC PARALLEL OPERATION
Parallel Manual mode and Parallel Auto mode.
Aim
To ensure the performance of OLTC parallel operation through AVR at parallel manual mode with
master, follower, and independent selection independently, parallel auto mode with master,
follower, and independent selection automatically with Breaker status and same operation with
auto according to the reference voltage of VT secondary voltage.
General
Tap position of the transformer shall be the same. MDU must be always in remote position. AVR is
put in manual and remote mode. Breaker operation shall also be done form remote. The first
Transformer is the master second will be follower and third will be independent at normal
operating condition.

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Test Preparation
 Ensure designation of AVR1 for IDT1, AVR2 for IDT2 and AVR3 for IDT3.
 Ensure all MDU are in remote position.
 Ensure all OLTC are in same tap position.
 Ensure the readiness of all MDU for operation.
 Ensure the supply input for all AVR.
 Ensure the readiness of DCS and SCADA
 Ensure the readiness of 132kV & 11 kV GIS.
 Ensure the clearance from the concerned departments for the operation of GIS(Breaker
closing and opening)
Procedure
Parallel-Manual Mode
 Switch on all AVR supply.

 Select all required parameters in all AVR.
 Put all AVR in hand /manual and remote mode.
 Manually select the first AVR in master and follower on second and third.
 With the above condition the operation of OLTC shall be checked from AVR, DCS and
SCADA and operation will be given below.
OLTC Operation Operation from

Result
IDT 1 IDT 2 IDT 3 AVR1/AVR2/AVR3 DCS SCADA
Operation as Operation as Operation as Ok/Ok/Ok/ Ok Ok
master (M) follower (F) follower (F) MFF/MFF/MFF MFF MFF
 Similarly the balance operation mentioned in the documents shall be checked by manually
selecting the required mode in each of the AVR at AVR, DCS and SCADA.
 MFF: MFF means AVR1 is the master of IDT1, AVR2 and AVR3 are the followers of IDT2,
IDT3 for the master.
 MFI: MFI means AVR1 is the master of IDT1, AVR2 is follower of IDT2 for the master and
AVR3 is the independent for IDT3

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 Master: (M) Master means the OLTC operation is possible from the master only.
 Follower: (F) Follower means the OLTC operation not possible form the follower but
operation followed by the master.
 Independent: (I) Independent means the operation of OLTC can be done individually.
Parallel Auto Mode:
 Select required parameters in all AVR

 Put all AVR in hand (manual) and remote mode.
 Check the breaker status.
 If the entire breaker are closed as shown in figure, the scheme will be configured in such
way that the IDT1 as master and IDT2 & IDT3 are followers.
As the above condition, open Bus Section one (BS1) breaker

 IDT1 will be separated from the circuit and it became independent
 IDT2 became master
 IDT3 became follower
 All operation with the above condition shall be checked at AVR, DCS and SCADA.
 Similarly all the operation mentioned in document shall be checked.
Auto Operation check with VT secondary voltage
 Put AVR in auto instead of had (manual)

 Give the VT secondary voltage with slide are to the terminals where the VT secondary
connections are to the AVRT after disconnecting the wires actually coming from the VT
secondary side.
 Set the voltage 110V
 Varying the voltage from 110 V to below and above in line with approved set values for
lower and raise operation of the OLTC.
 With the above raise/lower conditions, the operation as stated in parallel auto mode shall
be repeated and ensure the performance.
29. OIL LEAK TEST
Aim
To ensure that the transformer is fully leak proof.
General

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Oil leak test is done to ensure any oil leakage through welds, gasket joints, devices and any point
of the transformer. During the continuous full load operation, the temperature of oil goes up. So
the oil viscosity will be reduced and oil level increased in the conservator and hence there are
more chances for oil leak. This condition is simulated by applying additional pressure over the
normal oil head for a particular period constantly. During this keeping time if there is no oil
leakage, it is presumed that oil leakage will not occur during continuous normal loading. Dry
nitrogen (N2) is normally used for applying pressure.
At test pressure of normal pressure plus 34N/m² shall be applied at top of oil in the conservator
or 69N/m² at bottom of the tank whichever is greater, constantly for 48Hrs.During this period no
oil leakage or ingress in to normal oil free spaces shall occur. It is suggested to apply the pressure
at maximum ambient temperature so that we can reduce the applied pressure during a whole
keeping period to avoid creating excess pressure which may cause the PRD operation.
Test preparation
 Ensure the rubber bag and rapture relay are normalized (If provided)
 Ensure the main tank and OLTC (if applicable) tanks are equalized.
 All the bolts and nuts are fully tightened and torque checked.
 Ensure new gaskets are used during erection.
 Ensure no oil trace at any where the transformer.
 Ensure proper cleaning of the transformer and its surroundings.
 Ensure the availability of nitrogen cylinder with regulator and pressure gauge.
 Ensure all gauges have proper valid calibration status.
 Ensure the availability of thermometer for ambient temperature.
 Ensure valve between main buchholz relay and conservator and between HV cable (if
applicable) box/boxes and conservator are open.
 Ensure all radiator valves are open.
 Ensure the valve between OLTC and conservator is open (If OLTC is provided)
 Ensure the PRD operating pressure.
Test procedure
 Remove OLTC and Main tank breather; connect the output of the nitrogen cylinder parallel
to the OLTC main tank breather line so as to apply the pressure both tank at time.
 Pressure gauges shall be connected at bottom (P1), at top of main tank (P2) and one (P3)
for the applied pressure measurement.
 Note down the pressure due to normal head at bottom and top of the tank.
 Note down the ambient and oil temperature.

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 Slightly open the N2 cylinder valve and regulated N2 shall be allow passing and pressured
the normal oil haed.When the pressure reaches at as stated above by simultaneously
monitoring the pressure gauges P1, P2 and P3 and maintaining continuously for 48hrs.
 During the pressurizing, ensure the pressure at tank top (P2) is less than the operating
pressure of PRD.
 During the keeping time, every one hour, the ambient temperature, top, bottom and
applied pressure shall be note down.
 During the keeping time there should not be any oil leakage.
 Test observation shall be reported and recorded.
30. OIL BDV TEST
IEC60076-1, 2000
Aim
To ensure the electrical strength of the insulating oil and BDV of the oil each stage meets the
requirements/Specifications.
General
This is one of the points to ascertain of oil. Sphere gap method with a gap of 2.5mm in oil is
normally used. The BDV of oil at above test condition shall be greater than 70KV.
Following precautions shall be taken during oil sampling.
It is suggested to take the oil sample directly to the BDV kit set. Special tools, gloves etc shall be
used.Dry, clean and good atmospheric condition is better for taking sample. Avoid talking during
sampling. Do not air bubbles in the sampling oil. Care shall be taken to avoid entry of moisture,
dust metal parts etc to the sampling oil. Required quantity of oil shall be taken in the kit at a time
for test. After sampling, immediately cover it properly, to avoid entry of air moisture through the
sampling portion of the transformer as well as the sampling oil.
Test preparation
The BDV kit with valid calibration status placed in a clean and closed room. Ensure the availability
of supply unit.
Test procedure

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Precautions shall be taken during sampling as stated above. The cleaned BDV kit vessel shall be
washed two to three times with the oil to be tested. Check any air bubbles in the sampling oil.
The oil sample shall be kept carefully inside the kit and covered. Minimum 15 minutes shall be
given as a settling time. Six set reading shall be taken at an appropriate intervals and reported
average. The average value will be greater than 70Kv.Ensure that none of the six readings is less
than 60Kv.If the test values are not satisfactory, decision shall be taken for taking sample again
for a retest or further oil processing is required to improve the values. After test, the kit shall be
switched off and clean the oil vessel.
Following oil sample shall be tested.

 Processed oil before filling in to the transformer.
 After hot oil circulation of the oil-----Main tank top and bottom.
 HV Cable box
Before cable HV test After cable HV test
Prior to Oil filling After Oil filling prior to filling After Oil filling
(Processed oil) (Processed oil)
 OLTC Chamber after circulation
31. TEST ON TRANSFORMER OIL (OIL CHARCTRESTICS)

IEC600296 - 2003
Aim
To ensure the properties and characteristics of transformer oil
General
This is purely an oil manufacturer’s test report which contains data to meet our
requirements/Specifications. If oil manufacturers test report is incomplete, test shall be done at
independent laboratory before conducting any oil processing.
Following are the properties and characteristics of oil.
 Kinetic viscosity

Page 48 of 52
 Flash point
 Pour point
 Dielectric Dissipation factor
 Appearance
 Density
 Interfacial tension
 Neutralization value
 Corrosive sulphur
 Total sulphur content
 Water content
 Total acidity
 Sludge
 Dissipation factor @90ºC
 Induction period
 Total sulphur content
 DGA
 Break down Voltage
36. SWEEP FREQUENCY RESPONSE ANALYSIS

IEC60076-1, 2000
Aim
To ensure any possible damages (Physical shifting/deformation etc) of the transformer winding,
core or internal parts have occurred during transportation or after any failure.
General
Frequency response analysis FRA is a valuable tool to verify the geometric and mechanical
integrity of electrical apparatus, especially transformers, providing accurate and repeatable
measurements. This is a proven field diagnostic technique capable of detecting damage arising
due to dislocation/movement of core and winding during transportation or after occurrence any
field.
FRA is based on the principle of measurement of steady electrical response against a steady
sinusoidal input given to the test object.

Page 49 of 52
The basis of the FRA technique is that the impedance of the transformer is a function of the
resistance, inductance, capacitance, and applied signal response. The resistance is related to the
physical construction of the winding .Capacitance and inductances are related to the construction
and geometry of the windings. Deformation and movements have an effect on both inductance
and capacitance that may be reflected in the resulting frequency response.
There are two basic methods to conducting FRA test; low voltage impulse method and
sweep frequency response analysis SFRA
Low voltage impulse method relies on indirect measurement of the frequency response. An
impulse or a set of impulse with assumed frequencies of interest is applied to the winding that is
under test. These frequencies are disentangled using signal analysis techniques (FFT) to produce
a frequency response plot by converting time domain to frequency domain. This technique is
dependent on good impulse signals, fast signal processing and analysis. However these produce
limited or poor response at lower frequencies, up to few hundred Hz, where much information
about internal construction of the transformer in terms of inductance is gained.
SFRA measurement is done with the frequencies being swept in a wide range; usually from 20Hz
to 2MHz.This is the simple direct measurement in frequency dimain.Also a direct relationship
exists between geometric configurations and RLC network constituted by winding and core
assembly identified by its frequency dependent transfer function. Measuring the frequency may
be performed by applying a simple varying frequency signal to the transformer that covers
frequency range of interest. Sweep frequency method has far higher repeatability and consistency
over impulse methods which are prone to variation due to lead arrangement and impulse shape.
Normally a factory FRA measurement is taken as reference (Signature) and later on site
measurement (after errection at site) is compared with the reference measurement. In practice
measurement after erection at site is taken as reference for the future measurements done at site
during the operational period of transformer.
Possible damages in the winding are indicated in relevant ranges of frequencies by shifting of
resonance points or by the introduction of new resonance, not being present in the reference
measurement.
The comparison of the traces belonging to different phases or different transformer of same
design (Sister Unit) may be useful, but with laminations.
A shifting of the resonant point (If any) of the open circuited admittance is noted. The difference
(ie, the shifts of resonant points or the introduction of new resonance not present in the reference
measurement) is evaluated as an indication of normal variation or faults in the winding.

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The plots of admittance (Reverse of impedance) verses frequency indicate a series of resonance
with the small value and anti resonance with high value. The resonance with low admittance
represents a parallel resonance circuit. The resonance with high admittance represents a series
resonant circuit.
Test preparation
Measuring the frequency response of a winding with in a transformer, or of a transformer transfer

functions from winding to winding, gives a finger point for that winding or transformer. The
process requires measurement of both input and output signals, which are then radioed to give
the response. This reduces the effect of the measurement of three lead systems involving input
measured input and measured response.
Signals are applied and measured with respect to ground. The amplitude and phases of the two
signals (S Measurement and R Measurement), are measured to determine the relative amplitude
and phase shift changes between them. The basic measurement is of the attenuation and phase
shift of signal after having passed through the winding from the input to the output terminals.
The test can also include voltage transfers between windings i.e. applying a signal to one winding
of a transformer and measuring the response at another winding to determine the amplitude
change and phase shift of the signal having been transferred along a winding, or form one
winding to other
Transformer under test should be completely reenergized and isolated from the power system.
This shall be solidly earthed which is common to FRA test equipement.FRA is performed as
response to electrical measurement at the terminals connected to the starting and end of any
winding. The test leads must be first connected to the FRA instrument and then to the
transformer bushings.
Connect the color code cable to the instrument.
1. Yellow : Excitation source cable

2. Block : Measurement cable
3. Red:Refernce cables
The main cable clamps red and the block are connected to bushings terminals accordingly. Also
connect the ground clips for each cable, red and block to the corresponding bushing flanges. Test
set up and actual test shall be done as per the manufacturer’s manual.
Test procedure

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Transformer tap number, earthing details, ambient temperature etc.are noted. Frequency range is
selected as 20Hz to 2Mz.The test connections are verified and measurements done for the
following combinations. The plot names are assigned wit reference to terminal markings as given
below.
 1U1N-LVoc, 1VN-LVoc, 1W1N-LVoc

 1U1N-LVsc, 1V1N-LVsc1W1N-LVsc,
 2U2V-HVoc, 2V2W-HVoc, 2U2W-HVoc,
The measured magnitude and phase plots are compared with corresponding reference plots
(Signature).If any abnormality/deviations in the measured plot is noticed, tightness and
correctness of connections may be confirmed before finalizing the test results.
Precautions and safety.
1) FRA measurement is sensitive to DC magnetization of the core and hence it has carried
before application of any DC voltage. If any DC measurement is carried out before FRA
measurement, it should be properly demagnetized.
2) The resultant plot may distort from the actual one in case of loose connection.
Interpretation
1) The exact comparison of the FRA measurement plots at site with the factory measurement
can be made only if the measuring equipements, measuring connection, setup, measuring
leads etc are the same. However idetintical test equipments with the same connection and
setup may give almost the same results.
2) Frequency response plot provides a finger print for a transformer. Fingerprints from similar
transformer have common features.
3) The core condition, in principle, cannot be checked by FRA method. However
magnetization of core affects low frequency results.
4) A Clear shifting of first resonance usually below 1000Hz indicates inter turn connection
failure.
5) Clear shifts of resonance or new resonance of the lower harmonics in the range 1000Hz to
10 kHz indicate the axial movement of bulk winding or radial hoop bucking.
6) Shifts of resonance or new resonance in the range of 10 kHz to 100 kHz indicate
movements of small winding parts e.g. tap winding.

Page 52 of 52
PROTECTION TESTS IN CONTROL PANELS
PROTECTION
TESTS

Page 1 of 26
DC SYSTEM
Battery Charger
1.0 PURPOSE
1.1. The purpose of this procedure is to explain in detail, the steps to be followed, for
testing of Battery Charger, DVR and DCDBs to ensure the device healthiness and
related scheme testing.
2.0 PROCEDURE
2.1. General
Charger details:
2.1.1. 110V Station charger is used for control and protection system, 48V charger is used
for SCADA communication system and 110V EL is used for emergency lighting
system.
2.1.2. At normal condition Battery charger feeds the load as well as charge the battery.
2.1.3. When mains supply to the Battery Charger fails, Battery will feed the load. After
resuming the input supply, charger will feed the load and battery will be charged in
boost charge mode.
2.1.4. After reaching 80% of the battery capacity charger shall automatically transfer to
float mode.
2.1.5. Blocking diode is used in charger output circuit to avoid reverse feeding from battery
to charger.
2.1.6. For 48V charger, the positive shall be grounded.
2.1.7. 110V charger has three modes of outputs
 Float mode voltage is 120.4V (86 Cells x 1.4V/Cell = 120.4 V)
 Boost mode voltage is137.6V (86*1 Cells x 1.6V = 137.6 V)
 Commissioning mode voltage is 141.9V (86 cells x 1.65V = 141.9 V)

Page 2 of 26
2.1.8. In 48V charger, three modes of outputs voltage is

 Float mode voltage is 53.2V (38 Cells x 1.4V=53.2V)
 Boost mode 60.8V (38 Cells x 1.6V)
 Commissioning mode 62.7V (38 cells x 1.65V=62.7 V)
CHARGER LOAD TEST:

2.1.9. Carry out the load test in float and boost mode at different loads as mentioned in the
test report and record values.
2.1.10. Verify, calculate and fill in the test report.
2.1.11. Check the ripple content in the charger output voltage and ensure that measured
values are within the specified limit.
2.1.12. Load the charger up to 110% (Over load), verify the battery current limit function and
record the values.
2.1.13. At this overload condition, charger will not deliver more than rated current and output
voltage will start reducing, while load is exceeding 100%.
2.1.14. Verify the operation of float mode to boost mode and boost mode to float mode.
2.1.15. Check the transfer time from boost to float mode
2.1.16. The charger revert back to float mode in case of high DVR output voltage (≥125V for
110V charger, ≥56V for 48V charger) or DVR cooling fan failures if any.
Charger Alarms Testing:
2.1.17. Check the remote alarm contacts are operating for the below alarms.
2.1.18. Switch off the charger input supply from LVAC and ensure the charger failure alarm.
Restore the input supply after testing.
2.1.19. Remove the input connection / fuse of each fan (if any) of charger and DCDB
separately. Ensure the fan failure alarm in the charger panel but charger will not
shutdown.
2.1.20. Push the micro switch to simulate AC incoming supply fuse failure. Ensure the
operation of charger failure alarm.

Page 3 of 26
2.1.21. Push the micro switch to simulate charger main transformer input fuse failure.
Ensure the operation of charger failure alarm.
2.1.22. Push the micro switch to simulate charger DC output fuse failure. Ensure the
operation of charger failure alarm.
2.1.23. Put the charger on boost mode and disconnect DVR relay supply to simulate
charger dropping diode failure. Ensure the operation of charger failure alarm. Ensure
charger shall revert back to float mode.
2.1.24. Disconnect thermal sensor connection of SCR heat sink (which is normally closed in
healthy condition) to simulate charger high temperature. Ensure the operation of
charger failure alarm. Ensure charger is shut down.
2.1.25. Verify the charger over load alarm.
2.1.26. Increase the output voltage of charger more than the set voltage to simulate charger
high voltage alarm. Ensure that charger is shut down. Reduce the output voltage to
normal value to restore charger operation.
2.1.27. Decrease the output voltage of charger less than the set voltage to simulate charger
low voltage alarm. Increase the output voltage to normal value to restore charger
operation.
2.2. DVR (Diode voltage regulator) test -
2.2.1. DVR regulates the charger output voltage. Load voltage should not exceed 10% of
nominal value of 110V.
2.2.2. In DVR, diodes are used to drop the voltage. Each diode is dropping 0.7V to 0.8V,
depending upon the load.
2.2.3. In DCDB there are two DVR stages. In float mode both stages are deactivated. Each
stage is activated and deactivated based on the specified setting during boost mode.
2.2.4. DVR is to be tested to ensure the set / reset voltage for switching close / open
condition of DVR stages to regulate the load voltage
2.2.5. During alarm testing, the charger shall be loaded for 10% of the rated current.

Page 4 of 26
DVR Testing:
2.2.6. Load the charger with minimum 20% of the rated current.
2.2.7. Change the charger to manual mode and increase the charger output voltage slowly.
When DVR stage-1 operates, measure voltage before & after the DVR and record in
the test format.
2.2.8. Further increase the charger output voltage to activate stage-2, measure voltage
before & after the DVR and record in the test format.
2.2.9. Start reducing the charger output voltage to deactivate stage 2 and stage 1,
measure voltage before & after the DVR and record in the test format.
2.2.10. The charger revert back to float mode in case of high DVR output voltage or DVR
cooling fan failures if any.
DCDB alarm test:
2.2.11. For 110V/48V DCDB reduce the output voltage of charger up to specified value.
Ensure the operation of DCDB low voltage alarm which is grouped with charger
failure alarm. Increase the voltage to more than the specified value and ensure the
alarm reset.
2.2.12. During DCDB high output voltage, the charger shall revert back to float mode. At the
same time ensure the DVR failure alarm also appears.
2.2.13. The earth fault alarms are to be tested by creating earth faults in the DCDB and at
the field. Earth faults created in one of 110V DCDB must not reflect in the other
110V DCDB. This alarm is grouped with earth fault alarm.
2.2.14. Simulate the MCB trip alarm from load side and ensure the indication in DCDB.
This alarm is local alarm only.
2.3. Bus coupler functional test
Bus coupler Details: (for 110V Station DCDB 1 &2 only)
2.3.1. The testing of bus coupler shall be carried out as mentioned in the test report.
2.3.2. The coupler should be in Auto mode, during testing if required it can be changed in
to Manual mode.

Page 5 of 26
2.3.3. If DCDB1 with low voltage alarm load shall transfer to DCDB2 by closing coupler
automatically. This operation shall operate vices versa.
2.3.4. In case of power failure for both chargers at a time bus coupler shall remain in open
condition, though the DCDBs are with low voltage alarms.
2.3.5. Restoration of bus coupler is by manually only.
2.3.6. The operation and sequence shall be followed as per test report and same shall be
recorded.
2.4. DCDB Outgoing cable check-
2.4.1. All MCBs in the DCDB must be clearly labelled to show their load details. Also a list
of load to be pasted in the DCDB.
2.4.2. Ensure the ferrule in all outgoing cables
2.4.3. All the cable shall be checked with continuity tester prior to the IR test.
2.4.4. Ensure that, all outgoing cables are disconnected and kept open at both ends.
2.4.5. The IR testing of the outgoing cables shall be carried out with insulation tester
(>500V).

Page 6 of 26
Battery Testing
1. Battery initial parameter measurement-

2. Before starting the battery initial charging, Battery initial parameter measurements i.e.,
Electrolyte level, specific gravity (1.20±0.01) and temperature of batteries shall be
checked and recorded in test report.
For Cells filled at site and
For Cells filled and charged in the factory and stored for lesser than 12 months:
Charge Discharge Recharge

At to 1.1V/ At
0 .2 C5A cell At 0 .2 C5A
for 10 0.2C 5A for for 10
Float mode Continues
Hrs. 5 Hrs. and W ait for Hrs.
for 1Hr to Float
or continue 0Hr to 4 Hr. or
12 Hr. mode
At the test up At
0 .1 C5A to 1.0V/ 0 .1 C5A
for 20 cell for 20
Hrs Hrs.
 Battery charging test
 Adjust the current limit in the charger in order to get 0.2C5A and charge the
battery for 10Hours by following the clause 6.5.1.1.
 If charger is limited to feed 0.2C5A, adjust the current limit in order to get
0.1C5A and charge the battery for 20 Hours by following the clause 6.5.1.1.
 Note : At the end of the charging, the cell voltage may reach 1.85V/cell
(Maximum allowed voltage is 1.85V/cell), thus the charger shall be able to
supply such voltage(Charger setting not to exceed 1.85V/cell).
1. Charge the battery and record the individual cell voltage, total battery voltage &
battery current on hourly basis in the test report. During charging, measure the

Page 7 of 26
battery electrolyte temperature in pilot cells and ensure that the measured value is ≤
45ºC.
2. In case the temperature of the electrolyte reaches 45ºC, charging shall be stopped
until the cells to cool down to temperature of ≤ 35ºC. Then charging shall be
continued.
3. After completion of charging test, keep the charger in float mode.
4. Acceptance discharge test shall be started with full battery bank between 1-12 hour.
1.1.2.1. Battery Discharging
1.1.2.2. Before starting the battery discharging test, check the battery electrolyte temperature
and ensure the measured value is ≤ 35ºC. If temperature is high, wait until
temperature cools down.
1.1.2.3. Discharge the Battery to 1.1V/Cell with 0.2C5 for 5 Hours and the cells should not
fall below 1.1V/cell, and then continue the test until the battery reaches to 1.0V/cell.
If any cell falls below 1.1V before 5 hrs, will be considered as defective cell to be
replaced with new cell.
1.1.2.4. Record individual cell voltage, total battery bank voltage & battery current in the test
report. Initial open circuit reading (1 sheet) for first 10min (1 sheet) then first three
hours, reading shall be taken on every 1 hour interval. (Total 3 sheets).Then
readings shall be taken on every 15 minutes interval. (Total 8 sheets)
1.1.2.5. After 5 hours of discharge test, verify the last (5th hrs) reading. Ensure that all cell
voltage shall be ≥1.1VDC. Then follow the clause 6.5.3.
1.1.2.6. If any cell voltage is measured < 1.1VDC, defective cells shall be replaced with new
cell. Follow the clause 6.5.2.6
1.1.2.7. Before replacing the cell, new cell to be charged / discharged by using mobile
charger by following the clause 6.5.1 and 6.5.2.1 up to 6.5.2.5. Then connect the cell
to the bank under test and proceed with clause 6.5.3
1.2 Battery recharging test

Page 8 of 26
 Adjust the current limit in the charger in order to get 0.2C5A and charge the
battery for 10 Hours by following the clause 6.5.3.1.
 If charger is limited to feed 0.2C5A, adjust the current limit in order to get
0.1C5A and charge the battery for 20 Hours by following the clause 6.5.3.1.
1.2.1.1. Recharge the battery and record the individual cell voltage, total battery voltage &
battery current on hourly basis in the test report. During recharging, measure the
battery electrolyte temperature in pilot cells and ensure that the measured value is ≤
45ºC.
1.2.1.2. In case the temperature of the electrolyte reaches 45ºC, charging shall be stopped
until the cells to cool down to temperature of ≤ 35ºC. Then charging shall be
continued.
1.2.1.3. After completion of recharging test, keep the charger in float mode.
1.2.1.4. Wait 0 Hours to 4hours. Until the cells to cool down to ambient temperature.
1.2.1.5. Check the electrolyte level of all cells after initial charge if required, top up with
Electrolyte (After this if electrolyte level is low it should be toped up with only distilled
or demineralised water) just below to the maximum level.

Page 9 of 26
DC SCHEME & TCS
3.1.1. General:
 The DC scheme test shall be performed with commissioned /temporary
battery bank with permanent charger.
 The DC scheme test shall be performed only after completion of auxiliary/trip
relay component test.
 Before starting the tests, confirm the fuse or MCB rating are as per
approved drawing
 Designation numbers and terminal numbers of fuses, MCB’s, relays and
switches initiation links, trip links and Auxiliary relays for the respective
feeder details shall be revised in test report as per approved drawing.
 Label text description of trip links, initiation links, switches and other relevant
labels for the feeder under test are to be ensured before starting the test.
3.1.2. Verification of Non-mixing of supplies un-grounding :
3.1.2.6. Keep all the DC fuse and links in isolated status or MCBs in “Switch off” Status as
mentioned in test report.
3.1.2.7. By using multi meter in Voltage mode, measure the voltage, in Positive terminal with
respect to earth and negative terminal with respect to earth at incoming and
outgoing terminals of fuse, links or MCB.
3.1.2.8. The voltage at positive and negative terminals shall be about 50 % of DC System
voltage at incoming terminals. Ensure that the voltage is zero at outgoing terminals
of Fuse and links or MCBs,
3.1.2.9. Energize only one DC circuit (according to application) at a time, measure the
voltages at outgoing terminals of Fuse & Links or MCBs of all circuits.
3.1.2.10. Measured voltage shall be about 50 % of DC total voltage at output terminals of fuse
& Links or MCBs of energized circuit. Record the values in test report.

Page 10 of 26
3.1.2.11. As per drawing, both in positive and negative bus, measure the voltage in relay, fuse
and other equipments terminals.
3.1.2.12. Measured voltage shall be zero at output terminals of Fuse and links or MCBs of de-
energized circuits. Record the values in test report.
3.1.3. Verification of DC path and supervision:
3.1.2.6. Confirm the operation of dc supply supervision relay for the energized circuit and
ensure that the respective supervision relay is connected at the end of circuit.
3.2..7. TCS & TSS Scheme Testing:
3.1.2.6. TCS & TSS scheme test shall be performed only after completion of DC Scheme
test and BCPU final setting (only for 11KV).
3.1.2.7. Designation numbers and terminal numbers of fuses, MCB’s, relays, switches,
initiation links, trip links and Auxiliary relays for the respective feeder details shall be
revised in test report as per approved drawing.
3.1.2.8. Ensure that the trip circuit ferrules are identified with red color and appropriate rating
of the resistor used in the TCS Circuits are as per the approved drawing.
3.1.2.9. TCS & TSS Scheme checks shall be performed in both CB open and closed
condition. Wherever the relay (TCS & TSS) operation is same for both in breaker
closed condition and breaker open condition, test shall be carried out in CB closed
condition only.
3.1.2. Verification of TCS & TSS path and Supervision:
3.1.2.6. The purpose of TCS checks is to ensure the healthiness of the Trip circuit. If the trip
circuit is braked / disconnected TCS relay should be operated.
3.1.2.7. In order to ensure the same, wherever multiple wires are connected for looping
purpose (in terminals like relay output contacts, TTB terminals) same shall be
removed for TCS checking.
3.1.2.8. Wherever one to one termination is available (like Terminal blocks) same shall not
be removed for checking. But ferrule numbers are to be ensured as per approved
drawing.

Page 11 of 26
3.1.2.9. Wherever Fuses/link/MCB is available, fuse/link cartridge shall be removed or MCB

to be switched OFF/ON to ensure the TCS & TSS checks. Ensure that frequent
operations of main supply fuse/link or main supply MCB is to be strictly
prohibited since main relays are required sufficient time for initialization.
3.1.2.10. Ensure that the TSS Relay is connected in the beginning of Trip circuit and TCS
relay at the end of the Trip circuit.
3.1.2.11. Keep the CB Open condition and remove the wire from the respective terminal as
mentioned in the test report (start with positive and end with negative path) and
check the operation of the TCS & TSS relay.
3.1.2.12. If separate TSS relay is not available in circuit (applicable for New philosophy
substations) ensure that main relay healthy LED is OFF during removing the wire
from the circuit.

Page 12 of 26
CT- PRIMARY INJECTION
5.1. Confirm CT ratio is selected and CT star point as per the setting template &
Drawing.
5.2. Check the tightness of CT disconnecting links in CTJB, CTMB, LCC, and relay
protection panel & BBP, for all the protection cores of particular feeder under test
with screw driver.
5.3. Check the single point grounding with a 500V insulation tester and record the same
in the test report.
5.4. Keep the bus isolator in open condition and keep the earth switch of bay under test
of the bus side in close condition.
5.5. Primary injection probe is to be connected across ‘R” phase CT by connecting one
lead at a test point provision given in the line earth switch and other lead to the
ground.
5.6. Gradually increase the primary current to 10 % of adopted CT ratio. Confirm CT
circuits are through by ensuring currents in the CT secondary circuits.
5.7. Gradually increase current up to 50% for feeders and 100% IDT/ICT of the adopted
CT ratio. Measure the secondary currents on all points as per the test format and
record the values.
5.8. Check and record the display measurements of each protection relays (if applicable)
and confirm values are matching with the adopted CT ratio.
5.9. The ‘R’ phase core identification shall be identified by shorting the CT secondary at
the CT secondary box or CTJB or PJB. Monitor the CT secondary current in the
relay display (if applicable) at relay panel reduce near to zero, with the
corresponding phase shorted in the CT secondary. Normalize the CT shorting.
5.10. Gradually reduce the current to zero.

Page 13 of 26
5.11. Repeat the clause 6.2.2.6 to 6.2.2.10 for R-Y, R-B phase injection with current probe
connected in the respective phases, measure and record the current in the
respective columns.
6. Busbar Protection Primary Injection Test (Full circuit checks
with typical feeder
Check the tightness of all BBP CT disconnecting links in all feeders and in BBP panels
with torque screw driver. Check the single point grounding with insulation tester and
record the same. Bypass the stabilising resistors in CZ, DZ1, DZ2 panels.
6.1.1. Primary injection test kit shall be connected in BBP CT circuit in bay1. Inject 500A
current in R-E phase and measure the secondary currents at respective BBP T.B in
PJB, measure at respective BBP T.B in BBP check/disc. zone panel and record in
test sheet
6.1.2. Keep busbar protection “In/Out” selector switch in “OUT” position and with “CT
supervision not operated condition” measure and record the currents in respective
terminals of “In/Out” selector switch, X95 T.T.B. and X87 T.T.B as mentioned in
test report.
6.1.3. Keep busbar protection ‘In/Out” selector switch in “IN” position and with “CT
supervision operated condition” measure and record the currents in respective
terminals of X95 T.T.B., X87 T.T.B. and F95 relay as mentioned in test report.
6.1.4. Keep busbar protection ‘In/Out” selector switch in “IN” position and “take out the CT
supervision relay from the case” (applicable only if MCAG relay is provided in BBP
panel) measure and record the currents in respective terminals of X95 T.B.,X87
T.B. and F87 relay as mentioned in test report.

Page 14 of 26
PROTECTION RELAY TESTING

Feeder Differential Relay
6.2.1.1. General Data.
 The testing engineer has to fill the General data (Relay Type, Serial No, Firmware
Version, Rated Current etc.) as mentioned in the test format.
 A general visual inspection is carried out to confirm the relay installation and
wirings are carried out as per the approved drawings.
 The polarity and voltage level for relay supply are checked and recorded
 Measure and confirm availability of 48 volt auxiliary from the relay.
6.2.1.2. Measuring communication signal strength:
 Measure the Transmit and Receive (Tx, Rx) Fibre Optic signal strength at both
ends and compare the values with the calculated optical budget.
6.2.1.3. Measurement Checks:
 Use the secondary injection test kit to inject current in ‘R’ phase and note down the
relay display reading. Repeat the current injection in Y & B phases and note down
the display readings in the test format.
6.2.1.4. Opto (BI’s) Check:
 Record the function of BI in the test format. Apply voltage and check the BI is
functioning.
6.2.1.5. LED Check:
 Each LED indications are to be checked separately by operating the particular
function to which it is assigned. LED resetting operation is checked by manually
resetting the indications.
6.2.1.6. Output relays Check:
 Record the function of BO in the test format. Each BO to be checked separately by
operating the particular function to which it is assigned. The BO is tested by
checking the continuity between contacts using a multi-meter.

Page 15 of 26
6.2.1.7. Differential protection checks:

 Use the secondary injection test kit and gradually increase / decrease the current
injection in R phase to record differential pick up / drop off. Note down the values in
the test format. The recorded value should be within the tolerance mentioned in the
test format.
 Repeat the test for other phases.
6.2.2.8. Bias Characteristic Test:
 For checking the lower slope of Areva P543 relay, inject 1 Amps current in the
phase as indicated in the format and ramp the current in the other phase till the
other phase element picks up. Record the differential pickup value as mentioned in
the format.
 For checking the upper slope, inject 5 Amps current in the phase as indicated in
the format and ramp the current in the other phase till the other phase element
picks up. Record the pickup value as mentioned in the format.
6.2.2.9. Broken conductor Check : (AREVA P543)
 Inject current such that the ratio of negative sequence current to positive current
can be varied.
 Ensure that at the relay pickup, the ratio of I2/I1 is within +/- 10% of setting.
 Inject current such that the ratio of I2/I1 is twice the setting and measure the relay
operation time.
6.2.2.10. Other checks.
 Confirm operation of trip relay by inserting the appropriate trip link. Also confirm
signals to fault recorder and SCADA system are send from the relay.
 Disturbance recorder and event recorder from the relay are to be down loaded to
the computer (laptop) and the printout to be attached with the test report.

Page 16 of 26
Transformer Differential Relay

6.2.2.11. Relay Data and General Inspection.
 The testing engineer has to fill the General data (Relay Type, Serial No, Firmware
Version, Rated Current etc.) as mentioned in the test format.
 A general visual inspection is carried out to confirm the relay installation and wirings
are carried out as per the approved drawings.
6.2.2.12. LED, Binary Inputs and Outputs:
 Record the function of BI/BO in the test format. Apply voltage and check the BI is
functioning.
 Each BO to be checked separately by operating the particular function to which it is
assigned. The BO is tested by checking the continuity between contacts using a
multi-meter.
 Each LED indications are to be checked separately by operating the particular
function to which it is assigned. LED resetting operation is checked by manually
resetting the indications.
6.2.2.13. Measurements Checks:
 Use the secondary injection test kit to inject 1 amps current in HV side CT’s and note
down the relay display reading. Repeat the current injection in LV side CT’s and note
down the display readings in the test format. Compare with expected current.
6.2.2.14. Differential protection checks.
 Differential protection settings are entered in the test report.
 Using the secondary injection test kit, gradually raise the current in R phase of HV
side CT till the relay picks up. Note the value of differential pick-up. Repeat the same
for the R phase of LV side CT.
 Check 3 phase pickup by gradually raising the current in all phases in HV side CT till
the relay picks up. Repeat the same for LV side CT.
6.2.2.15. Differential protection checks:

Page 17 of 26
 Bias characteristics are checked by injecting a balanced current in HV side and LV

side CT secondary, and then gradually increasing current in HV side till differential
pickup. Record the trip value of current in CT side-1.
6.2.2.16. CT saturation check: (MICOM P632)
 CT saturation Check is tested by applying 1 Amps at 100 Hz to R, Y and
B phases. The setting of vector group will be “YY0”, setting for 2nd
harmonic should be “disable” and zero sequence filter “OFF” .Confirm
the relay detect CT saturation and Block differential function.
6.2.2.17. Timing Tests:
 Inject current 1.0 amp current as mentioned in test format in HV side R phase and
note down the operating time value in the test format. The operating time should be
less than that indicated in the test format.
 Repeat the test for other phases in HV side. Repeat the same for LV side also.
6.2.2.18. Testing 2’nd Harmonic restraint.
 2nd harmonic blocking is set at 15%.
 16% 2nd Harmonic is generated using the secondary injection kit is applied to HV
side R phase of relay and check differential is blocking. Relay should not trip.
 Reduce harmonics percentage in the injected current till the relay trips. Record the
value in the test format.
 Repeat the test for HV side Y and B phase.
6.2.2.19. Differential High set (I diff>>)test:
 Inject in R phase a current below “I diff>> setting and observe the tripping time. The
tripping time should be the normal differential tripping time.
 Repeat injection, gradually raising the current till the tripping time is less than the
differential operating current. Record the threshold value of “I diff>>” pickup current.
 The operating time of HIGH SET will be tested by injecting 2 times of high set
differential setting current and record the time.
6.2.2.110. Other Checks

Page 18 of 26
 Disturbance recorder and event recorder from the relay are to be down loaded to the
computer (laptop) and the printout to be attached with the test report.
 Confirm operation of trip relay by inserting the appropriate trip link. Also confirm
signals to fault recorder and SCADA system are send from the relay.
Busbar Protection.
High Impedence Relay

6.3.1.1. Operation Voltage calculation :
 Expected operation voltage (Vs) shall be calculated based on relay plug setting,
stabilizing resistor set value.
6.3.1.2. Differential pickup tests :
 Using the test kit with stabilising resistor in series, gradually raise voltage in R
phase till the relay picks up. Record the value of voltage and current. Repeat the
same for the other phases and record the measured operating values.
6.3.1.3. Differential function Operating time :
 Inject five times of setting current in R phase and record the relay operating time
in the test format. . Repeat the same for the other phases and record the
operating time.
6.3.1.4. Other checks
 Check the initiation of trip relay, SCS and FRP from the differential rely.
CT Supervision Relay
6.4.1.1. General data :

Page 19 of 26
 The testing engineer has to fill the General data (relay type, rating, serial No.,
rated current etc.) as mentioned in the test format.
 A general visual inspection to be filled after the confirmation of relay installation
and wirings as per the approved drawings.
 Adopt the approved final setting in the relay.
6.4.1.2. Pickup / Drop off test :
 Using the test kit, gradually raise the voltage in R phase till the relay picks up.
Record the value of voltage and current. Then reduce the voltage until the relay
drop off, record the value of voltage and current in drop off column. Repeat the
same for the other phases and record the measured operating values.
6.4.1.3. Operating time tests :
 Inject two times of setting voltage in R phase and record the relay operating time
in the test format. . Repeat the same for the other phases and record the
operating time.
6.4.1.4. Output checks :
 Each output (alarm, CT shorting contact) is to be checked one by one by
operating the relay. The operation of output is checked in respective output
terminals by using multi meter.
Busbar Protection Sensitivity test by Primary injection
6.3.3.1. Connect the multi meters in respective terminals according to scheme drawing to
measure relay current, relay voltage, Metrosil voltage, Stabilizing resistor voltage,
frequency, connect clamp meter in primary to measure primary current and connect
clamp meter in respective secondary terminals to measure secondary current.
Note:
For N=Minimum, connect the bay under test to Bus-1 and open both disconnector
of other bays. For N=Maximum, connect all the bays to Bus-1.

Page 20 of 26
6.3.3.2. Connect the bay under test to Bus-1 and open both disconnectors of other bays.
Primary injection test kit shall be connected in R phase of BBP CT circuit in any one
of the feeder in Zone 1 with N=Minimum (i.e., possible minimum connected feeder
in a particular zone). Slowly increase the current until the operation of CT
supervision relay. Record the measured values in DZ1 test sheets. Remove the CT
supervision relay from case (applicable where MCAG and MVTP relay provided)
and increase the current until the operation of BBP relay. Record the measured
values. Ensure the primary operating currents are with in limits as per final setting.
6.3.3.3. Repeat the clause 6.3.3.2 for Y, B phase sensitivity test.
6.3.3.4. Repeat the clause 6.3.3.2 and 6.3.3.3 with N=Maximum in respective CZ and DZ1
and record the measured values.
6.3.3.5. Repeat the clause 6.3.3.2 to 6.3.3.4 for DZ2 and record the measured values in
DZ2 test sheets.
6.3.3.6. For 400kV BBP, repeat the clause 6.3.3.2 to 6.3.3.4 for additional zones and record
the measured values in respective test sheets.
Busbar Protection Balance Stability test
6.3.4.1. Connect the primary injection kit between reference feeder and feeder under test
(current magnitude is equal and current direction is opposite) in R phase and close
both feeder breakers.
6.3.4.2. Connect the multi meters in respective terminals according to scheme drawing to
measure relay current, relay voltage, metrosil voltage and connect clamp meter in
primary to measure primary current. Also connect clamp meters in respective phase

Page 21 of 26
secondary terminals to measure secondary current of both reference feeder and

feeder under test.
6.3.4.3. Increase the current to 25% of busbar protection CT rating, confirm that the spill
current is very low (only few micro amps/milliamps), measure and record the
readings. Ensure the non operation of BBP relay and CT supervision relay.
6.3.4.4. Repeat the clause 6.3.4.3 for Y, B phase stability test.
6.3.4.5. Select both feeders in Bus-2 and repeat the clause from 6.3.4.2 to 6.3.4.4
6.3.4.6. Shift the primary injection test kit to next feeder and consider the previous tested
feeder as reference feeder. Repeat the clauses 6.3.4.2 and 6.3.4.5 for all feeders
and record the measured readings.

Page 22 of 26

Page 23 of 26
DIFF PROTECTION THROUGH FAULT TESTS (Primary Injection)
Apply primary voltage at LV side while HV side shorted as per DIFFERENTIAL protection
stability scheme diagram

Page 24 of 26
HV 64REF THROUGH FAULT STABILITY TEST(Primary Injection)

Following arrangement to be made for IDT HV REF through fault stability test through primary
injection

Page 25 of 26
64REF STABILITY TEST –LV(Primary Injection )
Following arrangement to be made for IDT HV REF through fault stability test through primary
injection

Page 26 of 26

Overall Method Statement - Substation Tests

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Overall Method Statement - Substation Tests

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What is the purpose of testing current transformers?

What is the purpose of testing current transformers?

What tests are performed on current transformers?

What tests are performed on current transformers?

METHOD STATEMENT

TESTING & COMMISSIONING

OBJECTIVE OF THE TEST:

 Company’s safety codes will be followed.

STANDARD/SPECIFICATION REFERENCE OF THE TEST:

DC VOLTAGE TO BE APPLIED Time

 ONE POINT EARTHING

OBJECTIVE OF THE TEST:

 Company’s safety codes will be followed.

STANDARD/SPECIFICATION REFERENCE OF THE TEST:

DC VOLTAGE TO BE APPLIED Time

NAME OF TEST: LVAC IR Test.

NAME OF TEST: LVAC Insulation Resistance & HV Test.

NAME OF TEST: LVAC Scheme.

ACCEPTANCE CRITERIA : All operations shall be according to the scheme.

TEST FORMAT : Attached as annexure.

NAME OF TEST: LVAC Switch / Lamp Indication.

ACCEPTANCE CRITERIA : All indications shall be as per Test Report.

NAME OF TEST: LVAC Breaker Travel.

NAME OF TEST: LVAC Outgoing feeder identification.

STANDARD/SPECIFICATION REFERENCE OF THE TEST: Approved Drawing.

NAME OF TEST: CB INSULATION RESISITANCE TEST

BETWEEN PHASE TOEARTH BETWEEN PHASE TO PHASE

Measured Insulation resistance shall be obtained in the unit of Giga ohms.

NAME OF TEST: MV SWGR Circuit Breaker contact resistance measurement

 Contact resistance of entire C.B shall be measured. It can be measured in different

ACCEPTANCE CRITERIA: Resistance should be ±5 % of the factory value.

NAME OF TEST: - MV CB Operational Functional Checks (Mechanical).

OBJECTIVE OF THE TEST: -

STANDARD/SPECIFICATION REFERENCE OF THE TEST: - IEC 60298

NAME OF TEST: - MV CB Operational Functional Checks (Electrical).

NAME OF TEST: CB Timing Measurement

STANDARD/SPECIFICATION REFERENCE OF THE TEST: IEC 62271-100.

Acceptance criteria are as per manufacturer standard.

NAME OF TEST: MV SWGR Circuit Breaker contact resistance measurement

Resistance should be ±5 % of the factory value.

NAME OF TEST:- High voltage test on MV SWG BUSBAR

STANDARD/SPECIFICATION REFERENCE OF THE TEST: - IEC 62271-100.

2. HV Test on Bus Bar:

NAME OF TEST:- High voltage test on 11 KV Circuit Breaker

4. HV Test on 11kV Circuit Breakers: (Open Condition)

1. Open all Circuit Breakers.

5. HV Test on 11kV CB Bus Section 1 & 2: (Close Condition)

NAME OF TEST:- Electro mechanical interlocks feeder earth switch

STANDARD/SPECIFICATION REFERENCE OF THE TEST: - IEC 62271-100.

Condition for closing the earth switch

 VCB should be in test position.

ACCEPTANCE CRITERIA: - Interlock shall satisfy all the above requirements

OBJECTIVE OF THE TEST:

STANDARD/SPECIFICATION REFERENCE OF THE TEST: IEC 62271, IEC 62271-203,

GIS SF6 Density Monitor Calibration (Alarm contact setting checks)

STANDARD/SPECIFICATION REFERENCE OF THE TEST:

NAME OF THE TEST: SF6 ALARM CHECKS

OBJECTIVE OF THE TEST

STANDARD/SPECIFICATION REFERENCE OF THE TEST