220 KV SWITCHYARD PACKAGE

FOR

REVIVAL OF
RAMAGUNDAM FERTILIZER COMPLEX
(Bidding Doc. No.: SM / A747-301-EB-TN-0015/1015)

JOB PROCEDURES
FOR
HT PANEL INSTALLATION & TESTING

PROJECT NO.: A747

For Approval
 JOB PROCEDURE FOR HT PANEL
INSTALLATION & TESTING

PROJECT :REVIVAL OF RAMAGUNDAM FERTILIZER PLANT

NAME OF WORK :220 KV SWITCHYARD PACKAGE

JOB NO :A747

LOA NO : SKS/A747/LOA/T/0015/1016/2016 – 17/05 dtd. 09/11/2016

OWNER :M/S RAMAGUNDAM FERTILESERS AND CHEMICALS LTD.

CONSULTANT :M/S ENGINEERS INDIA LTD.

CONTRACTOR :M/S L&T

L&T L&T EIL EIL

SIGN SIGN SIGN SIGN

NAME NAME NAME NAME

DATE DATE DATE DATE

Prepared by Approved by Reviewed by Approved by

CONTENTS

1.0 PURPOSE -4
2.0 SCOPE -4
3.0 CODES & STANDARDS -4
4.0 GENERAL INSTALLATION PROCEDURE -4
5.0 PRE COMMISSIONING TEST -6
 Name of the Work : 220 KV SWITCHYARD PACKAGE FOR REVIVAL OF RFCL
Job No : A 747
Job Procedure No : L&T/RFCL/A747 /E/JP 01 R-0

PROCEDURE FOR HT PANEL INSTALLATION

1.0 PURPOSE:
The purpose of generating this method statement is to define the procedure step by step to
implement the correct practices for Medium Voltage switchgear panel installation & its accessories through
the guidelines contained herein so as to ensure that the job execution complies with specification and
serves the intended function to satisfactory level. This method is also applicable for LV HV Switchgear as
well.

2.0 SCOPE
This method statement covers all processes related to Installation of switchgear installation as the
following:
Installation of switchgear installation and its accessories.
This procedure is to be read in conjunction with the relevant ITP, outlining the responsibility and the quality
verification to be performed by various parties.

2.1 Codes & Standards

The installation conforms to the following latest standards/statutory provisions.
IS: 2071, IS: 2705, IS:3156, IS:3231, IS:3427, IS:9921, IS:10601, IS:12729, IS:13118,
IEC:62271

2.2 REFERENCES:

1. EIL specification – 6 – 51 – 0001 Rev 6

2. Approved drawings.
3. Specifications
4. Project HSE plan
5. Manufacturer’s Data sheets & Manufacturer recommendations.
6. Approved Material submittal

2.3 DEFINITIONS:  
PQP                                        : Project Quality Plan
PSP                                        : Project Safety Plan
QCP                                        : Quality Control Procedure
HSE                                        : Health, Safety and Environment
MS                                          : Method Statement
ITP                                         : Inspection Test Plan
QA/QC                                   : Quality Assurance / Quality Control Engineer.
SK                                           : Store Keeper.
WIR                                       : Inspection and Test Request
MIR                                       : Material Verification Record.
HT                                         : Medium Voltage

50 3.0 INSTALLATION PROCEDURE

3.1 Work Sequence And Methodology

 Delivered materials will be check at site and inspected properly by Engineer and check if it is stored
properly as per manufacturer’s recommendations.
 MIR shall be raised for the inspection of materials received at site by Engineer to the Main
Consultant Engineer.
 Work shall be carried out by the site staff under strict supervision and guidance of the concerned
Supervisors / Foremen / Engineers.
 3.2 Handling and Storage
On receipt of HT Panel and accessories at site, necessary precautions shall be taken for unloading,
shifting and storage, as follows:
 
 Material shall be stored in a covered / dry space at all the time.
 All materials received at site shall be inspected and ensured that the materials are as per approved
material submittal. Any discrepancies, damage etc., found will be notified and reported for further
action.
 Site Engineer has to ensure that the HT panels used at site are of free from any damage or
deformity of any kind. Any minor damages observed shall be repaired suitably and in case if the
repairs could not be done properly, the panels are to be sent to assembler for rectification, after all
formalities carried on.

3.3 General Installation Procedure

 

 Ensure the installation of HT Panel are carried out in accordance with manufacturer’s installation
recommendations, requirement of applicable standards and in accordance with recognized
industrial practices and specified in project specification to ensure that installation complies with
requirements.

 Prior to start the installation, refer to the approved shop drawings related to the area of installation
and ensure that required materials are available at site as per approved material submittals.

 Ensure the materials are stored properly and there is no mark of damage or deformity of any kind
before issuing the material from site store. All materials and accessories should also be free of dust,
scale, or oil.

 Ensure that the issued materials are of approved specifications / submittals and as per the
requirement of the area shop drawings. (i.e. Make, Size, Model / Type etc.,).

3.4 Installation Procedure for Switchgear Panel  

 
 All required Installation shall be accordance to applicable regulations.

 All components such as relays, fuses. CT’s contractor’s meters, breakers size, bus bar sizes etc.
shall be verified against the approved material submittal.

 All installation shall be carried out according to the approved shop drawing construction for the
panels.

 Ensure the floor surface is ready with base frames grouted on the open trenches inside the HV
room to install the HT Panel.

 Minimum clearance of 800 mm shall be maintained at rear side of the panel so that easy access for
50 termination of cables and other maintenance works can be carried out.

 HT Panel shall be installed in accordance with the Manufacturer’s recommendations, approved site
layout and as per site requirement.

 All knockouts made on the panel covers shall be filed and provided with grommets to avoid sharp
edges and unused knockouts shall be covered.

 The connection of bus bar trucking with HT panel shall be done rigidly with proper supports.

 Cables bending radius should be not less than 12 times of the cable diameter in line with the
Manufacturer’s recommendation & as per Specifications Cable pulling, termination & crimping
shall be done as per cables method statement.

 Termination of cables shall be done using approved material submittal for cable glands and lugs.

 Glanding and connections should be done only by competent technicians / electricians.

  Identification labels of approved type shall be fixed on the HT panel.

 Ensure that all cable entries and other openings of Electrical / HV Room, Wall / Floor are carried out
with proper approved sealant.

 The manufacturer’s representative to verify the site installations and provide acceptance of same
prior to Energisation of HT Panel after obtaining clearance from Site Engineer.

 Ensure that Adequate A/C provided to the HT panel room and the Unit of the A/C shall not be
installed inside HT room as per contract drawing. The A/C unit shall be installed outside the room
and to be connected with duct to HT room. And no water services allowed inside HV room as per
authority regulation.

 Connecting cables between the switchboard and battery unit, and between the switchboard and AC
control panel shall be neatly run on cable trays supplied by the Contractors.

 The connecting cables between the switchboard and battery unit shall be at least 4 mm in size and
shall be run in a ring configuration. Physically, the cables for entry and exit of the same loop should
not be the same. All wiring and termination of connecting cables shall be carried out by the
Contractor.

 Conductors used for AC and DC circuits shall not be mixed in the same multi-conductor cable.

 Upon completing the installation of HT Panel, ensure all the works carried out as per authority
regulations.

 Raise (WIR) for installation of switchgear Panel along with glanding and termination to Consultant.

4.0. PRE COMMISSIONING PROCEDURE

1. Close Operation Test – Local—Remote

This test is conducted by manual, Local and Remote.

For the manual Operation test, we will charge the spring manual and breaker is also closed my manual
and opening also done. For the Local operation we give Control supply and A.C supply for spring charge
motor.

We close the Circuit Breaker using the TNC (Trip Neutral Control) switch.

2. Trip Operation Test – Local-Remote

This test is conducted by manual, Local and Remote. For the manual Operation test, The manually charged
breaker is opened using the Trip switch.. For the Local operation we give Control supply and A.C supply for
spring charge motor. We open the Breaker using the TNC switch.

3. Protection Trip

For this test the breaker has in closed position at initially. We provide an auxiliary rated voltage to Master trip
relay, and observe the opening of the breaker and the position of the trip coil.

50 4.2 FUNCTIONAL CHECK

1. Emergency Trip
 2. Aux. Switch Operation

When the breaker is in open condition we check the Aux. contact of the breaker using continuity tester, to
conform the contact is in NO /NC. Then we close the Circuit Breaker and check the same contact with
continuity tester, to conform the contact is in NC /NO.

3. On-Off Indications (Lamp + Flag)

When the breaker is in open condition we check the Lamp + Flag of the relay. Then we close the Circuit
Breaker and check the same Lamp operation.

4. Trip / Trip circuit healthy Lamp Indication

The relay is operated and we observer the Trip lamp indication.

5. Limit Switch for spring charge motor

We give an A.C power to motor and observer the operation of motor and charging of spring, on the
indication of fully charged spring the motor operation has to get stopped

6. Test / Service Limit Switch

This test is conducted to check the Test / Service Limit Switch Operation. During rack out the Breaker we
obverse the indicator to change to test position and during rack in the breaker we obverse the indicator to
change to service.

7. Operation Counter

This test is conducted if operational counter provision is available in breaker. We operated the breaker
and look for the change in counter for counting the operation.

8. Heater / Heater Switch / Thermostat

The control A.C supply is given for heater and we look for heater operation.

9. Function of illumination and socket switch

In this test we look for the panel internal illumination and socket switch operation. We operate the limit
switch manually and observe the operation of illumination circuit.

FOLLOWING TESTING ARE CARRIED OUT DURING THE PRE COMMISSIONING AND
TESTING FORMATS ATTACHED.

 INSULATION RESISTANCE TEST

 CONTACT RESISTANCE
 BREAKER TIMING
 COIL RESISTANCE