Testing and Commissioning Manual-Final

TESTING & COMMISSIONING
MANUAL
Prepared by
Team E&MR Division, Berhampur
Page 1 of 68
Contents
Sl.
Particulars Page No.
No.
Typical SLD with available EHV equipments in a AIS
220 kV Feeder Bay, Transformer Bay & Bus Coupler Bay
1 132 kV Feeder Bay, Transformer Bay & Bus Coupler Bay 3-5
Typical SLD with available EHV equipments in a GIS
2 132 kV Feeder Bay, Transformer Bay & Bus Coupler Bay 6-7
3 Testing of Current Transformer 8-10

4 Testing of Lightning Arrester 11-12
5 Testing of Capacitive Voltage Transformer 13-14
6 Testing of IVT/VT 15-16
7 Testing of Circuit Breaker 17-19
8 Testing of SI/DI & Earth Switch 20-22
9 Testing of Battery Charger and Battery Bank 26-27
10 Testing Station auxiliaries (ACDB, DCDB) 28-29
11 Testing of Bus Bar Protection 30-30
12 Testing of Event Logger system 30-30
13 Testing of ADMS system 52-53
14 Testing of Metering system 31-32
15 Testing of EHV Cables 33-33
16 Testing of Auto Transformer 34-42
17 Testing of Power Transformer 43-50
18 Testing of Station Transformer 50-51
19 Testing of GIS EHV Equipments 23-25
20 Precommissioning Tests of 220/132/33 kV AIS substation without SAS 55-64
21 Precommissioning Tests of AIS substation with SAS 65-65
22 Precommissioning Tests of GIS substation with SAS 66-68
Precommissioning Tests of Auto Transformer/Power Transformer/Station
23 Transformer 62-64
Page 2 of 68
TYPICAL SLD WITH AVAILABLE EHV EQUIPMENTS IN AIS
BUS-1
BUS-2
220 kV Auto 220 kV Bus Coupler

220 kV Feeder Bay
Transformer Bay Bay
 Lightning Arrestor  Lightning Arrestor  Inductive Voltage
 Capacitive Voltage  Current Transformer Transformer
Transformer (Used in  Single Isolator  Current Transformer
feeder bays)  Circuit Breaker  Single Isolator
 Current Transformer  NCT  Circuit Breaker
 Single Isolator  Section Isolators
 Earth Switch
 Circuit Breaker
Page 3 of 68
MAIN BUS
TRANSFER BUS
132 kV Transformer 132 kV Bus Coupler

132 kV Feeder Bay
Bay Bay
 Capacitive Voltage  Current Transformer Transformer
Transformer (Used in  Single Isolator  Current Transformer
feeder bays)  Double Isolator  Single Isolators
 Current Transformer  Circuit Breaker  Circuit Breaker
 Single Isolator  NCT  Section Isolators
 Double Isolator
 Earth Switch
 Circuit Breaker
Page 4 of 68
MAIN BUS
TRANSFER BUS
33 kV Transformer 33 kV Bus Coupler

33 kV Feeder Bay
Bay Bay
 Current Transformer  Current Transformer Transformer
 Single Isolator  Single Isolator  Current Transformer
 Double Isolator  Double Isolator  Single Isolators
 Earth Switch  Circuit Breaker  Circuit Breaker
 Circuit Breaker  NCT  Section Isolators
Page 5 of 68
TYPICAL SLD WITH AVAILABLE EHV EQUIPMENTS IN GIS
132 kV
Q8, Q15,Q25: High Speed Earth Switch

Q9/Q53, Q10/Q51, Q20/Q52: Disconnector with insulated Earth Switch
Q0: Circuit Breaker
T1-D1: Current Transformer
Q1/Q51: Disconnector with Earth switch
Q2: Disconnector
T5,T15,T25: Voltage Transformer
132 kV Transformer 132 kV Bus 132 kV Bus VT
132 kV Feeder Bay
Bay Coupler Bay bay
 Lightning Arrestor-  Lightning Arrestor-  Current  Inductive
Outdoor Outdoor Transformer Voltage
 Voltage  Current  Circuit Breaker Transformer
Transformer Transformer  Isolators with  Isolators
 Current  Circuit Breaker Earth switch with Earth
Transformer  Isolators with Earth switch
 Isolators with Earth switch
switch  Earth Switch
 Earth Switch
 Circuit Breaker
Page 6 of 68
33 kV
QZD: Bus 1 Disconnector with Earth switch

QBD: Bus 2 Disconnector
QAB: Vacuum Circuit Breaker
BCT: Bushing CT & Cable CT
BPT: Bus Potential Transformer
QZD1 & QZD2: Bus Coupler Bay Disconnector
33 kV Feeder Bay 33 kV Transformer Bay 33 kV Bus Coupler Bay
 Lightning Arrestor-  Lightning Arrestor-  Inductive Voltage
Outdoor Outdoor Transformer
 Current Transformer-Cable  Current Transformer-  Current Transformer
CT and Bushing CT Cable CT and Bushing  Circuit Breaker
 Disconnector with Earth CT  Disconnector with Earth
Switch  Disconnector with Switch
 Disconnector Earth Switch
 Circuit Breaker  Disconnector
 SI with Earth Switch -  Circuit Breaker
Outdoor
Page 7 of 68
CURRENT TRANSFORMER:
A. INSULATION RESISTANCE TEST
Insulation resistance test is carried out on all Current Transformer using a 5 kV IR
Tester from Primary (P1 or C1) to Body & Primary to secondary winding
(1S1/2S1/3S1/4S1) with applied voltage of 5 kV in-between them. As a thumb rule if
the IR value (in MΏ) is equal to or higher than twice the rated highest system
voltage, the CT will be permitted for charging. If the IR value is below the above said
value, necessary measures like filtration of transformer oil or other steps may be taken
by the O&M wing/executing agency to bring the value above permissible limit. If it is
still below the limit, the CT is recommended for replacement. Similarly, IR Test is
conducted between Secondary Winding of one core to Secondary Winding of other core
and Secondary Winding to Body of the CT with applied voltage of 500V in between.
The same thumb rule as mentioned above is applicable here as well. If the value is
below the permissible limit necessary steps like drying of the core insulation in case
moisture ingress and other necessary steps may be taken by O&M wing/executing
agency prior to energization.
The Format for Above Test as conducted at site is as follows:

MAKE
SPECIFICATION OF
MODEL
KIT USED:
Sl. No.
Weather: Temperature:
Applied
MODE R-Ph Y-Ph B-Ph REMARKS
Voltage
Primary -Body 5 kV
Primary-1S1 5 kV
Primary-2S1 5 kV
Primary-3S1 5 kV
Primary-4S1 5 kV
1S1-2S1 500 V
1S1-3S1 500 V
1S1-4S1 500 V
2S1-3S1 500 V
2S1-4S1 500 V
3S1-4S1 500 V
1S1-Body 500 V
2S1-Body 500 V
3S1-Body 500 V
4S1-Body 500 V
B. CAPACITANCE & TAN-DELTA TEST

Tan-Delta & Capacitance Test is done for 132 kV and above Voltage level CTs. The
test is carried out between Primary and Cx point (Tan-Delta Point) using Tan-Delta &
Capacitance test kit at 2kV, 5kV and 10kV with nominal Frequency in UST
(Ungrounded Specimen Test) mode. The results are compared with the name plate
values. If the Tan-Delta value are less than 0.5% (for new CT) and less than 0.7 % (for
old CTs), the equipment may be permitted for energization. It should be ensured that
the CT is cleaned and dried properly prior to testing. If the values are beyond the above
said limit values, then the CT is under suspicion and is recommended for replacement.
Page 8 of 68
The Format for Above Test as conducted at site is as follows:
MAKE
SPECIFICATION OF KIT
MODEL
USED:
Sl. No.
Watt Loss Tan δ Capacitance
MODE kV mA
(in Watt) (in %) (pF)
R PHASE UST 2
Make:
UST 5
Sl.No.:
YOM: UST 10
Similarly the test should be conducted for Y & B phase as well.
C. CT RATIO TEST
CT Ratio test is carried out by injecting Current in Primary of the CT between P1 and
P2 by using Primary current injection Kit (in the range of 10% -120% of rated
current mentioned in the nameplate) and corresponding values are measured in
different CT secondary at all the available ratios by using Clamp-on meter. The test is
passed if the obtained values are within the range of allowable deviation according to
the class of accuracy. If the values are beyond the error limits, then the CT is
recommended for replacement. If it is a new CT, necessary intimation will be given to
the executing agency/OEM for necessary repair or replacement. The Test format is as
follows.
Measured Current In Secondary (Amperes)
Applied Current In
Core Adopted CTR= 200/1A
Primary
R ph Y ph B ph
Core 1(1s1-1s2) 200A
Core 2(2s1-2s2) 200A
Core 3(3s1-3s2) 200A
D. CT SECONDARY WINDING RESISTANCE MEASUREMENT
Winding resistance of each CT secondary winding is measured using a standard multi-

meter at different secondary winding tapings and the results are compared with the
name plate values. Any deviation observed may be intimated to the OEM for necessary
action for repair/replacement. Then the resistance value is converted for 75°C using the
formula given below.
R75 = R measured * ( 235 +75) / (235+ OTI Temperature at the time of Measurement)
Page 9 of 68
E. CT KNEE POINT VOLTAGE TEST
This test is carried out only on Protection class CT Cores (PS Class). CT knee point
voltage test is carried out by applying variable AC voltage from a variable AC source
at the CT secondary terminals of one protection core with all other core terminals and
primary terminal remaining open. The knee point is the voltage at which a 10% increase
in applied voltage increases the magnetizing current by 50%. The measured voltage
should be below the mentioned name plate knee point voltage (Vk). If the result is
beyond the CT name plate value then the performance of the CT is suspicious due to
early saturation. The deviation should be intimated to the OEM for necessary action for
repair/replacement.
F. CT POLARITY TEST
CT Polarity test is done using a 1.5 V and above rated Battery and a Galvanometer
with the connection as per the diagram below. On pressing the Push Button If the
deflection of the Galvanometer is first towards –ve side then towards +ve side and then
comes to Zero position then the polarity of the CT is said to be correct.
S1 S2
P1 P2
Page 10 of 68
LIGHTNING ARRESTER:
Insulation resistance test is carried out on a LIGHTNING ARRESTER with a 5 kV IR

Tester from LA Top to Earth with applied voltage of 5 kV in-between. As a thumb
rule if the IR value is 3 times the MCOV (Maximum Continuous Operating Voltage)
than the LA is considered healthy and can be charged. (For Example: If MCOV is 180
KV IR value should be greater than 540MΩ). If the IR value is less than the healthy
limit but greater than the value equivalent to MCOV rating then the LA can be charged
but it will be considered suspicious and kept under observation. If the value found to be
lower than the specified value, necessary measures like cleaning dirt from the porcelain
body of LA, cleaning the connecting terminals by sand paper etc. are to be done by
O&M wing. But only the IR test values does not determine the healthiness of the LA
and other tests like watt loss test and Online 3rd Harmonic leakage current test are
to be done on the LA to ensure its healthiness. The format for
Reference Measured IR values

R ph Y ph B ph
Top- Earth
B. WATT-LOSS TEST
This is another method to determine the healthiness of LA by measuring the watt loss
of the LA (132 kV and above). This test is carried out using Tan-Delta & Capacitance
test kit in GST (Grounded Specimen Test) mode by applying 2kV, 5kV & 10 kV
AC between LA top and Ground. The measured watt-loss value at 10 kV should be
less than 150 mW. If the value found to be higher than the specified value, necessary
measures like cleaning dirt from the body of LA, cleaning the connecting terminals by
sand paper are to be done by O&M wing. And further if the value does not improve,
the LA is considered suspicious and needs to be replaced. Also during this test, the LA
under test is to be completely separated from other connected EHV equipments.
MAKE
MODEL
USED:
Sl. No.
MODE kV mA
R PHASE GST 2
Make:
GST 5
Sl.No.:
YOM: GST 10
Page 11 of 68
C. ONLINE 3rd HARMONIC LEAKAGE CURRENT TEST
This test is carried out only when the LA is in energized condition. This test measures
the resistive leakage current of the LA. The corrected value of this resistive leakage
current (Ir corrected) determines the healthiness of the LA. This is generally specified
by the LA manufacturer. The condition of LA is as follows
Ir. Corrected is less than 25% of Ir max. Very good

Ir. Corrected falls between 26% to 50% of Ir max Good
Ir. Corrected between 51% and 75% of Ir max Satisfactory
Ir. Corrected between 76% and 100% of Ir max Check Frequently
Ir. Corrected value is beyond Ir max. Critical
N.B: In a general practice the value of Ir Max is taken as 500 µA for all LAs unless
the value is specified by the OEM of the LA.
Page 12 of 68
CAPACITOR VOLTAGE TRANSFORMER (CVT)
 INSULATION RESISTANCE TEST
Insulation resistance test is carried out on a CVT with a 5 kV IR Tester from CVT
primary to Body and primary to each core with applied voltage of 5 kV in-between.
As a thumb rule if the IR value is equal to higher than twice the rated highest system
voltage the insulation is treated as healthy and the CVT may be permitted for
energisation. If the value found to be lower than the specified value, necessary measures
like cleaning dirts from the porcelain body of CVT, cleaning the connecting terminals
by sand paper etc. are to be done by O&M wing.
MAKE
SPECIFICATION OF
MODEL
KIT USED:
Sl. No.
Applied
Voltage
Primary -Body 5 kV
Primary-1a 5 kV
Primary-2a 5 kV
Primary-3a 5 kV
1a-2a 500 V
1a-3a 500 V
2a-3a 500 V
1a-Body 500 V
2a-Body 500 V
3a-Body 500 V
 MEASUREMENT OF CAPACITANCE:
A capacitor voltage Transformer consists of 2 Nos. of Capacitors between each phase
to ground and an Electro Magnetic Unit. This equivalent capacitance between primary
and earth is measured by Capacitance and tan-delta kit in GST (Grounded Specimen
Test) mode at 2kV, 5kV and 10 kV. The value of the capacitance should be within the
permissible range as specified in the name plate detail at each test voltage.The format
for this test is as follows.
MAKE
MODEL
USED:
Sl. No.
MODE kV mA
R PHASE GST 2
Make:
GST 5
Sl.No.:
YOM: GST 10
Page 13 of 68
 MEASUREMENT OF WINDING RESISTANCE
Winding resistance of each CVT core is measured using a standard multimeter between
secondary winding tapings (between a-n) and the results are compared with the name
plate values to ensure the continuity of the winding. Then the resistance value is
converted for 75°C using the formula given below.
 CVT RATIO TEST

CVT ratio is tested by applying 1 Phase LT Voltage between CVT Primary and ground
and induced secondary voltage is measured in the secondary winding of each core using
a standard multimeter. The ratio of the primary applied voltage and secondary measured
voltage is calculated and it should be within limit of the ratio specified in the name
plate.
Applied Voltage Measured Voltage In Secondary (Volts)
Core between
R ph Y ph B ph
Primary and Ground
Core 1(1a-1n) 240V
Core 2(2a-2n) 240V
Core 3(3a-3n) 240V
Page 14 of 68
INDUCTIVE VOLTAGE TRANSFORMER (IVT)/ POTENTIAL TRANSFORMER
 INSULATION RESISTANCE TEST
Insulation resistance test is carried out on a CVT with a 5 kV IR Tester from IVT/PT
primary to Body and primary to each core with applied voltage of 5 kV in-between.
As a thumb rule if the IR value is equal to higher than twice the rated highest system
voltage the insulation is treated as healthy and the IVT/PT may be permitted for
energisation. If the value found to be lower than the specified value, necessary measures
like cleaning dirts from the porcelain body of IVT, cleaning the connecting terminals
by sand paper etc. are to be done by O&M wing.
MAKE
SPECIFICATION OF
MODEL
KIT USED:
Sl. No.
Applied
Voltage
Primary -Body 5 kV
Primary-1a 5 kV
Primary-2a 5 kV
Primary-3a 5 kV
1a-2a 500 V
1a-3a 500 V
2a-3a 500 V
1a-Body 500 V
2a-Body 500 V
3a-Body 500 V
 TAN-DELTA & CAPACITANCE TEST
Tan-Delta & Capacitance Test on a CT (132 kV & Above) is carried out between
Primary and Cx point (Tan-Delta Point) using Tan-Delta & Capacitance test kit at
2kV, 5kV and 10kV in UST(Ungrounded Specimen Test) mode. The results are
compared with the name plate values. If the Tan-Delta value is within 0.5% (for new
CT) OR 0.7 % (for old CT) the equipment may be permitted for energization.
MAKE
MODEL
USED:
Sl. No.
MODE kV mA
R PHASE UST 2
Make:
UST 5
Sl.No.:
YOM: UST 10
Page 15 of 68
 MEASUREMENT OF WINDING RESISTANCE
Winding resistance of each IVT/PT core is measured using a standard multimeter

between secondary winding tapings (between a-n) and the results are compared with
the name plate values to ensure the continuity of the winding. Then the resistance value
is converted for 75°C using the formula given below.
R75 = R measured * (235 +75) / (235+ OTI Temperature at the time of Measurement)
 IVT RATIO TEST

IVT/PT ratio is tested by applying 1 Phase LT Voltage between IVT/PT Primary &
ground and induced secondary voltage is measured in the secondary winding of each
core using a standard multimeter. The ratio of the primary applied voltage and
secondary measured voltage is calculated and it should be within limit of the ratio
specified in the name plate.
Applied Voltage Measured Voltage In Secondary (Volts)
Core between
R ph Y ph B ph
Primary and Ground
Core 1(1a-1n) 240V
Core 2(2a-2n) 240V
Core 3(3a-3n) 240V
Page 16 of 68
CIRCUIT BREAKER
Insulation resistance test is carried out on a Circuit Breaker with a 5 kV IR Tester from
CB Top-Earth, Bottom-Earth and Top-Bottom with applied voltage of 5 kV in-
between. As a thumb rule if the IR value is equal to higher than twice the rated
highest system voltage the insulation is treated as healthy and the CB may be permitted
for energisation if other test results mentioned below are found to be satisfactory. If the
IR values are found to be lower than the specified value, necessary measures like
cleaning dirts from the porcelain body of CB, cleaning the connecting terminals by sand
paper etc. are to be done by O&M wing.
MAKE
MODEL
USED:
Sl. No.
R-Phase(GΩ) Y-Phase(GΩ) B-Phase(GΩ)

Reference
I/C-Earth
(Top-Earth)
O/G-Earth
(Bottom-Earth)
I/C-O/G
(Top-Bottom)
B. CB TIMING TEST
Circuit Breaker Timing test is carried out on each pole of the CB of any voltage level
to ensure if the Close, Open and Close-Open operation time is within permissible limit
by using a CB-Time Interval Tester. The allowable time of close operation is less
than 5 Power Cycles (100 ms) and open operation is less than 3 Power Cycles (60
ms). If the test values are more than the above limit necessary mechanical adjustment
of CB driving mechanism is to be done.
Page 17 of 68
The test Format for above Test is as follows.
Details of Kit used
Make:
Model :
Serial No:
OPERATION R-Phase (mSec) Y-Phase (mSec) B-Phase (mSec)
CLOSE
OPEN (TC1)
CLOSE-OPEN (TC1)
OPEN (TC2)
CLOSE-OPEN (TC2)
C. CONTACT RESISTANCE MEASUREMENT

Contact resistance between male and female contact of the CB is measured by applying
DC current though each pole of the CB from a CRM kit (Contact Resistance
Measurement). The allowable contact resistance is within 50µΏ unless specified by the
OEM. If the value is found to be higher, then cleaning of CB terminal pads are to be
done. While conducting this test it is to keep in mind that the voltage sensing
terminals of the kit should be placed inside the current injecting terminals.
Page 18 of 68
The Test Format for CRM test is as follows
Details of Kit used
Make:
Model :
Range:
Serial No:
Applied Current- R-PH Y-PH B-PH

100A
(μΩ) (μΩ) (μΩ)
CIRCUIT
BREAKER
D. CB OPERATIONAL CHECK
Operational Checks like Local Electrical & Remote Electrical and Manual operation
are to be do. Protection Trip Check, Measurement of Resistance of Tripping and
Closing coil and Spring Charging motor are to be done by Multimeter and cross-
checked with the rated specifications. The format is follows.
AVAILABLE SCHEMES Remarks
Manual Close
Manual Open
Electrical Close (Local/Remote)
Electrical Open (Local/Remote)
Protection Trip
On-Off Indication
Mechanical Spring Operation
Electrical Spring Operation
Spring charge limit switch & Indication
Trip circuit healthy
Page 19 of 68
DOUBLE ISOLATORS WITH EARTH SWITCH / SINGLE ISOLATORS
Insulation resistance test is carried out on the post insulators of a DI/SI with a 5 kV IR
Tester. IR values are taken between Fixed Contact to Earth and Moving Contact To
earth with applied voltage of 5 kV in-between. As a thumb rule if the IR value is equal
to higher than twice the rated highest system voltage, the insulation between isolator
contacts and earth is treated as healthy and may be permitted for energisation. If the IR
values are found to be lower than the specified value, necessary measures like cleaning
dirts from the porcelain body of the isolator Post insulator, cleaning the connecting
terminals by sand paper etc. are to be done by O&M wing. The format for IR Test of SI
and DI are as follows
FORMAT FOR SINGLE ISOLATOR

REFERENCE Measured IR values
Rph Yph Bph
Fixed Contact 1 - Earth
Moving Contact 1- Earth
Fixed Contact 2 - Earth
Isolator Closed-Earth
FORMAT FOR DOUBLE ISOLATOR

Reference Measured IR values
Rph Yph Bph
Fixed Contact 1 – Earth(89L)
Moving Contact 1- Earth(89L)
Fixed Contact 2 – Earth(COMMON)
Moving Contact 2- Earth(89T)
Fixed Contact 3 -Earth(89T)
Isolator Closed –Earth(89L)
Isolator Closed –Earth(89T)
B. CONTACT RESISTANCE MEASUREMENT

Contact resistance between male and female contact of the ISOLATOR is measured by
applying DC current though each pole of the ISOLATOR using a CRM kit (Contact
Resistance Measurement). The allowable contact resistance is within 150µΏ unless
specified by the OEM. If the value is found to be higher, then cleaning of ISOLATOR
terminal pads are to be done. While conducting this test it is to keep in mind that the
voltage sensing terminals of the kit should be placed inside the current injecting
terminals. The format for above test is as follows:
Page 20 of 68
Details of Kit used
Make:
Model :
Range:
Serial No:
Applied Current- R-PH Y-PH B-PH

100A (μΩ) (μΩ) (μΩ)
C. ISOLATOR OPERATIONAL CHECK

Operational Checks like Motorized operation (Local Electrical & Remote Electrical)
and Manual operation are to be done to ensure proper making of isolator contacts.
Also Inter-Lock check (Electrical & Mechanical) has to be done to ensure safe
operation of Isolators. The format is as follows:
Sl.
No
SCHEME REMARKS
a. Mechanical- Close
b. Mechanical- Open
Page 21 of 68
MEASUREMENT OF EARTH PIT RESISTANCE
Measurement of Earth pit resistance of all treated earth pits without connected to mesh
are to be carried out using Earth Resistance measurement test kit. The test is done using
3 point method (Fall of Potential method) as specified in the diagram below.
As a thumb rule, the individual earth pit resistance should be less than 10 Ώ. If the
values are found to be higher than 10 Ώ, then re-treatment of earth pits is required by
applying Bentonite Slurry at the ratio of 1:6 (Bentonite Powder: Water). Also the
combined earth pit resistance connected to mesh should be measured and the value
should be less than 1Ώ. In addition to this earth pit resistance of Non-treated Earth pits
(used for earthing of Switch-Yard Fencing, gates and columns etc.) are to be measured.
Page 22 of 68
TESTING OF GIS EHV EQUIPMENTS
132 KV SIDE
 Current Transformer
 CT Knee Point Voltage Test
o CT Ratio test by Primary Current Injection Method These will be same as
o Winding Resistance Measurement tests for an AIS CT
o CT Polarity test
o CT Secondary AC Dielectric Test
 Apply 2.5 kV AC between individual Core and all remaining cores
connected to Earth for 1 min. The Permissible Limit: 12.6 mA
 Voltage Transformer
o Ratio Test These will be same as
o Winding Resistance Measurement tests for an AIS VT
o VT Secondary AC Dielectric Test
 Apply 2.5 kV AC between individual Core and all remaining cores
connected to Earth for 1 min. The Permissible Limit: 12.6 mA
 Circuit Breaker/ Disconnectors
o Circuit Breaker Timing Test
o Operational check from Local/Remote(BCU & SCADA)
o Contact Resistance Measurement Test of Disconnectors and CB
 As the primary terminals are not accessible, Contact resistance
measurement of individual disconnector or Circuit Brekaer is not
possible. The CRM is measured in a combined manner with bay to bay
connections as mentioned by the OEM at accessible points like cable
termination ends and insulated earth switch ends. Factory Test report to
be referred for permissible Limit of different connections of CRM
measurement.
 GIS
o AC Hi-POT Test followed by Partial Discharge Measurement: This test
allows to detect essentially the presence of dust or particles inside the GIS. It is
generally followed by PD measurement in order to detect small defects that
might degenerate into major failures in the future:
 Bouncing particles
 Protrusion or sharp edges
 Floating Potentials
 Insulator Defects
Test Voltage:
 Electrical Conditioning: Ucond = 1.2 X Ur/√3_ for 180 Sec.
 Test Voltage: Uhv-test = 0.36 X BIL X Fx for 60 Sec. (Fx for pre-
commissioning test is 1.0 and for re-testing is:0.8) & BIL for 132 kV
system is 650 kVp.
 Partial Discharge measurement: Upd-test =1.2X Ur for X Sec. (X =
60 secs or more depending on PD pattern)
o Ur= Rated Voltage of equipment
o Ucond= Conditioning Voltage
o Uhv-test =High Voltage test voltage
o Upd-test=Voltage for PD measurement
Page 23 of 68
 The test equipment should withstand the Hi Voltage AC (235 kV) for 1 min.
 The limits for allowable Partial Discharge is 5 pC at 174 kV.
 If the Equipment fails to withstand the specified Voltage or if the PD
measurement value is more than 5 pC, then necessary actions to be taken by
the OEM.
 SF6 GAS COMPARTMENT
o The tests pertaining to Sf6 Gas: Sf6 Gas Purity Check, Dew Point Check and
Moisture Content Check (ppmv) are carried out using a SF6 Gas Analyzer kit.
Permissible limits are mentioned in the table below. If the values are beyond the
limit values necessary intimation to be given to OEM to take early action.
Sf6 Gas Purity Check Permissible Limit: >=98%

Permissible Limit: <(-10) °C (For other Compartments except CB)
Dew Point Check <(-15) °C (For CB)
Moisture Content Check Permissible Limit: 346 PPM (For other Compartments except CB)
(PPMv) 240 PPM(For CB)
o Functionality Check Of Sf6 Density Monitors: Checking of SF6 gas low and
lockout pressures in gas density monitors for all the gas compartments of the
GIS which is done using Gas Handling cart available at Site by trained
personnel. The permissible limits are mentioned below:
SF6 LOW ALARM: 5.8 Bar at 20°C
SF6 LOW LOCK-OUT: 5.5 Bar at 20°C
Nominal Pressure: 6.3 Bar at 20°C
 LCC
o LCC Panel Scheme check, Operational Check of All Disconnectors/Earth
switches with indications all associated Interlocks as per schematic logic.
o Checking of various LCC signals in the Facia Annunciator.
33 KV SIDE
 Current Transformer (Cable CT and Bushing CT)
 CT Knee Point Test
o CT Ratio test by Primary Current Injection Method These will be same as
o Winding Resistance Measurement tests for an AIS CT
o CT Polarity test
o CT Secondary IR test
Page 24 of 68
 The test is performed using a 5 kV IR test kit. Apply 500 V between
secondary winding to earth and between secondary windings.
 Voltage Transformer
o Ratio Test These will be same as
o Winding Resistance Measurement tests for an AIS VT
o VT Secondary IR Test
 The test is performed using a 5 kV IR test kit. Apply 500 V between
secondary winding to earth and between secondary windings.
o Timing Interval Test of CB
These will be same as
o Contact Resistance Measurement Test tests for an AIS CB
 GIS
o AC Hi-POT Test
 The Hi-POT Voltage: 56 kV (80% of BIL) is applied for 1 min for
various combinations of switchgears and bus bar as mentioned by the
OEM and the GIS needs to withstand the same to pass the test. Any
deviation noticed will be intimated to OEM to take up necessary action
 Sf6 Gas Compartments
o The tests pertaining to Sf6 Gas: Sf6 Gas Purity Check, Dew Point Check and
Moisture Content Check (ppmv) are carried out using a SF6 Gas Analyzer kit.
Permissible limits are mentioned in the table below. If the values are beyond the
limit values necessary intimation to be given to OEM to take early action.
Sf6 Gas Purity Check Permissible Limit: >=95%

Dew Point Check Permissible Limit: <(-27.3) °C
Moisture Content Check Permissible Limit: 346 PPM (For other Compartments except CB)
(PPMv) 240 PPM(For CB)
o Functionality Check Of Sf6 Density Monitors: Checking of SF6 gas low and
lockout pressures in gas density monitors for all the gas compartments of the
GIS which is done using Gas Handling cart available at Site by trained
personnel. The permissible limits are mentioned below:
GAS PRESSURE UNHEALTHY: Below 1.2 Bar at 20°C

INSULATING PRESSURE: 1.3 Bar at 20°C
HIGH PRESSURE: 1.5 Bar at 20°C
BURSTING PRESSURE: 1.9 Bar at 20°C
 LCC
o Panel Scheme check, Operational Check of All Disconnectors/Earth switches
with all associated Interlocks
Page 25 of 68
BATTERY CHARGER & BATTERY BANK
INSTALLATION & COMMISSIONING PROCEDURE OF BATTERY BANK:
The Installation and Commissioning procedure for a 350 AH, C10 Rated Plante type battery bank bank
is as follows.
1. Fill the battery electrolyte of specific gravity 1185 up to filling level on the battery
container.
2. Allow batteries to soak acid for a minimum of eight Hrs.
3. Meanwhile connect the inter cell connectors & charger to battery cables. Make battery
bank ready for initial charging.
4. Start initial charging at the starting rate 10% of battery capacity i.e. for 350 AH battery
the initial charging current should be 35 A or as mentioned by the OEM in its
commissioning manual. The initial charging should be done till the cell voltage
reaches 2.35V to 2.45V or as mentioned by the OEM in its commissioning manual.
5. It is to keep in mind to take hourly reading of cell voltage, specific gravity and
temperature.
6. Once cell voltage reaches 2.35V to 2.45V, reduce charging current to finishing rate
(Finishing rate is 5% battery capacity) and continue the charging. Ensure that total
AH input remains same.
7. In the process of charging cell temperature should not exceed 50 degree centigrade. If
it exceeds, stop the charging. Allow temperature to come down to 40 degree centigrade
and continue charging at finishing rate. Ensure that the total AH input is maintained.
8. Cells are considered fully charged once the three consecutive hourly reading of cell
voltage and electrolyte specific gravity is found to be constant that is above 1200.
9. Keep batteries idle for 4 Hrs.
10. Make preparation for battery discharging. During discharging isolate battery from
charger. Battery discharging can be done by means of water load or resistive load
(Heater) whichever is available/suitable.
11. Discharge batteries at C-10 rate.
12. Record Specific gravity and cell voltage and temperature of all cells.
13. Stop discharging after 10 hours or average cell voltage reaches 1.82V per cell
whichever is earlier.
14. Note down the serial numbers of battery cells for which cell voltage has gone bellow
1.82V.
15. Recharge the battery bank; follow steps 4 to 6, Record Specific gravity and cell
voltages and temperature of all cells during recharging.
16. Follow the steps 10 to 14 for second discharge cycle.
Page 26 of 68
17. If specific gravity of some of the cells is found below 1200 during second discharging,
adjust the specific gravity by adding concentrated electrolyte.
18. For recharging, keep batteries on float charging the battery bank i.e. final charging;
follow steps 4 to 6. Record Specific gravity and cell voltages of all cells during
recharging.
19. After completion of procedure keep batteries on float charging.
SOME KEY POINTS FOR BATTERY OPERATION & MAINTENANCE:
D. Leakage Indication lamps should be mandatorily connected on the Control room panel
for continuous indication of healthiness of DC source.
E. Leakage in DC circuit should be attended on priority basis.
F. Once in everyday AC supply to charger should be switched off and DC voltage is to be
measured
G. The performance of battery bank is to be ensured by switching off the AC supply to the
charger and making operation of the CB of any un-important feeder.
Beside this other important activities like taking pilot cell reading (Measurement of Voltage of
each cell and Specific gravity of electrolyte) is to be done by O&M wing.
TESTS DURING INSTALLATION & COMMISSIONING OF BATTERY CHARGER
In General all Grid Sub-stations of OPTCL, the available battery chargers have 2 modules:
FLOAT MODULE & FLOAT CUM BOOST MODULE.
Also in some GSS the available battery chargers are of DUAL FCBC Type.
Below are some points to be checked during Installation & Commissioning of battery
charger
 Ensure proper connection of AC sources to the charger. Also ensure if Battery (B+, B- &
TC) & DC Load (F+ & F-) cables are connected properly in the charger.
 Checking of General scheme of the Charger as per the available schematic drawing
 Ensure all the protective functions are working satisfactorily.
 Ensure the Earth fault Indicator Module is installed in the charger
 Check if all indication and annunciation circuit is working properly.
 Check auto mode operation of FCBC module for Boost Charging.
 Check when Float Charger Module fails FCBC should operate in Float Mode.
 Ensure during AC Supply Fails Battery bank is connected to the load.
Page 27 of 68
TESTING OF ACDB & DCDB
ACDB
 In General the 433V ACDBs are having 3 No of 800A BUSBARS (3 Phase: R, Y & B)
mounted inside the panel. The insulation of these Bus bars with respect to panel is very
important. Therefore the IR test of each Bus-bars to panel Body is to be carried out by
applying 500V through IR testers. If the IR value comes out to be in MΏ range it is
considered to be good insulation.
 The IR Test of the Air Circuit Breakers inside the ACDB is to be conducted by applying
500V through IR testers.
 Scheme check as per available schematic drawing is to be done.
 Checking of Indication and Annunciation circuit is to be done
 Checking of functionality of Tri-Vector Meters, Ammeters & Volt-meters and associated
Transducers (If any) are to be done
 Testing of O/C E/F relays available in the ACDB is to be done.
 Checking of I/L scheme like Automatic ON of Bus-coupler when any of the source-1 or 2
fails and Automatic OFF of the same when the failed source supply restores is to be
checked.
 Checking the functionality of SPP relay/ UV Relay/OV Relay available in the ACDB
 Ensure all the MCBs/MCCBs/Switch Fuse Units available in the ACDB are working
properly.
Page 28 of 68
DCDB
 In General the 220V DCDBs are having 2 No of 200A BUSBARS (Positive & Negative)
mounted inside the panel. The insulation of these Bus bars with respect to panel is very
important. Therefore the IR test of each Bus-bars to panel Body is to be carried out by
applying 500V through IR testers. If the IR value comes out to be in MΏ range it is
considered to be good insulation.
 Scheme check as per available schematic drawing is to be done.
 Checking of Indication and Annunciation circuit is to be done
 Checking of functionality of all Ammeters & Volt-meters and associated Transducers (If
any) are to be done
 Checking of I/L scheme like Automatic ON of Bus-coupler when any of the source-1 or 2
fails and Automatic OFF of the same when the failed source supply restores is to be
checked.
 Ensure all the MCBs/MCCBs/Switch Fuse Units available in the ACDB are working
properly.
Page 29 of 68
TESTING OF BUS BAR PROTECTION (FOR 220 kV AND ABOVE)
 Panel Scheme check (As per schematic logic: DC fail/AC fail/Bus Zone IN/OUT etc.)
 Panel Annunciation, Indication check
 All the 220 kV Feeders/Transformer/Bus coupler bay Circuit Breaker and BUS Isolators
Status check.
 Configuration, Programming and testing of Numerical Bus-bar relay.
 Auxiliary tripping relay functional check.
 Testing of Bus-bar Protection Scheme like Bus-bar differential stability test, Differential
slope test, Individual tripping of Bus Zone-1, Zone-2 with Check zone, Blocking of
Bus bar protection, LBB test, End fault protection checks etc.
 Events and disturbance recorder check for numerical Bus-bar relay.
 Checking of time synchronization.
TESTING OF EVENT LOGGER SYSTEM

 Panel Scheme check (As per schematic drawing: DC fail/AC fail/etc.)
 Panel Annunciation, Indication check.
 Configuration, programming of different Signals as per scheme at event logger HMI.
 Checking of protection signal and control signal of all the 220kV feeders /Trf/Bus coupler
bay integrated through Event Logger HMI.
 Checking of event generation report.
 Checking of Time Synchronization.
 Checking of other accessories functionality of event logger HMI like Printer, Inverter etc.
Page 30 of 68
TESTING OF ENERGY METERS/METRING SYSTEM (APEX)
 The Energy meters in Feeder and Transformer bays can be tested in On-load condition or
in Off- Load Condition.
 Energy meters can be tested while the Feeder/Transformer is in On-Load condition by
connecting another Standard/Calibrated meter (Accucheck HT+) in series with it by optical
pulse count method and the error in MW and MVAr are determined. The errors should be
within +/- 0.2% as all the meters are of 0.2s Class.
 The correct advance in Import/Export are to be ensured after Testing. In addition to this,
checking of metering parameters like Current/Voltage/Power Factor are also to be checked
and to be ensured if it is correct after testing of meters.
o For 220kV & 132 kV Feeders/Transformers: Import advance needs to be ensured if
Power is being fed by the Feeder/Transformer to the Bus (Bus is reference). Export
Advance to be ensured if Power is being fed to the Feeder/Transformer by the Bus
(Bus is reference)
o For Beneficiary Feeders (220kV/132kV/33kV): Import Advance in Apex meter
needs to be ensured.
o For Transformers (33 kV): Import Advance in Apex meter needs to be ensured.
 Tightness of CT & PT Terminals in the TTB (Test Terminal Block) are to be checked
during testing of Energy Meters. Also connection of Earthing link to the body of energy
meter as per standard Installation Procedure is be ensured.
 Checking of Healthiness of Auxiliary Supply (AC/DC) to the Energy meter is to be
checked.
 Checking of communication via meter Reading Instrument from OPTICAL Port/ USB port
is to be checked.
 Also Time Synchronization of Energy meter is to be done by the Executing Agency and it
is to keep in mind that after Time Synchronization only change in IP Demand and
Date/time occurs and all other parameters remain same.
 While initial commissioning of Energy Meters, the meters are to be tested in Off-Load
Condition by using Phantom Loading Kit at different power factors and different
percentage of loads and the error in MW and MVAr are determined and the errors should
be within +/-0.2%. Also, during AMC of Energy meters, if a particular Feeder or
Transformer is in shutdown/no load condition, testing needs to be done using Phantom
Loading Kit.
 For Beneficiary Consumers (Industries and Distribution) proper sealing of the TTB and
Energy meters needs to be done in the presence of E&MR representative, O&M
representative and/or EHT(Con) wing (if the GSS is under Construction wing of OPTCL).
Page 31 of 68
 In case of Billing meters, the Energy meters needs to be tested in presence of the
representative of DISCOM MRT Engineer or Industry representative and
EHT(O&M)/EHT(Con) representative ((if the GSS is under Construction wing of OPTCL).
 Also for Station Transformer (250 kVA and above) the metering scheme used is known as
LT CT METERING SCHEME which is generally done by the DISCOMs.
(LT CT METERING SCHEME)
Page 32 of 68
TESTING OF EHV CABLES
Insulation Resistance Test is Conducted in Between Conductor to Metallic Sheath and
Metallic Sheath to Outer Sheath by applying 5 kV DC using a 5kV IR Tester.
1. Metallic Sheath
Grounding Cable
2. Mettalic Sheath
3. Conductor
4. XLPE Insulation
5. Outer Sheath
B. DC Hi-POT TEST
10 kV DC is applied between Conductor to Metallic Sheath for a period of 1 min and checked
if no breakdown of insulation occurs.
Similarly DC Hi-POT test between corrugated Al Sheath and Outer Sheath is conducted and
the SOP for this test is mentioned below.
 Remove semi-conducting layer or Graphite over sheath at least 8 inch from both the
cable ends.
 Measure the thickness of Outer Sheath
 Connect the semi-conducting layer (over outer sheath)/ Graphite Coating to earth
terminal of DC High Voltage Source,
 Connect Metallic layer below outer sheath (copper wire screen or lead sheath or
Aluminium corrugated sheath) to DC High Voltage Source
 Ensure Metal drum & high voltage source is solidly earthed
 Apply 4 kV per mm of specified thickness of extruded over sheath or 10 kV DC
whichever is lower,
 After 1 min slowly reduce the voltage
 Manually discharge the metallic part of cable, conductor and drum.
This test interprets only if it meets the requirement i.e. No Breakdown of the over sheath should
occur during the test. IR test before and after DC Hi POT test needs to be conducted.
C. CHECKING OF CABLE CONTINUITY
Cable Continuity check is done by use of multimeter to ensure the continuity of conducting
core.
Page 33 of 68
TESTING OF AUTO TRANSFORMER
1. IR and PI test
2. Magnetic Circuit IR Test
3. Capacitance and tan delta test of windings
4. Capacitance and tan delta test of 220 kV and 132 kV bushings
5. Transformer Turns Ratio test
6. Transformer Winding Resistance Measurement Test
7. Open Circuit Test
8. Short Circuit Test
9. Magnetic Balance Test
10. Vector Group Test
11. Testing of Auxiliary Protections
12. Cooler control circuit check
13. Dissolved Gas Analyser Test
14. Oil BDV Test
15. SFRA Test
16. Transformer Stability test
17. REF Balance Test (Both HV &LV)
INSULATION RESISTANCE AND POLARIZATION INDEX TEST:
The test will be conducted using a 5KV Insulation Resistance Test Kit. Proper cleaning of the
transformer bushings must be done prior to the IR test. All the HV terminals (R,Y,B) and all
the IV terminals with neutral (N) are shorted and Tertiary LV winding of the transformer is
also shorted. Then shorted HV/IV terminals to ground (HV/IV-E), shorted LV terminals to
ground (LV-E) and shorted HV/IV terminals to LV terminals (HV/IV-LV) Insulation
Resistance values are measured using the IR Test Kit in PI mode. PI value= (IR value at 10
min)/ (IR value at 1 min) The PI value of greater than 1.5 and less than 4 is considered healthy
for each of the three cases. If the PI value is greater than 4 then the insulation of the transformer
has become very dry which is undesirable for each of the three cases. If the PI value is less than
1.5 then the transformer condition is considered suspicious. Oil samples should be sent for
BDV test and DGA analysis. The format for testing is as follows:
POLARISATION INDEX TEST

MAKE
MODEL
USED:
Sl. No.
WEATHER: TEMPERATURE:
MODE R60 R600 PI VALUE REMARKS

HV/IV - E
HV/IV - LV
LV - E
Page 34 of 68
CAPACITANCE AND TAN DELTA TEST OF BUSHINGS
Tan-Delta & Capacitance Test on the bushings of a transformer (132 kV & Above) is carried
out between Primary and Cx point (Tan-Delta Point) using Tan-Delta & Capacitance test kit
at 2kV, 5kV and 10kV in UST mode. The results are compared with the name plate values.
If the Tan-Delta value is within 0.7 % the bushing is considered healthy. If the value is more
than desired then the bushing is considered suspicious and replacing the same is recommended.

MODE kV mA
R PHASE UST 2
Make: UST 5
Sl. No.:
YOM: UST 10
Similar test should be conducted for other 2 phases ( Y & B phase) as well
CAPACITANCE AND TAN DELTA TEST OF WINDINGS:
For this test all the HV terminals, IV Terminals together with its neutral are shorted and all the
LV terminals (Tertiary) are shorted. Firstly the HV cable of the tan delta & capacitance kit is
connected to HV/IV and LV cable of the tan delta and capacitance kit is connected to LV side.
Then test is conducted at 2KV, 5KV and 10KV in three different modes such as UST (for CHL
value), GSTg (For CHG value) and GST-Gnd (for CHL+CHG). Then the HV cable of the tan
delta & capacitance kit is connected to LV of transformer and LV cable of the tan delta and
capacitance kit is connected to HV/IV side of transformer. Then test is conducted at 2KV, 5KV
and 10KV in three different modes such as UST (for CLH value), GSTg (For CLG value) and
GST-gnd (for CLH+CLG). If the tan delta value is within 0.7% in all cases then the transformer
windings are considered healthy. If it is more than desired then the condition of windings of
the transformer is considered suspicious. The Test Format is as follows.
MAKE
MODEL
USED:
Sl. No.

MODE kV mA
CH+CHT (Parallel) GST 2
CH (HV-Earth) GST-g 2
FORWARD CH (HV-Earth) GST-g 5
CHT (HV-Tertiary) UST 2
CT+CHT (Parallel) GST 2
CT (Tertiary-Earth) GST-g 2
REVERSE CT (Tertiary-Earth) GST-g 5
CT (Tertiary-Earth) GST-g 10
Page 35 of 68
TRANSFORMER TURNS RATIO TEST:
Turns ratio test of transformer is conducted using Transformer Turns Ratio Kit between its HV
side and IV side. The test is conducted for all the taps of the transformer from 1 to 17. At each
tap the test result is compared with the calculated turns ratio of the transformer at that tap. If
the test result matches with the calculated turns ratio then the transformer is healthy if not, the
condition of the transformer is suspicious and there might be problem in the tap changer. The
test format is follows:
MAKE
SPECIFICATION OF KIT USED: MODEL
Sl. No.
MAKE
OLTC SPECIFICATION MODEL
Sl. No.
TAP MEASURED Iexc MEASURED Iexc MEASURED Iexc CALCULATED

REMARKS
NO R-PH RATIO (mA) Y-PH RATIO (mA) B-PH RATIO (mA) RATIO
1 1.515
2 1.532
3 1.550
4 1.568
5 1.587
6 1.606
7 1.626
8 1.646
9(N) 1.667
10 1.687
11 1.709
12 1.731
13 1.754
14 1.777
15 1.808
16 1.826
17 1.851
OPEN CIRCUIT TEST:

For this test 3 phase AC supply (415V RMS Line-Line) is supplied to the HV windings of the
transformer keeping the secondary i.e. IV terminals in open ckt condition. Then the no load
currents in the primary i.e. HV in all the 3 phases are measured using leakage clamp on meter.
This test is conducted on 3 Taps of the transformer i.e. Minimum, normal & Maximum. If there
is no abnormality in the currents observed then the transformer is considered healthy. The Test
format is as follows.
TAP
VRY VYB VBR VRN VYN VBN Vry Vyb Vbr Vrn Vyn Vbn IR IY IB IN
NO
1
9
17
Page 36 of 68
SHORT CIRCUIT TEST:
transformer keeping the secondary i.e. IV terminals in short circuit condition. The short circuit
currents in the primary terminals i.e. HV and in the secondary terminals i.e. IV are measured
using leakage clamp on meter. This test is conducted on 3 Taps of the transformer i.e.
minimum, normal & Maximum. If there is no abnormality in the currents observed then the
transformer is considered healthy. The Test format is as follows.
TAP
VRY VYB VBR IR IY IB IN Ir Iy Ib In
NO
1
9
17
MAGNETIC BALANCE TEST:
In this test, at a particular tap, single phase supply is connected between HV terminal of any
one phase and Neutral keeping the secondary i.e. IV open. Then phase to neutral voltage is
measured for each phase of both HV and IV. The same process is repeated for other two phases
also. The voltage applied at the terminal should be equal to the sum of voltages measured at
other two terminals in HV. And for IV the voltage of the terminal in which voltage is applied
on HV side should be equal to the sum of voltages measured at other two terminals of IV. For
Example, Suppose single phase voltage is applied at R terminal (HV) i.e. VRN. Then the voltage
at r phase IV will be voltage supplied at HV divided by turns ratio. So if the transformer is
healthy then sum of voltages measured at other two phases of HV should be equal to V RN i.e.
VRN = VYN + VBN. Similarly Vrn = Vyn + Vbn. If this condition is met for all the phases then the
transformer is considered healthy. If not, there might be some problem in the placement of
conductors inside the core. This test is also conducted on 3 Taps of the transformer i.e.
Minimum, normal & Maximum. The Test format is as follows.
TAP
VRN VYN VBN Vrn Vyn Vbn REMARKS
NO
1
9
17
VECTOR GROUP TEST

This test is conducted to verify the vector group of the transformer. In this test standard 3
phase supply is applied at the HV terminals and following conditions are checked. For Vector
Group between HV-IV
Cond 1: R-N = (R-r) + (N-r)

Cond 2: R-r = Y-y = B-b
Cond 3: B-y = Y-b
Page 37 of 68
If all the conditions are satisfied then Vector Group YNa0 is
confirmed.
For Determination of Vector group of YNd11, R Phase (1U) to r

Phase (3U) are shorted.
For Vector Group YNd11, Between HV/IV – LV;

Cond 1: R-N = (R-b) + (b-N)
Cond 2: R-B > Y-y
Cond 3: B-b = Y-b
CHECKING OF AUXILIARY PROTECTION:
Different auxiliary protections provided in the transformer are, Buchholz, PRV (Main Tank),
PRV (OLTC), OTI, WTI LV and WTI HV, OSR etc. For testing operation of buchholz relay,
valves on the two sides of the Buchholz are closed and then the oil is drained from the relay.
Oil level in the buchholz relay reduces and consequently Buchholz alarm is operated and after
further draining of oil the relay trips.
PRV (Main Tank) and PRV (OLTC) are operated manually to check whether it trips or not.
OSR is also operated manually to check whether it trips or not.
OTI: The needle of the OTI gauge is increased manually. With gradual increase at first the
alarm is operated at a particular reading and it trips after some time at another reading. Both
the readings are recorded and if found faulty, it is again adjusted according to our requirement
i.e. Alarm: 80°C and Trip: 85°C.
WTI LV: The needle of the WTI LV gauge is increased manually. With gradual increase at
first the alarm is operated at a particular reading and it trips after some time at another reading.
Both the readings are recorded and if found faulty, it is again adjusted according to our
requirement i.e. Alarm: 90°C and Trip: 95°C.
WTI HV: The needle of the WTI HV gauge is increased manually. With gradual increase at
TAP CONTROL AND COOLER CONTROL CIRCUIT CHECK:
Local/Auto/Manual operation of cooler control circuit is checked. It is rectified if found faulty.

Condition of fans are also checked i.e. they are running properly or not or making weird noises
etc. Temperature at which fans operation starts and operations stops are also adjusted and
noted. Tap Operation from Local/Remote (RTCC) is also checked and rectified if required.
Page 38 of 68
DISSOLVED GAS ANALYSIS TEST OF TRANSFORMER OIL:
This test is conducted using dissolved gas analyser test kit. For this test oil sample is collected
from the top valve and bottom valve of the transformer using the apparatus (syringe) provided
with the kit. Then the oil is transferred to the gas analyser bottle and DGA test is conducted
using the test kit in the prescribed procedure. The obtained results are compared with standard
results to analyse the condition of the transformer. • Various Diagnostic Tools are also present
in the test kit itself such as Duvals Triangle Analysis, Rogers Ratio Analysis, Japan’s ETRA
analysis which provides different possible faults present in transformer according DGA test
results.
Gas High Limit High-High

(in ppm) Limit (in ppm)
Hydrogen 50 100
Carbon Dioxide 5000 8000
Carbon Monoxide 350 570
Ethylene 50 100
Ethane 50 100
Methane 100 200
Acetylene 3 5
TDCG 720 1500
Page 39 of 68
BREAKDOWN VOLTAGE TEST OF TRANSFORMER OIL:
Break-down Voltage test of Transformer oil is carried out by using BDV Test Kit in which
high voltage is applied within 2.5mm gap filled with transformer oil. The breakdown voltage
of the transformer oil should be 60KV for 2.5mm gap. If the BDV value of the oil sample is
below this threshold then the oil should be filtered or changed (in extreme cases)
SFRA TEST
This is very reliable and sensitive method or tool for condition monitoring of the physical
condition of transformer windings.
The winding of transformer may be subjected to mechanical stresses during transportation,
heavy short circuit faults, transient switching impulses and lightening impulses etc. These
mechanical stresses may cause displacement of transformer windings from their position and
may also cause deformation of these windings.
Windings collapse in extreme cases, such physical defects eventually lead to insulation failure
or dielectric faults in the windings. Sweep Frequency Response Analysis Test or in short SFRA
Test can detect efficiently, displacement of transformer core, deformation and displacement of
winding, faulty core grounds, collapse of partial winding, broken or loosen clamp connections,
short circuited turns, open winding conditions etc.
Hence after performing SFRA test at field, its graph needs to be compared with the factory
SFRA test graph if any deviation is observed between these graphs we can assess that there is
mechanical displacement and deformation occurred in the winding. In that case, manufacturer
has to be contacted for further suggestion and rectification.
The SFRA signature is generally taken for 3 different taps i.e. for minimum, normal and
maximum.
For each tap, phase to neutral readings for all HV terminals (1U-1N,1V-1N, 1W-1N) are taken
keeping LV terminals open and then phase to neutral reading are taken for HV (1U-1N,1V-1N,
1W-1N) keeping LV terminals shorted. Then SFRA signature reading is taken for each LV
terminals (2U-2N, 2V-2N, 2W-2N) at normal tap keeping HV terminals open.
WINDING RESISTANCE MEASUREMENT TEST
Winding Resistance Test is performed using Winding Resistance Test Kit.
Winding Resistance is measured for all three phases in HV side (1U-1N, 1V-1N, 1W-1N) for
all Taps at a particular OTI reading
Winding Resistance is measured for all three phases in LV side (1U-1N, 1V-1N, 1W-1N) for
normal tap only at a particular WTI reading.
Then the resistance value is converted for 75°C using the formula;
Page 40 of 68
If the results are in accordance with the factory test results of the transformer then the
transformer is healthy. If any deviation is observed then there might be a possibility of shorted
turns or loose connection or detoriating contacts in the tap changer. In this case overhauling
and physical inspection of the transformer need to be done
STABILITY TEST
 The objective of this test is confirm that the differential relay or REF relay doesn't operate
at normal conditions even though load currents are high, where It should operate when a
fault occurs in its zone.
 For this test standard 3 Phase supply is given at the three LV side CTs of the transformer
with shorting the three HV side CTs at outside.
 Then current is observed in all relays and meters. The current flowing at the LV side should
be turns ratio times the current flowing at the HV side.
 If this is observed then the transformer is stable. Otherwise, connection CTs need to be
checked and rectified.
Page 41 of 68
REF BALANCE CIRCUIT FOR AUTO TRANSFORMER
Page 42 of 68
TESTING OF POWER TRANSFORMER
1. IR and PI test
2. Magnetic Circuit IR Test
3. Capacitance and tan delta test of windings
4. Capacitance and tan delta test of 132 kV bushings
6. Transformer Winding Resistance Measurement Test
10. Vector Group Test
11. Testing of Auxiliary Protections
12. Cooler control circuit check
13. Dissolved Gas Analyser Test
14. Oil BDV Test
15. SFRA Test
16. Transformer Stability test
17. REF Balance Test (Both HV &LV)
transformer bushings must be done prior to the IR test. All the HV terminals (R,Y,B) with its
neutral (N) are shorted and all the LV terminals (r,y,b) with its neutral (n) are shorted. Then
shorted HV terminals to ground (HV-E), shorted LV terminals to ground (LV-E) and shorted
HV terminals to LV terminals (HV-LV) Insulation Resistance values are measured using the
IR Test Kit in PI mode. PI value = IR value at 10 min/ IR value at 1 min.
The PI value greater than 1.5 and less than 4 is considered healthy for each of the three
cases. If the PI value is greater than 4 then the insulation of the transformer has become
very dry. If the PI value is less than 1.5 then the transformer condition is considered to be
suspicious and needs further investigation. Oil samples should be sent to OTL/STL for BDV
test and DGA analysis for checking of moisture ppm content in main tank and OLTC tank
which should be less than 10 ppm prior to energisation. The test format is as follows.
POLARISATION INDEX TEST

MAKE
MODEL
USED:
Sl. No.
MODE R60 R600 PI VALUE REMARKS

HV- E
LV-E
HV-LV
Page 43 of 68
CAPACITANCE AND TAN DELTA TEST OF BUSHINGS
Tan-Delta & Capacitance Test on the bushings of a transformer (132 kV & Above) is carried
out between Primary and Cx point (Tan-Delta Point) using Tan-Delta & Capacitance test kit
at 2kV, 5kV and 10kV in UST mode. The results are compared with the name plate values.
If the Tan-Delta value is within (0.5% for new Transformer and 1% for Old Transformer)
the bushing is considered healthy. If the value is more than desired value then the bushing is
considered suspicious and replacing the same is recommended.

MODE kV mA
R PHASE UST 2
Make: UST 5
Sl. No.:
YOM: UST 10
CAPACITANCE AND TAN DELTA TEST OF WINDINGS:
For this test all the HV terminals (R, Y, B, N) are shorted and all the LV terminals (r,y,b,n) are
shorted. Firstly the HV cable of the tan delta & capacitance kit is connected to HV and LV
cable of the tan delta and capacitance kit is connected to LV side. Then test is conducted at
2KV, 5KV and 10KV in three different modes such as Ungrounded Specimen Test -UST (for
CHL value-Capacitance between HV and LV), Grounded Specimen Test with Guard- GSTg
(For CH value-Capacitance between HV to Trafo body) and Grounded Specimen Test- GST
(For CHL+CH). Then the HV cable of the kit is connected to LV side of transformer and LV
cable of the kit is connected to HV side of transformer. Then test is again conducted at 2KV,
5KV and 10KV in three different modes such as Ungrounded Specimen Test -UST (for CLH
value-Capacitance between HV and LV), Grounded Specimen Test with Guard -GSTg (For
CL value- Capacitance between LV to Trafo body) and GST-gnd (for CLH+CL). If the tan
delta value is within (0.5% for new Transformer and 1% for Old Transformer) in all cases
then the transformer windings are considered healthy. If it is more than desired then the
condition of windings of the transformer is considered suspicious.
MAKE
SPECIFICATION OF KIT USED: MODEL
Sl. No.
MODE kV mA
CH+CHL (Parallel) GST 2
FORWARD CH (HV-Earth) GST-g 5
CHL (HV-LV) UST 2
CHL (HV-LV) UST 5
CHL (HV-LV) UST 10
CL+CHL (Parallel) GST 2
CL (LV-Earth) GST-g 2
REVERSE CL (LV-Earth) GST-g 5
CL (LV-Earth) GST-g 10
CHL(HV-LV) UST 2
CHL (HV-LV) UST 5
CHL (HV-LV) UST 10
Page 44 of 68
Turns ratio test of transformer is conducted using Transformer Turns Ratio Kit. The test is
conducted for all the taps of the transformer from 1 to 17. At each tap the test result is compared
with the calculated turns ratio of the transformer at that tap. If the test result matches with the
calculated turns ratio then the transformer is healthy if not, the condition of the transformer is
suspicious and there might be problem in the tap changer.
TAP MEASURED Iexc MEASURED Iexc MEASURED Iexc CALCULATED
REMARKS
NO R-PH RATIO (mA) Y-PH RATIO (mA) B-PH RATIO (mA) RATIO
1 1.515
2 1.532
3 1.550
4 1.568
5(N) 1.587
6 1.606
7 1.626
8 1.646
9 1.667
10 1.687
11 1.709
12 1.731
13 1.754
14 1.777
15 1.808
16 1.826
17 1.851
OPEN CIRCUIT TEST:

transformer keeping the secondary i.e. LV terminals in open ckt condition. Then the no load
is no abnormality in the currents observed then the transformer is considered healthy.
TAP
VRY VYB VBR VRN VYN VBN Vry Vyb Vbr Vrn Vyn Vbn IR IY IB IN
NO
1
9
17
SHORT CIRCUIT TEST:

transformer keeping the secondary i.e. terminals in short ckt condition. The short circuit
currents in the primary terminals i.e. HV and in the secondary terminals i.e. LV are measured
Minimum, normal & Maximum. If there is no abnormality in the currents observed then the
transformer is considered healthy.
TAP
VRY VYB VBR IR IY IB IN Ir Iy Ib In
NO
1
9
17
Page 45 of 68
one phase and Neutral keeping the secondary i.e. LV open. Then phase to neutral voltage is
measured for each phase of both HV and LV. The same process is repeated for other two phases
as well. The voltage applied at the terminal should be equal to the sum of voltages measured at
other two terminals in HV. And for LV the voltage of the terminal in which voltage is applied
on HV side should be equal to the sum of voltages measured at other two terminals of LV.
For Example, Suppose single phase voltage is applied at R Phase terminal (HV) i.e. VRN.
Then the voltage at r phase LV will be voltage supplied at HV divided by turns ratio. So
if the transformer is healthy then sum of voltages measured at other two phases of HV
should be equal to VRN i.e. VRN = VYN + VBN. Similarly Vrn = Vyn + Vbn. If this condition is
met for all the phases then the transformer is considered healthy. If not, there might be some
problem in the placement of conductors inside the core. This test is also conducted on 3 Taps
of the transformer i.e. Minimum, Normal & Maximum.
VECTOR GROUP TEST

This test is conducted to verify the vector group of the transformer.
In this test standard 3 phase supply is applied at the HV terminals and following conditions are
checked.
Cond 1: 1U2n + 1N2n = 1U1N

Cond 2: 1W2w = 1V2v
Cond 3: 1W2v = 1V2w
Cond 4: 1W2w < 1W2v
If all the condition is satisfied then Vector Group YNyn0 is confirmed.
AUXILIARY PROTECTION:
Different auxiliary protections provided in the transformer are, Buchholz, PRV (Main Tank),
PRV (OLTC), OTI, WTI LV and WTI HV, OSR etc.
For testing operation of buchholz relay, valves on the two sides of the Buchholz are closed and
then the oil is drained from the relay. Oil level in the buchholz relay reduces and consequently
Buchholz alarm is operated and after further draining of oil the relay trips.
PRV (Main Tank) and PRV (OLTC) are operated manually to check whether it trips or not.
OSR is also operated manually to check whether it trips or not.
Page 46 of 68
OTI: The needle of the OTI gauge is increased manually. With gradual increase at first the
alarm is operated at a particular reading and it trips after some time at another reading. Both
the readings are recorded and if found faulty, it is again adjusted according to our requirement
i.e. Alarm: 80°C and Trip: 85°C.
WTI LV: The needle of the WTI LV gauge is increased manually. With gradual increase at
WTI HV: The needle of the WTI HV gauge is increased manually. With gradual increase at
TAP CONTROL AND COOLER CONTROL CIRCUIT CHECK:
Local/Auto/Manual operation of cooler control circuit is checked. It is rectified if found faulty.

Condition of fans are also checked i.e. they are running properly or not or making weird noises
etc. Temperature at which fans operartion starts and operations stops are also adjusted and
noted. Tap Operation from Local/Remote (RTCC) is also checked and rectified if required.
results to analyse the condition of the transformer.
REF BALANCE TEST

REF Balance Test done to check the stability of REF relay during faults outside the zone of
protection and tripping of REF relay within zone of protection (Transformer Internal Fault).
Page 47 of 68
 In Restricted Earth Fault scheme the common terminals of phase CTs are connected to
the secondary of Neutral CT in such a manner that secondary unbalance current of phase
CTs, and the secondary current of Neutral CT will oppose each other. If these both currents
are equal in amplitude there will not be any resultant current circulates through the said
closed path. The Restricted Earth Fault Relay is connected in this closed path. Hence the
relay will not respond even there is an unbalancing in-phase current of the power
transformer.
 In this test standard 3 phase supply is applied at HV or LV terminals. Then of the phases is
earthed inside the zone of protection once and outside the zone of protection once. REF
should show any unbalance current for the fault inside the zone of protection but it should
show zero current for the fault outside the zone of protection.
 If it is not the case then CT connection should be checked and rectified.
STABILITY TEST
 The objective of this test is confirm that the differential relay or REF relay doesn't operate
at normal conditions even though load currents are high, where It should operate when a
fault occurs in its zone.
 For this test standard 3 Phase supply is given at the three LV side CTs of the transformer
with shorting the three HV side CTs at outside.
 Then current is observed in all relays and meters. The current flowing at the LV side should
be turns ratio times the current flowing at the HV side.
 If this is observed then the transformer is stable. Otherwise, connection CTs need to be
checked and rectified.
Page 48 of 68
results to analyse the condition of the transformer. • Various Diagnostic Tools are also present
in the test kit itself such as Duvals Triangle Analysis, Rogers Ratio Analysis, Japan’s ETRA
analysis which provides different possible faults present in transformer according DGA test
results.
Gas High Limit High-High

(in ppm) Limit (in ppm)
Hydrogen 50 100
Carbon Dioxide 5000 8000
Carbon Monoxide 350 570
Ethylene 50 100
Ethane 50 100
Methane 100 200
Acetylene 3 5
TDCG 720 1500
Page 49 of 68
BREAKDOWN VOLTAGE TEST OF TRANSFORMER OIL:
Break-down Voltage test of Transformer oil is carried out by using BDV Test Kit in which
high voltage is applied within 2.5mm gap filled with transformer oil. The breakdown voltage
of the transformer oil should be 60KV for 2.5mm gap. If the BDV value of the oil sample is
below this threshold then the oil should be filtered or changed (in extreme cases)
TESTS OF STATION TRANSFORMER:

1. IR and PI test
transformer bushings must be done prior to the IR test. All the HV terminals (R,Y,B) with its
neutral (N) are shorted and all the LV terminals (r,y,b) with its neutral (n) are shorted. Then
shorted HV terminals to ground (HV-E), shorted LV terminals to ground (LV-E) and shorted
HV terminals to LV terminals (HV-LV) Insulation Resistance values are measured using the
IR Test Kit in PI mode. PI value= IR value at 10 min/ IR value at 1 min The PI value of greater
than 1.5 and less than 4 is considered healthy for each of the three cases. If the PI value is
greater than 4 then the insulation of the transformer has become very dry which is undesirable
for each of the three cases. If the PI value is less than 1.5 then the transformer condition is
considered suspicious.
Turns ratio test of transformer is conducted using Transformer Turns Ratio Kit. The test is
conducted for all the taps of the transformer from 1 to 7. At each tap the test result is compared
with the calculated turns ratio of the transformer at that tap. If the test result matches with the
calculated turns ratio then the transformer is healthy if not, the condition of the transformer is
suspicious and there might be problem in the tap changer.
OPEN CIRCUIT TEST:
transformer keeping the secondary i.e. LV terminals in open circuit condition. Then the no load
is no abnormality in the currents observed then the transformer is considered healthy.
SHORT CIRCUIT TEST
transformer keeping the secondary i.e. terminals in short ckt condition. The short circuit
currents in the primary terminals i.e. HV and in the secondary terminals i.e. LV are measured
Minimum, normal & Maximum. If there is no abnormality in the currents observed then the
transformer is considered healthy.
Page 50 of 68
one phase and Neutral keeping the secondary i.e. LV open. Then phase to neutral voltage is
measured for each phase of both HV and LV. The same process is repeated for other two phases
as well. The voltage applied at the terminal should be equal to the sum of voltages measured at
other two terminals in HV. And for LV the voltage of the terminal in which voltage is applied
on HV side should be equal to the sum of voltages measured at other two terminals of LV. For
Example, Suppose single phase voltage is applied at R terminal (HV) i.e. VRN. Then the voltage
at r phase LV will be voltage supplied at HV divided by turns ratio. So if the transformer is
healthy then sum of voltages measured at other two phases of HV should be equal to V RN i.e.
VRN = VYN + VBN. Similarly Vrn = Vyn + Vbn. If this condition is met for all the phases then the
transformer is considered healthy. If not, there might be some problem in the placement of
conductors inside the core. This test is also conducted on 3 Taps of the transformer i.e.
Minimum, normal & Maximum.
VECTOR GROUP TEST

This test is conducted to verify the vector group of the transformer. In this test standard 3 phase
supply is applied at the HV terminals and following conditions are checked. With R to r shorted.
 Cond 1: RY = Rn + Yn
Cond 2: Bb < By
Cond 3: Yy = Yb
 If all the conditions are satisfied then Vector Group Dyn-11 is confirmed.
Page 51 of 68
TESTING OF ADMS (Automatic Demand Management Scheme)
It is required to restrict drawl of power by the Distribution companies from the grid to comply
with the specified frequency requirements so as to overcome any threat to system security in
an interconnected system on account of overdrawal from the grid. The Central Electricity
Regulatory Commission (CERC) of India mandates manual as well as automatic demand
disconnection from the distribution network under overdrawal conditions and on crossing the
defined frequency limits. As the manual control at times become ineffective to decrease drawal
by a certain quantum within the time limit and hence the Automatic Demand Management
Scheme assumes significant importance to restrict drawl of power. The Automatic Under
frequency Load Shed (AUFLS) and load relief by rate of change of frequency relay are the
defence mechanism whereas Automatic Demand Management System (ADMS) acts as a tool
for ensuring security and reliability of the interconnected system. Under this system real time
information is gathered through the transmission Supervisory Control and Data Acquisition
(SCADA) System and based on logics developed for the scheme, automatic load disconnection
is achieved through the control output of Remote Terminal Unit (RTU) installed for SCADA
System of Transmission network .
ADMS (Automatic Demand Management System) helps OPTCL to limit state overdrawal
from national gird and help maintain grid frequency.
33kV feeders are tripped in 132kV/33kV OPTCL substation when following conditions are
achieved
1. System Frequency < 49.9 Hz
2. Odisha over-drawl > 12% of Schedule or 150 MW(Odisha Limit) whichever is lower
3. DISCOM over-drawl > 12% of Schedule or OERC approved share percentage of 150
MW(DISCOM Limits) whichever is lower.
The DC supply to an ADMS panel are provided from the DCDB of the GSS. For a 33kV feeder
status of breaker ON, OFF are taken from the respective CR panel to the Relays (operating
voltage level 220V) of ADMS panel which is communicated to the main ADMS server at
SLDC via OPGW or wireless communication link of Telecom wing .Also the tripping
command from the remote server arrives to the ADMS panel of the GSS by the same method.
Page 52 of 68
The tripping relay (operating voltage level 24V) executes the trip command directly to the trip
coil of the breaker of the concerned feeder provided the ADMS system is in Auto mode.
If the ADMS panel is kept at Auto mode then tripping of the breaker can be done from that
ADMS panel as well as from the remote end (SLDC). If the panel is kept in Manual mode then
tripping from the ADMS panel is blocked. (both from local end and SLDC end) .
The 24 hours of a day is to be divided into 15 minutes block periods, If above condition persists
for a 15 minutes block with average data then generate tripping command at 16th minute for
First group. (e.g. G1). That will cover all the sub-station under this group with selected feeders.
After tripping of one group of feeders, the logic is blocked for that DISCOM for 30 minutes.
After half an hour if condition persists in the next 3 minute block period, then send tripping
command to second group (e.g. G2) at the 4th minute .Repeat the logic for next group if above
condition persists after next 30 min. The tripping Group order should every day at 23:59Hrs.
For example if on a particular day tripping for Group-1, 2,3 & 4 for a DISCOM operated, on
the next day the tripping starts from Group-1 again and not from Group-5.
Page 53 of 68
 PRE-COMMISSIONING TESTS OF 220/132/33 kV and
132/33 kV AIS without SAS
 PRE-COMMISSIONING TESTS OF TRANSFORMERS
(AUTO TRANSFORMER/ POWER
TRANSFORMER/STATION TRANSFORMER)
 PRE-COMMISSIONING TESTS OF AIS WITH SAS
 PRE-COMMISSIONING TESTS OF 132/33 kV GIS
Page 54 of 68
PRE-COMMISSIONING TESTS OF 220/132/33 kV AIS & 132/33 kV AIS without SAS
220 KV FEEDER BAY
 Testing of 220 kV LA
o Insulation Resistance Test
o WattLoss Test
o Surge Counter test
 Testing of 220 kV CVT
o Capacitance and tan delta test
o Ratio Test
o Winding resistance measurement
o Primary Voltage injection test
 Testing of 220 kV CT
o Ratio Test
o Polarity Test
o Knee point voltage test
o Primary Current Injection Test
 Testing of SI/DI/Earth switch
o Contact Resistance measurement
o Operational check & Mechanical/ Interlock check
 Testing of 220kV Circuit Breaker
o Contact Resistance Measurement Test
o Operational check (Electrical Close/open operation from Local/Remote)
o SF6 Gas Functionality Check(SF6 gas low and Lockout)
o TC coil and Closing coil resistance measurement
o Anti-pumping relay functional test
o Pole discrepancy relay functional test
 Testing of Control/Relay Panel
o Panel Scheme check (As per schematic logic: DC fail/AC fail/Trip circuit
supervision/DC selection/Trip relay supervision/Trip Transfer Scheme etc.)
o Panel Annunciation, Indication and Semaphore check
o Operational Check of Circuit Breaker, Isolators/ Earth-switches with all
associated Interlocks.
o Testing of Numerical Relays (Distance Protection Relay-Settings as per
Ramakrushna committee and O/C & E/F Relay)
o Testing of Protection scheme
 Functions in Distance Protection Relay: Zone Protection, SOTF,
VTFF, Broken conductor, Power Swing Block, Carrier Aided
Protection,A/R function.
 Functions in O/C & E/F Relay: Directional O/C & E/F Protection,
VTFF, LBB scheme.
o Testing of Auxiliary and Multiplication Relays.
o Testing of Panel meters-Energy Meters, MW, MVAR, A, V meters etc.
 Testing of energy Meters (Apex Meters)
Page 55 of 68
o Checking of Proper termination of CT & PT cables.
o Accuracy check (MW and MVAR) by using Phantom Kit.
o Checking of Auxiliary power Supply (AC/DC)
o Checking of Proper Earthing connection of Meter body.
o Checking of Advance in Import/Export mode
o Checking of Time Synchronization.
220 KV TRANSFORMER BAY
 Testing of 220 kV LA
o WattLoss Test
o Surge Counter test
o Ratio Test
o Polarity Test
o Primary Current Injection Test
 Testing of SI/DI/Earth switch
o Testing of Numerical Relays (Differential Protection Relay, O/C & E/F
Relay& REF Relay)
 Functions in Differential Protection Relay: Differential Relay Slope
test, Differential Pickup test, Stability test, 2nd& 5th Harmonic
Blocking Test, Over Fluxing Protection (V/f)
 Functions in O/C & E/F Relay: Directional O/C & E/F Protection,
VTFF, LBB scheme.
 REF protection check.
o Testing of Auxiliary Relays in the CR Panel i.e. Buchholz Relay (Alarm/Trip),
HV WTI (Alarm/Trip), IV WTI (Alarm/Trip),LV WTI (Alarm/Trip), OTI
(Alarm/Trip), MOG Alarm, OSR(R,Y,B-Ph) Trip, PRV Trip (Main
tank/OLTC), Aircell rupture Alarm.
Page 56 of 68
o Testing of Inter-tripping between HV and IV Circuit breaker.
 Testing of RTCC panel
o Checking of Panel scheme as per drawing
o Panel Annunciation, Indication check as per drawing.
o Checking of Cooler control operation from RTCC panel
o Checking of OLTC DM box operation from RTCC
o Checking of WTI, OTI temperature with TPI meter signal at RTCC.
o Checking of windings (1U,1V,1W ,2u,2v,2w),oil and core temperature fiber
optic signal at RTCC.
 Testing of energy Meters (Apex Meters)
o Checking of Proper termination of CT & PT cables.
o Accuracy check (MW and MVAR) by using Phantom Kit.
o Checking of Auxiliary power Supply (AC/DC)
o Checking of Proper Earthing connection of Meter body.
o Checking of Advance in Import/Export mode
o Checking of Time Synchronization.
220 kV BUS COUPLER BAY
o Ratio Test
o Polarity Test
o Primary Current Injection test
 Testing of 132 kV Bus PT
o Ratio Test
o Primary Voltage Injection test.
 Testing of SI/DI & Section Isolators
o Testing of Numerical Relays (Non Directional O/C & E/F Relay)
Page 57 of 68
132 KV FEEDER BAY
H. Testing of 132 kV LA
a. Insulation Resistance Test
b. WattLoss Test
c. Surge Counter test
I. Testing of 132 kV CVT
b. Capacitance and tan delta test
c. Ratio Test
d. Polarity Test
e. Winding resistance measurement
J. Testing of 132 kV CT
c. Ratio Test
d. Polarity Test
e. Knee point voltage test
f. Winding resistance measurement
K. Testing of SI/DI/Earth switch
b. Contact Resistance measurement
c. Operational check & Mechanical/ Interlock check
L. Testing of Circuit Breaker
b. Circuit Breaker Timing Test
c. Contact Resistance Measurement Test
d. Operational check
e. SF6 Gas Functionality Check
M. Testing of Control/Relay Panel
a. Panel Scheme check (As per schematic logic: DC fail/AC fail/Trip circuit
b. Panel Annunciation, Indication and Semaphore check
c. Operational Check of Circuit Breaker, Isolators/ Earth-switches with all
d. Testing of Numerical Relays (Distance Protection Relay-Settings as per
Ramakrushna committee and O/C & E/F Relay)
e. Testing of Protection scheme
i. Functions in Distance Protection Relay: Zone Protection, SOTF,
VTFF, Broken conductor, Power Swing Block, Carrier Aided
Protection
ii. Functions in O/C & E/F Relay: Directional O/C & E/F Protection,
VTFF, LBB scheme.
f. Testing of Auxiliary and Multiplication Relays.
g. Testing of Panel meters-Energy Meters, MW, MVAR, A, V meters etc.
N. Testing of energy Meters (Apex Meters)
a. Checking of Proper termination of CT & PT cables.
b. Accuracy check (MW and MVAR) by using Phantom Kit.
c. Checking of Auxiliary power Supply (AC/DC)
d. Checking of Proper Earthing connection of Meter body.
e. Checking of Advance in Import/Export mode
f. Checking of Time Synchronisation.
Page 58 of 68
132 KV TRANSFORMER BAY
O. Testing of 132 kV LA
b. Watt-Loss Test
P. Testing of 132 kV CT
c. Ratio Test
d. Polarity Test
Q. Testing of SI/DI
R. Testing of Circuit Breaker
S. Testing of Control/Relay Panel
d. Testing of Numerical Relays (Differential Protection Relay, O/C & E/F Relay
& REF Relay)
i. Functions in Differential Protection Relay: Differential Relay Slope
test, Stability test, 2nd & 5th Harmonic Blocking Test, Over Fluxing
Protection (V/f)
ii. Functions in O/C & E/F Relay: Directional O/C & E/F Protection,
VTFF, LBB scheme.
iii. REF protection check.
f. Testing of Auxiliary Relays in the CR Panel i.e. Buchholz Relay (Alarm/Trip),
HV WTI (Alarm/Trip), LV WTI (Alarm/Trip), OTI (Alarm/Trip), MOG
Alarm, OSR Trip, PRV Trip (Main tank/OLTC)
g. Testing of Panel meters-Energy Meters, MW, MVAR, A, V meters etc.
T. Testing of Energy Meters (Apex Meters)
b. Accuracy check (MW and MVAR) by using Phantom Loading Kit.
f. Checking of Time Synchronisation.
Page 59 of 68
132 kV BUS COUPLER BAY
U. Testing of 132 kV CT
c. Ratio Test
d. Polarity Test
V. Testing of 132 kV Bus PT
c. Ratio Test
d. Polarity Test
W. Testing of SI/DI & Section Isolators
X. Testing of Circuit Breaker
Y. Testing of Control/Relay Panel
d. Testing of Numerical Relays (O/C & E/F Relay)
f. Testing of Panel meters-Energy Meters, MW, MVAR, A, V meters etc.
33 kV FEEDER BAY
Z. Testing of 33 kV LA
b. WattLoss Test
AA. Testing of 33 kV CT
c. Ratio Test
d. Polarity Test
BB. Testing of SI/DI/Earth switch
Page 60 of 68
CC. Testing of Circuit Breaker
DD. Testing of Control/Relay Panel
i. Functions in O/C & E/F Relay: Directional O/C & E/F Protection,
LBB scheme.
f. Testing of Auxiliary and Multiplication Relays.
g. Testing of Panel meters-Energy Meters, MW, MVAR, A, V meters etc.\
33 kV TRANSFORMER BAY
EE. Testing of 33 kV LA
b. Surge Counter test
FF. Testing of 33 kV CT
b. Ratio Test
c. Polarity Test
d. Knee point voltage test
GG. Testing of SI/DI
HH. Testing of Circuit Breaker
II. Testing of Control/Relay Panel
d. Testing of Numerical Relays (O/C & E/F Relay & REF Relay)
i. Functions in O/C & E/F Relay: Directional O/C & E/F Protection
ii. REF protection check.
Page 61 of 68
JJ. Testing of energy Meters (Apex Meters)
b. Accuracy check (MW and MVAR) by using Phantom Kit.
f. Checking of Time Synchronisation of Meters
33 kV BUS-COUPLER BAY
KK. Testing of 33 kV CT
b. Ratio Test
c. Polarity Test
d. Knee point voltage test
LL. Testing of 33 kV Bus PT
b. Ratio Test
c. Polarity Test
d. Winding resistance measurement
MM. Testing of SI & Section Isolators
NN. Testing of Circuit Breaker
OO. Testing of Control/Relay Panel
220/132 KV AUTO TRANSFORMERS
After a new Transformer reached at site, very first job for site engineer is to download the
Impact recorder data which is mounted on a transformer body and compared it with pre-
specified transformer design GTP data.
 Tests to be done prior to Oil Filtration
o Capacitance and Tan Delta test prior to erection of Bushing
o IR, Ratio, Polarity and Winding Resistance test of Turret or Bushing CT.
o Magnetic Circuit IR test (C-F-T IR test)
o SFRA test
Page 62 of 68
o Oil BDV Test
 Tests to be done after Oil Filtration
o Oil BDV Test (OTL and STL)
o Oil DGA Test (OTL and STL)
o IR & PI test
o Capacitance and Tan Delta test of Winding
o Capacitance and Tan Delta test of Bushing
o Transformer Turns Ratio test
o Winding Resistance test (HV & LV)
o LV Tests
 Open circuit test(Magnetizing current test)
 Short circuit test
 Magnetic balance test
 Vector group test
 Voltage Ratio test
o Auxiliary protection check
o Calibration of WTI and OTI meters with a standard Thermometers.
o OLTC Operation check (Local & Remote)
o Cooler control scheme check (Auto/ Manual & Local/Remote)
o Transformer Stability test
o REF Balance Test (Both HV &LV)
o HV & LV NCT
 IR test
 Ratio test
 CT Polarity test
 Winding Resistance Measurement
132/33 KV POWER TRANSFORMERS
After a new Transformer reached at site, very first job for site engineer is to download the
Impact recorder data which is mounted on a transformer body and compared it with pre-
specified transformer design GTP data.
 Tests to be done prior to Oil Filtration
o Capacitance and Tan Delta test prior to erection of Bushing
o Magnetic Circuit IR test (C-F-T IR test)
o SFRA test
o Oil BDV Test
 Tests to be done after Oil Filtration
o Oil BDV Test (OTL and STL)
o Oil DGA Test (OTL and STL)
o IR & PI test
o Capacitance and Tan Delta test of Winding
o Capacitance and Tan Delta test of Bushing
o Transformer Turns Ratio test
o Winding Resistance test (HV & LV)
o LV Tests
 Open circuit test (Magnetizing current test)
 Short circuit test
 Magnetic balance test
 Vector group test
 Voltage Ratio test
o Auxiliary protection check
o OLTC Operation check (Local & Remote)
o Cooler control scheme check (Auto/ Manual & Local/Remote)
Page 63 of 68
o Transformer Stability test
o REF Balance Test (Both HV &LV)
o HV & LV NCT and TURRET CT
 IR test
 Ratio test
 CT Polarity test
 Winding Resistance Measurement
TESTING OF STATION AUXILIARIES (ACDB, DCDB, BATTERY CHARGER,
STATION TRANSFORMER)
 Testing of Station Transformer
o IR & DAR Test
o Open circuit test (Magnetizing current test)
o Short circuit test
o Magnetic balance test
o Vector group test
o Voltage Ratio test
o Winding Resistance test
 Testing of ACDB
o Bus Bar IR test
o Operational Check & associated Inter-lock Scheme check
o Testing of (O/C & E/F Relay)
o Testing of Panel meters-Energy Meters, Tri-Vector meter, A, V meters etc.
o Panel Annunciation, Indication check
o Checking of MCCBs and MCBs
o Testing and operational Check of Air Circuit Breakers
 Testing of DCDB
o Bus Bar IR test
o Operational Check & associated Inter-lock Schemes
o Testing of Panel meters- A, V meters etc.
o Panel Annunciation, Indication and check
o Checking of MCCBs and MCBs
 Testing of Battery Charger
o Operational Check of battery Chargers (Both FC & FCBC Module)
o Scheme check (as per schematic logic)
o Annunciation, Indication check
 Testing of Bus Bar system and Event Logger system (For 220 kV and above only)
 Testing Of Earth Pits
Page 64 of 68
PRE-COMMISSIONING TESTS OF AIS & GIS GRID SUBSTATIONS WITH SAS
SAS ARCHITECTURE
AVAILABLE COMPONENTS IN A SAS SUB-STATION
 Bay Control Unit(BCU) / Bay Control & Protection Unit (BCPU)
 Ethernet Fiber Switch (EFS)
 Main/Stand-By SCADA Server PC-HMI
 Disturbance Recorder PC
 Gateway PC
 RedBox (Redundancy Box)
 GPS Unit
 Media Converter
 Visual Display Unit
NECESSARY CHECKS AND TESTINGS:
 Remote Operation of Each bay Switch Gears (CB, SI, DI) from SCADA HMI as well
as from Local BCU is to be ensured
 Ensure if the Status of Each bay Switch Gears (CB, SI, DI) is showing properly in the
SCADA HMI.
 Ensure if the Soft Inter-lock scheme provided by the Executing Agency is correct and
as per standards. Correction and necessary modifications if any are to be done in the
I/L Scheme and to be implemented.
 Ensure all the metering parameters are displayed properly in the HMI Screen.
 Ensure all the protection signals and other necessary signals are properly mentioned in
the HMI and working properly.
 Ensure if all the SCADA servers are working properly during AC Fail through Inverter.
 Ensure all the protective Relays/BCUs are synchronized with GPS clock.
 Checking of all BI/BO signals of BCU and Protective relay are working properly.
 Checking of all analog signals like OTI/WTI Temperature, Tap Position of Transformer
etc. are showing correctly in the HMI.
 Checking of Analog signals in the HMI such as AC Voltage current of ACDB, DC
Voltage & Current of 220 V DCDB and 48 V DCDB as per schematic logic.
 Operation of ACDB, 220 V DCDB, 48 V DCDB from SCADA HMI as per schematic
logic.
 Checking of additional annunciation signals from ACDB, DCDB, Battery Charger,
Station Transformer etc. in the SCADA HMI as per schematic logic.
 All the IEDs (Intelligent Electronic Devices) are to be interconnected with the EFS in
double ring as per approved SAS architecture and it is to be ensured that if one ring is
disconnected from the system, the communication between IEDs and EFS will remain
healthy through the other ring. This needs to be demonstrated by the executing agency.
Page 65 of 68
PRE-COMMISSIONING TESTS OF GIS GSS WITH SAS
In addition to the above checks mentioned for AIS substations with SAS, the following
additional checks need to be done in a GIS GSS with SAS
 Ensure that all the signals from LCC (Local Control Cubicle) are displayed in the
SCADA HMI as per schematic logic
 An additional SLD needs to be made available in the HMI illustrating the Gas
Healthiness status of each Gas chamber. Also, change of display color during gas
pressure low and lockout needs to be implemented accordingly.
 All signals especially Gas Pressure Alarm and Lockout of each gas chamber of the GIS
needs to be checked in the SCADA HMI.
132 KV SIDE
 Current Transformer
o CT Secondary AC Dielectric Test
o CT Knee Point Voltage Test
o CT Ratio test by Primary Current Injection Method
o Winding Resistance Measurement
o CT Polarity test
o VT Secondary AC Dielectric Test
o Ratio Test
o Contact Resistance Measurement Test of Disconnectors and CB
 GIS
o AC Hi-POT Test & Partial Discharge Measurement
 SF6 GAS COMPARTMENT
o Sf6 Gas Purity Check
o Dew Point Check
o Moisture Content Check(Ppm)
o Functionality Check Of Sf6 Density Monitors
 LCC
o Panel Scheme check, Operational Check of All Disconnectors/Earthswitches
o Checking of various LCC signals in the Facia Annunciator.
 SAS
o Scheme Check Of SAS Panels
o Testing of Numerical Relays
o Checking of Soft Inter-lock logic as per scheme
o Testing of BCU
 Networking panel
o Scheme Check & Testing of Auxiliary BCU
o Network System Architecture Check
 SCADA HMI
o Checking of single Line Diagrams, Position of Disconnectors & CB and their
operation from Local SCADA HMI, Checking of analog signals.
o Checking of GAS SLD
Page 66 of 68
 XLPE Cables
o DC Hi-POT TEST (DC High Voltage withstand Test)
33 KV SIDE
 Current Transformer (Cable CT and Bushing CT)
o CT Secondary IR Test
o CT Knee Point Test
o CT Ratio test by Primary Current Injection Method
o CT Polarity test
o VT Secondary IR Test
o Ratio Test
o Timing Interval Test of CB
 GIS
o AC Hi-POT Test
 Sf6 Gas Compartments
o Sf6 Gas Purity Check
o Dew Point Check
o Moisture Content Check(Ppm)
o Functionality Check Of Sf6 Density Monitors
 LCC
o Panel Scheme check, Operational Check of All Disconnectors/Earth switches
 SAS Panel
o Scheme Check of SAS Panels
o Testing of BCU
o Testing of Numerical Relays
o Testing of REF relays (Electromagnetic relays/Numerical Relays)
 XLPE Cables
o DC Hi-POT TEST (DC High Voltage withstand Test
 ACDB/DCDB
o Operational check from Local/Remote (BCU & SCADA)
o Interlock Check
o Testing of O/C & E/F Relays in ACDB
 Battery Charger & Dropper Diode Circuit
o Operational Check as per scheme
 Testing Of Earth Pits
Page 67 of 68
 The test reports of the above tests are to be prepared by executing
agency/Construction Wing/O&M Wing in consultation with E&MR wing
 After due deliberation, the test reports will be submitted to executing
agency/Construction Wing/O&M Wing for onward submission to CEI for
necessary Statutory inspection prior to charging of the Bay/Transformer/GSS.
---------------The End----------------
Page 68 of 68

Testing and Commissioning Manual-Final

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Testing and Commissioning Manual-Final

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TESTING & COMMISSIONING

3 Testing of Current Transformer 8-10

220 kV Auto 220 kV Bus Coupler

132 kV Transformer 132 kV Bus Coupler

33 kV Transformer 33 kV Bus Coupler

Q8, Q15,Q25: High Speed Earth Switch

QZD: Bus 1 Disconnector with Earth switch

The Format for Above Test as conducted at site is as follows:

B. CAPACITANCE & TAN-DELTA TEST

D. CT SECONDARY WINDING RESISTANCE MEASUREMENT

Winding resistance of each CT secondary winding is measured using a standard multi-

Insulation resistance test is carried out on a LIGHTNING ARRESTER with a 5 kV IR

Reference Measured IR values

Ir. Corrected is less than 25% of Ir max. Very good

 CVT RATIO TEST

 TAN-DELTA & CAPACITANCE TEST

Winding resistance of each IVT/PT core is measured using a standard multimeter

 IVT RATIO TEST

R-Phase(GΩ) Y-Phase(GΩ) B-Phase(GΩ)

Details of Kit used

C. CONTACT RESISTANCE MEASUREMENT

Applied Current- R-PH Y-PH B-PH

FORMAT FOR SINGLE ISOLATOR

FORMAT FOR DOUBLE ISOLATOR

B. CONTACT RESISTANCE MEASUREMENT

Applied Current- R-PH Y-PH B-PH

C. ISOLATOR OPERATIONAL CHECK

Sf6 Gas Purity Check Permissible Limit: >=98%

Sf6 Gas Purity Check Permissible Limit: >=95%

GAS PRESSURE UNHEALTHY: Below 1.2 Bar at 20°C

SOME KEY POINTS FOR BATTERY OPERATION & MAINTENANCE:

TESTING OF EVENT LOGGER SYSTEM

(LT CT METERING SCHEME)

INSULATION RESISTANCE AND POLARIZATION INDEX TEST:

POLARISATION INDEX TEST

MODE R60 R600 PI VALUE REMARKS

Watt Loss Tan δ Capacitance

CAPACITANCE AND TAN DELTA TEST OF WINDINGS:

Watt Loss Tan δ Capacitance

TAP MEASURED Iexc MEASURED Iexc MEASURED Iexc CALCULATED

OPEN CIRCUIT TEST:

MAGNETIC BALANCE TEST:

VECTOR GROUP TEST

Cond 1: R-N = (R-r) + (N-r)

For Determination of Vector group of YNd11, R Phase (1U) to r

For Vector Group YNd11, Between HV/IV – LV;

CHECKING OF AUXILIARY PROTECTION:

TAP CONTROL AND COOLER CONTROL CIRCUIT CHECK:

Local/Auto/Manual operation of cooler control circuit is checked. It is rectified if found faulty.

Gas High Limit High-High

INSULATION RESISTANCE AND POLARIZATION INDEX TEST:

POLARISATION INDEX TEST

MODE R60 R600 PI VALUE REMARKS

Watt Loss Tan δ Capacitance

CAPACITANCE AND TAN DELTA TEST OF WINDINGS:

OPEN CIRCUIT TEST:

SHORT CIRCUIT TEST:

VECTOR GROUP TEST

Cond 1: 1U2n + 1N2n = 1U1N

TAP CONTROL AND COOLER CONTROL CIRCUIT CHECK:

Local/Auto/Manual operation of cooler control circuit is checked. It is rectified if found faulty.

DISSOLVED GAS ANALYSIS TEST OF TRANSFORMER OIL:

REF BALANCE TEST

Gas High Limit High-High