LT SWGR Test SCH

STATION: NTPC SIMHADRI
BHEL REF NO : PS-DC-186-500NTPC REF NO: SIM/1/TS/

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PLANT AREA : ELECTRICAL SYSTEM

TESTING SCHEDULE : LT SWITCHGEAR
LIST OF CONTENTS
1. PLANT DETAILS
2. TESTING OBJECTIVES
3. TESTING PROPOSALS
4. SERVICES REQUIRED
5. SAFETY PRECAUTIONS
6. EMERGENCY PROCEDURES
7. STATE OF THE PLANT
8. COMMISSIONING PROCEDURE
9. COMPLETION CRITERIA
10.APPENDICES
SHEET 1 OF 20

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SHEET 2 OF 20

1.0
PLANT DETAILS :
1.1
415 Volts LT switchgear consists of two bus sections A &

B with a bus coupler between them. The two sections are
fed from two individual power transformers 1A and 1B in
case of switchboard & upstream breakers in case of MCCs &
ACPs.
The Transformers get their supplies from 11KV unit
switchgear feeders TRF1 & TRF2.

switchboard feeds
415 Volts Unit
the boilers and turbine
service
auxiliaries,
(MCCS) Soot blower MCCs,Battery chargers(220 V ,24 V DC)

Emergency switchgear and other unit auxiliaries.
The
single line diagram of the Unit service switchboard
is
given below :
11 KV UNIT BUS 1A
11 KV UNIT BUS 1B
TRF 1
TRF 2
2000 KVA UNIT

TRANSFORMER
1A
2000 KVA UNIT

TRANSFORMER
1B
I/C 2
I/C 1
B/C
415 UNITS SERVICE

SWITCHBOARD NO-1
Single Line Diagram Unit Service Switchboard

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SHEET 3 OF 20

LT SWITCHGEARS in NTPC Simhadri Project:

I.SWITCHBOARDS
1. Unit emergency switchboard(1DG,2DG)
2. Unit Service Switchboard(1DA,2DA)
3. ESP-1 to 4 LT Main switchboard
(1DC,1DD,1DE,1DF,2DC,2DD,2DE,2DF)
4. Station service switchboard(0DA,0DB,0DC)
5. Ash system compressor switchboard(0DD)
6. Ash water Power House switchboard(0DF)
7. Off side plant services switchboard(0DG)
8. Switchyard Service Switchboard(0DH)
9. CHP Switchboard-1
10.CHP Switchboard-3
11.CWPH Switchboard
12.ADM Bldg. Switchboard
13.Raw Water Pump House Switchboard
14.Ash Water Recirculation Service switchboard
15.Sea Water Power House switchboard
16.Bunker service switchboard
17.Sweet Water Makeup Power House switchboard
II Motor Control Centres
1. Turbine MCC(1KA,2KA)
2. Turbine valves MCC(1KB,2KB)
3. Coal mill MCC (1HE,2HE)
4. Boiler MCC(1HA,2HA)
5. Boiler Valve MCC(1HB,2HB)
6. Boiler Damper MCC(1HC,2HC)
7. Boiler AC Distribution Board(1HD,2HD)
8. Track Hopper MCC
9. PT MCC
10.DM Plant MCC
11.CMB MCC
12.ETP MCC
13.Hydraulic Generation Plant MCC
14.Chimney lighting MCC
15.Emergency Chimney board
16.ESP Area MCC
17.ESP A/C & Vent MCC
18.Ash SILO MCC (1QA,2QA)
19.Air Washer MCC(1SA,2SA)
20.AC & Vent MCC (1TA,2TA)
21.Aux. Boiler MCC(0SA)
22.Station AC Distribution Board
III.Aux Control Panels:
ESP 1 to 4 Aux Control Panels (Unit # 1 & Unit # 2)

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SHEET 4 OF 20

2.0
TESTING OBJECTIVES :
2.1
The
objectives
of
these
tests
on
the
415
Volts
unit
service switchgear are to ensure that the equipment has

been erected satisfactorily, is suited for the duty it is
required
to
perform,
meets
the
design
and
contact
specifications and is to the appropriate Indian, NTPC and

other relevant engineering standard or code of practices.

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SHEET 5 OF 20

3.0
TESTING PROPOSAL :
3.1
Every
415
LT
switchgear
consists
of
number
of
equipments and it is proposed that these will be checked

individually
procedures
using
which
standard
will
be
check
lists
recorded
in
and
the
test
testing
schedule.
3.2
Certain
protections
and
inter-tripping
tests
will
be
detailed in the testing schedule.

3.3
The 415 V unit service bus sections B&C will be charged

through the 2000 KVA unit service transformers A or B as
per availability of the transformers and 11 KV unit bus.
3.4
Other LT switchgears are thereafter charged as per the

requirement and availability of supplies
3.5
It will be the duty of the Testing team leader to ensure

that when the system is operating under load condition,
all the equipment which is the subject of this testing
schedule shall be externally inspected for any sign of
stress
or
abnormality
and
that
report
is
prepared
recording the results of inspection and a copy attached

as an appendix to this schedule.

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SHEET 6 OF 20

4.0
SERVICES REQUIRED :
4.1
In General for carrying out these tests the services
the items listed below are required variable 220
Volts
of
D.C
and 415/240 Volts A.C supplies.

4.2
INSULATION TESTER 500V DC- HAND OPERATER
4.3
CALIBARATION
SOURCE
METERS/TRANSDUCERS.
4.4
MICRO OHM METER.
KID
FOR
CALIBARATION
OF

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SHEET 7 OF 20

5.0
SAFETY PRECAUTIONS :
5.1 SAFETY OF THE PLANT :

5.1.1
The test method must be strictly adhered to at all

times except in the following situation.
a.
b.
c.
In an emergency situation.
By agreement with the working party.
On instruction of the test team leader.
5.2
SAFETY OF THE PERSONNEL :
5.2.1
All
the
members
of
the
testing
team
and
persons
associated with this testing/commissioning schedule

should be familiar with the testing procedures and
the equipments involved in testing.
5.2.2
There should be safe access to and escape routes

from confined areas.
5.2.3
The area under test should be clearly defined.
5.2.4
Access to the area under test should be restricted,

proper caution boards should be displayed at the
test area.
5.2.5
Permanent and adequate lighting facilities should be

available at all times.
5.2.6
All
handrail,
stairs,
guards
and
trench
covers
should be properly fitted/replace.

5.2.7
The test area should be clear of obstructions.
5.2.8
Safety clearance certificates and safety clearance

notifications
should
be
in
force
for
the
installations to be energised.
5.2.9
The
operating
about testing.
personnel
should
be
kept
informed

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SHEET 8 OF 20

6.0
EMERGENCY PROCEDURE :
6.1
It will be the responsibility of the testing team leader

to inform all members of the testing team what actions
are to be taken in the event of fire, accident or other
major incident.
6.2
Telephone numbers for first aid/ambulance, fire stations

and hospitals should be per monthly displayed adjacent to
every telephone.
6.3
First aid charts for treatment of electrical shock should

be displayed near the test area.
6.4
In the event of any sign of abnormality, the source of

supply
for
the
particular
isolated immediately.
equipment/area
should
be

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SHEET 9 OF 20

7.0
STATE OF THE PLANT :
7.1
The following items and their associated equipments

must be erected, complete, accessible for testing
and available for use.
In case of charging Unit Service switchboard
1.
11KV cables from 11KV unit bus 1A and 1B to 2000 KVA

unit service transformers 1A and 1B respectively
2000 KVA (11KV/415V) unit service transformers 1A
and 1B.
2.
415 V bus ducts from unit service transformers 1A

and 1B to 415V unit service switchboard 1 section A
& B and tie from section A to section B.
3.
415 V unit service switchboard no.1 complete with

all its circuit breakers contractors and associated
equipments.
7.2
As above other Switchboards, MCCs and Aux. Control

panels are to be charged according to their
readiness and the availability of upstream supply.
7.3
Erection completion certificates and manufacturers

test certificates should be available for contactors
and associated equipments.
7.4
The tie between emergency switchboard and the 415V

unit service switchboard must be dead and isolated
from
all
sources
of
supply
and
safety
procedure
followed to ensure that the tie remain dead.

7.5
For the checks and tests to be carried out by

energising the equipment to normal working voltage,
the 11KV unit switchgear no-1 sections A&B should be
in an energised condition and the SCLs for the

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SHEET 10 OF 20

feeder Outgoings to A&B unit service transformers

should be completed and found satisfactory.
7.6
For carrying out standard check lists and test

procedures which from a part of this testing
schedule, all equipments covered by this testing
shall be dead and isolated from all sources of
supply.
7.7
The associated DAS/Annunciation scheme is complete,

tested and in service.
7.8
The control supplies are available.

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SHEET 11 OF 20

8.0
COMMISSIONING PROCEDURE :
8.1.1
Carry out functional checks to prove the operation

of interlocks/inter-tripping between the 415 Volts
incoming and buscoupler breakers in each switchboard
& MCC
8.1.2
Carry out functional checks to prove the operation

of interlock and intertripping between the 11 KV
upstream
and
415
Volts
circuit
breaker
wherever
required.
GENERAL CHECKS:
i)
INSPECT ANY PHYSICAL DAMAGE IN THE BUSBAR,

INSULATION, PANEL DOORS, POWER & SLIDING CONTACTS
ETC. AND TO BE RECTIFIED IF FOUND
ii)
MAKING THE PANEL INSIDE DUSTFREE & FREE FROM FOREIGN

MATERIALS
iii) CHECKING THE TIGHTNESS ALIGNMENT & CLEARANCE OF BUS

BARS ,SMOOTHNESS IN RACKING IN & RACKING OUT OF
MODULES,PROPER MAKING OF SLIDING CONTACTS, TIGHTNESS

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SHEET 12 OF 20

OF INPUT POWER CABLES AND MODULE POWER CONTROL O/PS

& CONTROL INTERNAL WIRINGS
iv)
INSPECT ALL RELAYS AND MAKE SURE THAT ANY BLOCKING

USED FOR SHIPPING PURPOSE IS REMOVED AND THE
ARMATURE
v)
MOVES FREELY.
CHECK ALL DOORS FOR PROPER MOUNTING WITH RESPECT TO

THE SWITCH HANDLE.
vi)
CHECK DOOR INTERLOCK MECHANISM
vii) TEST THE PTs,CTs & RELAYS INVOLVED. KEEP THE

RECOMMENDED SETTINGS FOR THE RELAYS LIKE
OVERCURRENT, UNDERVOLTAGE & OVERLOAD PROTECTIONS,
CALIBRATE THE METERS (AMMETERS, VOLTMETERS, POWER
METERS & ENERGY METERS ETC)
viii) TEST THE INSULATION OF BOARDS WITH 500 V DC MEGGER &
THE VALUE SHOULD BE AS PER THE RELEVANT IS
SPECIFICATION (MORE THAN 5 MEGA OHMS)
ix)
CHECK CLOSING & TRIPPING INTERLOCKS,OVERLOAD RELEASE

SETTING OF ALL ACBs IN THE PANEL
x)
CHECK THE PROTECTION CIRCUIT WIRING CONNECTIONS BY

CONDUCTING PRIMARY INJECTION CURRENT
xi)
CHECK
THE INPUT POWER CABLE TERMINATIONS FROM
TRANSFORMER SECONDARY

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SHEET 13 OF 20

xii) ENSURE
THE PHASE SEQUENCE AND CT LINKS ARE PROPER
BEFORE CHARGING THE PANEL.

xiii)
CHECK CLOSING & TRIPPING MECHANISM OPERATES

SMOOTHLY BOTH MANUALLY AND ELECTRICALLY
xiv) SPACE HEATERS & THERMOSTAT SHALL BE IN GOOD

CONDITION

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SHEET 14 OF 20

8.2 ENERGISING CHECKS
8.2.1
Check that safety Notices have been displayed at the

test area and that the safety clearance certificate
has been issued and is effective.
8.2.2
Check
that
communications
have
been
stabilised
between 11 KV switchgear,415 Volts switchgear and

the UCB.
8.2.3
Ensure that the 11 KV and 415 Volts circuit breakers

for
charging
breakers
are
between
in
isolated
Emergency
position.
switchboard
Also
tie
No-1
and
buscoupler breaker at unit service switchboard No-1

are OFF and isolated.
8.2.4
Ensure that the 415 volts V.T.s for Section A & B

are in position and
8.2.5
Ensure
that
all
fuses
the
in service.
outgoing
feeder
breakers,
contactors and Isolators of 415 Volts switchgear are

off and isolated.
8.2.6
Ensure that the control circuit fuses for 11 KV and

415
volts
circuit
breakers
for
the
power
transformers and those for the 415 volts bus coupler

breaker of switchboard are put on.

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SHEET 15 OF 20

8.2.7
Ensure that protection relay settings are correct

for feeder VCBs at HT switchgear and incomers at LT
switchgear.
8.3 ENERGISING PROCEDURE:
8.3.1
Energise the 415 volts switchgear control circuit

bus
8.3.2
from its normal source of supply.
Put the 415 volts circuit breaker(Incomer 1) in test

position with selector switch in LOCAL
8.3.3
close and open the breaker from local and check that
the status indications are correct.
8.3.4
Carry out the tests 8.3.2 & 8.3.3 for the next
incomer and
buscoupler for the same LT
Switchgear.
8.3.5
Put the 11 KV breaker for power transformer - A in

test position with the selector switch to interlock
OUT position.
8.3.6
Close and open the 11 KV breaker from local and
check that status indications are correct

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SHEET 16 OF 20

8.3.7
Put the selector switch to interlock IN and close

and open the breaker from UCB and check that status
indications are correct.
8.3.8
Carry out the tests 8.3.6 8.3.8 for 11 KV breaker

Transformer B
8.3.9
Put the 11 KV breaker transformer A in service

position with the selector switch to interlock IN
position.
8.3.10
Close the 11 KV breaker from UCB to first
energise
the Power Transformer A

8.3.11
Open and close the 11 KV breaker
8.3.12
Note the ammeter for the transformer H.V side for

any
abnormal
current.
Check
the
transformer
externally for any abnormality.

8.3.13
If 8.3.13 is O.K.,put the 415 Volts breaker (Incomer

1) for Transformer A in SERVICE position with the
selector switch in REMOTE.
8.3.14
Close the 415 Volts Incomer 1 breaker from UCB to

first energise the section A of LT switchboard.
8.3.15
Note the ammeter in section A for any abnormal

current. Also note the voltmeter in SEC A and check
that the bus voltages are O.K. and that the under

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SHEET 17 OF 20

voltage
relays
are
in
picked
up(energised)
condition. Check phase rotation.

8.3.16
Check externally for any abnormality with the 415

Volts LT switchboard.
8.3.17
Initiate tripping through overcurrent relay on the

11 KV side and check that both the 11 KV and 415
Volts breakers of the power transformer A trip.
8.3.18
If 8.3.16 and 8.3.17 are O.K., put the 415 Volts

buscoupler breaker for LT switchgear in SERVICE
position with the selector switch in REMOTE
8.3.19
Close the 11 KV and 415 Volts breakers(Incomer 2)

for power transformer B in TEST position
8.3.20
Close the 415 volts buscoupler breaker from UCB to

first energise the section B of the LT switchgear
8.3.21
Note the ammeter in incomer-A panel for any abnormal

current. Also note the voltmeter in bus section B
for correct bus voltages.
8.3.22
Check that the undervoltage relays in section B are

in pickuped condition (energised) condition.
8.3.23
Check externally for any abnormality with the 415

Volts in bus section B
8.3.24
Switch off the bus coupler breaker

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SHEET 18 OF 20

8.3.25
If 8.3.22 to 8.3.24 are O.K., put the 11 KV breaker

for power transformer B in SERVICE position with
its selector switch to interlock IN
8.3.26
Close the 11 KV breaker for power transformer B from

UCB to first energise the transformer.
8.3.27
Open and reclose the 11 KV
8.3.28
Note
the
ammeter
on
the
breaker
11
KV
side
of
the
with
the
transformer for any abnormal current

8.3.29
Check
externally
for
any
abnormality
transformer B
8.3.30
If 8.3.29 and 8.3.30 are O.K., put the 415 Volts

breaker(Incomer 2) for Transformer B in SERVICE
position with its selector switches in REMOTE
8.3.31
Close the 415 volts breaker for the transformer to

energise the bus section B
8.3.32
Note the ammeter and voltmeter in bus section B for

any abnormal current and voltage.
8.3.33
Check phase rotation of B section and phase in &

phase out between section A & B
8.3.34
If
everything
with
the
transformers
and
the
LT
switchgear are O.K. keep the transformers and the

415 volts bus energised for 24 hours.

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SHEET 19 OF 20

8.3.35
After 24 hours check that there is no abnormality

with
the
transformers
and
the
415
Volts
LT
switchgear. Also check periodically bucholtz relay

for any chapped gas on in.
8.3.36
For MCCs & Aux. Control panels ,Upstream breakers

and interconnecting cables will come into picture in
stead
of
11
KV
outgoing
feeder
and
power
transformers.
9. COMPLETION CRITERIA
RESPECTIVE LT POWER TRANSFORMERS & 415 V SWITCHGEAR

PANELS
ARE CHARGED. VOLTAGE SUPPLY EXTENDED UPTO
SWITCHBOARD,MCC or ACP as the case may be AND VOLTAGES ARE

FOUND IN POSITIVE PHASE SEQUENCE WITH NO ABNORMALITY IN
CURRENT AND EXTERNAL BODY OF THE PANEL.

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SHEET 20 OF 20

10. APPENDICES
DRAWINGS
: SLD OF ELECTRICAL SYSTEM AUX POWER

DISTRIBUTION
SCHEMATIC DIAGRAM OF LT SWITCHGEARS (USS,MCC,ACP)
MANUALS
: O &
M MANUAL FOR LT SWITCHGEAR (PE-OM-186506-0328)
DATA FOR LT SWITCHGEAR (PE-OM-186-5060327)
LOG SHEETS :
I)
IR VALUES,BUS BAR RESISTANCE
VALUES
OF LT SWITCHGEAR
II)
TEST REPORT OF RELAYS,PTs,CTs INCLUDED IN

THE SYSTEM
III)
UNDERVOLTAGE,OVERCURRENT& EARTHFAULT
SETTINGS RECOMMENDED/KEPT

LT SWGR Test SCH

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STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO: SIM/1/TS/

PLANT AREA : ELECTRICAL SYSTEM

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO: SIM/1/TS/

PLANT AREA : ELECTRICAL SYSTEM

415 Volts LT switchgear consists of two bus sections A &

The Transformers get their supplies from 11KV unit

switchgear feeders TRF1 & TRF2.

415 Volts Unit

the boilers and turbine

(MCCS) Soot blower MCCs,Battery chargers(220 V ,24 V DC)

single line diagram of the Unit service switchboard

2000 KVA UNIT

2000 KVA UNIT

415 UNITS SERVICE

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO: SIM/1/TS/

PLANT AREA : ELECTRICAL SYSTEM

LT SWITCHGEARS in NTPC Simhadri Project:

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO: SIM/1/TS/

PLANT AREA : ELECTRICAL SYSTEM

service switchgear are to ensure that the equipment has

specifications and is to the appropriate Indian, NTPC and

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO: SIM/1/TS/

PLANT AREA : ELECTRICAL SYSTEM

equipments and it is proposed that these will be checked

detailed in the testing schedule.

The 415 V unit service bus sections B&C will be charged

Other LT switchgears are thereafter charged as per the

It will be the duty of the Testing team leader to ensure

recording the results of inspection and a copy attached

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO: SIM/1/TS/

PLANT AREA : ELECTRICAL SYSTEM

In General for carrying out these tests the services

the items listed below are required variable 220

and 415/240 Volts A.C supplies.

INSULATION TESTER 500V DC- HAND OPERATER

MICRO OHM METER.

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO: SIM/1/TS/

PLANT AREA : ELECTRICAL SYSTEM

5.1 SAFETY OF THE PLANT :

The test method must be strictly adhered to at all

SAFETY OF THE PERSONNEL :

associated with this testing/commissioning schedule

There should be safe access to and escape routes

The area under test should be clearly defined.

Access to the area under test should be restricted,

Permanent and adequate lighting facilities should be

should be properly fitted/replace.

The test area should be clear of obstructions.

Safety clearance certificates and safety clearance

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO: SIM/1/TS/

PLANT AREA : ELECTRICAL SYSTEM

It will be the responsibility of the testing team leader

Telephone numbers for first aid/ambulance, fire stations

First aid charts for treatment of electrical shock should

In the event of any sign of abnormality, the source of