STANDARD EQUIPMENT MANUAL

POWER TRANSFORMERS AND OIL FILLED REACTORS

CHECKLIST FOR
FUNCTIONAL ACCEPTANCE TEST IN THE
FACTORY AND PRE-COMMISSIONING
TEST ON SITE

SUBSTATION DESIGN STANDARDS

Document Number: A472649
Revision Number: 3.0 Revision Issue Date: 21/7/2014
Prevision Revision No. 2.0 Approved By: Lagath Ganepola

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Manufacturer: - ………………………….. Rating - ………………………………………

Serial Number: - …………………………...
Site: - ……………………………
Contract: - ……………………………
Project: - ……………………………

The functions, controls, alarm and trip circuits have been tested and found to be in working condition. The
timer and other control settings have been left as stated on following pages.

It remains the Contractor's responsibility to ensure full compliance with all the specified requirements under
the Contract including any TIRs and contract variations. It is also the Contractor’s responsibility to perform
any additional checking and testing, if required, to ensure that the equipment is fit for service. Powerlink
accepts no responsibility for any omissions or oversights in this checklist or during functional checking.
Further it is noted that the contractual provisions relating to the submission of Contractor supplied
documents continue to apply.

Manufacturer Representative

……………………………………………….. …………………………..
Manufacturer Representative / Installation
Contractor (Print name and sign off) Date

Program for On Site Inspection and Test:

(or similar in agreement with both parties in advance and indicated in approved Site Inspection and Test Plan)

At Delivery – Initial Inspection, Vapour Pressure Test…

Before Oil Fill – Inspection, Oil and Vacuum Log, Oil Test Moisture and Dielectric Breakdown,
Functional test (Oil Level, Bag Rupture & Buchholz contacts are ON)

Pre-commissioning - Day 1
Tailgate Meeting
Oil Leak Check after 24 h Pressure Test
Inspection General
Mechanical Inspection
Functional Test

Pre-commissioning - Day 2
Functional Test Continuation
(Must be fully finished before start of Electrical Test)
Equipment data collection
Remedy issues from first day inspection
CTs Test
Paint Dry Thickness Test on touch up/repair job

Pre-commissioning - Day 3
Electrical Test in order below:
(Mag. Current > IR > DC Res. > Continuity check TV E to internal earth > DLA Tank > DLA Bushings > SFRA)

Note: There shall be no pumps operation, TC operation or 10 kV testing while transformer is pressurised or under vacuum!

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Function
Mechanical/Visual Check on Arrival
Impact Recorder Check and Interpretation
Oil test results before vacuum oil fill in
This test to be witnessed by Powerlink’s
representative before start of fill in, for each of
bulk supplies. Oil polish – minimum one pass
before test for each bulk supply.
Oil sample taken before vacuum oil fill (2x
500ml)
Temporary Earthing Connection in place
Dry Air Pressure (on Arrival ~0.3bar@20’C)
Vacuum Filling
Arrival inspection Log provided – External
Arrival inspection Log provided – Internal
Point to point check for secondary wiring prior
to start of Functional Test
Bag Rupture Device, Oil Level Indicators and
Buchholz Relay contacts checked in terminals
to be in an appropriate position before oil fill.
Specification for Paint Touch Up
Mechanical/Visual Check
Equipment Serial Numbers
24 H Pressure Test (Oil Leak Test)
Conservator Bag Set Up
Terminal Boxes
Visual Check Before Crew Evacuation
Control / CT / OLTC Cubicles
Silica Gel Breather, Oil Bath Level
All labels and signs in place
Paint / Touch-up – follow Paint Repair Spec
procedure
Valve Diagram Plate
Radiators Butterfly Valves
All HV, LV, TV, N and n bushing terminals
shorted and earthed for induction purposes.
Oil Samples taken from the Main Tank (top
and bottom - 2 x 500ml) and TC (2 x 500ml)
before departure
Oil Samples taken from the Main Tank (top
and bottom - 2 x 500ml) and TC (2 x 500ml)
before departure
Blanking Plates on pallet and stored on
agreed location within substation boundaries.
Site to be clear from rubbish and material and cleaned
before departure from the site. All swarf removed.
All cubicles cleaned and swarf removed.
Set Point /
Check
To be presented to Powerlink Office immediately
after delivery
Valid Laboratory Calibration Certificate for Test
Equipment shall be available at site!
Oil Dielectric Breakdown > 60 kV as per IEC 60156
Moisture in Oil < 10 ppm
To be labelled and delivered as soon as possible Oil Temp.
to Powerlink Oil Lab. Record oil temp.
Log to be presented on site
Log to be presented on site
Log to be presented on site
Log to be presented on site
Log to be presented on site
This test to be witnessed by Powerlink’s
representative before start of fill in.
To be presented on site
Use Equipment Data Collection Sheet, prepared
and provided by the Manufacturer - confirm
bushings are in right position.
50 kPa above head of oil
(0.5bar, 375mmHg, 7.25 PSI)
Follow manufacturer’s instruction. Check alarm
before and after set up. Log to be presented on
site.
Ensure all terminal boxes are water proof – cable
entry from the bottom, water drain pin halls on the
bottom, glands water proof etc.
Pocket provided – drawings in
Colour, oil level correct
Confirm
Confirm finished and OK in accordance to Paint
Repair Spec / perform dry film thickness test
Check all valves are in for ‘Operation’ position
Open
Use min. 95 mm2 Cu wire.
After all electrical test finished.
To be labelled and tested by the Contractor as per Oil Temp.
Specification. Record oil temperature.
To be labelled and delivered to Powerlink Oil Lab. Oil Temp.
Record oil temperature.
Location to be discussed and agreed with the
Principal or Construction Manager or follow
minutes from pre-delivery on site meeting.
Confirm OK
Confirm OK
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Function Set Point /

Check
CTs
Withstand 2kVrms AC / 1 min. – CT’s Factory Test - All
secondary cores – from the CT Marshalling Site Test – Not Required
and Main Control Cubicle terminals

Insulation Resistance 500 VDC / 1 min. shall Factory Test – Not Required
be measured between CT’s secondary cores Site Test – All
(all taps shorted) to ground – from the CT
Marshalling and Main Control Cubicle
terminals

CT Resistance measured from the CT Refer also to drawing and check terminal
Marshalling Box terminals numbers are correct.

CT Polarity and CT Ratio measurement from Factory Test - All

the terminals in the CT Marshalling Cubicle. Site Test – Shall be done where secondary cables
are disconnected for transportation. Refer also to
drawing and check terminal numbers are
correct

Secondary winding magnetizing curve Factory test only

Peak secondary open circuit voltage Factory test only or CT Manufacturer’s test results

CT Shorts removed from the WTIs and Lockout

CTs or any other loaded CTs

Check continuity for WTI, TC Lockout or any

other loaded CT circuit
CT shorts in place for all non loaded CTs Shorts shall be hard wired under terminal screws
on X20 and X27 interface strips on Powerlink’s
interface side. Shorts shall be visible (i.e. not
provided via adjacent wire duct)
Check continuity between Earth bar and CT’s
earthed terminals. Refer to drawings.

Check CT cable screens are earthed on both

ends

Check all spare cable cores are earthed on

one end only - at the CT cubicle end!

Check that compression blade type lugs are

used for all CT cable cores

Check only SAKC10 are used for CT terminals

and no more than two cores are terminated in
each terminal block

Check that proprietary links are not used for

CT terminals

Check that numbered ferrules are used and

coded correctly as per A1-H-132097-03

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Function Set Point

Check
Main Control Cubicle
Withstand 2kVrms AC / 1 min. – Secondary Factory Test - All
Wiring – CT Marshalling and Main Control Site Test – Not Required
Cubicle terminals

Cubicle Light
Cubicle Cooling Fan(s) Stage 1 Thermostat settings (on 50 ºC) ºC
Cubicle Cooling Fan(s) Stage 2 where appl. Thermostat settings (on 55 ºC) ºC
Cubicle Condensation Heater Thermostat settings (off 35 ºC) ºC

Urgent Circuit Supply Fail

Main Isolator M1 Operate at full current load On/Off
Pump and Fan Supply CBFP Trip Terminals X14: 80 – 82
Pump Supply CBP trip Terminals X14: 80 – 82
Pump Control CBPC Trip Terminals X14: 80 – 82
Fan Supply CBF Trip Terminals X14: 80 – 82
Fan Control CBFC Trip Terminals X14: 80 – 82
Phase Failure Relay CBPFR Trip Terminals X14: 80 – 82
Main Supply CB1 Trip Terminals X14: 80 – 82
Transducer Supply CB Trip (if applicable) Terminals X14: 80 – 82

Non Urgent Circuit Supply Fail

CT Marshalling Cubicle Supply CBMC Trip Terminals X14: 80 – 83
Main Control Cubicle Atmospheric Control Terminals X14: 80 – 83
CBC Trip

CT Marshalling cubicle Atmospheric Control Terminals X14: 80 – 83

CBC Trip

TC Motor or Control Supply Failed

Tap Changer Motor Thermal Protection Q1 Terminals X14: 18 – 21
Tap Changer Supply Fail CBTC Terminals X14: 18 – 21
Tap Changer Control Supply Fail CBTCC Terminals X14: 18 – 21

Phase Failure Relay

PFR settings to be verified at Factory and on Rated volts 400 VAC VAC
Site Operates on -15% %
Time delay 10 Sec. Sec.
400 V AC Phase Failure Alarm (loss of one or Terminals X14: 80 – 81
two or three phases, under voltage)
Phase rotation correct Confirm
Ensure that phasing is correct for temporary Confirm
400 VAC power supply when connected in
factory or on site
Operate Pumps, Fans and TC Motor @ 340 Factory Test Only
VAC for 10 min. or 10 operations No CB trip shall be observed
Fan Control Locked Out when PFR activated Confirm OK
Pump Control Locked Out when PFR Confirm OK
activated.
OLTC Control Locked Out when PFR Confirm OK
activated.

Phase Failure Flag

Operates on phase failure Flag can be reset manually only

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POWER TRANSFORMERS AND OIL FILLED REACTORS

Function Set Point

Check
Pumps Control Circuits
Pumps Run Manual Test On/Off – SW2 Check Rotation, Noise, Cavitations, Soft Start
for each Pump - SW3 – confirm OK

Oil Flow Failure Timer P1T Timer Setting (10 sec.)

Sec
Oil Flow Failure Alarm - Terminals X14: 30 - 62
Pump Change Over (oil flow failure) Test both Pumps SW3

Pump 1 Run Indication Terminals X14: 30 – 51

Pump 2 Run Indication Terminals X14: 30 - 53
Pump 1 Fail Indication Terminals X14: 30 - 52
Pump 2 Fail Indication Terminals X14: 30 - 54
Pump Local Indication Lights Confirm OK

Pump Run Auto – SW2 OTI Setting ON (70 ºC) ºC

Activation by OTI contacts OFF (60 ºC) ºC

Activation by operating HV WTI contacts HV WTI Setting ON (70 ºC) ºC

OFF (60 ºC) ºC
Activation by operating LV WTI contacts LV WTI Setting ON (70 ºC) ºC
OFF (60 ºC) ºC
Activation by operating TV WTI contacts TV WTI Setting ON (70 ºC) ºC
OFF (60 ºC) ºC
Activation by Current Injection Current Sensing Rel. Setting ON Amp
Activation by Current Injection (as above) and Winding Gradient Change Over Relay WTIG–
by OTI & WTI contacts (as above) confirm operates OK
Pump Start Delay Timer PCDT (On Delay) Time Setting (30 sec.) Sec
Pump Minimum Run Timer PMRT (Off Delay) Timer setting (30 min) Min
Pump starts 10 off Cold
Pump starts 10 off Hot Factory Test Only

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Function Set Point

Check
Cooler Fan Controls
Fans Run SW1 in Manual Rotation, Noise, Correct Groups & Order–
Test On/Off –individual and groups check for all Groups and Fans and confirm OK
Fan Group Start Timers Group 1 setting Sec
Group 2 setting Sec
Group 3 setting Sec
Group 4 setting Sec
Group 5 setting Sec
Group 6 setting Sec
Group 7 setting Sec
Group 8 setting Sec
Group 9 setting Sec

Fans Run SW1 in Auto

Activation by operating OTI contacts OTI Setting ON (75 ºC) ºC
OFF (65 ºC) ºC
Activation by operating HV WTI contacts HV WTI Setting ON (75 ºC) ºC
OFF (65 ºC) ºC
Activation by operating LV WTI contacts LV WTI Setting ON (75 ºC) ºC
OFF (65 ºC) ºC
Activation by operating TV WTI contacts TV WTI Setting ON (75 ºC) ºC
OFF (65 ºC) ºC
Activation by Current Injection Current Sensing Rel. Setting ON Amp
Activation by Current Injection (as above) and Gradient Change Over Relay WTIG– confirm
by OTI & WTI contacts (as above) operates OK
FOR ONAF JOBS ONLY!
Fans Minimum Run Timer FMRT (Off Delay) Timer setting (30 min) Min
Fans Start Delay Timer FCDT (On Delay) Time Setting (30 sec.) Sec

Remote Fan Indication

Fan Group 1 Run Terminals X14: 30 - 31
Fan Group 2 Run Terminals X14: 30 - 32
Fan Group 3 Run Terminals X14: 30 - 33
Fan Group 4 Run Terminals X14: 30 - 34
Fan Group 5 Run Terminals X14: 30 - 35
Fan Group 6 Run Terminals X14: 30 - 36
Fan Group 7 Run Terminals X14: 30 - 37
Fan Group 8 Run Terminals X14: 30 - 38
Fan Group 9 Run Terminals X14: 30 - 39
Fan Group 1 Fail Terminals X14: 30 - 41
Fan Group 2 Fail Terminals X14: 30 - 42
Fan Group 3 Fail Terminals X14: 30 - 43
Fan Group 4 Fail Terminals X14: 30 - 44
Fan Group 5 Fail Terminals X14: 30 - 45
Fan Group 6 Fail Terminals X14: 30 – 46
Fan Group 7 Fail Terminals X14: 30 - 47
Fan Group 8 Fail Terminals X14: 30 - 48
Fan Group 9 Fail Terminals X14: 30 – 49
All Fans Fail Alarm Terminals X14: 30 - 40
Fans and Pumps in Auto control Terminals X14: 30 – 50
Local Indication Lamps Confirm OK for all Fans and Groups

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Function Set Point

Check
Temperature Settings/Alarms/Trips
OTI Alarm ON (95 ºC) Terminals X14: 30 – 63 ºC
OFF (85 ºC) ºC
OTI Trip ON (115 ºC) Terminals X13: 11 – 12 ºC
OFF (105 ºC) ºC
OTI Transducer indication: - 40º ~ 8 mA Terminals X15: 10 – 11 mA
80º ~ 12 mA Terminals X15: 10 – 11 mA
120º ~ 16 mA Terminals X15: 10 – 11 mA
150º ~ 20 mA Terminals X15: 10 – 11 mA
Verify top oil temp reading FAT: Compare with Glass in Oil Thermometer
SAT: Compare with Ambient Temperature and
other WTI
HV WTI Alarm ON (110 ºC) Terminals X14: 30 – 64 ºC
OFF (100 ºC) ºC
HV WTI Trip ON (135 ºC) Terminals X13: 13 - 14 ºC
OFF (120 ºC) ºC
HV WTI Transducer indication: - 40º ~ 8mA Terminals X15: 4 – 5 mA
80º ~ 12 mA Terminals X15: 4 – 5 mA
120º ~ 16 mA Terminals X15: 4 – 5 mA
150º ~ 20 mA Terminals X15: 4 – 5 mA
Verify HV WTI temp reading FAT: Compare with F/O Thermometer
SAT: Compare with Ambient Temperature and
other WTI
Shunt Setting / Calibration Current Injection to observe correct HS Gradient Reading
0
(keep cover mounted, feed a stable current ONAN HSGr. = ……….. C I= …………A ºC
0
and wait 30 min. before reading Gradient) ODAN(F) HSGr. = ……….. C I= …………A ºC
LV WTI Alarm ON (110 ºC) Terminals X14: 30 – 65 ºC
OFF (100 ºC) ºC
LV WTI Trip ON (135 ºC) Terminals X13: 15 – 16 ºC
OFF (120 ºC) ºC
LV WTI Transducer indication: - 40º ~ 8 mA Terminals X15: 6 – 7 mA
80º ~ 12 mA Terminals X15: 6 – 7 mA
120º ~ 16 mA Terminals X15: 6 – 7 mA
150º ~ 20 mA Terminals X15: 6 – 7 mA
Verify LV WTI temp reading FAT: Compare with F/O Thermometer
SAT: Compare with Ambient Temperature and
other WTI
Shunt Setting / Calibration. (keep cover Current Injection to observe correct HS Gradient Reading
0
mounted, feed a stable current and wait 30 ONAN HSGr. = ……….. C I= …………A ºC
0
min. before reading Gradient) ODAN(F) HSGr. = ……….. C I= …………A ºC

TV WTI Alarm ON (110 ºC) Terminals X14: 30 – 66 ºC

OFF (100 ºC) ºC
TV WTI Trip ON (135 ºC) Terminals X13: 17 – 18 ºC
OFF (120 ºC) ºC
TV WTI Transducer indication: - 40º ~ 8 mA Terminals X15: 8 – 9 mA
80º ~ 12 mA Terminals X15: 8 – 9 mA
120º ~ 16 mA Terminals X15: 8 – 9 mA
150º ~ 20 mA Terminals X15: 8 – 9 mA

Shunt Setting / Calibration Current Injection to observe correct HS Gradient Reading

0
(keep cover mounted, feed a stable current ONAN HSGr. = ……….. C I= …………A ºC
0
and wait 30 min. before reading Gradient) ODAN(F) HSGr. = ……….. C I= …………A ºC

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POWER TRANSFORMERS AND OIL FILLED REACTORS
Function Set Point
Check
Fibre Optic Probes
Verify F/O probes temp reading Factory Test Only. Compare to other available
instrumentation and measured/calculated
temperatures during heat run.

Oil Level Indicators

Main Tank High Oil Alarm Terminals X14: 30 – 68
Main Tank Low Oil Alarm - before oil fill Terminals X14: 30 - 67 On
Main Tank Low Oil Alarm - after oil fill (by Terminals X14: 30 - 67 On
putting short on contacts) Off
OLTC High Oil Alarm Terminals X14: 18 – 24
OLTC Low Oil Alarm - before oil fill Terminals X14: 18 – 23 On
OLTC Low Oil Alarm - after oil fill (buy putting Terminals X14: 18 – 23 On
short on contacts) Off
Oil Level Indicator - Main Tank Correct
Oil Level Indicator - OLTC Correct
Oil Level Indicators - Bushings Correct

Buchholz Relay
Oil Surge Trip - before oil fill Terminals X13: 1 – 2 On
Oil Surge Trip - after oil fill (plunger) Terminals X13: 1 – 2 On
Off
Low Oil Trip - before oil fill Terminals X13: 3 – 4 On
Low Oil Trip - after oil fill (plunger) Terminals X13: 3 – 4 On
Off
Gas Alarm - before oil fill Terminals X14: 30 - 61 On
Gas Alarm - after oil fill Terminals X14: 30 - 61 On
Off

Conservator Bag
Rupture Alarm - before bag set up Terminals X14: 30 - 70 On
Rupture Alarm - after bag set up Terminals X14: 30 - 70 Off
On
Check bag rupture relay alarm after pressure Terminals X14: 30 - 70
tests. (Conservator must be bled before
pressure test)

Pressure Relief Devices

Main Tank 1 Trip Terminals X13: 5 - 6
Main Tank 2 Trip Terminals X13: 5 – 6
OLTC Pressure Relief 1 Trip Terminals X13: 9 – 10
OLTC Pressure Relief 2 Trip Terminals X13: 9 – 10
OLTC Pressure Relief 3 Trip Terminals X13: 9 – 10
OLTC Pressure/surge Relay 1 trip Terminals X13: 7 – 8
OLTC Pressure/surge Relay 2 Trip Terminals X13: 7 – 8
OLTC Pressure/surge Relay 3 Trip Terminals X13: 7 – 8

CT Metrosil
Thermal Short Operated Alarm Terminals X14: 80 - 84 Off
On

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Function Set Point

Check
Tap Changer Operation

Manual Operation Local - Up and Down Confirm OK

Remote Raise Terminals X12: 12 - 11
Remote Lower Terminals X12: 12 - 13
Upper limit
Lower limit
Electric lock out with manual Handle Inserted
Tap Indication Operating
Counter operating
Heater
Light
Number of operation Record Counter Number
Tap Changer Lockout Relay Confirm TC locked
Activation by Current Injection Current Setting ON Amp

TC Alarms

Tap Changer NOT at Remote Terminals X14: 18 – 19

Tap Change In Progress Terminals X14: 18 – 20
Tap Changer Lockout Terminals X14: 18 - 22
Tap Changer out of Step Terminals X14: 18 - 25

Remote Tap Indication

Binary Indication Analogue Indication
Enter: X – High O - Low
Tap Terminals Terminals Terminals Terminals Terminals 4-20 mA
No. X14: 2-3 X14: 2-4 X14: 2-5 X14: 2-6 X14: 2-7 X15: 1-2
1 2 4 8 16
1 X
2 X
3 X X
4 X
5 X X
6 X X
7 X X X
8 X
9 X X
10 X X
11 X X X
12 X X
13 X X X
14 X X X
15 X X X X
16 X
17 X X
18 X X
19 X X X
20 X X
21 X X X

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Minor Defect List

10

11

12

13

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14

15

16

17

18

19

20

21

22

23

24

25

26

27

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