11KV Switchgear SA and SB

NTPC TESTING SCHEDULE TELANGANA
O&M COMMISSIONING DEPARTMENT
STATION: NTPC-TELANGANA,ST-I 2X800MW UNIT:

SYSTEM: 11KV Station Switchgear
LOCATION: 3.5Mtrs AB Bay
ITEM LIST OF CONTENTS

1.PLANT DETAILS
2. COMMISSIONING OBJECTIVES
3.COMMISSIONNIG PROPOSALS
4.SERVICES REQUIRED
5.SAFETY
6.EMERGENCY PROCEDURES
7.STATE OF PLANT
8.COMMISSIONING METHOD
9.PROGRAMME
10.RESULTS
11.REINSTATEMENT & PRESERVATION
12.STAFFING RESPONSIBILITIES & COMMUNICATIONS
13.APPENDICES
Schematic Drawing

ITEM PLANT DETAILS

1.0
1.1 Station Transformer of 130/65/65MVA 400/11.5/11.5KV duel secondary
transformer will feed the two nos of 12KV 3600A Station Switchgear SA and
SB. The Station Transformer is located in transformer yard area outside A Row
beside Generator Transformers.
There is a provision for charging of station boards (1SA and 1SB) from
Construction power with power cable. Further, a Tie is also provided for
forming station grid i.e to import/ export of power from one unit to other unit
(1SA-2SA) and (1SB-2SB). One Tie panel is envisaged for charging of Unit
switchgears UA and UB with SA and SB boards respectively via 11KV, 2800A
bus duct.
The following Motors/ Transformers/Switch boards fed from 1SA Board:
i) Compressor service Transformer-1

ii) Fire water service T/F-1
iii) Station service T/F-1
iv) ESP T/F-1G
v) Feeder to 11KV CHP Board
vi) Feeder to 11KV DM/PT/RW board
vii) Switchyard service T/F-1
viii) Aux. boiler T/F-1
ix) MDBFP-1B (Future)
x) FGD (Future)
xi) Excitation T/F

The following Motors/ Transformers / Switch boards fed from 1SB Board:
i) Feeder to 11KV AHP Board

ii) MDBFP-1A
iii) FGD Future
iv) Station Service T/F-2B
v) Bunker Service T/F-1
vi) Service Building T/F-1
vii) Workshop T/F-1
viii) Fuel Oil Service T/F-1
ix) ESP T/F-1H
AC/ DC Supply Details:
DC Feeder 1: AC Feeder 1:
DC Feeder 2: AC Feeder 2:
Switchgear Details:
Make: ABB, Nashik
Breaker: Vacuum
Rated /Service Voltage: 12KV/11.5KV
Rated Current Rating:3600A


ITEM
TESTING OBJECTIVES
2.0
2.1 To ensure that HT switchgear panels and bus ducts are correctly
assembled, erected and tested in accordance with good engineering
practices.
2.2 To ensure that equipments and all its components conform to the
specifications agreed in the terms and conditions of the contract.
2.3 To prove the equipments are capable of operation under service conditions.
2.4 To provide record for future reference.
2.5 To prove all controls, interlocks and safeguards.
2.6 To ensure the equipment is charged and is ready for energizing the
outgoing feeders as required.
ITEM TESTING PROPOSALS.

3.0

3.1 Testing will be carried out for all the individual 12 KV Vacuum breakers
contained in 11 KV switch gear room as per their standard check list and
test procedures.
3.2 All relays and protection/control circuit will be tested according to their
standard check lists and testing procedures. Different inter locks as per the
scheme will be proved.
3.3 It will be the duty of the testing team leader to carry out detail possible
inspection while all the equipments are in service to ensure that they are
functioning satisfactorily, in case of any sign of stress or abnormality the
same is to be recorded for necessary rectification/replacement by the
supplier/manufacturer through erection and a copy of the results of their
inspection and rectification is to be attached as an annexure to this
schedule.
ITEM SERVICES REQUIRED

4.0

4.1 220 V D.C supplies from DC Distribution board for protection and control
ckts.
4.2 AC supplies from Station ACDB.
4.3 All test sets and equipments required for testing of individual equipments
as detailed in respective of standard check list and test procedures (Brief
list of testing equipment required are as follows).
i) Primary injection kit.
ii) Secondary injection kit.
iii) Single phase transformer 600/230V
iv) Clamp Meter and Multi Meter.
v) DC Hi Pot kit for conducting
vi) Single Phase Variac.
vii) Contact Resistance Measurement kit.
viii) Breaker Timing Kit.
ITEM SAFETY
5.0

5.1 The Engineer in charge of the testing team will inform to each member
of his team as to the exact nature and extent of his contribution and
responsibilities towards the tests carried out .
5.2 Only the nominated persons will take part in the tests. All others will keep them
away from the defined test area.
5.3 All persons must acquaint themselves with use and location of fire
extinguisher and first aid posts.
5.4 Adequate lighting facilities will be provided.
5.5 Each test will be carried out under the control of the team leader.
5.6 A strict and safe method of using test leads shall be practiced. Bare wires shall
not be inserted into sockets.
5.7 A record note of alteration made during the test such as shorting and
disconnections, shall be made and annexed to relevant test procedures.
5.8 Each test will be carefully planned and carried out so that there is no danger
of mechanical or electrical damage to the equipment under test . There
will be safe and easy access to all equipment under test. Test area will be
kept clean and clear of all obstructions.
5.9 During HIGH VOLTAGE test the area will be cordoned off. Danger/Warning
notices shall be fixed at relevant points to ensure safety.
5.10 Incomer breakers shall be kept in withdrawn position.
5.11 The operating personnel must be kept informed of the program of
testing.
5.12 Safety clearance certificate and safety clearance notifications should be in force
for the installations to be energized.
5.13 Operating procedure should be displayed in the switch gear room.


5.14 Availability of fire extinguishers at the time of charging and in operation.
5.15 First aid charts for treatment of electrical shock should be displayed at the test
area/switch gear room. Telephone numbers of first aid/ambulance, fire station
and hospitals should be permanently displayed near every telephone.
ITEM EMERGENCY PROCEDURE

6.0

6.1 First aid chart for acid injury and electric shock will be displayed.
6.2 In case of any accident involving acid burn neutralizing solution must be
applied.
6.3 All the persons working on battery shall wear acid proof aprons.
6.4 All the members of Testing team and persons associated with this Testing
6.5 Schedule should be familiar with the testing procedures and the equipments
involved in testing.
6.6 There should be safe access to, and escape routes from confined areas.
6.7 The area under test should be clearly defined.
6.8 Access to the area under test should be restricted. Proper caution boards should
be displayed at the test area.
6.9 Permanent and adequate lighting facilities should be available at all times.
6.10 All handrails, stairs, guards and trech/ manhole covers should be properly fitted/
in place.
6.11 The test area should be clear of obstructions.
6.12 Safety Clearance Certificates and Safety Clearance Notifications should be in
force for the equipments to be energized.
6.13 Operating staff should be kept informed of the programmes of testing.
6.14 It will be the responsibility of the testing team leader to instruct all members of
the testing team what actions are to be taken in the event of fire, accident or
other major incident.
6.15 Telephone numbers of First Aid/ Ambulance Fire Station and Hospitals should
be permanently displayed near each telephone.
6.16 In the event of any sign of abnormality, the source of supply for the particular
area/ equipment should be immediately isolated.


ITEM
STATE OF THE PLANT
7.0
7.1 Installation of switchgear is completed in all respects and necessary


FQA checks are completed (Protocol to be provided).
7.2 Installation of connecting bus duct is completed and necessary FQA

checks are completed (Protocol to be provided).
7.3 For carrying out SCL’s and testing procedures which from a part of this
Testing Schedule, all the equipments covered by this schedule shall be dead
and isolated from all sources of supply.
7.4 TRF I/C and TIE Bkrs are in withdrawn position and castle keys are kept
away in a secured place.
7.5 All circuit breakers of the switch gear concerned are in withdrawn
position.
7.6 Clearances are accorded from erection for carrying out testing.
7.7 Upstream source is isolated.
7.8 Both control supply is available (220V DC and 24V DC)
7.9 Single phase AC supply is available at panel.
7.10 Area illumination is adequate.
7.11 Working group should be formed.
ITEM
TEST METHOD
8.0
Checks and Tests To be Carried out:
1. Ensure that switchgear factory test reports are submitted and Vacuum

circuit breaker test report is also submitted.

2. Ensure that checks and tests of individual breakers (as per
manufacturer’s recommended format) are carried out in presence of
commissioning representative and reports are submitted.
3. Ensure that all CTs and PTs are tested in presence of commissioning
representative and reports are submitted.
4. Ensure that all protective relays are tested in presence of
commissioning representative, recommended settings are done
(marking should be available) and reports are submitted.
5. 100% bus bar tightness checking will be done in presence
commissioning representative.(FQA Protocol to be submitted).
6. Ensure smoothness of rack IN/OUT mechanism by physical operation,
also ensure mechanical I/L to prevent over travel.
7. Check insertion of contact by impression method.
8. Ensure same locks are provided both on the rear and front side of one
particular panel and those are working.
9. Ensure general cleanliness of bus bar cabinet and breaker.
10. Ensure smooth rack IN/OUT mechanism of PT trolley by operating the
same and also ensure contact matching by impression method.
11. Synchronization circuit checking for auto changeover.
12. Check IR value of both DC supply cables and AC supply cable at bus
VT module by isolating them at both ends and also do Continuity test
for these cables (put a sticker of feeder detail on the bus VT panel) .
13. Check DC supply coupling diodes for correct polarity and resistance.
14. Ensure and measure DC voltage (control supply, P-E, N-E & PN) from
individual source and both sources. If DC earth is observed, remove it.
15. Ensure that control fuses and PT fuses provided are of proper rating.
16. Ensure that check nuts are provided at ON/OFF indication (flap
switch) operating rod.
17. Ensure correct operation of DI contacts for all breakers by Millimeters.

18. Check polarity and confirm continuity of KFC1/KFO1 diodes from
relay end.
19. Ensure that CT/PT secondary terminal connections are tight.

20. Check CT terminal s connection (these are disconnecting type TBs)

and tightness.
21. Check TB tightness and their lugs.
22. Check rear door opening I/L for I/C with PT Voltage.
23. Check Operation of breaker both at test and service position (at service
by pressing KFC1/KFO1)
24. Ensure that 4mA transducer output is available at both the output TBs
(this is to be checked after switching on the DC supply).
25. Check the E/S I/L for I/C breaker and also E/S operation.
26. See that under voltage protection checking for motors is done.
27. See that reverse blocking scheme checking for motors and transformer
feeders is done.
28. PT IN-CIRCUIT Test
Keep PT module in racked out condition and do Meggering
continuously by 500 V megger from one end of the switch gear then
put PT in service and observe IR value for ZERO, repeat it for other
phase combination.
29. Check trip logic (electrical) for upstream I/C breaker to downstream
I/C breaker.
30. Check downstream breaker CLOSE permissive with upstream breaker
ON.
31. Check downstream breaker CLOSE permissive with upstream breaker
E/S Open.
32. Check availability of 1-phase AC supply at all panels.
33. Ensure that charging clearance protocol is prepared and duly signed by
AGENCY, EE & COMMISSIONING.
34. Ensure that ECC, SRCC & RIOC are prepared.
35. Collect minimum 02nos operating handles and 01 manual spring
charging handle.
36. Check phase sequence at VT module. If both UA & UB buses are
charged do phasing out of bus voltages at VT modules – record Ra-Rb,
Ra-Yb, Ra-Bb, Ya-Rb, Ya-Yb, Ya-Bb
37. All other pre-commissioning tests carried out by the agency will
be integrated part of the commissioning report. And all such
tests are to be carried out in presence of commissioning

personnel.
38. Ensure that AC/DC higt pot test (high voltage test) is carried out
and following format is filled up.
39. Checking general cleanliness by opening inspection covers of bus
duct.
40. Check end termination tightness and clearance. Also ensure that
bi-metallic strips are provided if material of bus duct and same of
bus bar are different.
41. Ensure that breathers are provided and silica gel color is blue.
42. Check IR value of heater circuit.
43. Water tightness test for outdoor portion of bus duct by fire hose.
44. Air tightness to be carried out bus duct.
45. Check with Multi-meter phase to earth openness of bus before
charging.
46. Ensure that no part of bus duct is open and supports are
permanent.
47. Ensure that bus duct earthing is done.
TESTS ON BUS BAR
AC/DC Hi-pot of Bus bar (To be done in presence of FQA) :
Pre HI-POT HI-POT HI-POT Time Leakage Post HI-POT

IR with 5kV phases Voltage MIN current IR with 5kV
R-E R-(B+Y+E) R-E
Y-E Y-(R+B+E) Y-E
B-E B-(R+Y+E) B-E
R-Y R-Y
R-B R-B
B-Y B-Y
IR value checking of Bus bar (pre charging) with 5KV megger :


With breakers in TEST position With breakers in SERVICE and

ON condition
R-E R-E
Y-E Y-E
B-E B-E
R-Y R-Y
R-B R-B
B-Y B-Y
Milli volt Drop test of Bus bar Joints :
Current Joint No./ mV Micro-ohm Remarks

injected identification
ITEM
PROGRAM
9.0

9.1 When STATE OF THE PLANT is as per checks of item no. 6 and
necessary approval is obtained from commissioning panel , the
tests can then be carried out in accordance with the agreed
program and as per the directive of the team leader. All the concerned
parties involved in test will be requested by the commissioning
team to work as per the program.
9.2
Date of commencement of the test shall be decided in the working group
meeting.
ITEM
RESULTS
10.0

10.1 On completion, the check lists and test procedures used for 11KV
switchgear will be filed with their unique number/identification as
enclosure of it.
ITEM
REINSTATEMENT & PRESERVATION.
11.0

11.1 When breakers are not required for service, they shall be kept in
withdrawn position.
11.2
Whenever any cable termination is to be done, it shall be with a
valid permit to work which will ensure that breaker is out of service.
ITEM
STAFFING, RESPONSIBILITIES AND COMMUNICATIONS
12.0

12.1 The Testing Team which has been approved by the station commissioning
panel shall consist of the following persons:
1) Testing Team Leader :

2) NTPC Commissioning Staff:
Name Department
a)
b)
c)
d)
3) Contractor / Manufacturer’s representatives:
Name Department
a)
b)
c)
d)

11KV Switchgear SA and SB

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NTPC TESTING SCHEDULE TELANGANA

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-TELANGANA,ST-I 2X800MW UNIT:

ITEM LIST OF CONTENTS

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-TELANGANA,ST-I 2X800MW UNIT:

ITEM PLANT DETAILS

beside Generator Transformers.

switchgears UA and UB with SA and SB boards respectively via 11KV, 2800A

The following Motors/ Transformers/Switch boards fed from 1SA Board:

i) Compressor service Transformer-1

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-TELANGANA,ST-I 2X800MW UNIT:

i) Feeder to 11KV AHP Board

AC/ DC Supply Details:

Make: ABB, Nashik

Rated /Service Voltage: 12KV/11.5KV

Rated Current Rating:3600A

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-TELANGANA,ST-I 2X800MW UNIT:

2.4 To provide record for future reference.

2.5 To prove all controls, interlocks and safeguards.

outgoing feeders as required.

ITEM TESTING PROPOSALS.

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-TELANGANA,ST-I 2X800MW UNIT:

scheme will be proved.

functioning satisfactorily, in case of any sign of stress or abnormality the

same is to be recorded for necessary rectification/replacement by the

supplier/manufacturer through erection and a copy of the results of their

inspection and rectification is to be attached as an annexure to this

ITEM SERVICES REQUIRED

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-TELANGANA,ST-I 2X800MW UNIT:

4.2 AC supplies from Station ACDB.

as detailed in respective of standard check list and test procedures (Brief

list of testing equipment required are as follows).

i) Primary injection kit.

ii) Secondary injection kit.

iii) Single phase transformer 600/230V

iv) Clamp Meter and Multi Meter.

v) DC Hi Pot kit for conducting

vi) Single Phase Variac.

vii) Contact Resistance Measurement kit.

viii) Breaker Timing Kit.

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-TELANGANA,ST-I 2X800MW UNIT:

responsibilities towards the tests carried out .

away from the defined test area.

extinguisher and first aid posts.

5.4 Adequate lighting facilities will be provided.

not be inserted into sockets.

disconnections, shall be made and annexed to relevant test procedures.

of mechanical or electrical damage to the equipment under test . There

kept clean and clear of all obstructions.

notices shall be fixed at relevant points to ensure safety.

5.10 Incomer breakers shall be kept in withdrawn position.

5.11 The operating personnel must be kept informed of the program of

for the installations to be energized.

5.13 Operating procedure should be displayed in the switch gear room.

O&M COMMISSIONING DEPARTMENT

STATION: NTPC-TELANGANA,ST-I 2X800MW UNIT:

5.14 Availability of fire extinguishers at the time of charging and in operation.

area/switch gear room. Telephone numbers of first aid/ambulance, fire station