Commissioning of Kudankulam Nuclear Power Project 6kV Switchgear

NUCLEAR POWER CORPORATION OF INDIA
LIMITED
(A GOVERNMENT OF INDIA ENTERPRISE)
KUDANKULAM NUCLEAR POWER

PROJECT
COMMISSIONING PROCEDURE
FOR
6KV SWITCHGEAR
DOCUMENT No: I01.KK.0.BBA.PN.PM.WD017

Preparation date June 2007 Rev number: 0 Next rev due on June 2012
Prepared by Checked by Reviewed by Approved by
M. Satheesh Kumar P.K.Mandal

SA/C(EM) SO/F(EM)
S.V.Jinna M. K. Balaji
MS CS
Md. Tauquir Alam Sathishkumar B.

SO/D ( EM) SME(E)
KKNPP COMMISSIONING PROCEDURE I01.KK.0. BBA.PN.PM.WD017
FOR 6KV SWITCHGEARS
REVISION CONTROL SHEET
Revision Changed
sheets Prepared by Checked by Reviewed by Approved by
Dateee Sheet
Total No.
_
0 June -- P.K.Mandal
M. Satheesh Kumar
2007 SA/C(EM) SO/F(EM)
S.V.Jinna M.K.Balaji
MS CS
Md. Tauquir Alam

Sathishkumar B.
SO/D(EM)
SME (E)
TABLE OF CONTENT
Sl. Content Page

Description
No number Number
Date of Issue Revision Number Page Number
June 2007 0 Page 2 of 154
FOR 6KV SWITCHGEARS
1. (i) Cover page 1
2. (ii) Revision control sheet 2
3. (iii) Table of content 3
4. 1.0 Introduction 7
5. 2.0 Purpose 7
6. 3.0 Pre-requisites & Initial conditions 7
7. 3.1 Requirement of other systems 7
8. 3.2 System requirements 8
9. 3.3 Manpower requirements 8
10. 3.4 Test instruments and other materials 8

requirement
11. 3.5 Requirement of outside agencies 9
12. 3.6 Hazards and special precautions 9
13. 4.0 General methods 9
14. 4.1 Installation checks 9
15. 4.2 Checks on bus ducts 11
16. 4.3 Cabling and connection checks 11
17. 4.4 Interfacing Checks 12
18. 4.5 Pre-commissioning checks on 6KV 13
switchgear (excluding working supply
and standby supply incomers, VT
cubicle & outgoing feeders)
19. 4.6 Pre-commissioning checks on working 15
supply and standby supply incomers
20. A Visual inspection of the cubicle 15
21. B Internal wiring checks 15
22. C Testing of circuit breaker 15
23. D Testing of current transformer 18
24. E Testing of potential transformer 19
25. F Testing of photo-thyristors, 19
electromagnetic locks, limit switches,
circuit breakers, fuses, resistances,
heaters & indication lamps
26. G Testing of relays 19
FOR 6KV SWITCHGEARS
27. H Testing of meters and transducers 20

28. I Logics and interlocks checks 20
29. 4.7 Pre-commissioning checks on main and 21
supplementary VT cubicles
32. C VT checks 22
33. D Testing of photo-thyristors, 22
miniature circuit breakers, fuses,
resistances, heaters & indication lamps
34. E Testing of relays 23
35. F Testing of meters and transducers 23
36. 4.8 Pre-commissioning checks on outgoing 23
feeders
39. C Circuit breaker checks 24
40. D Testing of current transformers 26
41. E Testing of potential transformers 27
42. F Testing of photo-thyristors, 28
miniature circuit breakers, fuses,
resistances, heaters & indication lamps
43. G Testing of relays 28
44. H Testing of meters and transducers 28
45. I Logics and interlocks checks 28
46. 5.0 Enersisation of switchgear 29
47. 6.0 Design intents 30
48. 7.0 Processing and evaluation of test results 31
49. 8.0 Work plans 35
50. 7.0 Test report formats 36
51. 8.0 References 36
52. 9.0 List of annexures 37
53. Annexure – 1 List of 6KV switchgears 39
54. Annexure – 2 Checklist for installation checks 41
55. Annexure – 3 Checklist for bus duct checks 44
56. Annexure – 4 Checklist for cabling and connection 46
checks
57. Annexure – 5 Checklist for interfacing checks 49
58. Annexure – 6 Checklist for pre-commissioning checks 52
on 6KV switchgear (excluding working
FOR 6KV SWITCHGEARS
supply and standby supply incomers,

VT cubicle & outgoing feeder)
59. Annexure – 7 Checklist for bus bar clearance checks 55
60. Annexure – 8 Checklist for joint tightness and contact 57
resistance checks of bus bars
on working supply and standby supply
incomers
62. Annexure – 10 Checklist for circuit breaker checks 62
63. Annexure – 11 Checklist for current transformer checks 68
64. Annexure – 12 Checklist for potential transformer 73
checks
65. Annexure – 13 Checklist for photo-thyristor, 76
circuit breakers, fuses, resistances &
indication lamps checks
66. Annexure – 14 Checklist for SIPROTEC digital relay 78
checks
67. Annexure – 15 Checklist for electromagnetic differential 82
relay checks
68. Annexure – 16 Checklist for electromagnetic 84
current/voltage/frequency/timer relay
checks
69. Annexure – 17 Checklist for electromagnetic auxiliary 88
relay checks
70. Annexure – 18 Checklist for current transducer checks 90
71. Annexure – 19 Checklist for voltage transducer checks 92
72. Annexure – 20 Checklist for power transducer checks 94
73. Annexure – 21 Checklist for voltmeter checks 96
74. Annexure – 22 Checklist for ammeter checks 98
75. Annexure – 23A Checklist for logics and interlocks 100
checks on working supply and standby
supply incomer feeder of NOPSS
76. Annexure– 23B Checklist for logics and interlocks 108
supply incomer feeder of EPSS
77. Annexure– 23C Checklist for logics and interlocks 112
supply incomer feeder of RPSS
FOR 6KV SWITCHGEARS

on main and supplementary VT cubicles
79. Annexure – 25 Checklist for VT checks 118
80. Annexure – 26 Checklist for pr-commissioning checks 121
on outgoing feeders
81. Annexure – 27A Checklist for logics and interlocks 124
checks of NOPSS outgoing
82. Annexure– 27B Checklist for logics and interlocks 141
checks of EPSS outgoing
83. Annexure– 27C Checklist for logics and interlocks 145
checks of RPSS outgoing
84. Annexure – 28 Checklist for energisation of switchgear 149
85. Annexure – 29 Checklist for relay settings checks 152

FOR 6KV SWITCHGEARS
1.0 Introduction:
6KV switchgears are intended for reception and distribution of a three
phase, 50Hz AC power to NPP auxiliary of loads more than 200KW.
6KV switchgears of group-3 include normal operation power supply
system switchgears and common station auxiliary power supply
system switchgears. 6KV switchgears of group-2 include reliable
power supply system switchgears and emergency power supply
system switchgears. Normal power supply system switchgears are fed
by unit auxiliary transformers (UAT), common station auxiliary power
supply system switchgears are fed by common station auxiliary
transformer (CSAT) and both are backed up by reserve power supply
system switchgears which are fed by reserve auxiliary transformer
(RAT) through automatic load transfer (ALT). 6KV switchgears of
group-2 are normally fed from 6KV switchgears of group-3 and are
having diesel generators (DG) as back up. The 6 KV switch gears
have been designed based on station requirement for smooth
operation by providing SF6 circuit breakers and all relevant
protections for electrical & process parameters.
2.0 Purpose:
This procedure is prepared for carrying out the pre-commissioning
checks, energisation and post energisation checks on 6 KV, Group – 3
and Group - 2 switchgears of KKNPP – 1 & 2. This procedure is
applicable for switchgears listed in annexure-1. Switchgear are tested
in order to ensure that it has not been damaged during transport and
erection and to ensure its trouble free operation.
3.0 Pre-requisites & initial conditions:
3.1 Requirement of other systems:
FOR 6KV SWITCHGEARS
1. The power transformer feeding to the 6KV switchgears are

commissioned and energized or other wise tie breaker and reserve
switchgear feeding the 6KV switchgear under commissioning is
charged and available.
2. SICAM panel associated with 6KV switchgear is installed, tested
and commissioned.
3. Control room panel and associated annunciation which are meant
for 6KV switchgear is installed, tested and commissioned in
switchyard control room or main control room.
4. Bus duct from transformers to 6KV switchgear is erected and
tested.
5. Lighting system of 6KV switchgear rooms is functional and
sufficient illumination is available.
6. 220 V DC Group - 1 power supply for control & protection of 6KV
switchgears is commissioned and is available.
7. Fire fighting equipments are installed in 6 KV switchgear room.
8. Ventilation system in 6 KV switchgear room is installed and
commissioned.
9. Telephone system is ready and available in 6KV switchgear room.
10. All civil works in and around 6 KV switchgear room is completed,
room floor painting is completed and room is in lockable condition.
11. 415 Volt, 3 phase power supply is available for testing.
3.2 System requirements:
1. Erection of 6KV switchgear is completed as per WD and ICC or
CCC is received from electrical construction group.
2. Nomenclature is written on switch gear panels and all incomer,
standby and outgoing feeders.
3. Power and control cabling of switchgear is completed.
4. 6 KV danger stickers are pasted at front and back of 6KV
switchgear.
5. 6 KV switchgear earthing is completed as per WD.
6. Manufacturer’s instructions, WDs, passports and approved
settings of relays are available.
7. Insulation mats of 6 KV grade are provided in front and back of
switchgear panels.
3.3 Manpower requirements:
1. Engineer -1
2. Supervisor – 1
3. Tradesman – 4
3.4 Test instruments and other materials requirement
1. 100V, 250V, 500V & 5 KV megger.
2. Earth tester.
3. Multimeter.
4. Tong tester.
FOR 6KV SWITCHGEARS
5. Primary injection test kit.

6. Secondary injection test kit
7. Single phase & three phase auto transformers.
8. Polarity tester.
9. CB timing kit/ CB Analyzer
10. Micro – Ohmmeter.
11. Electrician Tool kit.
12. HV test kit.
13. Infra red type thermo meter.
14. SF6 gas leak detector.
15. Cleaning agent.
16. Gada cloth.
17. Extension Board.
18. Lubricating grease.
3.5 Requirement of outside agencies:
1. Electrical construction group/erection contractor for attending
deficiencies.
2. 6KV switchgear and relay manufacturer’s representative (if
applicable).
3.6 Hazards and special precautions:
1. Post “ENTRY RESTRICTED” board near switchgear under test to
restrict personnel entry to switchgear area.
2. Proper electrical isolation shall be ensured before taking up any
work and “DO NOT OPERATE” tags should be provided at isolation
points as per work permit system document
no:I01.KK.0.0.OE.PC.WD001
3. 6KV switchgear shall be connected to station grounding grid at two
points.
4. 6KV grade insulation mats shall be provided at the front and back
side of the 6KV switchgear.
5. Insulated hand gloves for 6 KV rating shall be used for any on line
job.
6. “6KV” danger stickers shall be pasted at front and back of 6 KV
switchgear panels.
7. Adequate illumination shall be maintained in 6KV switchgear
room.
8. Proper house keeping shall be ensured in switchgear room.
9. No CT secondary shall be left open circuited during testing. Spare
CT if any shall be shorted.
10. No temporary earthing or discharge rod shall be left connected at
the time of charging.
11. Ventilation system in switchgear area shall be functional.
12. Phase sequence of main and standby supply shall be matched.
4.0 General Methods:
FOR 6KV SWITCHGEARS
4.1 Installation checks:

1. Installation checklist enclosed as annexure-2 shall be filled.
2. Check the designation of 6KV switchgear is as per WDs and
indicate same in checklist.
3. Check that name plate details and ratings of incomer, standby
incomers, outgoing feeder, PT etc. are as per WD.
4. Check and ensure that the 6KV switchgear is installed completely
as per the WD, note down pending points relating to installation if
any.
5. Check and ensure that the MS base frame is welded to EP as per
WD.
6. Check and ensure that inter-cubicle bolts are tightened.
7. Check and ensure that bus bars are installed as per WDs in bus
bar chamber and all flexible connections are installed.
8. Check and ensure that bus duct erection and connections from
transformer to the switchgear is completed.
9. Check and ensure that phase sequence of feeding transformer to
the 6KV switchgear, 6KV bus duct and 6KV switchgear are
matching.
10. Check and ensure that all cubicles are bolted to earthing bus bar
at rear side and the earthing bus bar is connected to station
grounding grid at two points.
11. Check the contact resistance between switch gear grounding point
and station grounding. Resistance shall not be more than 0.1 ohm.
12. Check that control and power cabling is completed as per design/
drawing.
13. Check and ensure that switchgear and surrounding area is clean
and free from debris.
14. Check and ensure that free access is available to all points of
installed components and especially to points requiring frequent
operations, maintenance and control.
15. Check and ensure that the bonding / blocking material for relays,
contactors etc is removed.
16. Check and ensure that all unused holes and openings are properly
plugged.
17. Check and ensure that “6KV” grade insulation mat is provided in
front and back of switchgear.
18. Check and ensure that “6KV” danger sticker is pasted at front and
back side of switchgear.
19. Check and ensure that no unwanted tools, tackles, equipments etc
are left nearby.
20. Check and ensure that adequate illumination is available in
switchgear room.

June 2007 0 Page 10 of 154
FOR 6KV SWITCHGEARS
21. Check and ensure that all WDs, passport, relay settings etc are
available.
22. Check and ensure that cubicle illumination lamps are provided
with lamps.
23. Check and ensure that all trench openings and unused floor
openings are closed.
24. Check and ensure that all civil works in and around 6KV
switchgears are completed, room floor painting is completed and
room is in lockable condition.
4.2 Checks on bus ducts:
1. Checklist for bus duct checks enclosed as annexure-3 shall be
filled.
2. Check and ensure that the bus ducts are installed as per the WD
and note down pending points related to installation if any.
3. Check and ensure the continuity of bus bars of bus duct from
transformer end to switchgears.
4. Check and ensure that phase sequence at transformer end is
matching with phase sequence at 6KV switchgear end.
5. Check and ensure bus ducts are earthed at transformer end as
well as at 6KV switchgear end.
6. Check the insulation resistance of bus duct with 2.5KV megger
before HV test.
7. Carry out HV test of the bus duct at 26KV AC voltage for 1 minute.
8. Check the insulation resistance of bus duct with 2.5KV megger
after HV test
4.3 Cabling and connection checks
1. Cabling and connections checklist attached as annexure-4 shall be
filled.
2. Check and ensure that external power and control cables are laid
and terminated as per the WDs and record all details in the data
sheet available in annexure-4.
3. Check and ensure all external cables (control, signal, power,
indication) connected at individual switchgear panels are dressed,
glanded, supported, clamped and provided by aluminium
identification tags at both ends as well as at intermediate points at
a regular interval of 15 meters. Cable number shall be punched in
aluminium tags.
4. Check and ensure spare cores of control cable shall be neatly
dressed and placed in its location. Also ensure that spare cores are
tagged as spare cores.
5. Check and ensure that armour of cable is earthed at switchgear
end only (applicable if armoured cables are laid).
6. Check and ensure that single core cables are laid in trefoil
formation and trefoil clamps are provided through out its length.

June 2007 0 Page 11 of 154
FOR 6KV SWITCHGEARS
7. Check for continuity, IR value, correct ferruling, lugging,

connection tightness, IR value of all external cables connected to
switchgear and also that they are connected as per WDs.
4.4 Interfacing checks:

1. Interfacing checklist enclosed as annexure-5 shall be filled.
2. Check interfacing cabling between individual cubicles of 6 KV
switchgear and ensure that continuity, correct ferruling, lugging,
connection tightness, IR value, tagging, proper dressing and
supporting have been checked as per annexure-4.
3. Check interfacing cabling between SIPROTEC digital relay and
connector of 6 KV switchgear cabinet and ensure that continuity,
correct ferruling, lugging, connection tightness, IR value, tagging,
proper dressing and supporting have been checked as per
annexure-4.
4. Check interfacing cabling between 6 KV switchgear and unified set
of hardware (SICAM) and ensure that continuity, correct ferruling,
lugging, connection tightness, IR value, tagging, proper dressing
and supporting have been checked as per annexure-4
5. Check interfacing cabling between 6 KV switchgear and TPTS and
ensure that continuity, correct ferruling, lugging, connection
tightness, IR value, tagging, proper dressing and supporting have
been checked as per annexure-4.
6. Check interfacing cabling between 6 KV switchgear and remote tap
change controller of transformer and ensure that continuity,
correct ferruling, lugging, connection tightness, IR value, tagging,
proper dressing and supporting have been checked as per
annexure-4.
7. Check interfacing cabling between 6 KV switchgear and
transformer protection scheme and ensure that continuity, correct
ferruling, lugging, connection tightness, IR value, tagging, proper
dressing and supporting have been checked as per annexure-4.
8. Check interfacing cabling between 6 KV switchgear and 220V
DCDB and ensure that continuity, correct ferruling, lugging,
9. Check interfacing cabling between 6 KV switchgear and 220V AC
panel and ensure that continuity, correct ferruling, lugging,
10. Check interfacing cabling between 6 KV switchgear and 220KV
circuit breaker and ensure that continuity, correct ferruling,
and supporting have been checked as per annexure-4.

June 2007 0 Page 12 of 154
FOR 6KV SWITCHGEARS
11. Check interfacing cabling between 6 KV switchgear and 24KV GCB

and ensure that continuity, correct ferruling, lugging, connection
tightness, IR value, tagging, proper dressing and supporting have
been checked as per annexure-4 (if applicable).
12. Check interfacing cabling between 6 KV switchgear and 400KV
circuit breaker and ensure that continuity, correct ferruling,
and supporting have been checked as per annexure-4 (if
applicable).
13. Check interfacing cabling between 6 KV switchgear and control
room and ensure that continuity, correct ferruling, lugging,
supporting have been checked as per annexure-4 (if applicable).
14. Check interfacing cabling between 6 KV switchgear and billing and
metering panel and ensure that continuity, correct ferruling,
15. Check interfacing cabling between 6 KV switchgear and
synchronizing panel and ensure that continuity, correct ferruling,
16. Check interfacing cabling between 6 KV switchgear panel and its
standby switchgear feeder and ensure that continuity, correct
ferruling, lugging, connection tightness, IR value, tagging, proper
dressing and supporting have been checked as per annexure-4.
17. Check and ensure the interfacing bus duct between 6 KV
switchgear and feeding transformer (RAT/UAT/CSAT).
4.5 Pre-commissioning checks on 6KV switchgear (excluding working
supply and standby supply incomers, VT cubicle & outgoing
feeders):
1. Checklist for pre-commissioning checks on 6KV switchgear
enclosed as annexure-6 shall be filled.
2. Note down the WD number.
3. Check that bus bars are installed as per WDs. Check that bus
ducts are correctly connected to the switchgear buses with respect
to phase sequence.
4. Check and ensure that bus bar modifications, CTs & PTs
secondary wire modifications are carried out in incomers of
10BCA, 10BCB, 10BCC, 10BCD (20BCA, 20BCB, 20BCC, 20BCD),
00BCE & 00BCF switchgears for phase sequence correction.
5. Check all bus bars are properly painted with red, yellow & blue
colors.

June 2007 0 Page 13 of 154
FOR 6KV SWITCHGEARS
6. Check and clean the bus bars and support insulators properly.
Check that there is no physical damage to any insulator or bus
bars.
7. Check and ensure that no foreign materials are left inside the bus
bar chamber.
8. Check the clearance of bus bars between phases and between
phases and earth and record the results in annexure-7.
9. Check all joint tightness and record the result in annexure-8.
Torque value of various size nut and bolt are as follows,
Nominal bolt thread Tightening torque N-m

M8 26.5+ 1.5
M10 48+ 4
M12 64+ 4
M16 96+ 4
10. Check the contact resistance of all joints i.e. carryout milli volt
drop test for each joint and record the results in annexure-8.
Contact resistance of various joints based on current carrying
capacity are as follows,
Sl. No. Nominal current rating of contact in Contact
Ampere resistance in
micro-ohm
1 400 ≤75
2 630 ≤60
3 1000 ≤50
4 1600 ≤40
5 ≥2000 ≤33
11.
Box up bus bar chamber.
12. Rack in & close all the circuit breakers and rack out VT.
13. Carryout insulation resistance test of bus bar with 2.5KV megger
before HV test.
14. Carry out HV test at 26KV AC voltage for 1 minute.
15. Carryout insulation resistance test of bus bar with 2.5KV megger
after HV test.
16. Randomly interchange the CB trucks between different CB
cubicles. Ensure free movement of CB trucks in any of the CB
cubicles. Similarly check for PT trucks.
17. Insert the CB and PT trucks inside their cubicles, check for their
free movement and check that the safety shutters over the cluster
contacts in the cubicle are operating satisfactorily.
18. Check and ensure that 220V DC bus is wired as per WDs.

June 2007 0 Page 14 of 154
FOR 6KV SWITCHGEARS
19. Carry out insulation resistance test of 220V DC bus wiring with
2.5KV megger.
20. Check and ensure that 220V AC bus is wired as per WDs.
21. Carry out insulation resistance test of 220V AC bus wiring with
2.5KV megger.
22. Check and ensure that all the rear doors of switchgear cubicles are
closed with nuts and bolts and handle knob is existing.
23. Prepare 4 sets of as built drawing and hand over one copy to TSS,
one copy to EMU doc centre and two copies with system engineer.
4.6 Pre-commissioning checks on working supply and standby supply

incomers:
A. Visual inspection of the cubicle:
a) Checklist for pre-commissioning checks on working supply and
standby supply incomers enclosed as annexure-9 shall be filled.
b) Note down WD number of the main/standby incomer feeder.
c) Check and clean the breaker compartment completely and
ensure that no foreign materials are left inside.
d) Check bill of material and ensure that all the components are
existing as per WDs.
B. Internal wiring checks:
Check and ensure that the internal wiring and control circuit are as
per WDs and tighten all wires and TBs.
i. Control & protection circuit checks:
a) Check the control & protection circuit is wired as per drawing
and check the continuity of each wire. Remove all extra /
unwanted wires.
b) Check IR of control & protection circuit at 250V.
ii. Monitoring and indication circuit checks:
a) Check the monitoring and indication circuit is wired as per
drawing.
b) Check the continuity of each wire.
C. Circuit breaker checks:
Checklist for checks on CB enclosed as annexure-10 shall be filled.
i. Physical inspection and mechanical interlocks checks
a. Inspect the CB for any physical damage & missing of parts.
b. Clean of all the insulators & interrupter surface with dry cloth.
c. Check and ensure SF6 gas pressure switch contact is not
closed.
d. Check and ensure for SF6 gas leak with gas detector.
e. Check and ensure lubrication of all the linkages, moving /
sliding parts as per manufacturer’s instructions.
f. Check blue matching of the female cluster contact with male
bus bar contact and ensure that blue matching is successful.
June 2007 0 Page 15 of 154
FOR 6KV SWITCHGEARS
g. Check and ensure manual spring charging is functional and

check the local operation of circuit breaker.
h. Carryout a closing-opening cycle and an opening-closing-
opening cycle of operation manually and check that CB is
functional and no abnormality is noticed. Check that CB
open/close status indicator and spring charged/uncharged
status indicator is functional.
i. Check and ensure that auxiliary contacts for CB status
(closing/opening) indication (52a & 52b) are functional.
j. Check and ensure the functioning of mechanical interlocks.
1. Check and ensure electromagnetic locks of CB truck and
earthing switch are functional.
2. Check and ensure that CB can not be racked into service
position if it is closed.
3. Check and ensure that CB can not be taken out of service
4. Check and ensure that CB can not be closed if it is in
intermediate position i.e. between service position and test
position.
5. Check and ensure that earthing switch can not be closed if
CB is in service position.
6. Check and ensure that if CB is moved from test position to
service position when it is closed, CB trips immediately.
7. Check and ensure that if CB is moved from service position
to test position when it is closed, CB trips immediately.
8. Check and ensure that earthing switch driving rod can be
inserted into the drive slot only after releasing of
electromagnetic lock.
9. Check and ensure that earthing switch drive blocking casing
can not be opened if circuit breaker is in service position.
10. Check and ensure that when earthing switch is closed then
earthing switch drive blocking casing can not be closed.
11. Check and ensure that breaker can be rolled out of service
position only after releasing electromagnetic lock.
12. Check and ensure that circuit breaker can not be racked
into service position if earthing switch is closed.
k. Check contact changeover of test position limit switch, service
position limit switch & earthing switch operation limit switch.
l. Insert the plug into the socket for control circuit connection
between fixed portion of cubicle and the CB truck; check that
the plug can be inserted in only one position i.e. correct
position.
ii. Contact resistance check:

June 2007 0 Page 16 of 154
FOR 6KV SWITCHGEARS
a) Close the circuit breaker and measure the contact resistance

between upper pole and lower pole for each phase. Acceptable
contact resistance of various capacity circuit breakers are as
follows,
Sl. No. Circuit breaker Nominal current Contact
type rating in Ampere resistance in
micro-ohm
1 LF2 1250 ≤40
2 LF3 2500 ≤33
3 LF3 3150 ≤33
LF2, ,
b) Rack in the circuit breaker into service position and check the
contact resistance of upper and lower cluster contacts
respectively with bus bars for each phase separately. Also
measure the contact resistance from upper bus to lower bus
with circuit breaker in closed position.
c) Check contact resistance between circuit breaker body (foot
paddle) and switchgear base frame. Contact resistance shall be
less than 0.1 ohm.
iii. Insulation resistance checks:
a) Measure the insulation resistance between upper and lower
contacts with CB in open condition for each phase with 2.5KV
megger.
b) Measure the insulation resistance between phase to phase and
phase to earth respectively with CB in close condition with
2.5KV megger.
iv. CB coils & spring charging motor checks:
a) Measure the insulation resistance of spring charge motor,
closing coil & tripping coil with respect to earth at 250V.
b) Measure the winding resistance of spring charging motor, coil
resistance of closing coil & coil resistance of tripping coil
respectively.
v. Spring charging time & CB timing checks:
a) Measure the spring charging time at 70%, 100% & 110% of
220V DC respectively across spring charging motor.
b) Measure the closing time of CB using CB timing kit at 70%,
100% & 110% of 220V DC respectively across closing coil. Note
down closing time of each pole.
c) Measure the CB opening time using CB timing kit at 70%,
100% & 110% of 220V DC respectively across trip coil-1. Note
down opening time of each pole.

June 2007 0 Page 17 of 154
FOR 6KV SWITCHGEARS
d) Measure the CB opening time using CB timing kit at 70%,

vi. Anti pumping & trip free feature checks:
a) Insert the CB trucks into the cubicle and check for anti
pumping and trip free feature. Press the close PB and keep it
pressed, the CB closes. Now press the trip PB, the CB trips, but
does not close again even though a persistent close command is
present. Now release the close PB and then again press it, the
CB closes now. Hence it is checked that the anti- pumping
feature is operating.
b) Check the trip free feature of the CB. Press the trip PB and keep
it pressed, breaker opens. Now press the close PB and check
that mechanism operates to close the CB but CB do not close.
This indicates that trip command over-ride close command and
trip free feature is functional.
D. Testing of current transformers:
a. Checklist for current transformer checks enclosed as annexure-
11 shall be filled.
b. Check that CTs are as per WDs. Note down name plate details
of CTs.
c. Inspect the CT for any breakages, damages, improper mounting
/ clamping
d. Verify the wiring as per drawing of the CT secondary and
earthing with respect to the scheme.
e. Check for earthing of CTs as per scheme.
f. Interchanging of CTs among protection CTs and measuring CTs
shall not be done even if VA rating is same.
g. Measure secondary winding resistance.
h. Carryout IR measurement at 2500V of CT for secondary to
earth & primary to secondary.
i. Using a battery operated polarity tester, check that positive emf
is induced between S-1 to S-2 terminal when a positive
current pulse is applied between P-1 to P-2
j. Using a primary injection test kit, inject rated primary currents
into the P1 & P2 terminals. Measure these currents and those
flowing out of CT secondary terminals. Tabulate the readings.
Calculate the ratio and compare with these name plate ratio.
k. For protection class of CT carry out saturation test as follows,
Using a 1 phase variac; apply increasing voltages across the CT
secondary winding. Increase the voltage up to Vk/2 mentioned
on CT name plate. Note the voltage applied and the current
flowing into the CT secondary at each step of increase in the
voltage. Draw a graph with voltage and current as the x and y-
June 2007 0 Page 18 of 154
FOR 6KV SWITCHGEARS
axis respectively and incorporate the tabulated readings into

the graph. When an increase in the current by 50% is observed
for an increase in the voltage by 10%, V knee is said to have
been reached. The magnetizing current Im at voltage Vk/2 shall
be within the limit as mentioned on CT name plate.
l. CBCTs (core balance current transformers) shall be tested for
ratio as follows,
Pass the known current to primary and measure the current in
the secondary of CBCT.
m. Measurement CTs shall be tested for primary injection with
burden connected into secondary.
n. Spare secondary terminals (if any) shall be shorted and earthed.
E. Testing of potential transformers:
a) Checklist for checks on potential transformer enclosed as
annexure-12 shall be filled.
b) Check that PTs are provided as per WDs and note down the
name plate details of PTs.
c) Inspect PTs for any breakages, damages, improper mounting /
clamping.
d) Check that the fuses at the primary and the secondary are as
per WD and check that fuse is OK.
e) Take the IR value of the PT secondary winding using a 250V
megger.
f) Conduct ratio test by applying 6KV across the primary with
6KV/240V step up transformer. Note voltage at secondary.
Tabulate and compare the values with the nameplate values &
manufacturers documents.
g) Using a battery operated polarity tester, check that positive emf
is induced between S1 to S2 terminal when a positive current
pulse is applied between P1 to P2.
F. Testing of photo-thyristors, electromagnetic locks, limit
switches, miniature circuit breakers, fuses, resistances, heaters
& indication lamps:
a) Checklist for checks on photo-thyristors, electromagnetic locks,
limit switches, miniature circuit breaker, fuses, resistances,
heaters & indication lamps enclosed as annexure-13 shall be
filled.
b) Note down the make, type, ratings & model number of photo-
thyristors, electromagnetic locks, limit switches, circuit breaker,
fuses, resistances, heaters & indication lamps.
c) Check the operation of electromagnetic lock manually and also
by supply DC voltage.
d) Check the operation of limit switches manually.
e) Check the operation of miniature circuit breaker manually.
June 2007 0 Page 19 of 154
FOR 6KV SWITCHGEARS
f) Check the operation of indication lamps.

g) Check the resistance values of resistances.
h) Check the resistance value and IR value of heaters.
G. Testing of relays:
a. Check the SIPROTEC digital relays as per annexure-14
b. Check electromagnetic differential relays as per annexure-15
c. Check electromagnetic current/voltage/frequency/timer relays
as per annexure-16
d. Check electromagnetic auxiliary relays as per annexure-17
H. Testing of meters and transducers:
a. Check current transducers as per annexure-18
b. Check voltage transducers as per annexure-19
c. Check power transducers as per annexure- 20
d. Check voltmeters as per annexure-21
e. Check ammeters as per annexure-22
I. Logics and interlocks checks:
a) Checklist for logics and interlocks checks on NOPSS incomers
enclosed as annexure- 23A shall be filled.
b) Checklist for logics and interlocks checks on EPSS incomers
enclosed as annexure- 23B shall be filled
c) Checklist for logics and interlocks checks on RPSS incomers
enclosed as annexure- 23C shall be filled
d) Ensure that installation checks are completed as per annexure-
2 and no deficiency exists.
e) Ensure bus duct checks are completed as per annexure-3 and
no deficiency exists.
f) Ensure that cabling and connections checks are completed as
per annexure-4 and no deficiency exist.
g) Ensure that internal wiring checks are done as per WDs and no
deficiency exists.
h) Ensure that circuit breaker is checked as per annexure-10 and
i) Ensure that relays are tested as per their testing procedure
attached in annexure 14, 15, 16 & 17 and no deficiency exists.
j) Ensure that meters and transducers are checked as per their
testing procedure attached in annexure 18, 19, 20, 21 & 22 and
k) Ensure that current transformers are tested as per annexure-11
and no deficiency exists.
l) Ensure that potential transformers are tested as per annexure-
m) Ensure that photo-thyristors, electromagnetic locks, limit
switches, circuit breakers, resistances, heaters and indication
lamps are tested as per annexure-13 and no deficiency exists.

June 2007 0 Page 20 of 154
FOR 6KV SWITCHGEARS
n) Check that TPTS/USH/LCB is commissioned and is functional.

o) Check that 220V DC is available in switchgear as per WDs.
p) Check that 220V AC is available in switchgear as per WDs.
q) Check local & remote closing of circuit breaker in both test
position and service position.
r) Check the local and remote tripping of circuit breaker in both
service position and test position with 220V DC supply
connected to only trip coil-1.
s) Check the local and remote tripping of circuit breaker in both
t) Check protection trips of circuit breaker by simulating faults
with only trip coil-1 energized.
u) Check protection trips of circuit breaker by simulating faults
v) Check protection trips of circuit breaker by simulating faults
with both trip coil-1 & trip coil-2 energized.
w) Check that indication/annunciation/alarm circuit is functional
as per WDs.
x) Check the interlock related to electromagnetic locks as per
WDs.
y) Check various contact changeovers as per WDs with respect to
circuit breaker positions.
z) Check the logics as per relay logic ladder diagram
J. Prepare 4 sets of as built drawing and hand over one copy to TSS,
4.7 Pre-commissioning checks on main and supplementary VT
cubicles:
a. Checklist for pre-commissioning checks on VT cubicles
b. Note down WD number of the main/standby VT feeder.
c. Clean the VT compartment completely and ensure that no
foreign materials are left inside.
d. Check bill of material and ensure that all the components are
e. Check and note down details of VT fuse e.g. type, make etc.
per WDs and ensure tightness of wires.
a. Check and ensure that control & protection circuit is wired as
per drawing and check the continuity of each wire. Remove all
extra / unwanted wires.
June 2007 0 Page 21 of 154
FOR 6KV SWITCHGEARS
b. Check IR of control & protection circuit at 250V.

ii. Monitoring and indication circuit checks:
a. Check that monitoring and indication circuit is wired as per
drawing. Check the continuity of each wire.
b. Check the IR value of circuit at 50V.
C. VT checks:
Checklist for checks on VT enclosed as annexure-25 shall be filled.
a. Inspect the VT for any physical damage & missing of parts.
b. Clean of all the insulator surface with dry cloth.
c. Check and ensure for lubrication of all the linkages, moving /
d. Check blue matching of the female cluster contact with male
e. Check and ensure functionality of MCB of VT secondary.
f. Check and ensure the functioning of mechanical interlocks.
1. Check and ensure that earthing switch can not be closed if VT
is in service position.
can not be opened if VT is in service position.
5. Check and ensure that VT can not be racked into service
position if earthing switch is closed.
g. Check and ensure contact changeover of test position limit
switch, service position limit switch & earthing switch operation
limit switch.
ii. Winding resistance checks:
a. Measure the primary and secondary winding resistance of VT.
b. Check contact resistance between VT body (foot paddle) and
switchgear base frame.
a. Measure the insulation resistance between phase to earth of
primary and secondary respectively with 2.5KV megger.
b. Measure the insulation resistance between primary and
secondary with 2.5KV megger.
iv. Ratio checks:
Conduct ratio test by applying 6KV across the primary with
June 2007 0 Page 22 of 154
FOR 6KV SWITCHGEARS
D. Testing of photo-thyristors, electromagnetic locks, limit

switches, miniature circuit breakers, fuses, resistances,
heaters & indication lamps:
a. Checklist for checks on photo-thyristors, electromagnetic locks,
limit switches, miniature circuit breaker, fuses, resistances,
filled.
b. Note down the make, type, ratings & model number of photo-
c. Check the operation of electromagnetic lock manually and also
d. Check the operation of limit switches manually.
e. Check the operation of miniature circuit breaker manually.
f. Check the operation of indication lamps.
g. Check the resistance values of resistances.
h. Check the resistance value and IR value of heaters.
E. Testing of relays:
c. Check electromagnetic current/voltage/frequency/timer relays
as per annexure-16
F. Testing of meters and transducers:
G. Prepare 4 sets of as built drawing and hand over one copy to TSS,
4.8 Pre-commissioning checks of outgoing feeders:
a. Checklist for pre-commissioning checks on outgoing feeders
b. Note down WD number of the outgoing feeder.
c. Clean the breaker compartment completely and ensure that
no foreign materials are left inside.
d. Check bill of material and ensure that all the components are
per WDs.
June 2007 0 Page 23 of 154
FOR 6KV SWITCHGEARS
a. Check and ensure that control & protection circuit is wired as

per drawing and check the continuity of each wire. Remove all
extra / unwanted wires.
b. Check IR of control & protection circuit at 250V.
ii. Monitoring and indication circuit checks

a. Check and ensure that monitoring and indication circuit is
wired as per drawing. Check the continuity of each wire.
C. Circuit breaker checks
Checklist for checks on CB enclosed as annexure-10 shall be filled.
a. Inspect the CB for any physical damage & missing of parts.
b. Clean all the insulators & interrupter surface with dry cloth.
c. Check and ensure that SF6 gas pressure switch contact is not
closed.
d. Check and ensure that SF6 gas leak with Gas detector.
e. Check and ensure for lubrication of all the linkages, moving /
f. Check blue matching of the female cluster contact with male
g. Check and ensure manual spring charging is functional and
check the local operation of circuit breaker.
h. Carryout a closing-opening cycle and an opening-closing-
opening cycle of operation manually and check that CB is
functional and no abnormality is noticed. Check that CB
open/close status indicator and spring charged/uncharged
status indicator is functional.
i. Check and ensure that auxiliary contacts for CB status
(closing/opening) indication (52a & 52b) are functional.
j. Check and ensure the functioning of mechanical interlocks.
1. Check and ensure that electromagnetic locks of CB truck
and earthing switch are functional.
2. Check and ensure that CB can not be racked into service
3. Check and ensure that CB can not be taken out of service
4. Check and ensure that CB can not be closed if it is in
intermediate position i.e. between service position and test
position.
5. Check and ensure that earthing switch can not be closed if
CB is in service position.
6. Check and ensure that if CB is moved from test position to
service position when it is closed, CB trips immediately.

June 2007 0 Page 24 of 154
FOR 6KV SWITCHGEARS
7. Check and ensure that if CB is moved from service position

to test position when it is closed, CB trips immediately.
can not be opened if circuit breaker is in service position.
11. Check and ensure that breaker can be rolled out of service
position only after releasing electromagnetic lock.
12. Check and ensure that circuit breaker can not be racked
into service position if earthing switch is closed.
k. Check and ensure contact changeover of test position limit
switch, service position limit switch & earthing switch operation
limit switch.
l. Insert the plug into the socket for control circuit connection
between fixed portion of cubicle and the CB truck; check that
the plug can be inserted in only one position i.e. correct
position.
ii. Contact resistance check:
a. Close the circuit breaker and measure the contact resistance
between upper fixed contact and lower moving contact for each
phase. Accepted contact resistance of various capacity circuit
breakers are as follows,
micro-ohm
1 LF2 630 ≤60
2 LF2 1250 ≤40
3 LF3 2500 ≤33
4 LF3 3150 ≤33
b. Rack in the circuit breaker into service position and check the
contact resistance of upper and lower cluster contacts
respectively with bus bars for each phase separately. Also

June 2007 0 Page 25 of 154
FOR 6KV SWITCHGEARS
measure the contact resistance from upper bus to lower bus

with circuit breaker in closed position.
c. Check contact resistance between circuit breaker body and
switchgear base frame.
a. Measure the insulation resistance between upper and lower
contacts with CB in open condition for each phase with 2.5KV
megger.
b. Measure the insulation resistance between phase to phase and
phase to earth respectively with CB in close condition with
2.5KV megger.
iv. CB coils & spring charging motor checks:

a. Measure the insulation resistance of spring charge motor,
closing coil & tripping coil with respect to earth at 250V.
b. Measure the winding resistance of spring charging motor, coil
resistance of closing coil & coil resistance of tripping coil
respectively.
v. Spring charging time & CB timing checks:
a. Measure the spring charging time at 70%, 100% & 110% of
220V DC respectively across spring charging motor.
b. Measure the closing time of CB using CB timing kit at 70%,
100% & 110% of 220V DC respectively across closing coil. Note
down closing time of each pole.
c. Measure the CB opening time using CB timing kit at 70%,
d. Measure the CB opening time using CB timing kit at 70%,
vi. Anti pumping & trip free feature checks:
a. Insert the CB trucks into the cubicle and check for anti
pumping and trip free feature. Press the close PB and keep it
pressed, the CB closes. Now press the trip PB, the CB trips, but
does not close again even though a persistent close command is
present. Now release the close PB and then again press it, the
CB closes now. Hence it is checked that the anti- pumping
feature is operating.
b. Check the trip free feature of the CB. Press the trip PB and keep
it pressed, breaker opens. Now press the close PB and check
that mechanism operates to close the CB but CB do not close.
This indicates that trip command over-ride close command and
trip free feature is functional.
June 2007 0 Page 26 of 154
FOR 6KV SWITCHGEARS
D. Testing of current transformers:

a. Checklist for current transformer checks enclosed as annexure-
11 shall be filled.
b. Check that CTs are as per WDs. Note down name plate details
of CTs.
c. Inspect the CT for any breakages, damages, improper mounting
/ clamping
d. Verify the wiring as per drawing of the CT secondary and
earthing with respect to the scheme.
e. Check for earthing of CTs as per scheme.
f. Interchanging of CTs among protection CTs and measuring CTs
shall not be done even if VA rating is same.
g. Measure secondary winding resistance.
h. Carryout IR measurement at 2500V of CT for secondary to
earth & primary to secondary.
i. Using a battery operated polarity tester, check that positive emf
is induced between S-1 to S-2 terminal when a positive
current pulse is applied between P-1 to P-2
j. Using a primary injection test kit, inject rated primary currents
into the P1 & P2 terminals. Measure these currents and those
flowing out of CT secondary terminals. Tabulate the readings.
Calculate the ratio and compare with these name plate ratio.
k. For protection class of CT carry out saturation test as follows,
Using a 1 phase variac; apply increasing voltages across the CT
secondary winding. Increase the voltage up to Vk/2 mentioned
on CT name plate. Note the voltage applied and the current
flowing into the CT secondary at each step of increase in the
voltage. Draw a graph with voltage and current as the x and y-
axis respectively and incorporate the tabulated readings into
the graph. When an increase in the current by 50% is observed
for an increase in the voltage by 10%, V knee is said to have
been reached. The magnetizing current Im at voltage Vk/2 shall
be within the limit as mentioned on CT name plate.
l. CBCTs (core balance current transformers) shall be tested for
ratio as follows,
Pass the known current to primary and measure the current in
the secondary of CBCT.
m. Measurement CTs shall be tested for primary injection with
burden connected into secondary.
n. Spare secondary terminals (if any) shall be shorted and earthed.
E. Testing of potential transformers:
a. Checklist for checks on potential transformer enclosed as
annexure-12 shall be filled.

June 2007 0 Page 27 of 154
FOR 6KV SWITCHGEARS
b. Check that PTs are provided as per WDs and note down the
name plate details of PTs.
c. Inspect PTs for any breakages, damages, improper mounting /
clamping.
d. Check that the fuses at the primary and the secondary are as
per WD and check that fuse is OK.
e. Take the IR value of the PT secondary winding using a 250V
megger.
f. Conduct ratio test by applying 6KV across the primary with
g. Using a battery operated polarity tester, check that positive emf
is induced between S1 to S2 terminal when a positive current
pulse is applied between P1 to P2.
F. Testing of Photo-thyristors, Electromagnetic locks, Limit
switches, miniature circuit breakers, Fuses, Resistances,
Heaters & Indication lamps:
a. Checklist for checks on photo-thyristors, Electromagnetic locks,
Limit switches, miniature circuit breaker, fuses, resistances,
filled.
b. Note down the make, type, ratings & model number of photo-
c. Check the operation of electromagnetic lock manually and also
d. Check the operation of limit switches manually.
e. Check the operation of miniature circuit breaker manually.
f. Check the operation of indication lamps.
g. Check the resistance values of resistances.
h. Check the resistance value and IR value of heaters
G. Testing of relays:
c. Check electromagnetic current/voltage/timer relays as per
annexure-16
H. Testing of meters and transducers:
June 2007 0 Page 28 of 154
FOR 6KV SWITCHGEARS
I. Logics and interlocks checks:

a. Checklist for logics and interlocks checks on outgoing feeder
enclosed as annexure- 27A, 27B & 27C shall be filled.
b. Ensure that installation checks are completed as per annexure-
c. Ensure bus duct checks are completed as per annexure-3 and
d. Ensure that cabling and connections checks are completed as
per annexure-4 and no deficiency exist.
e. Ensure that internal wiring checks are done as per WDs and no
deficiency exists.
f. Ensure that circuit breaker is checked as per annexure-10 and
g. Ensure that relays are tested as per their testing procedure
attached in annexure 14, 15, 16 & 17 and no deficiency exists.
h. Ensure that meters and transducers are checked as per their
testing procedure attached in annexure 18, 19, 20, 21 & 22 and
i. Ensure that current transformers are tested as per annexure-11
and no deficiency exists.
j. Ensure that potential transformers are tested as per annexure-
k. Ensure that photo-thyristors, electromagnetic locks, limit
switches, circuit breakers, resistances, heaters and indication
lamps are tested as per annexure-13 and no deficiency exists
l. Check local & remote closing of circuit breaker in both test
position and service position.
m. Check the local and remote tripping of circuit breaker in both
n. Check the local and remote tripping of circuit breaker in both
o. Check protection trips of circuit breaker by simulating faults
p. Check protection trips of circuit breaker by simulating faults
q. Check protection trips of circuit breaker by simulating faults
with both trip coil-1 & trip coil-2 energized.
r. Check that indication/annunciation/alarm circuit is functional
as per WDs.
s. Check the interlock related to electromagnetic locks as per
WDs.

June 2007 0 Page 29 of 154
FOR 6KV SWITCHGEARS
t. Check various contact changeovers as per WDs with respect to

circuit breaker positions.
u. Check other logics as per relay logic ladder diagram
J. Prepare 4 sets of as built drawing and hand over one copy to TSS,
5.0 Energisation of switchgear:
1. Checklist for charging of switchgear enclosed as annexure-28 shall
be filled.
2. Check and ensure that installation checks as per 4.1 are completed
and no deficiency exits.
3. Check and ensure that checks on bus duct as per 4.2 is completed
4. Check and ensure that cabling and connection checks as per 4.3 are
completed and no deficiency exits.
5. Check and ensure that interfacing checks as per 4.4 is completed
6. Check and ensure that pre-commissioning checks on 6KV
switchgear (excluding working supply and standby supply incomers,
PT cubicle & outgoing feeders) are completed as per 4.5 and no
deficiency exists.
7. Check and ensure that pre-commissioning checks on main and
supplementary VT is completed as per 4.7 and no deficiency exists.
8. Check and ensure that pre-commissioning checks on outgoing
feeders are completed as per 4.8 and no deficiency exists.
9. Rack in main or standby incomer circuit breakers into service
position and keep it “OFF”.
10. Rack in main and supplementary voltage transformers into service
position.
11. Rack out standby incomer or main incomer and all the outgoing
feeders into repair position and keep it “OFF”. Put “DO NOT
OPERATE TAG” to standby incomer or main incomer and all the
outgoing feeders.
12. Reset all the relays and note the position of flag or LEDs indication
of relays is as per scheme.
13. Charge the transformer feeding the 6KV switchgear. Ensure 6 KV is
available up to the PTs in the switchgear and 6KV voltage is
indicated in the incomer cubicle relay/voltmeter.
14. Switch ON main incomer and check the availability of all three
phase voltage in voltmeter.
15. Record various parameters on hourly basis for 2 hours.
6.0 Design intents:
1. Contact resistance between switch gear grounding point and
station grounding shall not be more than 0.1 ohm.
2. Bus bar minimum clearance shall be as indicated below,
June 2007 0 Page 30 of 154
FOR 6KV SWITCHGEARS
a. Between phases > 127 mm

b. Between phase to earth > 72 mm
3. Contact joint tightness for various size nut and bolt shall be as indicated bellow
Sl. No. Nominal bolt thread Tightening torque N-m
1 M8 26.5+ 1.5
2 M10 48+ 4
3 M12 64+ 4
4 M16 96+ 4
4. Contact joint resistance for various joints shall be as indicated bellow
Sl. No. Nominal current rating of Contact resistance in micro-
contact in Ampere ohm
1 400 ≤75
2 630 ≤60
3 1000 ≤50
4 1600 ≤40
5 ≥2000 ≤33
7.0 Processing and evaluation of test results:

1. High voltage kit should not trip and no flash over should occur
during high voltage test.
2. Ammeter percentage error shall not be more than + 1.5%.
3. Voltmeter percentage error shall not be more than + 1.5%.
4. Bus bar minimum clearance shall be as indicated below,
a) Between phases > 127 mm
b) Between phase to earth > 72 mm
5. Contact joint tightness for various size nut and bolt shall be as indicated bellow,
Sl. No. Nominal bolt thread Tightening torque N-m
1 M8 26.5+ 1.5
2 M10 48+ 4
3 M12 64+ 4
4 M16 96+ 4
6. Bus bar contact resistance shall be as indicated below,

Sl. No. Nominal current rating of Contact resistance in micro-
contact in Ampere ohm
1 400 ≤75
2 630 ≤60

June 2007 0 Page 31 of 154
FOR 6KV SWITCHGEARS
3 1000 ≤50
4 1600 ≤40
5 ≥2000 ≤33
7. Spring charging time should be between 6 to 7 sec.

8. Circuit breaker closing time should be between 60 t0 70 msec.
9. Circuit breaker opening time should be between 40 to 50 msec.
10. Voltage relay (under voltage/over voltage)
a) The relative mean error of relay operating voltage at each setting
shall not exceed ±5% for DC relays and ±10% for AC relays.
b) If adjusted by additional variable resistor, error shall be ±3%.
c) Additional ±3% error if operating frequency changes by ±3% for
AC relays.
d) Operating time of over voltage relay shall not exceed 0.06s at
1.2Unom & 0.04s at 2Unom.
e) Operating time of under voltage relay shall not exceed 0.06s at
Unom to 0.8Ureset.
11. Pick up voltage of auxiliary relays shall be less than 80% of DC
operating voltage.
12. Pick up voltage of auxiliary relays shall be less than 85 of AC
operating voltage.
13. Increased sensitivity current relays
a) Operating current shall be within ±3% of setting
b) Operating time at two times operating current shall be less than
0.06s.
14. Over current relays
a) Operating current shall be within ±5% of setting for AC
operating relays.
b) Operating current shall be within ±7.5% of setting for DC
operating relays.

June 2007 0 Page 32 of 154
FOR 6KV SWITCHGEARS
c) Relative additional error of relay operating current when the

input frequency of operating parameter changes by ±3Hz shall
not be more than ±3%.
d) The relay reset ratio shall be more than 0.9.
e) Time of operation shall be less than 0.06s for 1.2Iopr & 0.035s
for 3Iopr.
15. The maximum permissible error in current/voltage/power
transducer is ±0.5%.
16. Reverse current relays
a) Deviation of operating current from set value shall not exceed
±10%.
b) The relay reset ratio shall be more than 0.95.
c) Relay operation time for 2Iopr shall be less than 0.05s for coil-1
& 0.045s for coil-2.
17. Differential current relay
a) The operating current shall be within ±7.5% of set value.
b) Relay reset ratio shall be more than 0.75.
c) The operating time for 3Iopr. shall be less than 0.04s.
18. Indicating auxiliary relays
a) Operating voltage for voltage operated shall be less than 70% of
nominal voltage.
b) Operating current for current operated relays shall be less than
85% of nominal current.
c) Time of operation for without auto reset type relays is 0.03s.
d) Time of operation for auto reset type relays is 0.01s.
19. Voltage relays (under voltage direct sequence relay & over voltage
reverse sequence relays)
a) The pick up voltage for both types of relays shall be within
±10%

June 2007 0 Page 33 of 154
FOR 6KV SWITCHGEARS
b) Relay reset ratio for voltage reverse sequence relays shall be

more than 0.95.
c) Relay reset ratio for voltage direct sequence relays shall be more
than 1.05.
d) The relay pick up voltage complementary error at frequency
change by ±3Hz of rate done shall not exceed ±7%.
e) Time of operation of voltage reverse sequence relays at 2Umean
shall not be less than 0.04 sec.
f) Time of operation of voltage direct sequence relay for input
voltage 1.1Unom to 0.8Unom shall not exceed 0.075s.
20. Frequency relays
a) The relay operating frequency shall be within ±0.25Hz of set
value with harmonics voltage up to 25% of main frequency
voltage.
b) Operating time of over frequency relays shall be more than 0.12
sec.
c) Operating time of under frequency relays shall be more than 0.1
sec.
21. Timer
a) The average basic time delay error () in percent from the setting
value shall not exceed the value calculated from the formula,
= ±│a + b. Tm/T│
Tm= Maximum setting from the nominal setting range
T= Set value of time on scale
a= 1.5 (constant for timers of all range)
b= 1.0 for timers of range 0.05-3.0
0.25 for timers of ranges 0.15-9.0, 0.5-30.0 & 6.0-90.0.
b) Reset time of the timers shall be less than 0.04s.
c) Operating voltage shall be less than 80% of nominal.

June 2007 0 Page 34 of 154
FOR 6KV SWITCHGEARS
8.0 Work plans:
Confirm the status of other

system as per clause no. 3.1
Confirm the status of SWGR

system as per clause no. 3.2
Confirm the availability of

manpower as per clause no. 3.3
Confirm the availability of

instruments and other materials
as per clause no. 3.4
Confirm the availability of outside

agency as per clause no. 3.5
Identify the hazards and taking

necessary precautions as per
clause no. 3.6
Check the completeness and

correctness of switchgear
installation as per clause no. 4.1
Check bus ducts as per clause no.

4.2

June 2007 0 Page 35 of 154
FOR 6KV SWITCHGEARS

correctness of cabling and
connections as per clause no. 4.3

correctness of SWGR interface as
per clause no. 4.4
Pre-commissioning checks on 6KV

switchgear (excluding working
supply and standby supply
incomers, PT cubicle & outgoing
feeders) as per clause no. 4.5
Pre-commissioning checks on
working supply and standby
supply incomers as per clause 4.6
main and standby VT cubicles as
per clause no. 4.7
outgoing feeders as per clause no.
4.8
Charge the switchgear as per

clause no. 5.0
Consolidation of commissioning
documentation
9.0 Test report formats:

Test formats are enclosed in annexure-1 to annexure-29 .

June 2007 0 Page 36 of 154
FOR 6KV SWITCHGEARS
10.0 References:
1. 6KV switch gear service manual
2. Set of switchgear documents supplied by manufacturers
11.0 List of annexures:
Annexure -1 List of 6KV switchgears

Annexure -2 Checklist for installation checks
Annexure -3 Checklist for bus duct checks
Annexure -4 Checklist for cabling and connection checks
Annexure -5 Checklist for interfacing checks
Annexure -6 Checklist for pre-commissioning checks on 6KV
switchgear (excluding working supply and standby supply
incomers, VT cubicle & outgoing feeder)
Annexure -7 Checklist for bus bar clearance checks
Annexure -8 Checklist for joint tightness and contact resistance checks
of bus bars
Annexure -9 Checklist for pre-commissioning checks on working
supply and standby supply incomers
Annexure-10 Checklist for circuit breaker checks
Annexure-11 Checklist for current transformer checks
Annexure-12 Checklist for potential transformer checks
Annexure-13 Checklist for Photo-thyristor, Electromagnetic locks, Limit
switches, Circuit breakers, Fuses, Resistances &
Indication lamps checks
Annexure-14 Checklist for SIPROTEC digital relay checks
Annexure-15 Checklist for electromagnetic differential relay checks
Annexure-16 Checklist for electromagnetic
current/voltage/frequency/timer relay checks
Annexure-17 Checklist for electromagnetic auxiliary relay checks
Annexure-18 Checklist for current transducer checks
Annexure-19 Checklist for voltage transducer checks
Annexure-20 Checklist for power transducer checks
Annexure-21 Checklist for voltmeter checks
Annexure-22 Checklist for ammeter checks
Annexure –23A Checklist for logics and interlocks checks on working
supply and standby supply incomer feeder of NOPSS
Annexure – 23B Checklist for logics and interlocks checks on working

June 2007 0 Page 37 of 154
FOR 6KV SWITCHGEARS
supply and standby supply incomer feeder of EPSS

Annexure – 23C Checklist for logics and interlocks checks on working
supply and standby supply incomer feeder of RPSS
Annexure – 24 Checklist for pre-commissioning checks on main and
supplementary VT cubicles
Annexure – 25 Checklist for VT checks
Annexure – 26 Checklist for pr-commissioning checks on outgoing
feeders
Annexure – 27A Checklist for logics and interlocks checks of NOPSS
outgoing
Annexure – 27B Checklist for logics and interlocks checks of EPSS
outgoing
Annexure – 27C Checklist for logics and interlocks checks of RPSS
outgoing
Annexure -28 Checklist for energisation of switchgear
Annexure -29 Checklist for relay settings checks

June 2007 0 Page 38 of 154
FOR 6KV SWITCHGEARS
ANNEXURE-1
LIST OF 6KV SWITCHGEARS
Sl. Unit KKS code Locations Locations Main feed Main feed Stand by
No of building Room Transformer/ 6KV feed
switchgear bus CB/Cubicle 6KV CB
1 0 00BCE UBG 03UBG10R003 00BCT01 00BCE11 00BCE01
2 0 00BCF UBG 03UBG10R003 00BCT01 00BCF08 00BCF01
3 0 0BCG 0UTF UTF10R009 00BCE 00BCG04 00BCG23
4 0 0BCH 0UTF UTF10R009 00BCF 00BCH04 00BCH19
5 0 00BDG 0 5UKD 05UKD10R105 DG(00XKA50) 00BDG01 NIL
6 0 00BDH 0 5UKD 05UKD10R205 DG(00XKA60) 00BDH02 NIL
7 1 10BBA 1 UBA 1UBA10R001 10BBT01 10BBA02 10BBA25
8 1 10BBB 1 UBA 1UBA10R002 10BBT01 10BBB02 10BBB25
9 1 10BBC 1 UBA 1UBA10R003 10BBT02 10BBC02 10BBC25
10 1 10BBD 1 UBA 1UBA10R004 10BBT02 10BBD02 10BBD25
11 1 10BCA UBG 01UBG10R004 10BCT01 10BCA04 NIL
12 1 10BCB UBG 01UBG10R004 10BCT01 10BCB04 NIL
13 1 10BCC UBG 01UBG10R005 10BCT02 10BCC04 NIL
14 1 10BCD UBG 01UBG10R005 10BCT02 10BCD04 NIL
15 1 11BDA 1 1UKD 11UKD10R019 10BBA 11BDA13 11BDA01
16 1 12BDB 1 2UKD 12UKD10R019 10BBB 12BDB13 12BDB01
17 1 13BDC 1 3UKD 13UKD10R019 10BBC 13BDC13 13BDC01
18 1 14BDD 1 4UKD 14UKD10R019 10BBD 14BDD13 14BDD01
19 1 10BDE 1 UBA 1UBA10R005 10BBA 10BDE02 10BDE11
20 1 10BDF 1 UBA 1UBA10R006 10BBD 10BDF01 10BDF11
21 2 20BBA 2 UBA 2UBA20R001 20BBT01 20BBA02 20BBA25
22 2 20BBB 2 UBA 2UBA20R002 20BBT01 20BBB02 20BBB25
23 2 20BBC 2 UBA 2UBA20R003 20BBT02 20BBC02 20BBC25
24 2 20BBD 2UBA 2UBA20R004 20BBT02 20BBD02 20BBD25
25 2 20BCA 02UBG 02UBG10R001 20BCT01 20BCA03 NIL
26 2 20BCB 02UBG 02UBG10R001 20BCT01 20BCB01 NIL
27 2 20BCC 02UBG 02UBG10R002 20BCT02 20BCC03 NIL
June 2007 0 Page 39 of 154
FOR 6KV SWITCHGEARS
28 2 20BCD 02UBG 02UBG10R002 20BCT02 20BCD01 NIL

29 2 21BDA 2 1UKD 21UKD20R019 20BBA 21BDA13 21BDA01
30 2 22BDB 2 2UKD 22UKD20R019 20BBB 22BDB13 22BDB01
31 2 23BDC 2 3UKD 23UKD20R019 20BBC 23BDC13 23BDC01
32 2 24BDC 2 4UKD 24UKD20R019 20BBD 24BDD13 24BDD01
33 2 20BDE 2 UBA 2UBA20R005 20BBA 20BDE02 20BDE11
34 2 20BDF 2 UBA 2UBA20R006 20BBD 20BDF01 20BDF11

June 2007 0 Page 40 of 154
FOR 6KV SWITCHGEARS
ANNEXURE – 2
CHECKLIST FOR INSTALLATION CHECKS
1. Switchgear KKS code:
2. Make of switchgear:
3. Location:
4. Date of check:
5. Details of checks:
Sl. Description of checks Observation

No.
1 Check the designation of 6KV switchgear as per WDs
and indicate same in checklist
2 Check that name plate details and ratings of
incomer, standby incomers, outgoing feeder, PT etc.
are as per WD
3 Check and ensure that the 6KV switchgear is
installed completely as per the WD, note down
pending points relating to installation if any.
a. Check feeder designation, rating (KW/KVA/A)
b. Check cubicle number and load designation
c. Check CB name plate details
d. Check and ensure CB test position limit switch
installation
e. Check and ensure CB service position limit
switch installation
f. Check and ensure earthing disconnector limit
switch installation
g. Check and ensure bus bar chamber over pressure
switch installation
h. Check and ensure circuit breaker chamber
overpressure switch
i. Check and ensure the photo-thyristor installation
j. Check and ensure electromagnetic lock of
earthing switch
k. Check and ensure electromagnetic lock of CB
position
l. Check and ensure that plug, socket, various
June 2007 0 Page 41 of 154
FOR 6KV SWITCHGEARS
switches, diodes, light holders and bulbs etc are

installed as per WDs.
m. Check and ensure electric heater installation
n. Check and ensure current transformer
installations as per WD
o. Check and ensure potential transformer
installations as per WD
p. Check and ensure numerical relay installation
q. Check and ensure electromagnetic relay
installation
r. Check and ensure power transducer installation
s. Check and ensure current and voltage transducer
installations
4 Check that the MS base frame is welded to EP as per

WD
5 Check and ensure that inter-cubicle bolts are
tightened
6 Check and ensure that bus bars are installed as per
WDs in bus bar chamber and all flexible connections
are installed
7 Check and ensure that bus duct erection and
connections from transformer to the switchgear is
completed
8 Check and ensure that phase sequence of feeding
transformer to the 6KV switchgear, 6KV bus duct
and 6KV switchgear are matching
9 Check and ensure that all cubicles are bolted to
earthing bus bar at rear side and the earthing bus
bar is connected to station grounding grid at two
points
10 Check the contact resistance between switch gear
grounding point and station grounding. Resistance
shall not be more than 0.1 ohm
11 Check that control and power cabling is completed
as per design/ drawing
12 Check and ensure that switchgear and surrounding
area is clean and free from debris

June 2007 0 Page 42 of 154
FOR 6KV SWITCHGEARS
13 Check and ensure that free access is available to all

points of installed components and especially to
points requiring frequent operations, maintenance
and control
14 Check and ensure that the bonding / blocking
material for relays, contactors etc is removed
15 Check and ensure that all unused holes and
openings are properly plugged
16 Check and ensure that “6KV” grade insulation mat is
provided in front and back of switchgear
17 Check and ensure that “6KV” danger sticker is
pasted at front and back side of switchgear
18 Check and ensure that no unwanted tools, tackles,
equipments etc are left nearby
19 Check and ensure that adequate illumination is
available in switchgear room
20 Check and ensure that all WDs, passport, relay
settings etc are available
21 Check and ensure that cubicle illumination lamps
are provided with lamps
22 Check and ensure that all trench openings and
unused floor openings are closed
23 Check and ensure that all civil works in and around
6KV switchgears are completed, room floor painting
is completed and room is in lockable condition
6. Remarks:
NPCIL Contractor
Name & Signature Name & Signature
designation designation
Technicians
Supervisor

June 2007 0 Page 43 of 154
FOR 6KV SWITCHGEARS
Engineer
ANNEXURE – 3
CHECKLIST FOR BUS DUCT CHECKS
2. Bus duct KKS code:
3. Location:
4. Date of check:
5. Ambient temperature:
6. Test instruments details:
Sl. Instrument Make & Serial Calibration valid up to
No. number

No.
1 Check and ensure that the bus ducts are installed as
per the WD and note down pending points related to
installation if any
2 Check and ensure the continuity of bus bars of bus
duct from transformer end to switchgears
3 Check and ensure that phase sequence at
transformer end is matching with phase sequence at
6KV switchgear end
4 Check and ensure bus ducts are earthed at
transformer end as well as at 6KV switchgear end
5 Check the insulation resistance of bus duct with IR value in MΩ
2.5KV megger before HV test.
a) (Y+E) to (R+B) a) ……….. MΩ
b) Y to (R+B+E) b) ………… MΩ
6 Carry out HV test on bus duct

a) Apply 26KV AC voltage on Y phase and short a) Withstood/Not
June 2007 0 Page 44 of 154
FOR 6KV SWITCHGEARS
circuit R phase & B phase to ground for one withstood

minute. Leakage
current………mA
b) Short R phase & B phase. Apply 26KV AC voltage b) Withstood/Not
on (R+B) phase and short circuit Y phase to withstood
ground for one minute. Leakage
current………mA
(Should withstand the voltage for one minute)
7 Check the insulation resistance of bus duct with IR value in MΩ
2.5KV megger after HV test.
a) (Y+E) to (R+B) a) ……….. MΩ
b) Y to (R+B+E) b) ………… MΩ
(IR value should not reduce from result obtained in

step 6)
8. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer

June 2007 0 Page 45 of 154
FOR 6KV SWITCHGEARS
ANNEXURE –4
CHECKLIST FOR CABLING AND CONNECTION

2. Location:
3. Date of check:
4. Test instrument details:

No. number
5. Details of check:
Sl. Description of checks Observations

No.
1 Check and ensure that external power and
control cables are laid and terminated as per
the WDs and record all details in the data
sheet available in annexure-4
2 Check and ensure all external cables
(control, signal, power, indication) connected
at individual switchgear panels are dressed,
glanded, supported, clamped and provided
by aluminium identification tags at both
ends as well as at intermediate points at a
regular interval of 15 meters. Cable number
shall be punched in aluminium tags
3 Check and ensure spare cores of control
cable shall be neatly dressed and placed in
its location. Also ensure that spare cores are
tagged as spare cores.
4 Check and ensure that armour of cable is
earthed at switchgear end only (applicable if
armoured cables are laid)
5 Check and ensure that single core cables
are laid in trefoil formation and trefoil

June 2007 0 Page 46 of 154
FOR 6KV SWITCHGEARS
clamps are provided through out its length

6 Check for continuity, IR value, correct
ferruling, lugging, connection tightness, IR
value of all external cables connected to
switchgear and also that they are connected
as per WDs
7 Perform continuity checks of all wiring and
cabling and ensure it is as per drawing
Glanding & Type and size IR
Sl. Cable Cable terminations of lugs Continuity value
No. number size & Source Load Source Load at
type end end end end 500V
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
June 2007 0 Page 47 of 154
FOR 6KV SWITCHGEARS
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
6. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer

June 2007 0 Page 48 of 154
FOR 6KV SWITCHGEARS
ANNEXURE – 5
CHECKLIST FOR INTERFACING CHECKS

2. Location:
3. Date of check:
No. number

No.
1 Check interfacing cabling between individual
cubicles of 6 KV switchgear and ensure that
continuity, correct ferruling, lugging, connection
tightness, IR value, tagging, proper dressing and
supporting have been checked as per annexure-4
2 Check interfacing cabling between SIPROTEC digital
relay and connector of 6 KV switchgear cabinet and
ensure that continuity, correct ferruling, lugging,
connection tightness, IR value, tagging, proper
dressing and supporting have been checked as per
annexure-4
3 Check interfacing cabling between 6 KV switchgear
and unified set of hardware (SICAM) and ensure that
and TPTS and ensure that continuity, correct
ferruling, lugging, connection tightness, IR value,
tagging, proper dressing and supporting have been
June 2007 0 Page 49 of 154
FOR 6KV SWITCHGEARS
checked as per annexure-4

and remote tap change controller of transformer and
ensure that continuity, correct ferruling, lugging,
connection tightness, IR value, tagging, proper
dressing and supporting have been checked as per
annexure-4
and transformer protection scheme and ensure that
and 220V DCDB and ensure that continuity, correct
and 220V AC panel and ensure that continuity,
correct ferruling, lugging, connection tightness, IR
value, tagging, proper dressing and supporting have
been checked as per annexure-4
and 220KV circuit breaker and ensure that
and 24KV GCB and ensure that continuity, correct
checked as per annexure-4 (if applicable)
and 400KV circuit breaker and ensure that
supporting have been checked as per annexure-4 (if
applicable)

June 2007 0 Page 50 of 154
FOR 6KV SWITCHGEARS

and control room and ensure that continuity, correct
and billing and metering panel and ensure that
and synchronizing panel and ensure that continuity,
correct ferruling, lugging, connection tightness, IR
value, tagging, proper dressing and supporting have
been checked as per annexure-4
panel and its standby switchgear feeder and ensure
that continuity, correct ferruling, lugging, connection
16 Check and ensure the interfacing bus duct between
6 KV switchgear and feeding transformer
(RAT/UAT/CSAT)
7. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer

June 2007 0 Page 51 of 154
FOR 6KV SWITCHGEARS
ANNEXURE –6
CHECKLIST FOR PRE-COMMISSIONING CHECKS ON 6KV
SWITCHGEAR (EXCLUDING WORKING SUPPLY AND STANDBY SUPPLY
INCOMERS, VT CUBICLE & OUTGOING FEEDERS)

2. Location:
3. Date of check:
5. Testing instrument details:
No. number
No.
1 Note down the WD number
2 Check that bus bars are installed as per WDs. Check
that bus ducts are correctly connected to the
switchgear buses with respect to phase sequence
3 Check and ensure that bus bar modifications, CTs &
PTs secondary wire modifications are carried out in
incomers of 10BCA, 10BCB, 10BCC, 10BCD (20BCA,
20BCB, 20BCC, 20BCD), 00BCE & 00BCF
switchgears for phase sequence correction
4 Check all bus bars are properly painted with red,
yellow & blue colors.
5 Check and clean the bus bars and support
insulators properly. Check that there is no physical
damage to any insulator or bus bars
6 Check and ensure that no foreign materials are left
inside the bus bar chamber
7 Check the clearance of bus bars between phases and
between phases and earth and record the results in
annexure-7
8 Check all joint tightness and record the result in
June 2007 0 Page 52 of 154
FOR 6KV SWITCHGEARS
annexure-8
9 Check the contact resistance of all joints i.e.
carryout milli volt drop test for each joint. Record the
results in annexure-8
10 Box up bus bar chamber
11 Rack in & close all the circuit breakers and rack out
VT
12 Check the insulation resistance of bus bar with IR value in MΩ
2.5KV megger before HV test.
a) (Y+E) to (R+B) a) ……….. MΩ
b) Y to (R+B+E) b).………… MΩ
13 Carry out HV test on bus duct

a) Apply 26KV AC voltage on Y phase and short a) Withstood/Not
circuit R phase & B phase to ground for one withstood
minute. Leakage
current………mA
b) Short R phase & B phase. Apply 26KV AC voltage b) Withstood/Not
on (R+B) phase and short circuit Y phase to withstood
ground for one minute. Leakage
current………mA
(Should withstand the voltage for one minute)
14 Check the insulation resistance of bus bars with IR value in MΩ
2.5KV megger after HV test.
a) (Y+E) to (R+B) a) ……….. MΩ
b) Y to (R+B+E) b) ………… MΩ
(IR value should not reduce from result obtained in

step 6)
15 Randomly interchange the CB trucks between
different CB cubicles. Ensure free movement of CB
trucks in any of the CB cubicles.
16 Randomly interchange the PT trucks between
different PT cubicles. Ensure free movement of PT
trucks in any of the PT cubicles.
17 Randomly interchange the disconnector trucks

June 2007 0 Page 53 of 154
FOR 6KV SWITCHGEARS
between different disconnector cubicles. Ensure free

movement of disconnector trucks in any of the
disconnector cubicles
18 Insert the CB trucks inside their cubicles, check for
their free movement and check that the safety
shutters over the cluster contacts in the cubicle are
operating satisfactorily
19 Insert the PT trucks inside their cubicles, check for
their free movement and check that the safety
shutters over the cluster contacts in the cubicle are
operating satisfactorily
20 Check and ensure that 220V DC bus is wired as per
WDs
21 Carry out insulation resistance test of 220V DC bus
wiring with 2500V megger
22 Check and ensure that 220V AC bus is wired as per
WDs
23 Carry out insulation resistance test of 220V AC bus
wiring with 2500V megger
24 Check and ensure that all the rear doors of
switchgear cubicles are closed with nuts and bolts
and handle knob is existing.
25 Prepare 4 sets of as built drawing and hand over one
copy to TSS, one copy to EMU doc centre and two
copies with system engineer
7. Remarks:
NPCIL Contractor
Technicians
Supervisor

June 2007 0 Page 54 of 154
FOR 6KV SWITCHGEARS
Engineer
ANNEXURE – 7
CHECKLIST FOR BUS BAR CLEARANCE CHECKS
3. Location:
4. Date of check:
No. number
Acceptance Measured
Cubicle
Clearance between value/Factory value in mm Remarks
No.
value in mm (minimum)
R---Y 127
Y---B 127
R---N 72
R---Body 72
Y---Body 72
B---Body 72
R---Y 127
Y---B 127
R---N 72
R---Body 72
Y---Body 72
B---Body 72
R---Y 127
Y---B 127
R---N 72
R---Body 72
Y---Body 72
B---Body 72
R---Y 127
Y---B 127
June 2007 0 Page 55 of 154
FOR 6KV SWITCHGEARS
R---N 72
R---Body 72
Y---Body 72
B---Body 72
R---Y 127
Y---B 127
R---N 72
R---Body 72
Y---Body 72
B---Body 72
R---Y 127
Y---B 127
R---N 72
R---Body 72
Y---Body 72
B---Body 72
R---Y 127
Y---B 127
R---N 72
R---Body 72
Y---Body 72
B---Body 72
8. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer

June 2007 0 Page 56 of 154
FOR 6KV SWITCHGEARS
ANNEXURE – 8
CHECKLIST FOR JOINT TIGHTNESS AND CONTACT RESISTANCE
CHECKS OF BUS BARS

3. Location:
4. Date of check:
No. number
Contact resistance
Tightness check check
Torque Torque value Factory Measured
Sl. Joint
value at at which value/Acc value
No. number or Bolt
which tightness eptance (micro ohm)
description size
tightness checked value
of joint
to be (micro
checked ohm)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
June 2007 0 Page 57 of 154
FOR 6KV SWITCHGEARS
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
a) Torque value of various size nut and bolt are as follows,
Nominal bolt thread Tightening torque N-m

M8 26.5+ 1.5
M10 48+ 4
M12 64+ 4
M16 96+ 4
b) Contact resistance of various joints based on current carrying

capacity is as follows,
Sl. No. Nominal current rating of contact in Contact

Ampere resistance in
micro-ohm
1 400 ≤75
2 630 ≤60
3 1000 ≤50
4 1600 ≤40
5 ≥2000 ≤33

June 2007 0 Page 58 of 154
FOR 6KV SWITCHGEARS
8. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE –9
CHECKLIST FOR PRE-COMMISSIONING CHECKS ON WORKING
SUPPLY AND STANDBY SUPPLY INCOMERS

3. Location:
4. Date of check:
6. Testing instruments details:
Sl. Instrument Make & Serial Calibration valid up
No. number to
June 2007 0 Page 59 of 154
FOR 6KV SWITCHGEARS
No.
1 Note down WD number of the main/standby
incomer feeder
2 Check and clean the breaker compartment
completely and ensure that no foreign materials
are left inside
3 Check bill of material and ensure that all the
components are existing as per WDs
4 Check and ensure that the internal wiring and
control circuit are as per WDs and tighten all the
wires and TBs.
5 Check that control & protection circuit is wired as
per drawing and check the continuity of each wire
and tighten all the wires. Remove all extra /
unwanted wires
6 Check IR of control & protection circuit at 250V
7 Check that monitoring and indication circuit is
wired as per drawing. Check the continuity of each
wire and tighten all the wires
8 Check IR of monitoring and indication circuit at
50V
9 Check circuit breaker as per annexure-10
10 Check current transformer as per annexure-11
11 Check potential transformer as per annexure-12
12 Check photo-thyristors, electromagnetic locks,
limit switches, miniature circuit breakers, fuses,
resistances, heaters & indication lamps as per
annexure-13
13 Check the SIPROTEC digital relays as per
annexure-14
14 Check electromagnetic differential relays as per
annexure-15
15 Check electromagnetic

June 2007 0 Page 60 of 154
FOR 6KV SWITCHGEARS
current/voltage/frequency/timer relays as per

annexure-16
16 Check electromagnetic auxiliary relays as per
annexure-17
17 Check current transducers as per annexure-18
18 Check voltage transducers as per annexure-19
19 Check power transducers as per annexure- 20
20 Check voltmeters as per annexure-21
21 Check ammeters as per annexure-22
22 Check logics and interlocks as per annexure-23
23 Prepare 4 sets of as built drawing and hand over
one copy to TSS, one copy to EMU doc centre and
two copies with system engineer
8. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE –10
CHECKLIST FOR CIRCUIT BREAKER CHECKS

2. Cubicle KKS code:
3. CB Serial number:
4. CB model number:
5. Make of circuit breaker:
6. Location:
7. Date of check:
June 2007 0 Page 61 of 154
FOR 6KV SWITCHGEARS

No. number

No.
1 Physical inspection and mechanical
interlocks checks
a Inspect the CB for any physical damage &
missing of parts
b Clean all the insulators & interrupter
surface with dry cloth
c Check and ensure SF6 gas pressure switch
contact is not closed
d Check and ensure SF6 gas leak with Gas
detector
e Check and ensure lubrication of all the
linkages, moving / sliding parts as per
manufacturer’s instructions
f Check blue matching of the female cluster
contact with male bus bar contact and
ensure that blue matching is successful
g Check manual spring charging is functional
and check the local operation of circuit
breaker
h Carryout a closing-opening cycle and an
opening-closing-opening cycle of operation
manually and check that CB is functional
and no abnormality is noticed. Check that
CB open/close status indicator and spring
charged/uncharged status indicator is
June 2007 0 Page 62 of 154
FOR 6KV SWITCHGEARS
functional
i Check and ensure that auxiliary contacts for
CB status (closing/opening) indication (52a
& 52b) are functional
j Check and ensure the functioning of
mechanical interlocks
1 Check electromagnetic locks of CB truck and
earthing switch are functional
2 Check that CB can not be racked into
service position if it is closed
3 Check that CB can not be taken out of
service position if it is closed
4 Check that CB can not be closed if it is in
intermediate position i.e. between service
position and test position
5 Check that earthing switch can not be closed
if CB is in service position
6 Check that if CB is moved from test position
to service position when it is closed, CB trips
immediately
7 Check that if CB is moved from service
position to test position when it is closed, CB
trips immediately
8 Check that earthing switch driving rod can
be inserted into the drive slot only after
releasing of electromagnetic lock
9 Check that earthing switch drive blocking
casing can not be opened if circuit breaker is
in service position
10 Check that when earthing switch is closed
then earthing switch drive blocking casing
can not be closed
11 Check that breaker can be rolled out of
service position only after releasing
electromagnetic lock
12 Check that circuit breaker can not be racked
into service position if earthing switch is
closed
June 2007 0 Page 63 of 154
FOR 6KV SWITCHGEARS
k Check contact changeover of test position

limit switch, service position limit switch &
earthing switch operation limit switch
l Insert the plug into the socket for control
circuit connection between fixed portion of
cubicle and the CB truck; check that the
plug can be inserted in only one position i.e.
correct position
2 Contact resistance check
a Close the circuit breaker and measure the
contact resistance between upper pole and
lower pole for each phase
i) R-R’
ii) Y-Y’
iii) B-B’
b Rack in the circuit breaker into service
position and check the contact resistance of
upper and lower cluster contacts
respectively with bus bars for each phase
separately. Also measure the contact
resistance from upper bus to lower bus with
circuit breaker in closed position
a) Upper R – Lower R
b) Upper Y – Lower Y
c) Upper B – Lower B
c Check contact resistance between circuit
breaker body (foot paddle) and switchgear
base frame. Contact resistance should be
less than 0.1 ohm.
3 Insulation resistance checks
a Measure the insulation resistance between
upper and lower contacts with CB in open
condition for each phase with 2500V megger
i) R phase to R phase
ii) Y phase to Y phase
iii) B phase to B phase
b Measure the insulation resistance between
phase to earth for each phase with circuit

June 2007 0 Page 64 of 154
FOR 6KV SWITCHGEARS
breaker in close condition with 2500V

megger.
i) R to earth
ii) Y to earth
iii) B to earth
c Measure the insulation resistance between
phase to phase with CB in close condition
with 2500V megger.
i) R phase to Y phase
ii) Y phase to B phase
iii) B phase to R phase
4 CB coils & spring charging motor checks

a Measure the insulation resistance of spring
charge motor at 250V
b Measure the insulation resistance of closing
coil at 250V
c Measure the insulation resistance of tripping
coil-1 at 250V
d Measure the insulation resistance of tripping
coil-2 at 250V
e Measure the winding resistance of spring
charging motor
f Measure coil resistance of closing coil
g Measure coil resistance of trip coil-1
h Measure coil resistance of trip coil-2
5 Spring charging time & CB timing checks

a Measure the spring charging time at 70%, 70%
100% & 110% of 220V DC respectively 100%
across spring charging motor in seconds 110%
b Measure the closing time of CB using CB R Y B
timing kit at 70%, 100% & 110% of 220V DC 70%
respectively across closing coil. Note down 100%
closing time of each pole in mill seconds 110%
c Measure the CB opening time using CB R Y B
100%
June 2007 0 Page 65 of 154
FOR 6KV SWITCHGEARS
respectively across trip coil-1. Note down

110%
opening time of each pole in mill seconds
d Measure the CB opening time using CB R Y B
respectively across trip coil-2. Note down 100%
opening time of each pole in mill seconds 110%
6 Anti pumping & trip free feature checks
a Insert the CB trucks into the cubicle. Press
the close PB and keep it pressed, the CB
closes. Now press the trip PB, the CB trips,
but does not close again. Now release the
close PB and then again press it, the CB
closes now.
b Check the trip free feature of the CB. Press
the trip PB and keep it pressed, breaker
opens. Now press the close PB and check
that mechanism operates to close the CB but
CB do not close.
Acceptance criteria:
a) Accepted contact resistance of various capacity circuit breakers
are as follows,
micro-ohm
1 LF2 630 ≤60
2 LF2 1250 ≤40
3 LF3 2500 ≤33
4 LF3 3150 ≤33
b) Coil resistance of close coil, trip coil 1 & 2 should be 1.1K

ohms.
c) Spring charging time for 70% to 110% of 220V DC should be
between 6 to 7 sec.
d) Circuit breaker closing time for 100% of 220V DC should be
between 60 to 70 msec.
e) Circuit breaker tripping time for 100% of DC should be between
40 to 50 msec.
11. Remarks:

June 2007 0 Page 66 of 154
FOR 6KV SWITCHGEARS
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE –11
CHECKLIST FOR CURRENT TRANSFORMER CHECKS

3. Make of current transformer:
4. Location:
5. Date of check:
7. Testing of instrument details:

June 2007 0 Page 67 of 154
FOR 6KV SWITCHGEARS

No. number
Sl. No. Description of checks Observations

1 CT make
2 CT model
3 Note down CT name plat in the below table
Phase Ratio Burden V Knee ( V) I Magn (MN) Accuracy

( VA ) class
Core Core Core Core Core Core Core 1 Core 2
1 2 1 2 1 2
RØ
T11/12
YØ
T21/22
BØ
T31/32
4 Inspect the CT for any breakages, damages, improper
mounting / clamping
5 Verify the wiring as per drawing of the CT secondary
and earthing with respect to the scheme
6 Check for earthing as per scheme
7 Interchanging of CTs among protection CTs and

measuring CTs shall not be done even if VA rating is
same
8 Measure secondary winding resistance
Core RØ YØ BØ
Core1
In m Ω

June 2007 0 Page 68 of 154
FOR 6KV SWITCHGEARS
Core 2
In m Ω
9 Carryout IR measurement at 2500V of CT for secondary to earth &
primary to secondary respectively
Core R-phase Y-phase B-phase
Core-1
prim to
sec
Core-1
sec to
earth
Core-2
prim to
sec
Core-2
sec to
earth
10 Using a battery operated polarity tester, check that
positive emf is induced between S-1 to S-2 terminal
when a positive current pulse is applied between P-1
to P-2
11 Using a primary injection test kit, inject rated primary currents into the P1
& P2 terminals. Measure these currents and those flowing out of CT
secondary terminals. Tabulate the readings. Calculate the ratio and
compare with these name plate ratio (Ratio error should not be more than
2% at specified temperature)
Current applied Current Ratio %error
In primary measured
In secondary
Core-1 Core-1 Core-1 Core-1
R Y B R Y B R Y B R Y B

June 2007 0 Page 69 of 154
FOR 6KV SWITCHGEARS
Current applied Current Ratio Core-2 % error Core-2

In primary Core- measured
2 In secondary
Core-2
R Y B R Y B R Y B R Y B
12 For protection class of CT carry out saturation test as follows,

Using a 1 phase variac; apply increasing voltages across the CT secondary
winding. Increase the voltage up to Vk/2 mentioned on CT name plate.
Note the voltage applied and the current flowing into the CT secondary at
each step of increase in the voltage. Voltage increase may be up to 10%
higher than the rated Knee point voltage at the output of step up
transformer. Draw a graph with voltage and current as the x and y-axis
respectively and incorporate the tabulated readings into the graph. When
an increase in the current by 50% is observed for an increase in the
voltage by 10%, V knee is said to have been reached. The magnetizing
current Im at voltage Vk/2 shall be within the limit as mentioned on CT
name plate.
Voltage
applied Core 1 secondary current at Core 1 secondary current at
at increasing decreasing
seconda secondary voltage secondary voltage
ry
R Y B R Y B

June 2007 0 Page 70 of 154
FOR 6KV SWITCHGEARS
Voltage Core 2 secondary current at Core 2 secondary current at

applied increasing decreasing
at secondary voltage Secondary voltage
seconda
ry
R Y B R Y B
13 Measure winding resistance of CBCT

14 Check the polarity of secondary winding of CBCT
15 Measure IR value from sec to earth at 1000V
16 Test the CBCTs (core balance current transformers) for ratio as follows, Pass the known
current to any one phase of primary and measure the current in the secondary of CBCT
Current applied Current Ratio % Error
in primary measured in
secondary
17 Test the measurement CTs for primary injection with burden connected
into secondary
Current applied Current Expected current % Error
in primary measured in
meter
June 2007 0 Page 71 of 154
FOR 6KV SWITCHGEARS
18 Ensure that spare secondary terminals (if any) is

shorted and earthed
9. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE –12
CHECKLIST FOR POTENTIAL TRANSFORMER CHECKS

3. Make of potential transformer:
4. Location:
5. Date of check:

June 2007 0 Page 72 of 154
FOR 6KV SWITCHGEARS

No. number

No.
1 Make of PT
2 Model number of PT
3 Note down the name plate details of PTs
R-phase Y-phase B-phase
Sl. No.
Accuracy
class
V.A
4 Inspect PTs for any breakages, damages,

improper mounting / clamping
5 Check that the fuses at the primary and the

secondary are as per WD and check that fuse is
OK
6 Check the primary fuse resistance value
(resistance value should be between 47.25 to
57.75 ohms)
7 Check winding resistance of primary winding
a) R phase
b) Y phase
c) B phase
8 Check winding resistance of primary winding
Core 1
a) R phase
b) Y phase
c) B phase
Core 2
June 2007 0 Page 73 of 154
FOR 6KV SWITCHGEARS
a) R phase
b) Y phase
c) B phase
9 Take the IR value of the PT secondary winding RØ YØ BØ
using a 500V megger (IR should be more than
1000 M ohms) Core 1 – Earth
Core 2 – Earth
Core 1 –Core 2
10 Take IR value of primary at 2.5KV (IR should RØ YØ BØ
be more than 1000 M ohms)
Primary –Earth
Primary – Core 1
Primary – Core 2
11 Using a battery operated polarity tester, check
that positive emf is induced between S1 to S2
terminal when a positive current pulse is
applied between P1 to P2
12 Conduct ratio test by applying 6KV across the
Primary with 6KV/240V step up transformer. Note voltage at secondary.
manufacturers documents
Sl. Primar Secondary core1 Ratio % error
No. y voltage
voltage
R Y B R Y B R Y B
Sl. Primar Secondary core2 Ratio % error

No. y voltage
voltage

June 2007 0 Page 74 of 154
FOR 6KV SWITCHGEARS
9. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE –13
CHECKLIST FOR PHOTO-THYRISTOR, ELECTROMAGNETIC LOCKS,
LIMIT SWITCHES, CIRCUIT BREAKERS, FUSES, RESISTANCES &
INDICATION LAMPS CHECKS

3. Location:
4. Date of temperature:
No. number
June 2007 0 Page 75 of 154
FOR 6KV SWITCHGEARS
No.
1 Check and note down name plate details of
photo-thyristor
electromagnetic lock for earthing switch
interlocks
electromagnetic lock for circuit breaker
position interlocks
limit switch of test position
limit switch of service position
limit switch of earthing switch
circuit breakers in control circuits
fuses in control circuit/ lighting/heating circuit
resistances in control circuit
heater
indication lamps
12 Check the operation of electromagnetic lock
manually and also by supply DC voltage
13 Check the operation of test position limit
switch manually and check the contact
changeover
14 Check the operation of service position limit
changeover
15 Check the operation of earth switch limit
changeover
16 Check the operation of switches/circuit
breakers manually and check contact
June 2007 0 Page 76 of 154
FOR 6KV SWITCHGEARS
changeover
17 Check that indication lamps are OK
18 Check that resistance values of resistances in
the control circuit are matching with WDs.
19 Check the resistance value and insulation
resistance of heaters
8. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE –14
CHECKLIST FOR SIPROTEC DIGITAL RELAY CHECKS

3. Make of digital relay:
4. Location:
5. Date of check:
7. Testing instrument details

No. number
June 2007 0 Page 77 of 154
FOR 6KV SWITCHGEARS

No.
1 Check the relay for visual inspection for any
physical damage
2 Note down the model no. of the relay
3 Note down the serial no. of the relay
4 Note down the relay bar code
5 Check the external wiring of relay as per WD
6 Measure IR value of control circuit by 250V
7 Switch on the auxiliary power supply and

measure the voltage at the relay terminals
8 Check the date, time and correct if deviated from
the local time
9 Check time maintained when auxiliary supply is Yes/No
removed
10 Check relay healthy LED glowing or not
11 Check for all LED’S functionality located on the
front panel
12 Check all binary inputs status by simulating and
resetting the inputs as per WD.
13 Check all output relay contact changeover by
forcing through keypad OR giving corresponding
input as per WD.
14 Ensure CT,PT details fed to the relay are correct
15 Check measurement function of relay:-
Inject gradually up to the rated current/voltage of each phase inputs and
compare the displayed value with the applied one
Applied Displayed Applied Displayed
current current voltage voltage

June 2007 0 Page 78 of 154
FOR 6KV SWITCHGEARS
16 Check whether specific function settings applied

or not. Enter the settings if deviated from the
setting sheet. Setting sheet enclosed as
annexure- 29 shall be filled.
17 Check that only those protection settings are
enabled which are applicable to the particular
feeder. All other protections are disabled.
18 Inject current, voltage at analog input terminals or initiate binary inputs
as per the setting values and check the actuation of output relays,
indicating LED’S configured to the corresponding protections
Protection Rated Output relay Confirm Resetted
parameter Actuated LED Yes/No
Yes/No Indication
And LED No.
50
50 AP
51
510L
51N
50 BF
27
59
87L
64
87T
46
66
50 LR
49
46V
21
19 Check and ensure all the binary output operation as per logic diagram

June 2007 0 Page 79 of 154
FOR 6KV SWITCHGEARS
Binary out put List of binary input Observations

number required for initiating (Checked/Not checked)
binary output
9. Remarks:

June 2007 0 Page 80 of 154
FOR 6KV SWITCHGEARS
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE –15
CHECKLIST FOR ELCTROMAGNETIC DIFFERENTIAL RELAY TEST

2. Cubicle KKS code:-
3. Make of relay:
4. Location:
5. Date of checks:

No. number to

June 2007 0 Page 81 of 154
FOR 6KV SWITCHGEARS

No.
1 Relay make
2 Relay model
3 Relay serial number
4 Check the relay by visual inspection for any

physical damage
5 Check the external wiring as per WDs
6 Check the contact status as per WDs
7 Set the parameter as per relay setting sheet
8 Switch ON the auxiliary power supply and find

relay healthiness
9 Measure the terminal voltage of auxiliary supply
10 Keep one differential input as zero and increase the current input of
second differential input ,ensure the pick up of the relay and vice-versa
Sl.No. Differential Differential Relay pick up

input No:1 input No:2 Yes/no
Current (A) Current (A)
11 Note down the final setting values

June 2007 0 Page 82 of 154
FOR 6KV SWITCHGEARS
a) The operating current shall be within ±7.5% of set value.
b) Relay reset ratio shall be more than 0.75.
c) The operating time for 3Iopr. shall be less than 0.04s.
9. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE – 16
CHECKLIST FOR ELECTROMAGNETIC
CURRENT/VOLTAGE/FREQUENCY/TIMER RELAY TEST

3. Make of relay:
4. Location:
5. Date of check:

No. number to

June 2007 0 Page 83 of 154
FOR 6KV SWITCHGEARS

No.
1 Relay make
2 Relay model
3 Relay serial number
4 Carry out visual check on the relay for any physical

damage
5 Note down the setting range
6 Note down the initial setting
7 Carry out settings as per setting sheet
7 Current/v Pick up Drop Operating Contact Remarks

oltage/fre current up time changeove
quency/ti /voltage current r
/frequen
me setting /voltage
cy
/freque
ncy
6 Note down the final setting
1. Voltage relay (under voltage/over voltage)

June 2007 0 Page 84 of 154
FOR 6KV SWITCHGEARS
a. The relative mean error of relay operating voltage at each setting

shall not exceed ±5% for DC relays and ±10% for AC relays.
b. If adjusted by additional variable resistor, error shall be ±3%.
c. Additional ±3% error if operating frequency changes by ±3% for AC
relays.
d. Operating time of over voltage relay shall not exceed 0.06s at
1.2Unom & 0.04s at 2Unom.
e. Operating time of under voltage relay shall not exceed 0.06s at
Unom to 0.8Ureset.
2. Increased sensitivity current relays
a. Operating current shall be within ±3% of setting
b. Operating time at two times operating current shall be less than
0.06s.
3. Over current relays
Operating current shall be within ±5% of setting for AC operating
relays.
Operating current shall be within ±7.5% of setting for DC operating
relays.
Relative additional error of relay operating current when the input
frequency of operating parameter changes by ±3Hz shall not be more
than ±3%.
The relay reset ratio shall be more than 0.9.
Time of operation shall be less than 0.06s for 1.2Iopr & 0.035s for
3Iopr.
4. Reverse current relays
Deviation of operating current from set value shall not exceed ±10%.
The relay reset ratio shall be more than 0.95.
Relay operation time for 2Iopr shall be less than 0.05s for coil-1 &
0.045s for coil-2.

June 2007 0 Page 85 of 154
FOR 6KV SWITCHGEARS
5. Voltage relays (under voltage direct sequence relay & over voltage
reverse sequence relays)
The pick up voltage for both types of relays shall be within ±10%
Relay reset ratio for voltage reverse sequence relays shall be more than
0.95.
Relay reset ratio for voltage direct sequence relays shall be more than
1.05.
The relay pick up voltage complementary error at frequency change by
±3Hz of rate done shall not exceed ±7%.
Time of operation of voltage reverse sequence relays at 2Umean shall
not be less than 0.04 sec.
Time of operation of voltage direct sequence relay for input voltage
1.1Unom to 0.8Unom shall not exceed 0.075s.
6. Timer
a. The average basic time delay error () in percent from the setting
value shall not exceed the value calculated from the formula,
= ±│a + b. Tm/T│
Tm= Maximum setting from the nominal setting range
T= Set value of time on scale
a= 1.5 (constant for timers of all range)
b= 1.0 for timers of range 0.05-3.0
0.25 for timers of ranges 0.15-9.0, 0.5-30.0 & 6.0-90.0.
b. Reset time of the timers shall be less than 0.04s.
c. Operating voltage shall be less than 80% of nominal.
7. Frequency relays
The relay operating frequency shall be within ±0.25Hz of set value with
harmonics voltage up to 25% of main frequency voltage.
Operating time of over frequency relays shall be more than 0.12 sec.
Operating time of under frequency relays shall be more than 0.1 sec.
9. Remarks:
June 2007 0 Page 86 of 154
FOR 6KV SWITCHGEARS
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE – 17
CHECKLIST FOR ELECTROMAGNETIC AUXILIARY RELAY TEST
1. Switchgear KKS code :

2. Cubicle KKS code :
3. Make of the relay :
4. Location :
5. Date of check :
6. Ambient temperature :

No. number to

June 2007 0 Page 87 of 154
FOR 6KV SWITCHGEARS

No.
1 Relay type and name plate details
2 Relay designation
3 Relay coil rated voltage
4 Check there is no physical damage to relay
5 Check wiring of relay terminals O.K.
6 Check insulation resistance of coil and all

terminals of the relay.
7 Check resistance of coil
8 Check pick up voltage
9 Check drop off voltage
10 Check the operation of electrical/mechanical

targets and flags
11 Check the operation of relay contacts
a) Pick up voltage shall be less than 80% of DC operating current.
b) Pick up voltage shall be less than 85% of AC operating current.
c) Operating voltage for voltage operated indicating auxiliary relay shall
be less than 70% of nominal voltage.
d) Operating current for current operated indicating auxiliary relays
shall be less than 85% of nominal current.
9. Remarks:

June 2007 0 Page 88 of 154
FOR 6KV SWITCHGEARS
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE – 18
CHECKLIST FOR CURRENT TRANSDUCER CHECKS

3. Make of current transducer:
4. Location:
5. Date of check:

No. number

June 2007 0 Page 89 of 154
FOR 6KV SWITCHGEARS

No.
1 Current transducer make
2 Current transducer model
3 Current transducer serial number
4 Current transducer input range
5 Current transducer output range
6 Check there is no physical damage
7 Check insulation resistance of terminals
8 Applied Applied Test Expected Measured % Error

current % current burden output output
value across current current
current
transducer
0
25
50
75
100
Acceptance criteria: The percentage error should not be more than ±0.5%
9. Remarks:

June 2007 0 Page 90 of 154
FOR 6KV SWITCHGEARS
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE – 19
CHECKLIST FOR VOLTAGE TRANSDUCER CHECKS

3. Make of voltage transducer:
4. Location:
5. Date of check:

No. number

June 2007 0 Page 91 of 154
FOR 6KV SWITCHGEARS

No.
1 Voltage transducer make
2 Voltage transducer model
3 Voltage transducer serial number
4 Voltage transducer input range
5 Voltage transducer output range
8 Applied Applied Expected Measured % Error

voltage % voltage value output output
current current
0
25
50
75
100
9. Remarks:
NPCIL Contractor
June 2007 0 Page 92 of 154
FOR 6KV SWITCHGEARS
Technicians
Supervisor
Engineer
ANNEXURE – 20
CHECKLIST FOR POWER TRANSDUCER CHECKS
1. Switchgear KKS code :

2. Cubicle KKS code :
3. Make of power transducer :
4. Location :
5. Date of check :
6. Ambient temperature :
7. Testing instrument details :

No. number to

June 2007 0 Page 93 of 154
FOR 6KV SWITCHGEARS
Sl. Description of checks

No. Observations
1 Power transducer make
2 Power transducer model
3 Power transducer serial number
4 Power transducer input range
5 Power transducer output range
8 Use 3-phase power meter to check power transducer
Applied Applied Test Expected Measured % Error

voltage % current burden output output
value across current current
power
transducer
0
25
50
75
100
9. Remarks:

June 2007 0 Page 94 of 154
FOR 6KV SWITCHGEARS
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE – 21
CHECKLIST FOR VOLTMETER CHECKS

3. Make of voltmeter:
4. Location:
5. Date of check:

No. number

June 2007 0 Page 95 of 154
FOR 6KV SWITCHGEARS

No.
1 Make
2 Model
3 Range of operating voltage/current
4 Range of measurement
5 Accuracy class
8 Applied input Expected output Measured % Error

parameter voltage output voltage
0%
25%
50%
75%
100%
Acceptance criteria: Maximum admissible error is ±1.5%
9. Remarks:
NPCIL Contractor

June 2007 0 Page 96 of 154
FOR 6KV SWITCHGEARS
Technicians
Supervisor
Engineer
ANNEXURE – 22
CHECKLIST FOR AMMETER CHECKS

3. Make of ammeter:
4. Location:
5. Date of check:

No. number

June 2007 0 Page 97 of 154
FOR 6KV SWITCHGEARS

No.
1 Make
2 Model
3 Range of operating voltage/current
4 Range of measurement
5 Accuracy class
8 Applied current Expected output Measured % Error

current output current
Acceptance criteria: Maximum admissible error is ±1.5%
9. Remarks:
NPCIL Contractor

June 2007 0 Page 98 of 154
FOR 6KV SWITCHGEARS
Technicians
Supervisor
Engineer
ANNEXURE –23A
CHECKLIST FOR LOGICS & INTERLOCKS CHECKS
ON WORKING SUPPLY AND STANDBY SUPPLY INCOMER FEEDER OF
NOPSS

3. Feeder description:
4. Location:
5. Date of check:

No. number
June 2007 0 Page 99 of 154
FOR 6KV SWITCHGEARS

No.
1 Ensure that installation checks are completed
as per annexure-2 and no deficiency exists
2 Ensure bus duct checks are completed as per
annexure-3 and no deficiency exists
3 Ensure that cabling and connections checks
are completed as per annexure-4 and no
deficiency exist
4 Ensure that internal wiring checks are done as
per WDs and no deficiency exists
5 Ensure that circuit breaker is checked as per
6 Ensure that relays are tested as per their
testing procedure attached in annexure 14, 15,
16 & 17 and no deficiency exists
7 Ensure that meters and transducers are
checked as per their testing procedure attached
in annexure 18, 19, 20, 21 & 22 and no
deficiency exists
8 Ensure that current transformers are tested as
per annexure-11 and no deficiency exists
9 Ensure that potential transformers are tested
10 Ensure that photo-thyristors, electromagnetic
locks, limit switches, circuit breakers,
resistances, heaters and indication lamps are
tested as per annexure-13 and no deficiency
exists
11 Check that TPTS/USH/LCB is commissioned
and is functional
12 Check that 220V DC is available in switchgear
as per WDs

June 2007 0 Page 100 of 154
FOR 6KV SWITCHGEARS
13 Check that 220V AC is available in switchgear

as per WDs
14 Interlocks check
(a) Interlock checks for main incomer breaker
(from UAT) of normal power supply system
ii. Closing circuit interlocks
1. Put the circuit breaker in test position and
switch ON DC control power supply of
closing circuit. Check that spring charging
motor started to charge the spring
2. Check the closing of circuit breaker from
numerical relay A11 by BO11 contact
remote contact
4. Check the breaker status indicators in
relay is functional to indicate the current
breaker position
iii. Trip circuit-1 interlocks
1. Switch ON DC control power supply of trip
coil-1 circuit and check the tripping of
circuit breaker by
protections(AP,51,51N,50BF,27,R.C) from
corresponding contacts in WD
2. Check the tripping of breaker by
protections of generator
transformer(51,51N-1,51N-2) from
3. Check the tripping of breaker by
protections of UAT(WTI,OTI) from
4. Check the tripping of circuit breaker by
generator protection from corresponding
contacts in WD
breaker position
iv. Trip circuit-2 interlocks
1. Switch ON DC control power supply of trip

June 2007 0 Page 101 of 154
FOR 6KV SWITCHGEARS
coil-2 circuit and check the opening of

circuit breaker from remote control
contacts
protections(51,27) from corresponding
contacts in WD
main VT protections(AP,50BF) from
protection of generator
transformer(51,64,50BF) from
protections of UAT(51N,WTI,OTI) from
breaker position
v. Put the circuit breaker in service position
and do all the checks mentioned above
vi. Check all the interlocks as per logic ladder
diagram of the feeder
(b) Interlocks checks for standby incomer

feeder (from RAT) of normal power supply
system
i) Closing circuit interlocks
1. Put the circuit breaker in test position and
switch ON DC control power supply of
closing circuit. Check that spring charging
motor started to charge the spring
numerical relay A11 by BO11 contact
remote contact
breaker position
June 2007 0 Page 102 of 154
FOR 6KV SWITCHGEARS
ii) Trip circuit-1 interlocks

1. Switch ON DC control power supply of
trip coil-1 circuit and check the tripping
of circuit breaker by
protections(87L,AP,51,50BF,RC) from
main incomer breaker status interlock
iii) Trip circuit-2 interlocks
trip coil-2 circuit and check the opening
of circuit breaker from remote control
contacts
protections(87L,51) from the
main VT protections(AP,50BF) from
4. Check the current breaker status is
indicated in the relay
iv) Put the circuit breaker in service position
v) Check all the interlocks as per logic ladder
diagram of the feeder
c) Interlocks checks for incomer breaker

feeder from RAT to reserve power bus
(i) Closing circuit interlocks
1. Put the circuit breaker in test position
and switch ON DC control power
supply of closing circuit. Check that
spring charging motor started to charge
the spring
2. Check the remote closing of circuit
breaker by B02 contacts of A11 relay in
WD
indicated in the cabinet
June 2007 0 Page 103 of 154
FOR 6KV SWITCHGEARS
(ii) Trip circuit-1 interlocks

of circuit breaker by B01 contacts of
A11 relay in WD
protection of RAT as per WD
(iii) Trip circuit-2 interlocks
of circuit breaker by RAT protection
contacts in WD
protections from corresponding
contacts of B014 in WD
VT interlocks from B01 relay contacts
in WD
(iv) Put the circuit breaker in service
position and do all the checks
mentioned above
(v) Check all the interlocks as per logic
ladder diagram of the feeder
d) Interlocks checks for main incomer from

CSAT to common station power supply bus
the spring
breaker by B011 contacts of A11 relay
in WD
June 2007 0 Page 104 of 154
FOR 6KV SWITCHGEARS

A11 relay in WD
protection of CSAT as per WD
A11 in WD
protections from VT circuit by B07
contacts of A11 in WD
protection of CSAT as per WD
mentioned above
e) Interlocks checks for standby incomer from

reserve power supply system switchgear
the spring
June 2007 0 Page 105 of 154
FOR 6KV SWITCHGEARS
WD
A11 relay in WD
B07 contacts of A11 as per WD
A11 in WD
protections from VT circuit by B04
mentioned above
9. Remarks:
NPCIL Contractor

June 2007 0 Page 106 of 154
FOR 6KV SWITCHGEARS

Technicians
Supervisor
Engineer
ANNEXURE –23B
EPSS

4. Location:
5. Date of check:

June 2007 0 Page 107 of 154
FOR 6KV SWITCHGEARS

No. number

No.
deficiency exist
deficiency exists
exists
and is functional
June 2007 0 Page 108 of 154
FOR 6KV SWITCHGEARS

as per WDs
as per WDs
14 Interlocks check
(a) Interlocks checks for main incomer from
NOPSS
the spring
breaker by K68 relay contacts in WD
indicated in the panel
of circuit breaker by protections from
K62 contact in WD
trip coil-2 circuit and check the remote
opening of circuit breaker by K69
contacts in WD
contacts in WD

June 2007 0 Page 109 of 154
FOR 6KV SWITCHGEARS
mentioned above
(b) Interlocks checks for DG incomer feeder

the spring
contacts in WD
contacts in WD
mentioned above
9. Remarks:
June 2007 0 Page 110 of 154
FOR 6KV SWITCHGEARS
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE –23C
RPSS

4. Location:
5. Date of check:
June 2007 0 Page 111 of 154
FOR 6KV SWITCHGEARS

No. number
No.
deficiency exist
deficiency exists
exists
and is functional
as per WDs
June 2007 0 Page 112 of 154
FOR 6KV SWITCHGEARS

as per WDs
14 Interlocks check
(a) Interlocks checks for main incomer feeder
from NOPSS
the spring
WD
3. Check the local closing of breaker by
B02 contact of A11 relay
of circuit breaker by B01 contact of A01
and B01 contact of A11 in WD
of circuit breaker by B04 contact of A11
relay in WD
protections from VT circuit B05 contact
of A11 in WD
B05 contacts of A11 for NOPSS feeder
interlock in WD

June 2007 0 Page 113 of 154
FOR 6KV SWITCHGEARS

mentioned above
(b) Interlocks checks for DG incomer feeder

breaker
the spring
WD
3. Check the closing of circuit breaker by
B02 contacts of A11 in WD
DG automatic control system
opening of circuit breaker by B08
June 2007 0 Page 114 of 154
FOR 6KV SWITCHGEARS
B01 contacts of A11 relay in WD
A11 relay in WD
B03 contacts of A11 in VT circuit
mentioned above
ladder diagram of the feeder.
9. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer

June 2007 0 Page 115 of 154
FOR 6KV SWITCHGEARS
ANNEXURE –24
CHECKLIST FOR PRE-COMMISSIONING CHECKS ON MAIN AND
SUPPLEMENTARY VT CUBICLES

3. Make of VT:
4. Location:
5. Date of check:
No. number
Sl. Description of checks

No. Observations
1 Note down WD number of the main/standby VT
feeder
2 Clean the VT compartment completely and ensure
that no foreign materials are left inside
4 Check and note down details of VT fuse e.g. type,
make etc
5 Check and ensure that the internal wiring and control
circuit are as per WDs and ensure tightness of wires
6 Check that control & protection circuit is wired as per
drawing and check the continuity of each wire.
Remove all extra / unwanted wires and ensure
tightness of wires.
7 Check IR of control & protection circuit at 250V
8 Check that monitoring and indication circuit is wired
as per drawing. Check the continuity of each wire
9 Check the IR value of circuit at 50V
June 2007 0 Page 116 of 154
FOR 6KV SWITCHGEARS
10 Check the VT as per annexure-25

11 Test the SIPROTEC digital relays as per annexure-14
12 Test electromagnetic differential relays as per
annexure-15
13 Test electromagnetic current/voltage/timer relays as
per annexure-16
14 Test electromagnetic auxiliary relays as per annexure-
17
15 Test current transducers as per annexure-18
16 Test voltage transducers as per annexure-19
17 Test power transducers as per annexure- 20
18 Test voltmeters as per annexure-21
19 Test ammeters as per annexure-22
20 Test CT as per annexure-11
21 Test PT as per annexure-12
22 Test of photo-thyristors, electromagnetic locks, limit
switches, miniature circuit breakers, fuses,
annexure-13
23 Prepare 4 sets of as built drawing and hand over one
copy to TSS, one copy to EMU doc centre and two
copies with system engineer
9. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer

June 2007 0 Page 117 of 154
FOR 6KV SWITCHGEARS
ANNEXURE –25
CHECKLIST FOR VT CHECKS

3. Make of VT:
4. Location:
5. Date of check:

No. number

No.
1 Inspect the VT for any physical damage &
missing of parts
2 Cleanliness of all the insulators surface with
dry cloth
3 Check and ensure lubrication of all the
linkages, moving / sliding parts as per
manufacturer’s instructions
4 Check blue matching of the female cluster
contact with male bus bar contact and
ensure that blue matching is successful
5 Check and ensure functionality of MCB of
VT secondary
6 Check and ensure the functioning of
mechanical interlocks
Check and ensure that earthing switch can
not be closed if VT is in service position
Check and ensure that earthing switch
driving rod can be inserted into the drive slot
only after releasing of electromagnetic lock
June 2007 0 Page 118 of 154
FOR 6KV SWITCHGEARS
Check and ensure that earthing switch drive

blocking casing can not be opened if VT is in
service position
Check and ensure that when earthing switch
is closed then earthing switch drive blocking
casing can not be closed
Check and ensure that VT can not be racked
into service position if earthing switch is
closed
7 Check contact changeover of test position
limit switch, service position limit switch &
earthing switch operation limit switch
8 Winding resistance checks
1. Measure the prim winding resistance
2. Measure the secondary winding
resistance
9 Insulation resistance checks at 2.5KV
1. IR value between primary to earth
2. IR value between secondary to earth
3. IR value between primary and secondary
10 Conduct ratio test by applying 6KV across
the primary with 6KV/240V step up
transformer. Note voltage at secondary.
Tabulate and compare the values with the
nameplate values & manufacturers
documents
11 Check and note down details of fuse of VT
12 Check contact resistance between VT body

(foot paddle) and switchgear base frame
(should be less than 0.1 ohm)
13 Prepare 4 sets of as built drawing and hand
over one copy to TSS, one copy to EMU doc
centre and two copies with system engineer

June 2007 0 Page 119 of 154
FOR 6KV SWITCHGEARS
9. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer

June 2007 0 Page 120 of 154
FOR 6KV SWITCHGEARS
ANNEXURE –26
CHECKLIST FOR PRE-COMMISSIONING CHECKS ON OUTGOING
FEEDERS

3. Load KKS code:
4. Load description:
5. Date of check:
No. number
No.
1 Note down WD number of the outgoing feeder
2 Check and clean the breaker compartment
completely and ensure that no foreign
materials are left inside
4 Check and ensure that the internal wiring and
control circuit are as per WDs and ensure
tightness of the wires.
5 Check that control & protection circuit is wired
as per drawing and check the continuity of
each wire and check tightness of wires. Remove
all extra / unwanted wires
6 Check IR of control & protection circuit at
250V
7 Check that monitoring and indication circuit is
wired as per drawing and check tightness of
the wires. Check the continuity of each wire
8 Check the IR value of circuit at 50V
9 Check circuit breaker as per annexure-10
June 2007 0 Page 121 of 154
FOR 6KV SWITCHGEARS
10 Test the SIPROTEC digital relays as per

annexure-14
11 Test electromagnetic differential relays as per
annexure-15
12 Test electromagnetic
current/voltage/frequency/timer relays as per
annexure-16
13 Test electromagnetic auxiliary relays as per
annexure-17
14 Test current transducers as per annexure-18
15 Test voltage transducers as per annexure-19
16 Test power transducers as per annexure- 20
17 Test voltmeters as per annexure-21
18 Test ammeters as per annexure-22
19 Test current transformers as per annexure-11
20 Test potential transformers as per annexure-12
21 Checks photo-thyristors, Electromagnetic

locks, Limit switches, circuit breaker, fuses,
annexure-13
22 Check logics and interlocks of NOPSS outgoing
feeders as per annexure-27A
23 Check logics and interlocks of EPSS outgoing
feeders as per annexure-27B
24 Check logics and interlocks of RPSS outgoing
feeders as per annexure-27C
25 Prepare 4 sets of as built drawing and hand
over one copy to TSS, one copy to EMU doc
centre and two copies with system engineer
9. Remarks:
June 2007 0 Page 122 of 154
FOR 6KV SWITCHGEARS
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE –27A
June 2007 0 Page 123 of 154
FOR 6KV SWITCHGEARS
ON NOPSS OUTGOING FEEDERS

3. Load KKS code:
5. Date of check:

No. number

No.
2 Ensure that checks on bus duct is completed
as per annexure- 3 and no deficiency exists
deficiency exist
deficiency exists
June 2007 0 Page 124 of 154
FOR 6KV SWITCHGEARS

exists
and is functional
as per WDs
as per WDs
14 Interlocks check
(a) Interlocks checks for line feeder to RPSS from
NOPSS
and switch ON DC control power supply
of closing circuit. Check that spring
charging motor started to charge the
spring
2. Check the closing of circuit breaker
from numerical relay A11 by BO11
contact
3. Check the closing of circuit breaker
from remote contact
protections(87L,AP,51,50BF,RC) from

June 2007 0 Page 125 of 154
FOR 6KV SWITCHGEARS

of circuit breaker from remote control
contacts
protections(87L,51,AP,51N,50BF) from
the corresponding contacts in WD
TPTS signal from corresponding
contacts in WD
mentioned above
(v) Ensure all the logics are checked as per
WDs. of the feeder.
(b) Interlocks checks for line feeder to EPSS from

NOPSS
spring
breaker by K-61 relay contacts in WD
protections(AP,51,51N) from K71 relay
contacts in WD
protections(87L,50BF) from K72 relay
contacts in WD
June 2007 0 Page 126 of 154
FOR 6KV SWITCHGEARS

K60 relay contacts in WD
opening of circuit breaker by K62 relay
contacts in WD
protections(AP,51,51N) from K81 relay
contacts in WD
protections(87L,50BF) from K82 relay
contacts in WD
mentioned above
WDs. of the feeder
c) Interlocks checks for operating transformer

with ATS and without ATS
spring
breaker by A-01 contacts in WD
numerical relay A11 contacts BO11
June 2007 0 Page 127 of 154
FOR 6KV SWITCHGEARS

protections(AP,50,50N,51,51N,WTI,RC)
from corresponding contacts in WD
opening of circuit breaker by A-01
contacts in WD
mentioned above
WDs. of the feeder
d) Interlocks checks for low power motor

spring
protections(AP,50,50N,50LR,49,46,66,2
7) from corresponding contacts in WD
June 2007 0 Page 128 of 154
FOR 6KV SWITCHGEARS

contacts in WD
protections(AP,50,50N,50LR,49,46,27)
emergency push button contacts of load
in WD
mentioned above
WDs. of the feeder
e) Interlocks of motor feeder with differential

protection
spring
protections(AP,50N,50LR,49,46,27)
from corresponding contacts of A-12 in
June 2007 0 Page 129 of 154
FOR 6KV SWITCHGEARS
WD
protection (87M) from corresponding
contact of A-11 in WD
contacts in WD
protections(AP,50N,50LR,49,46,27)
WD
protection(87M) from corresponding
contact of relay A-11 in WD
in WD
mentioned above
WDs. of the feeder
f) Interlocks checks for pump motor feeder

spring
breaker by corresponding LCB contacts
in WD
June 2007 0 Page 130 of 154
FOR 6KV SWITCHGEARS

protections(AP,50,50N,50LR,49,46,27)
LCB command contact in WD
opening of circuit breaker by LCB
command contacts in WD
protections(AP,50,50N,50LR,49,46,66,2
in WD
mentioned above
WDs. of the feeder
g) Interlocks checks for RCP motor speed-1

feeder
spring
June 2007 0 Page 131 of 154
FOR 6KV SWITCHGEARS

protections(AP,50N,50LR,46,27,87M)
contacts in WD
protections(AP,50N,50LR46,27,87M)
mentioned above
WDs. of the feeder
h) Interlocks checks for RCP motor speed-2

feeder
spring
June 2007 0 Page 132 of 154
FOR 6KV SWITCHGEARS

protections(AP,50N,50LR,49,46,37,27,8
7M) from corresponding contacts in WD
contacts in WD
protections(AP,50N,50LR,49,46,27,37,8
7M) from corresponding contacts in WD
mentioned above
WDs. of the feeder
i) Interlocks checks for standby transformer

spring
numerical relay A-11 & A-12 contacts
in WD
June 2007 0 Page 133 of 154
FOR 6KV SWITCHGEARS

WD
opening of circuit breaker by numerical
relay contacts of A-11&A12 in WD
mentioned above
WDs. of the feeder
j) Interlocks checks for 6/0.4KV auxiliary

transformer
spring
breaker by numerical relay A-11
contacts in WD
June 2007 0 Page 134 of 154
FOR 6KV SWITCHGEARS
of circuit breaker by protections(RC,86)

opening of circuit breaker by relay A-11
contacts in WD
protections(AP,50,50N,51,51N,WTI,RC,8
mentioned above
WDs. of the feeder
k) Interlocks checks for tie feeder of unit-1&unit-

2 at reserve power supply bus
spring
WD
of circuit breaker by B01 contacts of A11
relay in WD
June 2007 0 Page 135 of 154
FOR 6KV SWITCHGEARS
B07 contacts of relay A21 for unit-2

breaker interlock
A11 in WD
protections from corresponding contacts
of B021 of A21 relay in WD for unit-2
interlocks
RAT protection contacts in WD
(iv) Put the circuit breaker in service position
WDs. of the feeder
l) Interlocks checks for NPCIL feeders of

common station power supply switchgear
spring
WD
June 2007 0 Page 136 of 154
FOR 6KV SWITCHGEARS
A11 relay in WD
A11 in WD
protections from K71 relay contacts as
per WD
mentioned above
WDs. of the feeder
m) Interlocks checks for working transformer
feeder of common station power supply
switchgear
spring
WD
A11 relay in WD
June 2007 0 Page 137 of 154
FOR 6KV SWITCHGEARS

A11 in WD
protections LV breaker and WTI of
transformer as per WD
LCB of desalination building
transformer feeder as per WD
mentioned above
WDs. of the feeder
n) Interlocks checks for standby transformer

feeder of common station power supply
switchgear
spring
breaker by B05 contacts of A12 relay and
B03 contacts of A11 relay as per WD
A11 relay in WD
June 2007 0 Page 138 of 154
FOR 6KV SWITCHGEARS

trip coil-2 circuit and check the
tripping of circuit breaker by B04
contacts of A12 in WD.
2. Check the tripping of circuit breaker
by protections LV breaker and WTI of
transformer as per WD.
indicated in the cabinet.
mentioned above
WDs. of the feeder
o) Interlocks checks for tie breaker between BCE

& BCG
spring
WD
A11 relay in WD
June 2007 0 Page 139 of 154
FOR 6KV SWITCHGEARS

A11 in WD
B05 & B021 contacts of A11 in WD for
CSAT incomer feeder interlock
mentioned above
WDs. of the feeder
9. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE –27B
June 2007 0 Page 140 of 154
FOR 6KV SWITCHGEARS
ON EPSS OUTGOING FEEDERS

3. Load KKS code:
5. Date of check:

No. number

No.
as per annexure-3 and no deficiency exists.
deficiency exist
testing procedure attached in annexure 14,15
16& 17and no deficiency exists
deficiency exists
June 2007 0 Page 141 of 154
FOR 6KV SWITCHGEARS

exists
and is functional
as per WDs
as per WDs
14 Interlocks check
(a) Interlocks checks for auxiliary transformer
feeder of EPSS
the spring
corresponding contacts of K71 in WD
K69 contact in WD

June 2007 0 Page 142 of 154
FOR 6KV SWITCHGEARS

contacts in WD
contacts of K81 in WD
3. Check the tripping of circuit breaker on
transformer protections
mentioned above
WDs. of the feeder
(b) Interlocks checks for EPSS motor feeders
the spring
3. Check the closing of compressor feeder
circuit breaker by K61 relay contacts in
WD
K69 contact in WD
June 2007 0 Page 143 of 154
FOR 6KV SWITCHGEARS

contacts in WD
contacts of K71 in WD
mentioned above
WDs. of the feeder
9. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE –27C
ON RPSS OUTGOING FEEDERS

June 2007 0 Page 144 of 154
FOR 6KV SWITCHGEARS

3. Load KKS code:
5. Date of check:
No. number
No.
deficiency exist
deficiency exists
June 2007 0 Page 145 of 154
FOR 6KV SWITCHGEARS

exists
and is functional
as per WDs
as per WDs
14 Interlocks check
(a) Interlocks checks for RPSS motor feeder
spring
3. Check the closing of compressor feeder
circuit breaker by K61 relay contacts in
WD
K69 contact in WD
contacts in WD

June 2007 0 Page 146 of 154
FOR 6KV SWITCHGEARS

protections from corresponding contacts
of K71 in WD
(vi) Put the circuit breaker in service
mentioned above
(vii) Ensure that checks on bus duct is
completed as per annexure-3 and no
deficiency exists
(b) Interlock checks for tie feeder between BDE &

BDF
the spring
WD
opening of circuit breaker by B03
B01 contacts of A11 relay in WD
June 2007 0 Page 147 of 154
FOR 6KV SWITCHGEARS

A11 relay in WD
VT interlocks from B011 contacts of
A11 in WD
mentioned above
(v) Ensure that checks on bus duct is
completed as per annexure-3 and no
deficiency exists
9. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer
ANNEXURE –28
CHECKLIST FOR ENERGISATION OF SWITCHGEAR


June 2007 0 Page 148 of 154
FOR 6KV SWITCHGEARS
3. Location:
4. Date of check:

No. number

No.
1 Check and ensure that installation checks as per
4.1 are completed and no deficiency exits
2 Check and ensure that checks on bus duct as per
4.2 is completed and no deficiency exits
3 Check and ensure that cabling and connection
checks as per 4.3 are completed and no deficiency
exits
4 Check and ensure that interfacing checks as per 4.4
is completed and no deficiency exits
5 Check and ensure that pre-commissioning checks
on 6KV switchgear (excluding working supply and
standby supply incomers, PT cubicle & outgoing
feeders) are completed as per 4.5 and no deficiency
exists
on main and supplementary VT is completed as per
4.7 and no deficiency exists
on outgoing feeders are completed as per 4.8 and no
deficiency exists
8 Rack in main or standby incomer circuit breakers
into service position and keep it “OFF”
9 Rack in main and supplementary voltage
transformers into service position
10 Rack out standby incomer or main incomer and all
June 2007 0 Page 149 of 154
FOR 6KV SWITCHGEARS
the outgoing feeders into service position and keep it

“OFF”. Put “DO NOT OPERATE TAG” to standby
incomer or main incomer and all the outgoing
feeders
11 Reset all the relays and note the position of flag or
LEDs indication of relays is as per scheme
12 Charge the transformer feeding the 6KV switchgear.
Ensure 6 KV is available up to the PTs in the
switchgear and 6KV voltage is indicated in the
incomer cubicle relay/voltmeter
13 Switch ON main incomer and check the availability
of all three phase voltage in voltmeter
14 Monitor the following parameters
Sl. Type of check Values achieved

No
Initial ½ hr 1 hr 1½ hrs 2 hrs
(i) Bus voltage
(iii) Any
abnormality
(iv) Any
annunciation/
alarm
(v) Any tripping
8. Remarks:
NPCIL Contractor
June 2007 0 Page 150 of 154
FOR 6KV SWITCHGEARS

Technicians
Supervisor
Engineer
ANNEXURE –29
CHECKLIST FOR RELAY SETTINGS CHECKS

June 2007 0 Page 151 of 154
FOR 6KV SWITCHGEARS
3. Load KKS code:

5. Date of check:
Cubicle No: Relay designation:

Sl. Address Parameter Recommended As Comments
No. setting found
setting

June 2007 0 Page 152 of 154
FOR 6KV SWITCHGEARS
8. Remarks:
NPCIL Contractor
Technicians
Supervisor
Engineer
DISTRIBUTION SHEET

June 2007 0 Page 153 of 154
FOR 6KV SWITCHGEARS
Copy
Distributed to Number of copies
Number
1. Project Director 1
2. Station Director 1
3. Chief Superintendent 1
4. TSS 1
5. OS 1
6. MS 1
7. TS 1
Commissioning Management 2
8.
Team
9. Working Group 2
Sub Working Group(each 2
10.
group)
11. Library 2
12. O&M Doc. centre 1
DIR(P) / CE (OMC) – NPC, 1
13.
Mumbai
14. KKHQ doc. centre 1

June 2007 0 Page 154 of 154

Commissioning of Kudankulam Nuclear Power Project 6kV Switchgear

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Commissioning of Kudankulam Nuclear Power Project 6kV Switchgear

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NUCLEAR POWER CORPORATION OF INDIA

KUDANKULAM NUCLEAR POWER

DOCUMENT No: I01.KK.0.BBA.PN.PM.WD017

Prepared by Checked by Reviewed by Approved by

M. Satheesh Kumar P.K.Mandal

Md. Tauquir Alam Sathishkumar B.

REVISION CONTROL SHEET

Md. Tauquir Alam

Sl. Content Page

1. (i) Cover page 1

2. (ii) Revision control sheet 2

3. (iii) Table of content 3

6. 3.0 Pre-requisites & Initial conditions 7

7. 3.1 Requirement of other systems 7

8. 3.2 System requirements 8

9. 3.3 Manpower requirements 8

10. 3.4 Test instruments and other materials 8

27. H Testing of meters and transducers 20

supply and standby supply incomers,

78. Annexure – 24 Checklist for pre-commissioning checks 116

Date of Issue Revision Number Page Number

1. The power transformer feeding to the 6KV switchgears are

5. Primary injection test kit.

4.1 Installation checks:

Date of Issue Revision Number Page Number

Date of Issue Revision Number Page Number

7. Check for continuity, IR value, correct ferruling, lugging,

4.4 Interfacing checks:

Date of Issue Revision Number Page Number

11. Check interfacing cabling between 6 KV switchgear and 24KV GCB

Date of Issue Revision Number Page Number

Nominal bolt thread Tightening torque N-m

Date of Issue Revision Number Page Number

4.6 Pre-commissioning checks on working supply and standby supply

g. Check and ensure manual spring charging is functional and

ii. Contact resistance check:

Date of Issue Revision Number Page Number

a) Close the circuit breaker and measure the contact resistance

Date of Issue Revision Number Page Number

d) Measure the CB opening time using CB timing kit at 70%,

axis respectively and incorporate the tabulated readings into

f) Check the operation of indication lamps.

Date of Issue Revision Number Page Number

n) Check that TPTS/USH/LCB is commissioned and is functional.

b. Check IR of control & protection circuit at 250V.

D. Testing of photo-thyristors, electromagnetic locks, limit

a. Check and ensure that control & protection circuit is wired as

ii. Monitoring and indication circuit checks

Date of Issue Revision Number Page Number

7. Check and ensure that if CB is moved from service position

Date of Issue Revision Number Page Number

measure the contact resistance from upper bus to lower bus

iv. CB coils & spring charging motor checks:

D. Testing of current transformers:

Date of Issue Revision Number Page Number

I. Logics and interlocks checks:

Date of Issue Revision Number Page Number

t. Check various contact changeovers as per WDs with respect to

a. Between phases > 127 mm

7.0 Processing and evaluation of test results:

6. Bus bar contact resistance shall be as indicated below,

Date of Issue Revision Number Page Number