Collective Engineering

Testing and Commissioning

          The testing works offered testing and commissioning to verify that the substation is designed and installed according to customer requirement and specification, the field test reports will be applied in conjunction with customer specification. To ensure that field tests is performed according to practical standard or customer requirement and specification. This report covers installation, test commissioning inspection and test at site which offers by CECO.

          The professionals at CECO have an extensive history of testing and commissioning all aspects of electrical substation to deliver reliable equipment testing results. The expertise of our engineers and technicians, combined with our project management knowledge, allow CECO to provide professional testing and commissioning on a comprehensive level.

          The field tests will be carried out on equipment at site and divided into three stages of test as follows

  • - Individual tests of each equipment
  • - Functional tests
  • - Final tests

Individual tests

After complete installation and adjustment of each equipment, individual test shall be carried out according the following list.

SF6 Gas HV Circuit Breaker
   a. Installation inspection
   b. Gas leakage test
   c. SF6 gas dew point test
   d. Insulation resistance test
   e. Insulation power factor (tan delta) test
   f. Contact timing measurement at minimum and rated voltage
   g. Contact resistance measurement
   h. Motor spring charge test
   i. Mechanism operation test
   j. Local electrical testing of the closing and tripping of the circuit breaker including interlocking operations.
   k. Emergency trip test (if any)
   l. Position indicator and operation counter test
   m. Heater (including heating circuit) test

Gas Insulated MV Switchgear
   a. Construction check
   b. Gas circuit breaker test (CB)
   c. Disconnecting switch test (DS)
   d. Earthing switch test (ES)
   e. CT/VT polarity test
   f. CT ratio test
   g. Phase arrangement check
   h. Main bus joint contact resistance measurement
   i. Gas leakage test
   j. SF6 gas dew point test
   k. Insulation resistance test
   l. Applied high potential test

Power Transformer
   a. Construction check
   b. Insulation resistance test (2500 V DC) including polarizing index of winding
   c. Insulation resistance test of all accessories
   d. Insulation power factor (tan delta) test
   e. Turn ratio test
   f. Winding resistance measurement
   g. Oil insulation test
   h. Bushing CT polarity test
   i. Cooling fan test
   j. OLTC test
   k. Heater (including heating circuit) test
   l. Functional test including operation and calibration test of all protective devices and accessories

Grounding Transformer Test shall be performed the same as "Distribution and Isolating Transformer “ if applicable.
Distribution and Isolating Transformer
   a. Construction check
   b. Insulation resistance test (2500 V DC) including polarising index of winding
   c. Insulation resistance test of all accessories
   d. Ratio test
   e. DC resistance measurement (in case Transformer assembly on site)
   f. Oil insulation test (in case Transformer assembly on site)

Lightning Arrester
   a. Construction check
   b. Insulation resistance test (2500 V DC)
   c. AC high voltage current leakage test
   d. Insulation power factor (tan delta) test (115kV only)

Current Transformer
   a. Construction check
   b. Insulation resistance test (High side 2500 V DC Low side 1000 V DC)
   c. Insulation power factor (tan delta) test (115kV only)
   d. Excitation test
   e. Ratio test
   f. Polarity test

Voltage Transformer
   a. Construction check
   b. Insulation resistance test (High side 2500 V DC, Low side 1000 V DC)
   c. Ratio test
   d. Polarity test

Coupling Capacitor Voltage Transformer
   a. Construction check
   b. Insulation resistance test (Capacitor unit -2500 V DC, intermediate & low side 1000 V DC)
   c. Insulation power factor (tan delta) test (115kV only)
   d. Ratio test
   e. Polarity test for voltage transformer

Coupling Capacitor
   a. Construction check
   b. Insulation resistance test (2500 V DC)
   c. Capacitance measurement

Power Fuse / Loadbreak Switch
   a. Insulation resistance test (2500 V DC)
   b. Operation check

MV Circuit Breaker
   a. Construction check
   b. Insulation resistance test (2500 V DC)
   c. Insulation resistance test of all accessories
   d. Contact resistance measurement
   e. Bushing CT polarity test (if any)
   f. Timing Test at rated voltage
   g. Leakage test
   h. Mechanism operation test
   i. Local electrical testing of the closing and tripping of the circuit breaker including interlocking operations.
   j. Emergency trip test (if any)
   k. Position indicator and operation counter test
   l. Heater (including heating circuit) test

Disconnecting Switch
   a. Construction check
   b. Insulation resistance test (2500 V DC)
   c. Insulation resistance test of all accessories
   d. Contact resistance measurement
   e. Operation test - Close & open by manual - Close & open by electrical
   f. Mechanism (including mechanical interlock) check
   g. All interlock check
   h. Heater (including heating circuit) test

AC & DC Distribution Boards
   a. Wiring check
   b. Metering instrument test including tests of at least as specified elsewhere for relevant instrument.
   c. Protective relay test (if any) including tests of at least as specified elsewhere for relevant relay
   d. Insulation resistance test (1000 V DC)
   e. Air circuit breaker functional test
   f. Operation test

Battery Set
   a. Polarity check of each cell
   b. Extra charging (1/10 of capacity at 8 hours rate for 24 hours)
   c. Voltage, specific gravity and random temperature test of each cell at the end of charging

Battery Charger
   a. Insulation resistance test (1000 V DC)
   b. Operation test of voltage adjusting range (manual)
   c. Operation test of load voltage compensatory, timer, ground detector, etc.
   d. Metering instrument test including tests of at least specified elsewhere for relevant instrument.

Steel Structure
   a. Construction check
   b. Tightness of bolt
   c. Grounding connection check

Bus, Bus Connectors and Fitting
   a. Insulation resistance test (2500 V DC)
   b. Contact resistance of connectors
   c. Phase sequence (conformity with drawing) of bus
   d. Tightness of bolt

Insulators and Fitting
   a. Insulation resistance test (2500 V DC)
   b. Crack check
   c. Cleanliness check
   d. Fitting (completeness, tightness) check

Overhead Conductor and Overhead Ground Wire
   a. Crack on conductors and wires check
   b. Sag check
   c. Grounding connection check

Grounding System
   a. Crack on wires check
   b. Grounding connection check
   c. Grounding resistance measurement

High Voltage Power Cable and Pothead
   a. Insulation resistance test (2500 V DC)
   b. DC high voltage test

Power Cable, Lighting Cable, Control Cable and Switch board Wire
   - Insulation resistance test (500 V DC)

Coupling Filter, Line Trap, Matching Unit
   - Loss measurement

Control and Relay Boards
Protective relay test at service setting
   a. Over current relay
       - Minimum pick up test
       - Time characteristics Test.
       - Instantaneous unit test
       - Indicating targets and seal-in operation test
   b. Transformer differential relay
       - Minimum pick up test
       - Ratio characteristics test
       - Instantaneous unit test
       - Indicating targets and seal-in operation test
       - Operating time
   c. Bus differential relay
       - Minimum pick up test.
       - Ratio characteristics test.
       - Indicating target and seal-in operation test
       - Operating time.
   d. Under/over voltage relay
       - Minimum pick up test
       - Time characteristics test
       - Indicating target and seal-in operation test
   e. Distance relay
       - Starting characteristics test at all types of fault
       - Measuring characteristics test for all zones and all types of fault
       - Time step test for all zones
       - Functional test base on setting.
   f. Re-closing relay
       - Re-closing time test
       - Reclaim time test
       - Lock out time test
       - Counter test
   g. Time delay relay
       - Time accuracy test
       - Indicating targets and seal-in operation test
   h. Synchronism-check relay
       - Voltage check unit test
       - Voltage difference test
       - Angle difference test
       - Time delay test
   i. Directional over current relay
       - Directional unit test
       - Over current unit test
       - Time characteristics test
       - Indicating target and seal-in operation test
   j. DC auxiliary relay
       - Operation test
   k. Unbalance relay
       - Minimum pick up test
       - Time characteristics test
       - Indicating target and seal-in operation test
   l. Current differential relay

The relay testing is performed according to the manufacture acceptance and commissioning test procedure.
   - Minimum pick up test
   - Operating time test.
   - Communication channel verification
   - Demodulated signal verification

CT & VT Circuit
  a. Connection check by secondary injection
   b. Insulation resistance test (500 V DC)

Metering instrument test
   a. AC indicating ammeter test
       - at 25%, 50%, 75% and 100% of full scale
   b. AC indicating and recording voltmeter test
       - at 25%, 50%, 75%, 100% of full scale
   c. AC indicating and recording meter test
       - Watt, Var input at rated input voltage with 25%, 50%, 75% and 100% of rated input current
   d. AC current, voltage, Watt and Var transducer test
       - Current input at 25%, 50%, 75% and 100% of rated input current
       - Volt input at 25%, 50%, 75% and 100% or rated input voltage
       - Watt, Var input at rated input voltage with 25%, 50%, 75% and 100% of rated input watt, Var
   e. Watt-Hour meter test
       - at rated input voltage with 50% and 100% rated input current at 1.0 power factor
       - at rated input voltage with 50% and 100% rated input current at 0.5 power factor
   f. Demand meter test
       - test input value KWH/impulse – time switch test
   g. Frequency meter test
       - at 45, 48, 49, 50, 51, 52 and 55 Hz.
   h. Synchroscope test
   i. Static inverter test
       - Function test
   j. Loss of potential alarm relay test

Annunciator system test Sequence of Events Recorder The testing is performed according to manufacture acceptance and commissioning test procedure.
   a. Visual check of mechanical and electrical parts
   b. Operation and function check

Transient Recording System The testing is performed according to manufacture acceptance and commissioning test procedure.
   a. Visual check of mechanical and electrical parts
   b. operation check and functional

Functional tests

               After complete erection of all equipment and all control systems including completion of individual test, the functional test shall be carried out according to the following :
          1. Remote manual control for all remote manual functions of each equipment which has this requirement including interlocking operation (if any).
          2. Sequence operation control of all relay contacts to actuate associated equipment by mean of secondary injection test.
          3. Recloser operations.
          4. Operation of synchronizing circuit.
          5. Voltage regulating operation
          6. Protective operation of DC source.
          7. Operation of annunciators and alarms.
          8. Operation of lamp test circuit.

Final Tests

After all individual tests and functional tests have been fulfilled and after all equipment being ready for operation, the final test shall be carried out according to the following :

         1. Measurement of Insulation Resistance
             Measurement of insulation resistance of the high voltage equipment shall be performed by 2500 V insulation tester before energizing.

         2. Energizing Test.
             After completion of the measurement of insulation resistance mentioned above, AC energizing test shall be applied by the normal operating voltage of the MV power system for ten (10) minutes or twenty four (24) hours for HV power system.
             During the test, the following shall be recorded or checked.
                     a. The indicating value of meters mounted on the control panel shall be recorded on the test record sheets.
                     b. The current and voltage magnitude and phasing shall be checked at the relay test terminals in order to confirm correct connection of all AC secondary circuits.
                     For distribution transformer, if possible, shall be on load energization and the current phasing shall be checked in order to confirm the correct sequence.
                     For power transformer, if possible, shall be on load energization and the current magnitude and phasing to the transformer differential relay shall be checked in order to confirm correct connection of the secondary circuit.

         3. Requirement for Energizing Test
             Power sources required for substation energizing shall be provided by customer. Customer is responsible for the operation of the existing power system and shall perform the required switching for energizing.

Records
Records of field tests is in the relevant inspection and test record of related equipment form which mention in the inspection and test plan working manual.