Instruction Bulletin Square D Services: Procedures For Startup and Commissioning of Electrical Equipment Class 0180

Instruction Bulletin Square D Services
0180IB0001R5/01 May 2001 Nashville, TN, USA
Procedures for Startup and Commissioning of Electrical Equipment Class 0180
Procedures for Startup and Commissioning of Electrical Equipment Table of Contents
Bulletin No. 018IB0001R5/01 May 2001
TABLE OF CONTENTS
SECTION 1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SECTION 2SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SECTION 3AC DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SECTION 4AIR SWITCHES: LOW VOLTAGE (BOLTED PRESSURE, QMB, OR EQUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SECTION 5AIR SWITCHES: MEDIUM VOLTAGE, METAL-ENCLOSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SECTION 6AIR SWITCHES: HIGH AND MEDIUM VOLTAGE, OPEN STYLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SECTION 7ANALOG METERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SECTION 8BUSWAYS, METAL-ENCLOSED . . . . . . . . . . . . . . . . . . . . 14 SECTION 9CABLES: LOW VOLTAGE AND MEDIUM VOLTAGE . . . 15 SECTION 10CAPACITORS: POWER FACTOR CORRECTION . . . . . 16 SECTION 11CIRCUIT BREAKERS: LOW VOLTAGE INSULATED CASE/MOLDED CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SECTION 12CIRCUIT BREAKERS: LOW VOLTAGE POWER (ANSI/IEEE C37.13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SECTION 13CIRCUIT BREAKERS: MEDIUM VOLTAGE SF6 . . . . . . 22 SECTION 14CIRCUIT BREAKERS: MEDIUM VOLTAGE VACUUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SECTION 15DIRECT CURRENT SYSTEMS: BATTERIES. . . . . . . . . 26 SECTION 16EMERGENCY SYSTEMS: AUTOMATIC TRANSFER SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SECTION 17GROUND-FAULT PROTECTION SYSTEMS . . . . . . . . . 29 SECTION 18GROUND RESISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . 31 SECTION 19GROUNDING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . 32 SECTION 20ISOLATED POWER SYSTEMS . . . . . . . . . . . . . . . . . . . 33 SECTION 21MOTOR CONTROL CENTERS: LOW AND MEDIUM VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 SECTION 22MOTOR STARTERS: LOW VOLTAGE . . . . . . . . . . . . . . 39 SECTION 23MOTOR STARTERS: MEDIUM VOLTAGE . . . . . . . . . . . 40 SECTION 24OIL SWITCHES: MEDIUM VOLTAGE . . . . . . . . . . . . . . . 42 SECTION 25PROTECTIVE RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . 43 SECTION 26STEP VOLTAGE REGULATORS . . . . . . . . . . . . . . . . . . 44 SECTION 27SURGE ARRESTERS: LOW VOLTAGE SURGE PROTECTION DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 SECTION 28SURGE ARRESTERS: MEDIUM AND HIGH VOLTAGE SURGE PROTECTION DEVICES . . . . . . . . . . . . . . . . . . . . . 47 SECTION 29 SWITCHGEAR AND SWITCHBOARD ASSEMBLIES: LOW AND MEDIUM VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 SECTION 30TRANSFORMERS: DRY TYPE: ALL VOLTAGES LARGE (GREATER THAN 167 SINGLE-PHASE AND 500KVA THREE-PHASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2000-2001 Schneider Electric All Rights Reserved
Procedures for Startup and Commissioning of Electrical Equipment List of Tables
SECTION 31TRANSFORMERS: DRY TYPE - SMALL (167KVA SINGLE-PHASE, 500KVA THREE-PHASE, AND SMALLER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 SECTION 32TRANSFORMERS, INSTRUMENT . . . . . . . . . . . . . . . . . 53 SECTION 33TRANSFORMERS: LIQUID-FILLED: ALL VOLTAGES . 55
LIST OF TABLES
Table 1: Table 2: Table 3: Table 4: Table 5: Table 6: Table 7: Table 8:
US Standard Bolt Torques for Bus and Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Insulation-Resistance Test Voltage for Electrical Apparatus and Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Transformer Insulation-Res. Acceptance Test Voltage and Min. Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Insulation Resistance Conversion Factors . . . . . . . . . . . . . 60 Power Frequency Dielectric Withstand Test . . . . . . . . . . . 61 Instrument Transformer Dielectric Tests . . . . . . . . . . . . . . 62 Square D Molded Case Circuit Breaker Watts Loss/Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Square D Type DS, DSII, DSL, and DSLII Circuit Breaker Contact Resistance. . . . . . . . . . . . . . . . . . . . . . . . 66
Procedures for Startup and Commissioning of Electrical Equipment Section 1Introduction
SECTION 1INTRODUCTION
This bulletin details the inspection and testing procedures that Square D Services technicians must follow during commissioning and startup of electrical equipment. These inspections and tests are performed on new equipment, after installation and prior to energizing, in order to: 1. check that the equipment has not been damaged during shipment or installation; 2. verify that the equipment is in compliance with the purchase specification and design intent; and 3. document test results that can serve as benchmarks for future tests. The standard deliverables to the customer are those inspections and tests listed under subsections A, B, and D (Instrument Transformers only) of each equipments startup procedures. Square D technicians will perform the optional tests listed in subsections C and E (Instrument Transformers only) if specified by the customer at the time the order is received. For testing of equipment not detailed in this document, Square D Services will refer to the InterNational Electrical Testing Associations (NETA) guidelines in Acceptance Testing Specifications for Electrical Power Distribution Equipment and Systems (NETA ATS 1999). For additional information, contact Square D Services at 1-888-Square D (1-888-778-2733).
Acknowledgement
Schneider Electric has been granted permission to publish insulation resistance acceptance criteria as listed in the Acceptance Testing Specifications for Electrical Power Distribution Equipment and Systems (NETA ATS 1999) published by the International Electrical Testing Association. Publication of data taken from this document may require permission of Schneider Electric and InterNational Electrical Testing Association.
Procedures for Startup and Commissioning of Electrical Equipment Section 2Safety
SECTION 2SAFETY
Proper safety procedures shall be reviewed and implemented before each activity listed in this procedure and the Square D / Schneider Field Service Safety, Health and Environmental Handbook. Job Safety Analysis followed by a toolbox/pre-job meeting shall be conducted prior to any activity listed in this procedure. The toolbox meeting shall be documented and attached to the FS101. Proper safety procedures as detailed in the Square D/Schneider Electric Field Services Safety, Health and Environmental Handbook, employee training, and customers requirements shall be implemented as dictated by each sites requirements. Services Employees are NOT authorized to work on live equipment. There may be occasions in which you are taking measurements or checking voltages within an energized enclosure, but you are NOT authorized to do Hands on Live repairs! Square D Company does not typically perform shutdown and/or switching operations, because these operations may result in damage to property or persons downstream of the equipment as a result of conduct, errors, or omissions made by others. If a customer requests Square D Company to perform such services, technicians must contact their District Manager for approval and proper procedures. Required personal protective equipment is detailed in the latest revision of procedure SQDS-SHE-001. A copy of this procedure may be obtained from the District Manager or from the Safety, Health, and Environment Manager.
Procedures for Startup and Commissioning of Electrical Equipment Section 3AC Drives
SECTION 3AC DRIVES
A. Physical Inspection 1. Document equipment nameplate data on the test report. Verify equipment nameplate ratings are in accordance with the final approved or record drawings and specifications. 2. Check for shipping damage: broken operators, switches, or pilot lights; dented or bent enclosure structures. 3. Check for any loose assemblies, excessive dirt, dust, or moisture. Clean up if necessary using a shop vacuum. 4. Tighten all power wiring connections to proper torque value. Check line and load side connections of all disconnect switches, breakers, contactors, and overloads. 5. Check for proper wire sizing per the manufacturers recommendations. Check insulation integrity; tighten to the specified torque per the manufacturers instructions. 6. Verify that a properly sized grounding conductor is connected to the drive grounding lug and terminates on a ground lug in the power distribution panel. 7. Verify that wires connected between the drive and the motor are correctly sized per the manufacturers instructions. Verify that these wires are separated from all other wiring (ideally in their own conduit). Note the length of wire between the drive and the motor on the test report. 8. Tighten all control wiring connections to the proper torque value. Check and tighten the drive control terminals. Check and tighten all terminal block connections. Check for proper insulation strip length on customer supplied control wiring. 9. Check door and disconnect switch alignment and opening/closing operation. 10. Test all mechanical interlocking devices. 11. Manually operate all contactors to verify freedom of movement. 12. Verify that customer supplied fusing agrees with the manufacturers recommendations. 13. Verify mechanical operation of isolation contactor. Tighten power and control connections. Verify the proper coil voltage rating. 14. Verify that the options board is securely fastened and plug-in terminals are present. 15. Check for proper heaters used in ISO/Bypass unit. 16. Verify that the location of the drive will not be allowed to be hotter than 100 F or colder than 32 F, and that no condensing moisture is present. 17. Verify the type of load: constant torque or variable torque (centrifugal pumps and fans). Note the machines functional name on the test report. 18. Verify that the proper Torque Type is selected (i.e., Constant, Variable, or Variable Low Noise). B. Electrical Tests The following tests involve the setup of the drive by using the programmable menus in the drive. Supply single-phase power at the rated system voltage level, +/-15, to the CL1 and CL2 terminals of the drive. 1. Set the Motor Nominal Current parameter to Motor nameplate Full Load Amp (FLA) value. 2. Set the High Speed Parameter to 60 Hz, or the maximum setting intended by the user.
Procedures for Startup and Commissioning of Electrical Equipment Section 3AC Drives
3. Set the Low Speed Parameter to 0 Hz, or the minimum setting intended by the user. 4. Set the Acceleration parameter to approximately 20 seconds. 5. Set the Deceleration parameter to approximately 30 seconds. 6. Check the Input/Output Map assignments. 7. Set the keypad to display four table scroll. 8. Set Output Phase Fault parameter to No. 9. Operate the drive with no motor connected. Cycle the unit through several Start and Stop sequences, ramping to full speed and to zero. (Use Keypad Mode if no external Start/Stop or Speed control is available.) 10. Return Output Phase Fault parameter to Yes. For the following tests, the equipment will be energized onto the power distribution circuit by the means provided (i.e., disconnect switch) for the drive. The connected motor will be bumped to verify proper rotating direction using the drive as well as any bypass to line feature, if provided. 11. Measure the output of ac control transformers to be within +/-5% of nominal output voltage. Measure dc control supplies (for customer use), and verify that they are within the manufacturers recommendations. 12. Measure the dc bus voltage and verify that it is equal to the measured RMS Line to Line input voltage x 1.414 +/-5%. 13. Measure the RMS values of Line to Line voltages: L1 to L2, L1 to L3, and L2 to L3. Verify that they are 208, 230, or 460 Vac rms +/-10%. Phase to Phase voltage imbalance must be less than +/-2%. Measure L1, L2, and L3 to ground. Phase to ground voltage imbalance should be less than +/-5%. Perform measurements in standby mode, medium motor load, and full motor load. 14. Verify that phase rotation in Bypass mode is per the manufacturers recommendations. If incorrect, swap any two line-side power wires at the disconnecting switch. 15. Verify that phase rotation in AFC mode at approximately 10 Hz is per the manufacturers recommendations. If incorrect, swap any two wires at the T lead connections on the drive. 16. Measure Output voltages at the T lead terminals of the drive with no motor connected (open circuit with output phase fail detection turned off) and the drive running at half speed and again at full speed. Verify that phase to phase output voltage imbalance is less than 2% at any output frequency. Repeat with the motor connected and running at medium motor load and again at full motor load. 17. Measure the motor current in each T lead at medium motor load and again at full motor load. Output Phase Current imbalance must be less than 5% at any load. Compare readings taken to displayed value of output current on the Keypad. Note any discrepancies on the test report. 18. Verify that speed control signals vary within the voltage or current range of the input to which they are connected. Check for proper shielding on wires connected to speed control inputs. Verify that signals are isolated from power wires. 19. Verify that I/O points are assigned to proper functions per factory drawings. 20. Verify that Hand and Auto controls, Start, Stop, and speed input, operate the drive correctly. 21. Check that all indicating lamps illuminate only for their assigned functions. Check all Push to Test lamps.
Procedures for Startup and Commissioning of Electrical Equipment Section 4Air Switches: Low Voltage (Bolted Pressure, QMB, or Equal)
SECTION 4AIR SWITCHES: LOW VOLTAGE (BOLTED PRESSURE, QMB, OR EQUAL)
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify equipment nameplate ratings are in accordance with the final approved and record drawings and specifications, if available. 2. Inspect physical and mechanical condition. 3. Confirm application of lubricants at manufacturer's recommended locations. 4. Verify appropriate anchorage and required area clearances. 5. Verify appropriate equipment grounding. 6. Verify correct blade alignment, blade penetration, travel stops, and mechanical operation. 7. Verify and record fuse sizes and types are in accordance with drawings and short-circuit and coordination studies, if available. 8. Verify tightness of accessible bolted electrical connections by calibrated torque-wrench method in accordance with manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 9. Check all interlocking systems for correct operation and sequencing, and key distribution, if applicable. 10. Verify correct phase barrier materials and installation. 11. Inspect all indicating and control devices for correct operation. 12. Check the condition of arc contacts and arc chutes. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance Panelboard industry standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform insulation-resistance tests on each pole, phase-to-phase and phase-to-ground with switch closed and across each open pole for one minute. Test voltage shall be in accordance with manufacturer's published data or Table 2 on page 59. 2. Switches equipped with solenoid trip, blown main fuse detector, etc., test each feature for proper operation. To test blown fuse detector, activate it and confirm by attempting to close the breaker without reset. 3. Square D BP switches, perform Blade Contact Resistance Test (a) With the device de-energized, operate the device closed and open several time using either manual or electrical means. (b) Apply a minimum current of 100 amperes dc through the closed contacts. If 100 A is not available, use the highest current available. If the device does not conform to the manufacturers specification, obtain equipment to perform the test at 100 A or consult the factory with full information about the details of the test. If the continuous current rating is less than 100 A, then test at a level not to exceed the continuous current rating.
Procedures for Startup and Commissioning of Electrical Equipment Section 4Air Switches: Low Voltage (Bolted Pressure, QMB, or Equal)
(c) Measure the contact resistance of each pole and compare with the following values:
BP Switch Rating
800 Amp. 1200 Amp. 1600 Amp. 2000 Amp. 2500 Amp. 3000 Amp. 4000 Amp.
Resistance
13 Micro-Ohms Max. 13 Micro-Ohms Max. 11 Micro-Ohms Max. 8 Micro-Ohms Max. 7 Micro-Ohms Max. 6 Micro-Ohms Max. 7 Micro-Ohms Max.
NOTE: Current Source Test Probes must be placed on extreme ends of the Jaw Terminal and the Hinge/Fuse Pad with the Potential Measuring Probes placed approximately one inch from each Current Source Test Probe, on the inside between the Current Source Test Probes. (d) If the resistances is below the value shown above, the condition of the device contacts is considered suitable for service. If the resistance exceeds the value above, open and close the device several more times. If high readings persists, increase the DC test current to a level equivalent to the continuous current rating of the device. Contact the factory if nominal values of resistance cannot be achieved. 4. Measure fuse resistance to check continuity. 5. Test the ground fault relay by current injection to verify that the switch trips at the proper setting. 6. Perform adjustments on the ground fault setting for final settings in accordance with the coordination study supplied by the owner, if applicable.
Procedures for Startup and Commissioning of Electrical Equipment Section 5Air Switches: Medium Voltage, Metal-Enclosed
SECTION 5AIR SWITCHES: MEDIUM VOLTAGE, METAL-ENCLOSED
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify equipment nameplate ratings are in accordance with the final approved or record drawings and specifications, if available. 2. Inspect physical and mechanical condition. 3. Confirm correct application of lubricants at manufacturer's recommended locations. 4. Verify appropriate anchorage and required area clearances. 5. Verify appropriate equipment grounding. 6. Verify correct blade alignment, blade penetration, travel stops, and mechanical operation. Check to make sure the interrupter blade for Square D type HVL switches securely latched with in the arc chute when the switch closes. A properly latched interrupter blade will stay latched within the arc chute until the main blades are about half way open in the opening cycle. 7. Verify that fuse sizes and types are in accordance with drawings and short-circuit and coordination studies, if available. 8. Inspect fuse holders for tightness and alignment. 9. Verify that expulsion-limiting devices are in place on all holders having expulsion-type elements. Verify that they are installed to vent in the proper direction. 10. Verify tightness of accessible bolted electrical connections by calibrated torque-wrench method in accordance with manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 11. Check all interlocking systems for correct operation and sequencing, and key distribution, if applicable. 12. Verify correct phase-barrier materials and installation. 13. Inspect all indicating and control devices for correct operation. 14. Verify that the Lightning arresters have been connected, verify that they have the proper voltage per the manufacturers drawings. 15. Inspect the linkage and gap adjustments on VISI-VAC switches to confirm that a sealing compound has been applied and that the adjustments are finger tight. 16. Check the condition of arc contacts and arc chutes. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with Switchgear industry standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform insulation-resistance tests on each pole, phase-to-phase and phase-to-ground with switch closed and across each open pole for one minute. Test voltage shall be in accordance with manufacturer's published data or Table 2 on page 59. 2. Perform a dielectric test (Hi-Pot) on each pole with switch closed. Test each pole-to-ground with all other poles grounded. Test voltage shall be in accordance with manufacturer's published data or Table 5 on page 61.
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Procedures for Startup and Commissioning of Electrical Equipment Section 5Air Switches: Medium Voltage, Metal-Enclosed
3. Verify that heaters have been connected and is operating properly. 4. Measure fuse resistance to verify continuity. 5. Perform a contact-resistance test for Square D HVL/cc and Visi-Vac devices. Use the following procedure: (a) With the device de-energized, operate the device closed and open several times using either manual or electrical means. (b) Apply a minimum current of 100 amperes dc through the closed contacts. If 100 A is not available, use the highest current available. If the device does not conform to the manufacturers specification, obtain equipment to perform the test at 100 A or consult the factory with full information about the details of the test. If the continuous current rating is less than 100 A, then test at a level not to exceed the continuous current rating. (c) Measure the contact resistance of each pole and compare with the following values: VISI-VAC .............. 85 Micro-Ohms HVL/cc ................. 75 Micro-Ohms HVL .....................no value available (d) If the resistance is below the value shown above, the condition of the device contacts is considered suitable for service. If the resistance exceeds the value above, open and close the device several more times. If high readings persist, increase the dc test current to a level equivalent to the continuous current rating of the device. Contact the factory if nominal values of resistance cannot be achieved. C. Optional Tests Check the erosion gap of VISI-VAC vacuum bottles per the manufacturers instructions (refer to Square D bulletin # 9845-4). Adjust as necessary to meet specified gaps.
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Procedures for Startup and Commissioning of Electrical Equipment Section 6Air Switches: High and Medium Voltage, Open Style
SECTION 6AIR SWITCHES: HIGH AND MEDIUM VOLTAGE, OPEN STYLE
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify equipment nameplate ratings are in accordance with the final approved or record drawings and specifications, if available. 2. Inspect physical and mechanical condition. 3. Confirm correct application of lubricants at manufacturer's recommended locations. 4. Verify that grounding is in accordance with industry standards and project specifications. 5. Verify tightness of accessible bolted electrical connections by calibrated torque-wrench method in accordance with manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 6. Perform mechanical operator tests in accordance with manufacturer's instructions. 7. Verify correct operation and adjustment of motor operator limit-switches and mechanical interlocks. 8. Verify correct blade alignment, blade penetration, travel stops, arc interrupter operation, and mechanical operation (over toggle). 9. Inspect fuse holders for tightness and alignment. 10. Check the condition of arc contacts and arc chutes. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with Switchgear industry standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform insulation-resistance tests on each pole, phase-to-phase and phase-to-ground with switch closed and across each open pole for one minute. Test voltage should be in accordance with manufacturer's published data or Table 2 on page 59. 2. Perform a dielectric test (Hi-Pot) on each pole with switch closed. Test each pole-to-ground with all other poles grounded. Test voltage shall be in accordance with manufacturer's published data or Table 5 on page 61. 3. Perform a contact-resistance test across each switchblade and fuse holder. Investigate any value exceeding 500 micro-ohms, or any values that deviate from adjacent poles or similar switches by more than 25 percent.
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Procedures for Startup and Commissioning of Electrical Equipment Section 7Analog Metering
SECTION 7ANALOG METERING
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify equipment nameplate ratings are in accordance with the final approved or record drawings and specifications, if available. 2. Inspect physical and mechanical condition. 3. Verify tightness of electrical connections. 4. Verify mechanically for freedom of movement, correct travel and alignment, and tightness of mounting hardware. B. Electrical Tests Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Check calibration of meters according to the manufacturers published data. 2. Electrically confirm that current transformer and voltage transformer secondary circuits are intact. C. Optional Tests 1. Calibrate watt-hour meters according to manufacturer's published data. 2. Verify all instrument multipliers.
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Procedures for Startup and Commissioning of Electrical Equipment Section 8Busways, Metal-Enclosed
SECTION 8BUSWAYS, METALENCLOSED
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify busway nameplate ratings in accordance with final approved or record drawings and specifications, if available. 2. Inspect the busway for physical damage and correct connection in accordance with the single-line diagram. 3. Inspect for appropriate bracing, suspension, alignment, and enclosure ground. 4. Using the calibrated torque-wrench method, verify that the tightness of accessible bolted electrical connections is in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. For Square D, Low Voltage, I-Line Busway, check to see that the outer head has been broken off. Verify that the red plastic disk (VISI-TITE) at each bus joint is automatically removed when the head is broken off. 5. To ensure adequate cooling, confirm that the physical orientation is in accordance with manufacturer's labels. 6. Examine the outdoor busway for removal of weep-hole plugs, if applicable, and the correct installation of joint shield. Verify that proper gasketing is in place. B. Electrical Tests Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Measure insulation resistance of each busway, phase-to-phase and phase-to-ground for one minute, in accordance with Table 2 on page 59. For Square D, Low Voltage, I-Line busway, with the load and line ends disconnected, and no overcurrent devices installed, use an insulation resistance tester rated at 1000 volts to ensure the system is free from short circuits and grounds (phase-to-phase, phase-to-neutral, and phase-to-ground). The megohm readings should not be less than the value calculated from the following formula. (If readings are less than the values calculated from the formula consider drying the air with in the building for at least a day and then remeasure. If low readings persist, contact the factory.) Megohms = 100 / length of run (in feet) or Megohms = 30.5 / length of run (in meters) 2. Visual confirmation of correct phasing on each busway tie section energized by separate sources. (De-energized) C. Optional Tests 1. Perform contact-resistance test on each connection point of non insulated busway. On insulated busway, measure resistance of assembled busway sections and compare values with adjacent phases. 2. Perform a dielectric test (Hi-Pot) on each busway, phase-to-ground with phases not under test grounded, in accordance with manufacturer's published data. Apply test voltage for one minute. Use test voltage values as shown in Table 5 on page 61.
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Procedures for Startup and Commissioning of Electrical Equipment Section 9Cables: Low Voltage and Medium Voltage
SECTION 9CABLES: LOW VOLTAGE AND MEDIUM VOLTAGE
A. Visual and Mechanical Inspection 1. Verify that cable sizing and insulation temperature rating are in accordance with final approved or record drawings and specifications, if available. Note any deviations. 2. Inspect the exposed sections of cables for physical damage and correct connection in accordance with single-line diagrams. 3. Using a calibrated torque wrench, verify that the tightness of accessible bolted connections is in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 4. Inspect compression-applied connectors for correct cable match and indentation. 5. Verify cable color coding with applicable engineer's specifications. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance industry standards. Verify that the opposite end of the cable run being tested is isolated form personnel during testing. Verify that the electrical test equipment is correctly selected and operates properly. Record the date of the last calibration date and the date re-calibration is due. 1. Cables and leads shall be tested for continuity to ensure correct cable connection and phasing rotation. 2. Perform an insulation resistance test on each conductor between one conductor and ground with the other conductors grounded. Each conductor shall be tested in the same manner. (a) The test shall be performed at 1000 volts dc for one minute. (b) Each 480V feeder cable shall be tested with the cable connected to the racked-in but open breaker or switch at the equipment. Connection at the other end of each of these cables shall be as follows: (i) Cables to Motor Control Centers shall be connected to the bus with the switches or breakers in the starters open. (ii) Cables to motors and other equipment shall be connected to the motors and equipment with feeder switches open. C. Optional Test Perform a dielectric test on medium voltage shielded cable per Table 5 on page 61. Refer to the manufacturers published data, and perform at 5 KV intervals, checking leakage current and decay voltage over the specified time period.
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Procedures for Startup and Commissioning of Electrical Equipment Section 10Capacitors: Power Factor Correction
SECTION 10CAPACITORS: POWER FACTOR CORRECTION
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on the test report. 2. Verify that the capacitor nameplate ratings are in accordance with the final approved or record drawings and specifications. 3. Inspect the physical and mechanical condition of the equipment. 4. Inspect the capacitors for the correct mounting and required clearances, per the manufacturers recommended procedures. 5. Verify that capacitors are electrically connected in their specified configuration, per the manufacturers recommended procedures. 6. Using a calibrated torque wrench, verify that the tightness of accessible bolted electrical connections is in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. B. Electrical Tests 1. Perform insulation-resistance tests from terminal(s) to case for one minute on capacitors with more than one bushing. The test voltage and minimum resistance shall be in accordance with the manufacturers instructions or Table 2 on page 59. 2. Measure the capacitance of all terminal combinations. 3. Measure the resistance of the internal discharge resistors.
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Procedures for Startup and Commissioning of Electrical Equipment Section 11Circuit Breakers: Low Voltage Insulated Case/Molded Case
SECTION 11CIRCUIT BREAKERS: LOW VOLTAGE INSULATED CASE/ MOLDED CASE
A. Visual and Mechanical Inspection (reference Square D Publication SD363-88-1987, Field Testing Industrial Molded-Case Circuit Breakers) 1. Document equipment nameplate data on test report. Verify equipment nameplate ratings are in accordance with the final approved or record drawings and specifications. 2. Inspect circuit breaker for correct mounting. 3. Operate circuit breaker to insure smooth operation. 4. Inspect case for cracks or other defects. 5. Verify tightness of accessible bolted connections and/or cable connections by calibrated torque-wrench method in accordance with manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 6. Verify that trip units, shunt trip coils, auxiliary contacts and all other accessories are in accordance with the job specifications. 7. Exercise the push to trip button to verify trip and reset. 8. If the circuit breaker contains a MICROLOGIC trip unit, perform the following inspections: a. Verify that the breaker is equipped with the correct rating plugs and current sensors. b. Verify that the breaker has the specified trip unit, LI, LS, LSI, and LSIG. c. Verify that the breaker has the specified accessories, such as Auxiliary Contacts, Cell Switches, Shunt Trip Devices, and Undervoltage Release. d. Verify that the Ground Fault System has been wired in accordance with the specified wiring diagram, and that the Sensor Grounds are either present or not present as specified. e. Verify that the secondary control plug/connections are in accordance with the wiring diagram and specifications. 9. If it is an SED or drawout MASTERPACT circuit breaker, perform the following inspections: a. Confirm that lubricants have been correctly applied at the manufacturer's recommended locations. b. Inspect anchorage, alignment, and grounding. Inspect arc chutes. Inspect moving and stationary contacts for condition and alignment. c. Verify that all maintenance devices are available for servicing and operating the breaker. d. Perform all mechanical operator and contact alignment tests on both the breaker and its operating mechanism. e. Check cell fit and element alignment. f. Check the racking mechanism.
B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with molded case circuit breaker industry standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due.
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1. Perform a contact-resistance test for Square D Circuit breakers listed in Table 7 on page 63 in accordance with the following procedure. NOTE: The following procedure assumes the breaker is new, but may have carried some previous load current. (a) Completely de-energize the equipment. (b) Operate the circuit breaker manually on and off several times to ensure the mechanism linkages are free and operate properly. Trip the circuit breaker with the push to trip button if so equipped. Reset and turn the breaker back on. Repeat to ensure operability. If the circuit breaker does not trip, or if it does not reset after tripping, it must be replaced. (c) Measure the voltage drop across each pole or the resistance with a digital low-resistance ohmmeter. (d) Calculate the Resistance (if necessary) (Vdc drop/Idc rating current) (e) Compare the Resistance (calculated or reading) with the values listed in Table 7 on page 63. (f) If the value calculated or read is higher than the values listed in Table 7 on page 63, repeat the process starting at (c) above operating the breaker several times. If high readings persist, recommend that the breaker be replaced. 2. Perform an insulation-resistance test at 1000 volts dc from pole-to-pole and from each pole-to-ground with breaker closed and across open contacts of each phase. Insulation resistance should be greater than 100 Megohms. 3. Perform adjustments for final settings in accordance with coordination study supplied by owner, if available. 4. Verify correct operation of any auxiliary features such as trip and pickup indicators, electrical close and trip operation, trip-free, and anti pump function. 5. If the circuit breaker contains a MICROLOGIC trip unit, perform the following tests: a. Make adjustments for the final settings in accordance with the coordination study supplied by the owner, if available. b. Determine the minimum pickup current by secondary current injection, using the manufacturers specified test device and procedures. c. Determine long-time delay by secondary current injection, using the manufacturers specified test device and procedures. d. Determine short-time pickup and delay by secondary current injection, using the manufacturers specified test device and procedures. e. Determine ground-fault pickup and delay by secondary current injection, using the manufacturers specified test device and procedures. f. Determine the instantaneous pickup value by secondary current injection, using the manufacturers specified test device and procedures.
g. Activate auxiliary protective devices such as undervoltage relays, to ensure that shunt trip devices are operating. Check the operation of electrically operated breakers in their cubicles. h. Verify auxiliary features, such as trip and pickup indicator, electrical close and trip operation, trip-free, and antipump function are operating correctly.
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i.
Check the electric charging mechanism, if applicable.
C. Optional Tests 1. Perform insulation-resistance tests in accordance with Table 2 on page 59. Do not perform this test on wiring connected to solid-state components. 2. Perform long-time delay time-current characteristic tests by passing 300 percent rated current through each pole separately unless series testing is required to defeat ground fault functions. 3. Determine short-time pickup and delay by primary current injection using the manufacturers current specified procedures. If the procedures are not available, set the pickup somewhere above minimum. 4. Determine ground-fault pickup and time delay by primary current injection using the manufacturers current specified procedures. If the procedures are not available, set the pickup somewhere above minimum. 5. Determine instantaneous pickup current by primary injection using runup or pulse method, per the manufacturers current specified procedures. NOTE: Values of pickup and delay found should agree with the manufacturers specifications.
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Procedures for Startup and Commissioning of Electrical Equipment Section 12Circuit Breakers: Low Voltage Power (ANSI/IEEE C37.13)
SECTION 12CIRCUIT BREAKERS: LOW VOLTAGE POWER (ANSI/IEEE C37.13)
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and specifications, if available. 2. Inspect the physical and mechanical condition of the equipment. 3. Confirm that lubricants have been correctly applied at the manufacturer's recommended locations. 4. Inspect anchorage, alignment, and grounding. Inspect arc chutes. Inspect moving and stationary contacts for condition and alignment. 5. Verify that all maintenance devices are available for servicing and operating the breaker. 6. Perform all mechanical operator and contact alignment tests on both the breaker and its operating mechanism. 7. Using the calibrated torque-wrench method, verify that the tightness of accessible bolted bus connections is in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 8. Check cell fit and element alignment. 9. Check the racking mechanism. 10. Verify that the breaker is equipped with the correct rating plugs and current sensors. 11. Verify that the breaker has the specified trip unit, LI, LS, LSI, and LSIG. 12. Verify that the breaker has the specified accessories, such as Auxiliary Contacts, Cell Switches, Shunt Trip Devices, and Undervoltage Release. 13. Verify that the Ground Fault System has been wired in accordance with the specified wiring diagram, and that the Sensor Grounds are either present or not present as specified. 14. Verify that the secondary control plug/connections are in accordance with the wiring diagram and specifications. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with Switchgear industry standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform a contact-resistance test. For Square D Type DS, DS II, DSL, and DSL II type circuit breakers, use the following procedure: (a) With the breaker de-energized, operate the breaker closed and open several times using either manual or electrical means. (b) Apply a minimum current of 100 amperes dc through the closed contacts. If 100 A is not available, use the highest current available. If the device does not conform to the manufacturers specification, obtain equipment to perform the test at 100 A, or consult the factory with full information about the details of the test. If the continuous current rating is less than 100 A, then test at a level not to exceed the continuous current rating. (c) Measure the contact resistance of each pole and compare with the values listed in Table 8 on page 66.
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Procedures for Startup and Commissioning of Electrical Equipment Section 12Circuit Breakers: Low Voltage Power (ANSI/IEEE C37.13)
(d) If the resistance is below the value shown in Table 8 on page 66, the condition of the breaker contacts is considered suitable for service. If the resistance exceeds the value in Table 8, the contacts can be abraded lightly with Scotchbrite or crocus cloth to remove oxides or other contaminants. Excessive abrading of contacts should be avoided since the silver plating could be abraded away. Contact the factory if nominal values of resistance cannot be achieved. 2. Perform an insulation-resistance test at 1000 volts dc from pole-to-pole and from each pole-to-ground, with the breaker closed and across open contacts of each phase. The minimum insulation resistance shall be in accordance with Table 2 on page 59. 3. Make adjustments for the final settings in accordance with the coordination study supplied by the owner, if available. 4. Determine the minimum pickup current by secondary current injection, using the manufacturers specified test device and procedures. 5. Determine long-time delay by secondary current injection, using the manufacturers specified test device and procedures. 6. Determine short-time pickup and delay by secondary current injection, using the manufacturers specified test device and procedures. 7. Determine ground-fault pickup and delay by secondary current injection, using the manufacturers specified test device and procedures. 8. Determine the instantaneous pickup value by secondary current injection, using the manufacturers specified test device and procedures. 9. Activate auxiliary protective devices such as undervoltage relays, to ensure that shunt trip devices are operating. Check the operation of electrically operated breakers in their cubicles. 10. Verify auxiliary features, such as trip and pickup indicator, electrical close and trip operation, trip-free, and antipump function are operating correctly. 11. Check the electric charging mechanism, if applicable. C. Optional Testing 1. Perform an insulation-resistance test in accordance with Table 2 on page 59. Do not perform the test on wiring connected to solid-state components. 2. Determine minimum pickup current by primary current injection, using the manufacturers specified procedures. If the procedures are not available, set the pickup somewhere above minimum. 3. Determine long-time delay by primary current injection, using the manufacturers specified procedures. If the procedures are not available, set the delay somewhere above minimum. 4. Determine short-time pickup and delay by primary current injection, using the manufacturers specified procedures. If the procedures are not available, set the pickup somewhere above minimum. 5. Determine ground-fault pickup and delay by primary current injection, using the manufacturers specified procedures. If the procedures are not available, set the pickup somewhere above minimum. 6. Determine instantaneous pickup value by primary current injection, using the manufacturers specified procedures. If the procedures are not available, set the pickup somewhere above minimum. 7. Activate the Blown Fuse detector and confirm by attempting to close the breaker without reset. NOTE: The values of pickup and delay should agree with the manufacturers specifications.
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Procedures for Startup and Commissioning of Electrical Equipment Section 13Circuit Breakers: Medium Voltage SF6
SECTION 13CIRCUIT BREAKERS: MEDIUM VOLTAGE SF6
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and specifications, if available. 2. Inspect the physical and mechanical condition of the breaker. 3. Confirm that lubricants have been correctly applied at the manufacturer's recommended locations. 4. Inspect anchorage and grounding. 5. Inspect and verify that adjustments of the mechanism are in accordance with the manufacturer's instructions. 6. Check indicators for gas leaks in accordance with the manufacturer's instructions. 7. Verify correct operation of all air and SF6 gas pressure switches, alarms and cutouts. (Note: For sealed interrupters, the pressure cannot be varied to change the state of pressure switches.) 8. Slow the close/open breaker and check for binding. 9. Use the calibrated torque wrench method to verify that the tightness of accessible bolted connections and/or cable connections are in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 10. Record as-found and as-left counter operations. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with the equipment standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Measure contact resistances using the following procedure: (a) Operate the breaker closed and open several. times. (b) Apply 100 amperes DC and measure the resistance of each pole. If 100 A is not available, use the highest current available. If the device does not conform to the manufacturers specification, obtain equipment to perform the test at 100 A or consult the factory with full information about the details of the test. If the continuous current rating is less than 100 A, then test at a level not to exceed the continuous current rating. (c) If the measured resistance is greater than 2000 micro-ohms, consult the manufacturer 2. Perform insulation-resistance tests pole-to-pole, pole-to-ground, and across open poles in accordance with Table 2 on page 59. 3. Perform a power frequency withstand test in accordance with the manufacturer's instructions. For Square D circuit breakers, perform the test in accordance with Table 5 on page 61. 4. Verify trip, close, trip-free, and antipump functions. 5. Trip the circuit breaker by operating each protective device.
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Procedures for Startup and Commissioning of Electrical Equipment Section 13Circuit Breakers: Medium Voltage SF6
C. Optional Tests 1. Perform an insulation-resistance test on all control wiring in accordance with Table 2 on page 59. Do not perform this test on wiring connected to solid-state relays. 2. Perform time-travel analysis using a travel distance timer. 3. Perform dissipation-factor/power-factor tests on breaker and bushings on each pole with the breaker open, and on each phase with the breaker closed. 4. Perform a minimum pick-up voltage test on trip and close coils.
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Procedures for Startup and Commissioning of Electrical Equipment Section 14Circuit Breakers: Medium Voltage Vacuum
SECTION 14CIRCUIT BREAKERS: MEDIUM VOLTAGE VACUUM
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and specifications, if available. 2. Inspect physical and mechanical condition. 3. Confirm that lubricants have been correctly applied at the manufacturer's recommended locations. 4. Inspect anchorage, alignment, and grounding. 5. Perform all mechanical operational tests on both the circuit breaker and its operating mechanism. 6. Measure critical distances, such as contact gap, as specified by the manufacturers service bulletin. 7. Use the calibrated torque wrench method to verify that the tightness of accessible bolted connections and/or cable connections are in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 8. Record as-found and as-left operation counter readings. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with the equipment standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform a contact-resistance test in accordance with the following procedure: (a) Operate the breaker closed and open several times. (b) Apply 100 Amperes dc and measure the contact resistance of each pole. If 100 A is not available, use the highest current available. If the device does not conform to the manufacturers specification, obtain equipment to perform the test at 100 A or consult the factory with full information about the details of the test. If the continuous current rating is less than 100 A, then test at a level not to exceed the continuous current rating.
CAUTION
HAZARD OF INJURY OR EQUIPMENT DAMAGE DC LIM Hi-Pot testing of vacuum breakers is not recommended. Read the label on the vacuum bottle for precautions to take against the danger of xray emission while performing AC Hi-Pot testing. Failure to follow these instructions can result in injury or equipment damage.
(c) Breaker pole units having a resistance exceeding 35 microhms shall be referred to the manufacturer for further evaluation. 2. Verify the trip, close, trip-free, and antipump functions. 3. Trip the circuit breaker by operating each protective device. 4. Perform insulation-resistance tests pole-to-pole, pole-to-ground, and across open circuit breaker separable contacts in accordance with Table 2 on page 59. 5. Perform a vacuum bottle integrity (over potential) test. Use an AC Hi-Pot across each vacuum bottle with the breaker in the open position, in strict accordance with manufacturer's instructions. For Metal-Clad Switchgear, apply the Maximum Test Voltage across the open gap in accordance with Table 5 on page 61 for a duration of one minute. Contact the manufacturer if repeated consistent breakdowns are encountered.
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Procedures for Startup and Commissioning of Electrical Equipment Section 14Circuit Breakers: Medium Voltage Vacuum
C. Optional Testing 1. Perform an insulation-resistance test on all control wiring in accordance with Table 2 on page 59. Do not perform this test on wiring connected to solid-state relays. 2. Perform breaker travel and velocity analysis, using a travel distance timer. 3. Perform minimum pickup voltage tests on trip and close coils. 4. Perform dissipation-factor/power-factor tests on each pole with the breaker open, and on each phase with the breaker closed.
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Procedures for Startup and Commissioning of Electrical Equipment Section 15Direct Current Systems: Batteries
SECTION 15DIRECT CURRENT SYSTEMS: BATTERIES
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on the test report. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and specifications. 2. Inspect the physical and mechanical condition of the equipment. 3. Use the calibrated torque wrench method to verify that the tightness of accessible bolted connections and/or cable connections are in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 4. Measure electrolyte specific gravity and temperature, and visually check the fill level. B. Electrical Tests Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Verify that all charger functions and alarms are operating properly. 2. Measure each cell voltage and total battery voltage with the charger energized and in float mode of operation. C. Optional Tests 1. Verify that flame arresters are present. 2. Set the charger float and equalizing voltage levels. 3. Perform a capacity load test in accordance with the manufacturer's specifications and ANSI/IEEE standards. ANSI/IEEE Std 450-1987. Recommended Practice for Maintenance, Testing and Replacement of Large Lead Storage Batteries for Generating Stations and Substations. ANSI/IEEE Std 1106-1987. Recommended Practice for Maintenance, Testing and Replacement of Nickel-Cadmium Storage Batteries for Generating Stations and Substations.
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Procedures for Startup and Commissioning of Electrical Equipment Section 16Emergency Systems: Automatic Transfer Switches
SECTION 16EMERGENCY SYSTEMS: AUTOMATIC TRANSFER SWITCHES
A. Visual and Mechanical Inspection 1. Compare equipment nameplate data with drawings and specifications. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and specifications. 2. Inspect the physical and mechanical condition of the equipment. 3. Confirm that lubricants have been correctly applied at the manufacturer's recommended locations. 4. Verify that manual transfer warnings are attached and visible. 5. Verify tightness of all control connections. 6. Use the calibrated torque wrench method to verify that the tightness of accessible bolted connections and/or cable connections are in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 7. Perform manual transfer operation. 8. Verify positive mechanical interlocking between normal and alternate sources. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with the equipment standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Measure contact-resistance. 2. Perform insulation-resistance tests, phase-to-phase and phase-toground, with the switch in both source positions at the minimum dc test voltage appropriate for the equipments Maximum Rated Voltage, in accordance with Table 2 on page 59. Record the resistances. 3. Verify the settings and operation of control devices. 4. Calibrate and set all relays and timers in accordance with Section 25 Protective Relays on page 43. 5. Perform the following automatic transfer tests: (a) Simulate loss of normal power. (b) Return to normal power. (c) Simulate loss of emergency power. (d) Simulate all forms of single-phase conditions. 6. Verify that the following functions have correct timing and are operating properly: (a) Normal source voltage-sensing relays (b) Engine start sequence (c) Time delay upon transfer (d) Alternate source voltage-sensing relays (e) Automatic transfer operation (f) Interlocks and limit switch function (g) Time delay and retransfer upon normal power restoration (h) Engine cool down and shutdown feature
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Procedures for Startup and Commissioning of Electrical Equipment Section 16Emergency Systems: Automatic Transfer Switches
7. Verify that the mechanical power is removed from the generator in the event of a phase to phase or phase to ground fault between the generator and generator protection means (i.e., Circuit Breaker or Fuses).
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Procedures for Startup and Commissioning of Electrical Equipment Section 17Ground-Fault Protection Systems
SECTION 17GROUND-FAULT PROTECTION SYSTEMS
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and specifications, if available. 2. Visually inspect the components for damage and errors in polarity or conductor routing. (a) Verify that the ground connection is made ahead of the neutral disconnect link, and on the line side of any ground fault sensor. NOTE: In some cases, Generator neutrals are also bonded to ground in a similar fashion as service entrance bonds are used for commercial power connections. In these cases, neutral sensors are used in the bond connection and differentially connected within the Ground Fault detection system. (b) Verify that proper polarity exists for both primary and secondary connectors to the neutral sensors. (c) Verify that all phase conductors and the neutral pass through the sensor in the same direction for zero sequence systems. (d) Verify that grounding conductors do not pass through zero sequence sensors. (e) Verify that the grounded conductor (usually Neutral) is bonded to ground in accordance with the power system specifications. Bonding to ground is permitted at the service entrance only with the exception of double ended systems with a single center bond and/ or on the secondary of a separately derived power systems including generators. Power systems may have multiple service entrances and multiple bonding at the multiple service entrances. Bonding to ground is not permitted downstream of the service and separately derived equipment. NOTE: Refer to the special operating and testing instructions supplied with the equipment, if available. 3. Verify tightness of all electrical connections, including control circuits. 4. Verify correct operation of all functions of the self-test panel. 5. Verify that the control power transformer has adequate capacity for the system. 6. Set pickup and time-delay settings in accordance with the settings provided in the owner's specifications. B. Electrical Tests Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Measure the system neutral-to-ground insulation resistance with the neutral disconnect link temporarily removed. Replace the neutral disconnect link after testing. 2. For a system: that involves only one source; is a ground fault protection system that uses a zero phase sequence sensor that encompasses all phase and neutral conductors; and has a test winding within the zero phase sequence sensor, test by injecting test current in the test winding, as long as the sensor is not differentially connected with another sensor. Such systems are typically used with fused switch systems, but are occassionally used with circuit breaker systems where the internal breaker GF protection system is not used. In this case, a primary current injection test method need not be used. The test is a self test that uses a feature integral to the unit. If instructions are not provided, use the technique in step 3 below.
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Procedures for Startup and Commissioning of Electrical Equipment Section 17Ground-Fault Protection Systems
3. For systems involving multiple sources or multiple levels of ground fault protection, perform the following pickup tests using primary current injection techniques. These tests shall be performed on each independent bus, with test current applied from each possible source. Example: If a power system consists of a Main, Tie, Main, and one generator breaker on one side, this system would contain three independent buses: the bus between the first Main and Tie; the bus between the Tie and the second Main; and the bus (or conductors) between the generator circuit breaker and generator. Test current would be injected on the source side of each Main and from the generator terminals. A grounding test lead would then be connected between each of the defined bus locations and ground. Check the manufacturers records for special testing procedures that would be applicable for the particular system being tested. (a) Verify that the relay does not operate at 90 percent of the pickup setting. (b) Verify that pickup is less than 125 percent of setting, or 1200 amperes, whichever is smaller. 4. For summation type systems utilizing phase and neutral current transformers, verify that polarities are correct by applying current to each phase-neutral current transformer pair. This test also applies to moldedcase breakers using an external neutral current transformer. (a) The relay should operate when the current direction is the same relative to polarity marks in the two current transformers. (b) The relay should not operate when the current direction is opposite relative to polarity marks in the two current transformers. 5. Verify non-tripping activity by applying primary current injection testing techniques as in number 2 above. Current setting for this test shall be above 125 of the relay pickup setting. The test cable would be connected between a phase conductor and the Neutral for that section of the gear. This test shall be repeated for each condition as was determined in number 2 above. 6. Verify that zone selective interlock systems are operating correctly. Source breakers to an independent bus should receive a restraint signal when a ground fault is detected by a lower stream device. Complex systems having multiple sources and tie breakers should operate in a logical manner as is determined by the power system involved. Example: For a Main, Tie, Main system, a restraint signal emanating from a feeder breaker should not restrain the Main breaker on the opposite side, unless that Main is the only means of protecting the bus to which that feeder breaker is connected. Since there are many different types of Ground Fault systemsElegant, Non-Elegant, relayed tie, or non-relayed tieit is not practical to set down one rule of operation. Each system must be evaluated on its own merit, and a logical operation must be determined for each. It is suggested that the project engineer be consulted in determining the correct operation. C. Optional Tests 1. Measure the insulation resistance of the control wiring in accordance with Table 2 on page 59. Do not perform tests on wiring connected to solidstate relays. 2. Measure the time delay of the relay at 150 percent or greater of pickup. Verify operability of I2t function, if being used, of the ground fault trip device. 3. Verify reduced control voltage tripping capability: 55 percent for ac systems.
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Procedures for Startup and Commissioning of Electrical Equipment Section 18Ground Resistors
SECTION 18GROUND RESISTORS
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on the test report. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and coordination study, if available. 2. Inspect the physical and mechanical condition of the equipment. 3. Verify that any shipping bracing, brackets, or fixtures are removed after final placement. 4. Use the calibrated torque wrench method to verify that the tightness of accessible bolted connections and/or cable connections are in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 5. Verify that all frame and enclosure grounds are correct. 6. Verify that tap connections are as specified, if applicable. 7. Perform a visual and mechanical inspection on all secondary wiring and instrument transformers per the manufacturers installation and operating procedures. B. Electrical Tests 1. Perform an instrument transformer polarity check. 2. Perform insulation resistance tests on each instrument transformer, each winding to ground at 500 volts dc. Do not perform this test on solid state devices. Resistance readings should be consistent with Table 2 on page 59 for test voltages of 500 volts dc. 3. Test all electrical controls (relays, lights, switches) to verify that they are operating properly.
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Procedures for Startup and Commissioning of Electrical Equipment Section 19Grounding Systems
SECTION 19GROUNDING SYSTEMS
A. Visual and Mechanical Inspection Verify that the ground system is in compliance with drawings and specifications. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance industry standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform a fall-of-potential test or alternative in accordance with IEEE Standard 81-1991 on the main grounding electrode or system. 2. Perform point-to-point tests to determine the resistance between the main grounding system and all major electrical equipment frames, system neutral, and/or derived neutral points.
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Procedures for Startup and Commissioning of Electrical Equipment Section 20Isolated Power Systems
SECTION 20ISOLATED POWER SYSTEMS
NOTE: All Square D Company equipment shall be assured to be complete and of acceptable quality. Inspection and testing of all applicable wiring and equipment must conform to Article 517 of the National Electrical Code (NEC) and Article 99 of the National Fire Protection Association (NFPA). A. Visual and Mechanical Inspection 1. Perform a functional check of all Square D Company equipment in the area. 2. Inspect all Square D equipment in the area for physical damage such as cracked meters or scratches. Any physical or electrical defect must be recorded and discussed with the appropriate people at the job site. If the damage appears to have occurred at the job site, note this on your report. 3. Inspect the room ground and the patient reference ground if installed. 4. Remove the stainless steel trim and the circuit breaker dead front. Examine the branch circuit wiring. 5. Verify that the proper breaker identification is on the circuit schedule. 6. Examine the receptacles, ground jacks, lights, switches, and miscellaneous electrical equipment for compliance to applicable electrical codes. B. Electrical Tests 1. Measure line-to-line and line-to-ground voltage with an ac voltmeter and record the voltage on the data sheet. 2. Measure the leakage current with an ac microammeter that is capable of being accurate within 3%. Record the value to three significant figures. Measure the current between L1 and ground and L2 and ground. NOTE: Before taking current measurements, verify that no phase conductor is at ground potential. 3. Use the following formulas to determine the individual line impedance based on the values calculated in step 2 and line-to-line voltage measurement:
Z (L1 to GD)
V (L1 to L2)
=
I (L2 to GD) V (L1 to L2)
Z (L2 to GD)
I (L1 to GD)
Line impedance measurements will include all receptacles, but are not required to include lighting fixtures or components of fixtures. All electrical equipment connected to the isolated power system must be unplugged, and permanently installed equipment must be switched off. For isolation panels with branch-circuit interlock (x-ray panels), branch circuits must be measured individually. Record the circuit with the lowest calculated impedance as the system impedance. For panels in which a combination of circuits may be energized (PLC laser panels), measure branch circuits individually; energize the combination of circuits that contributes the highest amount of leakage current. This value is used to calculate the system impedance. If a line impedance is below 200,000 ohms (NFPA-99 1996, 3-3.2.2.2), the probable cause should be determined. If you cannot correct the problem at this time, you must note it on the report.
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4. Line Isolation Monitor (LIM) Calibration Tests: Determine the exact trip point of the LIM by slowly lowering the impedance between each isolated conductor and ground until the LIM goes into an alarm condition, and then measure the total hazard current with an ac milliammeter. Apply the following test faults between the isolated conductors and ground: Single resistive L1 to ground Single resistive L2 to ground Single resistive L3 to ground (three-phase systems) Balanced resistive L1 to ground and L2 to ground (one-phase systems only) Single capacitive L1 to ground Single capacitive L2 to ground Single capacitive L3 to ground (three-phase systems) Balanced capacitive L1 to ground (one-phase systems only) NOTE: The correct trip point of a 2 mA ISO-GARD (series D) LIM is 1.95 mA, +0.15 mA. The correct trip point of a 5 mA ISO-GARD (series D) LIM is 4.85 mA, +0.25 mA. 5. In patient care areas, determine the effectiveness of the equipment grounding system by using voltage and impedance measurements. Take these measurements with respect to a reference grounding point such as the ground bus in the isolation panel. Take voltage measurements between the reference point and the exposed conductive surfaces (including ground contacts of receptacles) in the patient care vicinity. NOTE: The voltage limit for new construction is 20mV. Take impedance measurements between the reference point and the grounding contact of each receptacle in the patient vicinity. NOTE: The impedance limit for new construction is 0.1 ohms. The grounding terminals of all receptacles and the conductive surfaces of fixed equipment, operating at over 100 volts, must be grounded by a conductor sized in accordance with NEC. NOTE: Conductive surfaces in the patient area that are not likely to become energized (such as windows, door frames, and towel dispensers) need not be intentionally grounded or tested. Ref: NFPA-99, 3-3.3.2.1 C. Hospital Staff Instruction Provide a thorough explanation of the isolated power systems to the appropriate hospital personnel. The instruction should include the following points: Basic theory of isolated power Advantages of isolated power systems versus grounded power systems Purpose of the Line Isolation Monitor Proper use of the grounding jacks Basic troubleshooting techniques Required periodic testing and record keeping
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D. Formal Customer Report Provide a report of the test results to the customer within two weeks. The report must include the following: A list of the isolation panels and areas that were tested Any code violations that were revealed by the testing and inspection Recommendations for corrections of any code violations A list of any damaged equipment. Note if these items will be replaced under warranty. Individual data sheets for the isolated power systems A logbook with initial hazard current readings of the isolated systems
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Procedures for Startup and Commissioning of Electrical Equipment Section 21Motor Control Centers: Low and Medium Voltage
SECTION 21MOTOR CONTROL CENTERS: LOW AND MEDIUM VOLTAGE
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and specifications. 2. Inspect the physical, electrical, and mechanical condition of structure and all electrical components. 3. Confirm that lubricants have been correctly applied at the manufacturer's recommended locations. 4. Verify appropriate anchorage, required area clearances, physical damage, and correct alignment and cleanliness. 5. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware. 6. Verify that fuse and/or circuit breaker sizes and types correspond to drawings and coordination study, if available, as well as to the circuit breaker's address for microprocessor-communication packages. 7. Verify that current and potential transformer ratios correspond to drawings. 8. Use the calibrated torque wrench method to verify that the tightness of accessible bolted connections and/or cable connections are in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 9. Confirm correct operation and sequencing of electrical and mechanical interlock systems. (a) Attempt closure on locked-open devices. Attempt to open lockedclosed devices. (b) Make key exchange with devices operated in off-normal positions. 10. Inspect insulators for evidence of physical damage or contaminated surfaces. 11. Verify correct barrier and shutter installation and operation. 12. Exercise all active components. 13. Verify that filters are in place and/or vents are clear. 14. Test the operation, alignment, and penetration of instrument transformer withdrawal disconnects, current carrying and grounding, in accordance with Section 32Transformers, Instrument on page 53. 15. Inspect control power transformers. (a) Inspect for physical damage, such as cracked insulation, broken leads, tightness of connections, defective wiring, and overall general condition. (b) Verify that primary and secondary fuse ratings or circuit breakers match drawings. (c) Verify that both primary and secondary tap connections are in accordance with manufacturers recommendations and drawings. 16. Verify that customer connections to remote power, operators, interlocks, and indicators have been made.
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B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with the equipment standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform insulation-resistance tests on each bus section, phase-to-phase and phase-to-ground at the minimum dc test voltage appropriate for the equipment Maximum Rated Voltage, in accordance with Table 2 on page 59. Record the resistances. If the resistance is lower than the recommended values in Table 2 on page 59, dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure. If low readings persist after vigorous drying, contact the manufacturer. 2. Perform a control wiring performance test by applying control voltage. Verify that the equipment operates as intended. 3. Verify that MCC heaters operate properly. 4. Perform tests on starters in accordance with Section 22Motor Starters: Low Voltage on page 39 or Section 23Motor Starters: Medium Voltage on page 40. C. Optional Tests 1. Determine the accuracy of all meters in accordance with Section 7 Analog Metering on page 13. 2. Perform insulation-resistance tests in accordance with Table 2 on page 59. Do not perform this test on wiring connected to solid-state components. 3. Perform tests on all instrument transformers in accordance with Section 32Transformers, Instrument on page 53. 4. Perform the following tests on control power transformers: (a) Perform insulation-resistance tests. Take measurements from winding-to-winding and each winding-to-ground. Test voltages shall be in accordance with Table 2 on page 59 unless otherwise specified by the manufacturer. (b) Perform a secondary wiring integrity test. Disconnect the transformer at secondary terminals, and connect secondary wiring to the correct secondary voltage. Confirm potential at all devices. (c) Verify that the secondary voltage is correct by energizing primary winding with system voltage. Measure the secondary voltage with the secondary wiring disconnected. 5. Perform the following tests on potential transformers: (a) Perform a secondary wiring integrity test. Disconnect the transformer at secondary terminals, and connect secondary wiring to the correct secondary voltage. Confirm correct potential at all devices. (b) Verify that secondary voltage is correct by energizing primary winding with system voltage. Measure the secondary voltage with the secondary wiring disconnected. 6. Perform a dielectric test (Hi-Pot) on each bus section, each phase to ground with phases not under test grounded, in accordance with the manufacturer's published data. If the manufacturer has no recommendation for this test, it shall be in accordance with Table 5 on page 61. The test voltage shall be applied for one minute.
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7. Perform ground-resistance tests in accordance with Section 19 Grounding Systems on page 32. 8. Perform a contact resistance test through all bus joints with a low resistance ohmmeter.
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Procedures for Startup and Commissioning of Electrical Equipment Section 22Motor Starters: Low Voltage
SECTION 22MOTOR STARTERS: LOW VOLTAGE
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify that equipment nameplate ratings are in accordance with the final approved and record drawings and specifications. This will include: contactor, fuses, overloads, circuit breakers, overload relay heaters, power factor correction capacitors, and the control power transformer. 2. Inspect the physical and mechanical condition of the equipment. 3. Use the calibrated torque wrench method to verify that the tightness of accessible bolted connections and/or cable connections are in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with the equipment standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Measure the insulation resistance of each combination starter, phase-tophase and phase-to-ground, with the starter contacts closed and the protective device open. Test voltage shall be in accordance with Table 2 on page 59. Refer to the manufacturer's instructions for devices with solid-state components. 2. Perform operational tests by initiating control devices. C. Optional Tests 1. Measure the insulation resistance of each control circuit-to-ground. Test voltage shall be in accordance with Table 2 on page 59. Do not perform tests on wiring connected to solid-state relays. 2. Test the motor overload relay elements by injecting primary current through the overload circuit, and monitoring the trip time of the overload element. 3. Test circuit breakers in accordance with Section 29 Switchgear and Switchboard Assemblies: Low and Medium Voltage on page 48 or Section 12Circuit Breakers: Low Voltage Power (ANSI/IEEE C37.13) on page 20 as appropriate. NOTE: Typically, Molded Case Circuit Breakers are usedrefer to Section 11Circuit Breakers: Low Voltage Insulated Case/Molded Case on page 17. If ANSI C37.13 Power Circuit Breakers are used, refer to Section 12Circuit Breakers: Low Voltage Power (ANSI/IEEE C37.13) on page 20.
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Procedures for Startup and Commissioning of Electrical Equipment Section 23Motor Starters: Medium Voltage
SECTION 23MOTOR STARTERS: MEDIUM VOLTAGE
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and specifications. 2. Inspect the physical, electrical, and mechanical condition of the equipment. 3. Confirm that lubricants have been correctly applied at the manufacturer's recommended locations, identified in their service bulletin. 4. Use the calibrated torque wrench method to verify that the tightness of accessible bolted connections and/or cable connections are in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 5. Test all electrical and mechanical interlock systems for correct operation and sequencing. 6. Inspect insulators for evidence of damage or contaminated surfaces. 7. Verify that barriers and shutters are installed and operating correctly. 8. Exercise all active components, and confirm that all indicating devices are operating correctly. 9. Inspect the contactors. (a) Verify mechanical operation. (b) Inspect and adjust contact gap, wipe and alignment in accordance with manufacturer's published data. (c) Use the calibrated torque wrench method to verify that the tightness of accessible bolted connections and/or cable connections are in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 10. Compare the overload protection rating with the motor nameplate to verify that the size is correct. Set adjustable or programmable devices according to the protective device coordination study, if available B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with the equipment standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due.
CAUTION
HAZARD OF INJURY OR EQUIPMENT DAMAGE DC LIM Hi-Pot testing of vacuum breakers is not recommended. Read the label on the vacuum bottle for precautions to take against the danger of xray emission while performing AC Hi-Pot testing. Failure to follow these instructions can result in injury or equipment damage.
1. Perform a control wiring performance test. Use the elementary diagrams to identify each remote control and protective device. Verify that each control feature performs satisfactorily. 2. Perform insulation-resistance tests on contactor, phase-to-ground, phase-to-phase, and across the open contacts for one minute in accordance with Table 2 on page 59. 3. Perform a vacuum bottle integrity test (overapologetic) test using AC HiPot across each vacuum bottle, with the breaker in the open position in strict accordance with manufacturer's instructions. Contact the manufacturer if repeated consistent breakdowns are encountered. 4. Test ground-fault protection by injecting a primary current through the sensor. Confirm pickup level and timing. 5. Perform setup and testing on protective relaying in accordance with the manufacturer's published data.
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Procedures for Startup and Commissioning of Electrical Equipment Section 23Motor Starters: Medium Voltage
6. Verify that the cubicle space heat operates properly. C. Optional Tests 1. Perform an insulation-resistance test in accordance with Table 2 on page 59. For devices with solid-state components, refer to the manufacturer's published data. 2. Perform ratio and polarity tests on all current and voltage transformers in accordance with Section 32Transformers, Instrument on page 53. 3. Test control power transformers in accordance with Section 29 Switchgear and Switchboard Assemblies: Low and Medium Voltage on page 48. 4. Energize the contactor using an auxiliary source. Adjust the armature to minimize operating vibration where applicable. 5. Test circuit breakers in accordance with Section 14Circuit Breakers: Medium Voltage Vacuum on page 24 or Section 13Circuit Breakers: Medium Voltage SF6 on page 22. 6. Perform an overapologetic test, as applicable, in accordance with the manufacturer's published data or Table 5 on page 61. The test voltage shall be applied for one minute. 7. Measure contact resistance.
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Procedures for Startup and Commissioning of Electrical Equipment Section 24Oil Switches: Medium Voltage
SECTION 24OIL SWITCHES: MEDIUM VOLTAGE
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on the test report. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and specifications, if available. 2. Inspect the physical and mechanical condition of the equipment. 3. Inspect anchorage, alignment, and grounding. 4. Perform all mechanical operation and contact alignment tests on both the switch and its operating mechanism. 5. Test all electrical and mechanical interlock systems for correct operation and sequencing. 6. Use the calibrated torque wrench method to verify that the tightness of accessible bolted connections and/or cable connections are in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 7. Verify that the insulating oil level is correct. 8. Verify that fuse sizes and types correspond to the final approved or record drawings. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with Switchgear industry standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Remove a sample of insulating liquid in accordance with ASTM D-923. The sample shall be tested for the following: Dielectric breakdown voltage: ASTM D-877. 2. Perform insulation-resistance tests pole-to-pole, pole-to-ground, and across open poles for one minute. The test voltage should be in accordance with manufacturer's published data or Table 2 on page 59. C. Optional Tests 1. Perform an insulation-resistance test in accordance with Table 2 on page 59. Do not perform this test on wiring connected to solid-state components. 2. Remove a sample of insulating liquid in accordance with ASTM D-923. The sample shall be tested for the following: (a) Dielectric breakdown voltage: ASTM D-877 and/or ASTM D-1816. (b) Acid neutralization number: ASTM D-974. (c) Specific gravity: ASTM D-1298. (d) Interfacial tension: ASTM D-971 or ASTM D-2285. (e) Color: ASTM D-1500. (f) Visual Condition: ASTM D-1524. (g) Parts per million water: ASTM D-1533. Required on 25 kV or higher voltages and on all silicone-filled units. (h) Measure dissipation factor or power factor in accordance with ASTM D-924.
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Procedures for Startup and Commissioning of Electrical Equipment Section 25Protective Relays
SECTION 25PROTECTIVE RELAYS
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on the test report. Verify that equipment nameplate ratings are in accordance with final approved or record drawings and specifications, if available. 2. Inspect relays and cases for physical damage. If appropriate, remove shipping restraint material. Relay inspections and testing shall be performed in strict compliance with the manufacturers instructions. 3. Tighten case connections. Inspect the cover for the correct gasket seal. Clean the cover glass. Inspect the shorting hardware, connection paddles, and/or knife switches. Remove any foreign material from the case. Verify target reset. 4. Inspect the relay for foreign material. On electromechanical relays, inspect disk slots of the damping and electromagnets, verify disk clearance, inspect spiral spring convolutions, and inspect disk and contacts for freedom of movement and correct travel, and verify the tightness of mounting hardware and connections. 5. Mechanically test the operation of electromechanical relays. 6. Set relays in accordance with the coordination study supplied by the owner, if available. If a coordination study is not available, the customer will be responsible for setting relays. B. Electrical Tests Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform an insulation-resistance test on each circuit-to-frame. Do not perform this test on solid state relays. 2. Inspect targets and indicators. 3. Verify the operation of all light-emitting diode indicators, if applicable. 4. Set contrast for liquid-crystal display readouts, if applicable. 5. Control Verification: Verify that each of the relay contacts performs its intended function in the control scheme, including breaker trip tests, close inhibit tests, 86 lockout tests, and alarm functions. 6. Verify that all pickup/dropout parameters are on each operating element. 7. Verify timing at three points on the time dial curve. C. Optional Tests System Test: After the equipment is initially energized, measure the magnitude and phase angle of all inputs and compare to expected values, in order to prove that the equipment has proper polarity and is correctly connected. (Optional second trip if the equipment cannot be energized)
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Procedures for Startup and Commissioning of Electrical Equipment Section 26Step Voltage Regulators
SECTION 26STEP VOLTAGE REGULATORS
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on test report. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and specifications. 2. Inspect the physical and mechanical condition of the equipment. 3. Inspect impact recorder prior to unloading regulator, if applicable. 4. Verify removal of any shipping bracing and vent plugs after final placement. 5. Verify that auxiliary devices operate correctly. 6. Using the calibrated torque-wrench method, verify that the tightness of accessible bolted electrical connections is in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 7. Verify that the motor and drive train operate correctly, and automatic motor cut-off at maximum lower and maximum raise. 8. Verify appropriate liquid level in all tanks and bushings. 9. Perform specific inspections and mechanical tests as recommended by the manufacturer. 10. Verify equipment grounding. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with the equipment standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform insulation-resistance tests on each winding-to-ground in the neutral position with the test voltage in accordance with Table 2 on page 59. 2. Perform special tests and adjustments as recommended by the manufacturer. 3. Perform a turns ratio test on each voltage step position. Verify that the indicator correctly identifies all tap positions. 4. Verify that the voltage range limiter operates accurately. 5. Verify functioning and accuracy of bandwidth, time delay, voltage, and line-drop compensation adjustments. 6. Perform a dielectric breakdown test with a field tester. C. Optional Tests 1. Remove a sample of insulating liquid in the main tank or common tank in accordance with ASTM D-923. The sample shall be tested for the following: (a) Dielectric breakdown voltage: ASTM D-877 and/or ASTM D-1816. (b) Acid neutralization number: ASTM D-974. (c) Specific gravity: ASTM D-1298. (d) Interfacial tension: ASTM D-971 or ASTM D-2285. (e) Color: ASTM D-1500. (f) Visual condition: ASTM D-1524.
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Procedures for Startup and Commissioning of Electrical Equipment Section 26Step Voltage Regulators
2. Remove a sample of insulating liquid in the tap-changer tank in accordance with ASTM D-923.The sample shall be tested for the following: (a) Dielectric breakdown voltage: ASTM D-877. (b) Color: ASTM D-1500. (c) Visual condition: ASTM D-1524.
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Procedures for Startup and Commissioning of Electrical Equipment Section 27Surge Arresters: Low Voltage Surge Protection Devices
SECTION 27SURGE ARRESTERS: LOW VOLTAGE SURGE PROTECTION DEVICES
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on the test report. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and specifications. 2. Inspect the physical and mechanical condition of the equipment. 3. Inspect for correct mounting and adequate clearances. 4. Using the calibrated torque-wrench method, verify that the tightness of accessible bolted electrical connections is in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 5. Verify that the ground lead on each device is individually attached to a ground bus or ground electrode.
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Procedures for Startup and Commissioning of Electrical Equipment Section 28Surge Arresters: Medium and High Voltage Surge Protection Devices
SECTION 28SURGE ARRESTERS: MEDIUM AND HIGH VOLTAGE SURGE PROTECTION DEVICES
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on the test report. Verify that equipment nameplate ratings are in accordance with the final approved or record drawings and specifications. 2. Inspect the physical and mechanical condition of the equipment. 3. Inspect for correct mounting and adequate clearances. 4. Using the calibrated torque-wrench method, verify that the tightness of accessible bolted electrical connections is in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 5. Verify that the ground lead on each device is individually attached to a ground bus or ground electrode. 6. Verify that the stroke counter, if present, is correctly mounted and electrically connected.
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Procedures for Startup and Commissioning of Electrical Equipment Section 29 Switchgear and Switchboard Assemblies: Low and Medium Voltage
SECTION 29 SWITCHGEAR AND SWITCHBOARD ASSEMBLIES: LOW AND MEDIUM VOLTAGE
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on the test report. 2. Verify that all of the manufacturers intended documentation is either stored with the equipment or in the operators possession. This include, but is not limited to, all elementary diagrams, wiring diagrams, and operational and service manuals for each component within the equipment. 3. Inspect the physical, electrical, and mechanical condition of the equipment and all components in accordance with the applicable section of the documentation. 4. Confirm that lubricants have been correctly applied at the manufacturer's recommended locations. 5. Verify appropriate anchorage, required area clearances, physical damage, and correct alignment and cleanliness. 6. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware. 7. Verify that fuse and/or circuit breaker sizes and types correspond to drawings and coordination study, if available, as well as to the circuit breaker's address for microprocessor-communication packages. 8. Verify that final approved or record drawings have the correct revision and date in accordance with customer and supplier records. 9. Verify that current and potential transformer ratios correspond to drawings. Perform visual and mechanical inspections on instrument transformers in accordance with Section 32Transformers, Instrument on page 53. 10. Using the calibrated torque-wrench method, verify that the tightness of accessible bolted electrical connections is in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 11. Confirm correct operation and sequencing of electrical and mechanical interlock systems. (a) Attempt closure on locked-open devices. Attempt to open lockedclosed devices. (b) Make key exchange with devices operated in off-normal positions. 12. Inspect insulators for evidence of physical damage or contaminated surfaces. 13. Verify that the barriers and shutters are installed and operating correctly. 14. Exercise all active components. 15. Inspect all mechanical indicating devices for correct operation. 16. Verify that filters are in place and/or vents are clear. 17. Inspect control power transformers. (a) Inspect the transformers for physical damage, cracked insulation, broken leads, tightness of connections, defective wiring, and overall general condition. (b) Verify that primary and secondary fuse ratings or circuit breakers match the final approved or record drawings. (c) Verify that both primary and secondary tap connections are in accordance with both the manufacturer's recommendations and the elementary diagrams.
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18. Set relays in accordance with the coordination study supplied by owner, if available. If a coordination study is not available, the customer will be responsible for setting relays. 19. Verify that drawout disconnecting and grounding contacts and interlocks function correctly. 20. Verify that customer connections to remote power, operators, interlocks, and indicators have been made. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance with Switchgear or Switchboard industry standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform insulation-resistance tests on each bus section, phase-to-phase and phase-to-ground, at the minimum dc test voltage appropriate for the equipments Maximum Rated Voltage in accordance with Table 2 on page 59. Record the resistances. If the resistance is lower than the recommended values in Table 2 on page 59, visually inspect the equipment for cleanliness and other potential causes. If the visual inspection does not reveal the causes, recommend for the contractor to dry the equipment for a minimum of 4 hours using heat and fans. Then re-measure. If low readings persist after vigorous drying, contact the manufacturer. 2. Perform a control wiring performance test by applying control voltage. Verify that the equipment operates as intended. 3. Perform a phasing check on double-ended switchgear (low voltage) to insure correct bus phasing from each source. {Optional second visit is required if equipment is not energized.} 4. Verify correct function of control transfer relays located in switchgear with multiple power sources. 5. Verify operation of switchgear/switchboard heaters. 6. Test protective relays in accordance with Section 25Protective Relays on page 43. 7. Test individual circuit breakers or switches in accordance with the applicable section of this document:
Section Reference
Section 4Air Switches: Low Voltage (Bolted Pressure, QMB, or Equal) Section 5Air Switches: Medium Voltage, Metal-Enclosed Section 6Air Switches: High and Medium Voltage, Open Style Section 11Circuit Breakers: Low Voltage Insulated Case/Molded Case Section 12Circuit Breakers: Low Voltage Power (ANSI/IEEE C37.13) Section 13Circuit Breakers: Medium Voltage SF6 Section 14Circuit Breakers: Medium Voltage Vacuum Section 24Oil Switches: Medium Voltage
Page
8 10 12 17 20 22 24 42
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8. Perform a dielectric test (Hi-Pot) on each bus section, each phase to ground with phases not under test grounded, in accordance with Table 5 on page 61 or the manufacturers published data. NOTE: This test is standard on medium voltage switchgear only. It is optional on all low voltage switchgear and switchboards. C. Optional Tests 1. Perform tests on all instrument transformers in accordance with Section 32Transformers, Instrument on page 53. 2. Perform insulation-resistance tests in accordance with Table 2 on page 59 on all control wiring. Do not perform this test on wiring connected to solid-state components. 3. Perform ground-resistance tests in accordance with Section 19 Grounding Systems on page 32. 4. Perform the following tests on control power transformers. (a) Perform insulation-resistance tests. Perform measurements from winding-to-winding and each winding-to-ground. Test voltages shall be in accordance with Table 2 on page 59 unless otherwise specified by the manufacturer. (b) Inspect primary winding tab connections and secondary terminal connections for correct wiring for primary and secondary voltages involved. (c) Perform a secondary wiring integrity test. Disconnect the transformer at secondary terminals and connect secondary wiring to correct secondary voltage. Confirm potential at all device (d) Verify correct secondary voltage by energizing primary winding with system voltage. Measure secondary voltage with the secondary wiring disconnected. 5. Perform a contact resistance test through all bus joints, using a low resistance ohmmeter. 6. Perform the following tests on potential transformers. (a) Perform a secondary wiring integrity test. Disconnect transformer at secondary terminals and connect secondary wiring to correct secondary voltage. Confirm correct potential at all devices. (b) Verify secondary voltage by energizing primary winding with system voltage. Measure secondary voltage with the secondary wiring disconnected. 7. Perform tests on ground fault protection system in accordance with Section 17Ground-Fault Protection Systems on page 29. 8. Perform current tests by primary injection on all metering and relaying circuits, other than ground fault, in each section of switchgear with magnitudes, such that a minimum of 1.0 ampere flows in the secondary circuit. Verify that the secondary current flow at each device is intended in the current circuit. 9. Determine the accuracy of all {Analog} meters per Section 7Analog Metering on page 13.
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Bulletin No. 0180IB0001R5/01 Procedures for Startup and Commissioning of Electrical Equipment May 2001 Section 30Transformers: Dry Type: All Voltages - Large (Greater Than 167 Single-Phase and 500KVA Three-Phase)
SECTION 30TRANSFORMERS: DRY TYPE: ALL VOLTAGES - LARGE (GREATER THAN 167 SINGLE-PHASE AND 500KVA THREE-PHASE)
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on the test report. Verify that transformer nameplate ratings are in accordance with final approved or record drawings and specifications, if available. 2. Inspect the physical and mechanical condition of the equipment. 3. Verify that the control and alarm settings on temperature indicators are as specified, if the settings are available. 4. Verify that cooling fans operate correctly and that fan motors have correct overcurrent protection. 5. Using the calibrated torque-wrench method, verify that the tightness of accessible bolted electrical connections is in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 6. Perform specific inspections and mechanical tests as recommended by the manufacturer. 7. Make a close examination for shipping brackets or fixtures that may not have been removed during installation. Insure that resilient mounts are free. 8. Verify that winding core, frame, and enclosure groundings are correct. 9. Verify that as-left tap connections are as specified. 10. Verify that customer connections have been made to remote power and operators. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance industry standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform insulation-resistance tests winding-to-winding and each windingto-ground, with test voltage in accordance with Table 3 on page 59. Test duration shall be for ten minutes with resistances tabulated at 30 seconds, one minute, and ten minutes. 2. Perform a transformer turns-ratio test on all tap connections. Verify that winding polarities are in accordance with nameplate. C. Optional Tests 1. For 5kV and above, perform power-factor or dissipation-factor (excitationcurrent) tests in accordance with the test equipment manufacturer's instructions. 2. Measure the resistance of each winding at each tap connection. 3. Verify that the core is grounded. If the core is insulated and a removable core ground strap is available, perform a core insulation-resistance test at 500 volts dc.
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Procedures for Startup and Commissioning of Electrical Equipment Section 31Transformers: Dry Type - Small (167KVA Single-Phase, 500KVA Three-Phase, and Smaller)
SECTION 31TRANSFORMERS: DRY TYPE - SMALL (167KVA SINGLE-PHASE, 500KVA THREE-PHASE, AND SMALLER)
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on the test report. Verify that transformer nameplate ratings are in accordance with final approved or record drawings and specifications, if available. 2. Inspect the physical and mechanical condition of the equipment. 3. Verify that resilient mounts are free and that any shipping brackets have been removed. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance industry standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform an insulation-resistance test. Measurements shall be made from winding-to-winding and each winding-to-ground. Test voltages and minimum resistance shall be in accordance with Table 3 on page 59. Results should be temperature corrected in accordance with Table 4 on page 60. 2. Using a TTR, verify that transformer winding turns-ratio measurements and polarities are in accordance with the nameplate. 3. Verify that as-left tap connections are as specified.
52
Procedures for Startup and Commissioning of Electrical Equipment Section 32Transformers, Instrument
SECTION 32TRANSFORMERS, INSTRUMENT
A. Visual and Mechanical Inspection 1. Verify equipment nameplate ratings are in accordance with the final approved or record drawings and specifications, if available. 2. Inspect the physical and mechanical condition of the equipment. 3. Verify correct connection of transformers with system requirements. 4. Verify that adequate clearances exist between primary and secondary circuit wiring. 5. Using the calibrated torque-wrench method, verify that the tightness of accessible bolted electrical connections is in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 6. Verify that all required grounding and shorting connections provide contact. 7. Verify that all shorting blocks are in the correct position, either grounding or open, as required. 8. Verify correct operation of transformer drawout mechanism and grounding operation. 9. Verify correct primary and secondary fuse sizes for potential transformers. B. Electrical Tests - Current Transformers Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform an insulation-resistance test of the current transformer and wiring-to-ground at 500 volts dc. Do not perform this test on solid-state devices. Resistance readings should be consistent with Table 2 on page 59 for a test voltage of 500 volts dc. 2. Perform a polarity test of each current transformer. 3. Perform a ratio-verification test using the voltage or current method in accordance with ANSI C5XVIII.1 (IEEE Guide for Field Testing of Relaying Current Transformers). C. Optional Tests - Current Transformers 1. Perform an excitation test on transformers used for relaying applications in accordance with ANSI C5XVIII.1. (IEEE Guide for Field Testing of Relaying Current Transformers). 2. Measure current circuit burdens at transformer terminals and determine the total burden. 3. When applicable, perform insulation-resistance and dielectric withstand tests on the primary winding with secondary grounded. Test voltages shall be in accordance withTable 5 on page 61 and Table 8 on page 66 respectively.
53
Procedures for Startup and Commissioning of Electrical Equipment Section 32Transformers, Instrument
D. Electrical Tests - Potential Transformers Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform insulation-resistance tests winding-to-winding and each windingto-ground. Test voltages shall be applied for one minute in accordance with Table 2 on page 59. Do not perform this test with solid-state devices connected. 2. Perform a polarity test on each transformer to verify the polarity marks or H1-X1 relationship as applicable. E. Optional Tests - Potential Transformers 1. Measure potential circuit burdens at transformer terminals and determine the total burden. 2. Perform a dielectric withstand test on the primary windings with the secondary windings connected to ground. The dielectric voltage shall be in accordance with Table 6 on page 62. The test voltage shall be applied for one minute.
54
Procedures for Startup and Commissioning of Electrical Equipment Section 33Transformers: Liquid-Filled: All Voltages
SECTION 33TRANSFORMERS: LIQUID-FILLED: ALL VOLTAGES
A. Visual and Mechanical Inspection 1. Document equipment nameplate data on the test report. Verify that transformer nameplate ratings are in accordance with final approved or record drawings and specifications, if available. 2. Inspect the physical and mechanical condition of the equipment. 3. Inspect impact recorder prior to unloading, if applicable. 4. Verify that alarm, control, and trip settings on temperature indicators are as specified. 5. Verify that cooling fans and pumps operate correctly and that fan and pump motors have correct overcurrent protection. 6. Verify operation of all alarm, control, and trip circuits from temperature and level indicators, pressure relief device, and fault pressure relay. (Optional second visit if the equipment cannot be energized.) 7. Using the calibrated torque-wrench method, verify that the tightness of accessible bolted electrical connections is in accordance with the manufacturer's published data. If no manufacturer's data is available, use the values in Table 1 on page 57. 8. Verify correct liquid level in all tanks and bushings. 9. Verify that positive pressure is maintained on nitrogen-blanketed transformers. 10. Perform specific inspections and mechanical tests as recommended by the manufacturer. 11. Verify correct equipment grounding. 12. Test load tap-changer in accordance with Section 26Step Voltage Regulators on page 44, if applicable. 13. Verify removal of any shipping bracing after final placement. B. Electrical Tests NOTE: When performing dielectric tests, you must disconnect all Instrument and Control Transformers, Arresters, TVSS units, and other sensitive electronic equipment that may cause erroneous results or cause damage to equipment that is not rated in accordance industry standards. Verify the proper selection and operation of the electrical test equipment. Record the date of the last calibration date and the date re-calibration is due. 1. Perform insulation-resistance tests, winding-to-winding, and each winding-to-ground with the test voltage in accordance with Table 3 on page 59. Test duration shall be for ten minutes with resistances tabulated at 30 seconds, one minute, and ten minutes. 2. Perform a transformer turns-ratio test on all no-load tap-changer positions and all load tap-changer positions. Verify that tap setting is as specified. Verify that winding polarities are in accordance with nameplate. C. Optional Tests 1. Perform insulation power-factor/dissipation-factor tests on all windings and correct to 20 C in accordance with the test equipment manufacturer's instructions. 2. Perform power-factor/dissipation-factor tests (or hot collar watts-loss tests) on bushings and correct for 20 C in accordance with the test equipment manufacturer's instructions. 3. Perform excitation-current tests in accordance with the test equipment manufacturer's instructions.
55
Procedures for Startup and Commissioning of Electrical Equipment Section 33Transformers: Liquid-Filled: All Voltages
4. Remove a sample of insulating liquid in accordance with ASTM D-923. The sample shall be tested for the following: (a) Dielectric breakdown voltage: ASTM D-877 and/or ASTM D-1816. (b) Acid neutralization number: ASTM D-974. (c) Specific gravity: ASTM D-1298. (d) Interfacial tension: ASTM D-971 or ASTM D-2285. (e) Color: ASTM D-1500. (f) Visual Condition: ASTM D-1524. (g) Parts per million water: ASTM D-1533. Required on 25 kV or higher voltages and on all silicone-filled units. (h) Measure dissipation factor or power factor in accordance with ASTM D-924. 5. Remove a sample of insulating liquid in accordance with ASTM D3613 and perform dissolved gas analysis (DGA) in accordance with ANSI/IEEE C5XVI4 or ASTM D-3612. 6. If a core ground strap is accessible, measure the core insulation resistance at 500 Vdc. 7. Measure the insulation resistance of each high-voltage winding in each no-load tap-changer position. Measure the resistance of each lowvoltage winding in each load tap-changer position, if applicable.
56
Procedures for Startup and Commissioning of Electrical Equipment Tables
TABLES
Table 1:
US Standard Bolt Torques for Bus and Cable Connections

Heat-Treated Steel - Cadmium or Zinc Plated
Grade
Minimum Tensile (P.S.I.) Bolt Diameter In Inches 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1.0
SAE 1 & 2
64K
SAE 5
105K
SAE 7
133K
SAE 8
150K
Torque (Foot Pounds) 4.0 7.2 12.0 19.2 29.6 42.4 59.2 96.0 152.0 225.6 5.6 11.2 20.0 32.0 48.0 70.4 96.0 160.0 241.6 372.8 8.0 15.2 27.2 44.0 68.0 96.0 133.6 224.0 352.0 528.0 8.4 17.6 29.6 48.0 73.6 105.6 144.0 236.8 378.4 571.2
Silicon Bronze Fasteners1 Torque (Foot-Pounds) Bolt Diameter in Inches

5/16 3/8 1/2 5/8 3/4
Non-lubricated
15 20 40 55 70
Lubricated
10 14 25 40 60
1 Bronze alloy bolts shall have a minimum tensile strength of 70,000 pounds per square inch.
Aluminum Alloy Fasteners2 Torque (Foot-Pounds) Bolt Diameter in Inches

5/16 3/8 1/2 5/8 3/4
Lubricated
8.0 11.2 20.0 32.0 48.0
2 Aluminum alloy bolts shall have a minimum tensile strength of 55,000 pounds per square inch.
Stainless Steel Fasteners3 Torque (Foot-Pounds) Bolt Diameter in Inches

5/16 3/8 1/2 5/8 3/4
Un-coated
14 25 45 60 90
3 Bolts, cap screws, nuts, flat washers, locknuts: 18-8 alloy. Belleville washers: 302 alloy.
57
Recommended Torque Values for Field Installed Wiring Terminal Socket Size Across Flats (inches)
1/4 Incoming lugs Branch lugs Neutral lugs Ground lugs 5/16 3/8 1/2 (see exception on next line) 1/2 (3/0750 kcmil)
Torque (lb-in.)
180 250 340 450 620
Multiple Conductor Neutral and/or Ground Bar Screw Type Lug Wire Range
Conductor Size
#14-10CU, #12-10AL
Torque (lb-in.)
20 25 35 36 45 100 275
#14-4 Slotted head
#8 CU-AL #6-4 CU-AL #14-8 CU-AL
#14-1/0 Socket head #6-300 kcmil
#6-1/0 CU-AL ALL ALL
Aluminum lugs are suitable for use with copper or aluminum conductors. Copper lugs are suitable for use with copper conductors only. Use 75 C copper or aluminum conductors except as marked on or near installed circuit breakers or switches.
Hardware that secures electrical joints must be torqued to the values shown in the following table:
Recommended Torque Values for Electrical Bus Joints Carriage Bolt Grade 5. Standard or Heavy Hex Nut. One Conical Washer Carriage Bolt Grade 5. Nut and Conical Washer Assy. Hex Head Bolt Grade 5, Standard or Heavy Hex Nut, 2 Conical Washers Standard or heavy hex nut. One conical washer lbs-inch
Description of Hardware
Square Head Bolt Grade 5
Bolt Diameter (inches)
Washer O.D. (inches)
lbs-inch
lbs-inch
Nut and conical washer assy. lbs-inch
lbs-inch
0.25 (1/4) 0.31 (5/16) 0.38 (3/8) 1.25 0.50 (1/2) 2.25 3.00 780900 (6575 lbs-ft)
5075 80125 0.87 175225 175225 1.00 1.25 250350 250350 2.25 3.00 450550 (38-46 lbs-ft) 130150 1.00 1.25 2.25 3.00 780900 (6575 lbs-ft) 130150 250280 0.90 0.87 145160 250280
58
Table 2:
Insulation-Resistance Test Voltage for Electrical Apparatus and Systems

Minimum dcTest Voltage
500 1,000 2,500 2,500 2,500 5,000 15,000
Voltage Rating
0 - 250 251 - 600 601 - 5,000 5,001 - 8,000 8,001 - 15,000 15,001 - 25,000 25,001 - 69,000
Recommended Minimum Insulation Resistance In Megohms

50 100 1,000 2,000 5,000 20,000 100,000
Reprinted with permission of the InterNational Electrical Testing Association Copyright 1997 Note: See Table 4 for Insulation Resistance Test Conversion Factors
Table 3:
Transformer Insulation-Res. Acceptance Test Voltage and Min. Results

Transformer Insulation Resistance Test Voltages
Transformer Winding Rated Voltage

0-600 601-5000 >5000
Minimum DC Test Voltage

1000 2500 5000
Recommended Minimum Transformer Insulation Resistance Results: In the absence of consensus standards for minimum acceptable transformer insulation resistance, the NETA Standards Review Council recommends the use of the following formula. Although the origin of this formula is not identified, NETA recognizes its wide use in the electrical testing industry.
IR = Minimum recommended one minute insulation resistance C = Constant E = Phase-to-phase voltage for delta connected windings; phase-to-neutral voltage for star connected windings. kVA = Rated kVA of transformer Values of C @ 20C for 60 Hz transformers Oil-filled C = 1.5 Dry-type C = 30 Reprinted from Acceptance Testing Specifications for Electrical Power Distribution Equipment and Systems (NETA ATS-1999).with permission of the InterNational Electrical Testing Association.
IR
CE kVA
59
Table 4:
Insulation Resistance Conversion Factors

For Conversion of Test Temperature to 20C Temperature Multiplier Apparatus Containing Immersed Oil Insulation
0.25 0.36 0.50 0.75 1.00 1.40 1.98 2.80 3.95 5.60 7.85 11.20 15.85 22.40 31.75 44.70 63.50
Apparatus Containing Solid Insulation

0.40 0.45 0.50 0.75 1.00 1.30 1.60 2.05 2.50 3.25 4.00 5.20 6.40 8.70 10.00 13.00 16.00
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
32 41 50 59 68 77 86 95 104 113 122 131 140 149 158 167 176
Reprinted from Acceptance Testing Specifications for Electrical Power Distribution Equipment and Systems (NETA ATS-1999).with permission of the InterNational Electrical Testing Association.
60
Table 5:
Power Frequency Dielectric Withstand Test

Dielectric tests for UL-891 Switchboards & I-Line Busway Rated Voltage AC
120 Vac 208 Vac 240 Vac 480 Vac 600 Vac
Power Frequency Field Test Voltage for 60 sec. duration

930 Vac 1062 Vac 1110 Vac 1470 Vac 1650 Vac
Dielectric tests for ANSI/IEEE C37.20.1 Low Voltage Switchgear & C37.23 Bus Rated Maximum Voltage AC
254, 508, 635 Vac
Power Frequency Field Test Voltage for 60 seconds duration

1650 Vac
Reference DC Field Test Voltage for 60 seconds duration

2325 Vdc
Dielectric tests ANSI/IEEE C37.20.2 & C37.20.3 Metal-Clad, Station-Type Cubical and Metal Enclosed MV Switchgear, C37.23 Bus, Outdoor Circuit Breakers, and ANSI C37.32 Air Switches Rated Maximum Voltage AC
4.76 kVac 8.25 kVac 15 kVac 15.5 kVac 25.8/27 kVac 38.0 kVac 72.5 kVac
Power Frequency Field Test Voltage for 60 sec. duration

14.25 kVac 19.5 kVac 27 kVac 37.5 kVac 45 kVac 60 kVac 120 kVac
Reference DC Field Test Voltage for 60 seconds duration

20.25 kVdc 27.75 kVdc 37.5 kVdc 52.5 kVdc -
The column headed DC Withstand is given as a reference only for those using dc tests to verify the integrity of connected cable installations without disconnecting the cables from the switchgear. It represents values believed to be appropriate and approximately equivalent to the corresponding power frequency withstand test values specified for voltage rating of switchgear. The presence of this column in no way implies any requirement for a dc withstand test on ac equipment or that a dc withstand test represents an acceptable alternative to the low-frequency withstand tests specified in this specification, either for design tests, production tests, conformance tests, or field tests. When making dc tests, the voltage should be raised to the test value in discrete steps and held for a period of one minute.
61
Table 6:
Instrument Transformer Dielectric Tests

BIL(kV) Applied Potential Tests Field Test Voltage (kV) ac dc1
4 10 15 19 26 34 34 40 50 50 70 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Nominal System (kV)
0.6 1.1 2.4 4.8 8.32 13.8 13.8 25 25 34.5 34.5 46 69 115 115 138 138 161 161 230 230 345 500 500 765
10 30 45 60 75 95 110 125 150 150 200 250 350 450 550 550 650 650 750 900 1050 1300 1675 1800 2050
3 7.5 11.25 14.25 19.5 25.5 25.5 30 37.5 37.5 52.5 71.25 105 138.75 172.50 172.50 206.25 206.25 243.75 296.25 345 431.25 562.5 600 690
Derived from Paragraph 8.8.2 and Tables 2 and 7 of ANSI/IEEE C5XVIII-1993 (Standard Requirements for Instrument Transformers). 1 DC potential tests are not recommended for transformers rated higher than 200 kV BIL. DC tests may prove beneficial as a reference for future testing. In such cases the test direct voltage should not exceed the original factory test RMS alternating voltages.
62
Table 7:
Square D Molded Case Circuit Breaker Watts Loss/ Resistance

Frame Size
(Amperes)
Circuit Breaker Type

Type
Circuit Breaker
Rating/Ampacity 15 20 25 30 35 40
Pole Resistance
Ohms x 10-3 31.11 18.75 12.00 8.44 6.37 4.88 4.20 3.40 2.36 1.90 1.45 1.16 0.94 21.25 14.40 10.00 7.35 5.94 4.69 4.00 2.78 2.45 1.88 1.60 1.30 2.78 2.13 1.94 1.57 1.31 1.02 0.73 0.55 0.44 0.36 0.29 1.20 1.06 0.87 0.64 0.58 0.48 0.42
FA, FH, FC
100
45 50 60 70 80 90 100 20 25 30 35 40 45
FI, IF 600V
100 50 60 70 80 90 100 70 80 90 100 110
KA, KH
225/250
125 150 175 200 225 250 110 125 150
KC, KI, IK
250
175 200 225 250
63
Square D Molded Case Circuit Breaker Watts Loss & Resistance (contd) Circuit Breaker Type
Type
Frame Size
(Amperes)
Circuit Breaker
Rating/Ampacity 125 150 175 200
Pole Resistance
Ohms x 10-3 1.2160 0.9778 0.7967 0.6250 0.4998 0.4096 0.2911 0.2163 0.1688 0.6240 0.4667 0.3837 0.3063 0.4778 0.4163 0.2500 0.2519 0.2320 0.1694 1.6000 0.9143 0.7250 0.5926 0.4880 0.3444 0.2612 0.2000 0.1460 0.1139 0.0939 0.0781 0.0679 0.0550 0.8500 0.5440 0.4000 0.3265 0.3000 0.2667 0.2480 0.2144 0.1878 0.1531 0.1333 0.1220
LA, LH
400
225 250 300 350 400 250 300
IL 480V
400 350 400 300 350 400
LX, LXI, LE
600 450 500 600 125 175 200 225 250 300 350
MA, MH
800/1000 400 500 600 700 800 900 1000 100 125 150 250 175 200 225
MX, ME 250 300 350 400 400 450 500
64
Procedures for Startup and Commissioning of Electrical Equipment Tables Square D Molded Case Circuit Breaker Watts Loss & Resistance (contd) Circuit Breaker Type
Type
Frame Size
(Amperes) 400
Circuit Breaker
Rating/Ampacity 600 700
Pole Resistance
Ohms x 10-3 0.1069 0.1000 0.0813 0.1069 0.1000 0.0813 0.0630 0.0535 0.1125 0.1061 0.0852 0.0821 0.0685 0.0563 0.1069 0.1000 0.0813 0.0716 0.0630 0.0535 0.0495 0.0410 0.0355 0.0315 0.0269
MX, ME 800
800 600 700 NH 1200 800 1000 1200 600 700 800 NA, NC, NX, NE 12000 900 1000 1200 600 700 800 900 1000 12002000 PA, PH, PC, PX, PE 1200 1400 1600 1800 2000 2500 2500
65
Procedures for Startup and Commissioning of Electrical Equipment
Table 8:
Square D Type DS, DSII, DSL, and DSLII Circuit Breaker Contact Resistance
Maximum Contact Resistance Bkr. Frame Size
DS206 DSL206 DS206S DS416 DSL416 DS416S DS420 DS632 DS840
Micro-ohms
200 200 200 65 70 65 65 40 40
Square D Company 1010 Airpark Center Drive Nashville, TN 37217 (615) 844-8300 1-888-Square D (1-888-778-2733) www.SquareD.com
Replaces Bulletin No. 0180IB0001R1/01 dated 01/01

Instruction Bulletin Square D Services: Procedures For Startup and Commissioning of Electrical Equipment Class 0180

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0180IB0001R5/01 May 2001 Nashville, TN, USA

Procedures for Startup and Commissioning of Electrical Equipment Class 0180

Procedures for Startup and Commissioning of Electrical Equipment Table of Contents

Bulletin No. 018IB0001R5/01 May 2001

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Bulletin No. 0180IB0001R5/01 May 2001

Procedures for Startup and Commissioning of Electrical Equipment List of Tables

Table 1: Table 2: Table 3: Table 4: Table 5: Table 6: Table 7: Table 8:

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Procedures for Startup and Commissioning of Electrical Equipment Section 1Introduction

Bulletin No. 018IB0001R5/01 May 2001

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Bulletin No. 0180IB0001R5/01 May 2001

Procedures for Startup and Commissioning of Electrical Equipment Section 2Safety

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Bulletin No. 018IB0001R5/01 May 2001

SECTION 3AC DRIVES

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Bulletin No. 0180IB0001R5/01 May 2001

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Bulletin No. 018IB0001R5/01 May 2001

SECTION 4AIR SWITCHES: LOW VOLTAGE (BOLTED PRESSURE, QMB, OR EQUAL)

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Bulletin No. 0180IB0001R5/01 May 2001

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Bulletin No. 018IB0001R5/01 May 2001

SECTION 5AIR SWITCHES: MEDIUM VOLTAGE, METAL-ENCLOSED

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Bulletin No. 018IB0001R5/01 May 2001

SECTION 6AIR SWITCHES: HIGH AND MEDIUM VOLTAGE, OPEN STYLE

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Bulletin No. 0180IB0001R5/01 May 2001

SECTION 7ANALOG METERING

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Bulletin No. 018IB0001R5/01 May 2001

SECTION 8BUSWAYS, METALENCLOSED

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Bulletin No. 0180IB0001R5/01 May 2001

SECTION 9CABLES: LOW VOLTAGE AND MEDIUM VOLTAGE

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Bulletin No. 018IB0001R5/01 May 2001

SECTION 10CAPACITORS: POWER FACTOR CORRECTION

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Bulletin No. 0180IB0001R5/01 May 2001

SECTION 11CIRCUIT BREAKERS: LOW VOLTAGE INSULATED CASE/ MOLDED CASE

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Bulletin No. 018IB0001R5/01 May 2001

Bulletin No. 0180IB0001R5/01 May 2001

Check the electric charging mechanism, if applicable.

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Bulletin No. 018IB0001R5/01 May 2001

SECTION 12CIRCUIT BREAKERS: LOW VOLTAGE POWER (ANSI/IEEE C37.13)

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SECTION 13CIRCUIT BREAKERS: MEDIUM VOLTAGE SF6

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Bulletin No. 0180IB0001R5/01 May 2001

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Bulletin No. 018IB0001R5/01 May 2001