PROJECT / CONTRACT REF.

2546 / GC07100300

ENGINEERING, PROCUREMENT, INSTALLATION AND

COMMISSIONING (EPIC) FOR BERTHS AND PORT
INFRASTRUCTURE FOR RAS LAFFAN PORT EXPANSION
PROJECT
DOCUMENT TITLE:

PRE-COMMISSIONING PROCEDURE FOR

415V SWITCHGEAR AT TERTIARY AND SECINDARY
DISTRIBUTION SUBSTATIONS

15-JUN09

ISSUED FOR REVIEW / COMMENTS

DM

MAS

AI

PRE-COMMISSIONING PROCEDURE FOR 415V SWITCHGEAR

AT TERTIARY & SECONDARY DISTRIBUTION SUBSTATIONS

DATE

REV.
NO.

REASON FOR REVISION

DOCUMENT NUMBER:

PREPARED

CHECKED

APPD.

SHT 1 OF 0 1 2

Contents
1

Scope

Reference Documents

Pre-commissioning Check List

Risk Assessment

Pre-commissioning Procedure

5.1
5.2
5.3
5.4

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Test Procedure
Punch List
Precommissioning Test Forms
List of Test Equipments

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8
11
11
12

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APPD.
QP

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PRE-COMMISSIONING PROCEDURE FOR 415V SWITCHGEAR

AT TERTIARY & SECONDARY DISTRIBUTION SUBSTATIONS

Scope
This scope describes the procedure for Pre-commissioning
activities of the new 415V Switchgears located at either
the Tertiary substations or at Secondary Distribution
Substations of all P 965 Berth & Port Infrastructure for
Ras Laffan Port Expansion project.
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PRE-COMMISSIONING PROCEDURE FOR 415V SWITCHGEAR

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Reference Documents
All pre-commissioning tests which are performed shall be
in accordance with specifications of International
Electrotechnical Commission (IEC) and the specifications
listed below:

RPGE-0-05-0041:

Pre-commissioning

&

Commissioning General Guide lines.

RPGE-0-05-0247:

Pre-commissioning

&

Commissioning System/ Sub-system Definitions for

Mile Stone - 1

RPGE-0-05-0381:

Pre-commissioning

&

Commissioning Note.

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PRE-COMMISSIONING PROCEDURE FOR 415V SWITCHGEAR

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Pre-commissioning Check List

S/N

ACTIVITIES

Check all Safety devices such as display of warning sign, barrication of access
limitation, key box for the panels and fire extinguishers are in compliance with HSC
requirements prior to start performing pre-commissioning activity, as required.

Perform verification of equipment to full compliance to manufacturer drawings, and

project specification & standards

Check the feeder labelling is correct. Verify all safety signs are in place.

Check the earthing bar and connections are firm & tight.

Check the Padlocking facilities for breakers are made available.

Check the cable terminations.

Check the mechanical closing and opening of incomer & outgoing breakers
Rack each circuit breaker from TEST position to SERVICE position and back several
times.
Record fuse type and rating for the control circuits.

10

Perform Ductor test.

11

Perform CT testing

12

Perform PT testing

13

Perform IR test.

15

Check the operation of safety shutters of ACB are correctly functioning.

16

Perform ACB/MCCB testing

17

Perform Relay testing with final settings

18

Perform Functional test for the switchgear including the ATS, as applicable.

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PRE-COMMISSIONING PROCEDURE FOR 415V SWITCHGEAR

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Risk Assessment
The risk assessment form is a safety management tool
which identifies the major potential risk factors,
preventive controls and additional control measures to be
undertaken prior to performing a specific task or the
whole task associated with the project subsystem
activities during pre commissioning stages of work.
This document is prepared by CCC/Subcontractor and
submitted to project CCC/QP HSE personnel for their
review prior to commencement of pre commissioning
activities
These features as prescribed in the risk assessment form
will be regularly monitored and audited by the field safety
personnel to ensure the pre commissioning activities are
performed in a safe manner for the successful completion
of the task.

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Pre-commissioning Procedure
Introduction
The procedure of Pre-commissioning test & checks are
required to ensure LV Switchgear is properly installed,
wired correctly, and the safety devices are tested to verify
the performance and the function to confirm the
suitability of the equipment for the application.
This procedure will be applicable for site testing of LV
Switchgear for readiness before the commencement of the
Commissioning activities.
The LV Switchgear and the control devices will be tested
in accordance with the vendor approved procedures,
applicable IEC standards and Project reference
documents.
General
Visual check shall be carried out to confirm the
correctness of the installation, and the equipment
structure is free-of-damage. Mechanical tests shall be
carried out to assure the operation/mechanize of the
mechanical parts. Electrical tests shall be carried out to
confirm either the conductivity or the quality of the
insulation. Functional tests shall carried out verify the
schematic/logic diagram. Protective relays shall be set
and tested in accordance with the requirement of the
system coordination and protective relay setting record.
Punch list, if any, shall be prepared and submitted to the
Vendor. Vendor will replace defective major components
that are critical for the successful operation of the
equipment.
Following is the minimum checks that will be performed
and confirmed:

Doc No.

Before performing any activity it shall be ensured

that the equipment is properly isolated and the
person can work safely.

Verify all fuse holders, fuses, and other protective

devices are not damaged and are of proper size, type
& rating in accordance with SLD.

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PRE-COMMISSIONING PROCEDURE FOR 415V SWITCHGEAR

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Check the bus bar ratings and the creepage and

clearance distances of the bus bar.

Verify type & rating of instrument transformers.

Check the proper phase rotation N-R-Y-B counting

from left to right, top to bottom, or front to rear when
viewing from front.

All megger readings will be taken preferably during dry

temperature weather.
Verify the busbar joints of Separate transport sections are
connected properly. Also check the tightness of busbar
joints
with
proper
torque
in
accordance
with
manufacturer recommended torque values. Ductor test
will be performed at all joints of the bus bar on completion
of torque.
Verify the interpanel wiring
wherever it is applicable.

is

connected

properly

Circuit breaker device that have adjustable settings such

as MCCB shall be set in accordance with system
protection
coordination
requirements.
Tripping
characteristic shall be tested in line with Vendors
recommendation.
Thermal overload relays shall be individually checked to
ensure proper ampere range has been installed and set
for the full load currents, where fuses are used their
ampere ratings and types shall be checked for
conformance with design requirements.
Protective relay settings and adjustments shall be made in
accordance with manufacturer instruction booklet.
The integrity of the circuits between protective relays /
meters and their associated CTs shall be verified.
Check the relay gives the trip signal to circuit breakers.
Following inspections and test shall be performed on all
the 415V Switch gear prior to Commissioning:

5.1

Perform IR test for phase to phase, phase to neutral,

phase to ground and neutral to ground.

Check all VT fuses are connected in the panel.

Test Procedure
a.

VISUAL CHECKS:

The visual checks are filled in the check sheet forms.

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The visual checks will be carried out to ensure the

installation work is done as per the approved layout
drawings and vendor procedures, and the equipment is
free-of-damage.
b.

MECHANICAL CHECKS:

The mechanical checks are filled in the check sheet forms.

The test is performed by operating the incoming and
outgoing circuit breakers operation manually for free
operation. The Mechanical Operation is performed for the
interlock between incomers wherever it is applicable.
c.

ELECTRICAL CHECKS:

The electrical checks are filled in the check sheet forms.

IR Test on Busbars:
The IR test is to measure the insulation level of the
equipment. This test is done by using a 1000V megger
for 1 minute between each phase to Neutral, each
phase to earth, phase to phase and neutral and earth.
Ductor Test for Busbars:
This test is to ensure the all the busbar joints are
properly aligned jointed and connected firmly. It can be
measured by using a Ductor tester. Keep the probes on
both sides of the busbar joint and apply some pressure
to be sure for better contact and press the test button.
Wait for few seconds to get a stable reading. The
measured values should be less than the specified
values. Refer vendor requirements and table or FAT
reports.
CT & VT TESTS:
CT POLARITY TEST:
Connect +Ve 9V battery to P1 of CT and Ve of 9V
battery to P2 of CT.
Connect the analog ammeter between S1-S2 of CT
secondary.

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Check the ammeter needle goes towards forward

direction.
VT RATIO TEST:
Connect the 3 phase supply to the P1 & P2 of VT
Measure the secondary voltage between S1 & S2
Verify the VT ratio is inline with the name plate details.
CT RATIO TEST:
Connect the primary injection kit across the P1-P2 of
CT.
Connect the ammeter between S1-S2 of CT secondary.
Inject the primary current and measure the secondary
current in the ammeter.
Verify the CT ratio is inline with the name plate details.
PRIMARY INJECTION TEST:
Connect primary injection kit across P1-P2 of CTs.
Make sure that all the CTs secondary wirings are
connected to the corresponding metering / protection
circuit.
Inject primary current and measure the CTs secondary
current in the relay circuit, metering circuit, etc.,
Measure the relay current/meter current through
display.
VOLTMETER: Apply the voltage in the voltage terminal
of the VT and check the voltage in the voltmeter/relay,
the voltage measured should be in acceptance level.
AMMETER: Inject the current to the CT terminals of
meter/relay and check the current in the ammeter/relay
the current measured should be in acceptance level.
MULTI FUNCTION RELAY TEST:
PICK UP TEST:
Set the current set value in relay.

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Inject current into relay by a secondary injection kit

after isolating CT.
Increase current until assigned LED to glow for pick up
test.
Reduce the current value until LED disappears for drop
off test.
DEFINITE TIME ELEMENT (50/64) TEST:
Set the current set value in relay and tipping time in
relay.
Inject current slightly more than set value in the relay.
Relay contact to be connected to secondary injection
test kit to stop the timer.
IDMT ELEMENT TEST (51/51N/51G):
Set the current set value in relay.
Set the Operating curve and TMS in relay.
Inject current two times and five times of the set value
in the relay.
Relay contact to be connected to secondary injection
test kit to stop the time.
Check the function of the existing shunt closing and
shunt opening releases by electrical operation.
Perform ACB/MCCB testing for trip conditions.

d.

FUNCTIONAL TESTS:

Functional tests shall be carried out to verify the

schematic/logic diagram.
ATS TEST
For ATS logic, wherever it is applicable, operation check
shall be carried out as following:
Simulate power
failure condition on incomer-1 and check that there is
an automatic closing of bus-coupler breaker and
transferring the load to the incomer-2. Resume the
power back on incomer-1. Then, simulate power failure

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condition on incomer-2 and check that there is an

automatic closing of bus-coupler breaker and
transferring the load to the incomer-1.
INTERLOCK TEST:
Check the mechanical / electrical interlock whichever is
applicable to the project. Ensure that only two breakers
out of three breakers can be closed at any time.
Check the operation of momentary
synchronization if available.

paralleling

MOMENTARY PARALLELING:
In manual mode, select the breaker to trip and give a
close pulse to the third breaker which is in open
position. Check that the third breaker closes first
achieving paralleling and the selected breaker will trip
within a short period (usually 1 to 3 seconds) as per the
project specification & requirement.
SYNCHRONIZATION:
Check the possibility of closing both the incomers and
bus-coupler breakers through synchronization relay.
INTERTRIP TEST:
Trip the incomer breaker through protection relay and
check a inter trip signal is ready to go to the respective
11kV RMU outgoing breaker.
GENERATOR FEEDER TEST:
Generator feeder functional test shall be in line with the
applicable schematic/logic diagram for Normal mode
operation logic and Test Mode operation logic.

5.2

Punch List
Exceptional punch list shall be created in line with the
punch list definition of categories in order to identify and
place in record the missing materials, pending
engineering discrepancies, field modifications, pending

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vendor document which do not provide a hindrance for

the commencement of commissioning activities
5.3

5.4

Precommissioning Test Forms

IR Test (FM-106)

Ductor Test (FM-107)

CT test (FM- 109)

VT test (FM-110)

Multi Function Relay /IPR Test (FM-111)

ACB / MCCB Test (FM-112)

List of Test Equipments

The test equipments used will comply with suitable
accuracy, by proper validation by third party for the
suitability of the device for the intended function prior to
performing the testing activity

0.5kV / 1kV megger

Multi meter

Clamp meter

Ductor Tester

Primary Injection Test Kit

AC High voltage Test Kit

Secondary Injection Test Kit / Protection Relay Test

Kit

Laptop

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