Xyz COMPANY

METHOD STATEMENT M & E NO.: M & E MST- 006/ REV 0 Page 1 of 7

TITLE: INSTALLATION AND TESTING OF RELAYS.

INSTALLATION AND TESTING OF RELAYS.

1.0 PURPOSE

The purpose of this procedure is to describe the method of installation

and testing of Protection Relays for electrical power systems.

2.0 SCOPE

2.1 This procedure shall be applicable for the installation and testing of
following types of relays.

 Inverse Time Over Current Relay.

 Motor Protection Relay (Conventional type and Microprocessor
based).
 Over / under Voltage Relay.
 Differential Relay.
 Timer Relay.

2.2 If relays other than that included in the scope of this procedure is to be
tested, then specific procedures for installation and testing of such relays
shall be developed and / or installation and testing shall be carried out as
per manufacturer’s instructions.

3.0 REFERENCE

3.1 QAP~050 Document & Data Control.

3.2 QAP~100 Inspection & Testing.

3.3 QAP~040 Design Control.

4.0 DEFINITIONS

4.1 Company XYZ.

4.2 Quality Engineer Nominated Quality Engineer at Site.

4.3 Discipline Engineer Company designated Electrical Engineer as

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TITLE: INSTALLATION AND TESTING OF RELAYS.

decided by the Management and assigned with

the responsibility of managing electrical part of
the Project.

4.4 Equipment For the purpose of this procedure equipment

shall mean LV / HV switchgear and other
electrical power system items where relays
form part of it.

4.5 LV Low Voltage.

4.6 HV High Voltage.

4.7 Field Mounted Relays The relays purchased separately and / or

supplied loose and subsequently mounted in
the equipment after installation of the
equipment.

5.0 PROCEDURE

5.1 Responsibility

5.1.1 The responsibility for carrying out this Method Statement shall be that of
the Discipline Engineer/ Foremen, unless otherwise specifically mentioned
in this procedure. The Quality Engineer/ Discipline Engineer/ Foremen
shall be responsible for inspection & testing.

5.1.2 Conflicting requirements for the installation and testing of the relays with
the manufacturer’s instructions and / or Customer’s specifications are
encountered, then such requirements shall prevail in addition to the non-
conflicting requirements of this procedure.

5.2 Preparation for Testing

5.2.1 Prior to start of the installation / testing of the relay the type of relay to be
installed / tested shall be identified and the appropriate test sheet shall be
selected.

5.2.2 Relevant data such as, contract title, contract number, name of the
Customer, Company, Job number, Customer’s job order number, area /
location where the equipment is installed, system / duty for which the
equipment is intended for use, identification of the panel in which the

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TITLE: INSTALLATION AND TESTING OF RELAYS.

relay is installed, the name of the manufacturer, type of relay,

manufacturer’s serial number of the relay and other data relating to the
relay as identified in the applicable test sheet shall be recorded.

5.2.3 Manufacturer’s test data / specification for the relay to be tested, as

applicable / available shall be obtained and maintained as record.

5.3 Installation of Relays & Preliminary Checks

5.3.1 Relays Supplied in “as Mounted Condition”

5.3.1.1 When relays are supplied in “as mounted condition”, forming part of the
equipment, then the relays shall be checked for the following:

 Type, model & rating.

 Mounting.
 Wiring & terminations.

5.3.1.2 The above details shall be checked and confirmed with the wiring diagram
and / or the general arrangement drawings. It shall be ensured that the
relays are free from physical damages.

5.3.2 Field Mounted Relays

5.3.2.1 The type, model, rating and type of mounting of the relays to be mounted
in the field shall be checked and confirmed with the applicable wiring
diagram / specification. It shall be ensured that the relays are free from
physical damages.

5.3.2.2 Relays shall be mounted after installation of the equipment at the

appropriate location of the equipment in conformance with the mounting
details. The wiring shall be carried out and the terminations provided in
conformance with the wiring diagrams / specification, same as above.

5.4 Removal of Transit Tabs & Devices

If the relays are provided with any tabs or devices to prevent transit
damages, such devices shall be removed prior to start of testing.

5.5 Testing

5.5.1 Inverse Time Over Current Relay

5.5.1.1 The following parameters of the adopted setting of the relay shall be
checked and recorded:

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TITLE: INSTALLATION AND TESTING OF RELAYS.

 Current sensitivity.
 Curve.
 Timer multiplier data.
 Instantaneous element.
 The above parameters shall be recorded for all the phases, viz. R, Y,
B & earth fault.

5.5.1.2 After recording the adopted settings as above, Secondary Injection Tests
A, B & C shall be carried out.

5.5.1.3 As part of the Test ‘A’, the Energisation Test shall be carried out and Relay
CT shorting switches shall be checked. The DC supply voltage shall be
recorded and the Trip Test shall be carried out.

5.5.1.4 After completion of the Test ’A’, Test ‘B’ comprising of the current level to
trip  inst., the current level not to trip  inst., and current sensitivity at
adopted setting for phases R, Y, B and earth fault shall be carried out and
the data shall be recorded.

5.5.1.5 The conformance of the setting of the relay shall be checked with respect
to the actual operation by injecting 2 times the set current and 5 times the
set current. The results shall be recorded under the Test ‘C’ column of the
test sheet.

5.5.1.6 All data as above and other pertinent data relating to the relay under test
as required in form number M & E QC~Form- 006-01/ REV. 0 shall be
recorded.

5.5.1.7 Verification of the recorded data against the manufacturer’s data /

specification shall be carried out if such data are available.

5.5.2 Motor Protection Relay (Conventional Type)

5.5.2.1 The specification of the relay including the name plate details, relay’s
available setting and adopted setting for thermal unit, over current unit,
negative phase sequence over current unit, motor start up unit and earth
fault unit shall be recorded.

5.5.2.2 The secondary injection test for Thermal unit, Inst. over current unit,
negative phase sequence over current unit, motor start up unit & earth
fault unit shall be carried out and recorded.

5.5.2.3 When the thermal unit is tested, the relay set current, injected current,
alarm unit operation time and trip unit operation time shall be checked and
recorded. For instantaneous over current unit, negative phase sequence
over current unit, motor start up unit and earth fault unit, the relay setting,
pick up current, injected current and the operation time of output unit shall
be checked and recorded.

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TITLE: INSTALLATION AND TESTING OF RELAYS.

5.5.2.4 The operation indicator of all the protection units tested shall be checked
for proper operation and conformance to the specification.

5.5.2.5 On completion of the test, the final relay settings, if available, shall be set
and the values shall be recorded.

5.5.2.6 The test data as above and other parameters as indicated in form number
M & E QC~Form- 006-02/ REV. 0 shall be recorded.

5.5.2.7 Verification of the recorded data against the manufacturer’s data /

specification shall be carried out if such data are available.

5.5.3 Motor Protection Relay (Micro Processor Based)

5.5.3.1 The relay shall be first tested for accuracy of current setting(s). The links
shall be kept at various positions and the pick up value of “negative phase
sequence unit”, “over current unit”, “instantaneous over current unit”
and“earth fault unit” shall be measured and recorded. The above test
shall be carried out for all the three phases and for the earth fault.

5.5.3.2 After completion of the above test, the relay shall be tested to check the
accuracy of the timer setting(s). Initially the timer shall be set at a suitable
value by keeping the links at different settings, the current shall be
injected on different phases and the “pick up current and “the pick up
time” at 150 percent of the set current shall be measured and recorded.

5.5.3.3 The data obtained as above and other pertinent data indicated in the
applicable test sheet shall be recorded in Form No. M & E QC~Form- 006-
03/ REV. 0.

5.5.3.4 The recorded data shall be verified against the Manufacturer’s data /
specification, if such data are available.

5.5.4 Over / Under Voltage Relays

5.5.4.1 The specifications and the ranges of voltage and time multiplier settings, if
applicable, shall be recorded.

5.5.4.2 The relay shall be tested for pick-up and drop off voltage levels for various
relay settings, by applying different percentages of set voltage. For time
delayed relays, the same shall be tested for various time multiplier
settings and the operation time shall be recorded.

5.5.4.3 All the test values and pertinent data shall be recorded in Form No. M & E
QC~Form- 006-04/ REV. 0.

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TITLE: INSTALLATION AND TESTING OF RELAYS.

5.5.5 Differential Relay

5.5.5.1 The pick up test of the relay shall be carried out by keeping the pick up
current tap at various settings. Current shall be injected on all three
phases and the pick up values shall be recorded.

5.5.5.2 The operating time of the relay shall be tested by setting taps at various
values. Current shall be injected on all the three phases and the
operating time shall be recorded.

5.5.5.3 Percentage bias current test shall be carried out. The relay shall be set at
various bias taps and current injected through the bias and operating coil
of the relay. The through current and the operating current shall be
recorded and the percentage bias arrived at shall be calculated
(according to manufacturer’s manual, if available) and the data recorded.

5.5.5.4 The bias test shall be conducted on all the three phases.

5.5.5.5 The test data as above and other pertinent data in the applicable test
sheet shall be recorded in the applicable columns of Form No. M & E
QC~Form- 006-05/ REV. 0.

5.5.5.6 The recorded data shall be verified against the manufacturer’s data /
specification, if such data are available.

5.5.5.7 The final setting of the relay shall be checked and the data shall be
recorded.

5.5.6 Timer Relay

5.5.6.1 The relay shall be tested for the operating time by injecting voltage at
various relay settings. The timing error shall be calculated and it shall be
within the permissible range as per the manufacturer’s data /
specification.

5.5.6.2 The operation indicators of the relay shall be checked for proper
operation.

5.5.6.3 The final setting of the relay shall be checked and the data shall be
recorded.

5.5.6.4 The data from the test as above and other pertinent data in the applicable
test sheet shall be recorded in the Form No. M & E QC~Form- 006-06/
REV. 0.

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TITLE: INSTALLATION AND TESTING OF RELAYS.

5.5.6.5 The recorded data shall be verified against the manufacturer’s data /
specification, if such records are available.

5.6 Acceptance

On completion of the test, the applicable forms as in 6.0 shall be fully

filled up and signed off by the person carrying out the test. If contractually
required, the signature of the Customer’s Representative, indicating
acceptance of the test shall be obtained.

6.0 DOCUMENTATION / RECORDS

6.1 Inverse Time Over Current M & E QC~Form- 006-01/ REV. 0.

Relay Test Sheet
6.2 Motor Protection Relay Test Sheet M & E QC~Form- 006-02/ REV. 0.
6.3 Motor Protection Relay Test Sheet M & E QC~Form- 006-03/ REV. 0.
6.4 Over / Under Voltage Relay Test Sheet M & E QC~Form- 006-04/ REV. 0.
6.5 Differential Relay Test Sheet M & E QC~Form- 006-05/ REV. 0.
6.6 Timer Relay Test Sheet M & E QC~Form- 006-06/ REV. 0.

M & E MST- 006/ REV 0 Date: January 26, 2001