Commissioning Procedure MCC

Doc No.
:
Project : Plant Water Package RAPP-7&8
RAPP-7&8-52540-CP-2-R1
Issue No: 02 Rev No: 1
Commissioning Procedure for 415 V of L&T Page 1 of 55
Date of Issue: Dec 2018
Commissioning Procedure
for
415 V AC OF L&T
Tag No.: 0-5254-MCC-M417,M418,M415,M416
and 0-7113-SDB-7110, 7002
Doc. No.: RAPP-7&8-52540-CP-2-R1
PREPARED BY REVIEWED BY APPROVED BY
Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

ENGINEER Sr. MANAGER RCM
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Commissioning Procedure for 415 V AC
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“This page is intestinally left blank”
Prepared by Reviewed by Approved by

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Revision Control Sheet
Rev. Details of
Date Prepared By Reviewed By Approved By
No. Revision
1 Revised as Ravindramani Suresh SRinivasan. Anand

Dec 2018
per clients Tiwari Chaturvedi
comments

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Contents
1.0 Title:.................................................................................................................................................................. 6
2.0 Purpose:......................................................................................................................................................... 6
3.0 Pre-requisites:............................................................................................................................................. 6
3.1 Requirement of other system: 6
3.2 System requirements: 6
3.3 Manpower requirements: 7
3.4 Requirements of instruments: 7
3.5 Requirement of outside agencies: 7
4.0 Hazards and precautions:..................................................................................................................... 7
5.0 Pre-job briefing:.......................................................................................................................................... 8
6.0 General methods:...................................................................................................................................... 8
7.0 Design intents........................................................................................................................................... 15
8.0 Expected process parameters.......................................................................................................... 16
9.0 Work plans.................................................................................................................................................. 15
10.0 Test formats............................................................................................................................................... 17
11.0 References................................................................................................................................................. 17
12.0 Verification process................................................................................................................................ 18
Annexure-1: Pre job Briefing 18
Annexure-2: Post installation checklist 21
Annexure-3: Earthing Checks 24
Annexure-4: Checklist for cubicle illumination 25
Annexure-5: Check list for Space Heater 26
Annexure-6: Testing of CT 27
Annexure-8: Testing of PT 31
Annexure-9: Checks on Control Transformer 33
Annexure-12: Test on Voltmeter 36
Annexure-16: Checks on Switch Fuse Unit (SFU) 37
Annexure-17: Checks on Contactor 39
Annexure-19: Checks on thermal overload relay 40
Annexure-25: Contact resistance of bus bar joint 42
Annexure-26: Minimum Clearance between bus bar 43
Annexure-27: HV and IR test on bus bar 44
Annexure-28: Cabling and connection check 47
Annexure-29: Functional checks on MCC 48

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Annexure-31: Technical specification 50
Annexure-32: Pre energisation check list 51
Annexure-33: Post energization check sheet 53
Annexure-34: Verification Sheet 54
Annexure-35: Distribution List55
1.0 Title:
Commissioning Procedure for 415 V AC PMCC and SDB of CLO2 Plant (Tag No.:
0-5254-MCC-M417, M418 and 0-7113-SDB-7110, 7002).
USI – 52540

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5 – Electrical
2 – Station Service Power System
5 – 415 V System
4-CL-IV
0 – General
2.0 Purpose:
This procedure is prepared for carrying out the commissioning checks,
energisation and post energisation checks on Class IV 415 V AC PMCCs/
SDBs of RAPP-7 & 8, Main Plant Water Package (M/s IOT).
3.0 Pre-requisites:
3.1 Requirement of other system:
)1 Class-IV 415 V AC power supply from Class-II, III & IV 415 V switchgear is
commissioned and is available.
)2 Adequate lighting is available.
3.2 System requirements:
)1 Installation of 415 V PMCC/SDB is completed and erection completion
certificate is obtained from electrical (construction).
)2 Installation related checks are completed.
)3 Power & control cabling up to 415V MCC/PMCC is completed.
)4 Fire-fighting system is available, completely installed and tested.
)5 Ventilation system (permanent or temporary) is functional and available.
)6 Building illumination (permanent or temporary) is available.
)7 3-phase 415 V AC power supply is available for testing.
)8 Telephone system is available near the equipment.
)9 Relevant approved drawings, Instruction manual, catalogues of MCC
components, PO copies; factory test reports, approved settings of relays
are available.
)10Keep the documents ready for collecting data during commissioning tests.
3.3 Manpower requirements:

Manpower NPCIL M/s IOTL M/s L&T
Engineer 1 1 Experienced
Supervisor 1 1

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Technician 1 1 representative
3.4 Requirements of instruments:

)1 250 V, 500 V& 1000 V Insulation tester
)2 Digital Multi meter
)3 Clamp-on meter, mA clamp-on meter
)4 Primary injection test kit
)5 Variac
)6 3-phase auto transformer
)7 Polarity tester
)8 Micro-Ohmmeter
)9 Tool kit with all necessary tools, torque wrench, torque screw driver, Air
blower, Vacuum cleaner, and waste cloth.
)10HV test kit
)11 Relay test kit
)12Temperature gun
Note: All the instruments shall have valid calibration certificate
during entire period of commissioning.
3.5 Requirement of outside agencies:

)1 NPCIL Electrical commissioning group for coordination
)2 M/s IOTL / M/s Purita for execution
)3 M/s L&T.
4.0 Hazards and precautions:

)1 Unauthorized persons should not be allowed to enter 415 V MCC/PMCC
room.
)2 Ensure that insulation mats suitable for 1.1 kV are provided along the 415
V MCC/PMCC.
)3 Adequate illumination must be maintained in 415V MCC/PMCC room.
)4 Ensure that 415 V MCC/PMCC room is clean.
)5 Ensure that no CT secondary is left open circuited during testing.
)6 Ensure that no earthing or discharge rod is left connected and that they
are cleared before charging.

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)7 Ensure that shut down and work permit system is followed strictly for
carrying out any work on the equipment already commissioned.
5.0 Pre-job briefing:

Pre job briefing shall be given daily before start of work as per attached
Annexure-1.
6.0 General methods:
6.1 Installation checks on MCC/PMCC:
)1 Check the rating and diagram nameplate details are as per drawing.
)2 Check that the 415 V PMCC/SDB are installed completely as per the GA
drawing. Verify the erection checklist. Note down pending points relating to
installation, if any.
)3 Thoroughly clean the PMCC-SDB from outside before opening bus bar
covers.
)4 Thoroughly clean the PMCC-SDB from inside after opening bus bar
covers.
)5 Check BOM as per approved drawing.
)6 Check that the base frames of all the PMCC/SDB are bolted to the
additional MS base frames and tightness is achieved to the specified
torque level. Check that washers as per site requirement have been
provided. Check that the MS base frame is welded to EP.
)7 Clean and check all insulators for healthiness. There should not be any
crack or chipping on insulators. Insulator and bus bar mounting bolts shall
be tight.
)8 Check all enclosures and metal parts are earthed after equipment
installation as per Annexure -3.
)9 Check the panel for any unwanted openings. Extra openings are sealed
properly.
)10Check indication lamps are in place and lamps are healthy (wherever
provided as per drawing).
)11 Check all cells of PMCC/SDB are identified with tags / nameplates and
ensure cell allocation is as per approved drawings.
)12Check Voltmeter / Ammeter for bus voltage and current are mounted and
have proper range.
)13Check Voltmeter selector switch operates freely.
)14Check Voltmeter selector switch continuity for all these positions.
)15Check the alignment of all doors.

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)16Check operation of all doors & panels and ensure panel covers have been
installed properly with door closing services.
)17Check cell cover of SDB/PMCC have interlocks i.e. cell cover cannot open
after isolator is switched ON.
)18Identify SDB/PMCC bus phases and check for proper phase identification
(colour coding) and connection at switchgear end.
)19Check that the tightness level of connection is achieved using a torque
spanner.
)20Ensure free access is available to all points of installed equipment and
especially to points requiring frequent operations, maintenance and
control.
)21Ensure that the bonding / blocking material for contactors, starters, relays
etc. is removed.
)22Measure contact resistance of each bus bar joint of 415 V SDB/PMCC
power bus; this value shall be compared with manufacturer’s specified
resistance. Note down results of contact resistance of bus bar joints in
Annexure -25.
6.2 Cabling and connection checks:
)1 Check that external power and control cables are laid and terminated as
per the approved cable schedule and interconnection cable schedule.
)2 Check that the cables for SDB/PMCC are well dressed, supported,
clamped and glanded.
)3 Check all external cables connected at marshaling panel are dressed,
glanded, supported, clamped and provided by aluminium identification
tags.
)4 Check for continuity, correct ferruling, lugging, connection tightness, IR
value of all external cables connected.
)5 Checklist for cabling and connection checks is enclosed in Annexure – 30.
6.3 Interfacing checks:
)1 Check the interfacing of cabling between 415V SDB/PMCC & 415V
switchgear.
)2 Check the interfacing of cabling between 415V SDB/PMCC & local
start/stop device of loads/motors.
)3 Check the interfacing of cabling between 415V SDB/PMCC & various
loads / motors..
6.4 Checks on Illumination and space heater:
)1 Check the cubicle illumination circuit as per Annexure-4.

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)2 Check the space heater circuit as per Annexure-5.
6.5 Checks on Incomer SFU:
6.5.1 General checks:
)1 Inspect the SFU for any physical damage.
)2 Door interlocks, electrical and mechanical interlocks shall be checked.
)3 Inspect and record in Annexure-16....
6.6 Testing of CT:

6.6.1 General checks:
)1 Check and compare the nameplate details of the CT with specification.
Check all CTs are provided as per the approved scheme.
)2 Inspect the CT for any breakages, damages, improper mounting /
clamping.
)3 Verify the wiring as per drawing of the CT secondary and earthing with
respect to the scheme.
)4 Check for earthing as per scheme.
6.6.2 Check on CT parameters:
)1 Measure the insulation resistance of the CT windings with respect to earth
and between windings using 500 V megger.
)2 Using a battery operated polarity tester, check that positive emf is induced
between S1 to S2 terminal when a positive current pulse is applied
between P1 to P2.
)3 Using a primary injection test kit, inject rated primary currents into the P1 &
P2 terminals. Measure these currents flowing out of CT secondary
terminals. Tabulate the readings. Calculate the ratio and compare with
name plate ratio.
)4 Using the multimeter in the ohmmeter mode, measure the secondary
winding resistance of CT.
)5 Spare secondary terminals of the CT shall be shorted and earthed.
)6 Refer Annexure 6 for test format.
6.7 Testing of PT:
6.7.1 Physical checks:
)1 Check and compare the nameplate details of the PT with the
specifications. Check all PTs are provided as per scheme.

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)2 Inspect PTs for any breakages, damages, improper mounting / clamping.
)3 Check for connection & tightness at all the terminals and earthing as per
drawing.
)4 Clean the PT with a clean & dry cloth.
)5 Check that the fuses at the primary and the secondary are as per the
scheme.
6.7.2 Checks on PT parameter:
)1 Take the IR value of the PT secondary winding using a 250 V megger.
)2 Using a battery operated polarity tester, check that positive emf is induced
between S1 to S2 terminal when a positive current pulse is applied
between P1 to P2.
)3 Conduct ratio test by applying 1 phase 240 V across the primary. Note
voltage at secondary. Tabulate and compare the values with the nameplate
values.
)4 Refer Annexure-8 for test format.
6.8 Testing of Meters:
)1 Perform the tests on ammeter as per Annexure 11.
)2 Perform the tests on Voltmeter as per Annexure 12.
6.9 Checks on MCC/PMCC Feeder cell:

6.9.1 General checks
)1 Check the cleanness of cell.
)2 Check free movement of cell during rack in and rack out.
)3 Check all components of cell are identified as per drawing. Confirm type of
MCC/PMCC cell as per the load requirement.
)4 Check the ratings of all components (i.e. fuses, contactors, O/L relays,
control transformer) of MCC/PMCC cell are as per drawing and load
requirements.
)5 Check control fuse and power fuse continuity.
)6 Check interlocks of isolator knob with cell cover and ensure when
MCC/PMCC isolator is switched ON, door cover is not opening.
)7 Check defeat interlock of isolator knob.
)8 Check electrical interlock for reverse and forward rotation type of loads.

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)9 Check power and control circuit wiring for the cell is as per drawing. Check
the tightness of all power and control terminations.
)10 Measure IR value of the power circuit and control circuit with 500V and
250VMegger respectively and record IR values.
)11 Check incoming and outgoing power contacts for any damage, alignment
and cleanliness.
)12 Check incoming and outgoing contacts are making proper contact.
)13 Check proper lifting of shutter and engagement of incoming and outgoing
contact during racking in the cell.
)14 Check that closing of shutter during racking out of cell.
)15 Check the alignment of control sliding contact for male-female
engagement.
)16 Check under voltage relays are provided as per drawings and ensure
these relays are calibrated.
)17 Check all interlocks/logics, alarms, window annunciation per scheme.
6.10 Feeder type A1 (feeder for SDB / PMCC up to 63A)
1) It has SFU only and is used for feeders up to 63A.
2) Check the SFU’s as per Annexure-16
6.11 Feeder type A2 (Feeder for MCC/PMCC above 63A):
1) It has a SFU, with earth fault protection and neutral link.
2) Check the SFU’s as per Annexure-16.
3) Check the healthiness of the SFU along with its neutral link.
6.12 Feeder Type C1 (Locally Controlled Pumps up to 50 kW):

1) It is feeder which is used for locally controlled pumps etc. up to 50 KW. It
has a SFU, contactor with local control and thermal overload relay.
3) Check the contactor as per Annexure-17.
4) Check the control transformers as per Annexure-9
5) Check the thermal overload relay as per Annexure – 19
6.13 Feeder Type C3 (Remotely Controlled, Pumps up to 50 kW):
1) It is feeder which is used for remotely controlled exhaust fans, pumps etc.
up to 50 KW. It has a SFU, contactor with remote control, interposing relay
(3C) and thermal overload relay.

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3) Check the contactor as per Annexure-17.
4) Check the control transformers as per Annexure-9.
5) Check the thermal overload relay as per Annexure – 19.
6.14 Thermal overload relay Curve details : -

1) List of OLR Relays with acceptable trip time setting
Sr. No OLR Relay Series Range (Acceptable limit for trip

time at 2*setting current (in sec))
1) MN2 1.4- 2.3 Amp.
2) MN2 2.0 – 2.3 Amp.
3) MN2 4.5 – 7.5 Amp.
4) MN2 9- 15 Amp.
5) MN5 30-50 Amp.
6) MN5 45-75 Amp.
6.1 HV & IR checks on bus bars of MCC/PMCC:

)1 Open bus bar covers and clean thoroughly.
)2 Inspect support insulators for tightness and crack (damage). Rectify, if any.
)3 Check tightness of all the connections on bus bar.
)4 Conduct IR test on bus bars as per Annexure 27.
)5 Conduct IR test on DC supply bus bars.
)6 Conduct IR test on Auxiliary AC Supply bus bars.
)7 Conduct IR test between DC supply bus bars and Auxiliary AC Supply bus
bars to ensure that there is no mixing.
)8 Conduct HV test on Power bus bars at reduced test value of 2 KV AC for
one minute. Note down the leakage currents at the start and finish of test.
Format is enclosed as per Annexure 27.
)9 After HV test, repeat IR test.

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)10Measure and note down contact resistance for joints in bus bar.
6.2 General checks before energization:
)1 Check that test certificates for type test are available and are matching
with the specifications.
)2 All power and control supply is available.
)3 Ensure fire-fighting system is ready.
)4 Check necessary approval for charging is obtained from competent
authority.
)5 No unwanted tools tackles, equipment are left nearby.
)6 Ensure that final check sheet as per Annexure-29 or 30 and 32 is
completely filled and the remarks are studied before going for
energisation.
6.3 Energization procedure:
)1 Check the cable & its termination from 415V switchgear feeders to 415V
MCC/PMCC is connected and tested.
)2 Put off isolators of all the MCC/PMCC outgoing feeders.
)3 Rack in MCC/PMCC incomer CB.
)4 Rack in the 415V switchgear feeder breaker (meant to feed the
MCC/PMCC).
)5 Close the 415V switchgear feeder breakers (meant to feed the
MCC/PMCC).
)6 Check tripping of source CB by pressing EPB on respective MCC.
)7 Close the 415 V MCC/PMCC incomer CB.
)8 The MCC/PMCC bus bars are charged. Check the voltage indicated on
the Voltmeter.
)9 Check for the correctness of phase sequence.
)10Load connected to MCC/PMCC feeders shall be checked and tested as
per their own commissioning procedures. After that, the feeder shall be
racked in and be put on.
6.4 Post energization checks:
)1 Check sheet for post energisation is enclosed in Annexure – 33.
)2 Record the values in Annexure-24 on three hourly bases.
)3 Record voltage on buses at regular interval for 24 hrs.
)4 Verification sheet to be certified by verifying agency as per Annexure-34.

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7.0 Design intents
)1 Nominal system voltage: 415 V
)2 Highest system voltage: 440V
)3 System frequency: 50 Hz
)4 No of phases: 3
)5 System neutral earthing: Solid earthed.
)6 Reference ambient air temperature: 45 deg C
)7 Short circuit withstand current and duration: One second rating: 50 kA
Dynamic rating: 105 kA (peak)
)8 One minute power frequency withstands voltage 2500V for power circuit &
1500 V for control circuit.
8.0 Expected process parameters

These are not applicable.
9.0 Work plans
Confirming the status of other systems
Confirming the status of 415V MCC/PMCC
Confirming the availability of manpower
Confirming the availability of test

instruments
Confirming the availability of outside

agencies
Identifying the hazards and taking

necessary precautions

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Checks for completeness and correctness

415V MCC/PMCC installation
Checks for completeness and correctness

of power circuit of 415V MCC/PMCC
Checks for interfacing with other systems

controlling, protecting and monitoring
415V MCC/PMCC
Electrical testing of individual

components of 415 V MCC /PMCC
Primary/secondary injection testing of

415V MCC/PMCC with burdens
connected
Interlocking, indication and annunciation

checks of MCC/PMCC equipment’s
CB/contactor closing, tripping checks by

simulating protection system
General checks on 415V MCC/PMCC
Commissioning of 415V MCC/PMCC as

per procedure

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Energisation and post energisation
checks of 415V MCC/PMCC
Consolidation of commissioning
documentation
Handing over the 415V MCC/PMCC to

NPCIL
10.0 Test formats

Test formats are enclosed in Annexures.
11.0 References
)1 Procurement specification of 415V motor control centers (PC-E-378, R-1
/E-4).
)2 Manufacturers scheme drawing for various typical feeders.
)3 Manufacturer’s instruction manual.
12.0 Verification process

Verification process is carried out as per Annexure-33.

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Annexure-1: Pre job Briefing
Unit No. : RAPP-7 / RAPP-8
Board No. : Location :
Date :
Note:
i. Pre-Job briefing is to be conducted for infrequently performed or non-

routine works, safety critical works and routine work involving a significant
change in procedure or plant configuration.
ii. Please tick (√) in appropriate column
1.0 Description of the Job

Mention the job
2.0 Scope
Briefly mention the scope of work.
3.0 Pre-requisites:
3.1 Adequate number of personnel of appropriate knowledge, skill and
experience are identified for the activity and all of them are present.
3.2 All the members are attentive and free of any distraction during the
briefing.
3.3 Adequate time is available for PJB.
3.4 Related procedure (operation or maintenance procedure) or other
relevant documents like surveillance test form required during the
briefing are available.
3.5 All required permits are available.
3.6 Instruments/tools/consumables are available.
4.0 Precautions.
4.1 Identified activities should not commence before the briefing.
4.2 Encourage questioning attitude to clear any ambiguity or doubt during
briefing.
4.3 Ensure communication is loud and clear. Ensure at least ‘two way’
communication and if required three way communication (repeat
back).
5.0 Procedure (Points to be discussed during Pre-job Yes Remarks
Briefing):
Discuss the following with the performers of the
task. Please tick (√) in appropriate column.
5.1 Objective of the task and why it is being
performed.
5.2 Role and responsibility of each member.
5.3 Expected duration for completing the task.

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5.4 Initial plant and equipment condition.
5.4.1 Identify the unit no. where activity is to be
performed.
5.4.2 Status of unit and equipment/system.
5.4.3 Equipment tag number.
5.4.4 Equipment location
5.4.5 System/component/equipment category. (Safety
related/ non-safety related)
5.4.6 Check whether history of equipment has been
reviewed.
5.4.8 Review/ Inform working conditions. (latest update)
5.5 Required Documentation.
5.5.1 Relevant procedure/documents to be referred.
5.5.2 Check whether procedure and drawings have
been studied and understood.
5.5.3 Check whether work permit, industrial safety /fire
permit is taken.
5.6 Tools and Materials
5.6.1 Check whether correct tools and tackles are
identified?
5.6.2 Requirement of special tools/instruments and
their calibration status.
5.7 Procedure and critical steps
5.9.1 Check points / hold points to be used after each
critical steps.
5.9.2 Explain expected system/ equipment response.
5.9.3 Decide and explain contingency action plan if
expected response is not observed or any
abnormal situation/transient is encountered.
5.9.4 Expected response for contingency.
5.9.5 Any error likely situation expected.
5.9.6 Review applicable requirements and discuss the
acceptance criteria.
5.8 Ensure the system test behaviour is as expected.
5.9 Possible hazards for the job, if applicable, with
respect to the following and precautions to be
taken:
5.9.1 Industrial and Fire Safety
5.9.2 Electrical Safety
5.10 Human performance aspects like STAR, self-
check, peer check, third party verification.
5.11 ‘Just In Time’ information about the job (if
available) or previous operating experience is

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available and discuss any problem faced in
performing similar activity:
5.12 Brief about Foreign Material Exclusion (FME)
aspects.
5.13 Housekeeping before start of the job, while doing
the job and cleaning of the equipment and area
after completion of the job.
5.14 Brief about operability of area phone before start
of work.
5.15 Identify the contact persons with telephone
number for exigency or clarification.
5.16 Post job/ maintenance testing requirements.
Pre-job Briefing is given to the following persons:
Sr. No. Name Signature Sr. No. Name Signature

1. 4.
2. 5.
3. 6.
Pre-job Briefing given
By
Name & Designation Signature

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Annexure-2: Post installation checklist
Date :
Sr. Description Status

No.
General checks on MCC/PMCC
1) Check the rating and diagram nameplate details are as per
drawing.
2) Check that the 415 V MCC is installed completely as per
the GA drawing. Verify the erection checklist. Note down
pending points relating to installation if any.
3) Check BOM as per approved drawing.
4) Clean and check all insulators for healthiness. There should
not be any crack or chipping on insulators. Insulator and
bus bar mounting bolts shall be tight.
5) Check the panel for any unwanted openings. Extra
openings are sealed properly in permanent manner.
6) Check & ensure identification with unit No. has been
prominently displayed on MCC/PMCC.
7) Check all cells of MCC/PMCC are identified with tags /
nameplates and ensure cell allocation is as per drawings.
8) Check indication lamps are in place and lamps are healthy
(wherever provided as per drawing).
9) Check the alignment of all doors.
10) Check operation of all doors & panels and ensure panel
covers have been installed properly with door closing
services.
11) Ensure door/cover gaskets have been provided and
gaskets are healthy.
12) Identify MCC bus phases and check for proper phase
identification (colour coding) and connection at switchgear
end.
13) Check and ensure same phase sequence has been
maintained up to outgoing terminals of cell/CB.
14) Check that the tightness level of connection is achieved
using a torque spanner.
15) Ensure that the bonding / blocking material for contactors,
starters, relays etc. is removed.
16) Check Voltmeter selector switch operates freely.

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No.
17) Check Voltmeter selector switch continuity for all these
positions.
18) Check & ensure, all interposing relays have been labelled
clearly for their identification.
19) Check & ensure, all protective relays have been labelled
clearly for their identification.
20) Ensure all protective relays have been calibrated as per
relay setting sheet.
21) Check & ensure danger sign board as per IS has been
provided on the MCC panel.
22) Check & ensure electrical safety instruction boards/posters
have been displayed in the MCC room.
23) Check & ensure insulating mat/paint has been provided on
the floor in front of MCC/PMCC.
General check on CB
24) Inspect the CB for any physical damage.
25) Lubricate all the linkages, moving / sliding parts as per
manufacturer’s instructions.
26) Use a torque gauge and check the tightness of all the bolts,
clamps & connecting terminals of ACB as per
manufacturer’s recommendations.
27) Check CB for its free movement, and check that the safety
shutters over the cluster contacts in the cubicle are
operating satisfactorily.
28) Check CB rack in- rack out for 10 times for its free
movements.
General check on MCC cell
29) Check the cleanness of cell, ensure FME.
30) Check free movement of cell during rack in and rack out for
10 times.
31) Ensure lubrication in cell draw out contacts (male/female).
32) Check proper lifting of shutter and engagement of incoming
and outgoing contact during racking in the cell.
33) Check interlocks of isolator knob with cell cover and ensure
when MCC isolator is switched ON, door cover is not
opening.
34) Check electrical interlock for reverse and forward rotation
type of loads.
35) Check control fuse and power fuse rating as per approved
drawing.
36) Check control fuse and power fuse continuity.
37) Check all interlocks/logics, alarms, window annunciation

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PMCC of L&T
No.
per scheme.
Performed by Checked by Witnessed by
IOT (ENGG) IOT (QA) NPCIL

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Page 24 of 55
PMCC of L&T
Annexure-3: Earthing Checks

Date :
1) Earthing Checks for MCC/PMCC:
Sr. Location of Earthing Visual & Remarks

No Tightness
Check
1) Check MCC/PMCC earth bus is linked across the
transport sections & is continuous.
2) Check that earth bus at both ends of MCC/PMCC is
connected to station grounding mat at distinct earth
pads.
3) Check that earth strips up to earth pad are
embedded in floor.
Test Instrument Details:
Sr. Instrument Calibration

Make Model Serial No. Range
No. Description valid up to

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PMCC of L&T
Annexure-4: Checklist for cubicle illumination
Unit No. :
Date :
Sr. Location Applied Voltage Current Drawn (A) Door LS Remarks

No. (OK / Not OK)
Test instrument details:


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PMCC of L&T
Annexure-5: Check list for Space Heater

Unit No. :
Date : Feeder No. :
Sr. Feeder Resistance IR Applied Drawn Thermostat Remarks

No. No Value Value Voltage Current operation &
(Ω) (M Ω) (V) (A) range check


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PMCC of L&T
Annexure-6: Testing of CT
Unit No. :
Date : Feeder No. :
6.1 Metering CT:
1) Name Plate Details:

R Y B
Serial No.
Ratio
Burden
Class
Make
Type designation
of CT
2) Insulation Resistance Test : AT 500 V DC
Sr. IR Value Between Measured Value (MΩ) Acceptance Remarks

No. Criteria
R Y B >10 MΩ
1) Primary – Earth
2) Secondary – Earth
3) Primary-Secondary
3) Polarity Check : OK/Not OK

R Y B
4) Ratio Test:

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PMCC of L&T
Remark
Sr. In (%) Injected Primary Measured Secondary Ratio Error (%)
No Current (A) Current (A)
s
R Y B R Y B R Y B
1) 20
2) 40
3) 60
4) 80
5) 100
Acceptance limit for ratio error shall be as per name plate of CT.
5) Secondary Winding Resistance:
Observed Value (Ω)
Rated Current Remarks
R-Phase Y-Phase B-Phase
6.2 Protection CT:

1) Name Plate Details :
R Y B
Serial No
Ratio
Burden
Class
Make
Type designation
2) Insulation Resistance Test : AT 500V DC
Sr. IR Value Between Measured Value (M Ω) Acceptance Remarks

No. R Y B Criteria
1) Primary – Earth >10 M Ω
2) Secondary – Earth >10 M Ω
3) Primary-Secondary >10 M Ω
3) Polarity Check :
R Y B
4) Ratio Test:

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PMCC of L&T
Sr. In (%) Injected primary Measured Ratio Error (%) Remarks
No. Current (A) secondary
Current (A)
R Y B R Y B R Y B
1)
2)
3)
4)
5)
Acceptance limit for ratio error shall be as per name plate of CT.
5) Secondary Winding Resistance:
Observed Value (Ω)
Rated Current Remarks
R Y B
6)Knee point Voltage

Sr. Applied Applied Measured Current (mA)
No. voltage (%) voltage on R Y B
secondary
Side (V)
10
20
30
40
50
60
Note:
1) Acceptance criteria for ration error and phase error shall be as per IS
2705:1992
2) Compare the result with factory test result and note deviation. If any deviation
is observed then confirm for acceptance of test.


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PMCC of L&T

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PMCC of L&T
Annexure-8: Testing of PT
Unit No : Board No : Location:
Feeder No : Date :
1) Name Plate Details :

R Y B
Serial No
Ratio
Burden
Class
Make
Type designation
2) Insulation Resistance Test : At 500 V DC

Sr. No. IR Value Between Measured Value (M ohm) Acceptance Remarks
Criteria
R Y B
1) Primary – Earth
2) Secondary – Earth
3) Primary-Secondary
3) Polarity Check :
R Y B
4) Ratio Test:
Sr. Vn Injected Primary Voltage Measured Secondary Remarks
No. (%) (V) Voltage(V)
R Y B R Y B
1)
2)
3)
4)

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PMCC of L&T
Note: 1) Acceptance criteria for ration error and phase error shall be as per IS
3156:1992
2) Compare the result with factory test result and note deviation, if any
deviation is observed then confirm for acceptance of test.

performed by Checked by Witnessed by
IOt (Engg) IOT (QA) NPCIL

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PMCC of L&T
Annexure-9: Checks on Control Transformer
Unit No.: Date:
Feeder Name: MCC/PMCC No.:
Sr.
Check Description Observation Remarks
No.
Check rating and name plate details of

1.0 control transformer, record and
compare with approved drawing.
Check control transformer physically

2.0
for any damage.
Check the cables connected to control

3.0
transformer as per scheme.
4.0 Check tightness of all terminals.
5.0 Measure the insulation resistance of winding.
5.1 Primary to Earth (M Ω)
5.2 Secondary to Earth (M Ω)
5.3 Primary to Secondary (M Ω)
Measure the resistance of Primary

winding. ( Ω)
6.0
Measure the resistance of Secondary
winding. (Ω)
Check the rating of control fuse as per

7.0
approved drawing, record fuse rating.
8.0 Check the continuity of control fuse.
Apply 415 V AC supply to primary and Secondary voltage = 110

9.0
measure the secondary voltage. V ± 5V
Confirm the transformer secondary

10
winding is earthed to station earth.

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PMCC of L&T
Sr.
No.
Confirm the control fuse rating is in

11
coordination with incomer fuse.


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PMCC of L&T
Annexure-11: Tests on Ammeter
Unit No : Board No
Feeder No : Location
Ammeter No : Date
Range : Ratio
% Error
Remarks
Sr. % Value of Applied Expected Observed
Acceptance Criteria
No. Current Current (as Per Reading of Reading of
Applied Requirement) Ammeter (A) Ammeter
(A) (A)
1)
2)
3)
4)
5)
Note : Source of acceptance criteria: As per IS 1248 (Part 9)


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PMCC of L&T
Annexure-12: Test on Voltmeter
Unit No : Location :
Board No : Date :
Feeder No : Voltmeter No :
Range : Input signal to voltmeter:
% Error
Acceptance Criteria
Remarks
Sr. % Voltage Value of Expected Observed
No Applied Applied Reading of Reading of
Voltage (V) Voltmeter (V) Voltmeter (V)
1)
2)
3)
4)
5)
Note : Source of acceptance criteria: As per IS 1248 (Part 9)

Test Instrument Details :
No Description valid up to
IOT (ENGG) IOt (QA) NPCIL

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PMCC of L&T
Annexure-16: Checks on Switch Fuse Unit (SFU)

Unit No.: Date :
Feeder Name: Board No. :
Location:
Sr.
No.
Check the type and name plate

details of switch fuse unit (SFU) and
1) cell and compare with approved
drawing. Record the rating and
observation.
Check SFU physically for any

2)
damage.
Check the cables connected to SFU

3)
as per scheme.
4) Check tightness of all terminals.
5) Check the ON/OFF operation of SFU.
Check the rating of power fuse,

6)
compare with drawing and record.
7) Check the continuity of power fuse.
8) Check tightness of fuse holder.
Place power fuse on SFU, put ON

the SFU and check resistance of
9)
power contacts. Resistance shall be
less than 0.5 ohm.
Ensure fuses are in coordination with

10)
upstream fuses, if any.
Test Instruments Details:

Sr. Instrument Make Model Serial No. Range Calibration valid

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PMCC of L&T
No
Description up to
.

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PMCC of L&T
Annexure-17: Checks on Contactor
Unit No.: Date :
Feeder Name: Board No.:
Location:
Sr.
No.
Check contactor type and name plate details and
1) compare with approved drawing. Note down make,
model no. and current rating.
2) Check contactor physically for any damage.
Check the cables connected to contactor as per
3)
scheme.
4) Check tightness of all terminals.
5) Check the smooth operation of plunger.
Check the auxiliary contact change over with
6)
contactor operation.
7) Measure insulation resistance (IR) of contactor coil. MΩ
8) Measure contactor coil resistance. Ω
9) Check Pick up voltage of contactor coil.
10) Check Drop off voltage of contactor coil.
Check the resistance of power contacts during pick
11) up condition of contactor. It should be less than 0.5
ohm.

Sr.
Instrument Calibration valid
No Make Model Serial No. Range
Description up to
.
M/s IOT (ENGG) M/s IOT (QA) NPCIL
Annexure-19: Checks on thermal overload relay

Unit No.: Date :

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PMCC of L&T
Feeder Name: Board No. :
Location:
Sr. Expected
No. value
Check Relay type and name plate
1) details as per drawing. Record the
same.
Check Relay physically for any
2)
damage.
Check the cables connected to relay
3)
as per scheme.
Remove the relay from cell for
4)
calibration.
Check the continuity of power
5) Continuity
contact.
Set the relay as per relay setting As per setting
6) Ith=____Amp
sheet and note down the value. sheet.
Connect all three phase in series and
inject the AC current and note down Injected
7) the value of injected current. current=
(For relay setting up to 80A: Inject 2 _______Amp
times current of Ith.)
Check the changeover of relay Should
8)
auxiliary contacts. change
Check the auto/manual reset function
9) of the relay. Keep reset function on On Manual
MANUAL.
No
Inject AC Current equal to Ith (setting)
Tripping/No
10) and observe for 10 minutes with
Contact
current in service.
Change Over
Install the relay in the MCC cell,
11) normalize relay connection and carry Normalised
out tightness on the relay terminals.

Sr. Instrument Make Model Serial No. Range Calibration valid
No Description up to

Doc No.:
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PMCC of L&T
.
M/S IOT (ENGG) M/s IOT (QA) NPCIL

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PMCC of L&T
Annexure-25: Contact resistance of bus bar joint
Unit No.: Date:
Feeder Name: MCC/PMCC No.:
Location:
Injected (A) Current
Contact Resistance
Acceptance Criteria
(in µ Ω)
Joint No.
Remarks
Sr
No
R Y B R’ Y’ B’ N
<5 µ Ω Per
Joint


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PMCC of L&T
Annexure-26: Minimum Clearance between bus bar
Unit No :
Board No : Location :
Feeder No : Date :
Minimum Acceptance
Sr. Measured
clearance location criteria Remarks
No in mm
between
1) R---E >19mm
2) Y---E >19mm
3) B---E >19mm
4) R---Y >25mm
5) Y---B >25mm
6) B---R >25mm

Sr.
Instrument Calibration
No Make Model Serial No. Range
Description valid up to
.

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PMCC of L&T
Annexure-27: HV and IR test on bus bar
Unit No :
Board No : Location:
Feeder No : Date :
Note:
()1 Open bus bar covers and clean thoroughly.
()2 Inspect support insulators for tightness and crack (damage). Rectify, if any.
()3 Check tightness of all the connections on bus bar.
()4 Conduct IR test on bus bars.
()5 Conduct HV test on bus bars at reduced test value of 2 KV AC for one minute.
Note down the leakage currents at the start and finish of test.
()6 After HV test, repeat IR test.
()7 Measure and note down contact resistance for joints in bus bar.
27.1 IR testing on Power Buses before HV:
S.No IR Value IR Value IN S.NO IR Value IR Value IN
Between (M) Between (M)
1) R-E 5) R-Y
2) Y-E 6) Y-B
3) B-E 7) B-R
4) N-E
27.2 HV testing:
SR HV Applied HV Value Leakage Leakage Remarks
NO Between Current AT Current at
Start end OF test
(mA) (mA)
1) R – (Y+B+E) 80% of 2.5 KV
AC = 2 KV
2) Y – (E+B) 80% of 2.5 KV
AC = 2 KV
3) B –(N+ E) 80% of 2.5 KV
AC = 2 KV
4) N-E 80% of 2.5 KV
AC = 2 KV
27.3 IR testing on Power Buses after HV test:

S.No IR Value IR Value IN S.No IR Value IR Value IN

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PMCC of L&T
Between (M) Between (M)
1) R-E 5) R-Y
2) Y-E 6) Y-B
3) B-E 7) B-R
4) N-E
27.4 IR testing of DC Bus

S.No IR Value Between IR Value IN (M)
1) + ve bus-E
2) - ve bus-E
3) + ve bus-- ve bus
27.5 IR testing of Auxiliary AC Supply Bus

1) Phase-E
2) Neutral-E
3) Phase to Neutral
27.6 IR testing between DC Bus and AC Supply Bus

Short DC positive and Negative bus.
Short Auxiliary AC buses (Phase and Neutral)
1) DC buses to Aux. AC Buses
Remove shorting.
Note: 1) HV test acceptance criteria – HV test withstood for one minute & no
increase in
Leakage current from start of the test to end of the test.
2) Insulation resistance test acceptance criteria – Value shall be > 1 MΩ
(Ref IS 10118 PART-III)
3)This Annexure is applicable for MCC/PMCC and bus ducts.

Sr. Instrument Make Model Serial No. Range Calibration

Doc No.:
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PMCC of L&T
M/s IOtL (ENGG) M/s IOT (QA) NPCIL

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PMCC of L&T
Annexure-28: Cabling and connection check
Unit No : Date:
Board No : Location:
Remarks
Sr Cable Cable Availability of Termination Insulation Check
No Number Size Cable Glanding Resistance Continuity
/Tag/Ferrule Value (OK/Not
(Yes/No) OK)
From To
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)

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PMCC of L&T
Annexure-29: Functional checks on MCC
Unit No.: Date :
Location: MCC/PMCC No. :
A. Functional &logic checks for MCC/PMCC
Sr. No. Description Observation Remarks
1. Cleaning of panel and feeder modules.

Lubrication of moving parts & application of
2. electrical contact resistance grease in feeder
modules.
Check rack in rack out of cells for smooth
3.
operation.
4. BOM checks in feeder modules.
Function of FN switch for smooth operation.
5.
Check continuity in open and close condition.
6. Check for door interlock with isolator ON.
Check and ensure control transformer fuses rating
7.
as per drawing.
Check and ensure control transformer rating as
8.
per drawing.
Test CBCT and its circuit at approved set point (if
9.
applicable).
10. Test CT and its circuit as per ANN-14.
11. Test PT and its circuit as per ANN-15.
12. Test earth leakage relay at approved setting.

Check power contactor operation and measure
13.
contact resistance as per ANN-20.
Simulate tripping of contactor from thermal
14.
overload K80 relay. Check for alarm in MCR.
Simulate tripping of contactor/MCCB from earth
15.
leakage relay.
Carry out Pick up and drop out test of interposing
16.
relay as per ANN-23.
17. Apply 240 AC and check space heater circuits.

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PMCC of L&T

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Annexure-31: Technical specification

Sr.
Description Of Specifications Value
No.
1) Rated voltage 415V
2) Number of phases 3
3) Rated frequency 50Hz
4) System neutral earthing Solid earthing
5) Maximum system voltage 457V

One minute power frequency voltage for power 2500V
6)
circuit
One minute power frequency voltage for control 1500V
7)
circuit
8) Reference ambient temperature 45 deg C
Maximum temperature of bus bars, droppers For Cu & Al bus bars with
and contacts at continuous current rating under tinned bolted joints – 90
9)
site reference ambient temperature deg C, for silver plated
joints – 105 deg C
Short circuit withstand for bus bars and 50KA, 1 Sec
10)
droppers
11) Dynamic rating 105KA (peak)

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PMCC of L&T
Annexure-32: Pre energisation check list
Unit No.: Date :
S. No. Description Status

1. Check that other systems required for energisation of
415V MCC/PMCC are ready.
2.
Check that no pending point exist in installation checklist.
3. Ensure that the bus bar joint contact resistance test has
been measured and results are acceptable.
4. Ensure that the bus bar HV & IR test has been performed
and results are acceptable.
Measure IR once again before giving clearance for
5.
energisation of MCC/PMCC. (M Ω)
R-E……..Y-E………B-E…….R-Y……..Y-B……….B-R……
Checks for cables connected at the MCC/PMCC is
6.
completed for termination and all the cables are terminated
as per the scheme.
7. Check that interfacing checks between the MCC/PMCC
and other equipment/system are completed.
Check that all relays are tested for removing of blocking &
8.
bonding material, calibration/operation, and are set as per
relay coordination chart.
9. Check that all meters are tested for removing of blocking &
bonding material and calibration/operation.
10. Check that the earthing of the MCC/PMCC is completed
as per scheme.
11. Check on auxiliary AC circuits of panel illumination and
space heaters is completed.
12. Check that the clearance between the bus bars is as per
the specifications.
13. Check that commissioning tests are carried out on all
feeder cells.
14. Check that primary injection checks for CTs with burdens
connected is performed.
15. Check that voltage injection checks for PTs with burdens
connected is performed.
16.
Check that unused cores of CT are shorted and earthed.

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S. No. Description Status
Check that picks up & drop off test on various auxiliary DC
17.
relays, contactors and lockout relays are performed and
the results are found acceptable.
18. Check that any discharging rod/earthing provided on the
MCC/PMCC is removed before energisation.
19. Check for coordination of relay settings between
MCC/PMCC incomer and its source at 415V switchgear.
20. No unwanted tools tackles, equipment are left inside the
MCC cell, marshaling panel and MCC/PMCC panel.
Check that Work permit system followed for any
21.
energisation and switching involving other systems which
are already commissioned
22. Check necessary approval for charging is obtained from
competent authority.
23.
Check the Pre-job briefing has been done.
24. Check & ensure danger sign board as per IS-2551 has
been provided on the MCC/PMCC panel.
25. Check & ensure electrical safety instruction boards/posters
have been displayed in the MCC room.
26. Check & ensure insulating mat/paint has been provided on
the floor in front & back of MCC/PMCC.
27. Observe and record deficiency/pending job, if any.

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PMCC of L&T
Annexure-33: Post energization check sheet

Unit No.: Date :
Measurement Interval Every Two Hours Starting

Sr. Description Of
With Charging
No. Measured Parameter
0 2 4 6 8
1) Bus voltage
Check for any
2)
abnormal sound
Check any one control
transformer Input and
3)
output voltage (one
time only)
Check for ambient
4)
temperature
Check for temperature
5)
rise on panel surface
Sr. No. Instrument Description Range Calibration Status
M/s BGRESL (ENGG) M/s BGRESL (QA) NPCIL

Doc No.:
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Commissioning Procedure for 415 V AC PMCC and SDB Of
Page 54 of 55
L&T
Annexure-34: Verification Sheet

Unit No.: Date :
Certification by verifying agency
Sr.
Activity Verified Acceptance Criteria Procedure Inspection Functional Results General
No.
Certification Witness Test Certification Remarks
Verifying
SME(E) EIC EIC EIC
Agency
Pre commissioning checks As per checklist/
1)
acceptance list
MCC/PMCC checks and As per checklist/
2)
testing acceptance list
Calibration of relay & their As per checklist/
3)
settings acceptance list
Functional checks As per checklist/
4)
acceptance list
Final check list As per checklist/
5)
acceptance list
Post energisation checks As per checklist/
6)
acceptance list
Ravindramani Tiwari Suresh Srinivasan Ananad Chaturvedi

ENGINEER Sr. Manager RCM
Doc No.:
RAPP-7&8-52540-CP-2-R1
Commissioning Procedure for 415 V AC PMCC
and SDB Of L&T Page 55 of 55
Annexure-35: Distribution List

Sr.
RRS / RAPP-7&8 NPC, Mumbai
No.
1) Site Director, RRS Director (O) / ED (O-PHWR)
O&M Construction Concerned Design Group

2)
SD PD ACE (DC & RI)
3)
CS CCE
4)
TSS ACE (Planning)
5)
MS
6)
OS
7) SME (M) / SME (E) /

SME (I) / SME (F)
8) Operation
* Documentation Cell
9) SCE Office / Main
* Control Room Copy
10)
Originator
*
Planning
11)
Documentation Cell /
*
Library
System
12)
Commissioning
Engineer
* By hard copy also.
PREPARED BY REVIEWED BY APPROVED BY
Ravindra Mani Tiwari Suresh Srinivasan Anand Chaturvedi

ENGINEER Sr. manager RCM

Commissioning Procedure MCC

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Revision Control Sheet

1 Revised as Ravindramani Suresh SRinivasan. Anand

Prepared by Reviewed by Approved by

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

Prepared by Reviewed by Approved by

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

3.3 Manpower requirements:

Prepared by Reviewed by Approved by

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

3.4 Requirements of instruments:

3.5 Requirement of outside agencies:

4.0 Hazards and precautions:

Prepared by Reviewed by Approved by

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

5.0 Pre-job briefing:

Prepared by Reviewed by Approved by

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

6.6 Testing of CT:

Prepared by Reviewed by Approved by

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

6.9 Checks on MCC/PMCC Feeder cell:

Prepared by Reviewed by Approved by

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

6.12 Feeder Type C1 (Locally Controlled Pumps up to 50 kW):

Prepared by Reviewed by Approved by

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

6.14 Thermal overload relay Curve details : -

Sr. No OLR Relay Series Range (Acceptable limit for trip

6.1 HV & IR checks on bus bars of MCC/PMCC:

Prepared by Reviewed by Approved by

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

Prepared by Reviewed by Approved by

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

8.0 Expected process parameters

9.0 Work plans

Confirming the status of other systems

Confirming the status of 415V MCC/PMCC

Confirming the availability of manpower

Confirming the availability of test

Confirming the availability of outside

Identifying the hazards and taking

Prepared by Reviewed by Approved by

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi

Checks for completeness and correctness

Checks for completeness and correctness

Checks for interfacing with other systems

Electrical testing of individual

Primary/secondary injection testing of

Interlocking, indication and annunciation

CB/contactor closing, tripping checks by

General checks on 415V MCC/PMCC

Commissioning of 415V MCC/PMCC as

Prepared by Reviewed by Approved by

Ravindra mani Tiwari Suresh Srinivasan Anand Chaturvedi