SECTION - 25: ERECTION, TESTING AND

COMMISSIONING
Section -25: Erection, Testing and Commissioning Technical Specifications

SECTION - 25: ERECTION, TESTING AND COMMISSIONING

25.01 GENERAL

The Contractor shall complete the erection, testing and commissioning of the substation
and shall hand over in proper working order in accordance with the Contract
Documents. All work of assembly, construction and erection shall be done in a neat,
first class workmanship manner according to the best practice applicable and as
approved by the Engineer.

The Contractor shall submit a detailed description of the field tests he intends to carry
out on his equipment, comprising test protocols, testing and commissioning procedures
etc. for Engineer's review well before starting of the field tests.

The Contractor shall be responsible for satisfactory field testing and commissioning of
equipment to the satisfaction of the Engineer prior to the energization. Engineer may
also ask the Contractor to perform additional tests, which may not be listed, to prove
that a particular equipment is fit for commissioning and energization.

A record of all performance tests shall be embodied in a report to be submitted by the

Contractor upon completion, to the satisfaction of the Engineer, of the tests described
herein together with such other tests as may be agreed between the Contractor and the
Engineer, which collectively shall constitute the Commissioning Tests.

The Engineer may, at his option, require that tests be made after the equipment has
gone into service in order to demonstrate that all performance guarantees have been
met. The Contractor will be permitted to have his representative present at his own
expense and make all necessary corrections. Additional tests shall then be made under
the directions of the Engineer to demonstrate to his own satisfaction the effectiveness of
these corrections. These additional tests shall be at the Contractor's expense. Until the
necessary corrections have been satisfactorily made, the conditions of the Contract shall
not be considered fulfilled.

The Contractor shall certify in writing to the Engineer that the equipment or part of the
equipment has been installed and tested to the satisfaction of the Engineer and is ready
for energization.

All instruments and test equipment required for complete installation, testing and
commissioning of plant shall be arranged by the Contractor.

The erection & testing equipment listed under item I of Volume-I of the
Bidding/Contract Documents, shall be handed over to NTDC in new, unused condition.
However, if Contractor is allowed to use certain equipment as per Contract these
equipment shall be returned in healthy condition.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

25.02 ERECTION AND INSTALLATION

25.02.01 High Voltage Bus-work

(1) General:

The Contractor shall install the conductor, insulators and the

hardware for strain and tubular buses and overhead shield wire in
accordance with approved drawings.

(2) Conductor and Buses:

Buses which are used in tension shall be free of joints or splices.

All bus connectors shall be clamped firmly and locked securely.
The equipment and methods used for stringing the conductors
shall be approved by the Engineer and shall be such that the
conductor will not be damaged during the stringing operation.

Tubings used for bus work and connections to equipment shall

be shaped and formed prior to installation to reduce the
possibility of damaging equipment terminals. All tubing shall be
installed in such a fashion that stresses between connecting
terminals will be reduced to a minimum. If connection is made to
the equipment on another foundation or structure then the tubing
shall have flexible connectors at one end.

The radius of tubing bends shall not be less than four times the
diameter of the tubing, and such bends shall be free from kinks,
indentations, or flattened surfaces. Tubing shall be utilized in
such a manner as to minimize the necessity of splicing. Splicing
will not be allowed unless unavoidable. All terminals shall be
bolted securely and locked. All connections shall be thoroughly
cleaned to remove oxide film. An oxide retarding compound of
approved type shall be used at all connections and precautions
shall be taken to seal moisture out of the joint to avoid galvanic
corrosion.

25.02.02 Transformers

(1) Installation:

The transformers shall be assembled on their respective

foundations in strict conformity with manufacturer’s erection
manuals and approved drawings.

While assembling, precaution shall be observed to prevent

condensation on any part within the tank. The tank and the
neutral shall be grounded as specified.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

The bushing holding down bolts shall be properly tightened to

avoid unequal clamping strains and subsequent damage to the
bushing porcelain or support.

(2) Wiring:

Connection to oil and winding temperature gauges and oil level

indications shall be with control cable run through conduit from
cable trench to the cabinet or terminal boxes.

(3) Oil Filling:

The oil shall be passed through filter press and shall be clean and
dry before filling the transformers and reactors under vacuum. It
shall be ascertained that no contamination takes place during oil
filling.

In case the gas has leaked from transformers and reactors, which
shall be supplied, inert gas filled during shipment, drying out
under vacuum shall be done by a suitable drying process.

25.02.03 Circuit Breakers

The circuit breakers shall be assembled, placed, leveled, aligned and grouted on their
concrete foundations and connected in accordance with approved drawings.

The circuit breaker control panels shall be factory wired. The control and power cables
shall be terminated at terminal blocks. Connections to control mechanism shall be with
control cables running through conduit from cable trench to mechanism cabinets.

25.02.04 Disconnectors

The Contractor shall assemble, mount and connect all gang operated switches. Each
pole of the disconnector shall be installed so that the base shall not be stressed
unequally when bolted to the supporting member. The poles of the disconnector shall
be aligned accurately and leveled on the supporting steel structures and shall be
adjusted to permit a smooth and completely controlled movement through the entire
operating cycle.

The bearing and the operating mechanism shall be lubricated properly. All contacts of
the switches shall be adjusted and aligned for proper contact pressure and coated with
corrosion inhibiting grease.

25.02.05 Surge Arresters

Surge arresters shall be mounted as close as possible to the apparatus being protected.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

25.02.06 Instrument Transformers

Instrument transformers shall be mounted and connected in accordance with standard

practice. Secondary connections to current transformers shall be made with minimum 6
sq.mm conductors and to voltage transformers with minimum 4 sq.mm conductors.

The connecting cables shall run in metallic conduits from trench/duct to instrument
transformers.

25.02.07 Substation Automation System and Protection System

Bay control units and bay mimic circuits and relay panels shall be erected on channel
iron bases. The channel irons shall be leveled and grouted in place and the control
board and relay board panels mounted thereon. The Contractor shall mount all
equipment and shall make all necessary connections and interconnections to the panels
in accordance with the approved standard practices.

All instruments and relays shall be properly installed, connected and tested to meet the
technical specifications in the presence of the Engineer.

25.02.08 Telecommunication and Scada Systems

Proper care shall be taken to avoid mechanical joints, shocks or vibrations to the
equipment. If any soldering etc. on site is necessary, the person making these
connections and tools will be properly grounded during the entire operation.
Commissioning shall include operational tests to verify all possible modes of operation
of SSB, protection and switching equipment. Signal to noise ratios will be monitored
and demonstrated to be equal or better than design values.

25.02.9 Control and Small Power Cables

Cables shall be installed on cable supports, in cable trenches or in conduits. Cables

shall be installed with sufficient slack to allow for expansion and contraction and tied at
each support point. If laid in trenches, the cables shall rest on cable supports suitably
spaced, and shall be fastened at appropriate points, using bolted galvanized straps,
which should not press tightly against the insulation.

Where group of cables enter or leave the trench, each shall be identified with stenciled
metal tags. Each tag shall indicate the terminal location to which it is attached. At each
cable termination, the cables shall be clamped below the terminal block. Cable glands
of appropriate sizes shall be used at cable entrances into control panels, relay panels and
marshalling boxes.

Cable runs shall be continuous from terminal to terminal to the extent permitted by
available commercial lengths. Splicing shall not be permitted.

Insulated wire and cable shall be handled with care so as to avoid kinking and damage
to insulation and outer jackets. Cables shall not be bent around a radius less than that
recommended by the manufacturer.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

Each wire terminating in a terminal block shall carry a permanent identification tag
(ferrule) bearing the same identification number as given on the drawings. Slip-in type
ferrules should not be used for this purpose.

The Contractor shall install all lugs, terminal blocks and terminals required and shall
make all connections required to provide a complete installation ready to operate. Cable
identification tags of a permanent type shall be provided and installed on both ends of
each power and control cable.

Connections in lighting wires and cables shall be insulated with layers of plastic
insulating tape or with high grade rubber tape over which friction tape shall be applied.

Sufficient slack shall be allowed in each run where a number of cables or wire
comprising a circuit are trained through a pull box, terminal box, trench or tray and
shall be neatly placed and tied together. Lacing shall also apply from the point of
leaving a cable-tray or raceway to the point of attachment on the terminals of the
switchgear, switchboard or other devices unless the run is in conduit.

25.02.10 Switchyard AC Power and Lighting

The Contractor shall install all required lighting, power and auxiliary apparatus, cables
and make all connections. Illumination level of the installed lighting fixtures shall be
measured according to the specified levels.

25.02.11 AC and DC Auxiliary Supplies

The Contractors shall install and connect the equipment under these specifications as
specified in Section -20.

25.03 TESTING AND COMMISSIONING

25.03.01 HV Buswork/Equipment Connections

1) Verification of tightness of nuts/bolts as per the recommended

torque.

2) Verification of sag and tension of the overhead conductors.

3) Measurement of contact resistance of the HV connections.

4) Thermovision survey of the HV connections after energization at

high voltage.

5) Check of visible corona after energization.

6) Voltage drop test with a minimum 100 A.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

25.03.02 Transformers

The operating mechanism and control circuits of the on-load tap changer
and forced air cooling equipment shall be tested for proper operation and
for tap changer position indications. All tests shall be made from the
remote control points as well as the local control points.

Tests, performed to the satisfaction of the Engineer, shall include, but not
limited to the following:

a) Drying shall be performed. The method and tests shall be subjected

to the approval of the Engineer.

b) Final sample testing of the insulation oil, after the completion of the
dehumidifying and degassing process to ascertain specified
chemical and physical characteristics.

c) Oil insulation test.

d) Windings insulation resistance tests.

e) Insulation power factor test.

f) Low voltage ratio test on each position of the tap changer.

g) Zero sequence impedance test.

h) Functional test for auxiliary equipment, buchholz relay, thermal

relay, oil level indicator etc.

i) Adjustment of the protective devices such as gas and oil

temperature relays and system to show compliance with operating
requirements, correct operation verification of oil-preservation and
oil-protection system.

j) Phasing test.

k) Vector group test.

l) Operational test for automatic tap-changing equipment, adjustment

of the protective devices such as gas and oil temperature relays and
system to show compliance with operating requirements, correct
operation of complete cooling system and verification of correct
operation of oil-preservation and oil-protection system.

m) Measurement of capacitance and dissipation factor (tan δ).

n) Checking the oil leaks.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

o) Measurement of winding resistances.

p) Verification of all alarm, trips and control circuits.

q) Energization to full voltage.

25.03.03 Circuit Breakers

a) Measurement of insulation resistance (Megger tests).

b) Measurement of air content and humidity in SF6 gas in the cylinder

before its filling into the breaker.

c) Measurement of air content in SF6 at four times after filling in the

breaker upto completion of maintenance period.

d) Recording of humidity content of the SF6 gas at four times after

filling in the breaker upto completion of maintenance period.

e) SF6 leakage tests.

f) Verification of ac and dc auxiliary supplies in respect of magnitude

and phasing/polarity.

g) Verification of pick-up and drop-off of each of the SF6 pressure

switches at rising and dropping pressures.

h) Verification for each hydraulic/pneumatic pressure switch in respect

of pick-up & drop-off

i) Verification of operation of pressure relief valves.

j) Verification of pressure thresholds for pump start/stop, breaker

automatic tripping/ blocking/lockout of close, trip and autoreclose
operations.

k) Measurement of starting and running currents, and direction of

rotation of hydraulic/compressor motors.

l) Measurement of time to reach the pump cut-off pressure:

- From zero pressure

- After close operation

- After open operation

- After CO operation

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Section -25: Erection, Testing and Commissioning Technical Specifications

- After OCO operation

m) Measurement of loss of hydraulic pressure over 24 hour period.

n) Measurement of current in the tripping/closing coils.

o) Measurement of operating times:

- Measurement of operating time at minimum, nominal and

maximum dc supply voltage.

- Measurement of operating times at maximum, nominal and

minimum hydraulic pressures.

- Measurement of time for "O", "C", "CO" and "OCO"

operations

While performing the timing tests, in addition to the numerical

printout, traces of contact travel and close/open positions i.e.
graphical recording of times should be appended to the test reports.

Timing of each interrupter and each pre-insertion resistor shall be

separately recorded and shall be graphically visible on the timing
strips.

p) Verification of pre-insertion time of closing resistors.

q) Verification of time variation between opening of series contacts on

any one phase.

r) Verification of time variation between opening of contacts of any

two phases.

s) Measurement of contact resistance.

t) Verification of functioning of auxiliary contacts.

u) Verification of setting of the hydraulic motor thermal protection

relay by secondary injection.

v) Verification of functioning/calibration of every timing relay used in

the control system.

w) Verification of trip free operation and pole discordance functions.

x) Functional tests in respect of local/remote controls, interlocking,

anti-pumping, annunciation, fault & events recording, SCADA
functions etc.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

y) Functional tests of heating and lighting for the panels and cubicles.

z) Verification of grounding connections and continuity.

aa) Check of visible corona after energization.

25.03.04 Disconnectors/Earthing Switches

a) Measurement of insulation resistance(Megger tests).

b) Verification of ac and dc auxiliary supplies in respect of magnitude

and phasing/polarity.

c) Verification of mechanical adjustments. Field measurements should

be compared with the manufacturer's recommended adjustments and
tolerances.

d) Measurement of contact resistance of the main contacts.

e) Verification of limit switch operation.

f) Verification of operation of auxiliary switches.

g) Measurement of operating times for opening and closing operations.

h) Measurement of starting and running currents of motors of

disconnecting and earthing switches at minimum., nominal and
maximum auxiliary supply voltage.

i) Verification of functioning of motor protection devices by

secondary injection.

j) Functional tests in respect of local/remote controls, interlocking,

annunciations, fault & events recording, SCADA functions etc.

k) Functional tests of panels'/cubicles' humidity control, ventilation,

internal illumination

l) Verification of grounding connections.

m) Check of visible corona after energization.

25.03.05 Surge Arresters

a) Test of insulation resistance:

- HV-Ground/Base

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 Section -25: Erection, Testing and Commissioning Technical Specifications

- Base-Ground

b) Verification of grounding connections and continuity.

c) Measurement of ground resistance.

d) Verification of surge counter operation.

e) Functional tests of surge arrester remote signalling, annunciations,

events and fault recording facilities which ever available with surge
arrester.

f) Measurement of leakage current with leakage current analyser

subsequent to energization of surge arrester.

g) Check of visible corona after energization.

25.03.06 Current Transformers/Bushing Current Transformers and Current

Circuits

a) Verification of insulation resistance (Megger test):

- Primary to ground

- Each secondary winding to ground

- Primary to each secondary winding

- Between secondary windings

b) Measurement of winding resistance at each tap of each secondary

winding.

c) Measurement of capacitance and dissipation factor.

d) Verification of winding polarities by flick test.

e) Verification of magnetization characteristics and knee-point

voltages.

f) Verification of ratios.

g) Verification of current circuits:

Following checks and tests shall be made for the current circuits fed
from the bay CTs, transformer bushing CTs and reactor bushing
CTs:

- Each CT circuit shall be verified for grounding at one point.

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Section -25: Erection, Testing and Commissioning Technical Specifications

- Phase-N loop resistance values shall be measured and

recorded.

- Loop resistance measurements shall also provide lead

resistance values.

- Resistance measurements shall be with wheatstone bridge.

- Verification of all current circuits associated with bay CTs

and bushing CTs with primary injection.

- Primary injection shall be carried out for at least the

following combinations:

- Each CT:

R-G
Y-G
B-G
R-Y
R-B

- Busbar 1 CT and Middle CT in series:

R-G
Y-G
B-G

- Busbar 2 CT and Middle CT in series:

R-G
Y-G
B-G

- Busbar 1 Protection: Busbar 1 CTs of new bays (if

more than one) in series

R-G
Y-G
B-G

- Busbar 2 Protection: Busbar 2 CTs of new bays (if

more than one) in series

R-G
Y-G

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Section -25: Erection, Testing and Commissioning Technical Specifications

B-G

- Busbar 1 Protection: Existing bay CT and New bay

CT in series (if applicable)

R-G
Y-G
B-G

- Busbar 2 Protection: Existing bay CT and New bay

CT in series (if applicable)

R-G
Y-G, B-G

- Secondary current measurements at each test block shall

include recording of current magnitude as well as relative
phase angle.

- Burden volts across each CT core shall be recorded during

primary injection.

- In addition to measurement of magnitude of current and its

relative phase angle at each test block during primary
injection, current in panels' internal wiring shall be checked.

- Changeover of current circuits in the bank selector kiosk and

with selector switches in the pole selector kiosk shall be
verified during these tests.

h) Verification of operation of protective devices at the final (fault)

settings during primary injection.

i) Dissolved gas analysis (D.G.A) and measurement of moisture

content of oil samples from each current transformer for future
reference.

j) Functional tests of panels'/cubicles' humidity control, ventilation,

internal illumination

k) Verification of grounding connections and continuity.

l) On-load tests on current transformer circuits:

- Secondary current measurements at each test block in

respect of current magnitude as well as relative polarity.

- Measurement of burden volts across each CT core.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

- Measurement of current magnitude in panels' internal

wiring.

m) Check of visible corona after energization.

25.03.07 Capacitor Voltage Transformers (CVTs)/Voltage Transformers (VTs)

and Voltage Circuits

a) Tests of insulation resistance (Megger tests) :

- Primary winding-ground

- Primary to each secondary winding

- Secondary to ground and between secondary windings

b) Measurement of winding resistance at each tap

c) Verification of polarities:

- In case polarity of CVTs/VTs windings cannot be verified

with the flick test, phase angle meter shall be used to check
the phase angle between the primary injected voltage and
secondary output.

d) Verification of voltage ratio at each tap by primary injection.

e) Capacitance and dissipation factor measurements.

f) Verification of voltage circuits:

- Verification of grounding of each voltage circuits at one

point

- If voltage circuits associated with CVTs/VTs cannot be

verified with primary injection, secondary injection shall be
made from the terminal box of the voltage transformers

- Measurement of related burden amperes for each core

- Voltage selection for synchronizing system for each

combination of circuit breakers' and disconnectors positions
shall be checked

g) Functional tests of panels'/cubicles' humidity control, ventilation,

internal illumination

h) Dissolved gas analysis (DGA) and measurement of moisture content

of oil samples from each voltage transformer for future reference.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

i) Verification of grounding connections and continuity.

j) On-load/post energization tests shall be in respect of voltage

magnitude, phase angle and phase rotation at the test blocks; voltage
magnitude and phase rotation at the terminals of the major devices
in the panels; measurement of burden current for each core.

k) Check of visible corona after energization.

25.03.08 Substation Automation System

a) Measurement of insulation resistance (Megger tests)

b) Verification of AC & DC auxiliary supply magnitude and

polarity/phasing.

c) Verification of grounding connections.

d) Verification of MCBs operation at settings of thermal/magnetic

releases.

e) Verification of calibration of adjustable devices such as timers

f) Verification of calibration of each analogue channel by secondary

injection.

g) Functional tests of analogue channels.

h) Functional tests/triggering verification for each logic channel.

i) Verification of functioning of each peripheral device.

j) Functional tests of indications, alarms, annunciation.

k) Verification of battery back-up and power-down and power-up

function of real time clock.

l) Verification of time synchronization with local event recorder.

m) Verification of time synchronization with remote time source i.e.

radio time signals or GPS signals.

n) Functional tests of panels'/cubicles' humidity control, ventilation,

internal illumination.

(1) Bay Control Units & Bay Mimic Panels

a) Measurement of insulation resistance (Megger tests)

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Section -25: Erection, Testing and Commissioning Technical Specifications

b) Verification of AC & DC auxiliary supply magnitude and

polarity/phasing.

c) Verification of grounding connections.

d) Verification of MCBs operation at settings of thermal/magnetic

releases.

e) Verification of calibration of adjustable devices such as timers

f) Verification of calibration of electrical indicating instruments:

- Calibration of each indicating instrument shall be verified by

secondary injection.

- Injected quantities shall correspond to 25%, 50%, 75%,

100%, 125% and full scale of the instrument.

- For MW and MVAR meters and recorders tests shall also be

carried out for at least the following combinations of
magnitude and power factor of the measurands.

- 100% Load Angle 0, +30, +60, +90,-30,-60,-90 degrees

- 50% Load Angle 0, +30, +60, +90,-30,-60,-90 degrees
- 25% Load Angle 0, +30, +60, +90,-30,-60,-90 degrees

g) Functional tests of controls, indications, alarms, annunciations.

h) Functional tests of panels'/cubicles' humidity control, ventilation,

internal illumination.

i) On-load tests:

- Current circuits: Measurement of current magnitude, relative

phase angle, burden volts

- Voltage circuits: Measurement of voltage magnitude, phase

angle, phase rotation and burden amperes

- Directional checks of power meters

(2) Metering Boards

a) Measurement of insulation resistance (Megger tests)

b) Verification of AC & DC auxiliary supply magnitude and

polarity/phasing.

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Section -25: Erection, Testing and Commissioning Technical Specifications

c) Verification of grounding connections.

d) Verification of MCBs operation at settings of thermal/magnetic

releases.

e) Verification of calibration of each energy meter and

MW/MVAR/Voltage recorder by secondary injection:

- Injected quantities for recorders shall correspond to at least

25%, 50%, 75%, 100%, 125% and full scale of the
instrument

- For MW and MVAR recorders and energy meters, tests shall

also be carried out for at least the following combinations of
magnitude and power factor of the measurands:

- 100% Load:Angle 0,+30,+60,+90,-30,-60,-90 degrees

- 50% Load: Angle 0,+30,+60,+90,-30,-60,-90 degrees
- 25% Load:Angle 0,+30,+60,+90,-30,-60,-90 degrees

f) Functional tests of panels'/cubicles' humidity control, ventilation,

internal illumination.

g) On-load tests:

- Current circuits: Measurement of current magnitude, relative

phase angle, burden volts

- Voltage circuits: Measurement of voltage magnitude, phase

angle, phase rotation and burden amperes

- Directional checks of power recorders and energy meters.

(3) Outdoor Marshalling Kiosks and Cubicles

a) Measurement of insulation resistance (Megger tests)

b) Verification of AC & DC auxiliary supply magnitude and

polarity/phasing.

c) Verification of grounding connections.

d) Verification of calibration of adjustable devices such as timers

e) Verification of MCBs operation at settings of thermal/magnetic

releases.

f) Functional tests to verify alarms, indications, annunciations.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

g) Functional tests of humidity control, ventilation, internal

illumination.

25.03.09 Protection Boards

a) Measurement of insulation resistance (Megger tests)

b) Verification of AC & DC auxiliary supply magnitude and

polarity/phasing.

c) Verification of grounding connections.

d) General tests on each protective device including contactors, timers,

auxiliary relays etc. as per the manufacturers' recommended
procedures and tests protocols.

e) Verification of protective devices' calibration at the final settings.

f) Verification of protective devices' characteristics.

g) Verification of MCBs operation at settings of thermal/magnetic

releases

h) Functional tests of protective devices including operation of power

swing blocking relays, autoreclosers etc.

i) Functional tests of protection tele-signalling.

j) Functional tests of complete protection schemes.

k) Functional tests of indications, alarms, annunciations.

l) Functional tests of panels'/cubicles' humidity control, ventilation,

internal illumination.

m) On-load tests:

- Verification of current circuits

- Verification of voltage circuits

- Directional tests

- Tests of differential protections by de-stabilizing the current

circuits.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

25.03.10 Telecommunication and SCADA Equipment

Site Tests shall be performed comprising, as a minimum, the following:

(1) Power Line Carrier System

a) Installation checks.
b) Wiring, termination and earthing checks in accordance with
interconnection drawings.
c) Return loss measurement for each PLC link.
d) Line attenuation measurement for each PLC link.
e) Functional tests on end to end DPLC/DPSE terminals. The tests
shall be determined from the Factory Test Procedures.
f) Setting of system functions i.e. AF signal levels, equalization etc.
g) Interfacing to RTU, PAX, Power supply etc.
h) Local and functional tests in conjunction with protection system.
i) Functional tests of command transmit and receive counters.
j) Verification of remote tripping of circuit breakers with direct
transfer trip commands.

(2) Fiber Optic System

a) Installation checks.
b) Wiring, termination and earthing checks in accordance with
interconnection drawings.
c) Functional tests, on link basis, for which test procedure shall be
determined from the Factory Test schedule.
d) Checking the system function such as BER, AF signal levels on all
possible routes, etc.
e) Verification of power budget calculations.
f) 1+1 equipment redundancy tests.
g) Switching time and path protection tests.
(3) Data Communication links

a) Installation checks.
b) Functional tests, on end to end basis, to determine the quality of
each data link between Moro and NPCC.

(4) Telephone (PAX) System

a) Installation checks.
b) Wiring, termination and earthing checks.

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Section -25: Erection, Testing and Commissioning Technical Specifications

c) Check all connections with the external MDF.

d) Functional tests of trunks and extensions.
e) Check of all types of tones in the system.
f) Check of BER (in case of 2 Mbit/s trunks), AF signal levels, etc.
g) Verification of trunk routes (direct & alternative).
h) Testing of all software features and facilities (local and network).
Proper working of network facilities (priority cut-in, forced release,
section dialling…) over analogue and digital trunks shall be
successfully demonstrated.
i) Tests of system reloading and resetting capabilities in the event of
occurrence of various categories of faults.
j) Tests to ensure correct receipt and logging of alarms and correct
functioning of automatic diagnostic routines

(5) 48V DC Power System

a) Installation checks.
b) Functional tests and settings on the 48V battery chargers to
demonstrate that they maintain their float and boost characteristics
within the power supply variations and meet the requirements of the
specifications.
c) Capacity test on the batteries at a discharge rate to be approved by
the Engineer.

(6) SCADA System

a) Installation checks.
b) Wiring, earthing and termination checks.
c) Local testing of each teleinformation point between RTU and
Process.
d) Test of each teleinformation point between RTU and SCADA/EMS
at NPCC.
e) End to end test of each teleinformation point between the Process
and SCADA/EMS (point to point test).

(7) Station Direct Wire Telephone System

a) Installation checks.
b) Wiring, earthing and termination checks.
c) Functional tests, to check the voice communication between
subscribers and control room operator and between the subscribers.

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(8) Public Address System

a) Installation checks.
b) Wiring, earthing and termination checks.
c) Functional tests, to check the voice communication between loud
speaker locations and the control room operator.

(9) Test Equipment

The Contractor shall arrange the test equipment for the above tests and shall
ensure that the test equipment is calibrated and suitable for these tests. List
of test equipment and calibration certificate for each instrument valid for at
least one year shall be provided with the SAT test books.

25.03.11 Control and Power Cables

(1) MV Cables

a) Verification of insulation resistance (Megger test):

- Core-Ground/Shield/Armour

- Core-Core

b) Verification of core(s) continuity.

c) High voltage/Dielectric tests.

d) Verification of shield continuity and grounding.

e) Verification of armour continuity and grounding.

f) Verification of tightness of connections.

(2) LV Cables

a) Verification of insulation resistance (Megger test):-core-core, core-

ground/shield

b) Verification of core(s) continuity

c) Verification of shield/armour continuity.

d) Verification of shield/armour grounding

e) Dielectric tests: - 2000V ac, one minute

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 Section -25: Erection, Testing and Commissioning Technical Specifications

f) Verification of tightness of connections.

25.03.12 Grounding and Lightning System

(1) Grounding System

a) Visual verification of each grounding connection

b) Verification of tightness of grounding connections as per

recommended torque.

c) Verification of effectiveness of substation grounding system by an

appropriate method commensurate with installations involving large
mesh.

d) Continuity tests of each grounding connection

e) Ground grid integrity test

f) Measurement of grounding resistance with earth resistance tester:

- Each neutral connection of shunt reactor

- Each surge arrester connection

- Buildings grounding

- Panels and equipment inside the buildings

(2) Outdoor and Indoor Lighting System

a) Measurement of insulation resistance (Megger tests)

b) Verification of AC & DC auxiliary/power supply magnitude and

polarity/phasing.

c) Verification of grounding connections.

d) Verification of MCBs operation at settings of thermal/magnetic

releases.

e) Verification of automatic and manual switching.

f) Measurement of circuit loading.

g) Verification of illumination levels.

h) Functional tests to verify alarms, indications, annunciations.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

i) Functional tests of humidity control, ventilation, internal

illumination.

(3) Outdoor and Indoor Power Sockets

a) Measurement of insulation resistance (Megger tests)

b) Verification of grounding connections.

c) Verification of MCBs operation at settings of thermal/magnetic

releases.

d) Check of voltage magnitude and phase rotation for each three phase
power socket.

e) Check of voltage magnitude and correct phase connection for

balanced load for single phase sockets.

f) Functional tests to verify alarms, indications, annunciations.

25.03.13 AC and DC Auxiliary Supplies

(1) DC Distribution Boards

Following tests shall be performed on MCBs in the DC distribution

boards:

a) Verification of breakers'/MCBs' operation at settings of

thermal/magnetic releases

b) On-load tests:-Measurement of loading of each circuit.

(2) AC Distribution Boards

Following tests shall be performed on MCBs in the AC distribution

boards:

a) Verification of voltage and phasing up to each outgoing

breaker/mcb

b) Verification of breakers'/MCBs' operation at settings of

thermal/magnetic releases

c) On-load tests: - Measurement of loading of each circuit

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 Section -25: Erection, Testing and Commissioning Technical Specifications

25.03.14 Temperature inside Panels, Cubicles, Marshalling Kiosks

Recording of temperatures inside the panels, cubicles and marshalling

kiosks:

- Temperature to be measured after panels, cubicles, marshalling

kiosks have been energized with ac and dc supplies and all devices
mounted therein have been in service for sufficient time.

- Ambient temperatures i.e. room temperature for indoor equipment,

yard temperature for outdoor equipment to be recorded.

25.03.15 Coordinated Functional Tests Of Control, Protection, Metering And

Monitoring Systems

Functional tests shall be carried out to verify coordinated functioning of the

control, protection, metering and monitoring systems.

25.03.16 Emergency Diesel Generating Set

(1) General: The set furnished by the Contractor under this Contract
shall be subject to tests in the shop and at site in the presence of the
Engineer for conformity to requirements of the Specifications. All
tests shall be conducted in accordance with the appropriate codes
for testing.

The diesel engine and AC generator shall be test-run continuously

for 24 hours to ensure smooth running and satisfactory operation of
the machines and accessories. Tests on the unit shall not be less than
the minimum requirements of ISO standard Practices for equipment.

(2) Generator: the following tests on the generator shall be performed

during commissioning.

a) Resistance of armature and field windings.

b) Polarity of field coils.

c) Check of mechanical balance

d) Check of no-load field current or exciter field current.

e) Voltage balance.

f) Phase sequence.

g) No-load saturation curve.

h) Insulation and high potential tests.

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 Section -25: Erection, Testing and Commissioning Technical Specifications

i) Over speed test at 125% speed for 1 minute.

(3) Performance Tests: At the conclusion of installation of the

Emergency Diesel Generating Set at site, commissioning tests shall
be carried out by the Contractor/Manufacturer to demonstrate the
satisfactory operation of the equipment and to verify the guaranteed
performance figures of the diesel unit. The tests shall comprise:

1. Preliminary tests on individual components.

2. Continuous one-hour heat run at 50 percent load rating in

parallel with the system.

3. Continuous one-hour heat run at 75 percent load rating in

parallel with the system.

4. Continuous four-hour heat run at 100 percent load rating in

parallel with the system.

5. Part load heat runs to demonstrate satisfactory operation and

establish fuel consumption at the respective loads.

6. The tests shall also include:

a) Performance of Governing characteristics and

protective systems.

b) Starting characteristics of the units. The units shall start

at least five (5) times in six (6) consecutive starting
attempts.

c) Starting power requirements to demonstrate the ability

of the machine to start the specified number of times
without need to recharge the batteries.

25.03.17 Miscellaneous

a) Performance of additional tests to verify characteristic(s) and

functions peculiar to the design of an equipment or system device
installed at the substation/utilized in the protection, control,
metering and monitoring systems shall be assessed at the detailed
engineering and implementation stages.

b) Visual inspections of equipment and devices shall be carried out in

respect of damage, labeling, alignment, dust proofing, sealing
against vermin etc.

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Section -25: Erection, Testing and Commissioning Technical Specifications

c) Humidity and vibration recording devices are fitted to the

equipment and systems for monitoring during transportation.
Recordings of these devices shall be inspected upon
arrival/installation at the site. Copies of the recordings shall be
made part of the site test books.

d) High voltage tests shall be performed on the equipment in

accordance with the standards.

e) Applicable tests and verifications mentioned in the above sections

and sub-sections shall be applicable to all the equipment and
systems not specifically mentioned herein above but may be
installed at the substations.

f) The functional testing of fire protection system shall be carried out

on one transformer by means of external input to pressure and
temperature/fire sensors.

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