INSPECTION / TESTING PROCEDURES

1. VISUAL AND MECHANICAL INSPECTION

. Visual inspection of the panel and components shall be carried out in

accordance with the Visual Check list form.
. Confirm if all hardware is per manufacturer’s specification and
Documentation Record any missing items.
. Compare the equipment nameplate in accordance with approved design
drawings.
. Check if all transport and shipping devices were removed.
. Check for correct MCB rating per section.
. Grounding of panel shall be done in accordance with grounding plan.
. All power, control and instrument cables shall be securely supported to
terminal strips, marked and numbered.
. Permanent identification wire numbers shall correspond to approved
Schematic / wiring diagram.
. Inspect the equipment for visual damage, scratches.
. Inspect for proper alignment fixing and grounding.
. Check Tightness of all accessible bolts per manufacturer’s
recommendations.
. Check CT’s are connected for Correct Ratios and are not shorted.
. Check PT’s for Correct Ratios and connections
. Check CPT for Correct Ratios and connections
. Check all metering and devices as per approved drawing.
. All doors/covers for panels shall be inspected for paint, dents,
scratches and fitted.
. All observations and readings shall be recorded on approved form.

2. ELECTRICAL TEST OF METRING AND COMPONENTS :

2.1 Voltmeter

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 . Check zero indication of instrument for no supply of transducer.
. Voltmeter will be checked, by applying dc current equal to 50%, 75%
and 100% of rated voltage directly on voltmeter terminals.
. All readings are to be recorded on the form # …

2.2 Ammeter
. Check zero indication of instrument for no supply of transducer.
. Ammeter will be checked by applying dc current, equal to 50%, 75%
and 100% of rated current directly on ammeter terminals.
. All readings are to be recorded on the test form.

2.3 Watt-meter
. Check zero indication of instrument for no supply of transducer.
. Watt-meter will be checked by applying dc current, equal to 50%,
75% and 100% of rated active power directly on wattmeter terminals.
. All readings are to be recorded on the test form.

2.4 Var-meter
. Check zero indication of instrument for no supply of transducer.
. Var-meter will be checked by applying dc current, equal to 50%,
75% and 100% of rated reactive power directly on var-meter terminals.
. All readings are to be recorded on the test form.

2.5 Energy Meter

. Check Energy meter, by applying nominal secondary value of
voltage and current.
. Phase sequence and angle between current and voltage, should be
checked as well. Check reading after time 10’.
. Check for reverse flow of energy.
. All readings are to be recorded on the test form.

2.6 Auxillary Relay

. Check operation of relay at 85% to 100% Un
. Check function of contact Open/Close
. All readings are to be recorded on the test form.

2.7 Check of Auxiliaries

. Check the auxiliary supply in accordance with design drawing, Check
logic control, signaling etc. in accordance approved design drawings.
. All readings are to be recorded on the test form.

2.8 Transducers Testing :

. All Transducer to be tested as per design.

. Before testing Check range, constants, auxiliary supply, proper way of
indication is as per design.
. Testing to be performed by secondary current and voltage injection on terminals.

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 . Checked Transducers by injecting 25, 50, 75 & 100 % of rated primary
values and compare secondary calculated –measured values.
. Metering to be tested according to the approved Test Form.
. Test result and all observation to be written in test Report.

a. Voltage Transducer
. Check for full scale value.
. Check for ½ scale & 60% of nominal value.
. All readings are to be recorded on the test form.

b. Current Transducer
. Check zero indication of instrument for no supply of transducer.
. CT’s / meter will be checked by applying current, equal to 25%,
50%, 75% and 100% of rated current.
. All readings are to be recorded on the test form.

c. Watt-Transducer
. Check zero indication of instrument for no supply of transducer.
. Watt-meter will be checked by applying dc current, equal to 50%,
75% and 100% of rated active power directly on wattmeter terminals.
. All readings are to be recorded on the test form.

d. Var Transducer
. Check zero indication of instrument for no supply of transducer.
. Watt-meter will be checked by applying dc current, equal to 50%,
75% and 100% of rated active power directly on wattmeter terminals.
. All readings are to be recorded on the test form.

3. TESTING OF PROTECTION RELAYS

3.1 Feeder Protection Relay (50/51, 50N/51N) :

. Feeder Protection Relay is tested with secondary injection set with

electronic meter.
. Ensure that the CT incoming on the Test Plug MMB01 is shorted before
inserting.

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 . Isolate the Relay Current Measuring Elements & Trip/.Alarm contacts by
inserting the Test Block MMB01.
. Connect correct polarity/rating of DC Voltage through Test Plug MMB01
to Relay. Ready “LED indicator” Should be illuminated.
. Connect the Relay to computer through Front RS232 Port or use the MM1
(Man Machine interface).
. Ensure Curve selection as required.
. Disable the instantaneous element and enable the time delayed element of
the Relay.
. Set the value and check start value for O/C protection.
. Inject single phase current into a convenient phase circuit and slowly
increase the current until the Pick-up LED lights.
. Connect the Relay time delayed output contacts to both trip the test set and
stop a timer.
. Set appropriate time setting.
. Inject single phase current into pole under test at a current level of “n” x
rated current (where “n” being the multiple of current setting of the Relay.
. Check operating time for the Relay.
. Inject single phase current into the pole under test at different current
levels.
. For instantaneous element operation, enable the instantaneous element of
the Relay.
. Adjust current setting for instantaneous element and connect instantaneous
trip output contact to trip the test set.
. Time delay element is set to operate in 4 s. The current level should be set,
and then suddenly applied. Test is done for each pole of Relay.

All readings are to be recorded on the test form.

3.2 A AC Under Voltage Relay (27) :

. AC Under voltage relay is tested with secondary Voltage test set with
electronic relay test set.
. Isolate the Relay Voltage Measuring Elements & Trip/Alarm contact by
inserting the Test Block MMLB01. If the test block available on the metering.
. Connect correct polarity/rating of DC Voltage through Test Plug
MMLB01 to Relay. Press the “Target Reset” button and check that all
target LED lights up.
. Set the time for instantaneous mode (all switches to the left).
. Set the Under voltage trip level on the relay.
. Apply 3-phase AC Voltage on phase A (terminals A1-B1), phase B

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 (terminals A2-B2) and phase C (terminals A3-B3) and slowly vary the
AC voltage and check that the relay trips within ±5% of voltage setting.
. Set the Under Voltage trip level on the relay to the minimum.
. Apply a voltage lower than the trip level on phase A (terminals A1-B1),
phase B (terminals A2-B2) and phase C (terminals A3-B3).
. Check that the time measured is less than 50ms.
. Set the time delay element of the Relay for time delayed Trip.
. Set the Under voltage trip level on the relay.
. Apply a voltage lower than the trip level on phase A (terminal A1-B1).
Phase B ( terminal A2-B2) and phase C (terminals A3-B3)
. Check that the time measured is within ± 5% or 30ms (which ever is
greater) than the expected value.

All readings are to be recorded on the test form.

3.2-B DC Under-Voltage Relay (27).

. Before testing technical data of devices to be checked.

. Testing to be performed by voltage injection on coil.
. Connect DC variable voltage to the coil and increase voltage until
relay close and decrease voltage until relay open. Note this
voltage. . Check operational of relay indicator or aux. contact for
Closed and Open.
. Repeat to apply DC voltage at the supply terminals. Check for pick-up
and drop-out values
. All readings are to be recorded on the test form.

3.3 RESTRICTED EARTH FAULT RELAY (87N) :

. Restricted Earth Fault Relay is tested with secondary injection test set with
electronic meter.
. Isolate the Relay current Measuring Element & Trip Alarm contact by
inserting the Test Block MMB01.
. Set the seal in coil rating to 0.2 A dc.
. Set the trip level value to 0.2 A.
. Connect the Relay trip output contacts (terminal # 1 & 2) to both trip the
test set, and stop a timer.
. Inject single phase current into current element (terminal # 5 & 6) &
slowly increase the current until the 0.2A is reached.
. Checked that the output contacts closed and right side flag (on the relay
front operated).

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 . Inject 5 times the current setting i.e. 1A, in the relay and note that the
timing is < 50ms.
. Connect the Relay Trip output contacts (terminals # 1 & 2) to REF-
Lockout Relay circuit (86-coil with series cut-off contact) and the
output of Lockout contact to both trip the test set, and stop a timer,
(refer schematic diagram)
. Apply 125VDC to lockout relay circuit.
. Inject single phase current into current element (terminal # 5 & 6) &
slowly increase the current until the 02.A is reached.
. Checked that the ouput contacts (terminal # 1 & 2) closed and both Flags
(left “Trip” flag and right” Seal in flag”) operated plus the operation of
lockout relay.

All readings are to be recorded on the test form.

3.4 Neutral Over-Current Relay (50n / 51N) :

. Neutral Over-Current relay is tested with secondary injection set with

electronic meter.
. Ensure that the CT incoming on the Test Plug MMLB01 is shorted before
inserting.
. Isolate the Relay Current Measuring Element & Trip /Alarm contacts by
inserting the Test Block MMLB01.
. Connect correct polarity (rating of DC Voltage through Test Plug MMLB01
to Relay. Ready “LED indicator” Should be illuminated. Press the “Target
Reset” button and check that all target LEDs light up.
. Ensure Curve selection as required.
. Disable the instantaneous element and enable the time delayed element of
the Relay.
. Set the value and check start value for O/C protection.
. Inject single phase current into the current element (terminal # B9 & B10)
and slowly increase the current until the Pick-up LED lights.

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. Connect the Relay time delayed output contacts (terminals # A3 & A6) to
both trip the test set, and stop a timer.
. Set appropriate time setting.
. Inject single phase current at a current level of “n” X rated current ( where
“n” being the multiple of current setting of the Relay.
. Check operating time for the Relay.
. Inject single phase current at different current levels/curve selection &
measure the operating times.
. For instantaneous element operation, enable the instantaneous element of
rhe Relay.
. Adjust current setting for instantaneous element and connect instantaneous
trip output contact (terminal # A3-A8) to trip the test set.
. Time delay element is set to operate in 4s. The current level should be set,
and then suddenly applied.

All readings are to be recorded on the test form.

=======================================================

3.5 TRIP CIRCUIT SUPERVISION RELAY (97)

. Trip circuit supervision relay is tested with variable DC power supply,

Variable Resistance, one Push button with set of NO + NC contacts and
Electronic Timer.
. Connect correct polarity/rating of DC Voltage to Relay (terminal # B9 &
B10). Press the “Target Reset” button and check that all target LEDs
lights up.
. UNDER VOLTAGE TEST
. Connect Variable DC power supply to Relay Breaker Voltage inputs:
teminal B1 (+ve) & B2 (-ve).
. Set the time to minimum in order to ease the test.
. Short all the Relay Trip coil monitoring inputs.
. Apply different Voltages and check that the undervoltage LED flashes
pick –up) with voltage (see table below). The LED remains
flashing, until the undervoltage condition disappears (drop out voltage).
When the drop-out voltage is reached, and the set time elapses, the LED
stop flashing and is lit permanently (fault memory function).

VOLTAGE PICK-UP VOLTAGE DROP-OUT VOLTAGE

SETTING (VOLTAGE FAILURE) (VOLTAGEOK)
50V 45V 55V

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 55V 50V 60V
60V 55V 65V
70V 65V 75V
90V 85V 95V
125V 118V 133V

. TIME DELAY TEST

. Connect 125VDC supply to Relay Breaker Voltage inputs: terminal B1
(+ve) & B2 (-ve).
. Connect the Push button NC contacts to Relay Trip coil # 1 monitoring input
(terminal # B3) & Breaker Voltage input (terminal # B2).
. Connect the Breaker circuit OK “NO” output contacts to stop the timer.
. Set the Time Delay according to the table given below: and check that the
results in the table are complied with. Repeat the test using coil # 2 &
31/P’s.

TIME DELAY MINIMUM MAXIMUM DROP-OUT TIME

SETTING OPERATING TIME OPERATING TIME (OUTPUT RELAY)
200ms 200ms 240ms
400ms 400ms 440ms
600ms 600ms 640ms
1s 1s 1.04 s 100 – 150ms

3.6 Relay MF - Restricted Earth Fault Protection (64)

Procedure #

. Before testing, relay technical data and set voltage value to be

checked.
. Relay connection to be checked according to approved technical
design. Particular attention should be paid to the correct wiring
and value of any external resistors indicated on the wiring
diagram/relay rating information.
. With the relay removed its case, check electrically that the CT
shorting switch is closed.
. Relay operating voltage to be tested by injection voltage by test plug.
Increase the voltage until the relay just operates. Noted
operating voltage which should correspond to the setting VR of
the relay with a tolerance of ± 10%. Note the current in the
relay, it should be approximately 38mA at setting. Note
Drop off/Pick-up ratio, should be greater than 50%.
. Stability test of the relay to be performed by secondary current
injection.

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 . Stability test to be performed for two cases: in protected zone and out
of protected zone.
. Operation of the relay trip contacts and indicators to be checked.
. Test result and all observation to be written in test Report.

======================================================

3.7 Relay 7PA 3030 or Similar -Trip Coil Supervision Relay (94)
Procedure #
. Pick-Up and Drop-Off voltage to be checked for all TCS relay.
. Before testing technical data of devices to be checked.
. Testing to be performed by voltage injection on coil terminals.
. Function check by simulation with nominal voltage of trip circuits.
. Connect DC Variable voltage to tripping relay coil and increase
voltage until relay trips. Note this voltage.
. Switch OFF the voltage.
. Connect the NO contact of the Tripping relay to stop the timer.
. Again apply the voltage and note the time of operation.
. Test result and all observation to be written in Test Report.

3.8 Trip & lockout Relay (86)

Procedure #
. Pick-Up and Drop-Off voltage to be checked for all Lockout relays.
. Before testing technical data of devices to be checked.
. Testing to be performed by voltage injection on coil terminals.
Connect DC variable voltage to trip coil and increase voltage
until relay trip. Note this voltage. Check operational of flag indicator
and reset the lockout relay.
. Switch OFF the voltage and reset the lockout relay.
. Connect the NO contact of Lockout relay to stop the timer.
. Again apply the voltage and note the time of operation.
. Operating time to be tested with the timer for rated voltage of coil.
. Check operation of flag indicator and reset the trip lockout of relay.
. Function check by simulation operation of all protection as per
approved drawing.
. Test result and all observation to be written in Test Report.

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 3.9 SYNCHRO-CHECK RELAY:
. Synchro-Check Relay is tested with 2-independent secondary Voltage
test set or a variable autotransformer in order to be able to
change the bus voltage when so desired.
. Isolate the Relay Voltage Measuring Elements & output contacts by
inserting the Test Block MMLB01.
. Connect correct polarity/rating of DC Voltage through Test Plug
MMLB01 to Relay.
. Set the rated frequency according the rated value.

SYNCHRONISM UNIT TEST:

. Activate the synchronism unit (4-1 setting ) ON.
. Deactivate the undervoltage unit (setting 4-2,4-3 & 4-4 to OFF.
. Due to the complexity of the necessary equipment, it is not
recommended to carry out the frequency difference test. To
check that the measurement is correct, The slip on the READOUT
menu (F5) is visualized by applying a voltage greater than 10V to the
line & buses. The readout should be 0mHz.
. Set the voltage difference setting to 15V.
. Apply continuous DC voltage to input 52/b (terminal # A5 (+) & B5 (-),
to simulating open circuit breaker.
. Apply AC voltage to Line voltage input (A1 & A2) and bus voltage
input (A3 & B3) With a difference less than 15V and voltage
level not greater than 220VAC.
. Check that the close enable contacts (A6-B6 & A7-B7) are closed and
red LED lit up.
. Reduce the voltage in bus until the relay drops, check that the
difference is greater than 15V.

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 . Repeat the test by changing the difference in voltage levels.

PHASE ANGLE UNIT TEST:

. Activate the synchronism unit (4-1 setting) ON.

. Deactivate the undervoltage unit (settings 4-2, 4-3 & 4-4 to OFF.
. Set the Phase angle difference to 15º
. Apply continuous DC voltage to input 52/b (terminal # A5 (+) & B5(-),
to simulating open circuit breaker.
. Apply 127VAC to the Line voltage input (A1 & A2) and bus voltage
input (A3 & B3), both in phase.
. Check that the close enable contacts (A6-B6 & A7-B7) are closed and
red LED lit up.
. Lag the bus voltage until the relay drops. This drop should clearly
occur at 17º greater than the set 15º.
. (When two independent supplies are not available the test is done by
reversing the polarity of the bus voltage, which means lagging
it to 180º , and in which case the relay will not close the close
enable contacts).

UNDERVOLTAGE UNIT TEST

. Deactivate the synchronism unit (4-1 setting) OFF.

. Deactivate the undervoltage unit (settings 4-3 & 4-4) to OFF.
. Activate the undervoltage unit (settings 4-2) to ON.
. Set the Undervoltage supervision threshold to 127V.
. Set the Live Line voltage level to 200VAC.
. Set the Dead Line voltage level to 100ACV.
. Set the Live Bus voltage level to 200VAC.
. Set the Dead Bus voltage level to 100VAC.
. Apply continuous DC voltage to input 52/b (terminal # A5 (+) & B5 (-)},
to simulating open circuit breaker.
. Apply 127VAC to the Line voltage input (A1 & A2) and bus voltage input
(A3 & B3).
. The middle segments corresponding to the line and bars will lit up on the relay
screen when the relay is in readout in the idle position.
. Check that the close enable contacts are not closed.
. Reduce the voltage to 73.3V on both Line & Bus.
. Check that the lower segments on the screen will lit up. The relay output close
Enable contacts should operate and the red LED 52 (close Enable) and 27
(undervoltage) lit up.
. (If there is no variable power supply available, the test can be done by
applying and removing a known volt).

MANUAL MODE TESTS

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 . Activate the synchronism unit (4-1 setting) ON.
. Deactivate the undervoltage unit (setting 4-2, 4-3 & 4-4 to OFF.
. Set the manual mode delay to 10s.
. Set the Live Line voltage level to 100VAC.
. Set the Live Bus voltage level to 100VAC.
. Apply continuous voltage to inputs MANUAL (B4-B5), ENABLE (A4-B5)
& 52b (A5-B5).
. Apply 127VAC in parallel to both Line & Bus Voltage element inputs.
. Check that after approximately 10s are passed (plus some delay with the
measurement units and the output relays, less than 80ms in any case ) the
relay should operate.
. Remove the voltage to input 52b (simulates closure of circuit breaker). The
relay should drop.

CONTINOUS MODE TESTS

. Activate the synchronism unit (4-1 setting) ON.

. Deactivate the undervoltage unit (settings 4-2, 4-3 & 4-4 to OFF.
. Set the continuous mode delay to 0.1s.
. Set the Live Line voltage level to 100VAC.
. Set the Live Bus voltage level to 100VAC.
. Apply continuous voltage to input 52b (A5-B5).
. Apply 127VAC in parallel to both Line & Bus Voltage element inputs.
. Check that after approximately 100ms are passed (plus some delay with the
measurement units and the output relays, less than 80ms in any case) the relay
should operate.
. Remove the voltage to input 52b (simulates closure of circuit breaker). The
relay should drop.

All readings are to be recorded on the test form.

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 3.10 Control Wiring Isolation Test
Procedure
. Check the relays / components operating coils, Digital inputs /
Outputs, Tripping / Alarm contacts, Measuring Inputs, Device
Ground terminals etc. are isolated / Disconnected from the
circuit, for the 500 VDC insulation test, as recommended by the
Relay / Component manufacturer depending upon the equipment
sensitivity to withstand such tests.
. Check and confirm that each and every control wire is included in the
circuit under test.
. Confirm that all the control supplies to the circuit are disconnected and
there is no potential in the circuit under test.
. Apply 500VDC in the circuit under test against grounding bus-bar of
the panel.
. Repeat the same test for all internal wiring.
. Record all results in approved test form.

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