SUBSTATION PRODUCT TESTING AND INSPECTION

TABLE OF CONTENTS

1.0 GENERAL REQUIREMENTS .................................................................................................. 2

2.0 SUB-CONTRACTORS............................................................................................................. 2
3.0 EQUIPMENT ACCEPTANCE TEST........................................................................................ 3
3.1 GENERAL ................................................................................................................................ 3
3.2 TYPE TESTS............................................................................................................................ 3
3.2.1 Validity of Type-test Certificates and/or Reports................................................................ 4
3.2.2 Costs of Type Test and Witnessing...................................................................................... 4
3.2.3 Notice of Type Test ................................................................................................................ 4
3.2.4 Testing Venue ......................................................................................................................... 4
3.2.5 Additional Witnessing............................................................................................................ 5
3.2.6 Certificates and Reports ........................................................................................................ 5
3.2.7 Type-Test Schedule................................................................................................................ 5
3.2.8 Mandatory IEC/BS/other standards type-tests and Additional Tests ............................... 8
3.2.8.1 500kV, 275kV and 132kV Circuit-Breakers........................................................................... 8
3.2.8.2 500kV, 275kV and 132kV Disconnectors and Earth Switches ........................................... 9
3.2.8.3 500kV, 275kV and 132kV Current Transformers ................................................................. 9
3.2.8.4 500kV, 275kV and 132kV Voltage Transformers ............................................................... 10
3.2.8.5 500kV, 275kV and 132kV Surge Arresters.......................................................................... 10
3.2.8.6 275kV and 132kV GIS Equipment ....................................................................................... 11
3.2.8.7 275kV and 132kV Capacitor bank ....................................................................................... 11
3.2.8.8 275kV and 132kV Damping Reactor ................................................................................... 12
3.2.8.9 132kV XLPE Cable and Accessories .................................................................................. 12
3.2.8.10 33kV and 11kV XLPE Cable and Accessories ................................................................... 12
3.2.8.11 33kV, 22kV and 11kV Switchgear........................................................................................ 12
3.2.8.12 33kV, 22kV and 11kV Neutral Earthing Resistor ............................................................... 13
3.2.8.13 33kV, 22kV and 11kV Neutral Disconnector ...................................................................... 13
3.2.8.14 Protective Relaying And Control Equipment..................................................................... 14
3.2.8.15 Telecontrol ............................................................................................................................ 15
3.2.8.16 Rigid Busbar ......................................................................................................................... 15
3.2.8.17 Stranded conductor ............................................................................................................. 15
3.2.8.18 Clamps and Connectors ...................................................................................................... 15
3.2.8.19 Insulators (Table format) .................................................................................................... 15
3.2.8.20 Bushing ................................................................................................................................. 15
3.2.8.21 Substation Earthing System and Joints Between Electrodes ......................................... 15
4.0 MATERIAL TESTS ................................................................................................................ 16
5.0 FACTORY INSPECTION / AUDIT ......................................................................................... 16
6.0 ROUTINE TESTS................................................................................................................... 16
7.0 TESTS AT SITE ..................................................................................................................... 18
8.0 COMMISSIONING PROCESS ............................................................................................... 19
9.0 EQUIPMENT TESTS.............................................................................................................. 19
10.0 TEST CERTIFICATE.............................................................................................................. 19
11.0 REJECTION OF PLANT ........................................................................................................ 19

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1.0 GENERAL REQUIREMENTS

The whole of the plant and equipment covered by this Contract will be subject to inspection
and test by the Engineer and the Employer’s inspecting agent during manufacture, erection
and on completion.

The approval of the Engineer of the results of any such inspection or test will not, however,
prejudice the right of the Employer to reject the plant if it does not comply with the
Specification or to give complete satisfaction in service.

Before any plant is packed or dispatched from the Main or Sub-Contractor' s works, all tests
called for shall have been successfully carried out in the presence of Employer representative
unless otherwise agreed. No Plant shall be dispatched without the expressed authority of the
Inspecting Engineer and the issuance of 'Release Certificates' .

Adequate notice shall be given when the plant is ready for inspection or tests and every
facility shall be provided by the Contractor and his Sub-Contractors to enable the Engineer to
carry out the necessary inspection and witnessing of tests.

The recorded results of all tests shall be verified by the Engineer or his representative and
triplicate copies be submitted to the Employer immediately after the tests for record purposes.
The same set of test results should be included in the Operation and Maintenance manual.

2.0 SUB-CONTRACTORS

Within two month of acceptance of the Tender, the Contractor shall forward to the Engineer, a
list of all sub-orders placed or intended. For the purpose of this Clause, interworks orders
shall be treated as sub-orders. The Engineer will select from his list those sub-orders that
require progress or inspection and so inform the Contractor. The Contractor shall then submit
three copies of all sub-orders as selected by the Engineer for progress or inspection together
with a copy of all drawings referred to in the sub-orders, unless otherwise agreed by the
Engineer.

The drawings and sub-orders submitted to the Engineer shall cover all components, which are
subject to electrical or mechanical pressure or stress when the plant is in operation and also
those items, which will be dispatched to Site direct from the Sub- Contractor’s works.

Sub-orders shall include a statement advising the Sub-Contractor that the items being ordered
will be subject to inspection and test by the Engineer and the Employer.

It is important that all copies of sub-orders are clearly marked with the name of the Contractor
and the following references:-

Employer’s Name:

Contract Number:

Sub-Contractors shall comply with all the requirements of this Specification and, in particular,
with this Section. Orders issued by the Sub-Contractor shall also include the Main
Contractor’s name and reference on their sub-order in addition to the above-mentioned
references.

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3.0 EQUIPMENT ACCEPTANCE TEST

3.1 GENERAL

Tests to be performed on all equipment shall be in accordance to the latest revision of

the relevant standard at the base date of tender.

Works tests shall include all routine electrical, mechanical and hydraulic tests in
accordance with the relevant IEC or British Standards except where departures
therefrom and the modifications there to are embodied in this Specification. For Plant
not covered by any IEC or British Standards nor specifically mentioned in this
Specification, such tests as are relevant shall be agreed with the Engineer.

Should the plant or any portion thereof fail under test to give the required performance,
further tests which are considered necessary by the Engineer shall be carried out by the
Contractor and the whole cost of the repeated tests shall be borne by the Contractor.
This also applies to tests carried out at the Sub- Contractor'
s works.

After satisfactory completion of the witnessed tests at the Works, the plant shall be
submitted for the Engineer’s approval during dismantling preparatory to shipping. No
item of plant shall be dispatched to Site until the Engineer has given his approval in
writing.

3.2 TYPE TESTS

One complete equipment of each type and rating being supplied shall be subject to
complete type tests as specified in the latest revision of the relevant IEC, British
Standards or other standards and to additional tests required by this Specification. The
notice and costs for tests, validity of certificates and/or reports, testing venue,
certification, reports, and witnessing criteria whichever relevant shall be in accordance
to the specification, in particular clauses 3.2 to 3.4.7 of this section.

All equipment offered SHALL HAVE SATISFACTORILY PASSED MANDATORY TYPE-

TESTS in accordance to the relevant IEC/BS/other standards. The Certificates of
Complete Type-Test and/or Reports of these tests shall be submitted together with the
bid. Non-compliance or failure to observe the requirements shall be subjected to
disqualification.

Type Test Certificate Of Complete Type Test is not required for equipment of the same
model and rating which has been installed in TNB system.
Where the type tests have been performed not on the exact equipment model and
rating offered, the applicability of the test report to the offered equipment shall be
verified by STL/STLA or Independent Accredited Laboratory.
Additional tests are those other than the mandatory IEC/BS/other requirements,
including tests classified as Special Test or Additional Test or Mandatory Test where
applicable as stated in the standards and TNB specified type tests. For these tests, if
the type tests certificates and/or reports are not submitted with the bid, the tests shall
be performed and the Certificates and/or reports furnished subsequent to tender
award in accordance to the specification, in particular clauses TYPE TEST
SCHEDULE of this section.
For tests performed subsequent to tender award, should the plant or any portion
thereof fail under test to give the required performance, subject to the Engineer’s
approval, the Contractor after due modification and rectification may perform only
ONE re-test. In the event the re-test fails, subject to the Engineer’s approval, the
Contractor shall propose and supply a different make of equipment that complies to
the specification. Due to the rectification and/or modification, further tests which are
considered necessary by the relevant STLA signatory shall also be carried out by the
Contractor and the whole of the costs of the re-test shall be borne by the Contractor.

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 Tenderers are required to complete the details of type tests in Schedule F - Type Test
Requirements.

The recorded results of all type tests shall be verified by the Engineer or his
representative and triplicate copies be submitted to the Employer immediately after
the tests for record purposes. The same set of test results should be included in the
Operation and Maintenance manual.

3.2.1 Validity of Type-test Certificates and/or Reports

The type test certificates and/or reports submitted, unless otherwise specified,
shall be in accordance to clause Certificates and Reports of this specification, and
of the same type and rating as the equipment offered in the bid.
The Certificate and/or Reports are valid for the date of test and must be valid at
the closing date of the tender. The Certificate and/or Reports will remain valid as
long as there is no significant change in the design as allowed by the standard or
as declared or deviation found during the implementation of this Contract.

3.2.2 Costs of Type Test and Witnessing

The costs of all Type Tests, Special Test or Additional Test or Mandatory Test
where applicable as stated in the standards and TNB specified type tests,
certificates, reports and verification process as required by the specification as
well as the travel and accommodation expenses of all TNB engineers witnessing
the test shall be borne by the Contractor and shall be deemed to be included in the
Contract Price. The air travel shall be by Business Class. The hotel
accommodation shall have business centre and, unless otherwise approved, rated
4 star minimum.

3.2.3 Notice of Type Test

TNB requires at least 35 days written notice for the witnessing of the type and/or
additional tests.

3.2.4 Testing Venue

The short circuit tests shall be performed at any one of the accredited STL member
laboratories such as those accredited by ASTA, CESI, ESEF, KEMA, PEHLA, SATS,
STLNA, CPRI and JISC.

a) Equipment other then Power Transformers, Earthing Transformers and Oil

Immersed Reactors

All tests other then short circuit test may be performed at any one of the
accredited STL member laboratories as stipulated above or at any Independent
Accredited Laboratory or at manufacturers work. Tests performed at
manufacturer’s work shall be witnessed by a representative of STL member
laboratory or an Independent Accredited Laboratory.

The Certificate and/or Report shall be produced or sanctioned by the witnessing

Laboratory. The test procedure, including passing or failure criteria, shall be in
accordance with the requirements of the equipment specification.

b) Power Transformers, Earthing Transformers and Oil Immersed Reactors

All tests other then short circuit test may be performed at manufacturers work.
The tests shall be witnessed by a representative of the STL member laboratory
and the Certificate and/or Report produced or sanctioned by the STL member

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 laboratory. The test procedure, including passing or failure criteria, shall be in
accordance with the requirements of the equipment specification.

3.2.5 Additional Witnessing

In addition to Clause 3.2.4, all Type Tests and/or Special Test or Additional Test or
Mandatory Test where applicable as stated in the standards and TNB specified
type tests to be performed subsequent to Tender award shall also be witnessed by
the Employer particularly to ensure that the tests are carried out according to TNB
specifications and requirements.

At least a group of 2(two) TNB engineers or its representatives will witness the
whole type test. The group will be available for a duration of at most two weeks at
one venue. Should the test schedule requires more than a group due to extended
duration and/or multiple venues to witness the full tests, all related costs shall be
deemed to be included in the contract price.

3.2.6 Certificates and Reports

For the primary equipment listed in the Type Test Schedule, ‘certificate’ shall mean
‘Certificate of Short Circuit Test”. The certificate shall be STL Agreement (STLA)
certificate issued by any of the STL signatory bodies. It shall clearly indicate that
the values obtained and the general performance are considered to comply with the
design and test standards and to justify all the rated characteristics assigned by the
manufacturer. All certificates shall be accompanied with the relevant reports.

Type-test reports, unless otherwise specified, shall mean Type Test Report of
Complete Type Test or Type Test Report of Performance of the specific test
whichever relevant. Where required it shall also be issued by a STL signatory body
or Independent Accredited Laboratory. The front sheet of the report shall contain
information that states clearly the status of the test.

The certificate and/or report shall apply only to equipment of the same manufacturer,
country of manufacture, type designation, design, construction and rating as offered
in the bid.

3.2.7 Type-Test Schedule

The following Type Test Schedule describes the equipment for which Certificates
and/or Reports are required to be furnished together with the tender bid. For
equipment manufactured overseas, Certificates and/or Reports for Additional Tests
(abbreviated AT in the schedule) may be furnished after performance of the test
subsequent to tender award. The ‘standard number’ mentioned in the schedule are
the main standards applicable to the equipment. Standards referred to by them shall
be considered applicable.

Certificate or report
No. Equipment Description IEC/ BS/ other standard number
required
1. HV (132, 275 & 500kV) Circuit-Breaker IEC 62271-100 (Mandatory) Certificate

IEC 62271-100 (Mandatory , where Report

applicable)
TNB Additional Test Report
2. HV Disconnector IEC 62271-102 Certificate

IEC 61128 (AT) Report

IEC 61129 (AT) Report
TNB Additional Test Report

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 Certificate or report
No. Equipment Description IEC/ BS/ other standard number
required
3. HV Current Transformer (CT) IEC 60044 Certificate
IEC 60044 Additional Tests Report
TNB Additional Test Report
4. Neutral Current Transformer for Power IEC 60044 Certificate
Transformers

5. HV Voltage Transformer (VT) IEC 60044 & Certificate

IEC 60186
TNB Additional Test Report
6. HV Capacitive Voltage Transformer IEC 60044, 60186 & Certificate
IEC 60358
Additional Tests Report
7. MV Disconnectors (11, 22 & 33kV) IEC 62271-102 Certificate

8. HV Inductive Voltage Transformer IEC 60044 & 60044-2 Certificate

9. HV Reactor ANSI C57.16 Certificate

10. HV Capacitor Unit employed in a IEC 60871-1, IEC 60871-2 and BS Certificate
capacitor bank 1650
11. HV Fuse for capacitor ANSI C57.16 Certificate

12. HV Surge Arrester IEC 60099-4 Certificate

TNB Additional Test Report
13. Neutral Earthing Resistor (NER) IEEE 32 Certificate

14. Disconnectors for NER IEC 60129 & Report

IEC 62271-1

15. CTs for NER IEC 60044 Report

16. Outdoor Cubicles and Enclosures of IEC 529 Report

Operating Mechanism and
Auxiliary/Secondary Circuits of Primary
Equipment

17. HV & MV Post Insulator IEC 60168 Certificate

18. Disk Insulator IEC 60168 Certificate

19. Disk Insulator String IEC 383 & Report

BS 3288 – Part 1
20. HV & MV Bushings (including that in a IEC 60137 Certificate
GIS) IEC 60507, Artif. Pollution (AT) Report

21. HV Rigid Busbars NEMA (No. 107-1964 and CC1) Certificate

22. HV Stranded Wire Conductors NEMA (No. 107-1964 and CC1) Certificate

23. HV Clamps and Connectors NEMA (No. 107-1964 and CC1) Report

24. Cable Ladders and Trays Report

25. Earthing (Riser and Grid ) Conductors Report

26. Earthing Conductor Joints IEEE 837 Certificate

27. Earthing Conductor Clamps Report

28. Earthing Conductor Accessories Report

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 Certificate or report
No. Equipment Description IEC/ BS/ other standard number
required
29. MV (11, 22 & 33kV) Switchgears IEC 62271-200 Certificate
(630A, 1250A and 2000A current rating) IEC 62271-200
& 60270 Partial Discharge (AT) Report
IEC 60529 Index of Protection (AT) Report
IEC 60932 (Aging/ Humidity, AT) Report
IEC 298 Internal Fault (AT) Report
30. Circuit-Breaker in a MV switchgear of all IEC 62271-100 Certificate
current ratings

31. Earth-switch in a MV switchgear IEC 62271-100 & 62271-200 Certificate

32. Busbar in a MV switchgear Report

33. Busbar Insulation in a MV switchgear Report

34. CT in a MV switchgear IEC 60044 Report

35. VT or PT in a MV switchgear IEC 60044 & IEC 60186 Report

36. Busbar support insulators in a MV Report

switchgear

37. MV GIS IEC 62271-203 Certificate

IEC 62271-102 and (isolators & Certificate
Earthing switch)
IEC 62271-100 (Circuit Breaker) Certificate
38. HV GIS IEC 62271-203 Certificate
IEC 61233 reactive switching, AT Report
IEC 62271-102 (isolators & Certificate
Earthing Switch)
IEC 62271-100 (Cercuit Breaker) Certificate
IEC 60044 CT Certificate
IEC 60044 & 186 VT Certificate
IEC 60099-4 Surge Arrester ( if Certificate
applicable)
39. Spacer in HV GIS Differential Pressure Test Report
Ageing Test Report
40. SF6 gas in MV & HV equipment (including IEC 60376 Certificate
that in a GIS)

41. GIS bus-ducts IEC 62271-203 Certificate

42. MV Cable Joints & Terminations IEC 60502-4 Report and TNB
Distribution Product
Certificate
43. LV (240 or 415V) Power Cables IEC Report and TNB
Distribution Product
Certificate
44. Control Cables IEC Certificate

45. MV (11, 22 & 33kV) Power Cables IEC 60502-2 Report and TNB
Distribution Product
Certificate
46. HV (132, 275kV) XLPE Power Cables IEC 60840 Certificate

47. HV (132, 275kV) Oil-filled Power Cables IEC 60141-1 Certificate

48. Straight-Through and termination joints IEC 60840 Report

for HV (132, 275kV) power cables

49. Straight-Through and termination joints IEC 60141-1 Report

for HV (132, 275kV) Oil-filled Power
Cables

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 Certificate or report
No. Equipment Description IEC/ BS/ other standard number
required
50. Transition joints for XLPE to Oil-filled IEC 60141-1 Report
Power Cables IEC 60502-4
IEC 60840
51. Transmission Lines Hardwares Report

52. Steel Structures for equipment support Report

53. Gantry Towers Report

54. Protective Relaying And Control IEC 60255 Report

Equipment

55. NiCD battery IEC 60623 Manufacturer’s Type

Test Report
56. 415V LVAC Switchboard IEC 60439, IEC 60947 and Manufacturer’s Type
IEC 60529 Test Report

3.2.8 Mandatory IEC/BS/other standards type-tests and Additional Tests

The specified mandatory type tests for the various equipment are according to the
relevant clause of the standard. The Additional Tests for the various equipment
under this Specification are summarized below. The type tests certificate and/or
report for equipment not listed below (for example components of a circuit-breaker
such as pulling rod, gaskets, terminal blocks, etc.) are not required for the bid.
However, the relevant type-test certificates and/or reports, not necessarily by STL,
when required shall be furnished to the satisfaction of the Engineer.

3.2.8.1 500kV, 275kV and 132kV Circuit-Breakers

The type tests shall be performed in accordance with the mandatory

requirements of IEC 62271-100, 62271-1 and shall include the following tests:-

Mandatory Type Test Remarks

1 All tests Refer IEC 62271-100

Mandatory Type Test, Where Applicable

(A test other than Mandatory Type and Routine Tests specified by the standard )

1 Verification of the degree of Refer IEC 62271-100 & IEC Applicable for the cubicle
protection 60529 By accredited independent
tester, but need not be
STL/STLA.
2 Extended mechanical Refer IEC 62271-100, Applicable for Class C2, M2
endurance tests on circuit- Clause 6.101.2.4 circuit breaker for capacitor
breakers for special service bank and shunt reactor.
conditions

3 Critical Current Test Refer IEC 62271-100, Applicable only if the

Clause 6.107 condition as stated in IEC
62271-100 Clause 6.107 is
met/arise/occur

4 Short-line Fault tests Refer IEC 62271-100, Required for three pole
Clause 6.109 circuit breaker connected to
overhead lines and intended
to break the short-line fault
conditions

5 Out-of-phase making and Refer IEC 62271-100,

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 breaking tests Clause 6.110

6 Single phase and double earth Refer IEC 62271-100, Clause

fault tests 6.108

3.2.8.2 500kV, 275kV and 132kV Disconnectors and Earth Switches

The type tests shall be performed in accordance with the mandatory

requirements of IEC 62271-102, 62271-1, 61128 and 61129 and shall include the
following tests:-

Mandatory Type Test Remarks

1 All tests Refer IEC 62271-102

Mandatory Type Test, Where Applicable

1 Verification of the degree of Refer IEC 62271-102 & IEC Applicable for the cubicle
protection 60529 By accredited independent
tester, but need not be
STL/STLA.
2 Radio Interference Voltage test IEC 62271-102

3 Busbar Transfer Current IEC 61128 Applicable for busbar

Switching disconnector

4 Rated Making Current IEC 61129 Applicable for line

(induced current )for Line disconnector
Disconnectors

3.2.8.3 500kV, 275kV and 132kV Current Transformers

The type tests shall be performed in accordance with the mandatory

requirements of IEC 60044 and shall include the following tests:-

Mandatory Type Test Remarks

1 All tests Refer IEC 60044-1

Additional Test :

1 Chopped (lightning) impulse Refer IEC 60044-1, DGA test on transformer oil
test on primary windings for Clause 9.1 to be conducted before and
inverted type CT (Top Core) after the tests according to
only sampling methods of IEC
60567 and the results not to
exceed the limits of
IEC60599 or EDF
Specification
2 Measurement of capacitance Refer IEC 60044-1,
& dielectric dissipation factor Clause 9.2
before and after HV tests on
primary

3 Multiple chopped impulse Refer IEC 60044-1, Annex B Transformer oil sampling
test on primary winding methods shall be in
accordance with IEC 60567
and the results not to
exceed the limits of
IEC60599 or EDF
Specification

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 3 Verification of the degree of (IEC 60529) Applicable for the cubicle
protection By accredited independent
tester, but need not be
STL/STLA.
4 Thermal Stability test Simultaneous application of This test simulates the
the voltage and rated thermal actual site conditions and
current and measurement of for evidence of any variation
capacitance and tan delta in insulation properties.
every one hour until the CT
reaches steady state
temperature.

3.2.8.4 500kV, 275kV and 132kV Voltage Transformers

The type tests shall be performed in acordance with the mandatory

requirements of IEC 60044 and shall include the following tests: -

Mandatory Type Test Remarks

1 All tests Refer IEC 60044-2 for

Inductive Voltage
Transformers (IVT) and IEC
60044-5 for Capacitor
Voltage Transformers (CVT)

Additional Test :

1 Verification of the degree of (IEC 60529) Applicable for the cubicle

protection By accredited independent
tester, but need not be
STL/STLA.
2 Measurement of capacitance & Refer IEC 60044-2 Applicable only for IVT.
dielectric dissipation factor Mandatory type test for
before and after HV tests on CVT already includes this
primary test.

3 Design Tests and Type Tests on (In accordance with IEC Applicable only for IVT with
composite insulators used as 61462) polymeric housing
housing,

4 Mechanical tests on instrument (In accordance with lEC Applicable only for IVT with
transformers with polymeric 60099-4, cI. 10.8.9, Test of polymeric housing
housing the bending moment)

5 Moisture ingress test on (In accordance with lEC Applicable only for IVT with
polymeric housing 60099-4) polymeric housing

6 Weather ageing test for (The design shall have Applicable only for IVT with
polymeric housing passed both the 1000 hour polymeric housing
(Test series A) and 5000
hour (Test series B) weather
ageing tests specified in IEC
60099-4)

3.2.8.5 500kV, 275kV and 132kV Surge Arresters

The type tests shall be performed in accordance with the mandatory

requirements of IEC 60099-4 and shall include the following tests :-

Mandatory Type Test Remarks

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 1 All tests Refer IEC 60099-4

Additional Test :

2 Partial Discharge test / IEC 60099-4 Clause 7.1 (8)

measurements during type test

3.2.8.6 275kV and 132kV GIS Equipment

The type tests shall be performed in accordance with the mandatory

requirements of IEC 62271-203 and shall include the following tests :-

Mandatory Type Test Remarks

1 All tests Refer IEC 62271-203

Individual component (eg

CB, DS/ES, CT, VT etc) tests
shall be according to the
relevant IEC/BS/IEEE
standard AND as specified
in this specification

Additional Test/Special Test :

1 Ageing Test of Spacer The procedure shall be

mutually agreed between
Employer and manufacturer
2 Extended Mechanical IEC 62271-100 Applicable for Class C2, M2
Endurance test of Circuit circuit breaker for capacitor
Breaker mechanism bank and shunt reactor.

3 Accelerated Ageing test of O- The procedure shall be

ring and gasket mutually agreed between
Employer and manufacturer
4 Test on Pressure relief facilities Vendor Test Report

5. Test of O-ring’s bed and Vendor Test Report

flange’s surface (275kV and
132kV)

6. Test at minimum and 2nd stage

alarm operating pressures
(275kV and 132kV GIS)

7. Differential pressure test Test on Spacer and support

insulator

3.2.8.7 275kV and 132kV Capacitor bank

The type tests shall be performed in accordance with the mandatory

requirements of IEC 60871-1 and shall include the following tests :-

Mandatory Type Test Remarks

1 All tests Refer IEC 60871-1

Additional Test/Special Test :

1 Endurance Tests IEC 60871-1 Clause 6.4

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 3.2.8.8 275kV and 132kV Damping Reactor

The type tests shall be performed in accordance with the mandatory

requirements of IEC 60076-6 and shall include the following tests :-

Mandatory Type Test Remarks

1 All tests Refer IEC 60076-6

Additional Test/Special Test :

1 Short-circuit current test IEC 60076-6 Clause 9.10.4

2 Inrush current withstand test for IEC 60076-6 Clause 9.10.4

filter and damping reactors

3 Mechanical resonance test IEC 60076-6 Clause 9.10.4

3.2.8.9 132kV XLPE Cable and Accessories

The type tests shall be performed in accordance with the mandatory

requirements of IEC 60840 and shall include the following tests:-

Mandatory Type Test Remarks

1 All tests Refer IEC 60840

Additional Test/Special Test

1 Type test on link boxes a) Water immersion test

external pressure 200mbar
b) 25kV DC @ 5 minute test
c) Sort circuit test 31.5kA @
3sec
d) Impulse test as per IEC
60230

3.2.8.10 33kV and 11kV XLPE Cable and Accessories

The type tests shall be performed in accordance with the mandatory

requirements of IEC 60840 and shall include the following tests:-

Mandatory Type Test Remarks

1 All tests Refer IEC 60502 & IEC 61442

3.2.8.11 33kV, 22kV and 11kV Switchgear

The type tests shall be performed in accordance with the mandatory

requirements of IEC 62271-200 and relevant standard on the component (eg
circuit breaker (IEC 62271-100), disconnector (IEC 62271-102) etc as stated in
IEC 62271-200 and shall include the following tests:-

Mandatory Type Test Remarks

1 All tests Refer IEC 62271-200

Mandatory Type Test, Where Applicable (A test other than Mandatory Type and Routine Tests
specified by the standard )

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 1 Verification of the degree of Refer IEC 62271-200, Clause
protection 6.7
& IEC 60529

2 Extended mechanical Refer IEC 62271-100, Clause Specifically to be imposed

endurance tests on circuit- 6.101.2.4 on circuit breaker
breakers for special service intended to be used for
conditions capacitor bank or power
reactor switching.
Circuit breaker is
classified as Class C2, M2

3 Critical Current Test Refer IEC 62271-200, Clause Applicable only if the
6.107 condition as stated in IEC
62271-200 Clause 6.107 is
met

4 Short-line Fault tests Refer IEC 62271-200, Clause Required for three pole
6.109 circuit breaker connected
to overhead lines and
intended to break the
short-line fault conditions

5 Out-of-phase making and Refer IEC 62271-100, Clause

breaking tests 6.110

6 Single phase and double earth Refer IEC 62271-100, Clause Previously it was Single
fault tests 6.108 phase short circuit test (as
in IEC 60056 Clause 6.108)

3.2.8.12 33kV, 22kV and 11kV Neutral Earthing Resistor

The type tests shall be performed in accordance with the mandatory

requirements of IEEE 32 and shall include the following tests :-

Mandatory Type Test Remarks

1 Hot-spot Rated-Time Refer IEEE 32 The test may be performed

Temperature Rise Test on a NER with different
voltage rating provided that
the active components are
of identical materials and
design.

Additional Test

1 Verification of the degree of IEC 60529 Applicable for the cubicle

protection

3.2.8.13 33kV, 22kV and 11kV Neutral Disconnector

The type tests shall be performed in accordance with the mandatory

requirements of IEC 60129 and 60265-1 and shall include the following tests:-

Mandatory Type Test Remarks

1 All tests Refer IEC 62271-102

Additional Tests

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 1 Verification of the degree of Refer IEC 62271-102 & IEC Applicable for the cubicle
protection 60529 By accredited independent
tester, but need not be
STL/STLA.

3.2.8.14 Protective Relaying And Control Equipment

The type tests shall be performed in accordance with the mandatory

requirements of IEC 60255 and shall include following tests:-

Technological Conformance and Mechanical International Standards Remarks

Requirements
1 High Voltage Test and Impulse Voltage Tests. IEC 60255-5, IEC 60255-6
2 Thermal requirement - Measurement of IEC 60255-6
maximum allowable temperatures at
maximum ambient and verification of
temperature range (operation and storage).
3 Input transformers - Thermal withstand value IEC 60255-6
of input energising quantities.
4 Input transformer - Short-time thermal IEC 60255-6
withstand value of input energising
quantities.
5 Current input transformer - limiting dynamic IEC 60255-6
value. (Not applicable for relay with voltage
input only)
6 Rated burden - Power consumption of input IEC 60255-6
current circuit and auxiliary circuits.
7 Insulation IEC 60255-6
8 Vibration test – mechanical resistance to IEC 60255-21-1
sinusoidal vibrations
9 Shock and bump test – mechanical resistance IEC 60255-21-2
to shock and bump
10 Seismic test - Mechanical resistance to single IEC 60255-21-3
axis sine sweep.
11 Damped oscillatory wave test at 100kHz, IEC 60255-22-1,Class 3
1
1MHz, 10MHz and 50MHz IEC60694
12 Electrostatic discharge test IEC 60255-22-2, Class 3
IEC61000-4-2, Class 3
13 Fast transient test IEC 60255-22-4, Class 4
IEC 61000-4-4, Class 4
14 Surge Test IEC 60255-22-5
IEC61000-4-5, Class 3
15 Conducted radio interference test IEC 60255-22-6
IEC 61000-4-6, Class 3
16 Variations and interruptions in AC and DC IEC 61000-4-11 for AC
auxiliary voltage IEC 60255-3 and IEC
60255-11 for DC
17 Electromagnetic fields IEC 61000-4-3, Class 3 or
ENV 50204, Class 3
2
18 50Hz power frequency magnetic fields IEC 61000-4-8, Class 5
19 Conducted RF interference on power supply CISPR11, Class A,
terminals and radiated interference. Group 1
Harmonics for AC supply IEC 60555-2
20 Flicker CISPR 14

Note:
1
Tests at 10MHz and 50MHz are only for device to be used with GIS equipment.
2
Pulse magnetic field and oscillatory wave magnetic field test according to IEC61000-4-9
and IEC61000-4-10 respectively may also be considered for equipment intended for HV
substation.

International standard other than stated above may be used only with clear evidence that it is
a new standard that has superseded the existing standard or it has the same test procedure
with the same or higher test requirements.

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 All tests should be performed by an independent test laboratory certified with ISO/IEC 17025
standard or equivalent.

3.2.8.15 Telecontrol

All type tests for Telecontrol shall be referred to document as follow :

No. Equipment Document

1 Remote Terminal Unit TTS – TK – RTU
2 Supervisory Interface Panel TTS – TK – SIP
3 SCADA Gateway TTS – TK – SGW
4 Transducer TTS – PT – PROT
5 Telecontrol Cable TTS – PT – APC

3.2.8.16 Rigid Busbar

The type tests shall be performed in accordance with NEMA (No. 107-1964 and
CC1) standards latest revision.

3.2.8.17 Stranded conductor

The type tests shall be performed in accordance with IEC 61089 standards
latest revision.

3.2.8.18 Clamps and Connectors

The type tests shall be performed in accordance with NEMA (No. 107-1964 and
CC1) standards latest revision.

3.2.8.19 Insulators (Table format)

The type tests shall be performed in accordance with the mandatory

requirements of IEC 60168. These type tests shall have been conducted for
the specific rated insulators proposed. The tests shall include the following
tests:-

Mandatory Type Test Remarks

1 All tests Refer IEC 60168

Additional Test :

1 Radio Interference Voltage test IEC 60168 Clause 6.1.2

2 Artificial Pollution test IEC 60168 Clause 6.1.2

3 Test for deflection under load IEC 60168 Clause 6.1.2

3.2.8.20 Bushing

The type tests shall be performed in accordance with the mandatory

requirements of IEC 60137.

3.2.8.21 Substation Earthing System and Joints Between Electrodes

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 The type tests of joints employed between electrodes and other metals shall
have been tested fully to the mandatory requirements of IEEE Standard 837.

4.0 MATERIAL TESTS

The Contractor shall provide test pieces as required by the Engineer to enable him to
determine the quality of the material supplied under this Contract. Such test pieces shall be
prepared and supplied free of charge and the costs of the tests shall be borne by the
Contractor. If any test piece fails to comply with the requirements of the Specification for the
material in question, the Engineer may reject the whole of the material represented by that test
piece. The Contractor' s designers and metallurgists will be consulted before any material is so
rejected.

In the event of the Engineer being furnished with certified particulars of tests which have been
carried out for the Contractor by the suppliers of material, he may, at his own discretion,
dispense with the previously mentioned test entirely.

5.0 FACTORY INSPECTION / AUDIT

The switchgear manufacturer must make their works available for inspection and audit.
Coordination between the manufacturer’s quality control department and TNB’s
representatives is necessary for this purpose. The cost of this activity shall be borne by
TNB.

The activities shall involve but not limited to the following:-

(1) incoming material inspection and test procedures

(2) inspection of inventory facilities
(3) testing equipment facilities
(4) testing equipment calibration
(5) manufacturing schedule and process throughput capability
(6) capability to conform to design tolerance
(7) factory cleanliness and dust proofing
(8) packaging, handling, transport and shipping methodology
(9) ISO 9000/quality documentation

6.0 ROUTINE TESTS

Works tests shall include all routine electrical, mechanical and hydraulic tests in accordance
with the relevant IEC or British Standards except where departures therefrom and the
modifications there to are embodied in this Specification. For Plant not covered by any IEC or
British Standards nor specifically mentioned in this Specification, such tests as are relevant
shall be agreed with the Engineer.

Should the plant or any portion thereof fail under test to give the required performance, further
tests which are considered necessary by the Engineer shall be carried out by the Contractor
and the whole cost of the repeated tests shall be borne by the Contractor. This also applies to
tests carried out at the Sub- Contractor'
s works.

After satisfactory completion of the witnessed tests at the Works, the plant shall be submitted
for the Engineer’s approval during dismantling preparatory to shipping. No item of plant shall
be dispatched to Site until the Engineer has given his approval in writing.

Routine tests shall be carried out on all main equipment or components of main equipment
ordered under this Contract, irrespective whether or not the type tests for the equipment are
required to be performed as specified above. The test shall be strictly in accordance with the
requirements set out in the appropriate IEC, BS, IEEE or other International Standards relevant
to the equipment stipulated in this specification.

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The costs of the Routine-tests shall be borne by the Contractor and shall be deemed to be
included in the Contract Price.

When the equipment is fully assembled before transport to the site, the tests shall be
performed on the fully assembled units.

When the equipment is not possible to be assembled at the works before transport, separate
tests shall be performed on all components in accordance to the relevant standard and this
specification.

To ensure that a plant is designed, manufactured and tested in accordance to TNB

specifications and requirements, the Factory Acceptance Test shall be witnessed by the
Employer.

The Factory Acceptance Test (FAT) that shall be witnessed by TNB representative are as
follow:

Equipment Unit Sample to witness

All primary outdoor equipment Numbers 10% or minimum of 1 no, of every
including busbars, connectors & batch, whichever is greater.
clamps, string & post insulators,
panels, Transformers,
All GIS switchgear, metalclad Numbers 10% or minimum of 1 no of each
typical bay, whichever is greater

All 33 & 11kV MV switchgear Numbers 10% or minimum of 1 no of each

typical bay, whichever is greater
Cables and all products meter 10% of batch length
manufactured in batch length
Other equipment, material or sub- Identified 10% or minimum of 1 part of every
orders during batch
manufacturing
Control and Protection Relay Panels, Numbers 1 number for each typical panel (OHL
feeder, UGC Feeder, Tx Feeder, B/C,
B/S, 1000MVA OHL feeder etc)
RTU and SIP Numbers All panels
SCS Numbers All panels

The cost of witnessing Factory Acceptance Tests (FAT) by Employer representative shall
be borne by the Employer.

All drawings and documents pertaining to the plant and it’s inspection and test procedures
shall be made available during witnessing.

The equipment shall be ready and made available at the factory according to the declared
quantity during the FAT. If the equipment is not ready or the tests is cancelled after the
witnessing personnel has been at the testing venue, or the tests fail, the cost of witnessing
the repeat test shall be borne by the contractor.

TNB requires at least fourteen (14) working days and thirty five (35) working days written
notice for the witnessing of the local and overseas tests respectively.

The recorded results of routine tests shall be verified by the Engineer or his representative
and triplicate copies be submitted to the Employer immediately after the tests for record

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purposes. The same set of test results should be included in the Operation and Maintenance
manual.

The Test reports shall be submitted to the Employer within 14 days after completion of the
tests. The relevant costs shall also deemed to be included in the Contract Price.

7.0 TESTS AT SITE

Tests on completion of erection shall be carried out by the Contractor in accordance with the
General Conditions of the Contract (FIDIC).

The Contractor shall provide all necessary test equipment to carry out the site tests, but where
required in the Schedule of Prices, shall include the cost of the equipment taking into account
the depreciation at the end of the tests so that the Employer may have the option to buy the
equipment on completion of the Contract. The prices quoted are again subject to the actual
conditions of the equipment at that material time which will be subject to mutual agreement
between the Contractor and the Employer.

The Contractor shall submit a written program of tests and checks according to this Clause
for the approval of the Engineer.

The Contractor shall provide experienced test personnel subject to the approval by the
Engineer (CV’s shall be submitted) and conditions imposed by the Board of Engineers,
Malaysia, (BEM), and the local laws ruling at that time on such practice. The Contractor shall
also have the option of engaging the Employer’s own testing personnel from the Protection (&
Testing) Department in carrying out such site tests based on the prices entered in the
Schedule of Requirements where separate quotations are entered/required. Under these
circumstances however, the overall responsibility to the Plant still lies in the hand of the
Contractor.

The testing shall be carried out during normal working hours as far as is practicable. Tests
that involve existing apparatus and outages may be carried out outside normal working hours.
The Contractor shall give sufficient notice to allow for the necessary outage arrangements to
be made in conformity with the testing program.

The Contractor shall advise the Engineer in writing at the time of commencement of site
erection of the site supplies which will be required for the operation of the test equipment, to
enable the Engineer to arrange accordingly or to agree with alternative arrangements should
this be necessary.

The Contractor shall record the results of the tests clearly, on an approved form and with clear
reference to the equipment and items to which they refer, so that the record can be used as
the basis for maintenance tests by the Employer during the working life of the equipment. The
required number of site test result records shall be provided by the Contractor to the Engineer
as soon as possible after completion of the tests. Both the Employer and the Engineer require
this information before the Plant will be accepted for initial energizing.

Initial energizing and all subsequent '

live'tests will be directed by the Engineer and carried out
jointly by the Employer, Contractor and Engineer. They will be subject to the Employer' s
standard safety procedures and all operational switching will be carried out by the Employer
according to a detailed program which the Engineer will prepare and which will be agreed in
advance between all three parties. During these ' live' tests the Contractor shall remain
responsible for the performance of his Plant.

No tests as agreed under the program of tests shall be waived except upon the instruction or
agreement of the Engineer in writing.

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The Contractor shall submit to the Engineer for his approval a list of recommended settings
for all protection and other types of automatic equipment, not less than three (3) months
before such equipment is required in commercial service. Where the settings involve
discrimination with settings of an existing network or plant supplied under another contract,
the relevant information will be supplied to the Contractor.

The Contractor' s test equipment shall be of satisfactory quality and condition and shall be
appropriately calibrated by an approved authority or standard at the Contractor' s expense.
Details of the test equipment and instruments used shall be noted in the test sheets in cases
where the instrument or equipment characteristics can have a bearing on the test results.

The testing requirements detailed under this Specification may be subject to some variation
upon the instruction or agreement of the Engineer where necessitated by changed conditions
at Site or by differing design, manufacture, or construction techniques or by latest revisions, if
any, of the Employer' s testing procedures.

The Tenderer is required to submit proposals for dielectric tests to be carried out at site and to
include in his price the costs of such tests and of such equipment as deemed necessary.

8.0 COMMISSIONING PROCESS

The contractor shall comply to the commissioning process required by TNB Transmission.
The detailed process is attached as per Appendix 1 of this section. This commissioning
process shall be deemed to be included in the Contract Price.

9.0 EQUIPMENT TESTS

A general check of all the main switchgear and ancillary equipment shall be made and shall
include a check of the completeness, correctness and condition of earth connections,
labelling, arcing ring and horn gaps, clearances, painted surfaces, cables, wiring, pipe
work, valves, blanking plates and all other auxiliary and ancillary items. Checks shall be
made for oil and gas leaks and that insulators are clean and free from external damage. A
check shall be made that loose items which are to be handed over to the Employer, e.g.
blanking plates, tools, spares, are in order and are correctly stored or handed over. The test
shall be strictly in accordance with the requirements set out in the appropriate IEC, BS,
IEEE or other International Standards relevant to the equipment stipulated in this
specification and TNB Transmission Site Acceptance Tests (SAT document).

10.0 TEST CERTIFICATE

Triplicate sets of all principle test records, test certificates and performance curves shall be
supplied for all tests carried out in accordance with the provisions of this Contract. These test
records, certificates and performance curves shall be supplied for all tests, whether or not
they have been witnessed by the Engineer. The information given in such test certificates and
curves shall be sufficient to identify the material or equipment to which the certificate refers
and should also bear the Contract reference and heading as given in Clause 2.0 above.

Test certificates shall include a photographic album of the actual tests carried out showing the
types of testing equipment used and indication of test performances etc.

11.0 REJECTION OF PLANT

This clause shall refer to Contract condition of contract (FIDIC).

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