VOLTECH ENGINEERS PRIVATE LIMITED.

OPERATIONAL CONTROL PROCEDURE

OCP NO: 04

PRE COMMISSIONING TEST PROCEDURE FOR ISOLATORS

1.0 Purpose
This procedure is prepared to carry out various pre- commissioning tests to be conducted in systematic
manner for isolators to ensure the healthiness and performance of the equipment
2.0 Scope
This procedure covers the Pre commissioning test for isolators as for the following
1. Insulation Resistance Test
2. Contact Resistance Test
3. Isolator Motor winding IR Test
3.0 Responsibility
Unit Head / Regional managers:
Unit heads / Regional managers have overall responsibility for health and safety management and role
includes:
 Planning and scheduling of activities with a view to execute the project
 Identify significant health and safety and eliminate or minimize them
 Maintaining all legal and statutory requirement
 Assist the safety team to conduct the safety training and audit at sites
 Ensure all safety rules and regulations are followed at work sites

Site Engineers:
Site engineers are responsible for all aspects of health and safety on site and are accountable to the Unit
head / Regional manager. Their roles include:
 Report any issue affecting health and safety issues at the work sites to the regional manager / unit
head / safety team
 Coordinate with end customer / client for the taking work permit and returning work permit
 Communicating the work content / hazard involved to working group through the medium of
Toolbox meeting before commencement of work every day
 Initiating proactive measures to minimize / eliminate accidents
 Reporting in detail in the event of incident
 Ensure effective use of appropriate PPE
 Ensure the quality of job at all times without any compromise on safety
 “Stop Work” in the event of any serious safety violation

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OPERATIONAL CONTROL PROCEDURE
OCP NO: 04
Safety Manger / Regional Safety Engineers:
Safety manger / Regional safety engineers are responsible for providing health and safety advice and
guidance to their Unit head/ Regional manager, site engineers and their roles include:
 Ensuring implementation of all instruction and procedures based on the occupational health and
safety
 Communicating all safety rules, regulations and practices to all site engineers / regional manager/
unit head
 Follow up for the closure of audit non conformances and help regional mangers / unit head to take
corrective action and preventive action
 Report and investigate all the incidents / Near misses to the top management
 Create awareness amongst site engineers / regional managers and also organize the regular training
program.
 Ensure that Tool box talk meetings are in being conducted daily at site and the workers are aware of
all the hazards at the work site
 Ensure adequate PPE’s and safety equipment as are required are available at sites and are being
used at site appropriately
 Reporting of any issues affecting the health and safety at the work site to the unit head / Regional
managers
 Ensure basic first aid facilities are available at sites
 Ensure that no unsafe act is performed at any site
 Ensuring that any unsafe condition observed at site is eradicated at the earliest
 Issuing of safety challans in the event of any safety violations.
4.0 Working Activity and descriptions
4.1 Pre-Testing Checks
 Check out the working condition of ELCB(30 mA)
 Check the insulation of power cable for equipment
 Ensure proper earthing and rubber mats available at the work location.
 Calibrated Testing equipment should be used and calibration reports available with engineers for
the same
 Check out the insulates hand tools available with the technician
 Ensure the Healthiness of the test leads (Check for any insulation Damages)
 Ensure appropriate PPE’s available at sites
4.2 Resources – Tools and Equipment Required
For Insulation Resistance measurement Test (IR Test):
a. 500 V, 5000 V Insulation Tester
b. Test Leads
c. Insulated Hand Tools

For Contact Resistance measurement Test

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OPERATIONAL CONTROL PROCEDURE
OCP NO: 04
a. Contact Resistance meter kit with test leads range of 200µΩ-2000µΩ

For motor winding resistance test

a. Multimeter with test leads

For motor insulation resistance test

a. 500/5000V insulation resistance tester/ MEGGER

b. Test leads
4.3 Operational Sequence of work(Test Procedure)
Insulation Resistance (IR) Test – isolators
 Take the work permit from the client
 Test equipment's to ensure zero energy state before beginning the work
 Ensure the isolator in close positions
 Connect the megger positive lead to isolator pole
 Connect the earth lead to the earth
 Switch “ON” the megger and press the test button note down the readings
 Connect the positive lead to one pole and negative lead to another pole when isolator in open
position
 Switch “ON” the megger Inject the voltage and note down the readings

MEGGER

MEGGER

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OPERATIONAL CONTROL PROCEDURE
OCP NO: 04
Motor Winding IR test (using 500V Meggar)

IR TEST BETWEEN PHASE TO PHASE:

 Connect the Megger across the motor Terminal “U1 & V1”
 Switch ON the megger and press the test button take down the readings
 Discharge the potential from the “U1 & V1” terminal with respect to earth
 Switch OFF the megger
 Repeat the above steps for other Terminals (V1 & W1), (W1 & U1)

IR TEST BETWEEN PHASE TO EARTH:

 Looped (Shorted) the motor Terminals U2, V2 & W2

 Then Connect the Megger across the motor Terminal “U1” & Earth
 Switch ON the megger and press the test button take down the readings
 Discharge the potential from the “U1” terminal with respect to earth
 Switch OFF the megger
 Repeat the above steps for other Terminals V1 & W1

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 VOLTECH ENGINEERS PRIVATE LIMITED.
OPERATIONAL CONTROL PROCEDURE
OCP NO: 04
Contact Resistance Measurement Test

 Take the work permit from the client

 Test equipment's to ensure zero energy state before beginning the work
 Connect CRM kit across the Moving & fixed Contacts of Isolators while Isolators in Close
Condition.
 Switch “ON” the CRM kit and test press the test button take down the readings
 Connect the CRM kit across the Connectors of Isolators while Isolator in Open Condition
 Switch “ON” the CRM kit and test the press button take down the readings

C+ V+ V- C-

CRM KIT

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OPERATIONAL CONTROL PROCEDURE
OCP NO: 04

4.4 Control Measures

 OCP for IR and CRM for Isolators is available with testing engineers
 Ensure PTW system in place for the particular bay
 Ensure all supply to the equipment is dead
 Unauthorized persons should not be allowed to enter Testing area
 Barricade the testing area with warning tape
 More than 2Mtr height shall be used proper working plat form man lifter and suggested for
complying with fall arrester or Full body harness
 Less than 2Mtr height shall be used the standard insulated ladder
 Inspect the ladders prior to work, keep both feet below 3rd rung from top, keep one hand on
ladder minimum at all times and suggested for complying with fall arrester
 Proper supervision, conduct job specific toolbox meeting and barricading the entire area
 Calibrated equipment shall be used
 Insulated hand tools shall be used
 Avoid joints for power cable and supply has to be taken via ELCB
 Avoid alone working
 Use appropriate insulated hand gloves

5.0 Final Checks & Restoration of work area after completion of work:

 Disconnect the temporary supply and remove the barricading tapes

 Ensure no loose materials / tools are kept in and around the area
 Leave the place by keeping it tidy and clean

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OPERATIONAL CONTROL PROCEDURE
OCP NO: 04

6.0 Personal Protective Equipment (PPE):

Personal
Protective
Equipment

YES / NO Yes Yes Yes Yes

Personal
Protective
Equipment

YES / NO No No Yes Yes

7.0 Communication and signing off register:

Communicate to all employees in Tool box talk and ensure it is signed by all personnel

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