OISD –STD -137

FOR RESTRICTED CIRCULATION

INSPECTION OF ELECTRICAL EQUIPMENT

OISD STANDARD - 137

First Edition, January 1990
Reaffirmed, August, 1999
Amended Edition, October, 2010

Oil Industry Safety Directorate

Government of India
Ministry of Petroleum and Natural Gas

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 OISD STANDARD - 137
First Edition, January 1990
Reaffirmed, August, 1999
Amended Edition, October, 2010

FOR RESTRICTED
CIRCULATION

INSPECTION OF ELECTRICAL EQUIPMENT

Prepared by

COMMITTEE ON
INSPECTION AND MAINTENANCE OF ELECTRICAL EQUIPMENT

OIL INDUSTRY SAFETY DIRECTORATE

7TH FLOOR, NEW DELHI HOUSE
27, BARAKHAMBA ROAD
NEW DELHI – 110 001
 NOTES

OISD publications are prepared for use in the Oil

and gas industry under Ministry of Petroleum and Natural
Gas. These are the property of Ministry of Petroleum and
Natural Gas and shall not be reproduced or copied and
loaned or exhibited to others without written consent from
OISD.

Though every effort has been made to assure the

accuracy and reliability of data contained in these
documents, OISD hereby expressly disclaims any liability or
responsibility for loss or damage resulting from their use.

These documents are intended only to supplement

and not replace the prevailing statutory requirements.
 FOREWORD

The Oil Industry in India is 100 years old. As such

variety of practices have been in vogue because of
collaboration / association with different foreign companies
and governments. Standardisation in design philosophies
and operating and maintenance practices at a national level
was hardly in existence. This, coupled with feed back from
some serious accidents that occurred in the recent past in
India and abroad, emphasized the need for the industry to
review the existing state of art in designing, operating and
maintaining oil and gas installations.

With this in view, the Ministry of Petroleum & Natural

Gas, in 1986, constituted a Safety Council assisted by Oil
Industry Safety Directorate (OISD), staffed from within the
industry, in formulating and implementing a series of self
regulatory measures aimed at removing obsolescence,
standardising and upgrading the existing standards to
ensure safe operations. Accordingly, OISD constituted a
number of Functional Committees of experts nominated from
the industry to draw up standards and guidelines on various
subjects.

The present document on “Inspection of Electrical

Equipment” was prepared by the Functional Committee on
“Inspection and Maintenance of Electrical Equipment. This
document is based on the accumulated knowledge and
experience of Industry members and the various national
and international codes and practices. It is hoped that
provisions of this standard if implemented objectively, may
go a long way to improve the safety and reduce accidents in
Oil and Gas Industry. Users of this document are cautioned
that no standard can be a substitute for the judgement of
responsible and experienced engineer.

Suggestions for amendments, if any, to this standard

should be addressed to:

The Co-ordinator,
Committee on
“Inspection & Maintenance of Electrical Equipment”
OIL INDUSTRY SAFETY DIRECTORATE
7th Floor, ‘New Delhi House’
27, Barakhamba Road
New Delhi – 110 001

.
 COMMITTEE ON PROCESS INSPECTION AND
MAINTENANCE OF ELECTRICAL EQUIPMENT.

LIST OF MEMBERS

----------------------------------------------------------------------------------------------------------------------------
Name Designation / Organisation Position in
Committee
----------------------------------------------------------------------------------------------------------------------------

S/Shri

1. R.K. Ghosh Chief Power and Utility Leader

Manager - IOC (R &P)

2. G.A. Patrachari Chief Tech.Services Manager

HPC(R) Member

3. B.M. Jayaraman Chief Engineer (Safety) Member

OIL

4. A.P. Kant Maint. Manager (Elect.) Member

BRPL

5. G.P. Paret Manager (Project - Electrical) Member

CRL

6. N.V. Mani Joint Director (OISD) Member

Co-ordinator
----------------------------------------------------------------------------------------------------------------------------
In addition to the above several experts from industry contributed in the preparation, review
and finalisation of the document.
 INSPECTION OF ELECTRICAL EQUIPMENT
CONTENTS

SECTION

1.0 Introduction

2.0 Scope

3.0 Definitions

4.0 Permit-to-work(Electrical)

5.0 Basis and types of inspection

6.0 Frequency of inspection

6.1 Rotating machinery
6.1.1 Generator
6.1.2 Motor
6.2 Stationary equipment
6.2.1 Switchboard & Panel
6.2.2 Transformer & Bus duct
6.2.3 Battery
6.2.4 Charger & D.C. board
6.2.5 UPS/Inverter
6.2.6 Reactor/Capacitor
6.2.7 Switchyard equipment
6.2.8 Lighting fixture & junction box
6.2.9 Test instruments for inspection
6.3 Protective Systems
6.3.1 Relay & meter
6.3.2 Earthing & bonding
6.3.3 Lightning protection
6.3.4 Flameproof/weather protection
6.3.5 Fire alarm system
6.3.6 Cathodic protection
6.3.7 Electric heat tracing
6.3.8 Protective & Safety appliances
6.4 Distribution network
6.4.1 Cable/conduit wiring
6.4.2 Cable duct/trench/tray support
6.4.3 Overhead line
6.5 Outdoor switchyard
6.6 Switchroom/substation building
6.7 Safe procedures & systems

7.0 Inspection procedures

8.0 Documentation

9.0 Precommissioning checks

10.0 References

ANNEXURES
I Protective relay inspection & test record
II Maintenance card of transformer & breaker
SECTION

III Cable maintenance card

IV Maintenance card of motor & breaker
V Failure analysis report
VI Details of authorised personnel (Format)
VII Cable fault detection
 INSPECTION OF ELECTRICAL EQUIPMENT
1.0 INTRODUCTION
Electricity constitutes one of the
major sources of ignition for fire accidents
and explosions in petroleum installations
where classified hazardous atmosphere is
normally encountered. In so far fire losses
due to electricity are concerned, it is
estimated to account for approximately
30% of all fire losses, as per the accident
statistics. Besides equipment damage
and property loss, electrical hazards also
include injuries and fatalities to personnel
due to electric shock.
Timely inspection and preventive
maintenance of electrical equipment and
its connected systems will go a long way
in ensuring safer operations, for a longer
period of time, of the electrical installations
in the Oil Industry.
2.0 SCOPE
This standard specifies the
minimum inspection requirements on the
installed electrical systems in the Oil
Industry, during their operation and
maintenance with special reference to the
safety aspects.
Items to be inspected, procedure
and scheduling of inspection are dealt
with. Also included are:
i) Permit-to-work(Electrical). or Electrical
Line Clearances covering special
safety requirements for jobs requiring
Electrical Isolation/.Lockout.
ii) Pre-commissioning check items for new
installations as well as for repaired
equipment.
This standard in no way
supersedes the statutory regulations of the
Chief Electrical Inspectorate, Factory
Inspectorate, Chief Controller of
Explosives, Director General Mines
Safety, or other government bodies, which
shall be followed as applicable.
3.0 DEFINITIONS
i) AUTHORISED PERSON
Authorised person is a responsible
person of the Electrical Section in the
owner organisation, authorised by
Electrical-in-charge to carry out Electrical
Isolation/Energisation. He is also
authorised under the provisions of Rule
No.3 in the Indian Electricity Rules
specifically referred in I.E. Rules 36(2),
51(1) (a), 64(1)(a). 64(2) (e) & (f), 110(2),
121(1), 121(4), 124 and 124 (8).
Annexures VI of this standard gives
suggestive format for exhibiting the details
of authorised personnel.
ii) TESTING ENGINEER
Testing Engineer is a competent
person in the electrical discipline, for
carrying out field tests as stipulated in the
approved standards/codes, covering all
the installed electrical systems. He shall
possess the competence required for
“Officer” generally as per Rule No.4B of
the Indian Electricity Rules.
iii) ENGINEER-IN-CHARGE (EIC)
EIC is competent person of the
owner organisation, in charge of the work,
to whom work permit shall be issued by
Unit-in-charge. In case the work involves
electrical jobs, EIC shall be an electrical
engineer.
EIC shall be responsible for
continuous supervision of the work and for
arranging safe Isolation/Energisation of
the electrical equipment through
Authorised Person as detailed in Section
4.0 to ensure safety while working on the
equipment and associated systems. He
shall also ensure the implementation of
effective safety measures by personnel/
agencies working under his supervision,
throughout the duration of work.
iv) UNIT-IN-CHARGE (UIC)
UIC is Owner-in-charge as defined
in OISD-STD-105 (Work Permit System)
authorised to issue Work Permit to work in
the respective Unit under his jurisdiction
(e.g. Chief Chemist shall be UIC for
Laboratory).
v) ELECTRICAL-IN-CHARGE
 Electrical-in-charge is a competent
person in charge of the Electrical
Department/Section of the owner
organisation responsible for safe operation
and maintenance of all electrical systems
The system of issuing Electrical Line
Clearances as detailed in Section 4.0 and
conformity of installations with statutory
requirements from time to time, shall also
be ensured by him.
vi) INSPECTOR
Inspector is a competent person in
the Electrical discipline of the owner
organisation who shall ensure carrying out
of periodical inspections of the electrical
systems as per the requirements of this
standard. He shall arrange to conduct
required tests, through a Testing Engineer
as defined in Section 3 ii), recommend
corrective actions through periodical
reports, and follow up for their timely
compliance. He shall possess the
competence required for Inspector
generally as per Rule No.4 of the Indian
Electricity Rules.
vii) PERMIT-ISSUING AUTHORITY
(ELECTRICAL)
Permit-Issuing Authority
(Electrical) is a competent person in the
Electrical Department/Section of the
Owner organisation, authorised by
Electrical in-charge to issue Permits
(Electrical Line Clearances) and related
safety instructions. He shall issue Permit
only after ensuring that required
competent electrical staff, depending upon
the specific nature of work, are actually
engaged in the work.
viii) ELECTRICAL LINE CLEARANCES:
These Clearances are electrical
safety requirements related to jobs
covered under Permit-to work(Electrical)
as described in Section 4.0
Both the terms “Permit-to work
(Electrical)” and “Electrical Line
Clearance” (briefly “ Permit or “Clearance”)
referred in this Standard covey the same
meaning and are interchangeable.
4.0 PERMIT-TO-WORK
(ELECTRICAL) OR ELECTRICAL
LINE CLEARANCES
4.1 SCOPE
This section shall be read in
conjunction with the OISD STD-105 (Work
Permit System). The scope in this section
covers the special requirements for any
job on electrical system where Electrical
Isolation-Lockout/Energisation or Earth
Excavation Clearances are also needed.
In the event of any in-consistency with the
provisions under OISD-STD-105, for jobs
connected with electrical system, the
special requirements specified in this
section shall prevail
For definitions of terms and
responsibilities of various categories of
staff involved in Permit System, Section
3.0 shall be referred.
4.2 APPLICATION
For any construction, repair,
testing, maintenance or inspection jobs on
an electrical system or for any work in
close proximity to energised electrical
circuits, or for that matter any job in
general where an Electrical Isolation is
needed, the requirements detailed in this
section shall apply.
Compliance to these requirements
is necessary to prevent:
i) The equipment/line becoming
accidentally or inadvertently
electrically charged when persons are
working on them, (as cautioned in
Rule No.36 of the Indian Electricity
Rules)
ii) Induction effect from the nearby
energised electrical systems.
iii) Accidental contact by the personnel
with any live part of electrical circuit.
The requirements detailed in Section
4.6 shall apply for obtaining clearances
during earth excavation.
4.3 TYPES OF CLEARANCES
Following Electrical Line
Clearances, through a written Permit-to-
work system, shall be obtained by EIC
from Permit-Issuing Authority (Electrical),
for any work covered under Permit system
as detailed in Section 4.3, in addition to
Work Permit from UIC.

i) Electrical Isolation-Lockout (or briefly
Isolation) Line Clearance (before
commencement of work).
ii) Electrical Energisation Line Clearance
(before energisation of isolated
equipment and circuits, after
completion of work).
iii) Earth Excavation Line Clearance.
4.4 PROCEDURE FOR ELECTRICAL
ISOLATION - LOCKOUT / i) Work Request by concerned EIC is
ENERGISATION LINE
CLEARANCES
Whenever the jobs covered under
Permit system fall into any of the following
four categories, the procedure detailed
below (applicable to the respective
category) and Special Instructions as per
section 4.5 shall be followed. Electrical
Isolation and Energisation shall be carried
out only by Authorised Person.
4.4.1 UIC requiring an electrical
system to get checked through
Electrical-in-charge (e.g. An
electric motor trips repeatedly
interrupting plant operation).
i) UIC issues Work Request along with
Work Permit to Electrical in charge to
carry out the work.
ii) Authorised Person after receiving
Work Permit does the positive
Electrical Isolation, completes all the
work, keeps the circuits ready for
energisation, reports to Electrical-in-
charge, and returns Permit.
iii) Electrical-in-charge verifies the
completion of all work, and returns
Work Permit to UIC, after ensuring
that the circuits are kept ready for
safe re-energisation.
iv) UIC decides when to start the
equipment for operation and
arranges for safe charging of the
equipment, after obtaining Electrical
Energisation Line Clearance.
4.4..2 Electrical-in-charge requiring to
complete departmental job of
checks/repair/test on an
electrical system.
Procedure identical to 4.4.1
except in I) which shall be substituted as:
“Electrical-in-charge requests and
obtains Work Permit from UIC for carrying
out the specific work”.
4.4.3 Another Department requiring
completion of a job on an
electrical system (e.g.
Revamping work or a design
improvement etc.)
issued to UIC.
ii) UIC requests Electrical-in-charge
in writing for positive Electrical
Isolation.
iii) Authorised Person does Electrical
Isolation, arranges to obtain
Electrical Isolation Line Clearance
and submits it to UIC.
iv) UIC issues Work Permit and
Electrical Isolation Line clearance
to EIC for carrying out the
specific work.
v) EIC on completion of the work
returns Work Permit and
Clearance to UIC, alongwith
document showing the
modification carried out, after
ensuring that the circuits are kept
ready for safe re-energisation.
vi) UIC thereafter requests Electrical-
in-charge for safe re-energisation
of circuits and hands over to him
the document showing the
modification carried out.
vii) Authorised Person energises
circuits as directed by electrical-in-
charge, arranges to obtain
Electrical Energisation Line
Clearance and submits it to UIC.
vii) UIC decides when to start the
equipment for operation and
arranges for safe charging of the
equipment.
4.4.4 Another Department requiring
completion of a job on a non-
electrical equipment (e.g. Pump,
compressor, fan, etc.) having
electric drive.

Procedure identical to section 4.4.3 shall
be followed.
4.5 SPECIAL INSTRUCTIONS
i) The system of issuing Work Request,
Electrical Line clearances (for
Isolation- Lockout/Energisation) and
Work Permit, shall be implemented
through a written Permit-work, system
in the prescribed format which shall be
developed by individual organisation
depending on the type of installation
and administrative set up, taking care
that the provisions of IE Rules
(No.3,29 and 36), IS:5216 and the
Owner-in-charge concept, as defined
in OISD-STD-105 (Work Permit
System) are incorporated in this
format.
ii) Authorised Person while carrying out
the work covered under Permit system
shall physically posses Permit duly
authorised by Permit-Issuing Authority
(Electrical).
iii) At times, different agencies area called
upon to work on same equipment. UIC
shall ensure that Work Permits of all
the agencies are closed before
recharging the equipment. Similarly,
the equipment may have more than
the one source of electric supply.
Before issuing any Permit to EIC, UIC
shall arrange through Electrical-in-
charge for:
(a) Positive Electrical Isolation (by
disconnection of all sources of
electric power supply) and
obtaining Electrical Isolation Line
Clearance.
(b) Effective earthing of line/
equipment (Isolated section)
iv) After completion of the work, EIC shall
arrange to deenergise and remove all
temporary installations, construction
materials, debris and withdraw
personnel from site, and returns Work
Permit/Clearances to UIC. UIC shall
arrange for safe charging of the
equipment after obtaining Electrical
Energisation Line Clearances.
v) Throughout the work, Authorised
Person shall ensure that the switches
and circuit breakers controlling the
supply to the equipment or line, shall
be kept tagged with caution boards
stating MEN WORKING ON LINE to
caution against anyone inadvertently
closing them. if possible, the control
switches/breakers should be locked
also. The area of work shall be strictly
cordoned off from unauthorised entry.
vi) While carrying out Electrical
Isolation/Energisation work, the
persons connected with the work shall
use only approved and tested
protective equipment (Rubber gloves,
shoes, insulating mats, safety
appliances, etc.,) taking all the safety
precautions described in IS:5216.
vii) Electrical Line Clearances shall be
taken even while working in proximity
of bare energized electrical conductor.
4.6 PROCEDURE FOR EARTH
EXCAVATION LINE
CLEARANCE
i) This Clearance shall be taken by
EIC, from Permit Issuing Authority
(Electrical), wherever earth
excavation is to be carried out.
Without such clearance, if excavation
is carried out, especially over
energised underground electrical
facilities it may cause fatal accidents
to the personnel, besides adversely
affecting the plant operation due to
possible damage of such
underground facilities (e.g. piercing
the insulation of live cable through
sharp tool like pickaxe).
ii) After first obtaining permission from
UIC for the work, Earth Excavation
Line Clearance shall be taken by EIC
from Permit-Issuing Authority
(Electrical) in an approved format to
be developed by individual
organisations depending on the type
of installations and administrative set
up. While designing the format, the
need of owner-in-charge concept
shall also be taken care of, as
defined in OISD-STD-105 (Work
Permit System).
iii) Permit-Issuing Authority (Electrical)
shall spell out the precautions to be
taken, while carrying out such earth
 excavation, in the Clearance itself.
Prior to issue of Clearance, he shall
ensure that the proposed excavation
does not interfere with existing
underground electrical facilities such
as power (H.T & L.T), telephone, fire
alarm, lighting, and control cables,
earthing, and cathodic protection
installations etc.,
iv) EIC shall ensure compliance of all the
safety measures including those
stipulated in the Clearance and
provide supervision throughout the
work for safe excavation and
protection of the underground facilities
from any damage due to excavation.
He shall promptly report to Permit-
Issuing Authority (Electrical) any
damage to underground facilities even
if it be of minor nature, and shall
proceed with the excavation work only
after complying with further
instructions, as endorsed in Permit, if
any.
v) Irrespective whether mentioned or not
in the Clearance, whenever
bricklayer, tiles or cables sleeves are
encountered during the excavation
work (which confirm electrical
facilities below), EIC, after stopping
excavation work, shall inform of the
same to Permit-issuing Authority
(Electrical) and obtain further
instructions to proceed.
vi) The Earth Excavation Line Clearance
shall be issued only after EIC first
obtains Work Permit from UIC for his
work in the particular location of the
unit.
vii) UIC shall ensure that EIC closes main
Work Permit only after his first
closing Earth Excavation Line
Clearance, and obtaining Clearance
from Permit-Issuing Authority
(Electrical) which shall confirm that
the excavation was carried out safely,
trenches backfilled, the construction
materials and debris cleared, and
personnel withdrawn from the site.
5.0 BASIS AND TYPES OF
INSPECTION
5.1 BASIS OF INSPECTION
Failures of electrical equipment gives rise
to any or all the following hazards:
i) Fatal accidents due to electric shock.
ii) Fire accidents and burn injuries due to
electric arcs/sparks/hot surfaces
iii) Abrupt interruption in plant operation..
The failures of electrical equipment can be
attributed to:
i) Imposed external conditions such as
deterioration of enclosure, insulation
and operating mechanism by
environment conditions like heat,
moisture, dust, chemical attack and dirt.
ii) Quality of power supply (like
undervoltage, powerdips, unbalanced
voltage, frequently failures of power
supply etc.)
iii) Overloading due to any reason.
iv) Internal faults in the equipment itself
mainly due to manufacturing defects,
or those crept in during installation,
maintenance and repairs.
v) Inferior quality of work due to factors
like poor workmanship by
unqualified/unskilled and untrained
workers, inadequate or incompetent
supervision, non-compliance of
safety and statutory requirements,
adoption of incorrect procedures, and
usage of poor quality of tools and
tackles.
vi) Usage of substandard materials and
equipment not in conformity with
original design specifications.
vii) Design deficiencies in the technical
specifications, improper sizing and
layout of installations and lack of total
system concept.
viii) Bypassing of protective and
interlocking devices/circuits during
operation though originally designed
for the system.
ix) Inability for carrying out shutdown
inspection/tests on the equipment in
time, as required by maintenance
inspection schedules, due to
 difficulties in taking the equipment out
of service.
Inspection programmed on electrical
equipment and associated circuits shall be
devised on the basis that the inspection
results will be able to pinpoint the trouble
spots in the installations, well in advance,
allowing ample time for the maintenance
personnel to take remedial measures, so
as to prevent failure of equipment leading
to unsafe conditions and hazards as
mentioned above. No equipment shall be
operated beyond its safe life period
assessed on the basis of inspections from
time to time and optimum replacement
schedule shall be followed. Manufacturer’s
recommendation shall prevail wherever
available.
5.2 TYPES OF INSPECTION
The field inspection of electrical equipment
in an operating unit is classified into
following three types:
i) ONSTREAM INSPECTION
This covers audio visual inspection items
(instrument aided or otherwise) for
checking of general equipment conditions,
while the equipment is in operation. (e.g.
an abnormal nose or vibration of motor,
leakage of transformer oil or overheating
of equipment etc., can be assessed
through such inspections).
ii) SHUTDOWN INSPECTION
This covers those inspection items for
checking conditions of equipment and
systems which cannot be revealed through
Onstream Inspection (such as internal
condition of equipment). This inspection
shall be carried out after taking the
shutdown of the related equipment after
obtaining the Electrical Line Clearance,
and Work Permit, requirements of which
are detailed in Section 4.0 and in OISD-
STD-105 (Work Permit System)
iii) INSPECTION OF STANDBY
EQUIPMENT AND SPARE
PARTS
The standby electrical equipment electrical
equipment shall be inspected on the same
basis and schedule applicable under item
(ii) above, so that changeover from normal
to standby equipment shall be possible
without any downtime of unit operation.
The standby rotary equipment shall
additionally be checked at least once
every two months for-
a) Free rotation of shaft
b) Proper functioning of space heater
circuit
c) Weather protection.
d) Insulation resistance of motor with
cable.
If, however, standby equipment was not
energised earlier, all applicable
Precommissioning checks, as detailed in
Section 9.0 shall be carried out before
taking it into service.
The spare parts shall be inspected to
ensure compliance with original
specifications as per manufacturers’
catalogue number.
6.0 FREQUENCY OF
INSPECTION
The inspection scheme given in the
following tabular format shall be followed
as minimum requirement for the items to
be inspected. Frequencies of inspection in
this format have been arrived at,
considering a typical installation and
therefore shall be treated as guidelines.
Depending on specific requirements of the
installation, considering severity of usage,
criticality of equipment, environmental
conditions and such other factors,
individual organisations shall review and
develop own inspection frequency
standards which shall be strictly followed.
The frequency of inspection for new or
special equipment, where previous
experience is not available, shall be
reviewed by the concerned organisation,
after one or two inspections and
reconsidered whether the interval could be
lengthened safely or should be shortened.
care shall be taken against the bad effects
of over maintenance especially for
flameproof and such critical installations.
No attempt should be made to replace or
repair a glass in a flameproof enclosure
(e.g. in lighting fixture or the parts) except
with the complete assembly or part
obtainable from the manufacturer for
which the flameproof certificate from the
competent authority shall be obtained to
confirm its flame proofness.
For inspection procedures, Section 7.0 vii) Surface overheating F
shall be referred. The safety Electrical viii) Ventilation F
Line Clearances as required in Section 4.0 ix) Abnormal noise F
shall be obtained for work where Electrical x) Functioning of meters F
Isolation is needed or when any work is to xi) Corrosion effects (external M
be carried out in close proximity to bare xii) Provision of Guards to M
energised electrical circuits. moving parts
xiii) any other inspection
Insulation resistance, earth resistance and recommended by the
continuity tests, when required to be manufacturer
carried out in an hazardous area, shall be Note:
carried out only with certified intrinsically
safe insulation/earth tester suitable for use For critical generators such as for Captive
in classified hazardous area, after taking plants, the frequency of inspection shall be
the shutdown of the related equipment Daily (D) basis for all items, except for
through permit system. items (XIII) and (XIV).

However, if such hazardous area is The following shall be Shutdown

rendered non hazardous and certified by Inspection items:
competent authority to be a safe area, i) Insulation resistance
usage of standard testing equipment shall ii) Earthing connections(checks
be permissible till such time the are shall include earth resistance
continues to remain non-hazardous. measurements, tightness of
connections, and continuity of
Additionally, the applicable provisions in conductors HY
the API Guide Chapter XIV (electrical iii) DC resistance of stator/ rotor
systems) Table 5 to 13 (methods of / exciter HY
Inspection) and the recommendations of iv) Air gap between stator and
the manufacturer shall be followed, while rotor HY
devising inspection schedules. v) Manual and automatic
synchornising and change-
LEGEND: over systems. HY
vi) Alignment of coupled
D : Daily HY : Half yearly machine HY
W: Weekly nY : Once in n years
F : Fortnightly TA : Turn around
M: Monthly ASCO: After specified
cycles of
operation
Q: Quarterly

6.1 ROTATING MACHINERY

-----------------------------------------------
Items to be inspected Frequency
-----------------------------------------------
6.1.1 Generator (including Exciter)

The following shall be Onstream

Inspection items:

i) Condition o commutator (for

sparking), brushes, and
collector rings W
ii) Bearing
condition(lubrication, noise, W
and temperature)
iii) Cooling system condition. W
iv) Housekeeping W
v) External damages W
vi) Leakage of OIl/Water F
vii) Operation of circuits
especially related to space
heater,temperature detector,
trippingdevices, annun-ciators
and interlocks. HY

viii) Availability of all protective

devices, and circuits in line as
per design, and all in
operating condition HY
ix) * Moisture absorption
(Dieelectric Absorption Test) Y

x) * Insulation deterioration
(Polarisation Index Test) Y

xi) Internal damages,

discolouration, open or short
circuits, and loose
connections. Y

xii) Condition of commutators,

brushes, and collector rings Y

xiii) Condition of foundation and

tightness of foundation bolts Y
xiv) Any other inspection
recommended by the
manufacturer Y

Note :

* Items (ix) and (x) are needed for critical

high voltage equipment only.

6.1.2 Motor (H.T and L.T)

The following shall be Onstream

Inspection items:
i) General Cleanliness M

ii) Corrosion effect (external) M

iii) Surface Overheating/sparking M
iv) Ventilation M
v) Vibration M
vi) Abnormal noise M
vii External damages M
viii Load (Amperes) M
ix) Lubrication M
x) Cooling System M
xi) Effect of supply system
disturbances such as voltage
drop, power dip etc. (as
given in the log entries at
substation) M
 xii Provision of Guards to
moving parts M
xiii Condition of commutator,
brushes, and collector rings
for slipring and
synchronous motors M
xiv any other inspection
recommended by the
manufacturer M

Note:

For critical motors, the frequency of

inspection shall be weekly (W) basis in
case of all items (I) to (xiv).

The following shall be Shutdown

Inspection items:

i) Mechanical freeness of rotor

shaft
ii) Insulation resistance
iii) Winding resistance
(Measurement)
iv) Earth resistance and
continuity
v) Operation of

--Space heater
--Temperature detector
--Interlocks,/trips
--Annunciation circuits
vi) Availability of all protective
devices and circuits in line
as per design, and all in
operating condition.
vii) Condition of remote tripping
devices & limit switches
viii) Limit & torque switches (in
the case of motor operated
valves) for proper
functioning.
ix) Oil level in lubricating
gearcase.
x) “Moisture absorption ( Di-
electric Absorption Test)
xi) Insulation deterioration
(Polarisation Index Test)

xii) Internal damage, discoloura-

tion and loose connections
xiii) Stator to rotor airgap
measurement
 v) Control supply availability W

xiv Condition of commutator, vi) Ventilation system W

carbon brushes, (for correct
brush pressure) and collector vii) Corrosion effect (external) W
rings
xv Condition of supporting legs, viii) Accessibility for
pedestal and base plate maintenance /operation M
xvi Condition of the foundation
and tightness of foundation ix) Functioning of meters, and
bolts. lamp indicators M
xvi Any carryover of oil or grease
inside the windings x) Oil level and leakage M
xvii Any carryover of oil or grease
inside the windings xi) Correctness of relay settings
xix Signature analysis (optional (for critical services) M
xx Tan delta test (optional)
xxi Any other inspection xii) Any other inspection
recommended by the recommended by the
manufacturer manufacturer
Note:

“ Items (x) and (xi) are needed for critical The following shall be Shutdown
high voltage equipment only. Inspection items:

in the case of synchronous/Slipring i) Dielectric strength of oil ( in

motors, following additional Shutdown breakers) and Oil HY/
Inspection items shall be carried out: Contamination ASC0

i) Tightness of the DC Poles ii) Condition of earthing Q/

fitted on the outer- connection ASCO
Periphery of the rotor HY
iii) Insulation and earth HY/
ii) Condition of end rings HY resistance ASCO

iii) Continuity of the leads iv) Electrical resistance of HY/

connecting the poles and the breaker ASCO
slip rings via brushes HY
v) Internal damages
iv) Any other inspection (breakage of barriers, are
recommended by the chute cracks,
manufacturer jamming solenoid, dirt/dust
accumulation in any part HY/
etc.) ASCO
6.2 STATIONARY EQUIPMENT vi) Operation of
--------------------------------------------------------
Items to be inspected Frequency --Protection, control and
-------------------------------------------------------- interlock circuits
6.2.1 Switchboard and Panel --Circuit breaker (rack-in-
out mechanism,
The following shall be Onstream springs of driver)
Inspection items: --Simultaneous
i) General Cleanliness W closing/opening of all the
three phases.
ii) Weather protection W --Contactor operation
--Space heater operation
iii) Dust and vermin-proofness W --Safety shutters HY

iv) External damages W vii) Tightness of all bolts, cable Y

connections, and terminals
 foundation and yard HY
viii) Condition of contacts,
contact alignment, and xvi) Dielectric strength and
clearances with live parts Y acidity tests of oil samples Y

ix) Breaker closing and xvii) Completeness with all

opening time & total relay accessories Y
operating time Y
xviii) Any other inspection
x) Checking and calibration of recommended by the
relays Y manufacturer

xi) Any other inspection The following shall be Shutdown

recommended by the Inspection items:
manufacturer Y
i) Terminal connection in
primary & secondary Y
6.2.2 Transformer & Bus duct ii) Operation of protection
and annunciation circuits Y
The following shall be Onstream iii) Internal damages, condition
Inspection items: of supports, busduct
i) Oil leakage D flexibles and insulators Y
iv) Insulation resistance of
ii) Oil level (in transformer & in primary and secondary
bushing) windings Y
v) Earth resistance and earth
iii) Condition of silicajel D continuity Y
vi) Earth resistance and earth
iv) Oil temperature /Winding continuity
temperature D vii) Any other inspection
recommended by the
v) Load (Amperes) D manufacturer Y

vi) Cleanliness D 6.2.3 Battery

vii) External damages W The following shall be Onstream

Inspection items:
viii) Operation of cooling fans & i) General cleanliness of
surface temperature W battery room W
ii) Functioning of ventilation
ix) Annunciation (for abnormal system W
conditions) W iii) Formation of acid vapours in
room W
x) Condition of cable end iv) Spillage of electrolyte W
sealing and terminal boxes W v) Level of electrolyte W
vi) Cell voltage and proper
xi) Insulators and bushing connections for correct
(check for any cracks) for polarity W
outdoor transformers M vii) Specific gravity of cell W
viii) Availability & condition of
xii) Corrosion effect (external) M safety equipment (such as
rubber apron, goggle, and
xiii) Condition of oil soak pit and acid proof hand gloves) M
oil drainage arrangement M ix) Caution boards (“No
smoking”) etc., M
xiv) Sealing of bus duct entry on x) Condition of acid-proof
both sides of wall (for flooring M
vapour /dust/water tightness HY xi) Any other inspection
recommended by the
xv) Condition of transformer manufacturer
 with annunciation W
Note:
ix) Insulation resistance HY
For critical/emergency and switchgear
power plant applications, the frequency of
inspection shall be Daily (D) basis, in case
of items (I) to (vii) and weekly (W) basis, in
case of items (viii) to (x).

The following shall be Shutdown

Inspection items:

i) Joints, terminal and bolted

connections for tightness
(for full electrical contact) M

ii) Blockage of vent plugs M

iii) Corrosion effects on

terminals and connectors M

iv) Condition of supports (racks)

M

v) Damages such as cracks in

containers M

vi) Capacity test M

vii) Any other inspection

recommended by the
manufacturer

Note:

For critical/emergency switchgear, and

power plant applications, the frequency of
inspection shall be Weekly (W) basis, in
case of items (I) to (v)

6.2.4 Charger & D.C. Board

i) General cleanliness W

ii) Ventilation system W

iii)
Float voltage & charging W
current

iv) Overheating W

v) External damages W

vi) Tightness of connections W

vii) Condition of contactors and

switches W

viii) Operation of charger circuit

x) Changeover circuits HY
(emergency backup)

xi) Insulation from earth (both +

ve and -ve of DC System

xii) Any other inspection

recommended by the
manufacturer

Notes:

1. For critical/emergency, switchgear, and

power plant applications the
frequency of inspection shall be Daily
(D) basis for items I) to v) Weekly (W)
basis for items 9vi) to (viii)

2. (vi) to (viii) shall be Shutdown

Inspection items.

6.2.5. U.P.S/Invertor

The following shall be Onstream

Inspection items:

i) General cleanliness,
(accumulation of dust, and
dirt on contactors, diodes,
thristors, transformers and
other components) and
external damages W

ii) Condition of ventilation and

detection of any
overheating W

iii) Any other inspection

recommended by the
manufacturer

The following shall be Shutdown

Inspection items:

i) Internal damages HY

ii) Pitting of contacts HY

iii) Voltage and wave forms on

all as specified by the HY
manufacturer

iv) Tightness of wiring

connections HY
 manufacturer HY
v) Operation of protective
devices and changeover
circuits HY 6.2.7 Switchyard Equipment (Circuit
breaker, Disconnect switch,
vi) Functional checks for all C.T, P.T, L.A)
circuits, and annunciation Y
The following shall be Onstream
vii) Any other inspection Inspection items:
recommended by the
manufacturer i) Overheating, and sparking D
( of contacts)

6.2.6 Reactor and Capacitor ii) Oil level and oil leakage D

The following shall be Onstream iii) Earthing connections, and

Inspection items: overhead earth mesh
condition D
i) General cleanliness W
iv) Cleanliness Housekeeping) W
ii) Structural support W
v) Damages W
iii) Damages (external) W
vi) Corrosion effect (external) M
iv) Condition of ventilation W
vii) Functioning of lamps and
v) Oil level W meters M

vi) Oil leakage W viii) Any other inspection

recommended by the
vii) Grounding connections W manufacturer

viii) Any other inspection

recommended by the The following shall be Shutdown
manufacturer W Inspection items:

i) Operation of switchyard
The following shall be Shutdown equipment with control,
Inspection items: trip, and annunciation
circuits HY
i) Insulation resistance Q
ii) Internal damages HY
ii) Discolouration on cable
connector clamps Q iii) Condition of insulators
HY
iii) Earth resistance Q iv) Alignment between
contacts HY
iv) Operation of protective
devices Q v) Insulation resistance HY

v) Dielectric strength and vi) Earth resistance HY

acidity of oil HY

vi) Tightness of wiring

connections HY

vii) Corrosion effects

viii) Any other inspection

recommended by the
 The following inspection items (common
vii) Dielectric strength and Y/ for all the instruments listed) shall be
acidity of oil ASCO carried out:

--Cleanliness
viii) Any other inspection
recommend by the --Breakages (of glass cover etc.)
manufacturer
-- Calibration test, and other safety checks
6.2.8 Lighting Fixture & Junction-box before use as per manufacturer’s
(installed for plant/yard/street and recommendation
building lighting.)
--Zero setting, errors
The following shall be Onstream
Inspection items; --Bent pointers, sticky or jerky movement

i) Cleanliness & external List of instruments (with the frequency of

damages W inspection marked against each item) is
given below:
ii) Fixture support W
i) H.V. discharge rod M
iii) Illumination in critical areas M
ii) Voltage & current detector M
iv) Condition of conduits,
Junction boxes M iii) Megger (for measuring
insulation resistance) M
v) Any other inspection
recommended by the iv) Megger (for measuring
manufacturer earth resistance) M

v) Cable fault locator HY

The following shall be Shutdown
Inspection items: vi) Avometer HY

i) Condition of gaskets Q vii) Tong tester HY

ii) Operation switches & viii) Relay test bench Y

circuits Q
ix) Motor test bench Y
iii) Insulation resistance HY
x) Oil filtering equipment Y
iv) Grounding connections HY
xi) Dielectric test equipment Y
v) Loose connections HY
xii) Phase sequency meter Y
vi) Changeover circuits
(emergency lights) HY xiii) Portable voltmeter,
ammeter, frequency meter,
vii) Corrosion effect, condition hydrometer, thermometer Y
of paint (lighting fixtures,
junction boxes, conduits, xiv) H.V. testing unit Y
poles and switches) HY

viii)Any other inspection recommended by 6.3 PROTECTIVE SYSTEMS

the manufacturer --------------------------------------------------------
Items to be inspected Frequency
6.2.9 Test Instruments for Inspection --------------------------------------------------------
6.3.1 Relay & Meter
The following shall be Onstream 6.3.2 Earthing & Bonding
Inspection items:
The following shall be General Inspection
i) Cleanliness W items:

ii) Brea kage’s of glass & i) Visual checks for external

cover M damages to earth
conductors, earth electrodes M
iii) Erratic operation (obser- and earthing connections.
vation from log book
entries) Q ii) Operation of earth leakage
annunciation and trip circuits
iv) Correctness of relay (Simulation Tests) HY
settings (for critical
services) Q iii) Corrosion effects and
tightness of connections HY

v) Any other inspection iv) Identification of earth

recommended by the electrodes in the field with
manufacturer permanent markers HY

v) Earth resistance on
The following shall be Shutdown individual electrodes once
Inspection items: in dry and one in wet HY
weather
i) Trip circuit operation
(simulation test) TA vi) Continuity of earthing
conductors Y
ii) Relay operation under fault
conditions simulated vii) Bonding and earthing of
(primary injection) TA all metallic structures, pipe
racks, armour of cables,
iii) Changeover circuit and electrical equipment
operation HY enclosures Y

iv) Contacts(for pressure, viii) Whether buried earthing

alignment, free operation, conductors are exposed at
freedom from corrosion any location
and burning effects) HY
ix) Earth loop impedance TA
v) Target operation HY (measurement)

vi) Condition of leather The following shall be the Special items

bellows, oil dashpot, timing Inspection applicable to different
devices and check for categories of installation:
missing nuts and screws
HY i) Neutral earthing of the
vii) Current, potential and electrical system HY
power at pick up, drop out
and intermediate point of ii) Body earthing of the
each relay element HY electrical equipment HY

viii) Checking and calibration of iii) Tankage (bonding of floating

all relays and meters
(KWA/KVA demand,
ammeter, volt meter)
ix) Any other inspection recommended by
the manufacturer
roof, ladder rollers, rails of
staricase and lubrication on
Y rollers) HY
iv) LPG bottling plants, loading
gantries /tank truck loading HY
• Check for:
 a) Earthing continuity of the enclosures have IP:55
loading arms, flexible weather protection) HY
hoses, and piping
vii) Corrosive effects Y
b) Earthing & bonding of
rail tracks within the
gantry premises viii)Any other inspection as recommended
by the manufacturer/designer of the
c) Earth connections in system.
carousal /tanks
6.3.5 Fire alarm system (Electrical
v) Process equipment in the circuits)
plant area (such as heat
exchanger, vessel, column, i) Operation of siren circuits
piping etc.) whether (simulation test) W
grounded Y
ii) Operation of breakglass field
station)actuation circuits W
6.3.3 Lightning Protection
iii) Checks to confirm no blown
i) Visual check for external fuses, and no fused lamps W
damages to earth electrodes
down conductors, lightning iv) Emergency supply system W
arrestors, supporting availability, and its auto
structures and insulators Y change over circuit
operation, condition of battery
ii) Cleanliness of insulators (as detailed in 6.2)

iii) Earth resistance and v) Visual check for

continuity damages/missing parts M

vi) Insulation resistance for cables

iv) Any other inspection items required and panels M
as per IS:2309 or BS 6651 as
applicable vii) Continuity of cables M
6.3.4 Flameproof/weather protection
viii) Any other inspection recommended
i) Visual checks for external by the manufacturer or system
damages ( to glasses, designer
casting etc.) M
6.3.6 Cathodic protection (Electrical
ii) Accumulation of dust & dirt M circuits)

iii) Effectiveness of earthing For tankages, underground piping,

connections Q ubmerged structures and cross-country
pipelines)
iv) Condition of gasket (water
tightness) Q i) Performance of transformer /
effective earthing connections W
v) Unauthorised odifications
(conformity with original ii) Pipe/structure to soil potential
specifications) in the measurements for impressed
flameproof equipment HY current and sacrificial anode
systems HY
vi) Completeness of bolts,
glands, stoppers and their iii) Anode current and all
tightness(In case of outdoor connections to anode /
newly installed equipment, structures (conformity to HY
check through manu- design requirements)
acturer’s test certificates that
iv)Any other inspection recommended by
system designer
Note:
The frequency of inspection is to be
increased if abnormal external corrosion
and breakdowns are encountered in the
cathodically protected system.
6.3.8. Protective and Safety Appliances
The condition of following appliances shall
be checked as per the requirements of IS:
4770 or as recommended by the
manufacturer. The frequency of
inspection shall be ‘HY” or everytime
before being put to use, whichever is
earlier.

6.3.7 Electric Heat Tracing. I) Gloves

i) Visual checks for functioning
of all panel indication lamps
(indicating tracer circuit
healthily condition)
ii) Temperature measurements at
inspection points
II) Rubber shoes, insulating mats
III) Safety belts
iv) Ladders
v) Earthing devices
W vi) Helmets
vii) Current testers/voltage detectors
viii) Goggles & face shields
W ix) Earth leakage circuit breakers.

iii) Check to confirm no buried 6.4 DISTRIBUTION NETWORK

power cable is exposed at any
location
iv) Current reading of each circuit
and check for any blown out
fuse
v) External damages to piping,
insulation and tracers
vi) Weathre proofness for
outdoorpanels and junction
boxes especially whether
doors / covers kept closed.
--------------------------------------------------------
W Items to be inspected Frequency
--------------------------------------------------------
6.4.1. Cable and conduit wiring
W i) Availability of permanent cable
route markers and joint
location markers in the field HY
W
ii) Condition of cable termination
/joints and clamping arrange-
ments HY
M iii) Provision of identification tags

vii) Voltage drop at the farthest end iv) Mechanical protection to under
of tracer M ground and overhead cables
(especially for energised
viii) Tightness of connections M cables) HY

ix) Sealing and termination M v) Insulation resistance HY

x) Insulation resistance of cables, vi) Insulation deterioration (Polari-

panel boards and tracers HY sation Index Test) HY

xi) Continuity checks HY vii) Continuity HY

xii) Any other inspection viii) Damages to cables, conduits,

recommended by the wires including clamps/cable
manufacturer or system supports HY
designer.
ix) Water tightness of conduit
system Y
Note:
x) Corrosive effects on conduits Y
Items (viii), (x) and (xi) shall be Shutdown & junction boxes.
Inspection items

Notes:
1. It shall be checked (through random viii) Infringement and growth
trial pits) that the underground cables of vegetation M
are protected with sand and bricks
thoughout and ensure that the cables ix) Any damages to
are not exposed at any location. Also insulators and other
armouring, pipe sleeves and such other devices M
mechanical protection requirements
shall be inspected. x) Earthing of staywire M

2. Item vi) shall be applicable only for xi) Safe mechanical

critical high voltage cables. condition (of both normal
and standby O.H. lines) M
3. Items (v) to (vii) shall be Shutdown
Inspection items.

6.4.2 Cable Duct/Trench/Tray support 6.5 OUTDOOR SWITCHBOARD

--------------------------------------------------------
i) Congestion of cable in Items to be inspected Frequency
the duct (conformity for --------------------------------------------------------
pipe fill 50%) HY i) Earthing of fencing, gage,
insulator supports and
ii) Damages to cable trench other metallic structures HY
including covers, duct
and tray support HY ii) Condition of fencing & all
metallic structures from
iii) Sealing cable trenches corrosion effects HY
/ducts (prevention of
entry of foreign materials- iii) Checking of pipe from
vermin, water, chemicals, transformer to soakpit for
dirt, reptiles, etc into any leakage HY
trenches, ducts) Y
iv) Provision of locking
iv) Corrosion on the metallic arrangement for gate and
tray supports Y isolators (especially
when the transformers &
O.H. line are energised) HY
6.4.3 Overhead line (Uninsulated)
v) Provision of metal jelli oil
i) Cleanliness of insulators soakpit and fire partition
and bushings M walls (as applicable) HY

ii) Condition of hardware, vi) Condition of trenches

supporting structure and cover slabs and earth
conductors M electrodes in the yard HY

iii) Abnormal sagging and vii) Condition of transformer

clearances M plinth and other concrete
foundations
iv) Joints in the O.H. lines M
viii) Accessibility for maint-
v) Continuity of earth enance and operation
conductors M of switchyard equipment
with component parts HY
vi) Provision of guards,
anticlimbing devices, ix) General illumination HY
danger boards, and
phase markings M 6.6 SWITCH ROOM/SUBSTATION
BUILDING
vii) Corrosion effects M --------------------------------------------------------
Items to be inspected Frequency or permanent) HY
--------------------------------------------------------
i) General illumination HY iv) Adherence to safety and
fire fighting requirements
ii) Emergency lighting provision as per standards HY
and its auto-changeover circuit
operation HY v) Compliance of items
pointed out by Electrical
iii) Ventilation HY Inspectorduring periodical
statutory inspection(IE Rule
iv) Roof leakage HY No.46) Y

v) Sealing of cable and bus duct vi) Electrical equipment and

entries (to make them water connected installations
and vapour tight) HY whether conform to
Hazardous area classif-
vi) Housekeeping HY ication from time to
time.(including pressurised
vii) Water drainage arrangement HY enclosures and press-
urisation facilities) Y
viii) Provision of insulating mats
conforming to IS:15652:2006 vii) Availability of updated
having ISI mark, shock documentation operating
treatment chart, fire and maintenance manuals Y
extinguisher (suitable for
electrical fires), sand filled viii) Safety audit systems
buckets, break-glass fire (internal & external) Y
alarm station and telephone HY
(for internal and external ix) Training programs of
communication) electrical staff. Y

ix) Condition of trench, cover x) Availability of adequate

slabs, and chequered plates HY illumi nation (Decide on the
basis of joint inspection
x) Marking on the switchboard, with UIC in all operational
for the identification of areas) Y
circuits and provision of
danger, caution boards HY xi) Preservation of idle
equipment, cables, and
xi) Damages and corrosion spare parts Y
effects if any HY
xii) Procedure for allowing
temporary electrical
6.7 SAFE PROCEDURES AND facilities Y
SYSTEMS
-------------------------------------------------------- xiii) Adherence to logging system
Checks for compliance: of hourly reading of current,
-------------------------------------------------------- voltage, frequency, P.F.
i) Compliance of Work Permit KW/KWH, tap positions of
System (Electrical Line transformers etc., and also
Clearances as detailed in registering of power
Section 4.0) HY failures,system distur-
bances, break-downs and
ii) Procedures adopted for other details on 24 hour
safety in jobs by external basis at the main
agencies HY substation Y

iii) Unauthorised additions or xiv) Accessibility for operation

modifications of install- and maintenance of electrical
ations (whether temporary facilities Y
xv) Fireproof construction (for
enclosures housing elec-
trical equipment / compo-
nents) Y ---For high voltage
7.0 INSPECTION PROCEDURES
Before initiating the inspection of
electrical equipment and associated
circuits, Inspector should familiarise
himself with the complete previous history
of the equipment/circuits, design
parameters, service, likely areas of
concern, manufacturer’s recommendations
and such other pertinent data to arrive at
the appropriate inspection procedure.
Most of the defects/faults in electrical
system can be discovered only through
tests and not by external inspection alone.
For the basis on the type of
inspection, Section 5.0 shall be referred.
For competence of the person conducting
the tests, Section 3-ii) shall be referred.
Unless otherwise mentioned, the
acceptable test values shall be the
compliance of I.E. Rule 29 and the related
standards published by Bureau of Indian
Standards.
I) INSULATION RESISTANCE TEST:
Insulation resistance is measured
to ensure absence of leakage current and
humidity. For a given insulation condition,
the acceptable value of resistance
depends on the size and type of the
equipment, and voltage rating.
The insulation resistance is directly
measured with the help of megger which
applies constant test voltage (d.c) on the
insulation. This test voltage has to be
applied for the time required for the
absorption current to die down, (normally 1
minute). Electrical installations shall be
tested for insulation resistance between all
conductors and earth and between the
conductors themselves.
General 1 megaohm per KV
should be acceptable value of insulation
resistance. However, in case of 0.415 KV
circuits 1 megaohm should be minimum
acceptable value.
Recommended test voltages:
---For medium voltage
circuits - 500 Volts (d.c)
circuits - 1000 Volts (d.c)
If the insulation resistance values
obtained are less than required value, the
approved method of drying out shall be
carried out until the required steady
insulation resistance value is obtained.
ii) MEASUREMENT OF EARTH-
RESISTANCE
a) Earth resistance can be directly read
through an earth test Megger which
has associated Test, auxiliary Current
and Potential electrodes. This
instrument which is a combination of
ohmmeter and generator works on ‘fall
of potential’ principle. Test voltage is
derived from the generator of the
Megger.
b) Allowable earth-Resistance Values
The resistance value of an
earthing system to general mass of the
earth should not exceed.
-- 4 Ohms for electrical systems and
metallic structures
-- 7 Ohms for storage tanks
-- 1 Ohm for main earth grid, and bonding
connections between joints in
pipelines and
associated facilities.
-- 2 Ohms for each electrode to the
general mass of the earth.
iii) EARTH CONTINUITY TEST
A separate test of every earth
continuity conductor should be made
(Ref:E.3 of Institution of Electrical
Engineers - IEE’s regulation)
Since the values of impedance
and resistance of earth continuity
conductors are subject to the requirements
for earth loop impedance should also be
tested. (Ref.:D22 of IEE regulation).
All the earth leakage sensing
devices along with their wiring connections
shall be periodically tested for their proper
functioning at set values of leakage
current.
iv) POLARISATION INDEX TEST
This test is used to determine the
insulation resistance level of cable,
transformers’ motors’ and similar electrical
equipment. Using a power driven
insulation tester, the test voltage is applied
to the equipment for a period of 10
minutes. The insulation resistance values
at the end of 1 minute and 10 minutes
period are recorded. The ration of the final
resistance to initial resistance is called the
Polarisation index.
A good to excellent index is 2.5, a
poor to questionable index is 1 to 2. When
index level starts at 2.5 to 4 base level and
begins to fall one or two years later to 1.5
or 2 it is apparent that either the cable has
become dirty or wet, or the insulation has
become weakened to an unsafe condition.
These values shall be considered
only relative and are used to know the
trend of insulation deterioration over a
period of time.
v) MOISTURE ABSORPTION TEST
Moisture absorption is usually
evaluated from the ration of two values of
insulation resistance measured with
Megohmeter after 60 seconds and 15
seconds respectively. This ratio is called
the Coefficient of moisture (dielectric)
absorption, denoted by ‘K’.
R60
K= -----
R15
Damp installation will have a
coefficient value close to 1. As the
insulation dries out, the coefficient rises
and when it becomes 1.3 or greater the
insulation is considered to be dry.
vi) CATHODIC PROTECTION
(ELECTRICAL TEST)
The underground or submerged
structures such as pipelines shall be
protected against electrolytic corrosion by
cathodic protection, either by the
“impressed current” or the “sacrificial
anode” methods.
Periodic testing of cathodic
protection system such as structure to soil
voltage, anode current, soil resistivity,
performance of transformer and rectifier
shall be carried out to ensure continued
protection.
Current output and voltages shall
be adjusted to maintain the degree of
cathodic protection.
Cathodic protection circuits shall
be ON all the hours of the day all the year
round.
Allowable values of structure to
soil voltage shall be -0.85 volts as
measured with a special meter with
respect to copper to copper sulphate half
cell. Current density requirement depends
on the condition of coating and soil
resistivity. Better the quality of coating,
lower will be the requirement of current.
vii) CABLE FAULT DETECTION
Annexure VII describes one of the
procedures for detection of cable fault
location, which shall be used as a
guideline if specific instruction from the
cable manufacturer is not available.
viii) TESTS ON LIGHTNING
PROTECTION SYSTEM
The ohmic resistance of lightning
protective system complete with air
terminations but excluding earth electrode
connections should not exceed 1 ohm.
The continuity of lightning conductors and
bonding connections of structures shall be
tested to ensure that there are no open
circuits. Also, checks shall be made to
ensure that the clearances from other
structures are maintained to prevent
flashover to the structure during lightning.
8.0 DOCUMENTATION
Documentation and record
keeping form an integral part of total
inspection management system. The
various records, which shall be maintained
in any unit, are summarised below:
8.1 FAILURE ANALYSIS REPORTS
Failure analysis shall be conducted on
I) High Voltage equipment
 a) Tanks, gantry structures & process
ii) Repetitive failures of any kind area

iii)Power system failure affecting plant b) Vessels/exchangers/columns

operation
c) Motors/generators
iv) Failure due to arcing or sparking, which
caused unsafe condition/accidents. d) Earthing pits.

v) Failure to newly installed or repaired e) Bonding and grounding of loading

systems arms and piping

vi) Critical equipment and systems. f) Substations/switchyards

For this, various data and records g) Lightning protection system

shall be regularly maintained through
Failure analysis reports (in the formats ii) Insulation resistance tests of all power
suggested for few, as per Annexure V), and control cables, motors, transformers
and monitored by Electrical in-charge. and other critical electrical equipment.

8.2 HISTORY CARDS iii) Cathodic protection tests (potentials at

identified locations of tank bottoms,
History cards for following structures/ pipelines etc.)
equipment shall be maintained by each
Unit-in-charge or Maintenance Planning iv) Transformer oil tests
Cell, which should be the basis for
carrying out failure analysis and enabling v) Calibration tests of meters /
replacement with identical equipment or instruments /relays
components during emergencies:
vi) Simulation test on protective relay
i) Motors/Generators with circuits.
associated switchgear
ii) Transformers with associated vii) Test records on battery
switchgear
iii) Cables viii)Other data
iv) Relays
v) Battery a) Compliance reports of previous audit
vi) Other critical electrical equipment reports and Electrical Inspector’s
and systems observations during periodical
statutory inspections under I.E. Rule
Formats for few of the above have 46 (for the last 5 years)
been suggested in the Annexures I to IV.
The entries also should include the data: b) Manufacturer’s shop test certificates &
field test records of critical equipment
First date of commissioning................... before energisation and after
subsequent repairs.
Last Capital maintenance carried out
on............. c) Updated equipment list (load summary)

8.3 TEST RECORDS AND OTHER d) Updated single line drawing,

DATA
Records for the following tests and other
data listed shall be available with each
Unit-in-Charge or Maintenance Planning
Cell:
incorporating details of electrical
power communication and fire alarm
system incorporating all changes.
f) Permit to-work (Electrical) or Line
clearance formats.

I) Earth resistance tests g) Schematic control circuit diagrams with

explanatory notes.
h) Authorisation register (Annexure VI)
I) Reports on investigation of accidents
(for the last 5 years), if any
j) Specifications for spare parts (for
ordering purposes) with original
Manufacturer’s catalogues and
descriptive technical data.
k) Operation and maintenance instruction
manuals (system wise)
l) Reference documents (International and
Indian Standards, Codes, I.E. Rules,
and other latest statutory regulations)
Relay co-ordination drawings and table of
relay settings.
n) Substation log register with updated
entries and observations.
9.0 PRECOMMISSIONING CHECKS
Before commissioning electrical
equipment after repairs and maintenance,
the following minimum Precommissioning
checks shall be carried out. Wherever
manufacturer’s recommendations are
available, the same shall prevail.
In the case of newly installed
facilities also, the same Precommissioning
checks shall be applicable but additionally
the following shall be ensured:
I) The statutory clearances from the
State Electrical Inspectorate/Director
General, Mines Safety, (as the case
may be) shall be obtained for the
schemes and installations.
II) Manufacturer’s test certificates shall
be obtained(for the successful
passing of shop tests.
III) Installations conform to acceptable
engineering standards and are
appropriate to the respective
hazardous area classifications (as
per ISI-NEC-1985). Installations
with all individual Isolating devices
(for safe disconnection of electrical
circuits) shall be easily accessible
for regular and emergency operation
and maintenance.
9.1 ROTATING MACHINERY
9.1.1 Generators
The following items shall be
checked/tested, before start up:
I) Cable connections
ii) Loose contacts in field circuit
iii) Open circuits in exciter/field coils
iv) Short circuits in the coils
(exciter/stator/field)
v) Blockage of ventilator openings
vi) Condition of bearings
vii) Turning of Oil rings
viii)Oil lubrication (adequacy & Oil quality)
ix) Alignment of coupled machines
x) Grounding of coils (especially exciter)
xi) Brush spring pressure
xii) Earthing connections (body & neutral)
xiii)Protection circuits (simulation tests)
xiv) Auto/manual starting and changeover
system
The following items shall be
checked after start up:
I) Exciter voltage (whether low)
ii) Load on the generator
iii) Overheating of
alternator/exciter/bearings
iv) Speed whether steady or hunting
(growling)
v) Sparking of brushes
vi) Commutator surface for uniformity
(projection, if any)
vii) Carbon dust collection (whether
consolidated between the commutator
segments)
viii) Audio visual annunciation
ix) Noise
x) Brush spring pressure.
9.1.2 Motors and Controlgear
The items listed below shall be
checked/tested before start up:
I) Mechanical and electrical checks as per
IS: 900
ii)Cleanliness (free from dirt, dust and
moisture)
iii)Insulation resistance (before and after
connection of the power cables)
iv)D.C. resistance of stator and rotor
windings(This should not differ from
manufacturers’ data by more than 2%)
v) Polarisation Index and Dielectric e) Vibration
Absorption tests (for critical equipment f) No load current
only) g) Speed

vi) Sliprings, brushgear polish and Note:

cleanliness of machine winding.
vii)Brushes in holders (check for clearance
and pressure
viii)Connection and operation of space
heater where provided. (ensure its
automatic switching off when motor is
started and switching on when motor is
stopped)
Run the uncoupled motor for a
minimum period of 4 hours for LT Motors
and 8 hours for HT Motors and ensure
trouble free operation.
9.2STATIONARY EQUIPMENT
/SYSTEMS
9.2.1 Switchboards & Panels

ix) Provision of emergency stop switches The following shall be checked/tested:

and coupling guard
I) Cleanliness (free from dirt, dust,
x) External damages, and missing moisture etc.)
components
ii) Any tool or foreign material inside the
xi)Functional checks of motor control and equipment
protective circuits with interlocks and all
audio visual annunciation (through iii)All circuit wiring and terminations in tact
simulation test)
iv) Tightness of connections/clamping of
xii)Freeness of rotation of motor shaft, and wires
lubrication.
v) Vermin proofness (whether unused
xiii)Cable termination (check also for openings closed)
proper size and type of cable)
vi)Protection and annunciation circuits
xiv)Ratings of fuses, thermal, short circuit including checking of relay settings,
& earth fault settings (protective and fuse ratings.
system)
vii) Relay and meter calibrations
xv) Earthing connections/earth resistance (simulation)

xvi)Flameproofness, corrosion and viii) Operation of interlocks and safety

weather protection. devices

xii)Voltage drop ix) Provision of caution notices, tags, and

xviii)Alignment with coupled machine.
The items listed below shall be checked
after start up:
I) Mechanical and electrical checks as per
IS: 900
danger boards
x) Provision of insulating mats conforming
to IS:15652:2006 having ISI mark
xi) Continuity of wires
xii) Insulation resistance

ii)Cooling system xiii)Conformity with updated schematic

and single line diagrams
iii)No load run of motors with observations (ratings/settings)
for
a) Supply voltage and frequency xiv) Timer checks
b) Direction of rotation.
c) Abnormal sound xv) Short in CTs,, blockage in relays
d) Temperature
xvi) External damage and dents
xvii) Cable bends within the switchboard
(whether required bending radius is
maintained)
xviii) Contact alignment of draw out type
switchgear
xix) Oil level, and oil condition for the oil-
immersed gear
xx) Anticondensation heater circuit
operation.
xxi) Control supply availability
xxii) Provision of fire fighting equipment
suitable for electrical fires.
xxiii) Electrical & manual closing and
tripping of all circuit breakers (remote
and local)
xxiv) Provision of phase barriers and
partitions (to avoid inadvertent
contact with live parts.
xxv) Corrosion effects (whether to be
painted)
xxvi) Condition of supporting structure
xxvii)Earthing connections/resistance
9.2.2 Instrument Transformers (CT’s
and PT’s)
The following checks/tests shall be carried
out:
I) Polarity
ii) Continuity
iii) Ratio error
iv) Tightness of wiring connections
v) Wiring (continuity and completeness)
vi) Other field checks as pr IS:2705 (for
CT) and per IS:3156 (for PT)
9.2.3 Transformer & Busduct
The following checks/tests shall be carried
out:
I) Provision of all the accessories
ii)External damages (especially on
bushings)
iii)Body and neutral earthing/earth
resistance
iv) Dielectric strength, & acidity tests of the
oil (Conforming to IS:335)
v) Oil leakage
vi) Oil level in the conservator, bushings
and thermometer pockets
vii) Condition of silicagel
viii) Blockage, if any, in the breather pipe
ix) Explosion vent diaphragm not having
any dents, accumulation of any
oil/air(whether released)
x) Buchholz relay (frinctionless movement
and floats)
xi)Protective checks on tips and alarms
(simulation)
xii) Polarity and ration tests
xiii) Arcing gaps for the bushings
xiv) Earthing connections for the surge
divertor
xiv) Operation of the tap changer circuits
on all the tap positions (simulation)
xvi) Identical indication of tap position on
transformer and on control panel
xvii) Operation of tap changer limit switch
on the maximum tap positions.
xviii)Oil condition and oil level in tap
changer tank
xix) Insulation resistance of all control
circuits and transformer windings.
xx) Cooling system (automatic starting and
stopping of fans)
xxi) Cleanliness of transformer surface
xxii) Space heater operation (marshalling
box)
xxiii) Parallel operation (auto/manual
modes) with protection and interlock
circuits (simulation tests)
xxiv) Neutral grounding resistor especially
for earthing connection and earth
resistance.
xxv) Phase sequence (when transformers
have to be paralleled)
xxvi) Sealing of busduct entries through
walls (for vapour, dust, water
tightness)
iv) Cell voltage, proper cell connections to
maintain correct polarity.
v) Normal operation of battery charging
equipment
vi) Corrosion problems (especially to
terminals), if any
vii) Damages, if any

xxvii) Vermin & dust proofness and earth viii) Spillage of electrolyte
connections of bus ducts
ix) Tightness of wiring connections
xxviii) Busduct supports
x) provision of required protective devices
xxix) Expansion joints and flexible and annunciations.
connection of busduct
9.2.5 Lighting System
xxx) Cable terminations
The following shall be checked/tested:
xxxi) Provision of caution boards
I) Installation and components meet the
After commissioning the requirements set by environmental
transformer, the following pints shall be conditions and conform to approved
observed, and recorded: drawings/specifications

I) Oil leakage, if any ii) Ensure no fuses blown and no lamps

fused
ii) The no-load current
iii) Circuit loading and balancing of loads
iii) Alarm, if any, or any relay flag has between phases
operated
iv) Provision of safety features such as:
iv) Voltage and current on all three phases a) Separation sheets
b) Fuse base screening
v) Transformer hum or abnormal noise, if c) Door switches & padlocks
any
v) Continuity and completeness of wiring
vi) Circulation of oil connections

vii) Current, voltage, and temperature vi) Tightness of wiring connections at the
readings (hourly for 24 hours when terminals
transformer is loaded)
vii) Cable terminals
viii) Cables end boxes for any overheating
viii) Ratings of fuses, MCBS and switches
9.2.4 Battery & Charger
ix) Insulation resistance between phases
The items listed below shall be and between phases & earth.
checked/ensured:
x) Weatherproofing and vermin proofness
I) Battery not affected by sunlight.
xi)Earthing connection/earth resistance
ii) Proper ventilation and provision of acid values
proof flooring in the battery room.
xii) Size and type of cables, wires and
iii)Conformity of electrolyte to IS:266 & its conduits used
level
xiii)Painting (corrosion effect
xiv) Functional checks of lighting circuits ix) Continuity of core to confirm no open
for operation circuit.

xv) Operation of emergency lighting 10.0 REFERENCES

circuits and its automatic starting
when normal use supply fails The following codes, standards and
(simulation) publications have either been referred to
or used in the preparation of this standard,
xvi) Condition of lighting fixtures, panels & and the same shall be read in conjunction
distribution boards with this standard:

xvii) Available illumination levels areawise I) Indian Electricity (i.E) Rules 1956/Act-
to confirm operation and safety 1910
requirements through field ii) Bureau of Indian Standards-ISI:s
inspection with UIC) publication: IS:2705, IS:3156, IS:3043,
IS:1554, IS:2309, IS:5216, IS:335,
xviii) Circuit identifications and markings in IS:266, IS:900, IS:3156, IS:10029,
the field. IS:1255, IS:732, IS:5572, IS:2148,
IS:7389, IS:3072, IS:4770, IS:10118,
9.2.6 CABLES IS:1866, IS:2516, IS:5124,

The items listed below shall be
checked/ensured:
I) Identification of the cable with equipment
tag no., circuit inscription, provision of
cable route markers and joint
location markers.
ii) Depth of laying and spacing between
cables of different voltage grades
(random checks on trial pit basis).
iii) Voltage rating, size and type of the
cable (to ensure correct specifications)
iv) Cable support/clamping arrangement
v) Cable terminals (especially for
flameproof, watertight terminaitions)
vi) Armour earthing and bonding
vii) Cable sleeves (whenever crossing the
roads, walls etc.,)
iii) ISI-national Electrical Code, 1985
iv) Model code of safe practice Electrical-
Part 1, 1974 (Institute of Petroleum
publication)
v) Guide for Inspection of Refinery
Equipment-Chapter XIV-Electrical
System-(API-Publication) 1976
vi) OISD-STD-105 (Work Permit system),
1988
vii) British Standard Code of Practice BS-
6651, CP-1013
viii) Regulations for the electrical
equipment of buildings. Fifteenth
eidtion 1976 (Institution of Electrical
Engineers - IEE’s publication)
ix) Oil Mine Regulation 1984
x) Petroleum Rules 1976

viii) Insulation resistance of every circuit xi) Asian Electricity Journal, Oct 96.
(phase to phase, phase to ground and
armour)
 ANNEXURE I

PROTECTIVE RELAY INSPECTION AND TEST RECORD

CIRCUIT LOCATION________________CIRCUIT DESIGNATION_____________________

RELAY______________________PHASE OR LOCATION IN PANEL__________________

MANUFACTURER___________TYPE__________STYLE NO._________FUNCTION______

C.T. RATIO_____________________________P.T. RATIO___________________________

TAP RANGE_____________________________INSTANTANEOUS RANGE____________

TIME OPERATIONS INDICATOR_______AND INSTANTANEOUS

INDICATOR_______AMP

RELAY INSPECTION
DATE
COVER
GLASS TIGHT
GLASS CLEAN
GASKET TIGHT
RELAY CONDITION
DUST
RUST
IRON FILINGS
BEARINGS STICKY
SHORTCOMING
BARS IN PLACE
CONNECTIONS
TIGHT
CONTACTS
DIRTY
PITTED
OPERATIONS
INDICATOR
ARMATURE FREE
TARGET FREE
INSTANTANEOUS
ATTACHMENT
ARMATURE FREE
TARGET FREE
DISC.RUBBING
INSPECTION
 ANNEXURE III

________________

CABLE MAINTENANCE CARD

_______________________________

CARD NO.

MAKE TYPE YEAR OF TAG NO. SIZE

INSTALLATION

VOLTAGE CURRENT LENGTH INITIAL NO. CABLE ROUTE

OF JOINTS LINE MARKER

DATE TYPE OF FAULT DISTANCE JOBS EXECUTED

FAULT LOCATION FROM LENGTH CARRIED BY
DETAILS (MTS) OUT
 ANNEXURE V

FAILURE ANALYSIS REPORT

INSTALLATION.......................................................
UNIT _________________________ EQUIPMENT TAG NO.:___________
DATE______________
------------------------------------------------------------------------------------------------------------------------------------------
1. Present Failure/Abnormality Last Failure/Abnormality
Date: Date:
Nature: Nature:

2. Component Damage/Abnormality Cause of Damage.

3. Principal Cause of Failure

4. Repair/Replacement Carried out

5. Steps taken to prevent repetition

------------------------------------------------------------------------------------------------------------------------------------------

Signature/name/Designation
(of the Officer preparing the
Report)
 ANNEXURE VI

DETAILS OF AUTHORISED PERSONNEL

(Requirement under I.E. Rules, 1956)

INSTALLATION .................................................................... DATE:.........................

___________________________________________________________________________________
Sl.No. Name Designation Technical No.of IE The work Signature of
Competency Rules 1956 for responsibility person in
which authorised entrusted to token of
authorised of
person authorisation
------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------

Signature/name/Designation
(of the Officer preparing the
Report)
 ANNEXURE VII
CABLE FAULT DETECTION
(Ref.Asian Electricity Journal Oct. ‘86)

GENERAL
The use of particular fault finding equipment
depends on the factors such as type of fault,
length of cable, location of cable, cable
construction and, very important, funds
available for procurement.
Broad guidelines for methods and
equipment necessary
The methods and equipment necessary are:
Fault locating procedure:
• Through diagnosis
• Accurate route measurement
• Trustworthy pre-location (i.e correct
instrument)
(a) Contact fault:
Pulse Echo Set if fault resistance is
suitable. If not, H.V. Or High Resistance bridge
or Impulse current set can be used.

Diagnosis -Ohm meter (b) Flashing Fault:

- Insulation Tester
Impulse Current Set
Pre-location - High voltage
Bridge or High • Pin-pointing
Resistance fault
locator Surge Generator-occasionally Audio
- Impulse current Frequency Sets for low resistance core to core
Equipment faults.

Fault Choice of instruments

Conditioning - Burn down set
(Sometimes necessary before pre-location) - For XLPE Insulated cable, a full set of
equipment incorporating Impulse current
Pin-pointing - Surge Generator equipment will be required, because it is
- Audio Frequency impossible to burn down faults on this
Set type of cable and pulse echo is, therefore,
Route tracing - Audio Frequency not possible for contact faults.
Set
Fault Confirmation - Acoustic Detector - For long cables, say up to 15 Km
- Audio Frequency presents few problems in pre-location but
set Pin-pointing equipment is essential
occasionally. because even a low-pre-location error
All above - Combination Sets results in a wide search area.
of
functions portable - For short route lengths a rough “one
equipment for Instrument” approach may be successful.
full fault location For Instance, assuming pre-location is
capability. possible, the application of modern-
powerful Surge generator to jest a few
Type of fault: hundred meters of cable and careful
patrolling of the route often gives a “spot-
In general, faults can be said to be on” location within a short time.
open or short circuits, However, in practice,
many conditions can arise i.e. a break may not Minimum essential equipment required
be “clean”-it may have resistance across it or,
more usually, to the sheath or earth. A contact - A High Impedance Fault locator.
fault may be “hard down” or exhibit hundred of - A Pulse Echo Set.
ohms, kiloohms or even megohms. - A Shock wave Generator.

Also faults occur on one or more of

the cores of conductors.
NOTES

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