AMARA RAJA INFRA PVT LTD
REPORT ON WATER DISTRIBUTION EQUIPMENT
TESTING
(By Janarthanan Venkatesan)
Rev No:0
Date:
04.08.2014
Introduction:
This
report of Water distribution System contains the Testing and commissioning
details of the Following Equipments
Description of Equipments:
A.
Main Incoming DB
B.
Control Panel of Over head Tank Pumps- (that
Controls 20HP Pumps – 3 Nos)
C.
Control Panel of the Filter Feed Pumps- (this
Controls 5HP Pumps -4 Nos)
D.
De-Watering Pump Control Panels
E.
20HP Pumps- 3 Nos
F.
5HP Pumps- 4 Nos
G.
5HP Submersible Pump-2 Nos
Testing and Commissioning Details:
A.Main Incoming DB-250A MCCB
The Incoming
Cable from the SBD is verified for its Proper Functioning as mentioned Below.
Continuity Test:
S.
No
|
Cable
Terminals
|
Continuity
|
Condition
|
1
|
R-Y
|
Nill
|
Normal
|
2
|
Y-B
|
Nill
|
Normal
|
3
|
B-R
|
Nill
|
Normal
|
4
|
R-N
|
Nill
|
Normal
|
5
|
Y-N
|
Nill
|
Normal
|
6
|
B-N
|
Nill
|
Normal
|
7
|
R-Y Short on one end
|
O.K -Verified on the Other end
|
Normal
|
8
|
Y-B Short on One End
|
O.K -Verified on the Other end
|
Normal
|
9
|
B-R Short on One End
|
O.K-Verified on the other end
|
Normal
|
Output Voltage Test:
The
Supply is Passed through the incoming cable and the from the SBD Feeder and the
Output voltages are observed as mentioned below
S.
No
|
Cable
Terminals
|
Voltage
in Volts
|
1
|
R-Y
|
410
|
2
|
Y-B
|
406
|
3
|
B-R
|
412
|
4
|
R-N
|
232
|
5
|
Y-N
|
236
|
6
|
B-N
|
231
|
7
|
N-G
|
450mv
|
B.Control Panel of Over Head Tank Pumps
The Control Panel contains the following partitions
1.
Incomer
2.
Starters
3.
Outgoing
1.INCOMER:
The incoming of the panel contains the Following parts
a.
MCCB
b.
CT’s and Bus Bars
a.
MCCB:
Rating – 160A
Before initiation
of the Tests all the equipments were removed and dried using the 250W light
fitting and the Natural Sun light.
Testing Proceeded:
1. Continuity
of the MCCB – Normal
2. By making
the MCCB in ON Condition Continuity from Incoming to Outgoing – Normal
3. Connected
the 250W 1 Phase light Fitting and operated the MCCB- 250W Light Fitting Found
Working Normal.
S.No
|
Description
|
Continuity
|
Continuity
when MCB ON
|
MCB
Function With 250W Light
|
1
|
160A MCCB
|
Normal
|
Normal
|
250W
light Found operative
|
b. CT’S And Bus Bars
Testing Proceeded:
1. Passed
the Supply into the Primary of the CT and Found the Secondary Voltage Normal
2. Bus
Bars Physically verified for any Damages and the Continuity of the same is
verified and Found Normal
S.No
|
Description
|
Physical
|
Electrical
|
1.
|
CT’s
|
Normal
|
Primary-230V Applied Secondary Found-5V
|
2
|
Bus Bars
|
Normal
|
Continuity -Normal
|
2.STARTERS:
The
panel contains three 20HP Motor Star-Delta Starters
For Three Starters
Testing Proceeded:
1. Removed
all the Terminations and Dried up with the 250W Metal Halide Light fitting and
also by direct Sunlight.
2. The
Mcb’s and the Contactors are verified as follows
a.
Continuity of the MCB – Normal
b.
By making the MCB in ON Condition Continuity
from Incoming to Outgoing – Normal
c.
Connected the 250W 1 Phase light Fitting and
operated the MCB- 250W Light Fitting Found Working Normal
3. Contactors
are Verified individually by supplying the Incoming and the Auxiliary Supply
and found the Contacts Working Normal.
Observation on Contactors:
One of the Contactor is not
operating as per the Requirement need Verification of the same. Specifically
the Delta Contactor of the 3rd Pump.
4. And
the Timer and the Single phase preventer is verified for its Operation as
mentioned below
Description
of Material
|
Operation
Status
|
Star-Delta Timer -1
|
Normal
|
Star-Delta Timer-2
|
Faulty
|
Star-Delta Timer-3
|
Faulty
|
Single Phase Preventer-1
|
Normal
|
Single Phase Preventer-2
|
Faulty
|
Single Phase Preventer-3
|
Faulty
|
5. Re-terminated
all the Connections and Verified the Following output Voltages
Output for Pump-1
Output
Terminals
|
Voltages
(Volts)
|
U1-V1
|
402
|
V1-W1
|
399
|
W1-U1
|
404
|
U2-V2
|
403
|
V2-W2
|
398
|
W2-U2
|
405
|
Output for Pump-2 (using 1St
Pump Timer )
Output
Terminals
|
Voltages
(Volts)
|
U1-V1
|
405
|
V1-W1
|
408
|
W1-U1
|
406
|
U2-V2
|
403
|
V2-W2
|
408
|
W2-U2
|
405
|
Output for Pump-3 (using 1St
Pump Timer )
Output
Terminals
|
Voltages
(Volts)
|
U1-V1
|
398
|
V1-W1
|
402
|
W1-U1
|
406
|
U2-V2
|
403
|
V2-W2
|
397
|
W2-U2
|
405
|
3.
OUTGOING:
All the Outgoing
Cables are verified as follows
Cables for Pump-1
Output
Terminals from Panel
|
Output
terminal Near Motor
|
Continuity
|
U1
|
U1
|
O.K
|
V1
|
V1
|
O.K
|
W1
|
W1
|
O.K
|
U2
|
U2
|
O.K
|
V2
|
V2
|
O.K
|
W2
|
W2
|
O.K
|
U1-V1
|
Normal
|
|
V1-W1
|
Normal
|
|
W1-U1
|
Normal
|
|
U2-V2
|
Normal
|
|
V2-W2
|
Normal
|
|
W2-U2
|
Normal
|
Cables for Pump-2
Output
Terminals from Panel
|
Output
terminal Near Motor
|
Continuity
|
U1
|
U1
|
O.K
|
V1
|
V1
|
O.K
|
W1
|
W1
|
O.K
|
U2
|
U2
|
O.K
|
V2
|
V2
|
O.K
|
W2
|
W2
|
O.K
|
U1-V1
|
Normal
|
|
V1-W1
|
Normal
|
|
W1-U1
|
Normal
|
|
U2-V2
|
Normal
|
|
V2-W2
|
Normal
|
|
W2-U2
|
Normal
|
Cables for Pump-3
Output
Terminals from Panel
|
Output
terminal Near Motor
|
Continuity
|
U1
|
U1
|
O.K
|
V1
|
V1
|
O.K
|
W1
|
W1
|
O.K
|
U2
|
U2
|
O.K
|
V2
|
V2
|
O.K
|
W2
|
W2
|
O.K
|
U1-V1
|
Normal
|
|
V1-W1
|
Normal
|
|
W1-U1
|
Normal
|
|
U2-V2
|
Normal
|
|
V2-W2
|
Normal
|
|
W2-U2
|
Normal
|
C.Control Panel of Filter Feed Pumps ( 5HP Pumps -4 Nos)
The
Control Panel for the Filter feed Pumps contains the Following
1.
Incomer
2.
Starter
3.
Outgoing
1.INCOMER:
The Incoming
to the panel is supplied from Main PDB in the Pump Room through
Testing Proceeded:
1. Continuity
of the MCCB – Normal
2. By making
the MCCB in ON Condition Continuity from Incoming to Outgoing – Normal
3. Connected
the 250W 1 Phase light Fitting and operated the MCB- 250W Light Fitting Found
Working Normal.
S.No
|
Description
|
Continuity
|
Continuity
when MCB ON
|
MCB
Function With 250W Light
|
1
|
63A MCCB
|
Normal
|
Normal
|
250W
light Found Working
|
2.STARTER:
Panel Contains
the 4 DOL Starters for Controlling 4 Nos of Filter Feed Pumps.
Testing Proceeded:
1. Removed
all the Terminations and Dried up with the 250W Metal Halide Light fitting and
also by direct Sunlight.
2. The
Mcb’s and the Contactors are verified as follows
d.
Continuity of the MCB – Normal
e.
By making the MCB in ON Condition Continuity
from Incoming to Outgoing – Normal
f.
Connected the 250W 1 Phase light Fitting and
operated the MCB- 250W Light Fitting Found Working Normal
3. Contactors
are Verified individually by supplying the Incoming and the Auxiliary Supply
and found the Contacts Working Normal.
Observation on Contactors:
One of the Contactor is not
operating as per the Requirement need Verification of the same. Specifically
the Delta Contactor of the 3rd Pump.
4. Re-terminated
all the Connections and Verified the Following output Voltages
Output for Pump-1
Output
Terminals
|
Voltages
(Volts)
|
U1-W1
|
408
|
V1-W1
|
404
|
W1-U1
|
403
|
Output for Pump-2
Output
Terminals
|
Voltages
(Volts)
|
U1-V1
|
404
|
V1-W1
|
403
|
W1-U1
|
401
|
Output for Pump-3
Output
Terminals
|
Voltages
(Volts)
|
U1-V1
|
406
|
V1-W1
|
403
|
W1-U1
|
402
|
Output for Pump-4
Output
Terminals
|
Voltages
(Volts)
|
U1-V1
|
406
|
V1-W1
|
405
|
W1-U1
|
403
|
3.OUTGOING:
All the Outgoing
Cables are verified as follows
Cables for Pump-1
Output
Terminals from Panel
|
Output
terminal Near Motor
|
Continuity
|
U1
|
U1
|
O.K
|
V1
|
V1
|
O.K
|
W1
|
W1
|
O.K
|
U1-V1
|
Normal
|
|
V1-W1
|
Normal
|
|
W1-U1
|
Normal
|
Cables for Pump-2
Output
Terminals from Panel
|
Output
terminal Near Motor
|
Continuity
|
U1
|
U1
|
O.K
|
V1
|
V1
|
O.K
|
W1
|
W1
|
O.K
|
U1-V1
|
Normal
|
|
V1-W1
|
Normal
|
|
W1-U1
|
Normal
|
Cables for Pump-3
Output
Terminals from Panel
|
Output
terminal Near Motor
|
Continuity
|
U1
|
U1
|
O.K
|
V1
|
V1
|
O.K
|
W1
|
W1
|
O.K
|
U1-V1
|
Normal
|
|
V1-W1
|
Normal
|
|
W1-U1
|
Normal
|
D.Control Panel Of the Dewatering Panel:
The
Panel that has been Commissioned Was Sunk up with the Water and the DOL Starter
of the Panel has got Short Circuited and Damaged.
On
Behalf of the Same the Spare Control Panel has been Replaced and the Same is
Verified as mentioned Below.
The
Following Tests are proceeded
1.
Incoming Voltage
2.
Outgoing Voltage test.
Incoming Voltage Test:
The
incoming to the De-Watering panel is supplied from the Main PDB and the Cable
Terminals are verified for its Voltages As mentioned
Cable
Terminals
|
Voltages
(Volts)
|
R-Y
|
406
|
Y-B
|
410
|
B-R
|
405
|
Output Voltage Test:
The
Control Panel is Switched ON without the Termination of the De-Watering Pump
and the Output Voltages are verified as mentioned below.
Output
Terminals
|
Voltages
(Volts)
|
R-Y
|
406
|
Y-B
|
408
|
B-R
|
404
|
E.20HP Pumps:
There were
about 3 Nos of 20HP Motors and the Following are the Tests Proceeded
Tests Proceeded: (All 3 Nos)
1.
Verified the Continuity of the Removed Motor
from Pump and found the following as mentioned below.
2.
Before Verification the Motor Stator and
Rotor Separated and the Rotor winding is dried using the Oven and Varnished to
remove the moisture
Motor
Terminals
|
Continuity
|
U1-U2
|
O.K
|
V1-V2
|
O.K
|
W1-W2
|
O.K
|
3.
And Before Switching on the Delta position
Continuity is also verified and observed as follows
Motor
Terminals
|
Continuity
|
U1-V2
|
O.K
|
V1-W2
|
O.K
|
W1-U2
|
O.K
|
4.
Insulation
Resistance of the Motor Using Megger
Motor
Terminals
|
Resistance
in Ohm
|
Condition
|
U1-U2
|
0
Ohm
|
Normal
|
V1-V2
|
0
Ohm
|
Normal
|
W1-W2
|
0 Ohm
|
Normal
|
U1-V1
|
2000 M.Ohm
|
Normal
|
V1-W1
|
2000 M.Ohm
|
Normal
|
W1-U1
|
2000M.Ohm
|
Normal
|
U1-G
|
2000M.Ohm
|
Normal
|
V1-G
|
2000M.Ohm
|
Normal
|
W1-G
|
2000M.Ohm
|
Normal
|
The Above Measurements are compared and found normal with NETA ATS 2007. Section 7.15.1
5.
Winding
Resistance
Motor
Terminals
|
Resistance
in Ohm
|
Condition
|
U1-U2
|
5.6 Ohm
|
Normal
|
V1-V2
|
3.5 Ohm
|
Normal
|
W1-W2
|
4 Ohm
|
Normal
|
U1-V1
|
Infinity
|
Normal
|
V1-W1
|
Infinity
|
Normal
|
W1-U1
|
Infinity
|
Normal
|
U1-G
|
Infinity
|
Normal
|
V1-G
|
Infinity
|
Normal
|
W1-G
|
Infinity
|
Normal
|
The above Measurements are Compared and Found Normal with IEEE45
6. Apart
from these all the winding Continuity is also verified with the Connection of
250W light Fitting in Series with the Coil.
Observation: Light Found Working.
Commissioning of the Motors: ( All 3 Nos)
1. The
Motors are installed with the pumps and the Electrical Terminations are done as
per the Requirement.
2. The
Motor Incoming Power is Supplied using the Healthy Single Phase Preventer and
the Star Delta Starter.
3. The
Starter is Switched ON and observed the Following
a. Motor Starts
Running in Star.
b. In Delta
Motor Stops Running by Tripping 40A MCB of Star Delta Starter.
The same is
observed for all the Motors.
After Analysis the
40A MCB is replaced with 80A MCB.
4. Then
the Motor is Switched ON and the Found the Following Observation.
a.
Motor Starts in Star and Runs in Star for 6 Sec
b.
And Converts to Delta with 60ms Delay and
Continues to Run Smoothly.
c.
And the Water Flow is also Observed through the
Flow meter and Physically.
F.5HP Pumps: (DOL Connection)
There were about 4 Nos of 5HP Motors and the Following are the Tests
Proceeded
Tests Proceeded: (All 3 Nos )
1. Verified
the Continuity of the Removed Motor from Pump and found the following as
mentioned below.
2. Before
Verification the Motor Stator and Rotor Separated and the Rotor winding is
dried using the Oven and Varnished to remove the moisture
Motor
Terminals
|
Continuity
|
Condition
|
U1-V1
|
Nil
|
Normal
|
V1-W1
|
Nil
|
Normal
|
W1-U1
|
Nil
|
Normal
|
3. Insulation Resistance of the Motor
Motor
Terminals
|
Resistance
in Ohm
|
Condition
|
U1-U2
|
0
Ohm
|
Normal
|
V1-V2
|
0
Ohm
|
Normal
|
W1-W2
|
0 Ohm
|
Normal
|
U1-V1
|
400 M.Ohm
|
Normal
|
V1-W1
|
200 M.Ohm
|
Normal
|
W1-U1
|
400 M.Ohm
|
Normal
|
U1-G
|
300 M.Ohm
|
Normal
|
V1-G
|
200 M.Ohm
|
Normal
|
W1-G
|
400 M.Ohm
|
Normal
|
The Above Measurements are compared and found normal with NETA ATS 2007. Section 7.15.1
4. Winding Resistance
Motor
Terminals
|
Resistance
in Ohm
|
Condition
|
U1-U2
|
5.6 Ohm
|
Normal
|
V1-V2
|
6.8 Ohm
|
1.8 Ohm Deviation
|
W1-W2
|
6.9 Ohm
|
1.9 Ohm Deviation
|
U1-V1
|
Infinity
|
Normal
|
V1-W1
|
Infinity
|
Normal
|
W1-U1
|
Infinity
|
Normal
|
U1-G
|
Infinity
|
Normal
|
V1-G
|
Infinity
|
Normal
|
W1-G
|
Infinity
|
Normal
|
The above Measurements are Compared and Found Normal with IEEE45
5. Apart
from these all the winding Continuity is also verified with the Connection of
250W light Fitting in Series with the Coil.
Observation: Light Found Working
Commissioning of the Motors: ( All 4 Nos)
a. The
Motors are installed with the pumps and the Electrical Terminations are done as
per the Requirement.
b. The
Motor Incoming Power is Supplied
c. The
Starter is Switched ON and observed the Following
d. Then
the Motor is Switched ON and the Found the motor running in Smooth Condition
e. And
the Water Flow is also observed through the Flow meter and physically.
F.De-Watering Pump:
There
were about 2 Nos of 5HP Submersible Pumps and the Following are the Tests
Proceeded
Tests Proceeded: (All 3 Nos )
1. Verified
the Continuity of the Removed Motor from Pump and found the following as
mentioned below.
Motor
Terminals
|
Continuity
|
Condition
|
R-Y
|
Nil
|
Normal
|
Y-B
|
Nil
|
Normal
|
B-R
|
Nil
|
Normal
|
Commissioning of the Motors: ( All 2 Nos)
a. The
Motors are installed with the pumps and the Electrical Terminations are done as
per the Requirement.
b. The
Motor Incoming Power is Supplied
c. The
Starter is Switched ON and observed the Following
d. Then
the Motor is Switched ON and the Found the motor running in Smooth Condition
e. And
the Water Flow is also observed through the Flow meter and physically
Conclusion:
All
the Motors are Found Operative and the Following are the Materials required as
per the above analysis to Commission the Water distribution system in a Full
Fledged Way
1.
Single Phase Preventer – 2 Nos
2.
Star- Delta Timer – 2 Nos
