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## GUJARAT TECHNOLOGICAL UNIVERSITY

Program Name: Diploma Engineering Level: Diploma Branch: Electrical Engineering Subject Code: DI04009031

Subject Name: Commissioning &amp; Maintenance of Electrical Equipments

w. e. f. Academic Year:

2025-26

Semester:

4 th

Category of the Course:

Professional Elective - II

| Prerequisite:   | Understanding of basic  electrical  engineering  principles,  electrical  machines,  safety standards and electrical measurements.                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                       |
|-----------------|--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|
| Rationale:      | Electrical  systems  in  power  generation,  industrial,  and  commercial  facilities  include a wide range of equipment and devices such as transformers, motors,  circuit  breakers,  and  other  machinery  operating  at  different  stages  and  often  situated  close  to  one  another.  These  components  must  be  properly  installed,  commissioned,  and  maintained  on  a  regular  basis  to  avoid  major  failures.  Diploma-level  engineers  are  frequently  responsible  for  overseeing  or  performing  these  tasks  in  power  plants,  substations,  and  industrial  environments.  This  course  is  designed  to  equip  students  with  a  thorough  understanding  of  the  correct  procedures  for  installation,  commissioning,  and  maintenance  of  electrical  equipment.  It  also  emphasizes  key  concepts  and  principles,  while  providing  hands-on  experience  to  develop  practical  skills  necessary for working with electrical systems in real-world settings. |

## Course Outcomes :

After Completion of the Course, Student will be able to:

|   No | Course Outcomes                                                                                   | RBT  Level*   |
|------|---------------------------------------------------------------------------------------------------|---------------|
|    1 | Follow safety procedures with respect to earthing and insulating material.                        | R, U          |
|    2 | Install  and  maintain  electrical  equipment  following  standard  practices  and  safety norms  | U, A          |
|    3 | Perform pre-commissioning tests and commissioning of transformer safely and  effectively          | U, A          |
|    4 | Perform standard tests and commissioning of rotating machines with adherence  to safety standards | U,A           |
|    5 | Commission switchgear and power cables through standard testing and safety  compliance            | U,A           |

*Revised Bloom's Taxonomy (RBT)

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## GUJARAT TECHNOLOGICAL UNIVERSITY

Program Name: Diploma Engineering Level: Diploma Branch: Electrical Engineering Subject Code: DI04009031

Subject Name: Commissioning &amp; Maintenance of Electrical Equipments

## Teaching and Examination Scheme:

| Teaching Scheme  (in Hours)   | Teaching Scheme  (in Hours)   | Teaching Scheme  (in Hours)   | Total Credits  L+T+ (PR/2)   | Assessment Pattern and Marks   | Assessment Pattern and Marks   | Assessment Pattern and Marks   | Assessment Pattern and Marks   | Total   |
|-------------------------------|-------------------------------|-------------------------------|------------------------------|--------------------------------|--------------------------------|--------------------------------|--------------------------------|---------|
| L                             | T                             | PR                            | C                            | Theory                         | Theory                         | Tutorial / Practical           | Tutorial / Practical           | Marks   |
|                               |                               |                               |                              | ESE (E)                        | PA(M)                          | PA (I)                         | ESE(V)                         |         |
| 3                             | 0                             | 2                             | 4                            | 70                             | 30                             | 20                             | 30                             | 150     |

## Course Content:

|   Unit  No. | Content                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                |   No. of  Hours | % of  Weightage   |
|-------------|------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|-----------------|-------------------|
|           1 | Unit 1 -Electrical Safety and Insulating Material  1.1 Do'sand  Don'ts  Regarding  Safety  in  Substation/  Power  Station  Operators.  1.2 Electrical  Safety  in  Industry/Power  Stations/  Substations  at  the  Time of Operation/ Control/ Maintenance.  1.3 Factors Affecting Life of Insulating Materials, Classifications of  Insulating Materials as Per Indian Standards.  1.4 Measuring Insulation Resistance by Different Methods Such As I)  Polarization, Ii) Dielectric Absorption, Iii) Megger.  1.5 Reconditioning of Insulation-Drying Out Procedures.  1.6 Insulating  Oil  -  Properties  of  Insulating  Oil,  Causes  of  Deterioration of Oil. |               7 | 14%               |
|           2 | Unit 2-Installation and Maintenance of Electrical Equipment     2.1 Requirements of Foundation for Static and Rotating Electrical   Machinery.     2.2 Concept of Levelling and Aligning- Procedure for Levelling and    Aligning, Alignment ff Direct Coupled Drive, Effects ff Mis-  Alignment. 2.3 Installation Procedure of Power Transformer as Per I.S. 2.4 Installation  Procedure  of  Rotating  Electrical  Machine  (Induction  Motor and Alternators) as Per I.S. 2.5 Installation  Procedure  of  Switchgear  (Circuit  Breaker,  Isolator  and Control Panel) as Per I.S.                                                                                 |              12 | 27%               |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

Program Name: Diploma Engineering Level: Diploma Branch: Electrical Engineering Subject Code: DI04009031

Subject Name: Commissioning &amp; Maintenance of Electrical Equipments

|    | 2.6 Devices  and  Tools  Required  for  Installation  ofElectrical  Equipment. 2.7 Concept of Maintenance, Types of Maintenance, Routine,  Preventive and Breakdown Maintenance. 2.8 Preventive Maintenance-Procedure for Developing Maintenance Schedules for Electrical Machines. 2.9 Factors Affecting Preventive Maintenance Schedules. 2.10 Maintenance Schedules of Following as Per IS: Power  Transformer, Three Phase Induction Motor, Alternator, Circuit   Breaker, Batteries, Solar and Wind Power Plants.   |    |     |
|----|--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|----|-----|
|    | Unit 3 - Commissioning of Transformer  3.1 Importance of Commissioning of Transformer.  3.2 Difference Between Type Test, Routine Test and Special Test.  3.3 Pre-Commissioning Checks-  Significance, Procedure and Standard Reference Values for Pre- Commissioning Tests:   3.3.1 Insulation  Resistance  Measurement  [Control  Wiring,  Cooling  System  Motor  and  Control  Circuit,  Main  Windings (Polarization Index), Tap Changer Motor and                                                                  |    |     |
| 3. | 3.3.3 Polarity and Vector Group Test.  3.3.4 Ratio Test on All Taps.  3.3.5 Magnetizing Current Test.  3.3.6 Magnetic Balance Test. (For 3 Phase Transformer).  3.3.7 Capacitance  and  Tan  Delta  Measurement  of  Winding  and Bushing.                                                                                                                                                                                                                                                                               | 10 | 23% |

w.e.f. 2025-26

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## GUJARAT TECHNOLOGICAL UNIVERSITY

Program Name: Diploma Engineering Level: Diploma Branch: Electrical Engineering Subject Code: DI04009031

Subject Name: Commissioning &amp; Maintenance of Electrical Equipments

|    | Equipment.                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                         |    |     |
|----|------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|----|-----|
|  4 | Unit  4  -  Commissioning  of  Rotating  Machines(Synchronous  Machine, Induction Motor, DC Machine).  4.1 Pre-Commissioning InspectionChecks for Rotating Machines.  4.2 Pre-Start Tests on Rotating Machines-  4.2.1 Winding Resistance Measurement  4.2.2 Insulation Resistance Measurement of Windings  4.2.3 High Voltage Tests (Power Frequency)  4.2.4 Trial Start  4.2.5 No Load Test  4.2.6 Vibration Measurement  4.3 Faults and Troubleshooting of Rotating Machines (Synchronous                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                       |  8 | 18% |
|  5 | Machine,Induction Motor, DC Machine).  Unit 5 - Commissioning of Switchgear and Power Cable  5.1 Pre-Commissioning Checks of Switchgear           5.1.1 Visual Inspection (Nameplate, Interlocks).           5.1.2 Insulation Resistance (IR) Measurement.           5.1.3 Contact Resistance Test of Circuit Breakers and Isolators.           5.1.4 CTs, PTs, And Protection Relay Connections Verification.  5.2 Functional Tests of Switchgear           5.2.1 Mechanical Operation Test.           5.2.2 Protection Relay and Control Circuit Testing.           5.2.3 Interlock Verification (Electrical & Mechanical).           5.2.4 SF₆ Gas / Vacuum Integrity Test.  5.3 On-Site Commissioning Tests of Switchgear           5.3.1 High-Voltage WithstandTest. (As Per IS/IEC).           5.3.2 Partial Discharge Test (For GIS).           5.3.3 Breaker Timing Test  5.4 Pre-Commissioning Checks of Power Cable           5.4.1  Physical  Inspection  (Joints,  Terminations,  Bending  Radius).           5.4.2 Conductor Resistance & Continuity Test.           5.4.3 Insulation Resistance Measurement (Megger Test).  5.5 Site Acceptance Tests of Power Cable |  8 | 18% |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

Program Name: Diploma Engineering Level: Diploma Branch: Electrical Engineering Subject Code: DI04009031

Subject Name: Commissioning &amp; Maintenance of Electrical Equipments

| 5.5.1 High-Voltage Withstand Test.           5.5.2 Sheath Integrity Test.           5.5.3  Capacitance  and  Tan  ⸹(Dissipation  Factor)  Measurement.  5.6 Post-commissioning           5.6.1 Load Test Under Service Conditions.           5.6.2 Temperature Monitoring During Initial Energization.           5.6.3 Documentation of Test Results.  5.7 Faults and Troubleshooting of Switchgear and Power Cable.   |    |     |
|------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|----|-----|
| Total                                                                                                                                                                                                                                                                                                                                                                                                                  | 45 | 100 |

## Suggested Specification Table with Marks (Theory):

## Distribution of Theory Marks (in %)

| R Level   | U Level   | A Level   |   N Level |   E Level |   C Level |
|-----------|-----------|-----------|-----------|-----------|-----------|
| 10 %      | 40 %      | 50 %      |        00 |        00 |        00 |

Where R: Remember; U: Understanding; A: Application, N: Analyze and E: Evaluate C: Create (as per Revised Bloom's Taxonomy)

## References/Suggested Learning Resources:

## (a) Reference Books:

- 1) S. Rao , Khanna Publication, New Delhi ,Testing Commissioning Operation and Maintenance of Electrical Equipments
- 2) Tarlok Singh, S. K. Kataria &amp; Sons, New Delhi, Installation, Commissioning and Maintenance of Electrical equipment
- 3) Deshpande.M.  V.  PHI  Learning  Pvt.  Ltd.,  2010,  Design  and  Testing  of  Electrical  Machines ISBN No 8120336453, 9788120336452.
- 4) Rao, B V S Asia Club House, First Reprint, 2011, Operation and Maintenance of Electrical Equip ment Vol-I, ISBN No 8185099022
- 5) Rosenberg.  Mc  GRAW-HILL,  1st  Edition,  May  2003,  Maintenance  and  Repairs,  ISBN  No 9780071396035
- 6) Sharotri,  S.K.  Glencoe/  Mcgraw-  Hill;  2ndEdition  ,  June  1969;  Preventive  Maintenance  of Electrical Apparatus, ISBN No 10: 007030839X 13: 978-0070308398

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## GUJARAT TECHNOLOGICAL UNIVERSITY

Program Name: Diploma Engineering Level: Diploma Branch: Electrical Engineering Subject Code: DI04009031

Subject Name: Commissioning &amp; Maintenance of Electrical Equipments

## (b) Open-Source Software and Website:

- 1) Industrial Safety Engineering - https://onlinecourses.nptel.ac.in/noc20\_mg43/preview
- 2) Electrical Safety Simulation- https://www.osha.gov/electrical.
- 3) IS 1271 : 2020 - Classification of Insulating Materials -https://www.services.bis.gov.in
- 4) Maintenance and Installation Section- https://www.electrical4u.com
- 5) https://electrical-engineering-portal.com.
- 6) https://cea.nic.in
- 7) NPTEL Course: High Voltage Engineering -https://nptel.ac.in

## Suggested Course Practical List:

|   Sr.  No. | Practical Outcome/Title of experiment                               |   Unit/  CO |   Approx.  Hours  required |
|------------|---------------------------------------------------------------------|-------------|----------------------------|
|          1 | Demonstration of electrical safety equipment and PPE                |           1 |                          2 |
|          2 | Measurement of insulation resistance using a Megger                 |           1 |                          2 |
|          3 | Polarization Index (PI) and Dielectric Absorption Ratio (DAR) test  |           1 |                          2 |
|          4 | Testing dielectric strength (BDV) of insulating oil                 |           1 |                          2 |
|          5 | Insulation resistance test of transformer windings (main + control) |           3 |                          2 |
|          6 | Transformer ratio test on all tap positions                         |           3 |                          2 |
|          7 | Transformer polarity and vector group test                          |           3 |                          4 |
|          8 | Measurement of winding resistance                                   |           3 |                          2 |
|          9 | No-load and trial run test of induction motor                       |           4 |                          2 |
|         10 | Measurement of vibration in rotating machine                        |           4 |                          2 |
|         11 | IR test and contact resistance measurement of circuit breaker       |           5 |                          4 |
|         12 | Visual and functional testing of protection relay and interlocks    |           5 |                          2 |
|         13 | Insulation resistance test of power cables                          |           5 |                          2 |
|         14 | Physical inspection and continuity test of LT/HT power cable        |           5 |                          2 |

Subject In-charge can add performance experiment only.

## List of Laboratory/Learning Resources Required:

1. Digital Multimeter (DMM) - 0-1000 V, 10 A, True RMS
2. Clamp-on Power Meter - for measuring 3-phase current, voltage, and power factor
3. Earth Tester (Megger type) - 0-2000 Ω range

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## GUJARAT TECHNOLOGICAL UNIVERSITY

## Program Name: Diploma Engineering Level: Diploma

## Branch: Electrical Engineering

Subject Code: DI04009031

Subject Name: Commissioning &amp; Maintenance of Electrical Equipments

4. Digital / Analog Insulation Resistance Tester-Range: 0-1000 MΩ; Test Voltage: 500 V, 1000 V, 2.5 kV, 5 kV
5. Oil BDV Test Set (Automatic / Manual)-Output Voltage: 0-60 kV / 0-100 kV AC; Rate of rise: 2 kV/s; Electrode gap: 2.5 mm
6. Transformer Turns Ratio Tester-Range: 0.8 to 10,000:1; Accuracy: ±0.1%
7. AC High Voltage Test Set-Output: 0-5 kV / 0-10 kV / 0-50 kV AC
8. Tan Delta Test Set / Capacitance Meter-Voltage: 0-12 kV; Frequency: 50 Hz
9. Relay Test Set / Secondary Injection Kit-0-250 V AC/DC, 0-20 A, variable output
10. Tachometer (Non-Contact Type)- Range 0-5000 rpm

## Suggested Activities for Students:

Other  than  the  classroom  and  laboratory  learning,  following  are  the  suggested  student-related  cocurricular activities which can be performed to achieve the attainment of the various outcomes of the course:  Students  should  perform  following  activities  individually  or  in  group  to  accomplish  distinct task  and  prepare  reports  of  about  min  5  pages  for  each  activity.  They  should  also  collect/record physical evidences for their (student's) portfolio which may be useful for their placement and may be beneficial during placement interviews:

- I. Visit  substation,  solar/wind  power  plant,  or  industrial  switchyard.  Observe  installation, maintenance, and safety practices.
- II. Prepare standard installation checklist for transformer, induction motor, and circuit breaker as per IS/IEC standards.
- III. Prepare poster/chart showing 'Do's and Don'ts' for substation operators and maintenance engineers.
- IV. Create a sample commissioning report with test results, IR values, BDV, tan δ, etc.
- V. Students adopt one lab machine (motor/transformer) and perform cleaning, inspection, and IR testing.
- VI. Presentation on topics like 'Transformer Drying Methods', 'Cable Testing Procedures'.
- VII. Create flowchart for fault finding in motor, transformer, or cable.
- VIII. Collect and tabulate nameplate details of machines, transformers, breakers, cables used in your Lab.

## Suggested Project List: Suggested Project List as given below:

- I. Design posters on substation safety, lockout-tagout, or rescue procedure.
- II. Preparation of Safety Operating Procedures (SOPs).
- III. Preparation of Maintenance Schedule Chart of Any Electrical Equipment.

w.e.f. 2025-26

http://syllabus.gtu.ac.in/

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## GUJARAT TECHNOLOGICAL UNIVERSITY

Program Name: Diploma Engineering Level: Diploma Branch: Electrical Engineering Subject Code: DI04009031

Subject Name: Commissioning &amp; Maintenance of Electrical Equipments

- IV. Prepare checklist for transformer, motor, and switchgear before energization.
- V. Preparation of Tool Inventory for Electrical Equipment Installation.
- VI. Prepare Commissioning Test Report of Any Electrical Equipment.
- VII. Maintenance Logbook Preparation for Any Electrical Equipment.
- VIII. Layout design of transformer substation showing earthing and cable routing.
- IX. Prepare report on tests conducted on Insulating oil in laboratory.
- X. Prepare  causes  of  faults  along  with  their  trouble  shooting  chart  for  any  of  electrical machines / Equipment.
- XI. Prepare chart with neat diagram for any of earthing methods along its significance.
- XII. Prepare chart for maintenance schedule of solar roof top installed at your institute premises.

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