UNIVERSITY TEKNIKAL MALAYSIA MELAKA

FACULTY OF ELECTRICAL & ELECTRONIC ENGINEERING

TECHNOLOGY

INDUSTRIAL TRAINING TECHNICAL REPORT

Name : Abdullah Hakim Bin Amir Radzuanuddin

Course : BEEI

Year : 4

Training Period : 6 Month

Industry Name : E.S.S Engineering Sdn. Bhd.

a
 INDUSTRIAL TRAINING TECHNICAL REPORT

AT

E.S.S ENGINEERING SDN BHD

Period of Training:

13/3/2023 – 25/8/2023

Submitted By:

Abdullah Hakim Bin Amir Radzuanuddin

This Technical Report for Industrial Training is submitted to

Faculty of Electrical & Electronic Engineering Technology

Universiti Teknikal Malaysia Melaka

In partial fulfillment for Bachelor of Electrical Engineering Technology (Industrial Power)

with Honours

Faculty of Electrical & Electronic Engineering Technology

Universiti Teknikal Malaysia Melaka

(August 2023)

b
 NON-CONFIDENTIAL DECLARATION BY INDUSTRY

“I hereby declare that this Industrial Training Technical Report was written by Abdullah Hakim

Bin Amir Radzuanuddin and all information regarding this company and the projects are NON-

CONFIDENTIAL and is true to my best knowledge.”

Approved by:

……………………………………………………..

Industrial Supervisor’s Name : Ir. Dr. Chan Seong Phun

Designation : Managing Director

Company’s Name : E.S.S. Engineering Sdn. Bhd.

Department : Service Electrical Engineer

Date : August 21, 2023

i
 INDUSTRIAL TRAINING DECLARATION FORM

UNIVERSITI TEKNIKAL MALAYSIA

MELAKA
Hang Tuah Jaya
76100 Durian Tunggal, MELAKA
BORANG PERAKUAN TAMAT LATIHAN INDUSTRI

Laporan ini adalah hasil usaha saya sendiri dan telah disahkan isi kandungannya oleh pihak
industri sebagai satu laporan lengkap setelah tamat menjalani latihan industri dalam tempoh yang
telah ditetapkan.

Tandatangan : ………………………………

Nama Pelajar : Abdullah Hakim Bin Amir Radzuanuddin

Tarikh : 21/8/2023

Disahkan oleh Penyelia Organisasi:

Tandatangan : ………………………………

Nama Penyelia : Ir. Dr. Chan Seong Phun

Jawatan : Managing Director

Cop Syarikat :

Tarikh : 21/8/2023

Diperiksa oleh Penyelia Fakulti:

Tandatangan :

Nama Penyelia :
Tarikh :

ii
 ABSTRACT

Students who participate in industrial training can gain professional work experience

while receiving expert advice in a secure setting. Students will benefit from industrial training by

developing professional qualities including communication, responsibility, and technical know-

how that may be valuable in the workplace in the future. Additionally, it will assist students in

applying their theoretical knowledge to the workplace. This report will go into detail on the 6-

month industrial training period that took place at E.S.S Engineering Sdn. Bhd. The student's

internship was with the testing team, working under faculty supervisor Datin Dr. Fadzilah and

company supervisor Ir Dr Sean Chan. The assignment comprises a variety of job scopes linked to

power systems, particularly power system protection, during the internship time. For instance,

one of the tasks assigned to the student is to assist the test engineer as they test various electrical

equipment, including isolators, earth switches, and power transformers. The major objective of

these tests is to confirm that the design specifications and industry standards are followed by all

electrical equipment at that location.

iii
 ACKNOWLEDGEMENT

First and foremost, thanks and worship to the Almighty God for encouraging me to

complete this report. Additionally, I want to express my gratitude to E.S.S. Engineering Sdn Bhd

for giving me the chance to do the internship at their company. As for my industrial supervisor Ir.

Dr. Chan Seoung Phun, thank you for the guidance throughout my internship program and giving

me the chance to pursue my dream. I am also thankful for my faculty supervisor, Datin Dr. Fadzilah

Binti Salim for her advice and guidance about how to complete this report and her follow up about

my internship. I am also grateful to the E.S.S Engineering teams for welcoming as an intern and

giving a good vibe working at the company. As for my fellow interns, I would like to thank them

for becoming my loyal companion and helping through hardship during the internship program. I

am also greatly indebted to my senior engineers, Encik Muhammad Faris Iskandar Bin Shuhaimi

and Encik Muhammad Izwan Bin Rusli for their patience, guidance, life lessons and spiritual

guidance. Finally, I would like to thank my family and friends for their understanding and

encouraging me in completing my internship for a 6-month period.

iv
 LIST OF TABLES

Table 1: List of equipment Test sets 19

Table 2: IR injecting standard 21

v
 LIST OF FIGURES

Figure 1: Company Logo 3

Figure 2: Company's Place 4
Figure 3: Company's Location 4
Figure 4: IR test training on 132kV cable. 21
Figure 5: Training on relays 22
Figure 6: Test Set for Relay calibration 22
Figure 7: Connection setup for CT analyzer 24
Figure 8: Circuit diagram of CT analyzer 24
Figure 9: Cast Resin Transfomer 25
Figure 10: Switchgear panel inside company's workshop 27
Figure 11: Rack out VCB 27
Figure 12: Training testing on VCB 28
Figure 13:Sungai Brooke Hydro Power Station 29
Figure 14: Switchyard of substaion Sri Layang 31
Figure 15: Reading check 32
Figure 16: Setting software QuickCMC 34
Figure 17: Connections test at relay 35
Figure 18: Documentation of result 36
Figure 19: Air product Sdn. Bhd. factory 37
Figure 20: XFMR-3 Main Transformer 38
Figure 21: Dismantled cable from windings 38
Figure 22: Example of Compact substation 40
Figure 23: Transformer inside compact substation 40
Figure 24: RMU inside compact substation 41
Figure 25: Xinyi Solar Malaysia Sdn. Bhd. 42
Figure 26: 3-winding Transformer 132/33/11 kV 43
Figure 27: Example list of testing 43
Figure 28: VCB of 11kV feeders 45
Figure 29: Setup of doing CT test. 46
Figure 30: PHENIX Hi-Pot Setup injecting busbas feeders 47
Figure 31: Control PHENIX injecting voltage 47
Figure 32: GIS 132kV substation 48
Figure 33: 132kV CT test 49
Figure 34: 132 CB test setup 49
Figure 35: Withstand Test on 132kV incomer. 50
Figure 36: Gauge meter 51
Figure 37: SF6 gas analyzer measurement result 52

vi
 ABBREVIATION

Symbols Means

IR : Insulation Resistance

CT : Current Transformer

VT : Voltage Transformer

TMS : Time Multiplayer Setting

VCB : Vacuum Circuit Breaker

PMU : Pencawang Masuk Utama

PMS : Plug Multiplayer Setting

TX : Transformer

IDMT : Inverse Definite Minimum Time

GIS : Gas Insulated Switchgear

PI : Polarization Index

TNB : Tenaga Nasional Berhad

IEC : International Electrotechnical

Commission

SAT : Site Acceptance Test

FAT : Factory Acceptance Test

HV : High Voltage

MV : Medium Voltage

LV : Low Voltage

vii
 TABLE OF CONTENTS

NON-CONFIDENTIAL DECLARATION BY INDUSTRY i

INDUSTRIAL TRAINING DECLARATION FORM ii
ABSTRACT iii
ACKNOWLEDGEMENT iv
LIST OF TABLES v
LIST OF FIGURES vi
ABBREVIATION vii
TABLE OF CONTENTS viii
1. INTRODUCTION 1
1.1 Objective 1
1.2 Scope of Training 1
2. INDUSTRY BACKGROUND 3
2.1 Company Background 3
2.1.0 Vision, Mission, and Values 5
2.1.1 Services 6
2.2 Organizational Chart 8
3. TRAINING ACTIVITIES 9
3.0 Introduction 9
3.1 Learning Sessions 9
3.1.1 Substation Layout (Primary & Secondary) 10
3.1.2 Type of tests 11
3.1.3 Equipment Test Set 17
3.2 Training sessions 20
3.2.1 IR and PI Test 20
3.2.2 Relay Calibration Training 22
3.2.3 CT Test Training 24
3.2.4 Transformer Test Training 25
3.2.5 Circuit Breaker Test 27
3.3 Site Visits 29
3.3.1 Sungai Brooke Hydro Power Station 29

viii
 3.3.2 PMU ULU KALI & SRI LAYANG 132/11 kV 31
4. PROJECT ACTIVITIES 33
4.1 Relay Calibration at PRIMA Residency Kampung Paloh 33
4.1.1 Process doing the calibration 34
4.1.2 The test 35
4.1.3 Documentation 36
4.2 Testing Job at Air Product Sdn. Bhd. (Prai 2) 37
4.2.1 Process of transformer test 38
4.2.2 The Test 39
4.2.3 Documentation 39
4.3 Testing Job at Texas Instrument 40
4.3.1 Transformer Test 40
4.3.2 Ring Main Unit Test 41
4.3.3 Documentation 41
4.4 Testing and Commissioning at Xinyi Solar Malaysia Sdn. Bhd. 42
4.4.1 132/33/11 kV 3-Winding Main Transformer 43
4.4.2 33/11 kV switchgear room 44
4.4.3 132 kV GIS Substation room 48
5. CONCLUSION 53
5.1 Internship summary 53
5.3 Conclusion 54
REFERENCE 55

ix
 1. INTRODUCTION

1.1 Objective

1. To develop skills and competencies specific to practical jobs according to my job

scope.

2. To be able to work effectively in different environments.

3. To put my knowledge and skills into practice.

4. To gain more knowledge about the working environment.

5. To build more network contact.

6. To practice my skills and knowledge based on my experience.

1.2 Scope of Training

An internship focusing on assisting a competent engineer in the testing and commissioning

of electrical systems ranging in voltage from 11kV to 275kV that offers a significant hands-

on experience and technical understanding in high-voltage and low-voltage engineering.

The scope of training that been provided in my internship:

1
1. Safety Protocols and Procedures – Safety is the most important one for a high–voltage

job environment. Receive complete training on safety protocol, hazard identification,

risk assessment, and the proper use of personal protective equipment (PPE).

2. Familiarization with equipment – Learned various types of high-voltage equipment

used in power systems, such as circuit breakers, transformers, switchgear, protective

relays, and more. This includes understanding their functions, components, and

operating principles.

3. Testing Methods – Gain hands-on experience in conducting a variety of tests on high-

voltage equipment, such as insulation resistance tests, turns ratio test, winding

resistance test, SFRA test, excitation test, circuit breaker test, vacuum test, timing test,

contact resistance test, power factor tests, and voltage withstand tests, trip testing timing

test, pickup test, polarity test. The testing is done to ensure that each component and

system meets design specifications and safety standards.

4. Instruments for testing – Learn to use specialized test instruments and equipment

required for high-voltage testing, including digital multimeters, megohmmeters, power

analyzers, oscilloscopes, and other diagnostic tools.

5. Data Analysis and Interpretation – Gain skills in analyzing test results, identifying

anomalies, and interpreting data to determine the condition and performance of the

tested equipment.

6. Documentation – Learn how to document testing and commissioning activities

thoroughly, including preparing test reports, equipment condition assessments, and

maintenance recommendations.

2
7. High-Voltage Substations – Understand the layout and components of high-voltage

substations, including busbars, isolators, surge arresters, and control systems.

8. Protection and Control – Gain insight into protective relay systems, control schemes,

and their role in maintaining the reliability and safety of high-voltage systems.

9. Field Work – Depending on the internship structure, you may have opportunities to

visit high-voltage substations and work on-site, gaining exposure to real-world

scenarios.

3
 2. INDUSTRY BACKGROUND

2.1 Company Background

Figure 1: Company Logo

Company’s Name : E.S.S Engineering Sdn. Bhd.

Managing Director : Ir. Dr. Chan Seong Phun

Company’s : 28a, Jalan Medan Ipoh 9, Bandar Baru Medan Ipoh, 31400

Address Ipoh, Perak

Contact No. : +60 (5) 5423 131 / +60 (5) 5423 130

Facsimile No. : +60 (5) 5423 130

Email : [email protected]

3
 Figure 2: Company's Place

Figure 3: Company's Location

Founded in 1984 and with over 40 years of expertise, E.S.S. ENGINEERING SDN. BHD.

is a one-stop provider of total engineering solutions with a focus on mechanical and

electrical contract works, CIDB Grade G7, Suruhanjaya Tenaga Class A, PKK 'A' Class A,

and PKK 'E' Class I.

4
2.1.0 Vision, Mission, and Values

Vision

Strive to best in class as electrical service company with electrical utilities,

independent power producers and large power consumers.

Mission

Dedicated to providing the highest quality electrical services exceeding our

customers’ expectations. We will continue to invest in equipment, up to date

technologies and highly trained technical personnel providing added value to our

business relationships.

Values

• Integrity

• Reliability

• Teamwork

• Responsiveness

5
2.1.1 Services

Expertise Works

• Installation, Maintenance, Testing & Commissioning of EHV Systems (GIS,

AIS, Insulation Test), 500kV, 275kV & 132kV.

• Installation, Maintenance, Testing & Commissioning of MV Systems

(Protection Relays, Current Transformers and Step-Down Transformers), 33kV

& 11kV.

Electrical Works

• Electrical Wiring works / Complete re-wiring (Single phase 230V and Three

Phase 415V).

• Electrical Contractor for Voltages, 230V, 400V/415V, 11kV, 33kV & 132kV

Services.

Air Conditioning Works

• York by Johnson Controls

• Daikin Cooling King / Ecoking / VRV

• Carrier / York / Trane Water Cooled Chillers

• Dunham Bush

• Air ducts installation

• Fan motors maintenance

Automation Works

• Siemens Apogee System – Building

6
 • Automation System (BAS)

• Siemens Gamma – KNX Home automation

• system

• SCADA

• Street Lighting

• Telekom Works

• Underground electrical cables 240V, 415V, 33kV & 132kV

• Lighting Protection Systems

• Energy efficiency checks

• Green Building

• Electrical metering

Fire Protection Works

• Sprinkler / Hose reel / Dry riser / Wet riser

• Conventional Fire Alarm Systems

• Siemens Addressable Fire Alarm Systems

• GE Vigilant Addressable Fire Alarm Systems

• Area Smoke Imaging Detection (OSID)

7
2.2 Organizational Chart

8
 3. TRAINING ACTIVITIES

3.0 Introduction

In this chapter, I have been introduced to the type of job of the company E.S.S Engineering

SDN. BHD. Basically, this company is doing the testing and commissioning job which is

for the site acceptance test (SAT). A Site Acceptance Test (SAT) is an important stage in the

process of installing new hardware, software, or technology at a particular site or location.

The SAT's goal is to confirm that the recently installed or implemented system complies

with the established criteria and standards and is prepared for use operationally in the

environment for which it was designed.

3.1 Learning Sessions

The student has been introduced to what the test that has been use as well as its equipment

for every type of test job. There are many tests that have been learned, different tests,

different equipment that has been tested and different types of equipment test has been used

during my six months of internship. The student was also exposed to a variety of primary

and secondary electrical equipment found in the store of the company. This exposure is

important to prepare students about the function of equipment before doing a site job.

9
3.1.1 Substation Layout (Primary & Secondary)

The substation is important for electrical power systems that provide the power

generation source to the end consumers with the most efficient, reliable, and safe

distribution of electricity. The substation consists of primary and secondary

electrical equipment. Which is:

Primary electrical equipment:

• Surge Arrestor – Protect the electrical equipment on primary by providing

a path of low resistance for excessive surge current caused by lightning.

• Voltage Transformer – A component of electrical equipment used to

accurately measure, control, and protect an electrical system by converting

high voltage levels to lower voltage.

• Isolator/Disconnector – Disconnectors are typically used for safety,

maintenance, and repair tasks because they protect workers from contact

with live electrical parts while they operate on a particular piece of

equipment or area of the electrical network.

• Current Transformer – a crucial tool for measuring and monitoring

electrical currents in electrical power networks. It works by converting

strong primary currents into proportional secondary currents that are lower

and safer for instruments, meters, relays, and safety equipment to measure.

• Circuit Breaker – It carries out the crucial task of stopping and regulating

the movement of electrical current in a circuit. Circuit breakers are used to

10
 safeguard electrical equipment, people, and the system against failures

including overcurrent and short circuits.

Secondary electrical equipment:

• Relay protection – A protection relay is a crucial component of electrical

power systems that monitors, detects, and reacts to abnormal circumstances

and malfunctions to guarantee the system's safe and reliable operation.

Protection relays are essential for promptly isolating malfunctioning

network segments and reducing the effects of malfunctions on employees

and equipment.

• Switchgear – Circuit breakers, disconnect switches, and protection relays

are just a few of the electrical components that make up switchgear, which

is used to manage, safeguard, and isolate electrical equipment and circuits

in a power system.

3.1.2 Type of tests

There are many types of tests that I’ve been learning, for every test shows many

different results and it is important that the test is done in a proper way. To evaluate

the system's performance, functionality, and general suitability for its intended

purpose, several planned procedures and tests are used in the test. The testing is

done for primary and secondary electrical system for high voltage (HV), medium

voltage (MV), and low voltage (LV). Also, the test result also refers to the Factory

acceptance test (FAT) result which needs to be compared with the test called site

11
acceptance test (SAT) result. The test result also needs to pass its passing criteria

which has been set to the standard IEC and TNB. The tests introduced is:

1. Insulation Resistance test:

Insulation resistance (IR) is a measurement used to describe the electrical

resistance existing between two conducting components that are spaced apart

by an insulating substance. The evaluation of insulation's quality and integrity,

which is intended to stop current from flowing between conductors and to the

ground, is a crucial component of electrical systems and equipment.

The IR test is usually performed in many types of electrical applications, such

as systems of power distributions, transformers, and cables. Its purpose is to

identify if there is any potential weakness or degradation in the insulation

material that could lead to electrical faults, shorts circuits, or breakdown.

The procedure to do the test is connect the positive (+) terminal of the cable or

primary terminal of electrical equipment. Then connect the negative (-)

terminal to the ground. Turn the operation rotary switch on the MEGGER

MT515/MT1025 to 5kV or 10kV and hold the press button ‘TEST’ until the

test set is operated. The test is done in 1 minute total.

12
2. Polarization Index Test:

To assess the insulation's general condition and find any issues that could cause

an electrical failure or breakdown. The polarization index test (PI) measures

the division insulation resistance (IR) at 1 minute and IR at 10 minutes.

𝐼𝑅(10minutes)
𝑃𝐼 =
𝐼𝑅(1𝑚𝑖𝑛𝑢𝑡𝑒𝑠)

3. Transformer test (some test includes for CT and VT):

• Turn ratio test (PT, CT VT) – A diagnostic test performed on the

transformer to verify the accuracy of their winding turns ratio. The test

is to ensure that the transformer functions correctly in stepping up and

stepping down the voltage intended.

• Polarity test(PT, CT, VT) – to establish the primary and secondary

windings' respective polarities. The test is to ensure that the transformer

will function as expected in terms of voltage transformation and phase

relationships if the connections between the windings are connected

properly.

• DC winding resistance test(PT) – To measure the DC resistance of its

winding. The test provided valuable information about the condition of

the winding conductors, connections, and overall, the health of the

transformer.

13
• Excitation current test(PT, CT, VT) – To measure the drawn currents

of the transformer’s primary winding when energized with no-load on

secondary winding. The test provided valuable information of the core

losses, magnetizing characteristics, and efficiency of the transformer.

• Short-Circuit Impedance Test(PT) – To determine the transformer’s

impedance, which is an important parameter to ensure its ability to

handle short-circuit currents. The test ensures that the transformer is in

proper condition in its protection devices and its safe operation within

electrical system.

• Sweep Frequency Response Analysis (SFRA)(PT) – To check the

mechanical and electrical integrity of transformer. By monitoring a

device's frequency response over a variety of frequencies, SFRA can

detect changes in the device's physical structure brought on by

mechanical deformation or other problems. The test shares the valuable

result for detecting winding displacement, deformation, and other

mechanical anomalies that could impact the transformer’s performance.

• Transformer Guard – Verifies that the device is operating properly

and can offer prompt protection in the event of internal failures.

Transformers include Buchholz relay test, winding temperature and so

on.

• Oil quality analysis – To evaluate the state and health of the

transformer insulating oil.

14
 • Saturated CT Test – A method for figuring out when a current

transformer becomes saturated when exposed to a specific amount of

primary current.

4. Circuit breaker test:

• Contact Resistance Test – Tests are done on high-current devices, such

as circuit breakers, to make sure they are reliable and function as

intended. When the circuit breaker is closed, it assesses how resistant

the electrical contacts are to current flow.

• Timing test – To evaluate the timing aspects of its opening and closing

procedures. This test is essential to make sure the circuit breaker reacts

appropriately and within the allotted time limits during fault conditions

or regular operations. The timing test assists in locating any anomalies

or variations in the circuit breaker's operation, enabling prompt repair

or changes.

• Medium interrupter test – To evaluate the medium interrupter or

medium chamber inside the circuit breaker for reliability and efficiency.

The type of medium for circuit breaker is vacuum and gas.

5. Relay calibration:

• Tripping test – A crucial process used to confirm the precision and

efficacy of the trip or trip-coil operation of a protective relay.

• Timing test –A vital step in ensuring the precision and consistency of

a relay's time-delay settings is to perform a timing test on it. Timing

15
 tests help to ensure that the relay responds to events or conditions within

the allotted time constraints.

• Pickup test – A test intended to establish the threshold or magnitude of

an input signal, such as voltage or current, at which the relay should

activate and begin performing the anticipated activity. This test makes

sure that the pickup setting on the relay is precise and reliable, enabling

the relay to turn on when the required conditions are fulfilled.

6. High Potential test (Hi-Pot):

A high potential test, often referred to as a dielectric withstand test, is a

kind of electrical test that evaluates the integrity and quality of insulation in

electrical equipment or components. In this test, a higher-than-normal voltage

is applied to the apparatus to see if the insulation can sustain the strain without

breaking down or failing. Hi-Pot tests are done to make sure they are safe and

reliable while in use, the tests are frequently done on cables, transformers,

switches, circuit breakers, and other electrical equipment.

16
3.1.3 Equipment Test Set

In order to execute the tests, the company introduce to the student of equipment test

set that they have to fully evaluate the condition of the electrical equipment on the

primary and secondary.

Equipment test set Test can be conducted

MEGGER Insulation resistance

MT515/1025

IR test & PI test

MEGGER VIDAR

Vacuum test on vacuum circuit

breaker

OMICRON CMC 353 & 356

17
 Relay calibration

OMICRON CP TD1

Transformer Test

OMICRON CPC 100

Transformer Test

OMICRON CT ANALYZER

CT test

OMICRON TESTRANO 600

18
 Transformer Test

OMICRON CIBANO 500

Circuit Breaker Test

OMICRON FRANEO 800

SFRA test

973-SF6 Analyzer

SF6 Gas analyzer

Table 1: List of equipment Test sets

19
3.2 Training sessions

3.2.1 IR and PI Test

Training doing the insulation resistance (IR) test and polarization index (PI)

test at company’s workshop. The test is commonly performed using a Megger

MIT515 (max voltage can injected = 5kV) and MIT1025 (max voltage can be

injected = 10kV), which is a portable instrument that measures high resistance

values. A Megger consists of a high-voltage generator and an indicating meter or

display. The megger is basically injecting voltage to the test object, and measure the

leakage current from the insulation object, so then it applies the ohm’s law of R=V/I

to calculate the value of the resistance and display through the megger. The voltage

that has been injected is in DC, so to do the injection, we need to follow the IEC

standard and TNB standard for certain test object such cables according to its rated

voltage.

Learn about the passing criteria on the IR test is the value of resistance need to be

above 1 G𝛺.

20
 Rated voltage Standard voltage Rating voltage for

(TNB supply) to be injected cables

500kV

275kV Vdc = 10kV 132kV to 500kV

132kV

33kV Vdc = 5kV 11kV to 33kV

11kV

6.6kV Vdc = 1kV 6.6kV to lower kV

Table 2: IR injecting standard

For PI test is using the same test equipment of megger MT515/1025, but to do the

PI test from this equipment the Vdc need to be injected for total 10 minutes to

verify this formula equation:

𝐼𝑅(10minutes)
𝑃𝐼 =
𝐼𝑅(1𝑚𝑖𝑛𝑢𝑡𝑒𝑠)

So, the passing criteria of the PI needs to be above 1.2 value.

Figure 4: IR test training on 132kV cable.

21
3.2.2 Relay Calibration Training

Figure 5: Training on relays

Figure 6: Test Set for Relay calibration

The primary function of a relay for a current transformer is to detect

overcurrent conditions and initiate an appropriate response. The relay may be

designed to trip a circuit breaker, open a contactor, or activate an alarm or warning

signal, depending on the specific application and the level of protection required.

Some common types of relays for current transformers include Overcurrent relays,

Directional relays, and Earth fault relays. The student trains how to set up and

22
conduct the relay calibration using CMC 356 test set. The CMC 356 is easy to use

and can be operated using the built-in control panel or via a PC using the

OMICRON Test Universe software. The software provides a user-friendly interface

for creating and executing test plans, as well as analyzing and reporting test results.

Every relay has a different type of setting which is type of curves, value of time

multiplayer setting, overcurrent setting, earth fault setting and so on.

There are 4 types of curves Inverse Definite Minimum Time (IDMT) which is

Definite Time (DT), Normal inverse (NI), Very Inverse (VI), Extremely Inverse (EI)

and Long Time Inverse (LTI). For each type of curves has their own constant value

of k and α to be put inside the formula to calculate its tripping time for clarification

of relay setting tripping time when measured. The formula:

𝑘
𝑡(𝑠) = 𝑇𝑀𝑆 ( 𝛼 )
𝐼
(𝐼𝑠) − 1

23
3.2.3 CT Test Training

Figure 7: Connection setup for CT analyzer

Figure 8: Circuit diagram of CT analyzer

The student trains how to conduct the current transformer (CT) test. The student

learns theoretically about current transformer about its type, specs, and the use of it

which is protection and metering. Learn the basic thing on site work of reading the

nameplate CT to get its specification information such as its serial no., CT ratio,

accuracy power, burden (VA), type of protection (5P20, etc.), metering (0.2, etc.)

and accuracy limit factor (ALF).

The test is conducted using CT analyzer, the student trains how to setup the

connection based on the software on CT analyzer given schematic. The type of test

executed is winding resistance test, excitation test, and ratio test.

24
3.2.4 Transformer Test Training

Figure 9: Cast Resin Transfomer

A cast resin transformer 2 unit is inside the workshop of this company

provided to do the training for the student. Cast resin transformer or other name is

dry type transformer which relies on solid insulation material and natural or forced

air convection for cooling. The transformer is rated 11/6.6 kV and the student trains

how to conduct the transformer test using the equipment test set of OMICRONS

TESTRANO 600. The tests that been executed is:

• Demagnetization – need to do this test before and after we conduct other

tests to eliminate the remaining magnetism inside the winding transformer.

• Vector Group – The test which detects and clarifies the winding

arrangement of three-phase transformer on HV and LV side.

25
• Turn ratio test – The test is to clarify the turn ratio of primary and secondary

side of transformer by injecting the voltage on primary side then measure the

secondary and do some calculations whether the step down or up is appropriate

according to the nameplate.

• DC winding resistance – The test is to inspect each resistance of three-

phase winding on primary and secondary.

• Short-circuit impendence – Put the transformer in a short-circuit condition

to monitor and measure their impedance and reactance under the short-circuit

circumstances.

• Zero-sequence impedance – Put the transformer in a zero-sequence

condition which grounded neutral point and grounding connections where the

current unbalanced flows.

26
3.2.5 Circuit Breaker Test

Figure 10: Switchgear panel inside company's workshop

Figure 11: Rack out VCB

Doing the training test on the Vacuum circuit breaker inside the air insulated

switchgear (AIS) that station inside the workshop to do the training and learning for

the students. Here, learn on how competent person chargemen do the switching and

rack in and out of the circuit breaker. The AIS inside workshop is not in load so the

session is doing just the demonstration on AIS in no load condition without supply

from incoming. Learn the sequence of how to bring out the VCB inside the

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switchgear. Need to wear an arc flash suit for safeness and follow step by step the

sequence of opening the whole switchgear to take out VCB. The procedure is:

• Isolating the power supply to prevent any accidental energization.

• Open the circuit breaker by pressing the button on switchgear.

• Manual open the VCB by turning lock key 20 times anti-clockwise on the

VCB case. The initial VCB inside the switchgear is called in service position

when it racks out the condition is called test position.

• To increase the safeness, switch on the earthing switch at the bottom using

the shaft key also.

• Bring the VCB out.

Figure 12: Training testing on VCB

When the VCB is on the trolly then the student can conduct the test using CIBANO

500, Megger IR and VIDAR which is:

• Contact resistance test – to determine the contact of the circuit in good

condition, injecting the Vdc to get resistance measurement result. The lower

the resistance the better its contact for circuit breaker of busbar and cable.
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 • IR test – do for every phase and for easy execution need to test in closed

circuit breaker condition.

• Timing Test – timing test to determine the time for CB to open and close

the circuit, the sequence test, which is open, close, close-open, and open-

close-open timing test.

• Vacuum Test – To check the condition of the vacuum flask on the CB, the

CB condition for this test needs to be open.

3.3 Site Visits

3.3.1 Sungai Brooke Hydro Power Station

Figure 13:Sungai Brooke Hydro Power Station

When to the first site visit at Sungai Brooke Hydro Power Station, Gua

Musang, Kelantan. Learning how the power is generated from the flow of water to

produce electricity power. The flowing water is called kinetic energy which will

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turn the rotor convert to mechanical energy, rotor then turning the shaft attach to the

turbine which then convert to electrical energy. This site visit is to monitor the

system hydro power plant condition. Observe and monitor the SCADA system and

every control panel inside the control panel room.

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3.3.2 PMU ULU KALI & SRI LAYANG 132/11 kV

Figure 14: Switchyard of substaion Sri Layang

Second site visit at PMU Ulu Kali And Sri Layang 132/11 kV to do monthly

maintenance checkup for a substation which refers to a regular inspection and

testing process conducted monthly to ensure the proper functioning, safety, and

reliability of an electrical substation. Electrical substations play a crucial role in the

power distribution system, transforming and distributing electricity from high-

voltage transmission lines to lower-voltage distribution lines that serve homes,

businesses, and industries.

Regular maintenance checks are essential to prevent equipment failures, extend

the lifespan of substation components, maintain a safe working environment for

personnel, and ensure the reliability of the power distribution system. Monthly

checkups provide a proactive approach to identifying and addressing potential

problems before they escalate into costly breakdowns or disruptions in power

supply.

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The type of job is such:

• Cleaning – Mopping, brooming the floor to prevent dusty room.

• Visual inspection – Check overall the condition of switchgears, screw,

lamp, and any other compartment related to the electrical equipment.

• Tightening and lubrication – Check every joining part of panels.

• Alarm & protection system testing – Checking the alarm LED, buzzer,

and any other indication.

• Environmental check – check the condition of switchyard, eliminate

that can cause any fault.

• Record keeping – Take the reading of voltage, current, power, reactive

power etc.

Figure 15: Reading check

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 4. PROJECT ACTIVITIES

4.1 Relay Calibration at PRIMA Residency Kampung Paloh

At PR1MA residency Kampung Paloh, E.S.S engineering Sdn Bhd are assigned to do the

relay calibration for the control room at the building. Relay calibration is the process of

adjusting and fine-tuning protective relays used in electrical systems to ensure their accurate

and reliable operation. Protective relays are devices designed to detect abnormal conditions

or faults in an electrical system and initiate appropriate actions, such as tripping circuit

breakers, to isolate faulty parts and prevent damage to equipment and personnel. Calibration

ensures that the relays respond appropriately to different fault scenarios and maintain the

desired settings within specified tolerances.

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4.1.1 Process doing the calibration.

Figure 16: Setting software QuickCMC

There is a total of 5 panels which is 5 relay that need to be calibrated. The relay

is being tested first using the Omicron CMC test kit. The type of relay that the

panel of the residential use is overcurrent, O/C and Earth fault, E/F relay

protection. The IDMT that needs to be checked for this residential is SI,

Standard inverse only. Every relay from the panel has its own setting of O/C,

E/F, TMS, PMS and its own CT ratio.

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4.1.2 The test

Figure 17: Connections test at relay

The test is done during life so the procedure must be followed carefully, and the

CT secondary cannot be opened because it will result in the high voltage output

at secondary and cause the CT to be saturated if leave it for too long. The CMC

353 test set is used to inject the current to the relay. The calculation of time to

trip and pick up current is done firstly to clarify and differentiate between the

time of calculation and measured. The test set OMICRON CMC 353 has their

own software to execute the relay calibration. The test kit will inject the current

of overcurrent to see the relay can detect the pickup current and test the trip

whether it’s functioning according to the relay setting or not. The test executed

is:

a) Pickup test – calculation done then inject the current (based on the

calculation value) from CMC and check the response on the relay

indication.

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 b) Timing test – calculation done for the fault current test and the timing

calculation for relay to trip. Then inject the current to the relay and check

the response of relay to trip then do the comparison.

For every test need to repeat for every phase red, yellow and blue.

4.1.3 Documentation

Figure 18: Documentation of result

The result of the test is then recorded, and the commissioning is recorded

and clarified at every relay then. Analyze the settings of the relay and based

on calculation and executed test. Record the test result on the report. For this

project overall the test is pass for all panel and phases.

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4.2 Testing Job at Air Product Sdn. Bhd. (Prai 2)

Figure 19: Air product Sdn. Bhd. factory

At Air Product Sdn Bhd, hear the safety induction for the first time about the safety regulation

and remind our-self to master the basics of safety. The basics of safety that been applied for Air

Product is:

• Be aware of our surroundings.

• Know our physical limitations.

• use the proper PPE.

• Follow our procedure.

• Think, think, think before we act.

Then before starting to do the work, the contractors require to attend a safety toolbox to get the

work permit. The job scope at Air Product Sdn Bhd is doing the transformer testing preventative

maintenance on the main transformer.

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4.2.1 Process of transformer test

Figure 20: XFMR-3 Main Transformer

Figure 21: Dismantled cable from windings

The type of transformer is an oil type transformer, and the primary and secondary

winding is enclosed in transformer body door because the cable incoming is from the

underground. Open the transformer and dismantle the cable primary and secondary

winding to do the injection on the 3-phase winding transformer.

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4.2.2 The Test

a) IR & PI Test:

– Do test is done before and after the other tests on the transformer.

– Using MEGGER MT515, injecting 5kVdc into the winding transformer.

b) Ratio Test (using OMICRON TESTRANO 600)

c) DC winding resistance test (using OMICRON TESTRANO 600)

d) Power factor test (using OMICRON CPT1)

e) Excitation test (using OMICRON TESTRANO 600)

f) SFRA test (using OMICRON FRANEO 800)

g) Oil Sampling – Took oil sampling and evaluate the quality of oil insulation.

4.2.3 Documentation

Record all the test results and create a report about the overall transformer condition

for reference if any unwanted event happen in the future.

39
4.3 Testing Job at Texas Instrument

Figure 22: Example of Compact substation

At Texas Instrument, E.S.S Engineering Sdn Bhd is assigned by client to the test on the compact

substation at construction site. The test that been done was transformer test and pressure test

on ring main unit (RMU). First before starting to do the work of testing, contractors are required

to attend the safety toolbox.

4.3.1 Transformer Test

Figure 23: Transformer inside compact substation

Open the compact substation to get access to do the injection on the transformer

primary and secondary winding. The type of test on the transformer:

40
 a) IR test – before and after the other test on the transformer 3-phase winding.

b) Ratio test (using OMICRON TESTRANO 600)

c) DC winding resistance (using OMICRON TESTRANO 600)

d) Contact resistance (using OMICRON TESTRANO 600)

4.3.2 Ring Main Unit Test

Figure 24: RMU inside compact substation

The distribution supply that efficiently controls and distributes electrical power while

preserving reliability and safety is known as a "ring main unit." The test on the RMU

is Hi-Pot Test or pressure test. Pressure Test on transformer using AC Hipot Primary

side (24kV @ 1 min) and Secondary (1kV @ 1 min). The test is done using PHENIX

technology Hi-Pot test set injecting Vac to the RMU.

4.3.3 Documentation

Record all the test results and create a report about the overall transformer and RMU

condition for reference if any unwanted event happens in the future.

41
4.4 Testing and Commissioning at Xinyi Solar Malaysia Sdn. Bhd.

Figure 25: Xinyi Solar Malaysia Sdn. Bhd.

At Xinyi Solar Malaysia Sdn Bhd, there is a new substation of 132/33/11 kV in construction

condition. E.S.S Engineering has taken the job of doing the testing and commission for the

whole substation of the client before the substation is powered up. The substation type is Gas

insulation substation (GIS) and there are many types of tests that students have been involved

in and learn how to do the commissioning job at the site. Before doing the starting the job,

contractors need to hear a safety toolbox to get the work permit.

42
4.4.1 132/33/11 kV 3-Winding Main Transformer

Figure 26: 3-winding Transformer 132/33/11 kV

There are 2 transformer stations at the substation named TX1 and TX2. Each transformer has

the same specification which is the transformer is a 3-Winding transformer having the

Primary (HV-132kV), Secondary (MV-33kV) and Tertiary (MV-11kV). Before doing all the

tests, the demagnetization needs to be done first to remove any magnetic hysteresis or

residual magnetism that may have accumulated in the transformer core during operation.

The type of testing on TX1 and TX2 is:

Figure 27: Example list of testing

43
 a) IR Test – Before and after doing the other test.

b) Ratio Test – Primary-Secondary, Primary-Tertiary

c) DC winding resistance test – every winding primary, secondary and tertiary

d) Excitation test

e) Short-circuit impedance test – Primary-Secondary, Primary-Tertiary, Secondary-

Tertiary

f) Zero-sequence test

g) Bushing capacitance test/Power factor test

h) SFRA test

4.4.2 33/11 kV switchgear room

Inside the 33/11 kV switchgear room there is a total of 12 panels and 29 panels for

each 33kV and 11kV. There are many tests been done on the electrical equipment

inside switchgear room including commissioning. Which is:

1. Vacuum Circuit Breaker (VCB)Test:

44
 Figure 28: VCB of 11kV feeders
The VCB test is done for 33 and 11 kV and need to rack out by applying the

training that been done at the workshop by following the same step. The type

of test for VCB that been executed is:

– IR test

– Vacuum test (Using MEGGAR VIDAR)

– Circuit breaker test (using CIBANO 500)

• Timing test (open, close, close open, open close open)

• Contact resistance.

45
2. Current transformer (CT) test:

Figure 29: Setup of doing CT test.

Doing all the CT and ZCT test inside 33 and 11 kV switchgear panels. Doing

the injection of current to the primary and secondary connections through the

terminal block. Before doing the injection on the primary side, every core at

secondary need to be shorted to prevent the unwanted fault possibility and

following the rule of electrical current cannot be measure if not shorted. The

type of test been done is:

– Secondary winding resistance test

– Excitation current test

– Ratio test

46
3. AC Hi-pot Test

Figure 30: PHENIX Hi-Pot Setup injecting busbar feeders

Figure 31: Control PHENIX injecting voltage

AC withstand or Hi-Pot test is required by the client and the injection done at

the busbar connection of incomer 1 and incomer 2 for every 33kV and 11kV

feeders. The Insulation resistance (IR) test need to be done first since the AC

Hi-Pot will be injecting 2 times the rated voltage of feeders, so the condition

of busbar need to be check first to know the insulation can withstand with high

voltage injection. For the 11kV feeder, we inject voltage 19.2kV as 11kV =

24kVac @80% = 19.2kV and for the 33kV feeder, we inject voltage 54.4kV

as 33kV = 68kVac @80% = 54.4kV. After the AC Hi-Pot test is done, the IR

test after the injection is done also to compare the results before and after IR

test. Then record all the results to do the report documentation.

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4.4.3 132 kV GIS Substation room

Figure 32: GIS 132kV switchgear

An electrical substation known as a gas-insulated switchgear (GIS) uses sulfur

hexafluoride (SF6) gas as an insulating and switching medium inside of a sealed

container. Compared to conventional air-insulated substations, GIS technology has

several benefits, such as a smaller footprint, increased safety, and superior

environmental performance. In a GIS 132kV substation room, the test conducted is

basically the same as before which is:

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 Figure 33: 132kV CT test
– CT Test

• Ratio Test

• Secondary winding resistance

• Excitation test

• Polarity test

– VT Test

• Ratio test

• Polarity test

Figure 34: 132 CB test setup

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 – CB test

• Timing test – Closed, Open, Close-Open, Open-Close-Open

• Contact Resistance

• Dynamic Contact resistance

– Gas analyzer SF6

– Voltage withstands test.

4.4.3.1 Hi-Pot Test

Figure 35: Withstand Test on 132kV incomer.

AC withstand or Hi-Pot test is required by the client and the injection done at the 3-

Phase winding of incomer 1 & 2 for 132kV. The test is done by using Frequency

Adjustable Series Resonance for the precise and safes way to do the inject because

the frequency of voltage can vary to low frequency so that the incomer busbars is

not damaged in high voltage injection with normal frequency of 50 HZ instead using

only 0.1 HZ. The Insulation resistance (IR) test needs to be done first since the test

50
 set will be injecting 2 times the rated voltage of feeders, so the condition of busbar

needs to be checked first to know if the insulation can withstand high voltage

injection. The is done by increasing the voltage step by step, so the time for the test

is 10 minutes:

• 90kV @ 5 minutes.

• 175kV @ 3 minutes.

• 235kV @ 1 minute.

After the withstand test is done, do the IR test for the result of high voltage

injection. Analyze before and after IR test and record the data.

4.4.3.2 Gas analysis SF6

Figure 36: Gauge meter

Gas insulated substations (GIS), an uncommon type of electrical substation, are

equipped with sulfur hexafluoride (SF6) gas, which serves a few crucial tasks. In an

enclosed enclosure, SF6 gas is used by GIS technology as an insulating and arc-

quenching medium. The test is done at the SF6 gas gauge meter since it’s attached

with the doorway of filling in and out the gas. The SF6 gauge meter station at every

51
bay and compartment of GIS substation, so the test is for the whole gauge that is

attached. The measure that is need for the result SF6 gas analyzer is:

Figure 37: SF6 gas analyzer measurement result

• Volume SF6

• Dew Point

• S02

• Vessel Pressure

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 5. CONCLUSION

5.1 Internship summary

I learned a lot about testing and commissioning methods for various electrical

systems and equipment during my internship in the electrical contracting sector. I actively

took part in practical duties involving testing, troubleshooting, and assuring the proper

operation of electrical installations throughout my employment with the company.

I’ve learned a lot about the equipment of electricity and got a better understanding

of its functioning and the importance parts they role. This company has an engineer that is

ready to do the teaching and training. The shared knowledge is useful and its play’s

important part during doing some real site work job.

Overall, this company job scope about testing and commissioning gives me a room

to gain more knowledge about electrical engineering with the help of the projects of this

company taken, there are so many types of works related to electrical.

53
5.3 Conclusion

In conclusion, my internship experience in the electrical contracting business about

testing and commissioning has been both educational and gratifying. I've had the chance to

immerse myself in the complexities of electrical systems throughout my internship, and I've

learned firsthand about the crucial role that testing and commissioning play in guaranteeing the

functioning, safety, and effectiveness of various electrical installations.

I have developed a thorough understanding of the testing procedures applied to various

electrical components and systems throughout my time as an intern. I've had the opportunity to

put my theoretical knowledge to use in practical situations, executing anything from insulation

resistance tests to functional inspections of power distribution units and control panels. Each

testing technique emphasized the value of accuracy, care, and adherence to industry standards

to spot any problems and guarantee top performance.

The knowledge, abilities, and experiences I've gained over this period of learning and

development will undoubtedly prove to be a great asset in my professional life, I'm confident

as I look back on it. I'm inspired to contribute to the field and assure the dependability, safety,

and innovation of electrical systems in the industrial context by putting the knowledge I've

learned from this program to work.

I'll sum up by saying that my testing and commissioning internship has given me a solid

foundation in electrical systems, testing techniques, and quality assurance procedures. The

encounters, difficulties, and successes have fueled my desire to work in this industry. I'm eager

to use the abilities and understanding I obtained from this internship as I start my career in the

electrical contracting sector.

54
 REFERENCE

i. megger Information- chrome

extension://efaidnbmnnnibpcajpcglclefindmkaj/https://www.instrumart.com/assets/Megge

r-Guide-to-Insulation-Testing.pdf

ii. SF6 breaker testing and maintenance. Industrial Tests. (n.d.). Retrieved April 21, 2022,

from http://industrialtests.com/sf6-circuit-breaker-testing-maintenance/.

iii. Switchgear: Features, working, components, types & functions. ElProCus. Retrieved April

21, 2022, from https://www.elprocus.com/what-is-a-switchgear-working-types-and-its-

functions/.

iv. https://chintglobal.com/blog/gas-insulated-switchgear-

gis/#:~:text=The%20main%20feature%20of%20a,to%20perform%20the%20same%20fu

nction.

v. https://www.ecmweb.com/test-measurement/article/20898954/understanding-insulation-

resistance-testing

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