GEDAC ELECTRIC

Limited Liability Co
C.R. 4030014356
Paid Capital SR 12,000,000

CUSTOMER :

PROJECT NAME :

EQUIPMENT :

REFERENCE :

GEDAC ELECTRIC
FACTORY ACCEPTANCE
TEST FOR
LOW VOLTAGE PANELS

Prepared By : NICK PINEDA

LV TESTING DEPT
 GEDAC ELECTRIC
Limited Liability Co
C.R. 4030014356
Paid Capital SR 12,000,000

1- Objective

To establish the procedures for the inspection and test – Low voltage MCC, SWBD, SWGR Panels

2- General

2-1 The following summary defines the standard factory tests and inspections performed during
manufacture of industrial control equipment. All Low Voltage equipment is tested and
inspected for conformance with NEMA and ANSI standards.

2-2 The tests do not include type testing or other destructive tests on equipment. Any additional
factory tests beyond those listed in the following paragraphs must be referred to QC. to verify
availability of test facilities and qualified manpower.

2-3 These tests and inspections are performed on manufactured products to verify conformance of
the equipment to the design and job specification requirements also encompass the
verification of physical configuration of assembly and workmanship, the mechanical
adjustment of parts and components and the sequencing and functional operations of the
control systems.

2-4 The test and inspection activities are performed in accordance with manufacturing quality
control, and engineering standards. These standards cover the practices, procedures, and
requirement for the material control and manufacture of products, in addition to inspection
requirements for workmanship and operational test.

2-5 Prerequisites for each test and inspection operation are specified and include the appropriate
quantitative and qualitative acceptance criteria.

2-6 Confirmation of these requirements are verified in accordance with checklist, shop travelers,
materials marking

2-7 Test and inspection results are documented and evaluated

2-8 Additional testing beyond the scope of the following standard commercial tests will affect
normal shipment schedules.

3- Inspection tests

Inspection tests will be carried out through two stages.

1- In – process inspection
2- Final Inspection tests
 GEDAC ELECTRIC
Limited Liability Co
C.R. 4030014356
Paid Capital SR 12,000,000

3-1 In – process and visually inspections

These Inspection tests will be carried out during manufacturing cycle to assure proper and
correct materials and workmanship for any damage conditions in accordance with
manufacturing documentation and drawings and the following are the items which will be
checked

- Components, parts and materials.

- Location and orientation of components and parts
- Physical condition of components, parts, wire insulation
- Finish – plating (silver / tin) – painting (Ansi 61 Grey with 1.5 mils thickness)
- Case and cabient assembly inspection
- Tightness of electrical connections and torque of bus bars bolts
- Wire / cable size, type, clamping support
- Wire termination’s, crimping of terminals
- Wire identification and terminal markers (where specified)
- Labeling of components, parts, etc.
- Mechanical, Electrical Clearance (potential hazards).

Notes
* The Documentation will be used on that stage is
1- Travelering Tag
2- In – process inspection check sheet
3- Checklist point

* The above tests will be carried out by the section group leader / QC. Inspector and
their acceptance signature should be on the used documents
* Customer Inspection on that stage is not required unless other wise specified

3-2 Final Inspection tests

3-2-1 Mechanical operation test

Mechanical operating tests shall be performed to insure proper functioning of operating

mechanisms and interchangeability.

a. The operation of shutters, mechanical interlocks, Circuit breaker door interlocks, operating
handles, trip mechanisms, solenoid armature travels, contact wipes, electromechanical
interlocks, physical clearances for mechanical and electrical isolation including any additional
mechanically related operating functions shall be verified.

b. The interchangeability of removable units designed to be interchangeable shall be verified as

well as the rejection function of non-interchangeability units.
 GEDAC ELECTRIC
Limited Liability Co
C.R. 4030014356
Paid Capital SR 12,000,000

3-2-2 Continuity tests - control wiring and power cables

The correctness of the individual wiring contained in each assembly and the assembly
wiring interfaces shall be verified as in accordance with the connection diagram, wiring
table, or elementary drawing. The continuity of each circuit shall be checked

Note :- In some cases, circuit connections may be verified by actual electrical

operation of the components and associated wiring

3-2-3 functional operations tests

All equipment shall be subjected to an operational test. The test shall verify the functional operation of the
control and power circuits and related components,

devices, and sub assemblies modules under simulated operating conditions (excluding
loading of the power circuits)

A- Devices All devices must be carefully inspected to insure that they have
proper voltage,current, ferquncey , time ratings and proper contact
arrangment. Elmentary digram will be used for this check.

All control fuses will be inserted in fuse holders according to the ampere
ratings designated on the circuit digram. For metering and relay circuits ,
current and potential (voltage) wiring is traced back from the coils to arrive at
source of current and potential.

It is not the intent of the device function test to provide a precise caliberation
of adevice but rather to verify the device function and electrical characteristics
in accordance with the instructions for each (Ex. Pick–up, Drop–out, Time
delay) And any additional characteristics peculiar to a device.

Contactors must pick-up and hold- in at or below the following percentage of

the rated coil voltage.

Device type Voltage Source Pick - up

DC DC 63 %
AC AC 85 %
DC AC with rectifier 70 -75 % with
Holding resistor

B- Sequence and timing circuits.

 GEDAC ELECTRIC
Limited Liability Co
C.R. 4030014356
Paid Capital SR 12,000,000

Assemblies and systems involving sequential operation of devices and time

delays shall be tested to assure that the devices in the sequence function
properly and in the order intended.
Circuits involving timing devices shall be set to specified delays and sequence
operation will be verified.

C. Polarity, Phase sequence

The polarity of direct current circuits and phase connections of alternating

current circuits shall be verified by application of power and measurement of
the relative polarities and phase sequence .

D. Polarity - Current / Voltage transformer polarity check

This is a visual check only to verify that current transformers and voltage
transformers are installed and wired in accordance with engineering drawings
released.

E. Grounding

By using low voltage continuity tester all the grounding to the equipment’s and
others to be checked to assure proper metal case grounding.

3-2-4. High Potential - Insulation test

Power cable, buses insulation and isolation tests

Power cables and buses shall be tested, phase to phase and phase to ground for
insulation breakdown resistanc. If the neutral is applicable it will be consider as
fouth phase. These tests conditions are as specified for newly constructed
equipment and performed at room temperature and up to 95 % relative
humidity at a location less than 2000 meters in altitude. Equipment under test
shall be de - energised.
The test voltage shall be (two times rated plus 1000) for one minute and the
frequency of test voltage shall not be less than the rated frequency of the
equipment tested and shall be essentially sinusoidal wave shape.
Consideration shall be made for low voltage devices, semi conductor, meters,
instruments, transformers, grounding circuits, etc. In preparation for the
dielectric tests

3-2-5. Insulation resistance ( Megger ) tests

 GEDAC ELECTRIC
Limited Liability Co
C.R. 4030014356
Paid Capital SR 12,000,000

Insulation tests measure the amount of circuit resistance to current leakage.

This test is performed when the resistance measurements is desired and so
specified. The value of insulation resistance is subject to variations with
temperature, humidity and cleanliness of the equipment and wiring. It is also
dependent of the type, size, Voltage rating, Kind of insulating materials, and
method of construction and past insulation records of the equipment.

Control wiring insulation tests A dielectric test shall be performed on

control wiring between field wiring terminals designed to be isolated from the
chassis and chassis (ground). 500Volt is the test voltage we are going to use .

ACCEPTANCE CRITERIA
1- Electrical clearances
2- Insulation resistance test
3- Torque values for electrical joints

(1) Electrical clearance

Between live parts with opposite polarity through air

0 – 125 V AC 126 – 250 VAC 250 – 600 VAC

1 / 2" 3/4“ 1“

Between live parts and ground metal through air

0 – 125 V AC 126 – 250 VAC 250 – 600 VAC

(2) Insulation resistance test

Test voltage Acceptance IR

DC M
500 10
1000 25

As per GE standard 10, 25 Mega Ohm to be considered acceptable value with the condition the
switching devices in closed position and all instrumentation and control fuses removed.

(3) Torque values for electrical joints

 GEDAC ELECTRIC
Limited Liability Co
C.R. 4030014356
Paid Capital SR 12,000,000

THE FOLLOWING ARE BOLTS & SCREW & NUTS USED IN LOW VOLTAGE – MCC ,
RECOMMENDED
PART NO. DESCRIPTION TORQUE VALUES

N22P23016B BOLT HEX HEAD 5/16 – 18X 1” 16 – 19 lb. ft

ZINC COATED STEEL

N46P21010B SCREW CAP 1/4 – 20 X 5/8” 8 – 10 lb. ft

ZINC COATED STEEL

N62P29032B BOLT CARRIAGE 1/2 – 13 X 2”, 2 ½” 35 – 40 lb. ft

ZINC COATED STEEL

N62P29048B BOLT CARRIAGE 1/2 – 13 X 3” 35 – 40 lb. ft

ZINC COATED STEEL

N140P17008B SCREW SELF TAPPING 10 – 24 X 1/2” 23 lb. ft

ZINC COATED STEEL

N657P25024B BOLT CARRIAGE 3/8 – 16 X 1 1/ 2” 23 – 27 lb. ft

ZINC COATED STEEL

N722P21010B SCREW THREAD ROLLING 1/4 - 20 X 5/8 8 – 10 lb. ft

ZINC COATED STEEL

SWBD , SWGR CCB, and LIGHTING SECTION FOR CONDUCTOR AND BUS JOINTS.

N245P221B NUT - 1/4 - 20 ZINC COATED STEEL

N245P221B NUT - 5/16 - 23 ZINC COATED STEEL
N245P221B NUT - 3/8 - 25 ZINC COATED STEEL
N245P221B NUT - 1/2 - 13 ZINC COATED STEEL

ATTACHMENTS
 GEDAC ELECTRIC
Limited Liability Co
C.R. 4030014356
Paid Capital SR 12,000,000

PAGE DETAIL PAGE #

ROUTE TRAVELLER--------------------------------------------------------------------------------8

IN–PROCESS INSPECTION / TESTING REQUEST-------------------------------------------9

INSPECTION CHECKLIST FORM -------------------------------------------------------------- 10

INSULATION RESISTANCE TEST FORM ---------------------------------------------------11

HI-POTENTIAL TEST FORM----------------------------------------------------------------------12

FUNCTIONAL TEST FORM----------------------------------------------------------------------- 13

Assembly Traveling Tag

Plant – I
 GEDAC ELECTRIC
Limited Liability Co
C.R. 4030014356
Paid Capital SR 12,000,000

□ LV □ MV
Job Number Item Number Section / s Panel type

Assembling Stage
No. Checklist Items Yes Name Sign / Date
1 Construction
2 Materials Status  Completed  Short
3 Fitting of materials and components
4 Wiring (Color, Labeling, type)
5 Panel neatly cleaned, No paint scratches

Inspection Requests Yes Date Signature

1 Request In Process Inspection

2 All the in-process finding had been rectified
and verified by Testing (Documented)
3 Panel Submitted To Final Testing
Testing Stage

Type Check list items Yes No/Comment Sign / Date

Visual Test
Material
IN Process

Wiring / All Identification

Workmanship
There’s pending items and already raised
Verify Pervious Pending Points
Comply with spec’s –Std. For the completed work
Final Testing

Function, Dielectric, Protection Test

There’s pending items and already raised
Final tests completed
All the pending items cleared and the panel ready
for tag
Panel tagged and ready to transfer to shipping

PAGE 8

Issue Date: 17/12/2005 APPENDIX – C GE-FM-PD-003 Rev (02)

In-Process Inspection / Testing Request

Job No. Item No. Sections Type Qty

 GEDAC ELECTRIC
Limited Liability Co
C.R. 4030014356
Paid Capital SR 12,000,000

► Production:
Requested By: Noted By (Prod. Mgr):
Sign / Date: Sign / Date:

Punch List items By Inspectors CAC Inspector/date

Inspector
Sign / Date:

Reply of Production By (CA or PA if required)

Signature:-

CA: Corrective Action PA: Preventive Action CAC: Corrective Action Completed

PAGE 9
GEDAC ELECTRIC
Limited Liability Co
C.R. 4030014356
Paid Capital SR 12,000,000