LOW VOLTAGE SWITCHGEAR

SITE ACCEPTANCE TEST

( SAT )

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 LIST OF CONTENTS

1. PURPOSE

2. CONTRACT DETAIL

3. SCOPE

4. METHOD STATEMENTS & CHECK LISTS

VISUAL INSPECTION

TORQUE TEST

CONTACT RESISTANCE TEST

ELECTRICAL TEST

o INSULATION RESISTANCE

o DI-ELECTRIC / FLASH TEST

FUNCTIONAL TEST

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 1. PURPOSE:

To ensure the Quality & proper functioning of the Main LV

switchboards & Motor Control Centers as per the defined test
procedures.

The inspection & testing of the boards consist of the following

 Structure Visual Inspection

 Quality Inspection
 Electrical Tests
 Functional Tests

2. CONTRACT DETAIL:

Project Detail: __________________________

Client: __________________________

Main Contractor: __________________________

P.O. No.: __________________________

Work Order No.: __________________________

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 Switchboard Detail: __________________________

3. SCOPE:

When the board to be tested is fully assembled, the following

steps / checks will start.

a) Full structural inspection to cover all aspects of

construction, Layout of compartments as per
approved drawing. Please refer Visual Inspection
Checklist.

b) Complete Visual Inspection on the Quality of the

panel. It includes external & Internal inspection of
each panel.

c) Manual Functional Check of all ACB’s, MCCB’s,

Contactors etc. to ensure their operation.

d) Torque Test

e) Insulation ( Megger ) Resistance Test at 1000V as

per the requirement.

f) Di-electric / Flash Test at 2.2kV for 1 minute.

g) Contact resistance Test

h) Continuity Test of Control Cables

i) Functional Test.

4. METHOD STATEMENTS & CHECK LIST:

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 In order to record the results of each type of test, attached are the
standard check list for each type of test to be carried out. Method
statement is also attached to know how to perform the above
tests.

METHOD STATEMENT FOR VISUAL INSPECTION

(COLD TEST)
1.)Visual inspection:

The Following will be checked for contamination on LV panels &

capacitor banks

 Thoroughly clean the chemical, soot, corrosion, smoke

carbon ashes deposit prior to commencement of the testing.
 Verify that the current carrying parts are appropriately
lubricated with contact lubricant and appropriate lubricants
on the moving and sliding surfaces.
 Inspect insulators for evidence of physical damage or
contaminated surface.
 Verify the existing barrier and shutter conditions as
applicable
 Check all the existing name plate details & Door Earthing
 Carry out physical inspection of the equipment. Check for
any physical damages. Check also for clearances and
alignment.
 Inspect all the sheet metal parts including doors, panels and
sections for corrosions, dents, scratches and any missing
points.
 Verify the Breakers Conditions and Operations

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  Verify the tightness of accessible bolted electrical
connections by calibrated torque wrench. The result of the
torque test shall be in accordance with the manufacturer’s
published data.
 Verify the labels and tag designation as per approved
drawings.
 Inspect all mechanical indicating devices of correct
operations.
 Carry out visual inspection check on instrument transformer.
 Carry out visual inspection check on ACB’s & MCCB’s.
 Carry out visual inspection check of HRC Fuses mechanical
operations
 Carry out visual inspection check of all capacitor
components
 Carry out visual inspection check all Electrical components,
Meters & Indication Components
 Carry out the visual inspection of Bus bar, Cables insulation
sleeves damage

2.) Joints: Complete checking of all bus bar joints cleaning and correct
torque

3.) Supports: Physical checking of hanger supports, fixed supports, and

horizontal Supports also the position of Red nuts on the spring bolt.

4.) Test Formats : Refer Enclosed Test Formats

Note :-
Contractor should provide necessary arrangements to carry out all testing
as required at site.

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 METHOD STATEMENT

TEST: TORQUE TESTING

PURPOSE: To ensure that all busbar bolts are tightened to the correct
torque values to maintain the integrity and safety of the
electrical connection.

INSTRUMENT: Calibrated Torque Wrench

PRELIMINARY
ACTIONS:
1. Verify the torque wrench calibration certificate is valid.
2. Ensure the work area is clean and free of obstructions.
3. Identify and mark the bolts to be tested.
4. Ensure all tools are insulated to prevent electrical shocks.

DESCRIPTION:
Set the torque wrench to the specified torque value for each bolt
size:
M8 Bolt: 17 Nm
M10 Bolt: 35 Nm
M12 Bolt: 60 Nm

Place the torque wrench on the bolt and apply a slow, steady
force until the wrench clicks, indicating that the set torque value
has been reached.
Repeat the process for all bolts in the busbar assembly.
If a bolt does not meet the torque requirement, recheck the
wrench settings, reapply the torque, or replace the bolt if
necessary.
Record the torque values for each bolt size in the Torque Test
Report.
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ACCEPTABLE CRITERIA:

Torque values must fall within the specified range for each bolt size.
Overtightening or undertightening of bolts is not acceptable.
METHOD STATEMENT

TEST: INSULATION RESISTANCE TEST (Busbar)

PURPOSE: To ensure that the system is free from short circuits &
grounds by measuring the values of the resistance
between phase to phase, phase to neutral and phase to
ground.
Perform this test before and after Di-electric / Flash / HV
Test.

INSTRUMENT: Megger Tester with Variable voltage selection

PRELIMINARY 1- Clean all the supporting isolators.

ACTIONS
2- Disconnect all lamps & meters, which are not
supposed to be subjected to 1000V.
3- Open / Isolate all incoming & outgoing circuits
( ACB / MCCB’s ) to limit the test to bus bars.

DESCRIPTION: 1) Connect the leads of Megger tester b/w phase to phase

2) First set the time as required i-e 1 minute.
3) Set the voltage to 1kV via voltage selection key.
4) Press Start (Red) button to commence the test
5) Note down the insulation resistance shown by the
Megger tester.
6) Repeat the above step to measure the resistance b/w
phase to Neutral & phase to ground.
7) Record the values in the test report sheets.

RECOMMENDED The values must come in the range of Mega-ohms.

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VALUES: ( Minimum 1 Mega Ohms )

Doc. No: MS-02

METHOD STATEMENT

TEST: DI-ELECTRIC / HIGH VOLTAGE / FLASH TEST

PURPOSE: To check the di-electric strength of the bus bars supports

by applying voltage of 2.2kV for 1-minute between phase
to phase and phase to ground.

Repeat the INSULATION RESISTANCE TEST after

high voltage test and compare the results.

INSTRUMENT: HV Test Equipment

PRELIMINARY 1) Disconnect all lamps & meters, which are not

supposed
ACTIONS to be subjected to 2200V.

2) Open / Isolate all incoming, bus couplers & outgoing

circuits ( ACB / MCCB’s ) to limit the test to bus bars.
3) Before performing the test make sure that Meggers
values are within acceptable range.
DESCRIPTION: 1) Connect the leads of 2500V HV test equipment to
Red-phase
2) Short the Y & B phase and connect to earth. Also
connect enclosure to earth.
3) Switch On the HV test kit control unit and apply
recommended test voltage by increasing gradually for 1-
minute to R-phase with respect to other phases earthed &
grounded.
4) After completion of 1-minute gradually reduced the
voltage to zero and then switch off the HV kit.
6) Discharge the pole and also HV kit.
7) Repeat the test for Y & B phases

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 CONTACT RESISTANCE TEST

PURPOSE: The contact resistance test is carried out on the joints of

bus bars randomly
to prove the contact making of bus bar joints.

INSTRUMENT: DLRO 10HD (Will mentioned the available equipment)

PRELIMINARY ACTIONS:

 Disconnect all lamps & meters.

 Open / Isolate all incoming, bus couplers & outgoing
circuits ( ACB / MCCB’s ) to limit the test to bus bars
joints.
 Before performing the test make sure that panel is
isolated.

DESCRIPTION:
 Connect the leads of Contact Resistance test
equipment to Joint One end to another end
 Set 10A current range to perform test
 Press ON button to start the test
 Record the Values in the test report
 Repeat the test for other phase’s
joints/transportation joints.

TEST FORMATS: Refer Enclosed Test format

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