GREENKO INTEGRATED MANAGEMENT SYSTEMS

PROCEDURE FOR CONTROL PANEL

(Factory and Site acceptance Tests)
1. PURPOSE:
To have a common practices to accept the manufacturing Quality of the product
and to ensure the Installation quality of the Control Panel.
2. SCOPE:
Factory acceptance test & site acceptance test.
3. RESPONSIBILITY:
Factory acceptance test by manufacturer & witness by Greenko Central
Quality and Greenko Site QA/QC for site acceptance test.
4. REFERENCE DOCUMENTS:
IS 8623- part 1 &2, Approved GTP & Approved Drawings, IEC 61439.
5. PROCEDURE:
5.1.
Factory acceptance test of Control Panel & Busbar trunking
systems :
All the factory acceptance test observations should be recorded on Material
Quality inspection report- F-CO-QA06-01.
5.1.1. For control panel:
Components incorporated in the control panel shall comply with the relevant IEC
standards.
The components shall be suitable for the particular application with respect to
the external design of the ASSEMBLY (control panel) (e. open type or enclosed),
their rated voltages, rated currents, service life, making and breaking capacities
short-circuit withstand strength, etc.
Components having a short circuit withstand strength and/or a breaking capacity
which is insufficient to withstand the stresses likely to occur at the place of
installation, shall be protected by means f current-limiting protective devices,
for example fuses or circuit-breakers. When selecting current limiting protective
devices for built-in switching devices, account shall be taken of the maximum
permissible values specified by the manufacturer of the device, having due
regard to co-ordination.
Co-ordination of components, for example co-ordination of motor starters with
short-circuit protective devices, shall comply with the relevant I EC standards.

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GREENKO INTEGRATED MANAGEMENT SYSTEMS

PROCEDURE FOR CONTROL PANEL
(Factory and Site acceptance Tests)
5.1.1.1. Type tests: (Only review of Test certificates issued by
CPRI, ERDA & Validity period up to 5 years only)
Type tests are intended to verily compliance with the requirements laid down in
this standard for a given type of ASSEMBLY.
Type tests will be carried out on a sample of such an ASSEMBLY or on such parts
of ASSEMBLIES manufactured to the same or a similar design.
They shall be carried out on the initiative of the manufacturer.
Specification limits should be as perIS 8623- part 1:
Type tests include:
5.1.1.1.1.
Verification
5.1.1.1.2.
Verification
5.1.1.1.3.
Verification
5.1.1.1.4.
Verification
circuit.
5.1.1.1.5.
Verification
distances.
5.1.1.1.6.
Verification
5.1.1.1.7.
Verification

of
of
of
of

temperature-rise limits.
the dielectric properties.
the short-circuit strength.
the continuity of the protective

of clearances and creepage

of mechanical operation.
of the degree of protection.

These tests may be carried out in any order and/or on different samples of the
same type.
5.1.1.2. Routine Tests:
Routine tests are intended to detect faults in materials and workmanship. They
are carried out on every new ASSEMBLY after its assembly or on each transport
unit. Another routine test at the place of installation is not required.
ASSEMBLIES which are assembled from standardized components outside the
works of the manufacturer of these components, by the exclusive use of parts
and accessories specified or supplied by the manufacturer for this purpose, shall
be routine-tested by the firm which has assembled the ASSEMBLY.
Routine tests include:
Specification limits should be as perIS 8623- part 1:
5.1.1.2.1.
Inspection of the ASSEMBLY including
inspection of wiring and, if necessary, electrical
operation test.
We have to verify the assembly of control panel as
per approved BOM, GA and schematic diagram.
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GREENKO INTEGRATED MANAGEMENT SYSTEMS

PROCEDURE FOR CONTROL PANEL
(Factory and Site acceptance Tests)
5.1.1.2.2.
5.1.1.2.2.1.

Dielectric test.
Requirement of Equipments for testing:
HV tester- (0-5) KV

5.1.1.2.2.2.
Testing procedure:
The test voltage shall be applied:
5.1.1.2.2.2.1.
Between all live parts and the
interconnected exposed conductive parts of the
ASSEMBLY;
5.1.1.2.2.2.2.
Between each pole and all the other poles
connected for this test to the interconnected
exposed conductive parts of the ASSEMBLY.
The test voltage at the moment of application shall not exceed 50% of the values
given in test voltage selection table that given below. It shall then be increased
steadily within a few seconds to this full value specified in the table and
maintained for 1 min. The a.c. power sources shall have sufficient power to
maintain the test voltage irrespective of any leakage currents. The test voltage
shall have a practically sinusoidal waveform and a frequency between 45 Hz and
62 Hz.
5.1.1.2.2.3.

Selection of test Voltage:

For main circuits:

Rated insulation voltage Ui (v)
Ui 60
60 < Ui 300
300 < Ui 660
660 <Ui 800
800 < Ui 1000
1000 <Ui 1500 ( for DC only)

Dielectric test voltage (ac) ( r m s ) ( v

)
1000
2000
2500
3000
3500
3500

For Auxiliary circuits:

Rated insulation voltage Ui (v)
Ui 12
12< Ui 60
Ui> 60
5.1.1.2.2.4.

Dielectric test voltage (ac) ( r m s ) ( v

)
250
500
2 Ui + 1000 with a minimum of 1500.

Results to be obtained:

The test is considered to have been passed if there is no

puncture or flash-over.

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GREENKO INTEGRATED MANAGEMENT SYSTEMS

PROCEDURE FOR CONTROL PANEL
(Factory and Site acceptance Tests)
5.1.1.2.3.
Checking of protective measures and of
the electrical continuity of the protective circuit.
Continuity of protective circuits shall be ensured by effective interconnections
either directly
or by means of protective conductors.
5.1.1.2.3.1.
When a part of the ASSEMBLY is removed from
the enclosure, for example for routine maintenance, the
protective circuits for the remainder of the ASSEMBLY
shall not be interrupted.
Means used for-assembling the various metal parts of an ASSEMBLY are
considered sufficient for ensuring continuity of the protective circuits if the
precautions taken guarantee permanent good conductivity and a current
carrying capacity sufficient to withstand the earth fault current that may flow
in the ASSEMBLY.
NW. - Flexible metal conduits should not be used as protective conductors.
5.1.1.2.3.2.
When removable or withdrawable parts are
equipped with metal supporting surfaces, these surfaces
are considered sufficient for ensuring continuity of
protective circuits provided that the pressure exerted on
them is sufficiently high. Precautions may have to be
taken to guarantee permanent good conductivity. The
protective circuit of a withdrawable part shall remain
effective from the connected position to the test
position inclusively.
5.1.1.2.3.3.
For lids, doors, cover plates and the like, the
usual metal screwed connections and metal hinges are
considered sufficient to ensure continuity provided that
no electrical equipment is attached to them.
5.1.1.2.3.4.
All parts of the protective circuit within the
ASSEMBLY shall be so designed that they are capable of
withstanding the highest thermal and dynamic stresses
that may occur at the place of installation of the
ASSEMBLY.
5.1.1.2.3.5.
When the enclosure of an ASSEMBLY is used as
part of a protective circuit, the cross-sectional area of
this enclosure shall be at least electrically equivalent to
the minimum cross-sectional area specified in below
table

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GREENKO INTEGRATED MANAGEMENT SYSTEMS

PROCEDURE FOR CONTROL PANEL
(Factory and Site acceptance Tests)
Cross-sectional area of
phase conductors S(mm2)
S 16
16< S 35
S > 35

Minimum cross-sectional
area of the corresponding
protective conductor S( mm2)
S
16
S/2

These tests may be carried out in any order.

5.1.2. For Busbar trunking systems:
5.1.2.1. Type test for Busbar trunking systems:
Specification limits should be as perIS 8623- part 2:
5.1.2.1.1.
Verification of temperature-rise limits.
5.1.2.1.2.
Verification of the dielectric properties.
5.1.2.1.3.
Verification of the short-circuit strength.
5.1.2.1.4.
Verification of the continuity of the protective
circuit.
5.1.2.1.5.
Verification of clearances and creepage
distances.
5.1.2.1.6.
Verification of mechanical operation.
5.1.2.1.7.
Verification of the degree of protection.
5.1.2.1.8.
Verification of resistance and reactance.
5.1.2.1.9.
Verification of structural strength.
5.1.2.1.10.
Verification of the endurance of trunking
systems with trolley type tap-off facilities.
These tests may be carried out in any order and/or on different samples of the
same type.
If modifications are made to the components of the assembly, new type tests
have to be carried out only in so far as such modifications are likely to adversely
affect the results of these tests.
5.1.2.2. Routine tests for Busbar trunking systems:
Specification limits should be as per IS 8623- part 2:
5.1.2.2.1.
Inspection of the ASSEMBLY including
inspection of wiring and, if necessary, electrical
operation test.( same as 5.1.1.2.1 clause of this
procedure)
5.1.2.2.2.
Dielectric test. (same as 5.1.1.2.2 clause of
this procedure)
5.1.2.2.3.
Checking of protective measures and of
the electrical continuity of the protective circuit.
(same as 5.1.1.2.3 clause of this procedure)
5.1.2.2.4.
Verification of resistance and reactance.
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GREENKO INTEGRATED MANAGEMENT SYSTEMS

PROCEDURE FOR CONTROL PANEL
(Factory and Site acceptance Tests)
5.1.2.2.4.1.
Direct measurement of resistance
and reactance:
The mean values of resistance and reactance are determined on a test specimen
having a total length of at least 6 meter including at least one joint.
R= the mean ohmic resistance value of the trunking system per metre length per
phase.
X= the mean reactance value of the trunking system per metre length per
phase.
The method of determination shall be chosen by the manufacturer. An example
of calculation from measurements is given below for a three phase A.C. Busbar
trunking System.
5.1.2.2.5.

Calculation of resistance and reactance:

The following measurements shall be recorded from the test data obtained
during the temperature- rise test:
V= the average r.m.s. line to line voltage drop in volts.
V12 + V23 + V31
V=
3
I= the average r. m. s. current in amperes
I1 + I2 + I3
I=
3
P = the total three- phase power in watts.
L= the length in metres from the voltmeter leads connected at the input end to
the point where the bus bars are connected together at the output end.
Calculate the impedance Z, the alternating current resistance R, and the
reactance X, in ohms per metre on line to neutral basis, as follows:
V
Z=
3 I L
P
R =

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3 I2 L

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GREENKO INTEGRATED MANAGEMENT SYSTEMS

PROCEDURE FOR CONTROL PANEL
(Factory and Site acceptance Tests)

X= (Z 2 R2)

0.5

The values measured directly should match with calculated value.

5.2.

Incoming Inspection at site:

Incoming Inspection shall be done as per the Incoming material site Inspection
report F-CO-QA06-02 & observation shall be recorded on it.
5.3.

Site acceptance test of Control panel:

Site acceptance test as per Vendor or Greenko- Inspection and test plan and
observation shall be recorded on Check list for erection of Control panel- F-COQA-16-01.
6. RECORDS:
6.1.Material Quality Inspection report
6.2.Incoming material site Inspection report 6.3.Erection Checklist of Control panel
-

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F-CO-QA06-01.
F-CO-QA06-02.
F-CO-QA-16-01.

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