CONTENTS

Page No.

TITLE PAGE

TABLE OF CONTENTS

1.0

PURPOSE

2.0

SCOPE

3.0

DEFINITIONS

4.0

REFERENCE STANDARDS AND CODES

5.0

RESPONSIBILITIES

6.0

TEST EQUIPMENT CONTROL

7.0

QUALITY CONTROL

8.0

TESTING PROCEDURE

9.0

DOCUMENTATION

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DISCIPLINE :

ELECTRICAL

TITLE

PROCEDURE FOR SITE ACCEPTANCE TESTING OF

LOW VOLTAGE MOTOR CONTROL CENTERS

1.0

PURPOSE
To ensure that the LV MCCs are installed in accordance with design
specifications, that their characteristics are within applicable standards and
manufacturers tolerances.

2.0

SCOPE
This procedure shall apply during the site acceptance testing of LV MCCs.

3.0

DEFINITIONS

3.1
3.2
3.3
3.5

C.E.
C.M.
T.T.
Q.C.

4.0

REFERENCE STANDARDS AND CODES

4.1
4.2
4.3

JCP-00-E9-GS-006 Electrical system check out and commissioning

JCP-00-E9-GS-005 Installation of electrical facilities
NEC National Electrical Code

5.0

RESPONSIBILITIES

Commissioning Engineer
Construction Manager
Testing Technician
Quality Control

5.1 The Commissioning Engineer (C.E.) shall be responsible for preparing the testing plan,
for the observance of all safety precautions required by the JAL Kent Safety Plan,
for supervising the testing activities.
5.2 The Testing Technicians (T.T.) shall be responsible for carrying out the tests, recording
the test values.
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5.3

The QC Department shall be responsible for conducting reviews of the test records
to ensure that all tests have been performed in accordance with the approved
inspection and test plan.

6.0

Test Equipment Control

The Commissioning Engineer shall carry out an inspection of the test equipment
when the test equipment arrives in the warehouse. Each piece of test equipment
shall have the calibration labels intact. The Commissioning Engineer shall ensure
that the test equipment manual is available and that the test equipment is calibrated
and calibration certificates are available.
The Commissioning Engineer will keep a record with the test equipment serial
numbers, date of calibration and copies of the calibration certificates. JAL will
submit copies of the calibration certificates of the test equipment to SENDAN.
The Commissioning Engineer shall ensure that test equipment that it is out of
calibration is isolated in a quarantine zone and will be sent as soon as possible to a
certified metrology laboratory for re-calibration against national standards.
The Testing Technicians shall ensure that the test equipment is tested for proper
operation before starting any test. Any defective test equipment will be isolated in a
quarantine zone and sent as soon as possible for repairs.
QC Department shall conduct periodic audits on the test equipment to ensure all
test equipment is within the required calibration period.

7.0

Quality Control
The Commissioning Engineer shall prepare the testing plan that will include the
equipment to be tested, the tests to be performed, the test equipment to be used,
the test procedure to be applied and the test records to be used. Based on the
testing plan, in coordination with the Construction Manager a testing schedule will
be developed.
The Commissioning Engineer shall organize, supervise and verify the
implementation of the testing schedule.
Any defects or variances from the approved specifications and standards will be
noted during the testing and shall be informed to the Construction Department by
the Inspection Report.
The Testing Technician shall use the pre-commissioning forms as checklists and to
record the results of the testing. The forms shall be the quality record documents
to identify that the inspection and testing has taken place.

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The following tests will be performed and recorded on the pre-commissioning

forms :
1. Visual and mechanical inspection
2. Low resistance test for bolted connections
3. Phasing test
4. Insulation resistance test
5. CVT test
6. LV contactor test
7. Overload relay test
8. Meters test-see TP 912
9. CT test-see TP 901
10. Circuit breaker test-see TP 905&TP-906
11. Protective relay test-see TP 920
The following test equipment will be used to perform the above tests:
1.
Calibrated torque wrench
2.
Microohmmeter, DLRO or T&R
3.
Battery box or DC voltage source with multiple outputs
4.
Megohmmeter AVO
5.
Digital multimeter
6.
Secondary injection test set Sverker 650 or 760
7.
Thermometer
8.
Humidity meter
8.0

TESTING PROCEDURE
The following shall be the guidelines for the testing personnel during the inspection
and testing of LV MCCs.

8.1 Visual And Mechanical Check

Compare equipment nameplate data with latest one-line diagram.

Verify appropriate anchorage, required area clearances, and correct alignment of the
MCC.
Inspect all doors, panels, and sections for corrosion, dents, scratches, fit, and missing
hardware.
Inspect for damaged covers on instruments and relays.
Inspect main bus for physical damage, cracks on bushings, damaged insulation or
connections.
Verify that fuses, contactors, circuit breakers, thermal overload relays sizes and types
correspond to drawings and coordination study.
Check that identification labels for all circuit breakers, isolators, earth switches,
contactors and fuses correspond with the single line diagram.
Check operation of heaters.
Check that the CTs, CVTs ratings are as per specifications and single line drawings.
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Torque-check the exposed connections/joints of the main bus and neutral/grounding

bus. The torquing values should be as per manufacturer recommendation
Check that the grounding of the switchgear is as per specifications.
Check the wiring schematic of each cubicle and panel, point to point, and highlight the
vendor drawings.
Operate the breakers and contactors manually.
Perform a complete functional check with control voltage applied of each individual
panel, cubicle and bucket.

8.2 Low Resistance Test for Bolted Connections

Test Equipment: Microohmeter DLRO or T&R

The test will be performed on the main bus and neutral/grounding bus joints.
Identify the joints to be tested. Ensure they have been torque-checked and that the
bolts are marked.
Check that the contact surfaces for the current and voltage probes are clean and dry.
Check that the instrument probes are clean and dry.
Check that the microohmmeter is switched off during making connections.
Ground the microohmmeter.
Connect the current and voltage cables, with
respect to the polarities, as in fig. 1. Always
connect the voltage cables inside the current
cables.
Switch on the microohmmeter. Increase the
current to the desired value. Read the
resistance value.
Compare measured values with manufacturers
specifications; compare results between
different connections. Differences greater than
50% between connections should be
investigated.
Fig. 1

8.3 Phasing Test

Test Equipment: Multimeter, Battery box or DV voltage source with multiple outputs

The phasing test is performed in order to check the continuity of main bus system and
the correct sequence of phases.
Disconnect all the cables and equipment connected to the main bus and rack-out the
PT drawers in order to achieve complete isolation of the main bus.
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Ensure that the main bus phases are not shorted together and that they are not
connected to ground.
Check that the phase identification labels correspond to the main bus arrangement and
vendor drawings. Ensure the phase sequence of the main bus corresponds with other
associated equipment such as busducts and cables.
Connect the battery box, at one end of the main bus:
0V to earth
4.5V to phase A
9V to phase B
13.5V to phase C
Using a multimeter, check if at the other end of the main bus the voltages for each
phase are correct.
Repeat the test for all the sections.

8.4

Insulation Resistance Test

Test Equipment: Ohmmeter, Megohmmeter AVO; Thermometer; Humidity meter

Measure and record the ambient temperature and humidity.

The insulation resistance of main bus system, each phase to ground and phase to
phase should be measured.
Disconnect the main bus section to be tested from other equipment and circuits.
Ensure that the PT drawers are rack-out or the PTs primary fuses are pulled out, that
surge arresters are disconnected. Ensure all the isolation switches of each panel are in
open position.
Ensure that the main bus insulation, insulation boots, and bushings are clean, free of
dust.
Check with an Ohmmeter that there is no electrical connection between the phases or
between phases and ground.
As shown in fig. 2 (a), connect the line terminal of the megohmmeter with one phase of
the main bus and all other phases together to ground and to earth terminal of the
megohmmeter.
Set the test voltage to the value recommended by the manufacturer
Measure the insulation resistance for one minute.
Repeat for all other phases.
Measure the insulation resistance for one minute between phases as shown in fig. 2 (b).
Connect the line terminal of the megohmmeter with one phase of the main bus and the
earth terminal of the megohmmeter to another phase with the remaining phase
grounded.
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(a)

(b)

Fig. 2

Repeat for all other phases.

Measured insulation resistance values should be temperature corrected and compared
to the values given by the manufacturer.

8.5 Control Voltage Transformer Test

The following tests should be performed on the CVTs: visual and mechanical inspection,
ratio test and insulation resistance test-see TP 902.
8.6 Contactor Tests
8.6.1. Contact Resistance Measurement Test
Test Equipment: Microohmeter DLRO or T&R

Make sure that the contactor is closed.

Ground the microohmmeter.
Check that the microohmmeter is
switched
off
during
making
connections.
Connect the current and voltage cables,
with respect to the polarities, as in fig.
3. Always connect the voltage cables
inside the current cables.
Switch on the microohmmeter.
Increase the current to the desired
value.
Read the resistance value.
Fig. 3
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Repeat for each phase of the contactor.

Compare measured values with manufacturers specifications; compare results between
different phases of the contactor. Differences greater than 50% between phases should
be investigated. When data from the manufacturer is not available for evaluation,
investigate any values higher than 200 micro-ohms.

8.6.2. Insulation Resistance Measurement Test

Test Equipment: Megohmmeter AVO; Thermometer; Humidity meter
Contactor open

Measure and record the ambient

temperature and humidity.
Disconnect the contactor to be tested
from other equipment and circuits.
Make sure that the contactor is open.
As shown in fig. 4, connect the line
terminal of the megohmmeter with one
pole of the contactor and all other poles
together to ground and to earth terminal
of the megohmmeter.
Set the test voltage as per manufacturer
recommendation.
Measure the insulation resistance for one
minute.
Repeat for all other phases.

Fig. 4

Contactor closed

Disconnect all connections between poles

and the connection to earth.
Close the contactor.
As shown in fig. 5, connect the line
terminal of the megohmmeter with one
phase of the contactor and the other
phases together to ground and to earth
terminal of the megohmmeter.
Set the test voltage as per manufacturer
recommendation.
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Measure the insulation resistance for one minute.

Repeat for other phases.
Compare the test results with the values given by the manufacturer.

8.7 Overload Relay Test

Test Equipment: Secondary injection test set Sverker 650 or 760
Overload relays should be given an overcurrent test to determine that the overloads will
open the starter contacts to provide protection to the motor at its overload pickup value.
The trip setting of the relay should also be evaluated to account for any ambient variations
between motor location and starter location.

Disconnect the overload relay to

be tested from all other equipment
and circuits.
As shown in fig. 6, connect one
current output (according to the
desired test current) of the
secondary injection test set to one
phase of the overload relay.
Connect the trip signaling contact
of the overload relay to the
secondary injection unit, so that
the contact will stop the timer
and the injection.
Set the output current of the
Fig. 6
secondary injection unit to 3
times the setting of the overload
relay.
Set the timer of the secondary injection unit to start at the same time with the current
injection and stop when the overload relay trips.
Start the current injection. Read the tripping time.
Allow the overload relay to cool then repeat the test for the remaining phases.
Check that the measured tripping time is correct according to manufacturers
specifications.

9.0

DOCUMENTATION

9.1
9.2

LV MCC instruction manual-vendor documentation

Test equipment operation manual
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