10069a 9 V06 Ebb3 00028

Titolo Identificativo Rev.
Pagina Di
title document no. rev. page of
ISOLATED PHASE BUS-DUCT 0553 F1BAAU670 00 1 35

COMPLETE SYSTEM -
PGESCo No. Classe di
PREOPERATIONAL TEST PROCEDURE Riservatezza 2
confidential class
Volume N. Prodotto/Struttura
volume no. product/structure
10069A-9-3PS-EBB3-00001
Tipo doc. Codice EmittenteTeamcenter Ente Emittente Edizione in lingua Derivato da Rev.
doc. type teamcenter issuer code issued by language derived from rev.
PRP ELE IPI/REA/ELE/CCE ENGLISH

Commessa Progetto Cliente/Client
job no. project
WEST DAMIETTA
0553 Power Project Phase II
Converting existing Simple Cycle
to Combined Cycle 10069A-CP-106 EAST DELTA ELECTRICITY
PGESCo
PRODUCTION COMPANY (EDEPC)
Rev. Descrizione
rev. kind of revision
00 FIRST ISSUE
Accepted by: Bruzzone
CARIBONI GROSSO F. BRUZZONE M.

00 U 27/08/2015
IPI/REA/ELE/CCE IPI/REA/ELE/CCE (TC)
Rev Scopo Preparato Controllato Verificato Verificato Approvato Data

rev. scope prepared checked verified verified Approved Date
Ansaldo Energia s.p.a. si riserva tutti i diritti su questo documento che non può essere riprodotto neppure parzialmente senza la sua autorizzazione scritta
Ansaldo Energia s.p.a. reserves all rights on this document that can not be reproduced in any part without its written consent
Progetto / Titolo Identificativo Rev. Pagina Di
Project / title document no. rev. page of
0553 F1BAAU670 0 2 35
WEST DAMIETTA Power Project Phase II
Converting existing Simple Cycle to PGESCo No. Classe di Riservatezza 2
confidential class
Combined Cycle 10069A-CP-106
SUMMARY
1. SCOPE .................................................................................................................................... 4
2. FAT/SAT PROCEDURE FOR IPB ........................................................................................... 4
2.1. Procedure for visual and dimensional inspection during FAT ............................................... 4
2.2. Procedure for inspection of painting and galvanization ......................................................... 5
2.3. Procedure for testing the pressurization cubicle ................................................................... 5
2.4. Procedure for electrical testing ............................................................................................. 6
3. FAT/SAT PROCEDURE FOR PT CUBICLE AND NEUTRAL GROUNDING CUBICLE ........... 7
3.1. Instructions IT P 04: Dielectric voltage test on auxiliary and operating circuits of MV
switchboards ................................................................................................................................. 7
3.1.1. Scope .............................................................................................................................. 7
3.1.2. Range of applicability ...................................................................................................... 7
3.1.3. Reference to standards ................................................................................................... 8
3.1.4. Instruments ..................................................................................................................... 8
3.1.5. Working formalities .......................................................................................................... 8
3.1.6. Test report ....................................................................................................................... 9
3.2. Instructions IT P 05: Industrial frequency voltage test on main circuits of MV
switchboards ............................................................................................................................... 10
3.2.1. Scope ............................................................................................................................ 10
3.2.2. Range of applicability .................................................................................................... 10
3.2.3. Reference to standards ................................................................................................. 10
3.2.4. Instruments ................................................................................................................... 10
3.2.5. working formalities ......................................................................................................... 11
3.2.6. Test report ..................................................................................................................... 14
3.2.7. Dielectric test on the main circuit on site ........................................................................ 14
3.3. Instructions IT P 06: Resistance measure on main circuits of MV switchboards ................. 14
3.3.1. Scope ............................................................................................................................ 14
3.3.4. Instruments ................................................................................................................... 15
3.3.5. Working formalities ........................................................................................................ 15
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3.3.6. Test report ..................................................................................................................... 16

3.4. Instructions IT P 07: Verification of insulation resistance on auxiliary circuits of MV
switchboards ............................................................................................................................... 16
3.4.1. Scope ............................................................................................................................ 16
3.4.4. Instruments ................................................................................................................... 16
3.4.6. Test report ..................................................................................................................... 17
3.5. Instructions IT P 08: Operation tests with switchboard under voltage (LV) ......................... 18
3.5.1. Scope ............................................................................................................................ 18
3.5.4. Instruments ................................................................................................................... 18
3.5.6. Test report ..................................................................................................................... 20
3.6. Instructions IT P 09: Visual inspection on LV and MV switchboard ..................................... 20
3.6.1. Scope ............................................................................................................................ 20
3.6.4. Instruments ................................................................................................................... 21
3.6.6. Test report ..................................................................................................................... 30
3.7. Instructions IT P 10: Mechanical inspection on LV and MV switchboard ............................ 30
3.7.1. Scope ............................................................................................................................ 30
3.7.4. Instruments ................................................................................................................... 30
3.7.6. Test report ..................................................................................................................... 32
3.7.7. Annex ............................................................................................................................ 32
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1. SCOPE
Scope of this document is to provide a detailed list of inspections and tests, together with the
relevant procedures, applicable to the Factory Acceptance Tests (FAT) and Site Acceptance Tests
(SAT) of Isolated Phase Busducts and related accessories.
2. FAT/SAT PROCEDURE FOR IPB
2.1. Procedure for visual and dimensional inspection during FAT
Dimensions of IPB and related accessories shall be verified to check their compliance with general
layout drawing and detailed (workshop) drawings. The workshop drawings are internal and
confidential but they will be available to inspectors during the FAT. For site inspection, the
compliance of installation with applicable drawings shall be verified all through the process, a final
inspection only could be too late to apply corrective actions if necessary.
For each IPB element and accessory all main dimensions are verified during the construction, e.g.:
length, diameter, position of insulators, supporting collars and flanges. Flanges and holes for
bolted connections are verified as regards holes diameter, holes distance and/or drilling pattern. In
general the correct matching with the coupled element shall be checked. For all others
components and accessories the relevant dimensions and drilling shall be checked. During the
shop test & inspection, the dimensions shall be verified on sample basis.
Reference markings and numbers matching with bill of materials are also checked.
Reference standard is UNI ISO 2768 Part 1, acceptance criteria are the following:
Coupling flanges
± 0,5 mm for holes diameters
± 1,0 mm for holes distances
± 4,0 mm for lengths
IPB elements and accessories

± 4,0 mm for measures up to 1.000 mm included
± 6,0 mm for measures from 1.000 mm to 2.000 mm included
± 8,0 mm for measures from 2.000 mm to 4.000 mm included
± 10,0 mm for measures over 4.000 mm
Test equipment / Instruments: calliper, measuring tape

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The positive result is registered on the inspection report, in case of unfavourable result the
necessary countermeasures shall be taken.
2.2. Procedure for inspection of painting and galvanization

The internal surface of enclosures and the external surface of conductors are painted matt black to
increase heat transfer, no inspection is required for this painting. The surfaces to be inspected are:
- external surfaces of IPB, that are painted RAl 7035, DFT (dry film thickness) 80 µm
according to manufacturer’s cycle
- supporting structures that are hot dip galvanized 85 µm according to EN ISO 1461
standard
The colour of IPB enclosure shall be visually compared with the colour card, the visual aspect shall
be also checked but it is important to remark that the coating is provided for identification and
aesthetical purposes only (not protective) and a paint touch up will be performed at site after
completion of installation: any small defect will be removed at site.
For the measurement of thickness of painting and galvanization, first of all a calibration of
instrument (Elcometer STD model 345 FN1 or Phynix Surfix model FN21) shall be carried out on a
bare surface of the same base metal: select the correct type of base metal (ferrous or non-ferrous
as applicable) then set the reading to zero after putting the probe on the bare metal.
Choose the calibration foil having a thickness equal to or similar to the required film thickness, and
use it to check the reading on bare metal, calibrate again to the foil thickness if necessary.
Finally, use the probe on the specimen and read the thickness of paint or galvanization in different
samples widely dispersed on the specimen.
2.3. Procedure for testing the pressurization cubicle

The purpose of the pressurization system is to keep a slight overpressure of dry and clean air
inside the IPB, so that internal pressure is always greater than external one at all operating
conditions.
As a consequence, air leakage will provide a small constant air flow from inside to outside and
internal space will remain dry and dust free.
In order to compensate the leakage, a control cubicle regulates the supply of dry and dust-free air
provided by plant instrument air network. Instrument air will be provided at 7 ~ 8 bar and the inlet
pressure is lowered to 0.5 bar by a pressure reducer.
The relative overpressure inside IPB is maintained between 5 and 20 mbar by the control cubicle,
where solenoid valve opens below 5 mbar and closes over 20 mbar according to electric signal
provided by pressure switch.
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If the overpressure does not reach the upper limit of 20 mbar within 10 minutes, the solenoid valve
is closed by a time switch and the low pressure status is highlighted by red light and by low
pressure signal. In order to avoid any accidental excessive overpressure, the pressurization
system is equipped with a safety valve (glycerine valve) calibrated to open the circuit at 30 mbar.
The high pressure signal is also given by a manometer to terminal blocks for remote alarm.
- The functional testing of control system, after successful check of wiring and piping as
per relevant drawings and diagrams, includes:
- check that air flow starts when overpressure is below 5 mbar ± 20%
- check that air flow stops when overpressure reaches 20 mbar ± 20%
- check that high pressure alarm switches on when overpressure exceeds 30 mbar (this
test can be performed in factory using an air receiver and shall not be repeated on site)
- check that low pressure alarm switches after 10 minutes of air flow without reaching the
required overpressure value of 20 mbar
- check of operation without air leakage from pneumatic circuit
2.4. Procedure for electrical testing

Before and after the voltage test, a measurement of insulation resistance between each conductor
and its enclosure must be carried out according to the following procedure:
- the test voltage of 5000 Vdc shall be applied with a megaohmmeter, and the steady
value shall be noted. The IPB section is accepted if the value of resistance is equal or
greater than 500 MΩ. The positive result shall be registered on the inspection report, in
case of unfavourable result the necessary countermeasures shall be taken
The arrangement of power frequency withstand voltage test shall comply with the following circuit
diagram:
I circuit breaker
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R regulator
T step-up transformer
V voltmeter
O object under test, disconnected from any other equipment
I, R, T, V are part of the test equipment.
The test shall be execute according to the following procedure:

- 75% of test value shall be achieved quickly
- the voltage shall be increased slowly up to the required maximum test level, 38 kV at
50 Hz in this case
- the test voltage shall be kept for one minute, the test is positive if no flashovers occur
- the positive result shall be registered on the inspection report, in case of unfavourable
result the necessary countermeasures shall be taken
In case of site testing, the procedure is the same but the test voltage to be applied is 80% of
nominal value, i.e. 30.8 kV, as per IEC 62271-200 clause 7.105.
In case of insufficient power of HV test set for site testing on the fully assembled IPB, DC testing
could be performed after agreement between Purchaser and Manufacturer.
3. FAT/SAT PROCEDURE FOR PT CUBICLE AND NEUTRAL GROUNDING CUBICLE
3.1. Instructions IT P 04: Dielectric voltage test on auxiliary and operating circuits of MV
switchboards
3.1.1. Scope
It describes all the activity relating to the tests and to final checks and quality control before
shipping, in order to assure that every supplied product and installation comply to the requested
technical specifications.
This instruction describes the execution of "Dielectric voltage test on auxiliary and operating
circuits of MV switchboards".
3.1.2. Range of applicability

This instruction applies to all the LV equipment manufactured by CASAGRANDE
ELETTROCOSTRUZIONI S.p.A.
To operate correctly the tests described below, check well the following:
- neccesary documentation available;
- instrument to be used must be suitable to the type of test to do;
- the ambient where the test are performed must be protect in safety way;
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- the test must be carried out by skilled people with proper instruction training and
informed on safety procedure.
3.1.3. Reference to standards
National Standard European Standard International Standard

CEI EN 62271-200 EN 62271-200 IEC 62271-200
CEI EN 62271-1 EN 62271-1 IEC 62271-1
3.1.4. Instruments
The following instruments are used:
- Instruments for verification of dielectric properties up to 5KV.
For more detail, see the list of testing instruments present in Quality Test Responsabile office; the
identification code of the used instrument is, usually, write also on the test report of the equipment
tested.
3.1.5. Working formalities

Auxiliary and control circuits of switchgear and controlgear are subjected to short-duration power-
frequency voltage withstand tests as for below instruction:
- between the auxiliary and control circuits connected together as a whole and the
frame of the switching device;
- if practicable, between each part of the auxiliary and control circuits, which in normal
use may be insulated from the other parts, and the other parts connected together and to
the frame.
The test voltage shall be 2000 V with a duration of 1 min.

The test, done with those time and values, is to be considered as Type Test, as for IEC 62271-1
ch. 6.2.10.
For convenience of testing, as defined in the IEC 62271-1 ch. 6.2.10 and 7.2, by agreement
between manufacturer and user, the voltage test used can be 1000 V and the duration may
generally be reduced to 1 s.
All the equipment of the assembly shall be connected for the test, except what clearly described in
the below notes.
Nevertheless, those apparatus which, according to the relevant specifications, are designed for a
lower test voltage, and current-consuming apparatus (e.g. windings, measuring instruments) in
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which the application of the test voltage would cause the flow of a current, shall be disconnected.
These apparatus shall be disconnected at one of their terminals unless they are not designed to
withstand the test voltage, in which case all terminals may be disconnected.
IMPORTANT NOTES:
Normally, the test voltage of motors and other devices used in the auxiliary and control circuits
shall be the same as the test voltage of those circuits. If such apparatus has already been tested in
accordance with the appropriate specification, it may be disconnected for these tests.
Current transformer secondaries may be short-circuited and disconnected from earth. Voltage
transformer secondaries may be open.
Voltage-limiting devices, if any, shall be disconnected.
During the test an instruments for verification of dielectric properties up to 5KV is used. The test
voltage at the moment of application shall not exceed 50% of the full value.
It shall then be increased steadily within a few seconds to this full value 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 and 62
Hz.
Anti-interference capacitors installed between live and exposed conductive parts shall not be
disconnected and shall be capable of withstanding the test voltage.
For the test:
- either all switching shall be closed, or
- the test voltage shall be supplied successively to all parts of the circuit..
The auxiliary and control circuits of switchgear and controlgear shall be considered to have passed
the tests if no disruptive discharge occurs during each test.
3.1.6. Test report

At the end of the tests the internal inspector records the results on the "MV Switchboard Test
report" (ISOP 06.18). Copy of this report will be attached to the job technical documentation.
The test report, upon request, will be released to the Client.
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3.2. Instructions IT P 05: Industrial frequency voltage test on main circuits of MV

switchboards
3.2.1. Scope
This instruction describes the execution of "Industrial frequency voltage test on main circuits of MV
switchboards".


CEI EN 62271-200 EN 62271-200 IEC 62271-200
CEI EN 62271-1 EN 62271-1 IEC 62271-1
CEI 42-1 EN 60052 IEC 60052
CEI 42-11 EN 60060-2 IEC 60060-2
3.2.4. Instruments
- Test bench with variable voltage feeder up to 80KV
tested.
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3.2.5. working formalities
On the main circuit of the MV switchboards the industrial frequency testing voltage is applied for 1
minute in accordance with Table 1:
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TABLE 1
Rated insulation Industrial frequency test voltage a.c.
voltage Ui (r.m.s.) (KV)
(r.m.s.) (KV) Between earth and phases On the insulating distance
(KV) (KV)
3,6 10 12
7,2 20 23
12 28 32
17,5 38 45
24 50 60
36 70 80
52 95 110
72,5 140 160
CEI EN 62271-1 / IEC 62271-1
The testing voltage is applied:
- between earth and phases

Testing voltages in Table 1 shall be applied connecting each main circuit phase conductor to the
test voltage terminal. All the others main and auxiliary circuits conductors shall be connected to the
earth conductor or to the assembly or to the earth source terminal.
The voltage test shall be performed with all the break apparatus in closed position and all the
withdrawable parts in service position to assure the continuity of the main circuit.
- on the insulating distance.

Each insulating distance of the main circuit shall be tested at a testing voltage specified in Table 1
Insulating distance is the distance between two sides of the main circuit studied to be connected
with an operating withdrawable switch or an isolator.
During the test a bench for verification of industrial frequency properties up to 80KV is used. The
test is considered to have been passed if there is no puncture or flash-over.
IMPORTANT (see. CEI EN 62271-200 ch. 6.2.6.1):

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Voltage transformers, power transformers or fuses may be replaced by replicas reproducing the
same configuration of the high-voltage connections. Overvoltage protective devices may be
disconnected or removed.
Use of test bench with ball – spark gap

Here below is described the test procedure in case of using of the test bench with ball – spark gap,
instead of the bech with step up transformer with capacitive divider, normally used.
The test bench for the industrial frequency test is composed of:
- operating bench;
- step up transformer 380/80.000 V;
- ball spark-gap. The test is applied as follow:
a. The ball spark-gap is connected to the transformer secondary terminal;
b. Then put the ball at a distance as in the following Table 2:
TABLE 2
Distance between Peak voltage Service voltage Primary voltage Rated current
the two ball of the (KV) (KV) (V) (A)
spark-gap
(cm.)
0,5 16,8 11,9 56,6 16
1 31,7 22,4 106,6 21
1,5 45,5 32,2 153,3 28,5
2 59 41,8 199 41
2,4 70 49 203 52
3 85 60 286 72
3,3 99 70,2
CEI standard 42-11 / IEC 60052
c. Increase the voltage on the primary of the transformer up to have a spark between
the two balls; verify the voltage on the primary of the transformer (V1) on the
voltmeter in the bench;
d. Connect the switchboard to the secondary terminal of the step up transformer, in
place of the spark-gap;
e. Repeat the same procedure as in c) point up to V1;
f. This full value shall be maintained for 1 min.
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3.2.6. Test report

3.2.7. Dielectric test on the main circuit on site

If necessary, when agreed between manufacturer and user, power-frequency voltage tests in dry
conditions may be carried out on the main circuits of metal-enclosed switchgear and controlgear
after the erection on site in exactly the same manner as specified in charter 5 above.
The power-frequency test voltage shall be 80% of the values indicated in Table 1 and shall be
applied to each phase conductor of the main circuit in succession with the other phase conductors
earthed. For the tests, one terminal of the test transformer shall be connected to earth and to the
enclosure of metal-enclosed switchgear and controlgear.
If the voltage test after erection on site replaces the routine test at the manufacturer premises, the
full power-frequency test voltage shall be applied.
NOTE 1: The reduction of the test voltage is motivated by the safety margin in the rated test
voltage values, which takes ageing, wear and other normal deterioration into account, and by the
statistical nature of the flashover voltage.
3.3. Instructions IT P 06: Resistance measure on main circuits of MV switchboards

3.3.1. Scope
This instruction describes the execution of "Resistance measure on main circuits of MV
switchboards".

This instruction applies by the operator, on every MV switchboard or equipment if requested by
applicable standard.
This test is not normaly foreseen as individual test, except special agreement between
manufacturer and user, but only as type test (see. IEC 62271-200 par. 7.3).
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CEI EN 62271-200 CEI EN 62271-200 IEC 62271-200
CEI EN 62271-1 EN 62271-1 IEC 62271-1
3.3.4. Instruments
- Instrument for the measurement of the resistance of the main circuit.
tested.

The resistance measure on the main circuit is performed, as an acceptance test, after the
verification of temperature-rise limits (type test), to compare the result with the same performed
before the verification of temperature-rise limits.
The measured resistance across the complete main circuit of an assembly of metal-enclosed
switchgear and controlgear is indicative of the proper condition of the current path. However, no
tolerance can be specifed.
The Measurement of the resistance of the main circuit is normally not applicable as individual test.
If required, subject to agreement between manufacturer and user, the d.c. voltage drop or
resistance of each phase of the main circuit shall be measured under conditions as nearly as
possible similar to those under which the corresponding type test was carried out.
The measure shall be performed in a.c. voltage, by measuring voltage (V) or resistance (Ohm) ,
among the terminals of each pole.
The testing conditions have to be the nearest to those of reference during the type test.
The test apparatus shall have an environment temperature and the current shall be, during the test
between 50A and the thermic rated current.
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The test is considered to have been passed if the resistance measure is no more than 1,2 Ru (with
Ru = resistance measured before verification of temperature-rise limits).
If the type tests of resistance measure and of verification of temperature-rise limits haven't been
performed, the routine test shall be performed to verify the resistance of the main circuits, without
any reference.
Sometime the Client provide to the inspector the measures and reference to compare the routine
to the type test.
3.3.6. Test report

3.4. Instructions IT P 07: Verification of insulation resistance on auxiliary circuits of MV

switchboards
3.4.1. Scope
This instruction describes the execution of "Verification of insulation resistance on auxiliary circuits
of MV switchboards".

ELETTROCOSTRUZIONI S.p.A..

CEI EN 62271-200 EN 62271-200 IEC 62271-200
CEI EN 62271-1 EN 62271-1 IEC 62271-1
3.4.4. Instruments
- Insulation measuring device at a voltage of at least 500V (MEGGER).
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tested.

For switchboard which not have been subjected to a dielectric test, an insulation measurement
shall be carried out.
The measurement in carried out with a proper insulation measuring device (MEGGER), at a
voltage of at least 500Vdc.
In this case, the test is deemed satisfactory if the insulation resistance between circuits and
exposed conductive parts is at least 1000Ohm/V per circuit referred to nominal voltage to earth of
these circuits.
Refer to Table 1 calculated for the more frequent circuit voltages.
TABLE 1
Rated insulation Rated insulation Minimum value to be
voltage Ui (V) voltage to earth Uo (V) measured for the insulation
resistance (KOhm)
Ui = 110 Uo = 64 Ri > 64
Ui = 230 Uo = 133 Ri > 133
Ui = 400 Uo = 230 Ri > 230
Ui = 690 Uo = 400 Ri > 400
By exception, items which according to their specific requirements are current-consuming

apparatus (e.g. windings, measuring instruments) at the application of the test voltage or are not
designed for the full test voltage shall be disconnected as appropriate.
3.4.6. Test report

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3.5. Instructions IT P 08: Operation tests with switchboard under voltage (LV)
3.5.1. Scope
It describes all the activity relating to the tests and to final fulfilment before shipping, in order to
assure that every supplied product and installation comply to the requested technical
specifications. This instruction describes the execution of "Operation tests with switchboard under
voltage (LV)".

ELETTROCOSTRUZIONI S.p.A..

CEI EN 62271-200 EN 62271-200 IEC 62271-200
CEI EN 62271-1 EN 62271-1 IEC 62271-1
CEI 17-13/1 EN 60439-1 IEC 439-1
CEI 17-13/1 ; V2 EN 60439-1/A2 IEC 60439-1/A2
CEI 17-9/1 e /2 HD 355.1 S3; EN 60265 IEC 265
CEI EN 60947-3 EN 60947-3 IEC 60947-3
3.5.4. Instruments
- Test bench with variable voltage feeder
- Test bench with variable voltage feeder a.c.
- Test bench with variable voltage feeder d.c. .
tested.

Operation tests with switchboard under voltage (lv)
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This test is carried out by feeding with rated voltage the auxiliary circuits of each cubicle and then
all the switchboard (LV switchboards and auxiliary circuits of MV switchboards).
The inspector, before starting this phase, operates a visual control on the wiring diagram in order
to find out possible project errors which could cause damages during the testing phase.
This control will help the inspector in the better knowing of the general operation of the equipment.
With the test bench in operation it is possible to check:
- the correct wiring of the switchboard in accordance with the diagrams;
- the operation of the electrical components of the switchboard such as: relays, metering,
measurement instruments, switches, pushbottons, signallers, etc.
- setting of electrical components
The test is considered satisfactory if no abnormalies occurs in comparison with the operating
required and described in the technical specifications.
Operation tests on switchboard devices

The correct operation of all instruments of the switchboard is further checked and additional
measures are carried out on main components such as:
- Switches: it is checked the operation of the switch and of his auxiliary circuits in manual
- and automatic sequence.
- Signallers: it is checked the operation of the signallers in manual and automatic
sequence.
- Protection relay: it is checked the setting value and operation time and threshold.
- Measurement instruments: it is checked, if required, the setting of the installed
instruments.
Operations sequence
Electrical and mechanical interlocks and all the other control devices with a defined operation
sequence must be tested five times without interruptions in scheduled working conditions and for
the auxiliary circuits with the heaviest working parameters.
During the test no regulation can be done.
The test is considered satisfactory if auxiliary devices have properly operated, if they are, after the
tests, in good working conditions and if the operational strain remain the same before and after the
tests.
In case of sequence repeat, for example during FAT test, the number of operation to do can be
reduced to 1.
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3.5.6. Test report

At the end of the tests the inspector records the results on the " LV/MV Switchboard Test report"
(ISOP 06.17 or ISOP 06.18). Copy of this report will be attached to the job technical
documentation. The test report, upon request, will be released to the Client.
3.6. Instructions IT P 09: Visual inspection on LV and MV switchboard

3.6.1. Scope
specifications.
This instruction describes the execution of "Visual inspection on LV and MV switchboards".

This instruction applies to all the equipment manufactured by CASAGRANDE

CEI EN 62271-200 EN 62271-200 IEC 62271-200
CEI EN 62271-1 EN 62271-1 IEC 62271-1
CEI EN 60439-1 EN 60439-1 IEC 60439-1
CEI EN 60439-1; V2 EN 60439-1/A2 IEC 60439-1/A2
UNI EN ISO 2081 EN ISO 2081
CEI EN 60529 EN 60529 IEC 60529
CEI 64-/1/2/3/4/5/6/7 HD 384.2/3/4/5/6/7 IEC 364; IEC 50-826:
Law 46/90; D.P.R. 447/91;
ENEL LV93
Painting Specification
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3.6.4. Instruments
The instruments used for the following tests are described in the single paragraphs explaining the
working formalities of the test.

Switchboard dimensional test
It shall be verified, with proper instruments (meters, calibrate):
- construction characteristics and switchboard dimension in compliance with drawing and
specifications;
- cubicle and components correspondance to the minimum requirement to the use;
- the absence of visible manufacture faults;
- the construction accuracy;
- the presence of all the defined components..
A special cure must be placed in the control of those dimensional measures most important for the
compartments coupling (in the workshop or to the plant).
Painting checks
The checks on painting refer to the internal procedure CASAGRANDE (ISOP 08.10 o ENEL
DY991), or, if present, to the Client Painting Specification.
During the final testing only some aspects of the painting are verified, as a most accurate control
takes place at the reception of the goods or through the painting certificate of the supplier. Painting
is made by external supplier.
The painting characteristics definitions, for the components for the job involved, is made through a
table (ISOP 06.21), for internal use of CASAGRANDE ELETTROCOSTRUZIONI S.P.A., or directly
on the Purchase Order to the supplaier, where are specified some or all the followings:
- paint color;
- quantity of the pieces of the set;
- commercial reference;
- type of finishing characteristics;
- particolar prescription.
During the final testing the following aspect are checked:

- COLOUR: for comparisation with painting champions;
- THICKNESS: a digital measure instrument is used to verify the painting thickness. The
instrument shall be tested at every utilisation.
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This verification is similar to that at the reception of the goods, so that only the 5% of the
switchboards are verified. Indications about the methodology of the verification are defined on the
technical instruction " ISOP 06.02". The result is positive if all the measure are up to the minimum
required value.
- IRREGULARITY: the inspector shall verify eventual irregularity in the painting surfaces
and correct it.
Special finish
The special finish listed below are normally done by external supplier.
During the final checks only some aspects are verified, as a control take place at the reception of
the goods or at the supplier premise or through supplier report / certificate:
- cold galvanizing: check of the minimum thickness, of the uniform distribution, and of
- eventual irregularities (standard UNI EN ISO 2081);
- hot galvanizing: check of the minimum thickness, of the uniform distribution, and of
eventual irregularities;
- epoxy resination: check of the uniform distribution, and of eventual irregularities;
- bars treatment (silvering, nicheling..) : check of the uniform distribution in the contact
zones.
Insulating material check

The following characteristics / components of the switchboard must be checked, in relation with
their insulating properties or capability to insulate live part.
- Check of wire insulation: in conformity to the purchasing specification ;
- Check of the post insulator (example height, position, material if resin or ceramic
respect to the specification);
- Check of shutters and screen;
- Check insulating partition panel;
- Check presence of warning labels.
Finishing of bus-bars and branch connections

It shall be verified:
- the correct busbar sizing respect to the prescriptions defined in the executive sketches
and drawings;
- the correct bolts and nuts tightening such to guarantee the sufficient contact impact in
the junction points;
- the executive arrangement in compliance with the drawings.
Auxiliary connections check

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- conductors numeration, colour and cross section in compliance with the prescriptions
of the wiring diagrams or operating drawings;
- conductors correct positioning in compliance to the identification and to the wiring
diagram;
- easy accessibility to conductors.
For some kind of panels equipping ENEL (Italian National Electrical Company) substation up to
380kV it is possible to use a machine "Sistema prova cablaggi KTX 40" (D 003), capable to effect
only resistive measures.
The system uses a personal computer; it is possible to prepare a program for each kind of
equipment to test. The result of the test is printed on a ticket.
Circuit labelling check

- the easy identification of individual circuits and of their protective devices
- that where items of equipment of the assembly are designated, the designation used
shall be identical with those in the wiring diagrams which may be supplied together with the
assembly.
- the conformity to the defined diagrams and standards of the labels of signalling lamps
- and of their the different colours in the different positions of open, closed, etc.
Data plates wording check

The requirements to be complied with, are given in the following standards:
- Norme EN 62271-200 (CEI EN 62271-200); IEC 62271-200
- Norme EN 62271-1 (CEI EN 62271-1); IEC 62271-1
- Norme EN 60439-1 (CEI EN 60439-1) ; IEC 60439-1
Must be checked conformity to the standards and to the project documents in according also to the
client specification.
Each assembly shall be provided with one or more plates, marked in a durable manner and located
in a place such that they are visible and legible when the assembly is installed.
The following information shall be given on the nameplates of MV and LV switchboards:
- manufacturer's name or trade mark;
- CE marking for LV switchboard, if applicable;
- type designation or identification number or other means of identification making it
possible to obtain relevant information from the manufacturer, as follow:
- job number.
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Only for MV switchboards, the following information shall be given on the nameplate:
- rated voltage;
- rated insulation voltage;
- rated frequency;
- rated current;
- short time withstand current (1 sec.).
- construction year
- designation and/or classification IAC
To be checkd also the correct installation position.
Electrical and mechanical diagram check

Check the correspondance of the electrical and mechanical diagrams used for construction with
what built, and evidence eventual important deviation.
If are present, check by a visual inspection the operation sequence plate with mimic diagram and
the drawings and the technical specifications.
Earthing and protection circuits check

The requirements to be complied with are given in the following standards:
- CEI standard CEI EN 60439-1, EN 60439-1; IEC 60439-1
- CEI standard 64-8
- IEC standard 364-4-41
- IEC standard 694 where applicable
Manual operating means (handles, wheels, etc.) shall be:

- Either electrically connected, in a secure and permanent manner, with the parts
connected to the protective circuits,
- or provided with additional insulation which insulates them from other conductive parts
of the assembly. This insulation shall be rated for at least the maximum insulation voltage
of the associated device.
Continuity of protective circuits shall be ensured by effective interconnections either directly or by

means of protective conductors:
- 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;
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- 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;
- 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. If apparatus with a voltage exceeding the limits of extra- low
voltage are attached to lids, doors, cover plates, etc., steps shall be taken to ensure
continuity of the protection circuits. It is recommended that these parts be fitted with a
carefully attached protective conductor whose cross-sectional area depends on the
maximum cross-section of the supply lead to the equipment attached. An equivalent
electrical connection especially designed for this purpose (sliding contact, hinges
protected against corrosion) shall also be considered satisfactory;
- when the enclosure of an assembly is used as a part of the protection circuit, the cross-
sectional area of this enclosure shall be at least electrically equivalent to the minimum
cross-sectional area specified in Table 1
- the protective circuit shall be interrupted only after the live conductors have been
interrupted and continuity shall be established before the live conductors are reconnected;
- in principle protective circuits within an assembly shall not include a disconnecting
device (switch, disconnector, etc.). The only means permitted in the run of protective
conductors shall be links which are removable by means of a tool and accessible only to
authorized personnel.
Continuity of protective circuits shall be ensured also in case of parts connected with metal painted
parts. In the connection zone it shall be necessary to remove the layer of varnish.
IMPORTANT: in general, it shall be verified that the different exposed conductive parts of the
assembly are effectively connected to the protective circuit.
A measurement may be carried out to verify that the resistance between the terminal for the
incoming protective conductor and the relevant exposed conductive part of the assembly is
sufficiently low.
The cross-sectional area of the protective conductor shall be not less than the appropriate value
shown in Table 1:
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TABLE 1
Cross-sectional area of phase Minimum cross-sectional area
conductors of the corresponding
S protective conductor
(mmq.) Sp
(mmq.)
S < 16 S
16 < S < 35 16
S > 35 S/2
These values are valid only if the protective conductor is made of the same metal as the phase
conductors. If this is not so, the cross-sectional area of the protective conductor is to be
determined in a manner which produces a conductance equivalent to that which results from the
application of Table 1.
Degree of protection
The degree of protection provided by any assembly against contact with live parts, ingress of solid
foreign bodies and liquid is indicated by the designation IP according to IEC 60529
The degree of protection must be verified with a visual inspection.
It is indicated by the designation IP and by two characteristic numerals:
- the first characteristic numeral represents "the protection against contact and protection
against ingress of solid foreign bodies";
- the second characteristic numeral represents "the protection against harmful ingress of
water";
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TABLE 2
1st Characteristic numeral 2nd Characteristic numeral
(CEI 70-1; IEC529) (CEI 70-1; IEC529)
IP TESTS IP TESTS
No protection No protection
0 0
Protection against solid bodies Protection against the vertical falling
1 greater than  50 mm. 1 of drops of water
2 greater than  12 mm. 2 of drops of water (max inclination
15°)
3 greater than  2,5 mm. 3 of drops of water (max inclination
60°)
Protection against solid bodies Protection against sprays of water
4 greater than  1 mm. 4
Protection against dust (no harmful Protection against jets of water from
5 deposit) 5 all directions
Total protection against dust Protection against projection of
6 6 waters similar to marina swells
Measurement of creepage and clearances distances

It shall be tested:
- apparatus forming part of the assembly shall have distances complying with the
requirement of their relevant specifications, and these shall be maintained during normal
service conditions;
- apparatus arranged within the assembly shall complied with the specified creepage
distances and clearances, taking into account the relevant service conditions;
- for bare live conductors and termination (e.g. busbars, connections between apparatus,
cable lugs) the creepage distances and the clearances shall at least comply with those
specified for the apparatus with which they are directly associated;
- in the case of functional units being mounted on withdrawable parts, the isolation
provided shall at least comply with the requirements in the relevant specification for
disconnectors with the equipment in new condition, taking account of the manufacturing
tolerances and changes in dimensions due to wear.
All the tests shall be carried out in conformity to the mechanical and electrical drawings, taking into
account creepage and clearance distances for each apparatus.
If necessary, these clearances and creepage distances shall be verified by measurement.
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If the assembly contains withdrawable parts, it is necessary to verify that both in the test position, if
any, and in the disconnected position, the clearances and creepage
distances are complied with.
Constructive form check

The constructive form of the cubicle must be checked with reference to the technical specifications.
The applicable forms are one of the following:
Form 1: no segregation;
Form 2a: segregation of the bars respect to the functional units, connection terminals are not
separated from the bars;
Form 2b: segregation of the bars respect to the functional units, connection terminals are
separated from the bars;
Form 3a: segregation of the bars respect to the functional units and segragation of all the funtional
units each other, with the exception of the connection terminals for the external conductors from
the functional units, but not one to the other;
Form 3b: segregation of the bars respect to the functional units and segragation of all the funtional
units each other. Segregation of the connection terminals for the external conductors from the
functional units, but not one to the other;
Form 4a: segregation of the bars respect to the functional units and segragation of all the funtional
units each other, including the terminals for the external conductors, which are part of the
functional unit;
Form 4b: segregation of the bars respect to the functional units and segragation of all the funtional
units each other, including the terminals for the external conductors, which are part of the
functional unit; furthermore, the terminals for the external conductors are segregated from the
functional units.
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Main reason of the segragation is to allow operation, maintenance, inspection or other operations
in the maximum safety also with the service continuity of the network.
See table below:
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3.6.6. Test report

documentation.
3.7. Instructions IT P 10: Mechanical inspection on LV and MV switchboard

3.7.1. Scope
specifications. This instruction describes the execution of "Visual inspection on LV and MV
switchboards".

CEI EN 62271-200 EN 62271-200 IEC 62271-200
CEI EN 62271-1 EN 62271-1 IEC 62271-1
CEI EN 60439-1 EN 60439-1 IEC 60439-1
DIN 267
CEI EN 60529 EN 60529 IEC 529
CEI 64-/1/2/3/4/5/6/7 HD 384.2/3/4/5/6/7 IEC 364; IEC 50-826:
Law 46/90; D.P.R. 447/91;
3.7.4. Instruments
The instruments used for the following tests are described in the single paragraphs explaining the
working formalities of the test.
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Bolts and nuts tightening
The test is applied in compliance with the DIN 267 standard and the technical specification of the
Client.
All bolts on power circuits are tightened to the required couple (see attached schedule SCH 019)
by operators with dynamometric key. This operation is evidenced by signing with a permanent pen
on the bolt.
Tests Responsible check at least the 10% of the tightened bolts by a dynamometric key in
calibration.
If he find more than 1% of the bolts not correctly tightened, he test the 100%, otherwise the test is
correct.
Circuit breakers and isolators operating test

The satisfactory mechanical operation of circuit-breakers and insulators shall be verified after the
installation in the assembly with a number of operating cycles of 5.
Also the removable parts shall be verified by 5 connections and 5 disconnections.
The test is considered to have been passed if the operating conditions of the apparatus, interlocks,
etc., have not been impaired and if the effort required for operation is practically the same as
before the test.
Compartment's accessories and rolling shutters

During the mechanical tests, it shall be verify the correct operating and positioning of all the
interlocks and auxiliaries.
Mechanical and electromechanical locks

The interlocks must be arranged in the specified position to prevent the break devices manoeuvres
and the removable parts connection / disconnection.
During the test, only ordinary efforts will be applied and no one regulation on break devices, on
removable parts and on interlocks could take place.
The test consists of 5 attempts for manage the break devices and 5 attempts for connecting and
disconnecting the removable parts, as in the functional diagram.
The interlocks are considered acceptable if:
- the break devices can't be managed;
- the removable parts can't be connected or disconnected;
- the break devices, the removable parts and the interlocks are still in good operating
conditions and the effort for the manoeuvre is still the same also after the test.
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3.7.6. Test report

documentation. The test report, upon request, will be released to the Client.
3.7.7. Annex
See table SCH 19
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Information schedule SCH019
BOLTS AND NUTS TIGHTENING

With reference to the position 5.1 of the Technical Instruction IT P 10 reference to the document
“Test Procedure”, this schedule give an indication to the operators about the recommended bolts
and nuts tightening values during the switchboards assembly.
The values showns in the Table 1 (Base Table), are valid for Cold Galvanized steel bolts and nuts,
depending on the resistance category, for the coupling of steel components.
Nominal Bolt Tightening torque MA (N·m) 1 kg·m = 9.81 N·m
section Standard UNI EN 20898/1
NORMAL HIGH RESISTANCE
4.6 5.6 6.9 8.8 10.9 12.9
M4 0,9 1,3 2,4 2,9 4,1 5
M5 1,9 2,5 4,9 5,8 8,2 9,8
M6 3,2 4,3 8,4 10 14,2 16,8
M8 8 10,7 20,3 24,4 34,6 40,7
M10 15,8 21,4 40,7 48,9 68,2 82,5
M12 27,5 36,6 71,3 84,6 119,2 142,7
M14 43,8 59,1 113,1 134,5 188,5 224,2
M16 67,2 89,7 173,2 203,8 290,5 346,5
M18 92,7 123,3 239,5 280,3 397,5 479,1
M20 130,4 174,3 336,3 397,5 560,6 672,7
Table 1
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The tightening torque for the fixing and connection of Copper bars, with Cold galvanized steel
bolts, must be reduced of 15% with reference to the Resistance category 8,8: see Table 2.
Nominal Tightening torque

Bolt MA (N·m) 1 kg·m =
section
9.81 N·m
M4 2,4
M5 4,9
M6 8,4
M8 20,6
M10 41,3
M12 71,4
M14 113,5
M16 172,0
M18 236,6
M20 335,5
Table 2
The tightening torque for the fixing and connection of Copper bars, with Stainless steel bolts, must
be reduced of 25% with reference to the Table 1 Resistance category 8,8; the same values must
be applied for the threaded connection elements used in the cubicle assembling and for the MV
support insulator fixing: see Table 3.
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The tightening torque for the fixing and connection of Aluminium bars, with Stainless steel bolts,
must be reduced of 45% with reference to the Table 1 Resistance category 8,8: see Table 4.
Furthermore, for this last kind of bars, these value must be considered together with plate washer
of big diameter (type UNI 6593), or with plastic washer (type DIN 2093), which allow a more
uniform distribution of the connection pressure; the bolts are self locked type.
The tightening torque for the fixing and connection of Copper bars, with Stainless steel bolts on
bushing and post insulators with brass insert, must be according to the Table 5.
Nominal Tightening torque
Bolt MA (N·m) 1 kg·m =
section
9.81 N·m
M4 -
M5 -
M6 9,8
M8 19,6
M10 29,4
M12 39,2
M14 -
M16 68,7
M18 -
M20 117,7
Table 5
Tightening torque tolerance +-10%
(Table are derived from the technical characteristic of the bolts and nuts used, considering the
attrition coefficent of the material coupled).

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Titolo Identificativo Rev.

ISOLATED PHASE BUS-DUCT 0553 F1BAAU670 00 1 35

PRP ELE IPI/REA/ELE/CCE ENGLISH

CARIBONI GROSSO F. BRUZZONE M.

Rev Scopo Preparato Controllato Verificato Verificato Approvato Data

3.3.6. Test report ..................................................................................................................... 16

2. FAT/SAT PROCEDURE FOR IPB

2.1. Procedure for visual and dimensional inspection during FAT

IPB elements and accessories

Test equipment / Instruments: calliper, measuring tape

2.2. Procedure for inspection of painting and galvanization

2.3. Procedure for testing the pressurization cubicle

2.4. Procedure for electrical testing

I, R, T, V are part of the test equipment.

The test shall be execute according to the following procedure:

3. FAT/SAT PROCEDURE FOR PT CUBICLE AND NEUTRAL GROUNDING CUBICLE

3.1.2. Range of applicability

3.1.3. Reference to standards

National Standard European Standard International Standard

CEI EN 62271-1 EN 62271-1 IEC 62271-1

3.1.5. Working formalities

The test voltage shall be 2000 V with a duration of 1 min.

3.1.6. Test report

3.2. Instructions IT P 05: Industrial frequency voltage test on main circuits of MV

3.2.2. Range of applicability

3.2.3. Reference to standards

National Standard European Standard International Standard

CEI EN 62271-1 EN 62271-1 IEC 62271-1

CEI 42-1 EN 60052 IEC 60052

CEI 42-11 EN 60060-2 IEC 60060-2

3.2.5. working formalities

The testing voltage is applied:

- between earth and phases

- on the insulating distance.

IMPORTANT (see. CEI EN 62271-200 ch. 6.2.6.1):

Use of test bench with ball – spark gap

3.2.6. Test report

3.2.7. Dielectric test on the main circuit on site

3.3. Instructions IT P 06: Resistance measure on main circuits of MV switchboards

3.3.2. Range of applicability

3.3.3. Reference to standards

National Standard European Standard International Standard

CEI EN 62271-1 EN 62271-1 IEC 62271-1

3.3.5. Working formalities

3.3.6. Test report

3.4. Instructions IT P 07: Verification of insulation resistance on auxiliary circuits of MV

3.4.2. Range of applicability

3.4.3. Reference to standards

National Standard European Standard International Standard

CEI EN 62271-1 EN 62271-1 IEC 62271-1

3.4.5. Working formalities

By exception, items which according to their specific requirements are current-consuming

3.4.6. Test report

3.5.2. Range of applicability

3.5.3. Reference to standards

National Standard European Standard International Standard

CEI EN 62271-1 EN 62271-1 IEC 62271-1

CEI 17-13/1 EN 60439-1 IEC 439-1

CEI 17-13/1 ; V2 EN 60439-1/A2 IEC 60439-1/A2

CEI 17-9/1 e /2 HD 355.1 S3; EN 60265 IEC 265

CEI EN 60947-3 EN 60947-3 IEC 60947-3

3.5.5. Working formalities

Operation tests on switchboard devices