Testing Of Control 6v1o2v

GREENKO INTEGRATED MANAGEMENT SYSTEMS PROCEDURE FOR CONTROL (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 . 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 & 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 : Components incorporated in the control 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 ) (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, 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.

PRO-XXX-YYY-NN 7

Revision No: xx

dd/mm/yyyy

Completeness Rigor and Accuracy for Excellence

1 of

GREENKO INTEGRATED MANAGEMENT SYSTEMS PROCEDURE FOR CONTROL (Factory and Site acceptance Tests) 5.1.1.1. Type tests: (Only review of Test certificates issued by RI, 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 the assembly of control as per approved BOM, GA and schematic diagram. PRO-XXX-YYY-NN 7

Revision No: xx

dd/mm/yyyy

Completeness Rigor and Accuracy for Excellence

2 of

GREENKO INTEGRATED MANAGEMENT SYSTEMS PROCEDURE FOR CONTROL (Factory and Site acceptance Tests) 5.1.1.2.2. 5.1.1.2.2.1.

Dielectric test. Requirement of Equipment’s 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
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 ed if there is no puncture or flash-over.

PRO-XXX-YYY-NN 7

Revision No: xx

dd/mm/yyyy

Completeness Rigor and Accuracy for Excellence

3 of

GREENKO INTEGRATED MANAGEMENT SYSTEMS PROCEDURE FOR CONTROL (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 ing 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

PRO-XXX-YYY-NN 7

Revision No: xx

dd/mm/yyyy

Completeness Rigor and Accuracy for Excellence

4 of

GREENKO INTEGRATED MANAGEMENT SYSTEMS PROCEDURE FOR CONTROL (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. PRO-XXX-YYY-NN 7

Revision No: xx

dd/mm/yyyy

Completeness Rigor and Accuracy for Excellence

5 of

GREENKO INTEGRATED MANAGEMENT SYSTEMS PROCEDURE FOR CONTROL (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 t. 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 =

PRO-XXX-YYY-NN 7

Revision No: xx

3 I2 L

dd/mm/yyyy

Completeness Rigor and Accuracy for Excellence

6 of

GREENKO INTEGRATED MANAGEMENT SYSTEMS PROCEDURE FOR CONTROL (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 :

Site acceptance test as per Vendor or Greenko- Inspection and test plan and observation shall be recorded on Check list for erection of Control - 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 -

PRO-XXX-YYY-NN 7

Revision No: xx

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

dd/mm/yyyy

Completeness Rigor and Accuracy for Excellence

7 of