Document: Site Test Procedure
Service: Electrical
System: Distribution Board
Reference: STP-ELECT- DB
Revision: 0
Company:
Name:
Signature:
Date:
Approval:
Name:
Signature:
Date:
Approval
Status:
Menara Citi Bank
Site Test Procedure
Document Control Sheet
Contract Number: MY0716-01-R0
Contract Name: Menara Citibank UPS Upgrade Works
Client: Citibank Berhad
Project Location: Menara Citibank, Kuala Lumpur, Malaysia
Document Reference: STP-ELECT-DB
Document Description: Distribution Board Testing
Prepared By: M.Palani
Checked By: K.Drake
Approved By: K.Drake
Rev: By: Date: Reason:
0 MP 29.9.16 For contractor review
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Menara Citi Bank
Site Test Procedure
Contents
1 Introduction………………………………….…… 4
2 Factory Test Documentation………………….. 4
3 Instrumentation Requirements ……………… 4
4 Scope of Tests..…………………………………. 5
5 Codes of Practice....……………………………. 8
6 Test Record Sheets………………….………… 8
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Menara Citi Bank
Site Test Procedure
1.0 Introduction.
1.1 The following test procedure has been prepared as a guideline for the testing of
Distribution Boards for this project.
1.2 This document is to be read by the manufacturer/supplier of the Switchboards and
enhanced to suit the comprehensive testing performed at site in accordance with
current codes of practice and minimum standards required by the Client.
1.3 The tests proposed in this document are not exhaustive nor are they considered an
acceptable alternative to the current site tests performed by the manufacturer.
1.4 Whilst this document may be considered as the minimum standard of inspections and
tests performed at site, the responsibility for thorough testing of the equipment within
the site environment remains with the manufacturer. Therefore, where the
manufacturer believes necessary tests have been omitted from the guidelines it is the
responsibility of the manufacturer to include these within the Site Test Procedures
Document.
2.0 Factory test Documentation.
2.1 Prior to any site testing being conducted, a full Factory Test Report is to have been
submitted and approved by the client or his representative.
2.2 Should this document be a combination of factory and site then it must highlight the
areas that are unsuitable or inapplicable to site tests.
3.0 Instrumentation.
3.1 All instrumentation used for the testing of the switchboards, must have up to date (with
at least 6 months validity) calibration certificates that is traceable to international
standards.
3.2 Please supply a list of all instruments to be used during the test including serial
numbers.
3.3 Instrumentation must be suitable to record the information obtained during testing i.e.
Waveform capturing should be high resolution and if required 3 phase.
3.4 Details of actual test instrumentation, complete with copies of valid calibration
certificates for each instrument, are to be appended to this method statement.
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Menara Citi Bank
Site Test Procedure
4.0 Scope of Tests.
4.1 The following tests are recommended only and should compliment the testing laid down
by manufacturer / supplier.
• Installation Checks
• Bolts & nut torque test
• Insulation Resistance test
• IDMTL protection relay calibration test
• Dielectric pressure test at 2000V DC for 1 minute.
• Busbar Joint Connection test
• Circuit Breaker Operational Checks
• Circuit breaker Setting Checks
• Circuit breaker Protection tests (Secondary Injection)
• Current Transformer Polarity Checks.
• Current Transformer Injection Test.
• Phase rotation & polarity check to every outgoing breaker terminals.
• Castell interlock of incoming ACB power failure change over check
• Inter tripping with HV feeder breaker, REF protection demonstration.
• Meter Calibration
• Instrumentation test
• Contact signal to interface such as BMS etc.
• Load Test & Thermal scanning (if require)
4.2 Installation Checks
After installation, the switchboard should undergo checks for the following:
• Base fixtures
• Assembly
• Paint finish
• Cable access
• Labelling
• Component Details
• Cleanliness
The above should be compared to the approved installation drawing and signed off
accordingly.
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Menara Citi Bank
Site Test Procedure
4.3 Insulation Resistance Test
Once the Switchboard has been installed a check on the Insulation Resistance of the
busbar system is required.
Open all outgoing Circuit breakers and close any bus tie circuit breakers then using a
Insulation Resistance tester 500V DC (Meggar) Check the values between the following
points.
• Each Phase to Phase
• Each Phase to Neutral
• Each Phase to Earth
• Neutral to Earth
The results should be documented for future reference
4.4 Busbar Joint Connection tests
There are 2 types of tests to check the busbar joints
1. Tightness check – Using a calibrated torque wrench, the bolts are to be tightened
until the recommended torque is met.
Metric Bolt Size Bolt Torque
(coarse thread) (Nm)
M6 7.2
M8 17
M10 28
M12 45
M16 91
Typical values for High-Tensile (8.8) Bolts
2. Low Ohm (Ductor) Test – A Low Ohm (Ductor) meter is connected across a joint or
series of joint and the measurement recorded or alternatively the test can be
conducted using a current source and a voltmeter with the result being a
mathematical calculation.
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Menara Citi Bank
Site Test Procedure
4.5 Circuit breaker operation Checks
Each circuit breaker is to be operated, Closed, Open and tripped so that they are
mechanically sound. If the Circuit Breaker has a motorised operation then the spring
charging mechanism is to be tested. Likewise should the unit be of the rack type, the
unit should be racked in and out to check for any mechanism issues.
4.6 Circuit Breaker Setting Checks
The circuit breakers have a protection setting fixed at time of delivery. These settings
are to be recorded prior to the Circuit breaker protection test.
4.7 Circuit Breaker Protection Test
These test may be performed using a manufacturer’s propriety test unit or with a
conventional test unit using current injection and timer set up. In either case full
certification of calibration will be required for all instruments / equipment.
All protection is to be tested at both factory guaranteed setting and at the setting
required for this project.
Each of the tests is to be recorded and witnessed by the client or their representative.
4.8 Current Transformer Polarity Checks
This can be demonstrated by connecting an analogue meter to the secondary terminals
of the CT and then introducing a D.C. source momentarily to the primary side, this
would then induce the CT and the pointer on the analogue device would move in a
positive direction. This is also known as a flick test as the source is D.C. and thus the CT
field is created only once.
-VE +VE
Simple circuit for polarity checks
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Menara Citi Bank
Site Test Procedure
4.9 Current Transformer Injection Test.
This test involves inducing a current into primary windings of the CT and measuring the
secondary winding output. This does not have to be at the full rating of the CT but the
results should be in line with the CT ratio i.e. a 100:5A CT injected with 10A should read
0.5A on the secondary winding.
4.10 Calibration of Meters
For this test, a certified calibrated meter is used in conjunction with the panel meter.
Measurements of the different units (Volts, Amps etc) are taken with the certified meter
and the results are compared with the panel meter. For analogue Meters manufactured
to Class 1.5 (usually written on the scale) then the accuracy is within 1.5% at Full scale
deflection. Other classes include 0.5 (0.5%) & 2.5 (2.5%) as for digital meters the
accuracy is usually higher than 1 %.
The replacement mechanism of the meter shall be tested. The test shall
demonstrate that the replacement of the meter does not require the switching off of
the respective switchgear. Current transformers shorting block to prevent open
circuiting the current transformers shall also be tested. Simulate temporary plug load to
verify the correct kwh has been display at the meter.
4.11 Switchboard Load Tests.
Conduct load tests of switchboards for the duration specified at full load.
During the test measurements of voltage, current and frequency shall be recorded for
each phase as specified.
Infrared scans of the switchboards are to be conducted during the load test as specified.
5.0 Codes of Practice
5.1 A list of all relevant codes of practice being used is to be submitted.
5.2 Any codes that are local and contravene international standards should be submitted to
the design engineers for their approval prior to implementation.
6.0 Test Record Sheets
6.1 Only approved records sheets shall be accepted and witnessed.
6.2 All sheets must be completed at the time of testing so authorised signatures may be
taken.
6.3 All computer data / printouts must be produced on the day of testing and signed by the
witnessing Engineer.
Distribution Board Test Page | 8
APPENDIX A
TEST REPORT SHEET
Item Title
001 Engineers Report
002 IR & Pressure Test Report Sheet
003 Polarity Check Test Report Sheet
004 Primary Injection Test Report Sheet
005 Secondary Injection Test Report Sheet
006 Temperature Rise Limit Test Report
007 Electrical Bus Bar Checks Test Report
008 Functional Checks of Distribution Board Test Report
009 Electrical Resistance (Ductor) Test Report Sheet
CLIENT: IKANO CONTRACTOR:
PROJECT: IKEA KL2 TEST ENGINEER:
SYSTEM: DATE:
LOCATION:
ENGINEERS REPORT SHEET
CLIENT: IKANO CONTRACTOR:
PROJECT: IKEA KL2 TEST ENGINEER:
SYSTEM: DATE:
LOCATION:
INSULATION RESISTANCE AND PRESSURE TEST
System
A. insulation Resistance Test (1000V Megger)
With all switchgear closed
Test With all switchgear open(Meg Ohm)
(Meg Ohm)
R TO E MΩ MΩ
Y TO E MΩ MΩ
B TO E MΩ MΩ
N TO E MΩ MΩ
R TO Y MΩ MΩ
Y TO B MΩ MΩ
B TO R MΩ MΩ
R TO N MΩ MΩ
Y TO N MΩ MΩ
B TO N MΩ MΩ
B. Pressure Test (2.5KV A. C. With all switchgear closed)
R-S-T-N TO E SEC. R-S- TO T-N SEC. R-T TO S-N SEC.
LEAKAGE CURRENT mA LEAKAGE CURRENT mA LEAKAGE CURRENT mA
C. Insulation Resistance Test (1000V Megger) After pressure test
Test With all switchgear open (Meg Ohm) With all switchgear closed
(Meg Ohm)
R TO E MΩ MΩ
Y TO E MΩ MΩ
B TO E MΩ MΩ
N TO E MΩ MΩ
R TO S MΩ MΩ
Y TO B MΩ MΩ
B TO R MΩ MΩ
R TO N MΩ MΩ
Y TO N MΩ MΩ
B TO N MΩ MΩ
REMARKS / INSTRUMENTS USED.
Tested By Name Signature Date
Witnessed By Name Signature Date
Witnessed By Name Signature Date
CLIENT: IKANO CONTRACTOR:
PROJECT: IKEA KL2 TEST ENGINEER:
SYSTEM: DATE:
LOCATION:
POLARITY CHECK FOR CURRENT TRANSFORMER
Satisfactory (√)
Unsatisfactory (X)
Remarks
NOT Completed (NC)
NOT Applicable (NA)
R
Measurement Y
CT B
N
R
Y
Protection CT
B
N
R
Measurement Y
CT B
N
R
Y
Protection CT
B
N
R
Measurement Y
CT B
N
R
Y
Protection CT
B
N
REMARKS / INSTRUMENTS USED.
Tested By Name Signature Date
Witnessed By Name Signature Date
Witnessed By Name Signature Date
CLIENT: IKANO CONTRACTOR:
PROJECT: IKEA KL2 TEST ENGINEER:
SYSTEM: DATE:
LOCATION:
PRIMARY INJECTION
For over-current relays and earth fault relays set at specified settings.
Secondary Current
Primary Current Spill Current
R Y B N
Ref
R–Y
Y–B
B-R
R-N
Y-N
B-N
Ref
R–Y
Y–B
B-R
R-N
Y-N
B-N
Ref
R–Y
Y–B
B-R
R-N
Y-N
B-N
REMARKS / INSTRUMENTS USED.
Tested By Name Signature Date
Witnessed By Name Signature Date
Witnessed By Name Signature Date
CLIENT: IKANO CONTRACTOR:
PROJECT: IKEA KL2 TEST ENGINEER:
SYSTEM: DATE:
LOCATION:
SECONDARY INJECTION TEST
Over-current Relay
Relay Setting Operating time (Sec)
Plug Setting Current inject (A)
Time Setting Normal Actual
%
R
R
R
Y
Y
Y
B
B
B
Earth Fault Relay
Relay Setting Operating time (Sec)
Plug Setting Current inject (A)
Time Setting Normal Actual
%
N
N
N
REMARKS / INSTRUMENTS USED.
Tested By Name Signature Date
Witnessed By Name Signature Date
Witnessed By Name Signature Date
CLIENT: IKANO CONTRACTOR:
PROJECT: IKEA KL2 TEST ENGINEER:
SYSTEM: DATE:
LOCATION:
TEMPERATURE RISE LIMIT TEST
AMBIENT AIR TEMPERATURE AT LOCATION 1 ………..Deg C
AMBIENT AIR TEMPERATURE AT LOCATION 1 ………..Deg C
AMBIENT AIR TEMPERATURE AT LOCATION 1 ………..Deg C
Position: Temperature rise at Steady State Deg C
No. (Position of test should include all joints and connections.
The following are for reference only.) Test Limit
1 Supply connection R phase
2 Supply connection Y phase
3 Supply connection B phase
4 Horizontal busbars R phase
5 Horizontal busbars Y phase
6 Horizontal busbars B phase
7 Vertical busbars R phase
8 Vertical busbars Y phase
9 Vertical busbars B phase
10 Switchgear incoming terminal R phase
11 Switchgear incoming terminal Y phase
12 Switchgear incoming terminal B phase
13 Connection busbar to switchgear R phase
14 Connection busbar to switchgear Y phase
15 Connection busbar to switchgear B phase
REMARKS / INSTRUMENTS USED.
Tested By Name Signature Date
Witnessed By Name Signature Date
Witnessed By Name Signature Date
CLIENT: IKANO CONTRACTOR:
PROJECT: IKEA KL2 TEST ENGINEER:
SYSTEM: DATE:
LOCATION:
ELECTRICAL BUS-BAR CHECK LIST
Item Check List Comments
1 Check the torque of the bolted connections as per the manufacturers instructions
2 Check gaskets
3 Check that wall and floor openings are sealed correctly
4 Check that supports are correctly installed
5 Check that phase sequence is as per drawings
6 Check clearance between bars and between bars and casing
7 Check bus-bar rating against drawings
8 Check if anti-condensation heaters have been fitted and tested (if required)
9 Check alignment and level
10 Check that fire barriers have been correctly installed
11 Check position and accuracy of nameplates against drawings
12 Check Tap-Off unit clearance
13 Carry out Ductor Test on entire length of Busbar.
REMARKS / INSTRUMENTS USED.
Tested By Name Signature Date
Witnessed By Name Signature Date
Witnessed By Name Signature Date
CLIENT: IKANO CONTRACTOR:
PROJECT: IKEA KL2 TEST ENGINEER:
SYSTEM: DATE:
LOCATION:
FUNCTIONAL TESTS FOR SWITCHBOARDS
Satisfactory (√)
Unsatisfactory (X)
Item Check (where applicable) Comments
Not completed (NC)
Not Applicable (NA)
1 Operation of ACB
2 Racking in and out of ACB
3 Operating of automatic shutter and padlock
4 Mechanical closing mechanism
5 Electrical closing mechanism
6 Mechanical tripping operation
7 Over-current trip operation
8 Earth leakage trip operation
9 Under-voltage release operation
10 ACB panel door interlock
11 Mechanical ON/OFF indicator
12 Operation of auxiliary switches
13 Alignment of contacts mechanism
14 Failure of incoming Supply A
Automatic closing onto System B through (insert
15
breaker ref)
16 Failure of incoming Supply B
Automatic closing onto System B through (insert
17
breaker ref)
18 BMS Interface (fail safe contacts)
REMARKS / INSTRUMENTS USED.
Tested By Name Signature Date
Witnessed By Name Signature Date
Witnessed By Name Signature Date
CLIENT: IKANO CONTRACTOR:
PROJECT: IKEA KL2 TEST ENGINEER:
SYSTEM: DATE:
LOCATION:
ELECTRICAL RESISTANCE (Ductor) TEST
Position
Resistance (Micro Ohm)
(Positions of test should include all joints and
connections. The following are for reference only)
Joints on main busbars
Connections between horizontal and vertical busbars
Connections of ACB/fuse switches
REMARKS / INSTRUMENTS USED.
Tested By Name Signature Date
Witnessed By Name Signature Date
Witnessed By Name Signature Date
