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INSPECTION AND
TESTING
PROCEDURE
 TABLE OF CONTENTS

I. General Inspection for Control Panels and Sampling Racks

A. Sheet Metal Inspection
1. Necessary Items
2. Inspection Procedure
3. Inspection Points
4. Dimensional Tolerances
5. Weld Defects on Sheet Metal
B. Paint-Finish Inspection
1. Necessary Items
2. Inspection Procedure
3. Inspection Points
C. Assembly and Appearance Inspection
1. Necessary Items
2. Inspection Procedure
3. Inspection Points
D. Dimensional Inspection
1. Necessary Items
2. Inspection Procedure
3. Inspection Points

II. Testing Procedure for Control Panels

A. Dielectric Strength Test (Insulation Resistance Measurement)
1. Necessary Items
2. Test Procedure
3. Inspection Points
4. Examples of Insulation or Withstand-Voltage Failures
B. Simulation Check(Sequence Test)
1. Necessary Items
2. Test Procedure
3. Inspection Points
4. Examples of Insulation or Withstand-Voltage Failures

III. Testing Procedure for Sampling Racks

A. Pneumatic Pressure Test (Pressure-leak test)
1. Necessary Items
2. Test Procedure
3. Inspection Points
4. Difficult to Locate Leaks
B. Hydrostatic Pressure Test (Pressure-leak test)
1. Necessary Items
2. Test Procedure
 3. Inspection Points
4. Difficult to Locate Leaks

INSPECTION AND TESTING PROCEDURE

I. General Inspection for Control Panels and Sampling Racks

A. Sheet-Metal Inspection
1. Necessary Items
(1) Sheet-metal drawing (Manufacturing drawing)
(2) Scale
(3) Steel measure (minimum: 1 meter long)
(4) Flashlight
(5) Vernier calipers
(6) Writing implements
2. Inspection procedure
(1) Check dimensions of the sheet metal against those specified on the sheet metal
drawing, using a pen.
(2) Check the dimensions and quantity of individual accessories, such as metal
fittings, handles, lot rods and pins.
(3) Make sure the sheet metal has been produced in accordance with the
manufacturing drawing.
(4) Check all welds (refer to item 5, “weld defects in sheet metal”).
(5) Measure the sheet’s flatness and squareness. (for methods of measurement, refer to
Part D, Dimensional Inspection)
3. Inspection points
(1) Place a steel measure or flat bar against the sheet metal, and check for vertical or
horizontal distortions.
(2) The back of the sheet metal is likely to be distorted by welding.
➢ Very inconspicuous distortions may appear once the sheet metal has been
painted.
(3) Mark non-conformances, such as spatters, pinholes, mis-aligned cuts and
distortions directly on the sheet metal with a chalk to clearly identify spots to be
 reworked.
(4) Mounting locations or directions of angles and metal fittings differ between front
view and back view. When looking at the drawing, take care not to confuse right
and left (the drawing itself is often wrong).
(5) Always have the sheet-metal processor attached to the door, intermediate plate,
Furnished hardware and switch box.
(6) Do not put excessive confidence in the sheet-metal processor. Always check the
work with your own eyes.
(7) Do not forget to check flatness and squareness.
(8) Check dimensions of each cut, then count the number of pieces.
4. Dimensional tolerances
5. Weld defects in sheet metal
➢ Incomplete welding: Areas that should have been welded are left unweld.
➢ Slag: A product that automatically comes off the welded area after welding
(similar to cinders).

Spatter: Slag or metal particles expelled during arc or gas welding.

➢ Pinhole: A small cavity in the weld formed by trapped gas:

Note: Fill pinholes larger than 1mm in diameter can be filled by
Welding.
Pinholes smaller than 1mm in diameter can be filled by
Painting.
 Overlap: The protrusion of weld metal beyond the weld toe. Overlap results from
incomplete melting of weld metal and base metal, and can be prevented by
manipulating electrode correctly at the proper welding current and speed.
➢ Undercut: A groove melted into the base metal adjacent to the weld toe and left

unfilled by weld metal. Undercut is apt to occur when the electrode angle
manipulation speed is improper, or when the welding current is too high.

B. Paint-Finish Inspection
1. Necessary items
(1) Colored sheets for reference, (may be supplied by the customer) Munsell scale.
(2) Manufacturing specifications or manufacturing drawing.
2. Inspection procedure
(1) Check the color against the colored sheet for reference.
(2) Check gloss.
3. Inspection points
(1) Check for complex or narrow areas that are often left unpainted, such as the
back of angles, corners and hardware.
 (2) Check carefully for rust in areas susceptible to rust development (ex.
Clearances between angle and iron plate and unweld surfaces in contact with
each other).
(3) The grounding plate and stainless steel wear plate must not be painted.
(4) Improve your knowledge in color and gloss inspection.

C. Appearance and Assembly Inspection

1. Necessary items
(1) Outline drawing.
(2) Nameplate drawing.
(3) Layout drawing
(4) Marker.
2. Inspection procedure
(1) Check the information on the nameplate and mark tube against those specified
on the latest nameplate drawing.
(2) Check the location of each measuring instrument and device against the layout
drawing.
(3) Check the color, size and other specification of the electric wire.
(4) Check specifications of each measuring instrument and device (model, range,
etc.).
(5) Pipelines and specifications.
3. Inspection points
(1) When checking the information on the nameplate, mark tube and tag affixed to
the measuring instrument, have a co-worker to help you.

D. Dimensional Inspection
1. Necessary items
(1) Scale
(2) Vernier calipers
(3) Outline drawing
2. Inspection procedure
(1) Measure dimensions to make sure they agree with those specified on the outline
drawing.
(2) Record the major outside dimensions and pipes fitting sizes after measuring
them. When multiple boards are connected together, measure and record the
sizes and locations of holes on the coupled surface.
 (3) Measure the following dimensions (which are not specified on the outline
drawing).

3. Inspection points
(1) Judge by referring to the dimensional tolerance table applicable to the job.
(2) Couple boards and channel bases as much as possible.
(3) A level or carpenter’s square may be helpful for checking the horizontals or
measuring tie-in sizes with external accessories.

II. Testing Procedure for Control Panels

A. Dielectric Strength Test
(Insulation-resistance measurement)
1. Necessary items
(1) Insulation-resistance tester. (DC 100V, 250V, 500V, 1000V)
(2) Dielectric-strength tester.
(3) Circuit diagram and exclusion item list.
(4) Thermometer and hygrometer.
(5) Insulating gloves.
(6) Voltage detector rod.
(7) Rotating lamp.
(8) Safety rope.
(9) Jumper cable and tools.
2. Test procedure
 (1) Prepare an exclusion item list.
(2) Connect jumper cable to the circuit to be tested to form a single circuit.
(3) Remove instruments and diode products noted on the exclusion item list.
(4) Connect the board’s ground wire to the ground wire at the site.
(5) Segregate the board to be tested using safety rope.
(6) Measure the temperature and humidity.
(7) Turn on the rotating lamp and put on insulating gloves.
(8) Measure resistance with the insulation resistance tester. (the higher the
resistance, the better)
(9) Let the residual voltage in the board dissipate into the ground.
(10) Set a tripping current for the dielectric strength tester.
(11) Activate the buzzer of the lamp.
(12) Measure voltage by applying AC 500V with the insulation resistance tester
(13) After voltage is measured, continue applying the test voltage for one minute.
(14) If no problem occurs, stop the buzzer of the rotating lamp, and let the
residual voltage escape into the ground.
(15) Measure insulation resistance after the withstand-voltage test.
(16) Turn off the rotating lamp, and put the items that have been removed back
into place.
3. Inspection points
(1) Certain wires are loosened because they are exclusion items; protect them in-
contact to the panel and ground wire
(2) Always measure insulation-resistance before and after withstand-voltage test.
(3) The insulation-strength tester has a dial that allows the tripping current to be
set. Set the correct tripping current for the board to be tested.
Instrumentation Rack = 3 mA
Control Board = 5 mA, 10 mA
Panel = 10 mA (137 mA max)
Caution: Use extreme care when using the maximum setting of 137 mA (to read
leakage current). This current is potentially fatal.
(4) When testing, button-up your sleeves and put on insulating gloves. Conducting
the test with rolled-up sleeves is strictly prohibited.
(5) When using the insulation-strength tester, take care not to mistake GND for
HV.
(6) If something is wrong, always check first to see whether an item was not
excluded that should have been. If all items that have been excluded correctly,
a problem solving shortcut is to test the circuit by dividing it into two parts.
4. Examples of insulation or withstand-voltage failures
(1) An insufficiency of exclusion items (instrument housing, graphic lamp, etc.).
(2) Too many live parts or tripping current is set to low.
(3) Terminal failure of the shielding wires.
(4) Poor soldering.
(5) The wire that is disconnected according to the exclusion item list is in contact
with the panel.
(6) The jumper wire is in contact with the panel, or too close to it. (Electric
discharged occurred because the jumper wire is closer to the silver mat)
(7) The instrument ground wire or fan ground wire is not disconnected.
 B. Simulation Test(Sequence Check)
1. Necessary items
(1) Simulation Board
(2) Simulation Cable
(3) Multimeter
(4) Power Supply Cable
(5) Marker
(6) Wiring Diagram
(7) Buzzer
(8) Jumper Wires
2. Test procedure
(1) Check in wiring diagram the power needed to supply all instruments, devices,
equipments, etc. in the control panel. Make sure that the input supply voltage is not
exceeded to the maximum rating of the instrument, devices, equipments, etc.
(2) Prepare the needed supply voltage by using power cables.
(3) Put a good grounding using grounding wires.
(4) By studying the wiring diagram, determine the number of simulation switches
and lamps needed.
(5) Prepare the simulation switches and lamps by using simulation boards and
simulation cable. Terminate the wiring in the terminal blocks of the control panel.
Termination in the PLC can be done if necessary.
(6) If power preparation is done already, let the power be on and using the
multimeter determine the voltage at the primary part of the circuit breaker based on the
wiring diagram.
(7) Using marker, highlight in the wiring diagram the part where you already
simulated. Write down the voltage reading in the wiring diagram
(8) After that, activate the breaker and check the voltage by using multimeter the
primary part of another breaker if they have and also the circuit protector.
(9) If there is a power supply in the wiring diagram, measure the output dc voltage
and write down it on the wiring diagram.
(10) After determining the voltages measured in the circuit break and circuit
protector, activates them one by one and check the devices, equipments, instruments, etc.
if they are also activated based on the wiring diagram. This includes the fan, heater, PLC,
industrial computer, lamps, indicators, etc.
(11) After that, simulation test can now be done.
(12) Using the simulation switches, activate them one at a time and see to it that
there is an output result in the control panel. This may include the indicators, relays,
lamps, DI part of the PLC depending on the design of the customer.
(13) Using a jumper wire, jumper the necessary part in the wiring diagram This
includes activating the relays, jumpering the contacts of the relays and DO part of the
PLC. See to it that there is an output results. This includes the simulation lamps,
indicators, relays, control panel lamps, etc. depending also on the design of the customer
.
3. Inspection points
(1) Make sure that all simulation boards and cables, power cables and jumper
wires are in good condition.
 (2) Determine the maximum output voltage of the equipments, devices,
instruments of the control panel. It must not be lower than the desire voltage input require
in the control panel.
(3) Check the color of the lamps when activating based on the wiring diagram/

III. Testing Procedure for Sampling Racks

A. Pneumatic Pressure Test (Pressure-leak test)
1. Necessary Items
(1) Drawings, and Tests and Inspection Procedures
(2) Pressure gauge, pressure jigs
(3) Tools, rags, snoop
(4) Maximum pressure list
(5) Instrumentation air, nitrogen gas cylinder
2. Test procedure
(1) Understand the design pressure, test pressure, pressure time and maximum
pressure by reviewing the drawings. Test and inspection procedures and
maximum pressure list.

(2) Attach a pressure gauge graduated over a range of two times the intended
test pressure.

(3) Make duration that all valves in the board are opened or closed properly.
Pay special attention to the instrument lines.
(4) Gradually increase pressure up to the test pressure.
(5) Sweep all joints with a snoop and maintain pressure for the duration of the
test interval.
(6) The test is acceptable if no joints leak and the pressure gauge indication
does not drop after the test interval concludes.
3. Inspection points
(1) Use a pressure gauge graduated over a range of two times the intended test
pressure
(2) For jig packing, neoprene rubber packing is recommended for pressure from
0 to 30 kg/cm²; Teflon packing for more than 30 kg/cm². Neoprene rubber is
apt to break under excessive torque.
(3) Keep the equalizing valves (including the three-way valve) open at all times.
(4) If leaks are difficult to locate, separate lines by operating the valves.
 4. Difficult-to-locate leaks
(1) T-joint

(2) Valve glands

(3) Asbestos packing
(4) Sealing tape
(5) Improperly assembled safety valve
(6) Non-bleeding pressure reduction valve
(7) Jig
(8) Difficult-to-tighten joints
(9) Filter drain
B. Hydrostatic Pressure Test (Pressure-leak test)
1. Necessary items
(1) Drawings, Test and Inspection Procedure
(2) Pressure gauge, blind flanges, packing
(3) Tools, rags, bucket
(4) Maximum pressure list
(5) Hydraulic pump
2. Test procedure
(1) Repeat steps (1) to (3) from the pneumatic-pressure test procedures.
(2) Make sure the pneumatic-pressure test has completed satisfactorily before
starting the hydrostatic pressure test. The relationship between hydrostatic
pressure and pneumatic pressure are as follows:
Hydrostatic Pressure Pneumatic Pressure
10 kg/cm² & lower Test pressure
10-50 kg/cm² 10 kg/cm²
50 kg/cm² & higher 20-30 kg/cm²
(3) After the pneumatic-pressure test has been successfully concluded, start the
hydrostatic pressure test.
(4) Apply hydrostatic pressure of 2 to 5 kg/cm² to all lines with a hydraulic pump,
and completely drain air from the test valve and the blind flanges connected to
external accessories. Air is completely drained if the sound of air escaping can
no longer be heard. Use a bucket and rags during the drainage process.
(5) Increase pressure to the test-pressure level.
(6) Drain air from each valve spindle by operating the valve. (Take care. Both
low-pressure and high-pressure drainage must be performed)
(7) After air is completely drained from the handle, increase pressure to the test-
pressure level again, and maintain for the given interval.
(8) The test is acceptable if no pressure drop occurs after the given interval has
elapsed.
3. Inspection points
(1) Keep drops of water off the floor surface and test board.
(2) Drain air from the handle at each test pressure. (In cases where test pressure is
applied in three steps: 20 kg/cm² - 50 kg/cm² - 80 kg/cm²)
(3) To drain air from the handle, always turn the handle clockwise (to close).
(4) Hydrostatic pressure is more affected by changes in temperature than
pneumatic pressure. Perform the hydrostatic-pressure test in the morning.
Ex. A rack was tested with 100 kg/cm² in summertime. Pressure increased to
106 kg/cm² by the end of test interval.