Office Buildings 12 B02 & 12 B03

METHOD STATEMENT: Method Statement for Ref Rev 00

Testing & Commissioning of low voltage equipment Date 9-11-2020 Page 1 of 40

METHOD STATEMENT FOR Testing & Commissioning

OF LOW VOLTAGE EQUIPMENT
 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

Objective

The purpose of these specifications is to assure that all installed Low voltage switchgear and
equipment system supplied by SEE (SCHNEIDER ELECTRIC EGYPT & NEA) are operational
and within applicable standards and design specifications.

This document lists all site tests available for assessing the suitability for service and reliability
of the Low voltage equipment system.

As a further note, it is important to follow the recommendations contained in the manufacturer’s

instruction manuals. Many of details of complete and effective acceptance testing procedure
could be obtained only from this manual.

This procedure details must be conducted during installation, commissioning and startup.
Schneider-Electric safety regulations should be followed.

These inspections and tests procedures are listed all site tests which are necessary to be done
on Low voltage, during and after installation or repair or prior to energizing, in order to confirm
that:

1. The equipment has not been damaged during shipment or installation.

2. The equipment is compliance with design intent.
3. Documented test records that can serve as benchmarks for future tests.

Application Prepared/ Approved

Index Description Modification reason
Date Modified by by
LV- Site Inspections, Testing and 01-Aug-15 Mahmoud Lotfy Osama • Creation of the procedure.
TP-01 Commissioning Procedures Elreweny
For L.V Equipment
LV- Site Inspections, Testing and 27-Dec-17 Sherif AbdelShafy Osama • Linking applicable test
TP-02 Commissioning Procedures Elreweny sheets to the procedure.
For L.V Equipment • Updating IEC standard
references codes.
LV- Site Inspections, Testing and 03-06-2018 Ahmed Adel Osama • Edit safety precautions of
TP-03 Commissioning Procedures Elreweny testing inspection of low
For L.V Equipment voltage components
 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

Contents
1. Scope .................................................................................................................................................................3

2. Safety precautions of testing and inspection of Low Voltage Components:...........................................3

3. References........................................................................................................................................................3

4. Low Voltage Equipment ..................................................................................................................................4

4.1 L.V Switchboard ...........................................................................................................................................4

4.2 LV Circuit Breakers:.....................................................................................................................................7

4.3 Capacitors (Power Factor Correction) ......................................................................................................9

4.4 LV Motor Starter & Power feeders: ........................................................................................................ 11

4.5 DC system.................................................................................................................................................. 13

4.6 Interposing Relay Panel ........................................................................................................................... 13

4.7 Active Harmonic Filter (AHF): ................................................................................................................. 14

4.8 Neutral Earthing Resistor (NER): ........................................................................................................... 15

4.9 AC/DC Power distribution boards: ......................................................................................................... 15

4.10 Protection Relay Testing and commissioning ...................................................................................... 16

5. APPENDIX A: List of tables: ....................................................................................................................... 17

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 2 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

1. Scope
Schneider Low voltage switchgear or equipment for rated voltage up to 1000 V that is supplied
and installed by Schneider Electric Egypt

2. Safety precautions of testing and inspection of Low Voltage Components:

1- Complete the safety documents “Risk Assessment, LOTO checklist & written work permit”
to identify site hazards and control measures before starting work.
2- Ensure safe manual handling of Low voltage components and use “mechanical gloves”
while handling sharp edges.
3- Ensure that you are working in safe site condition with good ventilation and sufficient
lighting.
4- Avoid working while other contractors are working above your working area to avoid fall
of object that may cause injury to Schneider’s employee or damage to equipment.
5- During insulation resistance test, Dielectric test and phase sequence test: Never touch
the test piece body till ensuring the disconnection of power of electrical testing equipment
(e.g.: Megger) using appropriate PPE.
6- Ensure that you are using the electrical testing equipment in a safe position.
7- Use appropriate Personal Protective Equipment (PPE) such as: Helmet, electrical
insulated gloves, mechanical gloves, safety shoes, safety glasses, ear plug, dust mask,
full body harness, arc rated face shield, arc rated coverall, …. etc.) and any other PPE
required according to site condition.
8- Use arc flash PPE in energizing the switchgear by qualified persons only and keep others
away from working area.
9- Ensure that the site condition is safe and if it is not safe, don’t do it.

3. References

IEC 60364 Low-voltage electrical installations

IEC 60947 Low-voltage switchgear and control gear

IEC 61439 Low-voltage switchgear and control gear assemblies

IEC 61921 Power capacitors - Low-voltage power factor correction banks

Installation manual of Schneider L.V products

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 3 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

4. Low Voltage Equipment

4.1 L.V Switchboard
4.1.1 Used Test sheet and/or check list:
Checklist for Visual & Mechanical inspection for LV switchgear [LV_CK_1].
Functional operational checks for LV switchgear [LV_CK_2].
Torque wrench verification test sheet [LV-MV_TS_8].
Insulation resistance test sheet [LV_TS_1].
Dielectric test sheet for low voltage [LV_TS_2].
Trip units’ test sheet for LV circuit breakers [LV_TS_3].

4.1.2 Pre-Commissioning visual & mechanical inspection:

1. Verify that equipment name plates are according to the corresponding drawings.
2. Inspect physical and mechanical condition of the equipment and all components for clear
damage.
3. Verify appropriate anchorage, required area clearances, physical damage, and correct
alignment and cleanliness.
4. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware.
5. Verify that the barriers and covers are installed correctly.
6. Verify that filters are in place and all ventilation openings are clear from any kind of obstacles.
7. Verify that main bus bar is connected between the cells.
8. Verify that the earth bars are connected between the cells and connected to the earth.
9. Verify the tightness of accessible bolted electrical connections using the calibrated torque-
wrench method in accordance Table 1.
10. Confirm that lubricants have been correctly applied at the recommended locations.
11. Inspect all mechanical indicating devices for correct operation.
12. Verify that draw out disconnecting contacts and interlocks function correctly.
13. Verify that fuse and/or circuit breaker size and type correspond to drawings.
14. Verify that current and potential transformer ratios correspond to drawings.
15. Verify that all the interconnection control wires between the cells have been made correctly
reference to the control drawings
16. Verify that customer connections to remote power, operators, interlocks, and indicators have
been made.

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 4 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

4.1.3 Commissioning:
1. Check the availability of the required auxiliary supply for control operation.
2. Check the phase sequence of the incoming cables using phase sequence device on the
secondary connection of the potential transformer.
3. Perform a control wiring performance test by applying control voltage and Verify that the
equipment operates as intended.
4. Test protective relays in accordance with “Section 3.10—Protective Relays” if found.
5. Perform function operation test to prove correct interaction of all sensing, processing and
protecting devices also proves that the control/auxiliary supply is connected properly and alarms
and indications are appearing correctly.
6. Perform functional interlock test to prove the proper operation and indications of interlock
scheme (electrical / mechanical)
7. Test the anti-condensation heaters by connecting the power supply and measure the consumed
current using clamp meter and check the settings of the thermostat.
8. Check ventilation fans operation.
9. Perform insulation-resistance tests (Megger Test) on each bus section, phase-to-phase and
phase-to-ground, at the DC test voltage appropriate for the equipment’s Maximum Rated
Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the
recommended values in Table 2, visually inspect the equipment for cleanliness and other
potential causes. If the visual inspection does not reveal the causes, clean the equipment well,
then re- measure. If cleaning does not reveal the causes, dry the equipment for a minimum of 4
hours using heat and fans. Then re-measure.
10. A power-frequency withstand test voltage value according to table 3 shall be performed on all
circuits for a duration of 1s in accordance to the following:
a- Between each pole of the main circuit and, the other poles and the earthed enclosure
connected together.
b- Between all the poles of the main circuit connected together and the earthed enclosure.
*When performing dielectric tests, all Instrument and Control Transformers, Arresters, TVSS
units, and other sensitive electronic equipment that may cause erroneous results or cause
damage to equipment shall be isolated before the test and put back in place after completing
the test.
*Megger test to be done before and after the Dielectric test.

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 5 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

* An alternative for assemblies with incoming protection rated up to 250A the verification of
insulation resistance will be measured and enough using insulation measuring device at voltage
at least 500 V d.c

*Dielectric Test not to be made at auxiliary circuits which are protected by a short circuit
protective device with a rating not exceeding 16 A.

*Test voltage at site shall be 80% of the values indicated in table 3

4.1.4 Pre-Energization Checks:

1. Check that Panels has been appropriately cleaned.
2. Check that lubricants have been applied to the recommended places.
3. Check that barriers and covers are installed in its place.
4. Check that fuses are installed correctly.
5. Incoming cables to the switchgear are connected with the right phase sequence.
6. Use Inspection Camera to inspect the bus bar compartment, any parts difficult to reach or
unreachable parts of the switchgear to be sure that everything is in correct position.
7. Check that all hand tools are complete and nothing is missing inside the switchgear.
8. Megger test has been performed successfully.

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 6 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

4.2 LV Circuit Breakers:

4.2.1 Used Test sheet and/or check list:
Torque wrench verification test sheet [LV-MV_TS_8].
Insulation resistance test sheet [LV_TS_1].
Trip units’ test sheet for LV circuit breakers [LV_TS_3].

4.2.2 Insulated Case / Molded Case C.B:

4.2.2.1 Pre-Commissioning visual & mechanical inspection:
1. Inspect circuit breaker for correct mounting.
2. Operate circuit breaker to insure smooth operation.
3. Inspect case for cracks or other defects.
4. Verify tightness of accessible bolted connections and/or cable Connections by calibrated torque-
wrench method in accordance with Table 1.
5. Verify that trip units, shunt trip coils, auxiliary contacts and all other accessories are in
accordance with the drawings.
6. Exercise the push to trip button to verify trip and reset.
7. If the circuit breaker contains a MICROLOGIC™ trip unit, perform the following inspections:
• Verify that the breaker is equipped with the correct rating plugs and current sensors.
• Verify that the breaker has the specified trip unit, LI, LS, LSI, and LSIG.
• Verify that the breaker has the specified accessories, such as Auxiliary Contacts,
Cell Switches, Shunt Trip Devices, and under voltage Release.
8. If it is a withdrawable ( MASTERPACT®) circuit breaker, perform the following inspections:
• Confirm that lubricants have been correctly applied at the recommended locations.
• Inspect anchorage, alignment, and grounding.
• Inspect moving and stationary contacts for condition and alignment.
• Check the racking mechanism.

4.2.2.2 Commissioning:
1. Verify trip and close functions.
2. Trip the circuit breaker by operating protective device (if found).
3. Make adjustments for the final settings in accordance with the customer requirements.
4. Perform insulation-resistance tests on each bus section, phase-to-phase and phase-to-ground,
at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 7 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

with Table 2. Record the resistances. If the resistance is lower than the recommended values in
Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual
inspection does not reveal the causes, dry the equipment for a minimum of 4 hours using heat
and fans. Then re-measure (that is done as part of switchgear Megger test).
Note: Megger test will be performed along with the switchgear (As a part of the switchgear at
the same time unless the C.B is supplied separately or as spare)

4.2.3 Low Voltage Power (Air C.B):

4.2.3.1 Pre-Commissioning visual & mechanical inspection:
1. Inspect circuit breaker for correct mounting.
2. Operate circuit breaker to insure smooth operation.
3. Verify that trip units, shunt trip coils, auxiliary contacts and all other accessories are in
accordance with the job specifications.
4. If the circuit breaker contains a MICROLOGIC™ trip unit, perform the following inspections:
• Verify that the breaker is equipped with the correct rating plugs and current sensors.
• Verify that the breaker has the specified trip unit, LI, LS, LSI, and LSIG.
• Verify that the breaker has the specified accessories, such as Auxiliary Contacts,
Cell Switches, Shunt Trip Devices, and under voltage Release.
5. If it is a withdrawable MASTERPACT® circuit breaker, perform the following inspections:
• Confirm that lubricants have been correctly applied at the recommended locations.
• Inspect anchorage, alignment, and grounding. Inspect arc chutes.
• Inspect moving and stationary contacts for condition and alignment.
• Check the racking mechanism.

4.2.3.2 Commissioning:
1. Perform insulation-resistance tests on each bus section, phase-to-phase and phase-to-ground,
at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance
with Table 2. Record the resistances. If the resistance is lower than the recommended values in
Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual
inspection does not reveal the causes, dry the equipment for a minimum of 4 hours using heat
and fans. Then re-measure.
2. Verify trip, close, trip-free, and anti-pump functions.
3. Trip the circuit breaker by operating protective device.

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 8 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

4. Adjust the final settings in accordance with the customer requirements.

Note: Megger test will be performed along with the switchgear (As a part of the switchgear at
the same time unless the C.B is supplied separately or as spare)

4.3 Capacitors (Power Factor Correction)

4.3.1 Used Test sheet and/or check list:
Torque wrench verification test sheet [LV-MV_TS_8].
Insulation resistance test sheet [LV_TS_1].
Visual & Mechanical inspection of LV Cap bank [LV_CK_3].
Capacitor bank test sheet [LV_TS_4]

4.3.2 Pre-Commissioning visual & mechanical inspection:

1. Verify that the equipment nameplate ratings are in accordance with the drawings.
2. Verify appropriate anchorage, fixation, required area clearances, physical damage, and correct
alignment and cleanliness.
3. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware.
4. Inspect the physical and mechanical condition of the equipment
5. Verify that bus bar connections are connected properly.
6. Verify that earth bars connect between the cells if any.
7. Verify that filters are in place and all ventilation openings are clear from any kind of obstacles.
8. Verify the tightness of accessible bolted electrical connections using the calibrated torque-
wrench method in accordance Table 1
9. Inspect all mechanical indicating devices for correct operation.
10. Verify that all protection and measuring devices are corresponding to drawings.
11. Verify that fuse and/or circuit breaker or contactor sizes and types are corresponding to
drawings
12. Verify that current and potential transformer ratios are corresponding to drawings.
13. Verify regulator connection (current, voltage and earthing) as per drawings.
14. Verify that all the interconnection control wires between the cells have been made correctly
referred to the control drawings (If any).
15. Verify that capacitors are electrically connected in their specified configuration as per the
drawings.

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 9 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

16. Verify that customer connections to remote power, operators, interlocks, and indicators have
been made.

4.3.3 Commissioning:
1. Check the availability of the required auxiliary supply for control operation.
2. Test the anti-condensation heaters by connecting the power supply and measure the consumed
current using clamp meter and check the settings of the thermostat.
3. Check ventilation fans operation.
4. Perform insulation-resistance tests on each bus section, phase-to-phase and phase-to-ground,
at the DC test voltage appropriate for the equipment’s Maximum Rated Voltage in accordance
with Table 2. Record the resistances. If the resistance is lower than the recommended values in
Table 2, visually inspect the equipment for cleanliness and other potential causes. If the visual
inspection does not reveal the causes, dry the equipment for a minimum of 4 hours using heat
and fans. Then re-measure
5. Apply the settings of the regulator as per the drawings (steps), measure and record the steps
value (µf) for each phase and record the regulator data as well.
6. Perform function operation test for C.B/Contactors, Remote operation, protection, alarms and
tripping indications.
7. Check the phase sequence of the incoming cables using phase sequence device on the
secondary connection of the potential transformer.

4.3.4 Pre-Energization Checks:

1. Check that Panels has been appropriately cleaned.
2. Check that lubricants have been applied to the recommended places.
3. Check that barriers and covers are installed in its place.
4. Check that fuses are installed correctly.
5. Incoming cables to the panels are connected with the right phase sequence.
6. Use Inspection Camera to inspect the bus bar compartment, any parts difficult to reach or
unreachable parts of the switchgear to be sure that everything is in correct position.
7. Check that all hand tools are complete and nothing is missing inside the switchgear.
8. Megger test has been performed successfully.

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 10 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

4.4 LV Motor Starter & Power feeders:

4.4.1 Pre-Commissioning visual & mechanical inspection:
1. Verify that equipment name plates are according to the corresponding drawings.
2. Inspect physical and mechanical condition of the equipment and all components for clear
damage.
3. Verify appropriate anchorage, required area clearances, physical damage, and correct
alignment and cleanliness.
4. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware.
5. Verify that the barriers and covers are installed correctly.
6. Verify that filters are in place and all ventilation openings are clear from any kind of obstacles.
7. Verify that main bus bar is connected between the cells.
8. Verify that the earth bar is connected between the cells and connected to the earth.
9. Verify the tightness of accessible bolted electrical connections using the calibrated torque-
wrench method in accordance Table 1
10. Confirm that lubricants have been correctly applied at the recommended locations.
11. Inspect all mechanical indicating devices for correct operation.
12. Verify that draw out disconnecting contacts and interlocks function correctly.
13. Verify that fuse and/or circuit breaker sizes and types correspond to drawings.
14. Verify that current and potential transformer ratios correspond to drawings.
15. Verify that all the interconnection control wires between the cells have been made correctly
reference to the control drawings
16. Verify that customer connections to remote power, operators, interlocks, and indicators have
been made.

4.4.2 Commissioning:
1. Check the availability of the required auxiliary supply for control operation.
2. Check the phase sequence of the incoming cables using phase sequence device on the
secondary connection of the potential transformer.
3. Perform a control wiring performance test by applying control voltage and Verify that the
equipment operates as intended.
4. Test protective relays in accordance with “Section 3.10—Protective Relays” if found.

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 11 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

5. Perform function operation test to prove correct interaction of all sensing, processing and
protecting devices also proves that the control/auxiliary supply is connected properly and alarms
and indications are appearing correctly.
6. Perform functional interlock test to prove the proper operation and indications of interlock
scheme (electrical / mechanical)
7. Test the anti-condensation heaters by connecting the power supply and measure the consumed
current using clamp meter and check the settings of the thermostat.
8. Check ventilation fans operation.
9. Perform insulation-resistance tests (Megger Test) on each bus section, phase-to-phase and
phase-to-ground, at the DC test voltage appropriate for the equipment’s Maximum Rated
Voltage in accordance with Table 2. Record the resistances. If the resistance is lower than the
recommended values in Table 2, visually inspect the equipment for cleanliness and other
potential causes. If the visual inspection does not reveal the causes, clean the equipment well,
then re- measure. If cleaning does not reveal the causes, dry the equipment for a minimum of 4
hours using heat and fans. Then re-measure.

4.4.3 Pre-Energization Checks:

1. Check that Panels has been appropriately cleaned
2. Check that lubricants have been applied to the recommended places.
3. Check that barriers and covers are installed in its place.
4. Check that fuses are installed correctly.
5. Incoming cables to the switchgear are connected with the right phase sequence.
6. Megger test has been performed successfully

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 12 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

4.5 DC system
4.5.1 Pre-Commissioning visual & mechanical inspection:
1. Inspect the physical and mechanical condition of the equipment.
2. Verify the tightness of accessible bolted electrical connections using the calibrated torque-
wrench method in accordance Table 1
3. Verify correct charger/ battery rack grounding.
4. Verify the operation of the charger’s cooling fans

4.5.2 Commissioning:
1. Verify that all charger functions and alarms are operating properly:
• Switching between automatic and manual modes
• Switching between floating and charge modes – Manual
• Switching between floating and charge modes - Automatic
• Manual operation (boost charge).
• Verify the operation of alarms.

4.6 Interposing Relay Panel

4.6.1 Pre-Commissioning visual & mechanical inspection:
1. Verify that equipment name plates are according to the corresponding drawings.
2. Inspect physical and mechanical condition of the equipment and all components for clear
damage.
3. Verify appropriate anchorage, required area clearances, physical damage, and correct
alignment and cleanliness.
4. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware.
5. Verify that the earth bar is connected between the cells and connected to the earth (if found).
6. Verify that all the interconnection control wires between the cells have been made correctly
reference to the control drawings (If any)
7. Verify that customer connections to remote power, operators, and indicators have been made.

4.6.2 Commissioning:
1. Check the availability of the required auxiliary supply for control operation.
2. Test the anti-condensation heaters by connecting the power supply and measure the consumed
current using clamp meter and check the settings of the thermostat.
3. Check that ventilation Fans are working properly.

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 13 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

4. Perform insulation-resistance tests (Megger Test) at the DC test voltage appropriate for control
wiring in accordance with Table 2.

4.7 Active Harmonic Filter (AHF):

4.7.1 Pre-Commissioning visual & mechanical inspection:
1. Verify that equipment name plates are according to the corresponding drawings.
2. Inspect physical and mechanical condition of the equipment and all components for clear
damage.
3. Verify appropriate anchorage, required area clearances, physical damage, and correct
alignment and cleanliness.
4. Inspect all doors and sections for paint, dents, scratches, fit, and missing hardware.
5. Verify that the earth bar is connected to the earth (if found).
6. Verify that all the interconnection control wires between the cells have been made correctly
reference to the control drawings (If any).
7. Verify that customer connections to remote power, operators, and indicators have been made.

4.7.2 Commissioning:
1. Check the availability of the required auxiliary supply for control operation.
2. Test the anti-condensation heaters by connecting the power supply and measure the consumed
current using clamp meter and check the settings of the thermostat.
3. Check that ventilation Fans are working properly.
4. Perform function operation test to prove correct interaction of all sensing, processing and
protecting devices also proves that the control/auxiliary supply is connected properly and alarms
and indications are appearing correctly.
5. Apply the required settings/ratings for the AHF.

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 14 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

4.8 Neutral Earthing Resistor (NER):

4.8.1 Pre-Commissioning visual & mechanical inspection:
1. Verify that equipment name plate is according to the corresponding drawings.
2. Inspect physical and mechanical condition of the equipment and all components for clear
damage.
3. Verify appropriate anchorage, required area clearances, physical damage, and correct
alignment and cleanliness.
4. Verify that the connection of the resistor is as per the attached drawings.
5. Verify that customer connections to voltage terminal blocks are as per the attached drawings.

4.8.2 Commissioning:
1. Check the availability of the required auxiliary supply for heater.
2. Test the anti-condensation heater by connecting the power supply and measure the consumed
current using clamp meter and check the settings of the thermostat.
3. Perform insulation-resistance tests at the DC test voltage appropriate for the equipment’s
Maximum Rated Voltage in accordance with Table 2. Record the resistances. If the resistance is
lower than the recommended values in Table 2, visually inspect the equipment for cleanliness
and other potential causes. If the visual inspection does not reveal the causes, dry the
equipment for a minimum of 4 hours using heat and fans. Then re-measure.

4.9 AC/DC Power distribution boards:

4.9.1 Pre-Commissioning visual & mechanical inspection:
1. Verify that equipment name plate is according to the corresponding drawings.
2. Verify that ratings and arrangement of inside components is according to the corresponding
drawings.
3. Inspect physical and mechanical condition of the equipment and all components for clear
damage.
4. Verify appropriate anchorage, required area clearances, physical damage, and correct
alignment and cleanliness.

4.9.2 Commissioning:
1. Make sure that incoming cables are connected correctly.
2. Make sure that covers are installed again after all cable works has been finished.
3. Make sure that setting for the MCCB has been applied if applicable.

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 15 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

4.10 Protection Relay Testing and commissioning

4.10.1 Visual Test
Procedures:
1- Inspect the physical, electrical, and mechanical condition of the equipment for any damage.
2- Verify that protection relay name plate matches the drawings (I/O module, RTD module,
Communication module …).
3- Tighten accessible wires and verify correct connection as per the drawings.
4.10.2 Functional test and secondary injection test
Procedures:
1- Inspect Outputs and indicators for correct operation according to protection relay control
matrix included in the drawings or in the relay coordination study.
2- Control and protection setting verification: verify that each relay contacts performs its
intended function in the control scheme, including breaker trip tests; close inhibit tests, 86
lockout tests, and alarm functions using secondary injection test kit.
3- Verify that all pickup/dropout parameters are on each operating element.
Notice:
1. The approved relay setting to submit to Schneider representative and commissioning
to be done on theses settings.

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 16 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

5. APPENDIX A: List of tables:

Table 1: Standard Bolt Torques for Bus and Cable Connections

(‫ ﻛﻬﺭﺑﺎء‬/ ‫ﺍﻟﺭﺑﺎﻁ ﺍﻟﻌﺎﻡ )ﻣﻳﻛﺎﻧﻳﻛﺎ‬

General mechanical & electrical assembly (N.m)

Bolt Hex.nut + contact Flanged nut Nylstop lock nut + Hex.nut + Flat
Size or picot washer with teeth contact or picot or split washer
used with washers
steel

‫ﻣﻘﺎﺱ‬ + ‫ﺻﺎﻣﻭﻟﺔ ﻣﺳﺩﺳﺔ ﻋﺎﺩﻳﺔ‬ ‫ﺻﺎﻣﻭﻟﺔ ﺑﻭﺭﺩﺓ‬ ‫ ﻭﺭﺩﺓ‬+ ‫ﺻﺎﻣﻭﻟﺔ ﻛﻭﻧﺗﺭ‬ ‫ﺻﺎﻣﻭﻟﺔ ﻣﺳﺩﺳﺔ‬
‫ﺍﻟﻣﺳﻣﺎﺭ‬ ‫ﻭﺭﺩﺓ ﻛﻭﻧﺗﺎﻛﺕ ﺍﻭ ﺷﻭﻛﺔ‬ ‫ﻣﺭﻭﺣﻳﺔ ﺗﺭﺑﻁ‬ ‫ﻛﻭﻧﺗﺎﻛﺕ ﺍﻭ ﺷﻭﻛﺔ‬ ‫ ﻭﺭﺩﺓ ﻣﺳﺢ‬+ ‫ﻋﺎﺩﻳﺔ‬
‫ﻋﻠﻰ ﺍﻟﺻﻠﺏ‬ ‫ﺍﻭ ﺷﻖ‬

M5 7 8 7.5 5

M6 13 13.5 14.5 8.5

M8 28 25 31 19

M 10 50 50 54 37.5

M 12 75 79 83 62

M 14 120 125 132 98

M 16 185 180 200 155

M 18 260 270 280 210

M 20 370 390 410 290

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 17 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

Table 2: Insulation-Resistance Test Voltage for Electrical Apparatus and Systems

Recommended Minimum
Minimum DC Test
Voltage Rating Insulation Resistance In Duration
Voltage
Megaohms

0 - 250 500 50 60 SEC

251 - 600 1000 100 60 SEC

601 - 5,000 2500 1000 60 SEC

5,001 - 8,000 2500 2000 60 SEC

8,001 - 15,000 2500 5000 60 SEC

15,001 - 25,000 5000 20000 60 SEC

25,001 - 69,000 15000 100000 60 SEC

Actual test results are dependent on the length of the conductor being tested, the temperature
of the insulating material, and the humidity of the surrounding environment at the time of the
test. In addition, insulation resistance tests are performed to establish a trending pattern and a
deviation from the baseline information obtained during maintenance testing enabling the
evaluation of the insulation for confined use.

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 18 of 19

 Site Inspections, Testing and REV: LV-TP-03
Commissioning Procedures Issue date: 01-August-2015
For L.V Equipment Total Pages: 19

Table 3: Power frequency withstand voltage for main circuits of the L.V

Schneider Electric Egypt-Projects & Services Execution Division-Field Operations Page 19 of 19

 Factory Acceptance Test Program
Low Voltage Switchgears

Revision Date Prepared by Checked by Approved by Modification

0 30‐Jan‐2018 Abdelrahman Orabi Mohamed Elsayed Mohamed Anany

Page 1 of 21
Project Description

:
Client
:
Project Name
:
Order Number
:
Item Number
:
Equipment
:
Quantity

Page 2 of 21
Table of Content:

Project Description: Page 2

Table of Content: Page 3

Introduction: Page 4

FAT Plan and Scope of FAT: Page 5‐6

FAT Procedures: Page 7‐14

FAT Documents (Test Sheet): Page 15‐21

Page 3 of 21
 1. INTRODUCTION

Working Location FAT (Factory Acceptance Test) shall be conducted by Badr testing team
and witnessed by Customer / End User representative(s). The test
procedure is applicable for routine testing of equipment at Schneider
Electric Badr Plant.

Safety & Risks To Control Risks During FAT, the following arrangement shall be done:

 All participants must have a safety induction and wear PPE.

 Dangers signs will be displayed to warm people who approach the
FAT Area.
 Red color flashing, warning lights will be displayed during supply of
power to the Panels under test.
 Safety tools will be placed for emergency usage in the FAT area.
 First aid box will be provided near the test area.
 keep a proper distance from energized parts during testing.
 Don't touch or deal with product unless authorized by testing
team.

Quality Assurance Routine tests are systematically carried out on our material, according to
our quality system which is qualified by certified body, ISO9001. Each
project is rigorously inspected according to the instructions and procedures
of the quality system. We propose to realize in your presence a part or all
inspections described in this document.

Routine tests occur at various stage and times during assembly (not
practical to be witnessed by a third party) and FAT is considered as
replication of part from routine tests Excluding the supplier tested
component as it supplied tested with a testing certificate or tests that
required special tools / need longer time for preparation that affects the
efficiency of FAT.

Test Condition Panels are presented as they are arranged in the switchboard as per
approved drawing as much as possible, they are not physically assembled
and not bolted together.

For testing them in their installation configuration, the frame earthing

between panels is connected by flexible connections, and inter‐panels L.V.
connections are all connected. main busbars are simulated by temporary
connection.

Page 4 of 21
 2. FAT Plan and Scope of FAT:

FAT Plan

No of FAT Days Per Item 1 Working Days

Scope of % of Test
INSPECTION AND TEST REQUIRED
FAT Cells
A. GENERAL VISUAL INSPECTION*
1. Presentation and labels Yes Sample
2. Rated Voltage Yes Sample
3. Busbar Rating & Conformity. Yes Sample
4. Short Circuit Level (KA). Yes Sample
5. Degree of Protection (IP). Yes Sample
B. ELECTRICAL TEST*
1. Functional Test. Yes Sample
2. Protection Relay & Metering Test. Yes Sample
3. CT / VT Polarity & Turns Ratio Test. Yes Sample
4. Dielectric Test on the Main Circuit. Yes Sample
C. MECHANICAL TEST*
1. Mechanical Functional Test. Yes Sample
2. Mechanical Interlocking. Yes Sample
D. DOCUMENTATION
1. Internal Test Report. Yes Review
2. Supplier Certificates. Yes Review
3. Testing Tools Calibration Certificate. Yes Review
4. FAT Test Report Yes Review
E. OPTIONAL ON‐DEMAND TESTS
1. Insulation Resistance Test on the Control Circuit. No Sample
2. Dielectric Test on the Control Circuit. No Sample
3. Insulation Resistance Test on the Main Ckt. No Sample

* For details please see section of “FAT Procedures”.

Page 5 of 21
 3. Notes on Scope of FAT:

3.1 Optional On demand tests are considered out of FAT scope and extra cost to be charged if
customer require any of it and subjected to change deliver date.

3.2 Any special test that been required from customer and it isn’t mention on that document should be
submitted before FAT date by minimum one Week to study it is applicability to be performed
during FAT. Extra cost to be charged and subjected to change deliver date.

3.3 Samples are based on the below Sampling criteria

According to AQL Table

Normal Inspection
(Level II)
Lot Size Sample Size
2 to 8 2
9 to15 3
16 to 25 5
26 to 50 8
> 50 8
*If customer required additional samples, Extra cost to be charged and subjected to change deliver date.

3.4 All Documentations to be submitted During FAT or After One WEEK by Maximum.

Page 6 of 21
 4. FAT Test Procedures:

4.1 GENERAL VISUAL INSPECTION

4.1.1 Presentation and labels:

Procedure Standard Tools Acceptance Criteria

Labels spelling Approved drawing Visual Conformity

Labels sticking Visual Visual Conformity
Wiring arrangement Visual Visual Conformity
Lay out of components Approved drawing Visual Conformity
Identification label Approved drawing Visual Conformity
Painting and Scratches Visual Visual Conformity
Cleanness Visual Visual Conformity
Assembly of the panel Visual Visual Conformity

4.1.2 Rated Voltage:

Procedure Standard Tools Acceptance Criteria

Confirm that the rated voltage of the equipment is as

Approved Drawing Visual Conformity
that mentioned in the Approved drawing.

4.1.3 Busbar Rating & Conformity.

Procedure Standard Tools Acceptance Criteria

Confirm that the rated current of the bus bar is as that

Approved Drawing Visual Conformity
mentioned in the Approved drawing.
Check the clearance distance between phases and Technical guide
Manual + Meter tape Conformity
earth and the distance between supports. Approved drawing

4.1.4 Short Circuit Level (KA).

Procedure Standard Tools Acceptance Criteria

Confirm that the short circuit level of the equipment is

Product catalogue
as that mentioned in the Approved drawing and the Visual Conformity
Approved drawing
installed products are established that level

Page 7 of 21
 4.1.5 Degree of Protection (IP).

Procedure Standard Tools Acceptance Criteria

Check IP according to enclosures and cubicles IEC 60529

Visual Conformity
catalogues. Approved Drawing

Page 8 of 21
 4.2 Electrical Tests

4.2.1 Electrical Function Test.

4.2.1.1 Electrical Operation.

Procedure Standard Tools Acceptance Criteria

Check the indication lamps Approved drawing Power supply Conformity

Check the operation of the auxiliaries Approved drawing Power supply Conformity

Check the operation of circuit breaker Approved drawing Power supply Conformity

As per sequence of
Check the automatism operation according to the
Approved drawing Power supply operation and timers
sequence of operation
delay

Check the phase continuity Approved drawing Power supply Conformity

Check Electrical Interlock according to the sequence of

Approved drawing Power supply Conformity
operation in drawing

4.2.1.2 Signaling.

Procedure Standard Tools Acceptance Criteria

Check any Remote Signals Approved drawing Buzzer Conformity

Check the signal of any sensors. Approved drawing Power supply Conformity

4.2.1.3 Heater.

Procedure Standard Tools Acceptance Criteria

Supply the proper voltage to the heater and check the

Approved drawing Power supply Conformity
operation.

Page 9 of 21
 4.2.2 Protection & Metering Test.

4.2.2.1 Protection.

Procedure Standard Tools Acceptance Criteria

Operation within
Protection Relay Secondary Injection
Check the operation of the protection function product accuracy
Manual Power Supply
Conformity
Approved drawing
Check the functionality of the output signals Buzzer Conformity

4.2.2.2 Micrologic Trip Unit

Procedure Standard Tools Acceptance Criteria

Operation within
Manual Test Kit
Automatic Trip Test for Master pact CB product accuracy
Approved drawing Power Supply
Conformity

4.2.2.3 Metering.

Procedure Standard Tools Acceptance Criteria

Check the measurement and metering equipment as

KW / KWH / KVARH / Ammeters / Voltmeters / PF / Approved drawing Visual Conformity
PM / …..
Operation within
Check the instrument setting range to the sensor Secondary injection
Approved drawing product accuracy
rating. Power supply
Conformity

4.2.3 CT & VT Polarity and turns Ratio Test.

4.2.3.1 CT Turns Ratio Test.

Procedure Standard Tools Acceptance Criteria

Check the name plate of the current transformer Approved drawing Visual Conformity

Inject a ratio or full rated of the turns ratio of the CT

Turns ratio within the
on the primary winding and measure the secondary
IEC61869‐2 Primary injection CT accuracy +
value on the secondary windings. (for Protection Cores
Conformity
only)

Page 10 of 21
 4.2.3.2 CT Polarity Test.

Procedure Standard Tools Acceptance Criteria

Checked by direction for Primary &Secondary

Approved drawing Visual Conformity
windings on the rating plate of the CT

4.2.3.3 VT Turns Ratio Test.

Procedure Standard Tools Acceptance Criteria

Check the name plate of the Voltage transformer Approved drawing Visual Conformity

Apply a fraction voltage on the primary winding and Turns ratio within the
measure the value on the secondary winding and IEC61869‐3 Power supply VT accuracy +
compare with the turns ratio Conformity

4.2.4 Dielectric Test on the Main Circuit.

Procedure Standard Tools Acceptance Criteria

Check the insulation level of the panel at ON position

Conformity (1 min.
by applying the voltage level on each phase separately IEC61439‐2 Dielectric tester
without breakdown)
and other phases are earthed

Page 11 of 21
 4.3 Mechanical Tests
4.3.1 Mechanical Operation.

Procedure Standard Tools Acceptance Criteria

Check CB / isolator switch operation (on, off, trip),

Approved drawing Visual Conformity
manual motor charging, rack in / out and trip reset.

Check that it is impossible to rack in/out the CB if the

Visual Visual Conformity
CB is switched ON.

Check the control plugs connection if applicable. Approved drawing Visual Conformity

Check the front doors opening and closing. Visual Visual Conformity

Check operation of all drawers (rack in/out) and be

sure that it is impossible to rack in/out the drawer Visual Visual Conformity
while the CB is switched ON.

Check penetration of all power contacts (input/

Visual Visual Conformity
output) of each drawer.

Check all types of mechanical interlock system (key

locks, cables, padlocks, rods, etc.) and its related Visual Visual Conformity
function.

4.3.2 Mechanical Interlocking.

Procedure Standard Tools Acceptance Criteria

Check all key locks operation system related to CB,

Approved drawing Manual Conformity
earthing switch, shutter, etc. (if applicable)

Check that identical breakers can be inserted at

Approved drawing Manual Conformity
another identical breaker cubicle “Interchangeability”.

Check that non‐identical breakers cannot be inserted

at other non‐identical breakers cubicles Approved drawing Manual Conformity
“Interchangeability”.

Page 12 of 21
 4.4 Optional on Demand Tests

4.4.1 Insulation Resistance Test on the Control Circuit

Procedure Standard Tools Acceptance Criteria

Apply 500 Vdc between Control wires and Earth

Conformity (Accepted
Precautions during testing:
if the insulation
‐ Electronics components and protective relays: to be Megger insulation
IEC61439‐2 resistance is equal to
disconnected tester
or more than 1000
‐ Short all terminals together using a fine copper wire
ohm/volt
or disconnect the relays

4.4.2 Dielectric Test on the Control Circuit

Procedure Standard Tools Acceptance Criteria

Injection of 1 KV voltage for 1 Sec between LV circuits

and earth
Precautions during testing:
AC Di‐Electric Tester Conformity (1 min.
‐ Electronics components and protective relays: to be IEC61439‐2
(0‐5000V) without breakdown)
disconnected
‐ Short all terminals together using a fine copper wire
or disconnect the relays

4.4.3 Insulation Resistance Test on the main Circuit

Procedure Standard Tools Acceptance Criteria

Conformity (Accepted
if the insulation
Apply 500 VDC between all phases& earth.
IEC61439‐2 Megger Tester resistance is equal to
or more than 1000
ohm/volt

Page 13 of 21
 1. FAT Documents:
5.1 Customer Inspection Checklist

Page 14 of 21
 5.2 Heater Test Sheet

Page 15 of 21
 5.3 Protection Relay Test Sheet

Page 16 of 21
 5.4 Power Meter Test Sheet

Page 17 of 21
 5.5 CT Test Sheet

Page 18 of 21
 5.6 PT Test Sheet

Page 19 of 21
 5.7 Di Elec Test Sheet

Page 20 of 21
 5.8 Micrologic Test Sheet

Page 21 of 21