FAT Procedures

1- Objective

To establish the procedures for the inspection and test – Low voltage MCC,
SWBD, SWGR Panels

2- General

2-1 The following summary defines the standard factory tests and inspections
performed during manufacture of industrial control equipment. All Low
Voltage equipment is tested and inspected for conformance with NEMA
and ANSI standards.

2-2 The tests do not include type testing or other destructive tests on
equipment. Any additional factory tests beyond those listed in the
following paragraphs must be referred to QC. to verify availability of test
facilities and qualified manpower.

2-3 These tests and inspections are performed on manufactured products to

verify conformance of the equipment to the design and job specification
requirements also encompass the verification of physical configuration of
assembly and workmanship, the mechanical adjustment of parts and
components and the sequencing and functional operations of the control
systems.

2-4 The test and inspection activities are performed in accordance with
manufacturing quality control, and engineering standards. These
standards cover the practices, procedures, and requirement for the
material control and manufacture of products, in addition to inspection
requirements for workmanship and operational test.

2-5 Prerequisites for each test and inspection operation are specified and
include the appropriate quantitative and qualitative acceptance criteria.

2-6 Confirmation of these requirements are verified in accordance with

checklist, shop travelers, materials marking

2-7 Test and inspection results are documented and evaluated

2-8 Additional testing beyond the scope of the following standard

commercial tests will affect normal shipment schedules.
3- Inspection tests

Inspection tests will be carried out through two stages.

1- In – process inspection
2- Final Inspection tests

3-1 In – process and visually inspections

These Inspection tests will be carried out during manufacturing cycle to

assure proper and correct materials and workmanship for any damage
conditions in accordance with manufacturing documentation and
drawings and the following are the items which will be checked

- Components, parts and materials.

- Location and orientation of components and parts
- Physical condition of components, parts, wire insulation
- Finish – plating (silver / tin) – painting
- Case and cabient assembly inspection
- Tightness of electrical connections and torque of bus bars bolts
- Wire / cable size, type, clamping support
- Wire termination’s, crimping of terminals
- Wire identification and terminal markers (where specified)
- Labeling of components, parts, etc.
- Mechanical, Electrical Clearance (potential hazards).

Notes
* The Documentation will be used on that stage is
1- In – process inspection check sheet
2- Checklist point

* The above tests will be carried out by the section group leader /
QC. Inspector and their acceptance signature should be on the
used documents
* Customer Inspection on that stage is not required unless other
wise specified
3-2 Final Inspection tests

3-2-1 Mechanical operation test

Mechanical operating tests shall be performed to insure proper

functioning of operating mechanisms and interchangeability.

a. The operation of shutters, mechanical interlocks, Circuit breaker door

interlocks, operating handles, trip mechanisms, solenoid armature
travels, contact wipes, electromechanical interlocks, physical clearances
for mechanical and electrical isolation including any additional
mechanically related operating functions shall be verified.

b. The interchangeability of removable units designed to be interchangeable

shall be verified as well as the rejection function of non-
interchangeability units.

3-2-2 Continuity tests - control wiring and power cables

The correctness of the individual wiring contained in each assembly

and the assembly wiring interfaces shall be verified as in accordance
with the connection diagram, wiring table, or elementary drawing.
The continuity of each circuit shall be checked

Note :- In some cases, circuit connections may be verified by

actual electrical operation of the components and associated wiring

3-2-3 functional operations tests

All equipment shall be subjected to an operational test. The test

shall verify the functional operation of the control and power
circuits and related components, devices, and sub assemblies
modules under simulated operating conditions (excluding
loading of the power circuits)

A- Devices All devices must be carefully inspected to insure

that they have proper voltage,current, ferquncey , time
ratings and proper contact arrangment. Elmentary
digram will be used for this check.

All control fuses will be inserted in fuse holders according

to the ampere ratings designated on the circuit digram.
 For metering and relay circuits , current and potential
(voltage) wiring is traced back from the coils to arrive at
source of current and potential.

It is not the intent of the device function test to provide a

precise caliberation of adevice but rather to verify the
device function and electrical.

B- Sequence and timing circuits.

Assemblies and systems involving sequential operation of

devices and time delays shall be tested to assure that the
devices in the sequence function properly and in the order
intended.
Circuits involving timing devices shall be set to specified
delays and sequence operation will be verified.

C. Polarity, Phase sequence

The polarity of direct current circuits and phase

connections of alternating current circuits shall be verified
by application of power and measurement of the relative
polarities and phase sequence .

D. Polarity - Current / Voltage transformer polarity check

This is a visual check only to verify that current
transformers and voltage transformers are installed and
wired in accordance with engineering drawings released.

E. Grounding

By using low voltage continuity tester all the grounding to

the equipment’s and others to be checked to assure
proper metal case grounding.
3-2-4. High Potential - Insulation test

Power cable, buses insulation and isolation tests

Power cables and buses shall be tested, phase to phase

and phase to ground for insulation breakdown resistance.
If the neutral is applicable it will be consider as fouth
phase. These tests conditions are as specified for newly
constructed equipment and performed at room
temperature and up to 95 % relative humidity at a location
less than 2000 meters in altitude. Equipment under test
shall be de - energised.
The test voltage shall be (two times rated plus 1000) for
one minute and the frequency of test voltage shall not be
less than the rated frequency of the equipment tested and
shall be essentially sinusoidal wave shape.
Consideration shall be made for low voltage devices, semi
conductor, meters, instruments, transformers, grounding
circuits, etc. In preparation for the dielectric tests

3-2-5. Insulation resistance ( Megger ) tests

Insulation tests measure the amount of circuit resistance

to current leakage. This test is performed when the
resistance measurements is desired and so specified. The
value of insulation resistance is subject to variations with
temperature, humidity and cleanliness of the equipment
and wiring. It is also dependent of the type, size, Voltage
rating, Kind of insulating materials, and method of
construction and past insulation records of the equipment.
 ACCEPTANCE CRITERIA
1- Electrical clearances
2- Insulation resistance test
3- Torque values for electrical joints

(1) Electrical clearance

Between live parts with opposite polarity through air

0 – 125 V AC 126 – 250 VAC 250 – 600 VAC

1 / 2" 3/4“ 1“

(2) Insulation resistance test

Test voltage Acceptance IR

DC M
500 10
1000 25

switching devices in closed position and all instrumentation and control fuses
removed.

(3) Torque values for electrical joints

THE FOLLOWING ARE BOLTS & SCREW & NUTS USED IN LOW VOLTAGE – MCC ,

M6 5-10 N.M
M8 20 N.M
M10 40 N.M
M12 70 N.M