TEST-ITC-007 PFC_Energization Checklist

• Project Name

• Job Number

• PFC ID

• FED FROM - Switchboard ID and CB No.

• Date

  Date

• Prepared by

• Position Title

• Location
  Address

PFC Inspection - Pre-Energization

• Confirm you have IFC/OEM drawings Onsite

  Yes

  No

  N/A

• Call your Supervisor to arrange for a set of drawings

• Check & Perform proximity test at the switchboard

• Check Isolation tags and locks installed at point of supply

• Check All Circuit Breakers are in the Off position.

• Check Labelling Against OEM Drawings

• Check PFC is labelled with a "FED FROM" details

• Check all covers/doors are available and fit correctly.

• Check compartments no foreign objects, loose nuts, bolts, cut metal, tools.

• Check compartments are free of metal fillings, cable ties etc– must be vacuumed & clean

• Check compartments to ensure that all connections are tight

• Check All Cable Entries are sealed and Glands are tight

• Check that all contactors have free moveable contacts.

• Check Visually the equipotential Earth Bond Connection (confirm all tight)

• Check Visually all internal connections including Submains (confirm all tight)

• PFC Submains are as per IFC/OEM Drawings (size & type)

  Pass

  Fail

• PFC Main Switch is as per OEM Drawings (part number, rating & Assembly location)

  Pass

  Fail

PFC Controller

• PFC Controller is as per OEM Drawings (part number & Assembly location)

  Yes

  No

  N/A

• Confirm and Check for Internal Fuses, Links and Control CBS - Isolate until energization

• Check for loose Connections on the back of controller

• Photo of the Controller Serial/Part Number

  Media

• Is there a Control Neutral Installed for the PFC

  Yes

  No

• Confirm size of Neutral

PFC CT

• Confirm the CT has been install on A phase in the supply board

  Yes

  No

  N/A

• Confirm CT Ratio

  Yes

  No

  N/A

• Photo of the CT Ratio/Manufacture/Serial No.

  Media

• Continuity Test (point to point) CT control cable from supply board to PFC Links

  Pass

  Fail

• Remove CT jumper links in PFC - Test from controller to links to ensure connection.

  Pass

  Fail
PFC Capacitor

• Capacitor is as per OEM Drawings (part number, rating & Assembly location)

  Yes

  No

  N/A

• Take Photos to capture Manufacturer, Serial Number, Ratings (A), (kVAR), System Voltage

  Media

Pre-Energization Tests

• Test 1: Earthing System

  START TEST

• The resistance of the main earthing conductor or any equipotential bonding conductor shall be not more than 0.5 Ohms.

• EARTH TEST 1 - Supply Earth Bar to PFC Earth Bar

• EARTH TEST 2 - PFC Earth Bar to PFC Equipotential Earth points

• Test 2: Insulation Resistance

  START TEST

• The Insulation Resistance between conductors should not be less than 1Mohm

• Complete a battery test on IR tester before conducting any tests

• Short IR tester leads to confirm working condition before conducting any tests

• Select Testing Voltage

  240v = IR of 500V

  415v = IR of 1000v

• IR1 - A phase to B Phase =

• IR2 - A Phase to C Phase

• IR3 - B Phase to C Phase

• IR5 - A Phase to Neutral

• IR4 - B Phase to Neutral

• IR6 - C Phase to Neutral

• IR7 - A Phase to Earth

• IR8 - B Phase to Earth

• IR9 - C Phase to Earth

• IR10 - Neutral to Earth

• IR Test Results

  Pass

  Fail

• Test 3: Polarity

  START TEST

• The polarity testing shall show that all active, neutral and protective earthing conductors in the electrical installation are correctly connected to the corresponding terminals of electrical equipment.

• Perform Polarity test by Shorting Phases to Earth

• POL1 - A Phase to Earth

  Pass

  Fail

• POL2 - B Phase to Earth

  Pass

  Fail

• POL3 - C Phase to Earth

  Yes

  No

• POL4 - Neutral to Earth

  Pass

  Fail

• Note: Reconnect Neutral

• Polarity Test Results

  Pass

  Fail

Final Pre-Energization Check List

• SAFETY CHECK - This is HIGH RISK WORKS, ALL WORKS TO BE DONE CAREFULLY and WITH CAUTION. Follow the SWMS and safe work procedures. REMEMBER to treat All equipment as energized until proven "DEAD".

• 5.1 Do you have a copy of the Permit to energize.

  Yes

  No

  N/A

• 5.2 Has a Site Toolbox been completed with ALL staff including other trades notified of the energization.

  Yes

  No

  N/A

• 5.3 Has the work areas been made safe with the correct exclusion zones put in place

  Yes

  No

  N/A

• 5.4 Has the correct notice of energization signage be install on the boards

  Yes

  No

  N/A

• 5.5 Confirm the ALL JLE staff have signed onto and are aware of the steps in SWMS (TBC)

  Yes

  No

  N/A

• 5.6 Confirm Switching Procedure and All other Isolations points have been locked out and tagged.

  Yes

  No

  N/A

• 5.7 Confirm All Internal Fuses, Voltage link and Control CBS are turned "On"/ Installed

• 5.8 Confirm Both ends are made safe and ready to energise

• 5.9 All covers and escutcheons have been install

• I have completed all the Final Checks and happy to procedure with Energization

  Sign

• Date and Time

  Date

PFC Post Energization Tests

• Switching has been completed and equipment ready for testing

  Energization Completed

• Test 1: 6 Point Voltage Test

  START TEST

• Phase to Phase Voltage 415v = Phase to Earth Voltage = 240v. Read the results out loud

• VT1 - A phase to Earth

• VT2 - B phase to Earth

• VT3 - C phase to Earth

• VT4 - A phase to B Phase

• VT5 - A phase to C phase

• VT6 - B phase to C phase

• 6 point voltage test Results

  Pass

  Fail

• Witness Photo of Results

  Media

• Test 2: Phase Rotation

  START TEST

• Test Location: Energized Equipment Line side of Main Switch

• Connection Method: Red, White, Blue leads on meter to match the Circuit Left to right (Not the cable colours)

• Rotation test

  Clockwise

  Anti Clockwise

• Mark Rotation on the PFC

• Photo of the results

  Media

• Isolate and roll A and B phase at the source

  Yes

  No

• Rotation test 2

  Clockwise

  Anti Clockwise

• Mark Rotation on Switchboard

• Photo of results

  Media

• Contact your supervisor stop tests

• Rotation MUST be clockwise - Stop and call your supervisor.

• Turn On PFC Main Switch

  Energization Completed

• Follow OEM Procedure for Programming controller.

• Quick set up will involve confirming Supply Voltage, CT ratio, Auto/Man, Switching timing etc

• Fill out the Customer Setting page in OEM Manual. (Tick if as per default, Add New setting if changed from default). Take a Photo of the settings

  Media

• Test voltage at CT links in PFC (Volatge to be < 1v AC.)

  Pass

  Fail

• IF Voltage is greater than 1v then re check connections

• Check the Display Current Matches the Current at the supply CT

  Pass

  Fail

• IF No load use a 10A load box on A phase to simulate a load

• Check the Display Voltage Matches the Supply Voltage

  Pass

  Fail

• Perform a functional check of Cooling Fans.

  Pass

  Fail

• If thermostat controlled reduce the cut in temp. If no thermostat then bridge the controller terminals.

Test PFC Capacitor Step

• Capacitor size

• Manually switch the Step "On"

• Tong A phase

• Tong B phase

• Tong C phase

• Confirm Phase Voltage at Capacitor

Test Equipment Details

• Insulation Tester

  Yes

  No

• Make/Model:

• Serial Number:

• Calibration Due Date:

  Media

• Mutli-Meter

  Yes

  No

• Make/Model:

• Serial Number:

• Calibration Due Date:

  Media

• Clamp Meter

  Yes

  No

  As Above

• Make/Model:

• Serial Number:

• Calibration Due Date:

  Media

• 10A Load Bank

  Yes

  No

• Photo of Remote Earth

  Media

Report Sign Off

• Mark Up/Highlight Projection Study As Builds and Take a Photo

  Media

• Onsite Sign Off: I am Satisfied that the PFC within this report meets the design Specifications provided

  Sign

• Engineer Review: I have reviewed the PFC results Inspected in this report and confirm that they meet the design specifications.

  Sign