ELECTRICAL DESIGN LIBRARY

Aspects of Electrical Testing

Contents

ABSTRACT .................................................................................................................... 1 TESTING BASICS .......................................................................................................... 2 MAJOR EQUIPMENT TEST STEPS .............................................................................. 4 TEST MANAGEMENT .................................................................................................... 6 CONCLUSION ................................................................................................................ 7

Electrical Design Library (EDL) publications are prepared for architects, consulting engineers, and qualified electrical contractors, as well as owners, developers, investors, and their electrical construction specifying personnel. Issued periodically by the National Electrical Contractors Association (NECA), the publications provide factual explanations of the increasing variety of sophisticated electrical systems and the economics of their installation by professional electrical contractors. They are distributed by the Associations chapters, located in all sections of the United States.

Copyright 2003 by the National Electrical Contractors Association. All rights reserved. Published by the National Electrical Contractors Association, 3 Bethesda Metro Center, Bethesda, Maryland 20814.

Index No. 3025108 Marketing 10K/9/03

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Abstract

id you get what you wanted? You paid for itdoes it work as you specified, as you were promised, as you need it to work? A good testing program allows construction users and their representatives to solve otherwise hidden equipment problems. Those problems can disrupt construction project progress, twist the critical path, incur rework costs, lower quality, void warranties and result in liability claims. Thus, a solid electrical testing plan is anything but a luxuryits a necessity. In designing and implementing an adequate testing program, one must be aware of: basic requirements of the tests; which standards apply; and who should perform those tests.

About NEIS
National Electrical Installation Standards (developed by NECA in partnership with other industry organizations) are the first performance standards for electrical construction. They go beyond the basic safety requirements of the National Electrical Code to clearly define what is meant by installing products and systems in a neat and workmanlike manner. All NEIS are submitted for approval by the American National Standards Institute (ANSI). Referencing NEIS saves spec-writing time and provides unprecedented control over workmanship and long-term performance. As an enforceable part of the contract documents, NEIS significantly reduce misunderstandings among engineers, electrical contractors, owners, and facility managers. With NEIS, the electrical instalation you design not only meets code, but it meets the shared expectations of everyone involved. Customers get a top-quality job and firms enjoy a reputation for long-term reliability. Find out more about the National Electrical Installation Standards (NEIS) at www.neca-neis.org.

Key to a cost-effective and proper testing program is learning which specific tests to performand why. In the following pages, well deal with these test types (listed in order of performance): 1. 2. 3. 4. 5. Factory Acceptance Testing (FATs) Testing upon delivery Construction Testing Pre-op Testing Maintenance Testing

Note: Reference is made in this document to National Electrical Installation Standards (NEIS)obtain details at www.neca-neis.org. Reference is also made to NETA, the interNational Electrical Testing Association; obtain more information at www.netaworld.org.

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Testing Basics

esting programs involve several different types of test, including factory acceptance testing (FATs), testing upon delivery, construction testing, pre-op testing, and maintenance testing. Each has distinct applications and requirements and the skill base required to apply each one varies.

Factory Acceptance Tests

Factory Acceptance Tests (FATs) often require a factory onsite visit, usually by a start-up engineer or test technician. This person will witnessor conductthe tests. FATs verify one or more of the following: 1. System construction meets design, which involves reviewing equipment against specifications; 2. Design meets process needs, which involves simulating operation; 3. System executes control functions properly, which involves simulating operations and faults; and 4. Labeling, cosmetics, and other non-performance issues meet specifications. Systems that are large, critical, tightly scheduled, or of unusual design are suitable for FATs. These tests may use random sampling or complete simulation; choices in this area vary with the critical nature of a specific application. For most applications, FATs are unnecessary. However, failure to verify that the equipment meets specifications may increase costs and introduce significant delays. Preferred verification methods, performed prior to shipment, include Requesting the manufacturer send quality control reports, Requesting the shop orders to compare to equipment orders, Requesting the as-built drawings to compare to equipment orders, and Paying the manufacturer to perform additional tests. Skill base: To perform FAT testing, a technician must have in-depth technical understanding of the equipment, the functions it performs, how to operate it, and how to test it. Also, a technician should have the ability to understand and compare electrical construction documents.

Photo 1. Testing at the construction stage identifies problems that would otherwise result in catastrophic failures.

Testing Upon Delivery

Delivery testingnormally performed when the equipment arrivesreveals damage that may have occurred during transport. Visual inspection, electrical tests, or mechanical tests may all be used, depending on how critical the equipment. For example, a delivery test for a small sump pump motor requires a quick visual inspection, while a 400-hp motor for the main air system requires electrical and mechanical tests. Failure to conduct the appropriate delivery testing means the discovery of damage is after installationa costly experience. Skill base: For delivery testing, a technician needs skills ranging from clerical level to extensive testing expertise.

Construction Testing
Testing during construction (see Photo 1) is a sound project management practice. The benefits of construction testing include the following:

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Enforcement of construction/subcontractor warranties in a timely manner, Reduction of rework and delays, Maintenance of the Critical Path, and Prevention of labor cost overruns.

These are normally static tests (de-energized equipment) and involve component testingas opposed to system testing. They include the following:

Current transformers (CTs) to ammeters to protective devices and back, Trip circuits from the control power source to the trip switch to the circuit breaker trip coil and back, and Voltage circuits from the fuses to contacts to indicating lights to relays and back.

Visual inspection for damage, missing parts, and incorrect connections; Visual inspections of workmanship (see NECA 12000, Standard Practices for Good Workmanship in Electrical Contracting (ANSI)); Visual inspections to ensure the installation meets ANSI-approved installation standards (see NECA 1000 - NEIS Specification System); Point-to-point connection verifications, with test equipment designed for the purpose; Cable tests (e.g., insulation resistance testing and high potential testing); and Specific tests per manufacturers manuals.

Skill base: Skills required for pre-op testing vary from journeyman electrician (non-critical installations, such as lighting panels) to specialized test technician (e.g., backup generator systems). Determining the correct skill base for adequate pre-op testing of a given system requires judgment and experience with electrical pre-op testing. If in doubt, consult a NETA-certified testing firm for guidance.

Maintenance Testing
A good understanding of maintenance requirementsup frontwill help prevent compromising maintainability during design and construction. Note that simply adhering to minimum working clearances (as detailed in the National Electrical Code) seldom provides adequate room. Rather, several points need attention, including:

Skill base: To perform construction testing, a journeyman electrician or higher is required.

Pre-op Testing
In pre-op tests, equipment systems are put through their pacesrun through operational and failure modes to ensure components function as a system. While other kinds of testing can usually follow standard procedures that detail each step, pre-op testing usually requires custom test procedures specific to a given installation. A key component of the pre-op testing is conducting loop checks prior to energizing the circuits. Field crews normally document the verification by highlighting each verified line on paper copies of the appropriate electrical drawings. An electrical loop begins at the circuit origin and travels a path through devices and back. Typical loops include:

Crews need safe paths for moving replacement electrical equipment from the installation point to a shipping dock. Room must be allowed for setting up test equipment, lifting devices, temporary power, temporary lighting, and other support systems. Location of electrical equipment may require a compromise between ease of maintenance and non-interference with operations when the area is roped off for maintenance.

Some maintenance tests can be done with the power on, but many require powering down specific equipment or the entire facility. To know which is which, see the standards referred to in the next section. For a critical facility, also get the recommendations of a NETA-certified testing firm. Skill base: For maintenance testing, technicians need various skills, from the level of junior maintenance technician to power quality engineer.

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Major Equipment Test Steps

his section provides a 50,000-foot view of major equipment test steps. Consult the appropriate NEIS and NETA testing specifications and manufacturers instructions for specific requirements.

Service Transformers
Service transformers (see Photo 2) are typically oil-filled. For new transformers, the following tests establish benchmarks for all future tests. Benchmarking permits intelligent trending and costeffective maintenance based on actual conditions rather than guesswork. Clean and Torque. Ensure the exterior insulators are perfectly clean. These are the only surfaces that maintain the high resistance that isolates the external connections from ground so they will not Photo 2. This service entrance transformer is undergoing some fault when energized. Torque on bolted checks after being set in place. connections must correspond with values supplied by the manufacturer (not to those obtained from standard charts). Insulating Oil Analysis: Reveals the chemical Clean and Torque: A switchgear assembly may condition of the oil. contain several types of insulation (e.g., porcelain Insulation Resistance: Tests integrity of the bosses, fiberglass standoffs, and galastic sheets). insulating materials of each winding. Each of these contributes to the overall integrity of Power Factor: Tests aggregate integrity of the the switchgear and must be free of dirt, dust, and insulating materials inside the transformer. contamination. Again, torque on bolted connections Transformer Turns Ratio (TTR): Reveals turn to should be applied to values supplied by the manufacturn shorts in any winding. No other test, short of turer (not to those found on standard charts). energizing the transformer and comparing the high Device Testing: Before energizing the equipment, voltage value to the low voltage value, will give this test the control devices (e.g., CTs, surge protectors). detailed information. Insulation Resistance: Perform this test on the Winding Resistance: Checks the conductivity of current-carrying buswork, phase-to-phase and the copper windings (similar windings should have phase-to-ground. This will require the disconnection similar resistances). of all control circuits (e.g., potential transformers, surge arrestors) from the bus prior to testing. See NECA 400-1998, Recommended Practice for Installing and Maintaining Switchboards (ANSI) and NECA 407-2002, Recommended Practice for Installing and Maintaining Panelboards (ANSI).

Service Switchgear

Service switchgear (see Photo 3) is typically multisection equipment. For new service switchgear, the following tests apply:

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Cabling, Feeder & Branch Distribution Gear

Industry practice generally assigns lowvoltage cable testing (insulation resistance testing) to the electrical contractor. Ensure that project specifications require the contractor to record (for each test) the followingtest values, date, and test technician name(s). For more details, see these installation standards:

NECA 408-2002, Recommended Practice for Installing and Maintaining Busways (ANSI), NECA 101-2001, Standard for Installing Steel Conduit (Rigid, IMC, EMT), NECA/NEMA 105-2002, Recommended Practice for Installing Metal Cable Trays (ANSI), and NECA 409-2002, Recommended Practice for Installing and Maintaining Dry-Type Transformers (ANSI).

Photo 3. During routine pre-op testing, the contractor identified and fixed a fault condition that would have caused a fireball-producing, plasma-spewing arc blast.

Motors
There are 72 different types of tests for motors. For new motors, few of these tests are necessary. The following guideline applies to most new motor situations:

Difficult to install or remove, Long lead time for replacement, Part of a critical process, or Expensive relative to facility budget.

All motors: Visually inspect upon delivery. Also ensure the rotor is straight and turns freely (rotors sometimes get bent in shipping and loading/ unloading operations). Motors over 50-hp: Insulation resistance test upon delivery. Critical motors: Insulation resistance test upon delivery, laser align before energizing, vibration test after energizing.

Grounding System
Conduct the test per standard such as IEEE-142 or Soares Book on Grounding. Follow the instructions that come with test equipment. Power to the facility must be off for a valid fall-of-potential ground test. Allow an hour or more, depending on circumstances, per service entrance for the testing. For meaningful results, reschedule if events, such as rain, add unusual moisture to the soil.

Exactly how does one determine if a unit is a critical motoror not? A critical motor will meet at least one of the following conditions:

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Test Management

ometimes, a contract will specify appropriate testing per industry standards. The testing must be thought out, planned for, and managedor it is likely to be expensive or incomplete. Testing that is undertaken as an afterthought will provide little or no value.

Scheduling
First, identify the testing needs. Then, estimate the time needed per testing activity. Finally, determine when each block of testing time can and should take placekeeping an eye toward reducing mobilization costs. Add the testing to the Work Breakdown Structure (or other project planning tool) in the appropriate places. Waiting until the project is nearly complete will incur additional costs and delays.

all of a projects testing needs. One reason they advocate this is to ensure they are working from precedent tests that were properly performed. A common example: A facility does its own ground testing incorrectly. To provide valid results from circuit breaker operation testing, the testing firm now must perform a complete program of ground testingat an inopportune time and on a compressed schedule. Best advice is that if testing is assigned to more than one party, make sure that all of those involved can document their training in the appropriate test techniques. Each should be able to demonstrate familiarity with the appropriate test standards. This extra step will help in obtaining properly performed testing.

Outsourcing
Economic considerations may lead firms to consider using as testers companies that are not certified testing firms. However, this money-saving route may actually be much more costly. Why? Testing performed by unqualified people leads to such mistakes as overpotential testing of motors or testing the utility neutral instead of the ground system. Testing firms often want to handle

Selecting A Testing Firm

Begin the selection process by using the same criteria as in the decision of whether to outsource. Next, look for NETA certification; this removes much of the uncertainty regarding the firms competence. Third, ask about similar projects in which the firm has participated. Experience speaks volumes! Ask to see reports or other documentation from the

Photos 4 and 5. Digital photos help document nameplate data, connection diagrams, and actual connections.

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Conclusion

testing of similar installations. Finally, ask the firm to review the project testing requirements against the project schedule.

Reports & Records

At project conclusion, a final test report should be available. The owner should be able to use this report. It is reasonable to provide the report in two hard and soft copy formats. Included in the final test report should be:

Detailed list of equipment tested, Test procedures used, List of discrepancies found, List of recommended corrections, and Detailed data sheets for each piece of equipment tested.

proper testing program that incorporates the five levels of testing helps ensure the project is delivered on time and within budget. It also supports warranty claims. Proper testing will result in a better product for the end-usernot just at project completion, but also over the installations life. Testing documentation serves as a defense against liability claims for personal injury, or loss of property or revenue. How does one go about fashioning a proper testing program? Determine testing needs, obtain the appropriate standards, and write testing requirements into project specifications.

A good way to document nameplate data is with a digital camera (see photo 4). This is also useful for documenting connection diagrams and actual connections (see photo 5). However, it requires close attention to image labeling and file management.

Find A Contractor And/Or Obtain Another Free EDL!

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Safety Issues
Project specifications should require contractors and subcontractors to follow appropriate electrical safety standards and meet OSHA requirements for safety training. NECA contractors, for example, can avail themselves of many safety training products and services from the association. Further, local electrician training programs NECA sponsors include significant investments and resources devoted to OSHA 10- and 30-hour training programs. Note: A significant percentage of electrical injuries happen to people who did not need to be in the area at the time of the injury! Thus, a project specification that limits access to electrical equipment on a need to be there basis can serve to protect life and health (as well as diminishing owner liability).

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The National Electrical Contractors Association, Inc., was founded in 1901. It represents the electrical contracting industry and is organized into independent, local chapters throughout the United States, Australia, Canada, and New Zealand. The headquarters office is located at 3 Bethesda Metro Center, Suite 1100, Bethesda, MD 20814-5372. Field service regional offices are located in Covington, LA, Schaumburg, IL, Syracuse, NY, and Oakland, CA. For help in locating a qualified electrical contractor in your area or for more information concerning this publication, contact the NECA Chapter Office nearest you. ALABAMA: Mobile (251-479-9534) ALASKA: Anchorage (907-561-1958) ARIZONA: Phoenix (602-263-0111), Tucson (520-323-1622) ARKANSAS: Little Rock (501-758-2224) CALIFORNIA: Bakersfield (661-3255937), Fresno (559-230-0990), Martinez (925-372-3222), Oakland (925-737-0460), Orange (714-634-8777), Petaluma (707765-1050), Menlo Park (650-328-3100), Sacramento (916-376-8980), Salinas (831-751-2080), San Bernardino (909824-7050), San Diego (619-298-1183), San Francisco (415-703-8333), San Jose (408-288-6100), Santa Maria (805-3481200), Stockton (209-478-8105), Los Angeles/Pasadena (626-792-6322) COLORADO: Denver (303-937-3900), Colorado Springs (719-636-3901) CONNECTICUT: Milford (203-287-1444) DELAWARE: Philadelphia, PA (215-732-1444) DISTRICT OF COLUMBIA: Annandale, VA (703-658-4383) FLORIDA: Orlando (407-426-9050), Tampa (813-253-0887), Jacksonville (904-633-9448), Miami (305-828-9918) GEORGIA: Atlanta (770-454-6400), Atlanta [Southeastern Line Constructors] (770-969-9209), Augusta (706-262-6322), Savannah (912-355-1252) HAWAII: Contact NECA Marketing Services in Bethesda, MD (303-215-4525) IDAHO: Boise (208-322-4744) ILLINOIS: Peoria (309-673-6900), Chicago (708-531-0022), Joliet (815-729-2288),

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