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 Association s
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
 PAGE 1

Abstract

D id you get what you wanted?

You paid for it does 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 luxury it s 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.
Key to a cost-effective and proper testing
program is learning which specific tests to
perform and why.
In the following pages, we ll deal with these
test types (listed in order of performance):
1. Factory Acceptance Testing (FATs)
2. Testing upon delivery
3. Construction Testing
4. Pre-op Testing
5. 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.
About NEIS
National Electrical Installation
Standards (developed by NECA in
partnership with other industry organi-
zations) are the first performance stan-
dards 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 docu-
ments, 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.
PAGE 2

Testing Basics

T esting programs involve several different

types of test, including factory acceptance
testing (FATs), testing upon delivery, con-
struction 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 techni-
cian. This person will witness or conduct the 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 Photo 1. Testing at the construction stage identifies problems
4. Labeling, cosmetics, and other non-performance that would otherwise result in catastrophic failures.
issues meet specifications.
Systems that are large, critical, tightly scheduled, or of
unusual design are suitable for FATs. These tests may use Testing Upon Delivery
random sampling or complete simulation; choices in this Delivery testing normally performed when the equip-
area vary with the critical nature of a specific application. ment arrives reveals damage that may have occurred
For most applications, FATs are unnecessary. However, during transport. Visual inspection, electrical tests, or
failure to verify that the equipment meets specifications may mechanical tests may all be used, depending on how
increase costs and introduce significant delays. Preferred critical the equipment.
verification methods, performed prior to shipment, include For example, a delivery test for a small sump pump
Requesting the manufacturer motor requires a quick visual inspection, while a 400-hp
send quality control reports, motor for the main air system requires electrical and
Requesting the shop orders to compare mechanical tests. Failure to conduct the appropriate
to equipment orders, delivery testing means the discovery of damage is after
Requesting the as-built drawings to compare to installation a costly experience.
equipment orders, and Skill base: For delivery testing, a technician needs skills
ranging from clerical level to extensive testing expertise.
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
Construction Testing
functions it performs, how to operate it, and how to test it. Testing during construction (see Photo 1) is a sound
Also, a technician should have the ability to understand and project management practice. The benefits of construction
compare electrical construction documents. testing include the following:

Enforcement of construction/subcontractor warran-
ties 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 testing as opposed to system
testing. They include the following:
Visual inspection for damage, missing parts, and
incorrect connections;
Visual inspections of workmanship (see NECA 1-
2000, 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: To perform construction testing, a journeyman
electrician or higher is required.
Pre-op Testing
In pre-op tests, equipment systems are put through their
paces run 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:
PAGE 3
Current transformers (CTs) to ammeters to protec-
tive 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.
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 judg-
ment 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 requirements up
front will 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:
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 equip-
ment, 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 techni-
cian to power quality engineer.
PAGE 4

Major Equipment Test Steps

T 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 cost-
effective 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
fault when energized. Torque on bolted
connections must correspond with values
supplied by the manufacturer (not to those
obtained from standard charts).
Insulating Oil Analysis: Reveals the chemical
condition of the oil.
Insulation Resistance: Tests integrity of the
insulating materials of each winding.
Power Factor: Tests aggregate integrity of the
insulating materials inside the transformer.
Transformer Turns Ratio (TTR): Reveals turn to
turn shorts in any winding. No other test, short of
energizing the transformer and comparing the high
voltage value to the low voltage value, will give this
detailed information.
Winding Resistance: Checks the conductivity of
the copper windings (similar windings should have
similar resistances).
Service Switchgear
Service switchgear (see Photo 3) is typically multi-
section equipment. For new service switchgear, the
following tests apply:
Photo 2. This service entrance transformer is undergoing some
checks after being set in place.
Clean and Torque: A switchgear assembly may
contain several types of insulation (e.g., porcelain
bosses, fiberglass standoffs, and galastic sheets).
Each of these contributes to the overall integrity of
the switchgear and must be free of dirt, dust, and
contamination. Again, torque on bolted connections
should be applied to values supplied by the manufac-
turer (not to those found on standard charts).
Device Testing: Before energizing the equipment,
test the control devices (e.g., CTs, surge protectors).
Insulation Resistance: Perform this test on the
current-carrying buswork, phase-to-phase and
phase-to-ground. This will require the disconnection
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).
 PAGE 5

Cabling, Feeder &

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

NECA 408-2002, Recommended

Practice for Installing and Maintain-
ing Busways (ANSI),
NECA 101-2001, Standard for
Installing Steel Conduit (Rigid,
IMC, EMT),
NECA/NEMA 105-2002, Recom-
mended Practice for Installing Metal
Cable Trays (ANSI), and
NECA 409-2002, Recommended Photo 3. During routine pre-op testing, the contractor identified and fixed a
Practice for Installing and Maintain- fault condition that would have caused a fireball-producing, plasma-spewing
ing Dry-Type Transformers (ANSI). arc blast.

Motors Difficult to install or remove,

There are 72 different types of tests for motors. For new Long lead time for replacement,
motors, few of these tests are necessary. The following Part of a critical process, or
guideline applies to most new motor situations: Expensive relative to facility budget.
All motors: Visually inspect upon delivery. Also
ensure the rotor is straight and turns freely (rotors Grounding System
sometimes get bent in shipping and loading/
Conduct the test per standard such as IEEE-142 or
unloading operations).
Soare s Book on Grounding. Follow the instructions that
Motors over 50-hp: Insulation resistance test upon
come with test equipment. Power to the facility must be off
delivery.
for a valid fall-of-potential ground test. Allow an hour or
Critical motors: Insulation resistance test upon
more, depending on circumstances, per service entrance
delivery, laser align before energizing, vibration test
for the testing. For meaningful results, reschedule if events,
after energizing.
such as rain, add unusual moisture to the soil.
Exactly how does one determine if a unit is a critical
motor or not? A critical motor will meet at least one of the
following conditions:
PAGE 6

Test Management

S ometimes, a
contract will
specify appropri-
ate testing per industry
standards. The testing must
be thought out, planned for,
all of a project s testing
needs. One reason they
advocate this is to ensure
they are working from
precedent tests that were
properly performed. A
and managed or it is likely common example: A facility
to be expensive or incom- does its own ground
plete. Testing that is under- testing incorrectly. To
taken as an afterthought will provide valid results from
provide little or no value. circuit breaker operation
testing, the testing firm now
must perform a complete
Scheduling program of ground
First, identify the testing testing at an inopportune
needs. Then, estimate the time and on a compressed
time needed per testing activity. schedule.
Finally, determine when each block Best advice is that if testing is
of testing time can and should take assigned to more than one party,
place keeping an eye toward make sure that all of those involved
reducing mobilization costs. Add the can document their training in the
testing to the Work Breakdown appropriate test techniques. Each
Structure (or other project planning should be able to demonstrate
tool) in the appropriate places. familiarity with the appropriate test
Waiting until the project is nearly standards. This extra step will help
complete will incur additional costs in obtaining properly performed
and delays. testing.

Outsourcing Selecting A Testing

Economic considerations may Firm
lead firms to consider using as
testers companies that are not Begin the selection process by
certified testing firms. However, this using the same criteria as in the
money-saving route may actually be decision of whether to outsource.
much more costly. Why? Testing Next, look for NETA certification;
performed by unqualified people this removes much of the uncer-
leads to such mistakes as over- tainty regarding the firm s compe-
potential testing of motors or testing tence. Third, ask about similar
the utility neutral instead of the projects in which the firm has
Photos 4 and 5. Digital photos help
ground system. participated. Experience speaks
document nameplate data, connection
Testing firms often want to handle volumes! Ask to see reports or
diagrams, and actual connections.
other documentation from the

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.
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.
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).
PAGE 7
Conclusion
A 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-user not just at
project completion, but also over the installation s 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.
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Date Title Index No.

8/99 Energy Savings Performance Contracting A New Frontier 302597
6/00 National Electrical Installation Standards 302599
12/00 Intelligent Building Distributed Networks 3025100
6/01 The Essentials of Quality Power 3025102
9/01 Specifying Integrated Building Systems 3025103
12/01 Guide to Energy Efficiency Options:
Using Today s Electrotechnologies 3025104
12/02 Guide to Quality Electrical Installations 3025105
12/02 Quality Lighting Design and Installation 3025106
4/03 Tips for Ensuring Best Quality Voice-Data-Video Installations 3025107
9/03 Aspects of Electrical Testing 3025108

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