SITE ACCEPTANCE TEST PROCEDURE

Bus way

EPS Ref:

ELECTRICAL POWER DISTRIBUTION BOARDS &

SWITCHGEAR LIMTED (EPS)
P.O. BOX 89249 – RIYADH 11682
SAUDI ARABIA

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 INDEX
SECTION-1 INTRODUCTION ..........................................................................................................3
SECTION-2 SAFETY .........................................................................................................................5
SECTION-3 MECHANICAL CHECKS AND VISUAL INSPECTION .................................................6
SECTION-4 INSULATION RESISTANCE TEST ...................................................................................7
SECTION-5 Bus way .......................................................................................................................9

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SECTION-1 INTRODUCTION
The purpose of these specifications is to assure that all tested electrical
equipment and systems supplied by either contractor or owner are
operational and within applicable standards and manufacturer’s
tolerances and that equipment and systems are installed in
accordance with design specifications.
The need for acceptance testing of electrical power systems is very
clear to those with extensive start-up and/or operating experience.
Shipping and installation damage, field and factory wiring errors,
manufacturing defects, and systems and components not in
accordance with drawings and specifications are some of the many
problems that can be detected by appropriate testing. When these
defects are found before start-up they can be corrected under
warranty and without the safety hazards and possible equipment and
consequential damages of loss of use/production that can occur if
discovered after start-up or energizing. In addition, test results obtained
during acceptance testing are invaluable as base reference data for
the periodic testing that is an essential element of an effective
maintenance program.
This document lists a majority of the field test available for assessing the
suitability for service and reliability of the power distribution system.
Certain tests have been assigned an “optional” classification. The
following considerations were used in determining the use of the
“optional” classification:
1. Did another test listed provide similar information?
2. How did the cost of the test compare to the cost of other tests
providing similar information?
3. How commonplace was the test procedure? Is it new technology?
While acknowledging the above, it is still necessary to make an
informed judgment for each particular system regarding how extensive
the testing should be. The approach taken in these specifications is to
present a comprehensive series of tests that is applicable to most
industrial and larger commercial systems. The guidance of an
experienced testing professional should be sought when making
decisions such as how extensive testing should be. In smaller systems
some of the tests can be deleted. In other cases, a number of the tests
indicated as optional should be performed.
As a further note, it is important to follow the recommendations
contained in the manufacturer’s instruction manuals. Many of the
details of a complete and effective acceptance testing procedure
can only be obtained from that source.

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 This document details the Field inspection, testing and commissioning
procedures that must be followed during commissioning and startup of
electrical equipment. These inspections and tests are performed on
new equipment, after installation and prior to energizing, in order to
confirm that:
1. The equipment has not been damaged during shipment or
installation.
2. The equipment is in compliance with the purchase specification and
design intent.

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SECTION-2 SAFETY
Proper safety procedures shall be reviewed and followed before each
activity listed in this procedure. Job Safety Analysis followed by a
toolbox/pre-job meeting shall be conducted prior to any activity listed
in this procedure. Proper safety procedures as detailed in the “Safety
At Work Sites” (Doc. Ref. PR-SER-201) and customers requirements shall
be implemented as dictated by each sites requirements.
Services Employees are NOT authorized to work on live equipment.
There may be occasions in which you are taking measurements or
checking voltages within an energized enclosure, but you are NOT
authorized to “do Hands on Live” repairs!
Company representative does not typically perform shutdown and/or
switching operations, because these operations may result in damage
to property or persons downstream of the equipment as a result of
conduct, errors, or omissions made by others. If a customer requests
Company representative to perform such services, technicians must
contact their Manager for approval and proper procedures.

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SECTION-3 MECHANICAL CHECKS AND VISUAL INSPECTION

3.1. OBJECTIVE:
Mechanical checks and visual inspection to be done on all electrical
installation to confirm that there is no physical damage, and all
electrical connections and specification of equipments matching with
the required one.

3.2. PROCEDURE:
The following points to be checked in mechanical checks and visual
inspection.
Visual inspection:
- Nameplate details
- Physical condition (damage/ defect)
- Installation checks
- Equipment verification against rating and matching with
requirement.

Mechanical checks:
- Power circuit connection tightness by torque method.
- Control wiring tightness.
- Interlock checks between equipment.
- Mechanical operations like rack in/ rack out.
The mechanical checks and visual inspection for equipments has been
listed in detail under respective section.

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SECTION-4 INSULATION RESISTANCE TEST
4.1. OBJECTIVE:
To determine the equipment is in proper condition to put in service for
which it was designed and to give some basis for predicting whether or
not that a healthy condition will remain or if deterioration is underway
which can result in abnormally short life. These results can be kept as a
record to compare in future and to understand the trend of insulation
during maintenance.

4.2. TEST INSTRUMENTS REQUIRED:

- Insulation tester up to 5000V DC.

4.3. TEST PROCEDURE:

The following precautions should be taken care, before starting the
testing.
- A visual inspection to be made to ensure the surface dust and
moisture has been removed from the component under test.
- Ensure the component is isolated from other connected system,
which may feed back to other components or circuits not under
test.
- A check shall be made to verify the ground for the component
under test and test equipment being connected to system ground
and equipment like Lightning arrestor, capacitor and VT/ control
transformer to be isolated.
Insulation test:
Insulation tester leads shall be connected between one phase
conductor and earth. Test voltage shall be selected according to table
4.1. The duration could be 1min to 10min, and the reading shall be
taken after this duration. Before disconnecting the test leads test object
shall be discharged through ground. The same procedure shall be
followed for other phases.
Influencing factors:
Insulation resistance value is influenced by various factors like
temperature, humidity, and moisture. The ambient temperature value
shall be noted during test. The relation between temperature and
insulation resistance is inversely proportional.
Test methods:
- Short time or spot reading:
In this method the megger instrument is connected insulation to be
tested and is applied for 60sec. The reading is recorded at the end of
that time.
- Time resistance method:
In this method the testing is fairly independent of temperature provides
considerably more information about the condition of insulation than
the spot measurement. The test voltage shall be applied for 10minutes
and readings are taken every 15sec for the first minute and every
minute for 10 minutes.
Dielectric absorption factor, polarization index could be calculated as
below,

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 Dielectric absorption factor = 60sec reading/ 30sec reading.
Polarization index = 10min reading / 1min reading.
The insulation condition could be categorized as shown in the table
4.2.
- Step or multi- voltage method:
This method requires a multi voltage megger instrument, preferably with
1:5 voltage ratio ranges. Any reduction of insulation resistance at higher
voltage is a sign of an insulation weakness.

The procedure of insulation test for equipments has been explained in

respective section.

Rated voltage Test voltage

100-1000V AC/DC 1000V DC
>1000 to <5000V
2500V DC
AC
> 5000V AC 5000V DC

TABLE 4.1
TEST VOLTAGE LIMITS

Insulation 10min/1min Ratio

condition (Polarisation Index)
Dangerous <1
Poor >1 to <1.5
Questionable >1.5 to <2
Good >2 to <4
Excellent >4

TABLE 4.2
POLARISATION INDEX

4.4. ACCEPTABLE LIMITS:

Value of insulation resistance should meet the manufacturer minimum.
If this value is not available, the component tested should have at least
one Meg Ohm for every 1000 volts of rated voltage plus an additional
one Meg ohm.

4.5. APPLICABLE STANDARDS:

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SECTION-5 BUSWAY
5.1. OBJECTIVE:
To verify the physical condition and electrical characteristics of Bus
way

5.2. TEST INSTRUMENTS REQUIRED:

Insulation tester
Micro ohmmeter
Multimeter

5.3. TEST PROCEDURE:

5.3.1. MECHANICAL CHECKS AND VISUAL INSPECTION:

 Inspect for physical damage/ defects.

 Check nameplate information for correctness.
 Check tightness for all bolted connections.

5.3.2. INSULATION RESISTANCE TEST:

The test voltage shall be between phase to earth and Phase to Phase.
With an insulation resistance tester rated at 1000 volts, ensure phase-to-
phase, phase-to-neutral, and ground isolation.
The applied test voltage limits shall be as per table 4.1.

5.3.3. PHASE IDENTIFICATION TEST/CONTINUITY TEST

This test is to verify the continuity of bus way and identify the correct
phase at both end
The test will be done by shorting one end of phase to ground and
measuring continuity using multimeter with ground at other end; with
other remaining phase continuity should not be present
Each phase and continuity can be identified and marked

5.3.4. CONTACT RESISTANCE TEST:

This test is to confirm the resistance of the main connection.
Inject 100A DC current through the R-Phase and Y-phase by shorting R
and Y Phase at other end, Repeat the test for Y-B and B-R, The voltage
drop across the contact is measured and resistance is calculated. In
many instruments resistance will be a direct reading.

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