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CONTENTS

Page No.

TITLE PAGE

TABLE OF CONTENTS

1.0

PURPOSE

2.0

SCOPE

3.0

DEFINITIONS

4.0

REFERENCE STANDARDS AND CODES

5.0

RESPONSIBILITIES

6.0

TEST EQUIPMENT CONTROL

7.0

QUALITY CONTROL

8.0

TESTING PROCEDURE

9.0

DOCUMENTATION

NO : Q2.ESD.19, REV :AA


DATE : JUNE 2012

DISCIPLINE :

ELECTRICAL

TITLE

PROCEDURE FOR SITE ACCEPTANCE TESTING OF


METAL-ENCLOSED BUSWAYS

1.0

PURPOSE
To ensure that the metal-enclosed busways are installed in accordance with design
specifications, that their characteristics are within applicable standards and
manufacturers tolerances.

2.0

SCOPE
This procedure shall apply during the site acceptance testing of metal-enclosed
busways.

3.0

DEFINITIONS

3.1
3.2
3.3
3.5

C.E.
C.M.
T.T.
Q.C.

4.0

REFERENCE STANDARDS AND CODES

4.1

4.2

TCP-P-105-00 Pre-commissioning Testing Procedure


NEC National Electrical Code

5.0

RESPONSIBILITIES

Commissioning Engineer
Construction Manager
Testing Technician
Quality Control

5.1 The Commissioning Engineer (C.E.) shall be responsible for preparing the testing plan,
for the observance of all safety precautions required by the JAL Safety Plan, for
supervising the testing activities.
5.2 The Testing Technicians (T.T.) shall be responsible for carrying out the tests, recording
the test values.
5.3
The QC Department shall be responsible for conducting reviews of the test records
to ensure that all tests have been performed in accordance with the approved
inspection and test plan.
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6.0

Test Equipment Control


The Commissioning Engineer shall carry out an inspection of the test equipment
when the test equipment arrives in the warehouse. Each piece of test equipment
shall have the calibration labels intact. The Commissioning Engineer shall ensure
that the test equipment manual is available and that the test equipment is calibrated
and calibration certificates are available.
The Commissioning Engineer will keep a record with the test equipment serial
numbers, date of calibration and copies of the calibration certificates. JAL will
submit copies of the calibration certificates of the test equipment to Al-Mashariq.
The Commissioning Engineer shall ensure that test equipment that it is out of
calibration is isolated in a quarantine zone and will be sent as soon as possible to a
certified metrology laboratory for re-calibration against national standards.
The Testing Technicians shall ensure that the test equipment is tested for proper
operation before starting any test. Any defective test equipment will be isolated in a
quarantine zone and sent as soon as possible for repairs.
QC Department shall conduct periodic audits on the test equipment to ensure all
test equipment is within the required calibration period.

7.0

Quality Control
The Commissioning Engineer shall prepare the testing plan that will include the
equipment to be tested, the tests to be performed, the test equipment to be used,
the test procedure to be applied and the test records to be used. Based on the
testing plan, in coordination with the Construction Manager a testing schedule will
be developed.
The Commissioning Engineer shall organize, supervise and verify the
implementation of the testing schedule.
Any defects or variances from the approved specifications and standards will be
noted during the testing and shall be informed to the Construction Department by
the Inspection Report.
The Testing Technician shall use the pre-commissioning forms as checklists and to
record the results of the testing. The forms shall be the quality record documents
to identify that the inspection and testing has taken place.
The following tests will be performed and recorded on the pre-commissioning
forms:
1. Visual and mechanical inspection
2. Contact resistance test
3. Phasing test
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NO : Q2.ESD.19, REV :AA


DATE : JUNE 2012

4. Insulation resistance test


5. AC Over-potential test
The following test equipment will be used to perform the above tests:
1. Calibrated torque wrench
2. Microohmmeter, DLRO or T&R
3. Battery box or DC voltage source with multiple outputs
4. Megohmmeter AVO
5. Digital multimeter
6. AC Hi-Pot test set Baur or Hipotronics
7. Thermometer
8. Humidity meter

8.0

TESTING PROCEDURE
The following shall be the guidelines for the testing personnel during the inspection
and testing of metal-clad busways.

8.1 Visual And Mechanical Check

Compare equipment nameplate data with latest one-line diagram.


Verify appropriate anchorage, required area clearances, and correct alignment of the
metal-clad busway. Inspect the suspension and the bracing.
Inspect busway for physical damage, cracks on bushings, damaged insulation or
connections.
Check operation of heaters.
Check the presence and correct type of draining plugs.
Check that the rating of the flexible connectors is as per specifications.
Torque-check the connections/joints of the bus. The torque values should be as per
manufacturer recommendation and it shall be recorded on the pre-commissioning
form.

8.2 Contact Resistance Test


Test Equipment: Microohmeter DLRO or T&R

NO : Q2.ESD.19, REV :AA


DATE : JUNE 2012

The test will be performed on the busways joints


and connections.
Identify the joints to be tested. Ensure they have
been torque-checked and that the bolts are marked.
Check that the contact surfaces for the current and
voltage probes are clean and dry.
Check that the instrument probes are clean and dry.
Check that the microohmmeter is switched off
during making connections.
Ground the microohmmeter.
Fig. 1
Connect the current and voltage cables, with
respect to the polarities, as in fig. 1. Always
connect the voltage cables inside the current cables.
Switch on the microohmmeter.
Increase the current to the desired value.
Read the resistance value.
Compare measured values with manufacturers specifications; compare results between
different connections. Differences greater than 50% between connections should be
investigated.

8.3 Phasing Test


Test Equipment: Multimeter, Battery box or DV voltage source with multiple outputs

8.4

The phasing test is performed in order to check the continuity of busway phases and
the correct sequence of phases.
Disconnect the equipment connected to the busway such as transformers and
switchgear in order to achieve complete isolation of the main bus.
Ensure that the phases are not shorted together and that they are not connected to
ground.
Check that the phase identification labels correspond to the main bus arrangement and
vendor drawings. Ensure the phase sequence of the busway corresponds with other
associated equipment such as switchgear and transformer.
Connect the battery box at one end of the busway:
-0V to earth
-4.5V to phase A
-9V to phase B
-13.5V to phase C
Using a multimeter, check if at the other end of the busway the voltages for each phase
are correct.
Insulation Resistance Test

Test Equipment: Ohmmeter, Megohmmeter AVO; Thermometer; Humidity meter


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DATE : JUNE 2012

Measure and record the ambient temperature and humidity.


The insulation resistance of the busway, each phase to ground and phase to phase
should be measured.
Disconnect the busway to be tested from other equipment and circuits.
Ensure that the busway insulation, insulation boots, and bushings are clean, free of
dust.
Check with an Ohmmeter that there is no electrical connection between the phases or
between phases and ground.
As shown in fig. 2 (a), connect the line terminal of the megohmmeter with one phase of
the busway and all other phases together to ground and to earth terminal of the
megohmmeter.
Set the test voltage to the value recommended by the manufacturer
Measure the insulation resistance for one minute.
Repeat for all other phases.
Measure the insulation resistance for one minute between phases as shown in fig. 2 (b).
Connect the line terminal of the megohmmeter with one phase of the busway and the
earth terminal of the megohmmeter to another phase with the remaining phase
grounded.
Repeat for all other phases.
Measured insulation resistance values should be temperature corrected and compared
to the values given by the manufacturer.

(a)

(b)

Fig. 2

8.5 AC Over Potential Test


Test Equipment: AC Hi-Pot test set Baur or Hipotronics; Thermometer; Humidity meter
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DATE : JUNE 2012

Measure and record the ambient temperature and humidity.


The insulation resistance test must be successfully completed immediately before
performing the AC Hi-Pot test on the busway.
Because of the combination of high voltage and high energy involved in high voltage
testing, the test area is always to be cordoned off, with safety rope barriers.
Only persons that are directly engaged in the testing process and who are well aware of
the risks involved are to be allowed in the cordoned off area.
Disconnect the busway to be tested from other equipment and circuits.
Ensure that the busway insulation, insulation boots, and bushings are clean, free of
dust.
When performing the over potential test between phase and ground, as in fig. 3 (a), the
test voltage should be applied from each phase to ground with the other phases
connected to ground.
When performing the over potential test between phases as in fig. 3 (b) the
Hipotronics AC Hi-Pot test set should be used.

(a)

(b)

Before beginning the test, ensure that the hi-pot main switch is in off position and that
the voltage control switch is turned to zero position.
Connect the hi-pot safety ground stud to a good electrical ground. Check that the
metal frame of the busway is connected to ground.
Connect the line cable of the hi-pot test set to the desired phase of the busway under
test. Make sure that connections are tight and without any sharp edges. The line cable
should be short and supported over its entire length so that its not touching any
grounded materials.
Switch on the hi-pot and select the desired range for the test voltage. The test voltage
value should be as per manufacturer recommendation and should be applied for one
minute.
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NO : Q2.ESD.19, REV :AA


DATE : JUNE 2012

The AC Hi-Pot test is a go or no go test. If the Hi-Pot test voltage is held for one
minute without any failure of the busway insulation the busway is considered to have
passed the test.

9.0

DOCUMENTATION

9.1
9.2

Busway instruction manual


Test equipment operation manual

NO : Q2.ESD.19, REV :AA


DATE : JUNE 2012