Chapter 5: Inspection and testing

5.1 Initial verification

5.2 Methods of testing
5.3 Procedures of testing
5.4 Completion and inspection certificates

5.1 Initial verification

Before any completed installation, or an addition/alteration to an existing installation, may

be connected to the supply all such installation work must be inspected and tested in order
to comply with national regulations (EBCS-10 in Ethiopia’s case).

Any such tests that are to be made should be such that no danger to persons or damage to
property can occur.

Prior to conducting any inspection and testing, the person or persons who are to undertake
this task must be provided with all the drawings, charts, tables and specifications associated
with the installation.

This is in order that the type and composition of circuits, protective devices used, methods
of earthing, presence of sensitive electronic devices, location of switchgear and equipment
may be determined.

In other words, full knowledge of the installation must be established in order to know
which tests are required, and whether any special conditions apply to that particular
installation.

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Visual Inspection

The visual inspection part of the initial verification is the process of assessing the installation
prior to testing. The inspection shall be made to verify that the installed electrical
equipment is:
• In compliance with the Electric Installation Code (in Ethiopia)
• Correctly selected and erected in accordance with the Electrical Installation Code
• Not visibly damaged or defective so as to impair safety

These three items form the objectives of the visual inspection that must be conducted
before any tests are made.

The inspection shall include at least the checking of the following items, where relevant to
the installation, and where necessary, during erection:

1. Connection of conductors
2. Identification of conductors
3. Selection of conductors for current-carrying capacity and voltage drop
4. Connection of single pole devices in phase conductor only
5. Correct connection of socket outlets and lampholders
6. Presence of fire barriers and protection against thermal effects
7. Methods of protection against direct contact:
a. Protection by insulation of live parts
b. Protection by barriers and enclosure
c. Protection by obstacles
d. Protection by placing out of reach
8. Protection by non-conducting location
9. Presence of appropriate devices for isolation and switching choice and setting of
protective and monitoring devices

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 10. Labeling of circuits, fuses, switches and terminals
11. Selection of equipment and protective measures appropriate to external influences
12. Presence of warning and danger notices
13. Presence of diagrams, instructions and similar information

Obviously in order to conduct such visual inspections, it is necessary to have a logical

sequence, otherwise much time may be lost by going over the ground twice or more. For
the larger installation a check list would simplify matters.

5.2 Methods of Testing

EBCS-10 Electrical Installation of Buildings Appendix lists the sequence of the tests to be
made, again appropriate to the particular installation and equipment installed.

The order and nature of tests to be made is:

a) Continuity of protective conductors

b) Continuity of ring final circuit conductors
c) Earth electrode resistance
d) Insulation resistance
e) Insulation of site built assemblies
f) Protection by electrical separation of circuits
g) Protection against direct contact by barriers or enclosures provided during erection
h) Insulation of non-conducting floors and walls
i) Polarity
j) Earth fault loop impedance
k) Operation of residual current devices

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It is only when the visual inspections and the first eight of these tests have been carried out,
that it is permissible to connect (on a temporary basis) the installation to the supply in order
that the remaining three tests may be conducted.

Due to the extremely low values of resistances to be measured for continuity tests, it is
important that all instruments to be used are regularly checked and re-calibrated to ensure
accuracy. When recording the values for the various tests on the check list or certificate of
inspection, it is advisable to record the serial number of the instrument used.

5.3 Procedures of testing

I) Measurement of consumer's earth-electrode resistance

If the earth-fault loop impedance test gives too high a result, it may be necessary to
measure the resistance of the earth electrode.

The resistance area of an earth electrode is the area of soil around the electrode within
which a voltage gradient measurable with commercial instruments exists. In the figure
below X is the earth electrode under test, and Y is an auxiliary earth electrode positioned so
that the two resistance areas do not overlap. Z is a second auxiliary electrode placed
halfway between X and Y.

Test of earth electrode resistance

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An alternating current of steady value is passed through the earth path from X to Y. This is
measured by the ammeter. On the assumption that X and Y are similar electrodes in similar
circumstances, the voltage drop from X to the circumference of its resistance area should be
half the total voltage drop. The other half of the total voltage drop would be in Y and its
resistance area. Between the resistance areas of X and Y there would be negligible
resistance and thus negligible voltage drop.

The voltmeter measures the voltage drop between X and Z.

Then, the resistance of X = Voltage drop between X and Z

Current between X and Y

To ensure that the resistance areas do not overlap, the auxiliary electrode Z is moved to
positions Z1 and Z2 respectively. The resistance values found should be of approximately
the same value in all three cases.

II) Insulation resistance

This is the resistance in ohms between the live parts of the installation and earth, measured
through the insulating covering of the conductors, etc. In the case of metal-covered wiring
or conduit wiring, the term 'earth' means in practice the metallic covering or conduit which
itself is connected directly to earth. Additionally, the insulation resistance is measured
between lines, that is, between the opposite poles of the installation with lamps or other
apparatus disconnected and switches on.

Measuring conductor resistance

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 Measuring insulation resistance

The difference between insulation and conductor resistance is shown in the sketches above.
In measuring the resistance of a conductor AB, the resistance is measured along the wire
from end to end, and increase of conductor length means increase of resistance. In
measuring the insulation resistance of the conductor, the measurement is made from the
conductor outwards.

The formula for conductor resistance is

R = (rl ) / a

where l is the length of the conductor,

a is the cross-sectional area, and
r is the resistivity of the conductor material.

Using a similar formula for insulation (it is sufficiently true for the purposes of this
argument),

R’ = (r’l’ ) / a’

where l’ is the thickness of the insulation, a' is proportional to the length of the wire, and r’

is the resistivity of the insulating material.

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Thus, if an insulated wire is increased in length, its conductor resistance increases while its
insulation resistance decreases. Therefore, the longer the conductor the less will be its
insulation resistance.

The insulation resistance of a completed installation cannot be calculated, it can only be

found by actual measurement. There are two kinds of leakage path: direct leakage through
the insulation, and surface leakage. Both are much affected by dampness. If the insulating
material is damp it will allow current to leak away, that is, the insulation resistance will be
low. This particularly applies to materials such as cotton, paper, asbestos, and badly glazed
porcelain, all of which are 'hygroscopic' - they absorb moisture. Surface leakage takes place
along the surface of the insulation, particularly at switches, ceiling roses, distribution
boards, etc., where dust may collect, and at the ends of cables especially if not properly
cleaned. Thus the insulation tests taken of an installation in a new building in which the
plaster and mortar are not properly dried out will be lower than those of an installation in a
dry situation.

The various tests of an installation which follow, are to be made before the installation is
connected to the supply.

Testing voltage

The voltage used for insulation resistance tests shall be a direct current voltage not less
than twice the normal direct current voltage, or in the case of alternating current not less
than twice the normal r.m.s. voltage; but it need not exceed 500 V. Thus a 500- V insulation
resistance tester is sufficient for general purposes.

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Testing the installation to earth

The test shall be made with all fuse links in place, all switches including the main switch
closed and, except where earth-concentric wiring is concerned, all poles or phases
electrically connected together.

If required, all lamps and appliances may be removed during the test, in which case each
piece of apparatus should be separately tested. The measured insulation to earth shall be
not less than 1 MW. The insulation resistance of each piece of apparatus measured

separately shall be not less than 0.5 MW to earth (between live parts and frame), and 0.5

MW between poles or phases.

Testing insulation resistance of completed installation

The sketch above shows the connections for testing the insulation resistance to earth of a
completed 2-wire installation with lamps and other apparatus disconnected. The wires of
both poles of the supply to the main switch are twisted together and connected to the 'line'
terminal of the ohmmeter. The 'earth' terminal of the ohmmeter is connected to the
consumer's earthing terminal. The three terminals of 2-way switches should temporarily be
connected together.

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Testing between conductors

This test is made between all the conductors connected to anyone pole or phase of the
supply, and all conductors connected to any other pole or phase of the supply. The
insulation resistance is to be not less than 1 MW.

Ail lamps should be removed, all current-using apparatus disconnected and all local
switches controlling lamps or apparatus closed. When the removal of lamps and apparatus
is not practicable, all local switches should be open.

A 3-wire 3-phase installation will require three tests:

1. between lines R and Y

2. between lines R and B,
3. between lines Y and B.

A 3-phase 4-wire installation will require six tests:

1. three separate tests between pairs of lines, R-Y, R-B, and Y-B,
2. three separate tests, R-neutral, B-neutral and Y-neutral.

Where R, B, and Y are three phases of the system.

The figure below shows the test connections in a simplified form.

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 Simplified diagrams of tests between conductors

With modern-day installations, electronic devices such as dimmer switches and thyristor
controls for motors are commonly used. Components within these devices are likely to be
damaged or destroyed by the 500 V test voltage. It is important therefore to disconnect
such sensitive devices before testing.

Another rare requirement that might entail measuring the insulation resistance of the floor
and walls of an area would be in a special test room or a laboratory. Here persons working
on live apparatus would be protected against direct contact conditions by having such walls
and floor covered with suitable insulating material.

The test should be applied at three positions within such an area, and where the working
voltage is 500 V the minimum insulation resistance should be 50 kohm.

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III) Verification of polarity of single-pole switches, etc.

It has to be ensured that all fuses and single-pole control devices are connected in the live
conductor only; that the outer contacts of center-contact bayonet and Edison-type screw
lampholders are connected to the neutral or earthed conductor; and that plugs and socket-
outlets have been correctly wired.

IEE Regulation requires that all single-pole non-linked switches are to be fitted in the phase
conductor. If the proper colored cable is used throughout the installation, i.e. in a 2-wire
installation, red for switch feeds and switch wires and black marked at both ends with a red
sleeve for light feeds, no confusion should arise.

Below is shown the means of testing with the supply disconnected.

Testing for polarity or switch with circuit dead

IV) Earth-fault loop testing

When earth-leakage protection relies on the operation of fuses or circuit breakers, the
effectiveness of earthing shall be tested by means of an earth-loop impedance test in
accordance with IEE Regulation.

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The figure below shows the path of leakage current from an earth fault on a 2-wire final
circuit. The path of the leakage current is from the earth fault (F) along the protective
conductor to the consumer's earthing terminal and thence to the consumer's earth
electrode. From here the fault current passes through the general mass of earth to the
supply authority's earth electrode at the supply transformer, through the transformer
winding and along the line through the consumer's wiring to the fault. This path is called the
line-earth loop, and it is this loop which is to be tested.

Line-earth loop

A line-earth tester such as the Megger line-earth tester would be used. The operation of
this instrument is as follows:

The instrument passes a short duration current through the loop, the value of the current
depending upon the impedance of the loop as well as upon the voltage of the tester. The
current passes through a 10ohm resistor in series with the loop, and the voltage drop across
it is measured by means of a ballistic instrument which is calibrated to read directly the loop
impedance in ohms.

It is necessary to conduct this test in order to establish that the test value does not exceed
that provided in lEE Wiring Regulations.

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5.4 Completion and inspection certificates

On completion of a new installation or of a major alteration, and after inspection and

testing as described in this chapter, the installation contractor is required to give a
completion certificate. This certificate, which is shown in full in the regulations, gives certain
details of the installation including the number of appliances, etc., the method of earthing,
and the value of the earth-loop impedance.

The certificate states that the work has been done in accordance with regulations. It also
recommends periodic testing and inspection.

An inspection certificate should accompany and be attached to the completion certificate.

This certificate, which is much lengthier than the previous certificate, gives the results of the
full range of tests of the installation. The form of this certificate is also given in full in the
regulations.

These certificates should be retained with all documents associated with the installation.

Below is Appendix 2 of the Ethiopian Building Code Standard.

Appendix 2: Forms of Completion and Inspection Certificate
1. Installation
• The forms of completion, inspection and testing shall be made out and
signed by competent persons in respect of the design, construction,
inspection and testing of work.
• Completed forms shall indicate a responsibility for design, construction,
inspection and testing, whether in relation to new work or further work on
an existing installation.

Note: More electrical installation works certificate is found in the Guide to the Wiring Regulations –
17th Edition IEE Wiring Regulation.

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