Intertek Cleeve Road, Leatherhead, Surrey KT22 7SB UK

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1 Intertek Cleeve Road, Leatherhead, Surrey KT22 7SB UK

2 Author: Craig Diack-Evans Senior International Business Development Manager ASTA Certification Intertek, Commercial & Electrical Division The challenges The manufacturers of power systems, electrical transmission and distribution equipment and switchgear systems face the same challenges as any other manufacturer the need to reduce costs in the production process, to comply with legislation that governs their product, to speed time to market to increase selling days and to gain competitive advantage over their rivals in the marketplace. These challenges however are made especially complex by the nature of the equipment itself. In many cases the equipment can be large, heavy or custom built for client. This can bring particular logistical and financial complications as well as potential issues with port authorities when getting the equipment shipped for testing. In this paper we will look at a lesser known route to compliance for this equipment that meets manufacturers challenges in a practical and effective way that of Witness testing. As a well known point of reference we ll use the ASTA type testing programme and product assessment system as an example of how witness testing works and look at the benefits it can bring. ASTA type testing is a well established certification system used in the electrical transmission, installation and distribution industry. Having been in place for decades, it has wide recognition and acceptance by regulatory authorities around the globe. A traditional route to compliance: ASTA type testing Normally, type testing for ASTA certification of equipment is only permitted and performed at ASTA Recognised Testing Laboratories. Such laboratories have been rigorously assessed to the requirements of ISO / IEC and are continuously monitored to ensure their ongoing performance and capabilities. They are also equipped with ASTA Observers, trained and appointed by ASTA, whose principal role is to ensure that the tests are performed in accordance with the requirements 1

3 of the standard, ASTA s requirements and any relevant Guides and Test Instructions. Finally they also take responsibility for accepting that the test results meet the requirements of the standard and for drafting the resulting certificates and test reports. Recognised laboratories invest a lot of time and money in achieving recognition and in training their staff to become ASTA Observers and in accepting ongoing assessment of their performance and compliance with ISO / IEC plus they pay an annual fee for the privilege of being ASTA Recognised. This is great news for the manufacturers that use these laboratories and it means that a strictly controlled group of dedicated facilities for testing low, medium and high voltage equipment to the requirements of a recognised testing and approval scheme like ASTA is permanently in place and can be conveniently used at any time. They can visit and witness the testing for themselves and use the permanent nature of these laboratories to plan their ongoing compliance activities and harness them as a source of additional technical expertise for their own technical staff. Issues As these laboratories are highly specialised only a relatively small number of them exist. This means that a product has to be shipped from the place of manufacture to be tested. With heavy, large or custom built equipment this can sometimes add significant extra logistical costs to the test fees, add time into the compliance cycle with a potential port authority review and the laboratories might be a significant distance from the manufacturer or end client who may want to oversee the test work themselves. Moreover, as these laboratories are in constant demand, their availability may not fit with the manufacturers schedule to get the product to market by a certain date. So for this type of equipment, manufacturers seek out an alternative route that minimise potential logistical delays and utilise alternative perhaps more convenient test locations (including their own in-house laboratories), while still participating in respected and valued test and certification schemes like, in this example, ASTA. 2

4 The solution Conducting testing at a non-recognised laboratory, but under the careful supervision of an expert, scheme recognised witness is an alternative route to compliance that can meet many manufacturers needs in these circumstances. For the ASTA Scheme, witness testing can be utilised for any product or Standard within the scope of ASTA s own accreditation, as shown in the table below. If a manufacturer wants testing outside of this scope, it can be undertaken, but the tests and the resulting certificate will not be regarded as accredited. ASTA s accredited scope includes: Product Standard LV Assemblies IEC / IEC LV Busbar Trunking Systems IEC LV Distribution Boards IEC LV Fuses / Fuse holders IEC Series LV Circuit Breakers IEC LV Fuse Switches IEC LV Starters / Contactors IEC Miniature Circuit Breakers IEC Power Transformers IEC Series HV Circuit Breakers IEC HV Metal Enclosed Switchgear & IEC Controlgear Internal Fault (Arc) Tests IEC Annex A The witness testing process In this type of project, there is no pre-set application form, but rather a client contacts the ASTA team describing the service required, the location, equipment to be tested, the test programme and required duration. The request is assessed and an appropriate expert assigned to the project. Once the expert s level of qualification and experience is accepted by the client, the test programme is planned and costed with extra time built into the test schedule to allow the witness (also known as an ASTA Observer ) to conduct a brief 3

5 assessment of the testing facilities. This is to verify that the laboratory has the necessary test equipment and that it is calibrated, has the capacity to perform the tests at the right test values and that competent personnel have been allocated to perform the tests. This pre-assessment is performed regardless of whether the laboratory is accredited or not. The ASTA Observer shall: Discuss and agree the test programme with the client and the laboratory and manage the test programme. Be satisfied of the validity of calibrations for all recording and measuring equipment before and after every series of tests and the results recorded for later reference. Witness all type tests Conduct an examination of the apparatus before, during and after a series of type tests to ensure that the requirements of the Standard and ASTA Test Instructions and Guides have been satisfied. Be responsible for the recording of the condition of the apparatus before, during and after a series of tests. Be present during all tests and examinations. Be responsible for verifying that any drawings and parts schedules submitted correctly identify the equipment tested. Draft and sign the official ASTA Certificate / Test Report. Their signature confirms that they vouch for the condition of the apparatus, the accuracy of the test results, the method of carrying out the tests and that the requirements of the Standard and ASTA Test Instructions and Guides have been satisfied. Where ASTA certification is not required but only an independent expert to witness tests on behalf of the client is needed, then the ASTA Observer will write a brief report of the tests witnessed for the client s agreement and signature. 4

6 Deliverables The deliverables from this approach will be ASTA test reports and or ASTA type test certificates that can be used to demonstrate regulatory compliance against identified Standards or sections of Standards (as required) and to reassure clients that your products are as safe as they can be. Benefits Witness testing enables manufacturers of large, heavy or custom built products that are costly to assess through traditional accredited laboratories routes to take advantage to local testing resources - internal or external, whilst still retaining the quality and integrity of scheme recognition. Witness testing reduces logistical costs, both in shipping of goods and in travel expenses of those who want to monitor the testing themselves reducing the impact on the overall compliance budget. Witness testing provides Manufacturers with a wider access for obtaining Certification and test reports on a global scale. Witness testing sometimes means that tests can be conducted earlier to help manufacturers get their product to market faster. Giving them more selling days helping them to increase their bottom line and helping them to secure a competitive advantage over their rivals with an earlier market footing. Important Note: Each application will be considered on a 'case-by-case' basis and there is no guarantee that the application will be accepted. For example, if there is a perfectly capable ASTA Recognized Testing Laboratory within reasonable distance of the manufacturer, then the application is likely to be declined. Conclusion While witness testing isn t suitable for all large, heavy or custom product projects, it does provide a flexible solution to meet most manufacturers ongoing commercial challenges, where using distant specialist laboratories is less practical. Time and inconvenience can be saved by using this route, so manufacturers should speak to their certification partner to establish whether this solution is appropriate to meet their individual needs. 5

7 Craig Diack-Evans joined ASTA Certification Services in January 1989 as a Product Certification Engineer and his current role is as Senior International Business Development Manager Certification Intertek, Commercial & Electrical Division, following the acquisition of ASTA BEAB Certification Services in Craig has extensive experience in all aspects of engineering from design to commissioning on sites throughout the world having started his career as an apprentice with GEC. Since joining ASTA, Craig has also gained considerable experience in the field of third-party certification and testing and has achieved an International profile and reputation in this field. Craig is an experienced assessor of management systems and provides his technical assessment expertise to other organisations. He is also authorised to witness tests at accredited laboratories on behalf of Intertek / ASTA BEAB and other organisations. Craig Diack-Evans Senior International Business Development Manager ASTA Certification Intertek, Commercial & Electrical Division craig.diack-evans@intertek.com UAE: UK: Al Moosa Tower II, 25th Floor, Sheikh Zayed Road, P.O. Box: Dubai, UAE Office: +971 (0) Ext 15 Mobile: +971 (0) Fax: +971 (0) Hilton House, Corporation Street, Rugby, Warwickshire, CV21 2DN, United Kingdom Office: Mobile: Fax: For more information on specific testing and certification information, please contact Intertek at , info.uk@intertek.com, or visit our website at uk.intertek-etlsemko.com. This publication is copyright Intertek and may not be reproduced or transmitted in any form in whole or in part without the prior written permission of Intertek. While due care has been taken during the preparation of this document, Intertek cannot be held responsible for the accuracy of the information herein or for any consequence arising from it. Clients are encouraged to seek Intertek s current advice on their specific needs before acting upon any of the content. 6