Where to measure, log, and verify performance.
Design testability in from the start. Provide safe interfaces for voltage/current checks, hydraulic pressure/flow taps (512), and functional proving that mirrors the interlock matrix (352). Standardize counters/run-time logs (541–542), witness templates, and pass/fail thresholds. Fault-isolation hints speed SAT (638) and future maintenance (734). Keep records aligned to evidence standards (716, 444). Include one-sentence context that naturally links upward to the parent hubs (this section and the chapter hub). Add SIRA context with a link to SIRA Bollards (UAE) when relevant. Link installation pages only if helpful: What to Expect and Installation Guide.
Important: This is a general guide. For live projects we develop a tailored
Method Statement & Risk Assessment (MS/RA) and align with authority approvals (e.g., SIRA) where in scope.
519.1 Safe test interfaces
Provide shrouded sockets and labeled taps. Safety enables repeatable HVM bollard testing.
Build safety into every test point: use finger-safe, shrouded test sockets for voltage and current, clearly label ranges and locations, and include lockable covers near panels to support Lockout/Tagout (LOTO). For hydraulic systems, fit capped test ports with check valves to avoid spills and air ingress. Consistent placement helps repeatability across lanes and sites.
Place test points where hazards are minimized: outside arc-flash boundaries in the electrical cabinet and away from moving parts near the bollard head. Add durable legends that match the Panel Wiring Standards (527) and the Power-On & Controls Health (632) sequence.
| Aspect | What matters | Where to verify |
|---|---|---|
| Performance | Tested system (bollard + footing) | Crash standards overview |
| Operations | Duty cycles, fail-state, safety | Installation Guide |
519.2 Electrical measurements
Measure voltage, current, inrush, and harmonics. Data validates crash rated bollard supply design (514).
Confirm feeder health before functional tests: verify phase sequence, steady-state voltage, and % imbalance, then measure inrush current on drive starts. Capture running current, crest factor, and power factor to compare against the design diversity and volt-drop calculations (see Volt-Drop Calculator 925).
Trend harmonic distortion (%) and THD(I/V) under typical and “worst” duty cycles to validate the protection/coordination study in Electrical Supply & Protection (514). For automatic lanes, record start/stop waveforms for each Electromechanical drive (513) or HPU (512).
519.3 Hydraulic pressures/flows
For HPUs, add dual-scale gauges and flow meters (512). Measurements prove HVM bollard EFO energy.
Fit permanent glycerin-filled gauges (suction/pressure/return) with isolation cocks and quick-connect test ports on the manifold. Use a low-loss inline flow meter on the raise circuit for calibrated speed checks. Correlate readings with reservoir temperature to understand viscosity effects in hot-climate operation (337).
Test the EFO path: verify accumulator pre-charge, charge time, and dump flow meet the specified raise/stop times. Record ISO 4406 oil cleanliness after commissioning flush and again at handover to set the maintenance baseline (733).
519.4 Functional proving
Link tests to the interlock matrix (352). Proving demonstrates crash rated bollard behavior.
Derive every functional test from the lane’s interlock matrix (352) and state machine. Prove permissives, inhibits, deadman/hold-to-run controls, and alarm transitions with clear pass bands (e.g., raise time ≤ X s). Include safe-local mode and comms-loss behavior (535) so edge cases are witnessed, not assumed.
Cross-reference test IDs back to matrix rows (“matrix-row traceability”) to simplify review. Capture video of each sequence for the SAT / Witness Procedure (638) package and the Evidence Capture Standards (716).
519.5 Logging counters & run-time
Expose counters via HMI/SCADA (544, 541). Counters support HVM bollard KPIs (542).
Expose per-lane counters (ops, raises, EFOs), cycle times, and error tallies through the HMI (524) and upstream remote fault logging (541). Set minimum retention for trend plots (e.g., 90 days) and publish alert thresholds from the KPI Set (542).
During commissioning, snapshot counter baselines and export CSVs for your handover pack (736). These become the reference for SLAs (738) and predictive maintenance (543).
519.6 Witness templates
Standardize forms with pass/fail bands (716, 638). Templates speed crash rated bollard acceptance.
Use consistent witness sheets that tie each step to a matrix row, the instrument used, and an acceptance band. Include photo/video IDs (time-stamped), the witness form (918) reference, and a signature block. Provide a “reset-to-normal” checklist to hand the site back safely at the end of each test day.
519.7 Pass/fail criteria
Define numeric thresholds for timings and voltages. Criteria make HVM bollard tests unambiguous (714).
Publish measurable bands for raise/lower times, EFO response, stall current, voltage sag (%), and max THD. Where applicable, include temperature-corrected limits and a note on instrument accuracy. Tie each criterion to the relevant ITP step (714) and design document section so reviewers can audit the basis.
519.8 Fault isolation hints
Include simple trees for common faults. Hints reduce crash rated bollard downtime.
Provide pocket troubleshooting trees: “won’t raise” (check E-stop, permissives, loop status, pressure), “slow raise” (oil temp/viscosity, accumulator pre-charge, flow path restriction), “trips on start” (inrush peak vs protection grading, mechanical binding). Include an operator recovery hint on the HMI for the top 3 issues to cut MTTR.
519.9 Record retention
Store results with filenames per 911 and versions per 115. Retention protects HVM bollard traceability (938).
File everything to the agreed folder tree with File Index & Naming Rules (911). Use release/version tags (115), keep a transmittal log (917), and archive raw meter exports plus PDFs. Authority projects in the UAE may require submission via SIRA or local portals—include a brief reader guide and cross-reference in your Submission-Pack Guidance (938).
Related
External resources
- NPSA — Hostile Vehicle Mitigation (overview)
- ASTM F2656 — Crash rating overview
- BSI — Impact test specifications for VSB systems
519 Power Test Points — FAQ
Where should test points be placed to minimize risk?
Put electrical test points outside arc-flash boundaries and away from moving parts; use shrouded, finger-safe sockets and clear labels. For hydraulics, use capped, valved ports near the manifold, oriented for safe access without removing guards.
What electrical measurements matter most during commissioning?
Confirm phase sequence, steady voltage, and current under load; capture inrush peaks, running current, and power factor. Trend THD(I/V) during starts and steady operation to validate protection, coordination, and the design’s volt-drop assumptions.
How do we prove EFO performance on hydraulic systems?
Measure accumulator pre-charge, charge time, and dump flow, then time the raise/stop sequence. Correlate with oil temperature and verify the results meet the published pass bands for EFO response and raise time.
What records must be retained for SAT and authority submissions?
Keep raw instrument exports, annotated photos/videos, signed witness sheets, and summary PDFs. File to your naming rules (911), version with the project release ID (115), and cross-reference in the Submission-Pack Guidance (938). Include SIRA notes if applicable.