05221e06

Eni S.p.A. Divisione Exploration & Production

Il presente documento è RISERVATO ed è di proprietà di ENI E&P. Esso non sarà mostrato a Terzi né sarà utilizzato per scopi diversi da quelli per i quali è stato inviato. This document is CONFIDENTIAL and the sole property of ENI E&P. It shall neither be shown to Third Parties nor used for purposes other than those for which it has been sent.

GENERAL SPECIFICATION

PROGRAM OF CHECKS AND TESTS FOR

ELECTRICAL INSTALLATIONS

05221.VAR.ELE.SPC

Rev. 6

March 2010

Eni S.p.A. Exploration & Production Division

05221 VAR.ELE.SPC Rev.6 March 2010

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FOREWORD

Rev. 1 Total number of pages 28 June 1988

Rev. 2 Total number of pages 20 August 1997 Computerized issue

Rev. 3 Total number of pages 21

July 2003 Issue for normative references revision and contents conformity


December 2004 General revision


October 2006 Revised pt. 6.14.2. for compliance to IEC 60364-6


March 2010 General Revision



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INDEX

1. SCOPE OF PROGRAM........................................................................................................................ 5 1.1 Normative References................................................................................................................... 5

2. DEFINITION OF TERMS...................................................................................................................... 6

3. PROGRAM DEFINITION CRITERIA.................................................................................................... 7 3.1 Checking of materials before installation................................................................................... 7 3.2 Mechanical Completion ................................................................................................................ 7 3.3 Pre-commissioning ....................................................................................................................... 8

4. DUTIES AND RESPONSIBILITIES ..................................................................................................... 9 4.1 Inspector......................................................................................................................................... 9 4.2 Scheduling and procedures ......................................................................................................... 9 4.3 Contractor's duties........................................................................................................................ 9

5. CHECK AND TEST RESULTS .......................................................................................................... 10 5.1 Documentation ............................................................................................................................ 10

6. MECHANICAL COMPLETION REQUIREMENTS ............................................................................ 10 6.1 General ......................................................................................................................................... 10 6.2 Conduct of Tests ......................................................................................................................... 10 6.3 Safety ............................................................................................................................................ 11 6.4 Generators ................................................................................................................................... 12 6.5 Power Transformers ................................................................................................................... 13 6.6 Neutral earthing resistors........................................................................................................... 14 6.7 MV & LV Motors .......................................................................................................................... 15 6.8 MV & LV Switchgear and Bus-bar.............................................................................................. 16 6.9 MV Power Cables......................................................................................................................... 19 6.10 L.V. Power & Control Cables...................................................................................................... 20 6.11 DC Supply System: UPS, Battery Charger and Batteries........................................................ 21 6.12 Lighting & Small Power Distribution System ........................................................................... 22 6.13 Navigation AIDS........................................................................................................................... 23 6.14 Earthing ........................................................................................................................................ 24 6.15 Electrical Heaters ........................................................................................................................ 26 6.16 Electrical Equipment & Device (Local Panel - Push Button - Power Socket) ....................... 26 6.17 Junction Box................................................................................................................................ 27 6.18 Electrical substations, HV switchyards, telephone exchanges, battery

rooms, etc .................................................................................................................................... 28 6.19 Chatodic protection system. ...................................................................................................... 29 6.20 Cable tray & rack. ........................................................................................................................ 30 6.21 Apparatus for Use in Hazardous Areas .................................................................................... 30

7. PRE-COMMISSIONING REQUIREMENTS ....................................................................................... 33 7.1 General ......................................................................................................................................... 33 7.2 Conduct of Tests ......................................................................................................................... 33 7.3 Safety ............................................................................................................................................ 33



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7.4 Generators ................................................................................................................................... 34 7.5 Power Transformers ................................................................................................................... 35 7.6 Neutral earthing resistors........................................................................................................... 36 7.7 MV & LV Motors ........................................................................................................................... 37 7.8 MV & LV Switchgear and Bus-bars ........................................................................................... 38 7.9 DC Supply System – UPS & Battery Charger and Batteries ................................................... 41 7.10 Lighting & Small Power Distribution System ........................................................................... 41 7.11 Navigation AIDS........................................................................................................................... 42 7.12 Electrical Equipment & Device (Heater, Panel, Junction Box, Push-Button

Station, Socket) ........................................................................................................................... 43

8. REFERENCE DOCUMENTS ............................................................................................................. 44 8.1 Specification, Standards and Codes......................................................................................... 44 8.2 Electrical Mechanical Completion Check Lists........................................................................ 44 8.3 Electrical Pre-Commissioning Record Sheet ........................................................................... 45

9 METHOD OF COMPANY STANDARS REQUEST / INFORMATIONS ............................................ 46



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1. SCOPE OF PROGRAM

The program defines checks and tests to be carried out on individual materials and electrical system during installation or on completion. Checks and tests aim at determining any abnormalities that may have occurred during transport, installation and assembly and at establishing the efficiency of systems and circuits and feasibility of components. These checks and tests do not aim at repeating inspections carried out at the supplier's premises and, therefore, at verifying the performance and correct construction of materials.

1.1 Normative References

All systems, equipment and materials shall be in accordance with regulations in force in the country where they must be installed. The rules applicable standards ENI are listed in the specification of Company: - List applicable regulatory standards at the time of electrical 20138.DOC.ELE.ELN Of that specific company, the Contract / Supplier will have to verify the validity of each rule (latest edition available) and also will check for the issuance of new regulations which follow



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2. DEFINITION OF TERMS

The following words and expressions shall have the meanings hereby assigned to them: - "COMPANY" (or “Employer”) shall mean the name of Company who has called for Tenders to provide and execute the works and who will employ the CONTRACTOR and the legal successors in title to the Employer but not (except with the consent of the CONTRACTOR) any assignee of the Employer; - “CONTRACTOR" means the person or persons, firm or company whose tender has been accepted by the Employer and includes the Contractor’s personnel representatives, successor and permitted assignees subject to Employer consent; - “INSPECTION AUTHORITY”, i.e. the organization nominated by COMPANY to supervise checks and tests.



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3. PROGRAM DEFINITION CRITERIA

The program described on the following pages takes into account the Client's requirements and has been defined considering that every check and test has a specific intrinsic value with regard to data or characteristics to be established. However, this value varies depending on the role played by the system, circuit or component to which it applies and this role is linked to implications concerning malfunction and safety of personnel and equipment. Therefore, depending on the importance of the circuit, checks and tests may be carried out only on a sample of identical or similar circuit components (e.g. motor starters). The program has been prepared by subdividing checks and tests as follows:

3.1 Checking of materials before installation

Before being installed, materials must undergo a "visual examination" to determine any damage or breakage to prevent the installation of materials that will require replacement at a later stage.

This check will, generally, be carried out at the warehouse. However, for some materials which must be transported to the place of installation in their packing (e.g. panels) it can be carried out on site. Note: In doubtful cases instrument checks and/or tests can be carried out.

3.2 Mechanical Completion

Mechanical Completion is defined as that point in the project when work to install, erect and fit out the facilities has been completed, and that fitting out work has been tested. Eg. Electric cables will have been installed, terminated, continuity and insulation resistance tested but not energised. Motors will similarly have been checked out but not run. Checks and tests must be carried out during construction or when systems or a constituent part of them are mechanically completed to ensure that the equipment and individual components are installed in accordance with design requirements, suppliers' instructions, technical codes and accident prevention codes and that there is no obvious damage or breakage. Mechanical equipment will be installed, aligned and fitted with any temporary devices (strainers, etc.) required for commissioning. Initial fill of lubricants, etc., will be made. Mechanical completion will be done on a methodical system by system basis, and checks will be documented and compiled in a similar manner. In the case of areas with potentially explosive atmospheres, checks must be carried out to ensure that the whole system and individual components are installed in compliance with appropriate codes. More particularly, checks and tests listed below must be carried out.



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In the case of parts of systems or materials which are not indicated below, checks and tests must be carried out by analogy with those of materials indicated and in accordance with the supplier's instructions.

3.3 Pre-commissioning

Pre-commissioning is defined as the activities following Mechanical Completion carried out to facilitate safe and efficient commissioning of a system. Eg. Electrical switchgear relays will be tested and settings verified. Motors will be run for 30 minutes without load (uncoupled). Cables will be energised as required. Mechanical equipment will be prepared for operation by testing and running auxiliaries, by checking trips and other functions. Seal oil and lube oil systems will be flushed. These checks and tests must be carried out during construction or on completion and, in any case, before commissioning in order to: a) determine any abnormalities that may have arisen during installation; b) ensure the efficiency of systems and circuits; c) ensure that components operate under safe conditions.



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4. DUTIES AND RESPONSIBILITIES

Duties and responsibilities relevant to checks and tests are as indicated in "Data Sheet for duties ant responsibilities of checks and tests of electrical installations" (MOD.ELE.FTC.001). The following prescriptions shall also apply:

4.1 Inspector

Tests and/or checks outlined with code (P) on Data Sheet for duties and responsibilities entrusted to qualified engineer who will be responsible for the organization of checks and tests and whose instructions must be complied with by all persons for whatever reasons they may be present. The above engineer is the "Inspector" and must therefore sign all documents associated with checks and tests.

4.2 Scheduling and procedures

The Company shall agree with the Contractor on the schedule and procedures for the execution of checks ant tests.

4.3 Contractor's duties

All duties connected with the Contractor's responsibilities shall be at his own expenses (e.g. labour equipment, instruments, documentation, etc.).



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5. CHECK AND TEST RESULTS

5.1 Documentation

Results of tests mentioned in paragraph 3.1 need not be recorded. Results of checks and tests mentioned in paragraphs 3.2 and 3.3 must be recorded on appropriate documents which must be attached to this PROGRAM so as to have complete and exhaustive file on the subject. For further information see the following chapter 8.

6. MECHANICAL COMPLETION REQUIREMENTS

6.1 General

The main scope of Mechanical Completion inspections and tests is to ensure conformity with the project specifications and drawings and to prove that all equipment and materials are suited to the duties they are intended to perform. This procedure covers the general responsibilities of the electrical contractor during checkout of electrical equipment. Specific requirements are given for the following types of testing: - General checks - Grounding system tests - Insulation resistance tests - Protective relay system tests - Load tests - Noise tests - Temperature tests - Vibration tests (where appropriate) - Illumination level tests - DC system tests - Navigation Aids Tests All work shall be executed in strict accordance with project specifications and the approved drawings. The written approval of the COMPANY is required for any deviations.

6.2 Conduct of Tests

a) The Mechanical Completion program shall demonstrate the proper installation of the complete electrical system.

b) Checkout tests shall be witnessed by the COMPANY as required. c) Checkout tests may be conducted concurrently with Pre-commissioning tests. d) Complete dossier shall be submitted to the COMPANY at completion of

Mechanical Completion. e) After the Mechanical Completion program has been completed and accepted by

the Company, the Contractor shall be responsible for maintaining the equipment in safe and protected conditions. All covers, doors and access plates shall be properly fastened. All wiring shall be completed..



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f) It should be noted that Mechanical Completion work may be carried out on

adjacent equipment to live installations. The safety precautions listed must be observed.

6.3 Safety

a) General Safety Precautions

The consequences of shock or burn from electrical systems are serious. Work on electrical equipment shall, therefore, be carried out only when the equipment is de-energised, and by qualified personnel, and who fully understand the electrical system of the project. One-line diagrams shall be available at all times. All feeding equipment and circuits shall be tagged-out and locked-out. The test/check operative’s own key or lock shall form part of the lock-out procedure. All equipment such as bus bars, circuit breakers, and motor shall be properly grounded as appropriate before any testing or other work is initiated.

b) Equipment Isolation

All equipment shall be physically disconnected from its power source to prevent accidental injury to personnel resulting from inadvertent re-energisation. Equipment isolation is necessary to ensure that voltages applied to the equipment under test are not allowed to feed-back into power transformers, generators and associated upstream synchronising and control circuits. The consequences of back-feeding voltages include danger to personnel and damage to equipment.

c) Medium-Voltage Testing

While any medium-voltage testing is being conducted shall be ensured that the test area is properly guarded to prevent unauthorised entry and that DANGER notices are posted adjacent to, and at all access ways to the test area during the period of the test. All cables must be discharged both before and after applying any test voltage. Any associated cables not being tested shall be grounded during the test, e.g., other phase conductors of a three-phase circuit. Temporary conductors used for test purposes shall not be sized less than the rating of the circuit under test. Caution notices shall be posted adjacent to, and at all access ways to the test area.

d) Portable Electrical Equipment

Unless portable electrical equipment is double insulated or connected to ground fault interrupters, the equipment shall be grounded using flexible supply cable that incorporates a ground continuity conductor.



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6.4 Generators

6.4.1 Installation and Mechanical Completion

a) Ensure that the equipment meets the area classification and specification requirements.

b) Note the nameplate ratings of the generators and compare with those given on

the approved drawings. c) Ensure that the enclosure IP rating meets specification requirements. d) Ensure the mechanical integrity of all components. e) Ensure that any shaft blocking or transit packing has been removed. f) With the coupling removed ensure that the generator rotates freely and that the

end play of the rotor is within tolerances. g) Without dismantling, inspect as far as possible oil rings, oil levels, grease packing

and bearings. Inspect for leakage. h) Inspect the paint finish for damage. Any damaged areas shall be repainted. i) Inspect the earthing stud and the connection to the general earthing system,

including those in the terminal box. j) Ensure that all terminal boxes are clean, dry and in good condition. Check that all

spare entries are plugged. k) Check that cables are properly terminated, connected and supported, that the

terminated box layout is satisfactory and that any current transformers are securely installed.

l) Check that terminal boxes are properly phase segregated, where applicable. m) Ensure that anti-condensation heaters are correctly installed and terminated. n) Ensure that all vibration and temperature monitoring equipment is properly

installed (if fitted). o) Ensure that internal are free from dust, debris, etc. p) Ensure that the installation and fixing of equipment is correct (level, alignment,

etc).

q) Ensure that gaskets and seals are correctly installed and are in good condition.

r) Ensure that the conductors are correctly connected to terminals (also in order to the direction of rotation) and that the insulation distance to earth is appropriate.

s) Ensure that drains are correctly installed and effective; t) Ensure that there are not obvious damages to mounted instruments.

u) Ensure that the air filters are correctly installed and clean.



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v) Ensure that the brushes, when existing, are transversally staggered on the surface of the rings without, however, being in contact with ring corners so that they do not splinter. The distance between brushes and ring surface is that anticipated by the manufacturer and the inclination, if any, is correct, i.e. opposite to the direction of rotation. Brushes move freely, there is even contact with rings and the brush spring pressure is that specified by the manufacturer. Braided brush leads do not touch the brush gear

w) Check that all mounting and holding down bolts are secure.

6.4.2 Test Certificates

a) Installation and Mechanical Completion shall be recorded on Check List CL-E001 (MOD.ELE.FTC.002).

6.5 Power Transformers

6.5.1 Installation and Mechanical Completion Checks


b) Note the nameplate ratings of the generators and compare with those given on

the approved drawings. c) Ensure that the enclosure IP rating meets specification requirements. d) Ensure the mechanical integrity of all components. e) Inspect the paint finish for damage. Any damaged areas shall be repainted. f) Ensure that the transformer is complete with all accessories and instruments. g) Ensure that there are not obvious damages to transformers, accessories and

instruments. h) Ensure that the oil level (or other dielectric liquid) in the conservator corresponds

to the level prescribed with regard to the oil temperature read on the dial thermometer. If the level is too low add new oil; if the conservator is fitted with a water collecting trap, drain it using the drain valve – Only for oil transformer.

i) Ensure that air bubbles have been evacuated by opening and closing appropriate

breather plugs in the tank, radiators and insulators – Only for oil transformer. j) Ensure that the thermometer bulb tube is full of oil – Only for oil transformer. k) Ensure that the oil level in the air dryer sump corresponds to that marked – Only

for oil transformer. l) Ensure that silica gel (silicon oxide) of the air dryer is dry (if blue: dry; if purple:

20-30% humidity; if pink: damp-saturated). It can be regenerated by removing the dryer with the air intake pipe blocked: the silica gel must then be spread on to a

metal sheet and heated to 180-200°C until it turns blue. Before turning down the dryer to remove the silica gel, the oil sump at the bottom of the container must be unscrewed – Only for oil transformer.



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m) Inspect tap change mechanism. n) Ensure that the pressure valve or bursting disk are not blocked in the "closed"

position and can operate freely – Only for oil transformer. o) Ensure that the level of the compound or oil in the cable terminal box corresponds

to that prescribed – Only for oil transformer. p) Ensure that insulators are clean. q) Inspect the earthing stud and the connection to the general earthing system,

including those in the terminal box. r) Check that cables or bus-bars are properly terminated, connected and supported; s) Ensure that all terminal boxes are clean, dry and in good condition. Check that all

spare entries are plugged. t) Ensure that internal are free from dust, debris, etc. u) Ensure that bus-bar or cable terminal protection boxes are well closed. v) Ensure that there are not loose or missing screws or nuts. Accessories are well

fixed. w) Ensure that rollers on rails are chocked. y) Ensure that gaskets and seals are correctly installed and are in good condition. x) Ensure that neutral connections are secure. z) Ensure that the padlocking facilities are satisfactory. a1) Ensure that enclosures suitable for protection against adverse weather conditions

and sun are securely installed. a2)Ensure that warning labels (high voltage, high temperature, etc) are properly

installed. a3)Inspect the transformer and auxiliary equipment for alignment and tightness of

foundation bolts and fixings in general.



6.6 Neutral earthing resistors



b) Note the nameplate ratings of the neutral earth resistors (NER's) and compare

with the approved drawings.



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c) Ensure removal of any temporary weatherproofing and any drying agents (e.g.

silica-gel).

d) Inspect the neutral earthing resistors for alignment, tightness of foundation, bolts and fixings.

e) Inspect the connections to the neutral earthing resistor. f) Inspect the frame earthing arrangement. g) Ensure all cable supports and glanding are satisfactory. h) Ensure all terminations are satisfactory. i) Ensure that all gaskets are installed correctly. j) Ensure that the internals of the NER are free from dust and debris. k) Ensure warning labels for sudden high temperature in the event of operation are in place.



6.7 MV & LV Motors



b) Note the nameplate ratings of the motors and compare with those given on the

approved drawings. c) Ensure that the enclosure IP rating meets specification requirements.

d) Ensure the mechanical integrity of all components. e) Ensure that any shaft blocking or transit packing has been removed.

f) With the coupling removed ensure that the motor rotates freely and that the end

play of the rotor is within tolerances. g) Without dismantling, inspect as far as possible oil rings, oil levels, grease packing

and bearings. Inspect for leakage. h) Inspect the paint finish for damage. Any damaged areas shall be repainted. i) Inspect the earthing stud and the connection to the general earthing system,

including those in the terminal box.



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j) Ensure that all terminal boxes are clean, dry and in good condition. Check that all spare entries are plugged. In addition, for MV motors check that terminations are satisfactory.

k) Check that cables are properly terminated, connected and supported. l) Ensure that anti-condensation heaters are correctly installed and terminated. m) Ensure that all vibration and temperature monitoring equipment is properly

installed (if fitted). n) Ensure that internal are free from dust, debris, etc. o) Ensure that the installation and fixing of equipment is correct (level, alignment,

etc). p) Ensure that gaskets and seals are correctly installed and are in good condition.

q) Ensure that the conductors are correctly connected to terminals (also in order to

the direction of rotation).

r) Check that all mounting and holding down bolts are secure.



6.8 MV & LV Switchgear and Bus-bar

6.8.1 Installation Completion


b) Note the nameplate ratings of the equipment and compare with those given on

the approved drawings. c) Ensure that the enclosure IP rating meets specification requirements. d) Inspect the switchboard assembly for alignment, level, tightness of foundation

bolts and fixing in general. Ensure that circuit breaker trucks can be easily manoeuvred in and out of their cubicles - applicable to all withdrawable equipment.

e) Compare the switchgear equipment with the Equipment Schedule, paying

particular attention to the rating and any circuit changes. f) Inspect the switchboard earth bar and earth cable for electrical and mechanical

continuity.



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g) Ensure that all panel doors and gland plates are bonded to the switchboard structure and that non-magnetic gland plates are fitted to single core cables.

h) Ensure that all equipment installed in the switchboard is in good condition,

particularly bus-bar insulation and bracing and joint insulation. i) Inspect bus duct connections. j) Inspect the inside of the switchgear for cleanliness, paying particular attention to

the insulators. k) Ensure that all equipment (i.e. circuit breakers, contactors, fuse, switches,

voltmeter, ammeter, protection relay, overload relay, current transformer, etc.) are in good condition and in particularly meet the drawings, data sheet and specification requirements.

l) Ensure that there are not obvious damages to equipment and instruments. m) Ensure that the mechanical operation of equipment, in particular circuit-breakers

and operating devices, is correct. In order to verify this, the circuit-breaker mechanisms and springs, if any, must be operated, mechanical locks must be checked and, if the breaker is withdraw able, and this operation should also be checked.

n) Ensure that switchboards and equipment are securely fixed to supports. o) Ensure that doors and panels close properly and there are keys for all locks. p) Ensure that holes that are not used but are planned for future equipment or

instruments are correctly plugged. q) Ensure that switchboards installed outdoors are protected against adverse

weather conditions and sun with suitable canopy. r) Ensure that warning labels, fitted by the manufacturer for special indications, are

intact.

6.8.2 Mechanical Completion Certification Testing

a) Prior to securely fitting the bus-bar covers, check the tightness of bus-bar joint bolts, measure the insulation resistance of the bus-bar. Ensure that cable and/or bus ducts are certified.

b) Test the switchboard earth system for electrical and mechanical continuity.

measure the earth path resistance at the earth bar to the general earth system. c) Measure the insulation resistance of the bus-bar and control wiring after ensuring

any sensitive equipment has been disconnected and also ensuring control wiring is not subjected to bus-bar test voltages. This test should be carried out prior to and immediately after the pressure test and before energizing the switchboard. The minimum acceptable resistance, together with the relevant test voltage, is given in the table below.



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SWITCHGEAR VOLTAGE

(V)

TEST VOLTAGE

(V)

MIN INSULATION RESISTANCE

(MΩ)

- Up to 1 kV

- Up to 4.6 kV - Above 4.6 kV

1000 Vdc

2500 Vdc 5000 Vdc

10

150 200

d) A DC high voltage test (pressure test) on both the main and auxiliary circuits shall

be carried out between phases and phase-to-earth. The following conditions must be adhered to for the tests:

(i) All current transformers secondaries will be short-circuited for the test. (ii) All voltage transformers shall be disconnected by removal of primary and

secondary fuses for the duration of the test. (iii) One pole of the testing supply shall be connected to earth and to frame of the

assembly for the phase to earth test.

MAX SYSTEM VOLTAGE (kV)

DC TEST VOLTAGE (FOR 1 MINUTE)

(kV)

- Up to 1 - 3.6 - 7.2 - 12 - 17.5 - 24 - 36

1,5

10 (*) 20 (*) 28 (*) 38 (*) 50 (*) 70 (*)

(*): or as recommended by Manufacturer

e) Upon completion of testing, reconnect all cables and function test the circuit to

ensure all links and fuses are replaced.


a) Installation Completion and Mechanical Completion shall be recorded on form CL-E004 (MOD.ELE.FTC.005).

b) All originals of test certificates generated by supplier must be attached to form CL-E004 (MOD.ELE.FTC.005) for inclusion in the system test dossier.



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6.9 MV Power Cables

6.9.1 Installation Completion a) Check that the cable installation is as per project specification and drawings.

b) Ensure that the gland certificates meet the Area Classification and Specification requirements.

c) Inspect the cable glands for tightness and good workmanship. Ensure that the correct type of gland has been used for the size and type of cable installed.

d) Where conductors have been terminated using crimped connections, ensure that the correct size and type of crimping lug bas been used.

e) Inspection the earth connections.

6.9.2 Additional Installation Completion Checks (MV Cables)

a) Ensure that cables have been glanded in accordance with Supplier's instructions.

b) Check that any incorporated stress relief measures and termination kits are satisfactory.

c) Ensure that the minimum cable bending radius has not been exceeded.


Before any cables are tested, all cleaning, supports, etc. shall be completed. Intermediate insulation resistance tests will be carried out before cleaning. Before making any measurements, the Inspector shall ensure that both ends of the cable have been disconnected and are clean of any metal and that core continuity of jointed cables is correct.

a) Measure the insulation resistance of the cable and record on the relevant test

certificate. The table below gives the test voltages and minimum acceptance values of insulation resistance. Where necessary, measure the conductivity of the earth conductor.

For all multicore cables, insulation resistance should be measured core-to-core, core-to-earth and screen-to-armour. Record only the lowest figure obtained.

CABLE OPERATING VOLTAGE (V)

TEST VOLTAGE

(V)

INSULATION RESISTANCE

(MΩ) (MINIMUM)

U0 /U

5000

200 (*)

(*) For cable length above 1 km = 200

Cable lenght (Km)



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6.9.4 Additional Mechanical Completion Certification Testing (M.V. Cables)

a) Apply a DC test voltage (pressure test) as per IEC code & regulations between the conductors of each high voltage cable and the copper tape screen of each conductor, also between each conductor and earth. Record test voltage and duration of test measure and record any leakage current.

Each cable shall be discharged after the above tests and the conductors earthed until the cable is out into service. The test voltage and duration are as tabulated below:

CABLE OPERATING

VOLTAGE (V)

BETWEEN

CONDUCTORS (V)

BETWEEN

CONDUCTORS AND EARTH

(V)

TIME (min)

U0 /U

4 U0

4 U0

15

b) As an alternative, and by agreement between the contractor and purchaser, an a.c. voltage test at power frequency, in accordance with the following points b1 and b2, can be used: b1) Test for 5 min with the phase-to-phase voltage of the system applied

between the conductor and the metallic screen; b2) Test for 24 hours with the normal operating voltage of the system;

Note: that the tests above mentioned are for new installations only; electrical tests on repaired installations are subject to installation requirements.


- MV cable check sheets and test certificates are for individual cables. - Mechanical completion certification testing of the M.V. cables shall be recorded

on forms CL-E005 and CL-E006 (MOD.ELE.FTC.006 and 007).

6.10 L.V. Power & Control Cables


a) Check that cable installation is as per project specifications and drawings.

b) Ensure that the gland certificates meet the Area Classification and Specification requirements.

c) Inspect the cable glands for tightness and good workmanship. Ensure that the

correct type of gland has been used for the size and type of cable installed and that, where specified, insulating gland adapters have been installed. Particular attentions should be paid to barrier glands.

d) Where conductors have been terminated using crimped connections, ensure that the correct size and type of crimping lug has been used.



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Before any cables are tested, all cleaning, supports, etc. shall be completed. Intermediate insulation resistance tests will be carried out before cleaning. Before making any measurements, the Inspectors should ensure that both ends of the cable have been disconnected and are clear of any metal and that core continuity of jointed cables is correct. a) Measure the insulation resistance of the cable and record on the relevant test

certificate. The table below gives the test voltages and minimum acceptance values of insulation resistance. Where necessary, measure the conductivity of the earth conductor.

For all multicore cables, insulation resistance shall be measured core-to-core, core-to-earth and screen-to-armour. Record only the lowest figure obtained.

CABLE OPERATING

VOLTAGE (V)

TEST VOLTAGE (V)

INSULATION RESISTANCE

(MΩ) (MINIMUM)

500 600 / 1000

500 1000

1 10


Installation Completion and Mechanical Completion certification testing of cables shall be recorded on Forms CL-E006 (MOD.ELE.FTC.007).

6.11 DC Supply System: UPS, Battery Charger and Batteries


a) Note the nameplate rating of the equipment and number, type and rating of batteries supplied. Compare with the ratings stated on the approved drawings for the equipment.

b) Ensure that the equipment certificates meet the Area Classification and Specification Requirements.

c) Inspect the chargers and battery stands for alignment, level and tightness of foundation bolts and fixing.

d) Inspect the earthing bolts and connections to the earth system, where applicable.

e) Check cleanliness. Where necessary clean the interiors of all control panels, chargers, etc. Remove any temporary silica-gel drying agents from the panels.

f) Note the type, size and rating of all fuses and protective devices and compare with the values stated on the approved drawings.



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g) Inspect all batteries for cracks, damage, tightness and cleanliness of terminals and connections.

h) Remove any transit bungs and store for possible future use.

i) Inspect all bolted connections between individual cells in a bank of batteries. Ensure that all battery terminals have been coated with vaseline or equivalent.

j) Inspect battery circuit breakers.

k) Where batteries and battery chargers are housed in the same cubicle or suite of cubicles, check the integrity of the gas tight seal between the compartments.

l) Ensure that there is not leakage of the electrolyte.

m) Ensure that connections between cells and blocks are such as to prevent any short circuit.

n) Ensure that connections from batteries to switchboards are well installed and suitably marked.

o) Ensure that warning labels, fitted by the manufacturer for special indications, are intact.


a) Ensure that all cables have been certified.

b) Measure the earth path resistance at the main earthing terminal. Note that special care must be taken when making tests on electronic equipment due to its susceptibility to damage by over voltage.


a) Installation Completion and Mechanical Completion shall be recorded on forms CL-E007 and CL-E008 (MOD.ELE.FTC.008 and 009).

6.12 Lighting & Small Power Distribution System


a) Ensure that the equipment meets the Area Classification and Specification requirements as laid down in the Design Specification and drawings.

b) Note the distribution board circuit numbering and the fuse rating of the circuits and compare with the approved drawings. Verify the operation of any safety features, such as interlocks, padlocks and door switches.

c) Note the location of the lighting fittings, sockets, etc. and compare with the approved drawings. Lighting equipment is correctly located and is no obstructed by pipes or other plant component thereby preventing the illumination of the areas

d) Inspect the earthing bus-bar and cable earthing connections inside the distribution boards and the earthing connections from individual items of equipment to the earthing grid where detailed on drawing refer to the earthing/bonding procedure.

e) Inspect lighting fittings, sockets and switches for neatness, weatherproofing, glanding, internal connections, general good workmanship and labelling.



Sheet 23 di 46


f) All equipment in hazardous areas should be inspected in accordance with the requirements of the procedure for the apparatus for use in hazardous areas.

g) Carry out inspection of junction boxes in accordance with the junction box inspection procedure.

h) Ensure that the circuits are correctly marked.

i) Ensure that the safety lighting system is installed as per the design project.

j) Ensure that glass and guards of lighting equipment are no broken.

k) Ensure that local lighting panels are suitably welded to the support structure. The mechanical operation of circuit-breakers is satisfactory.

l) Ensure that protection against corrosion has been provided and is complete or made good where necessary.

m) Ensure that poles and floodlights are complete with accessories and are earthed.

n) Ensure that road lighting equipment and floodlights are correctly orientated.


a) Confirm that all cable certification is complete, including supply cable to distribution boards.

b) Measure insulation resistance of distribution board phases to ground.

c) Measure each distribution board and sub-circuit insulation resistance to earth.

d) Check the earth continuity of each outgoing circuit.

e) Check the operation of MCCB, ESD and RCD isolation, where applicable, on each circuit.

f) Check that each circuit is correct to latest drawing revision.

g) As each sub-circuit from a distribution board is inspected, complete an inspection tag and attach it to the sub-circuit control switch in a prominent position.



6.13 Navigation AIDS


a) Check that the equipment certification meets the Area Classification and Specification requirements.

b) Note the nameplate rating of the supplied equipment and compare this rating with that on the approved drawings.

c) Inspect the installation of equipment for alignment, level and tightness of foundation bolts and fixings.

d) Ensure that the insides of any control panels, etc, have been cleaned out.



Sheet 24 di 46


e) Inspect the earthing arrangements, including earthing connections, inside the connection boxes.

f) Inspect the paint finish, paying particular attention to externally located equipment. Any damaged areas shall be made good.

g) Inspect the weatherproofing and bolting of the connection boxes. Weatherproofing should not be dependent upon the application of paint, tape or plastic compounds.

h) Ensure that the appropriate requirements of the procedure for the apparatus for use in Hazardous areas are carried out, if applicable.

i) Note the size, type and rating of all fuses and protective devices. Compare with the values stated on the approved drawings.



6.14 Earthing


a) Compare the earth connection type and size with the Schedule.

b) Where conductors have been terminated using crimped connections, ensure that the correct size and type of crimping lug has been used.

c) Ensure all connections are tight and greased.

d) In the case of instrument earths, refer to installation specification.

e) Ensure that buried conductors and earth rods are located in accordance with the design.

f) Ensure that conductors installed without protection are sheathed (yellow/green).

g) Ensure that the continuity of the protective conductors (PE), equipotential conductors and other conductors which form part of the earthing system has been verified.

h) Ensure that conductors rising from the floor or ground are protected by means of a conduit section.

i) Ensure that buried joints of conductors are protected against damp with a bitumen or similar mixture.

j) Ensure that earthing and equipotential connections are provided for machines, panels, equipment, components and structures, including those outside the

electrical installation, as anticipated in the design and in accordance with reference codes.

k) Ensure that down conductors and other apparatus relevant to lightning protection system comply with the design.

l) Ensure that transformer neutrals are correctly earthed.



Sheet 25 di 46


m) Ensure that earthing of concrete reinforcing bars has been carried out, if required by the design.

n) Ensure that terminals and earth bus-bars are correctly installed.

o) Ensure that protective conductors (PE) and earthing conductors are sized in relation to the design and are correctly fixed and protected.

p) Ensure that metal sheaths and cable armouring are earthed.

q) Ensure that protection against corrosion has been provided and is complete or made good where necessary.


a) Measurement of grounding grid resistance (RE):

- The measurements shall be carried out before the start-up of the plant and subsequently with a periodicity dictated by regulations.

b) Measurement of step and touch voltages (US and UT):

The measurement of step and touch voltages is not necessary if the ground potential rise (UE: maximum electrical potential that a grounding grid may attain relative to a distant grounding point assumed to be at the potential or remote earth. This voltage (GPR) is equal to the maximum grid current (IE) times the grounding grid resistance (RE)), measured and/or calculated, does not exceed the maximum allowable values of step and touch voltages;

c) Measurement of earth fault loop impedance (ZS): The measurement of earth fault loop impedance shall be taken into account in TN systems. The measurements aim to establish if the protection device against indirect contacts (carried out by means of automatic breaking of the circuit), operates correctly. The relationship to be met is the following:

ZS(m) ≤ 2/3*U0/Ia

Where:

- ZS(m): measured impedance of fault loop (Ω); - U0: rated voltage between the system phase and earth (V); - Ia: verified and recorded current causing the tripping of the protection device

within the times indicated in the applicable standards (A);

The situations that can occur are the following:

- The protection device is a residual current relay: the relationship is always respected;

- The protection device are fuses, circuit-breaker or other overcurrent protection devices: the relationship should be verified;

When the above mentioned relationship is not verified, it is necessary to proceed by:

- increasing the cross section of phase conductor and protective conductor (PE); - replacing, if possible, the protection device (circuit-breaker, overcurrent release

of circuit-breaker, fuses, etc); - inserting a residual current protection device;



Sheet 26 di 46


6.14.3 Mechanical Completion Certification Testing and Test Certificate

a) Installation Completion and Mechanical Completion shall be recorded on form CL-E011 (MOD.ELE.FTC.012). Tests shall be recorded on form MOD-ELE-FTC-015 and 016.

6.15 Electrical Heaters


a) Ensure that the equipment meets the Area Classification and Specification requirements.

b) Ensure that the equipment identification is correctly shown.

c) Ensure that the heater is free from damage and the paintwork is correct.

d) Ensure that the cables are supported correctly, glands are made off correctly and spare entries are plugged.

e) Ensure that flanges are undamaged and that seals and gaskets are correctly fitted.

f) Inspect the earthing for mechanical and electrical continuity. Refer to earthing/bonding procedure.

g) Inspect the terminal box of the heater for neatness of connections and general good workmanship.

h) All equipment in hazardous areas should be inspected in accordance with the requirements of the procedure for the apparatus for use in hazardous areas.

6.15.2 Mechanical Completion certification testing

a) Confirm all cable certification is complete.

b) Measure insulation resistance of heater.

c) Check the earth continuity of the heater.



6.16 Electrical Equipment & Device (Local Panel - Push Button - Power Socket)



b) Note the nameplate of the devices and compare with those given on the approved drawings.

c) Ensure that the enclosure IP rating meets specification requirements.

d) Inspect for correct alignment, level, tightness of foundation bolts and fixing in general.



Sheet 27 di 46


e) Ensure that the equipment is free from damage and that the paintwork is correct.

f) Ensure that cables are supported correctly, glands are installed correctly, spare entries are plugged, flanges are undamaged and seals and gaskets are correctly fitted.

g) Ensure that all panel doors and gland plates are bonded to the panel structure.

h) Inspect the earthing for mechanical and electrical continuity. Refer to earth procedure.

i) Ensure that all terminal shrouds are correctly fitted.

j) Ensure that all ferrules and crimps are correct and that all internal wiring is neatly fitted.

l) Inspect the inside of the panel for cleanliness.

m) Ensure that door locking arrangements are correct.

n) Ensure that access is satisfactory.

o) All equipment in hazardous areas should be inspected in accordance with the requirements of the relevant procedure.

p) Ensure that all equipment is securely fixed to the ground (if applicable).

q) Ensure that the base-plate is correctly executed (if applicable).

r) Ensure that the position is as specified in the design.

s) Ensure that covers have been installed as indicated in the drawings.

t) Ensure that there are not obvious damages to switches and they operate correctly.

u) Ensure that instrument glasses and warning lamp covers are not broken.

v) Ensure that warning lamp covers are of the correct colour.

w) Ensure that boxes are complete with all bolts and are securely closed.

x) Ensure that plugs fit properly and mechanical interlocks operate correctly 6.16.2 Test Certificates

a) Installation Completion and Mechanical Completion shall be recorded on forms CL-E013 (MOD.ELE.FTC.014).

6.17 Junction Box



b) Note the nameplate of the devices and compare with those given on the approved drawings.

c) Ensure that the enclosure IP rating meets specification requirements.

d) Ensure that the junction box location is correct.

e) Ensure that the junction box is adequately supported and identified.



Sheet 28 di 46


f) Ensure that the terminal type, size, fixing and identification are correct.

g) Ensure that the earthing, internal and external, is correct.

h) Ensure that the glands and accessories are correctly fitted and that unused cable entries are plugged.

i) Ensure that grease and gaskets are correctly installed, as required.

j) Ensure that the box is correctly sealed.

k) For hazardous area installation, procedure for apparatus for use in hazardous areas must be followed.


a) There are no specific standard forms for recording that the requirements of this procedure have been implemented, however, form CL-E013 (MOD.ELE.FTC.014) may require endorsement to show that the requirements of these procedures have been complied with.

6.18 Electrical substations, HV switchyards, telephone exchanges, battery rooms, etc


a) Ensure that doors and hatches close properly, are provided with keys and, from the inside, can be opened using the handle or crash-bar only as anticipated in the design.

b) Ensure that fencing and boundary limits for keeping persons away from equipment installed outdoors (e.g. transformers) are correctly installed.

c) Ensure that glass panels are not broken.

d) Ensure that ventilation openings are not blocked off and are fitted with gratings and insect nets.

e) Ensure that the artificial ventilation system in the panel room and/or battery room operates correctly.

f) Ensure that the layout of panels and equipment meets requirements as regards working and safety space, as anticipated in the design.

g) Ensure that all parts of civil works are complete and comply with the design. The floor slope is correct and the drain pit is clean.

h) Ensure that the floor and walls of the battery room are coated and/or painted with acid-resistant paint (where necessary). The floor slope is correct and the drain pit is clean. The floor is fitted with insulating footboards.

i) Ensure that the lighting system and socket outlets are correctly executed.

j) Ensure that the earthing system is complete.

k) Ensure that the floor is fitted with insulating footboards, where necessary.

l) Ensure that canopies are installed on transformers if anticipated in the design.

m) Ensure that fencing and boundary limits for keeping unauthorized persons away are correctly installed and connected to the earthing system (where necessary).



Sheet 29 di 46


n) Ensure that protection against corrosion is provided and is complete or made good where necessary.

o) Ensure that rooms are clean.

p) Ensure that warning labels are fixed to access doors, fencing of transformer bays, battery room door, etc.

q) Ensure that a set of electrical diagrams is available for whoever must operate the electrical plant. The one line diagram is correctly displayed and updated.

r) Ensure that first-aid equipment and fire-extinguishers are suitably positioned and available for whoever must operate and maintain the plant. Selectors with automatic extinction prearrangement and relevant signalling are correctly installed and operative.

s) Ensure that energy tripping pushbutton, if any, is operative and clearly identified.



6.19 Chatodic protection system.


a) Ensure that control panels are clean and there are no foreign bodies or dust in them.

b) Ensure that there is no obvious damage to mounted instruments and equipment.

c) Ensure that protection devices are set in accordance with the design value.

d) Ensure that doors close properly and are supplied with keys.

e) Ensure that cables and conductors are correctly installed. Conductors of the protection circuit are correctly connected.

f) Ensure that holes which are not used but which are anticipated for future equipment and cable inlets are plugged.

g) Ensure that measuring points are correctly positioned in accordance with design and properly installed.

h) Ensure that measuring points are correctly numbered.

i) Ensure that characteristics of the anodes and reference electrodes for the measurements are as anticipated in the design.

j) Ensure that the number and location, both plan and depth-wise, of the anodes and reference electrode are as indicated in the design.

k) Ensure that characteristics of the anodic bed (material surrounding the anodes) are as laid down in the design.

l) Ensure that the ground of the anode has been compacted and is not subject to future settlement.



Sheet 30 di 46


m) Ensure that passive protections against corrosion are provided; these are in complete execution and do not present faults when restored, if required (painting, thermoplastic sheaths).

n) Ensure that dielectric joints are correctly positioned and are adequate for the utilization (operating temperature, isolating and conducting fluids etc.)

o) Ensure that the field connections are properly executed, the connections through bolts and brazing are protected against corrosion (stainless steel bolts, bituminous or thermoplastic insulations for buried joints).

p) Ensure that the current absorbed by the protection system is compatible with that of project design in relation to the adopted protection system: CV constant potential supply – constant current CC – CV constant potential with base current Ib.

q) Ensure that protective overloads dischargers of insulation joints and those towards earth are correctly positioned and adequate to the installation site.

r) Ensure that cathodic protection system does not present interferences with other protected structures and earthing system.



6.20 Cable tray & rack.


a) Ensure that the equipment meets the area classification and specification requirements, where applicable.

b) Ensure the mechanical integrity of all components.

c) Inspect the paint finish for damage. Any damaged areas shall be repainted.

d) Inspect the equipment assembly for alignment, level, etc.

e) Inspect the earthing for mechanical and electrical continuity. 6.20.2 Mechanical Completion Certification Testing


6.21 Apparatus for Use in Hazardous Areas


The following is a general inspection guide for all types of equipment used in hazardous areas or specified accordingly and installed in non-hazardous areas.

The particular requirements for special equipment used in these locations will be listed individually and should be read in conjunction with hazardous area classification data sheet.



Sheet 31 di 46


a) Ensure that the apparatus is appropriate to the area classification, the surface

temperature class is correct, the apparatus group is correct and that any special conditions on the certificate have been followed.

b) Ensure that there are no unauthorised modifications and that it carries correct circuit identification.

c) Ensure that all bolts, glands and stoppers are tight and that the condition of the enclosure gaskets is satisfactory.

d) Inspect the interior of the equipment for dust or dirt accumulation and ensure that all electrical connections are tight. A check should also be made that the electrical protection is adequate for the drive rating where applicable.

e) Inspect the equipment earthing for security and tightness.

f) Ensure that there is not damage to any cables and that the equipment is adequately protected against corrosion, weather, vibration and other adverse factors.

g) Ensure that the lamp rating and type are correct.

h) Where guards are used, ensure that they are correctly located and that motor fans and couplings are not rubbing.

i) The following additional checks are required on special equipment as listed (where applicable):

(i) Ex'd', Flameproof Enclosure

Ensure that: - Obstructions in the vicinity of the equipment do not impair the efficient operation of the flame-path.

- All gaps are correct and free from damage, corrosion, dirt and paint.

- The machined surface may be protected with one of the approved greases.

- All conduit runs are tight and free from corrosion.

(ii) Ex'e', Increased Safety

- A seal must be provided between the gland and the enclosure by means of a sealing washer.

- Unused cable entries should be closed with plugs to maintain as a minimum,

the same IP rating as the enclosure, using a tool for insertion and removal.

(iii) Ex'n'

- Any unused cable entries shall be closed with plugs that maintain the degree of protection of the enclosure.

(iv) Ex'i', Intrinsically Safe

- All installation should be inspected to ensure that any cable screens are earthed in accordance with the relevant standard drawing.



Sheet 32 di 46


- All diode safety barrier installations should be inspected to ensure that the correct type of barriers has been fitted and that they remain firmly fixed to the barrier earth bar.

- Boxes containing diode safety barriers and junction boxes should be

inspected to ensure that they do not contain wiring other than that specified in the documentation for the intrinsically safe system.

- All installations should be inspected to ensure that relays and similar devices

which act as safety barriers between circuits have not become damaged be repeated operation or vibration in a way which reduces the segregation afforded.

- The earth path resistance must be measured. - Ensure Ex'i' earth system is segregated from other earthing systems.

(v) Ex'p', Pressurised or Purged

- The purge medium is from an uncontaminated source. - Any filters are clean and accessible. - The purge system shall be thoroughly checked to ensure that the purge

pressure, cycle times, interlocks, lock out sequence, etc. are correct. (vi) General

The particular earthing requirements of any of the above equipment must be clarified with reference to the specific Code of Practice for the equipment. It is also recommended that where there is any ambiguity in the interpretation of the requirements, reference should be made to the relevant Code of Practice.


The diversity of equipment and special components which are contained in a particular type of apparatus does not permit a generalisation of the testing required to demonstrate suitability for service in a hazardous area. Special requirements for testing may be contained in the standard or specific Code for the equipment and this should be compiled with prior to final energisation of the circuit. Supplier manuals shall be examined to ensure that electrical components and equipment have been certified in compliance with appropriate code, National Standards and that relevant certificates are available. Such certificates must also be examined to determine whether the validity of the certificate is subject to specific installation instructions and further testing after installation, e.g. testing of cables for intrinsically safe apparatus.


There is no specific standard for recording that the requirements of the Procedure have been implemented; forms should be used to record the results of any checking and testing required by the Standard and Code certificate to demonstrate suitability for use in a hazardous area.



Sheet 33 di 46


The forms, however, make reference to this Procedure and require endorsement to signify that the equipment and the standard of installation is suitable for use in hazardous areas.

7. Pre-Commissioning requirements

7.1 General

This section covers the general responsibilities of the electrical contractor during Pre-commissioning of electrical equipment.

a) All work shall be executed in strict accordance with project specifications and the approved drawings. The written approval of the COMPANY is required for any deviations by the CONTRACTOR from specifications.

b) The CONTRACTOR shall bring to the attention of the COMPANY any areas of this specification which conflicts with or does not meet safe and acceptable electrical practices.

c) The CONTRACTOR shall be responsible for the protection and security of all equipment during all stages of checkout and commissioning.

d) The CONTRACTOR shall not perform any electrical equipment or system tests that would either void warranties or damage equipment.

7.2 Conduct of Tests

a) Written programmers for commissioning electrical equipment shall be developed by the CONTRACTOR.

b) The Pre-commissioning program shall detail the final tests to be conducted on all electrical equipment after the checkout program is complete. The Pre-commissioning program shall demonstrate the proper operation of the complete electrical system.

c) All checkout and Pre-commissioning may be witnessed by the COMPANY.

d) Pre-commissioning tests may be conducted concurrently with Mechanical Completion.

e) The CONTRACTOR shall submit a full test dossier to the COMPANY at completion of Pre- commissioning.

f) After the checkout and Pre-commissioning program has been completed and accepted by the COMPANY, the CONTRACTOR shall be responsible for leaving the equipment in a safe and operable condition. All covers, doors, and access plates shall be properly fastened. All wiring shall be complete and all jumpers used in testing shall be removed. Some items may be left energised, on agreement with COMPANY.

7.3 Safety

a) General Safety Precautions The consequences of shock or burn from electrical systems are serious. Work on

electrical equipment shall, therefore, be performed only when the equipment is de-energised, and by qualified personnel, and who fully understand the electrical system of the project.One-line diagrams shall be available at all times. All feeding equipment and circuits shall be tagged-out and locked-out. The test/check operative’s own key or lock shall form part of the lock-out procedure.



Sheet 34 di 46


The CONTRACTOR shall be completely responsible for the safety of his own

operatives, and other personnel, at all times. All equipment such as bus bars, circuit breakers, and motor shall be properly

grounded before any testing or other work is initiated.

b) Equipment Isolation All equipment shall be physically disconnected from its power source to prevent accidental injury to personnel resulting from inadvertent re-energisation. Equipment isolation is necessary to ensure that voltages applied to the equipment under test are not allowed to back-feed into power transformers, generators, and associated upstream synchronizing and control circuits. The consequences of back-feeding voltages include danger to personnel and damage to equipment. A lock-out procedure will be developed.

c) Medium Voltage Testing

While any high or medium voltage testing is being conducted, the CONTRACTOR shall ensure that the test area is properly guarded to prevent unauthorized entry and that DANGER notices are posted adjacent to, and at all access ways to the test area during the period of the test. All cables must be discharged both before and after applying any test voltage. Any associated cables not being tested shall be grounded during the test, e.g., other phase conductors of a three-phase circuit. Temporary conductors used for test purposes shall not be sized less than the rating of the circuit under test.

d) Portable Electrical Equipment

Unless portable electrical equipment is double insulated or connected to ground fault interrupters, the equipment shall be grounded using flexible supply cable that incorporates a ground continuity conductor.

7.4 Generators

7.4.1 Pre-Commissioning Certification Testing

a) Check that all factory checks and tests have been completed as par specification requirement.

b) Check that all original of suppliers checks list and test records are available.

c) Ensure that all cables and/or bus ducts have been certified in accordance with the Cable and/or bus ducts Test Procedures.

d) Verify that incoming circuit breaker has been tested in accordance with the requirements of Electrical Procedure.

e) Short and earth all semi-conductors and carry out insulation resistance checks on the exciter field. Remove shorts and earths after test.

f) Measure the status phase-to-frame insulation resistance. After separating the windings at the star point, measure the insulation resistance between windings. Reconnect the windings on completion of test.

g) Measure the polarization index of the generator carried out by supplier (only if original certification records are not available from the manufacturer).

h) Measure the insulation resistance of the anti-condensation heater.



Sheet 35 di 46


i) Remove earth strap on driven end of generator and measure non-driven end bearing pedestal insulation. Replace driven end earth strap on completion of test.

j) Test the circuit continuity of temperature protection devices. Insulation resistance tests shall not be carried out on thermistors.

k) Confirm that torque of generator lubrication and cooling systems are operational.

l) Confirm that generator lubrication and cooling systems are operational

m) Ensure that all protection and metering has been tested in accordance with the requirements of the specification and relevant procedures.


a) Pre-commissioning certification testing shall be recorded on Form RS-E001 (MOD.ELE.FTC.020).

b) Any certificates generated by the requirements of electrical procedures (i.e.

protection relay etc.) shall be attached to Form RS-E001 (MOD.ELE.FTC.020) for inclusion in the system test dossier.

c) Supplier test sheets shall be attached to Form RS-E001 (MOD.ELE.FTC.020) for

inclusion in the system test dossier.

7.5 Power Transformers




c) Test the alarm and trip circuits.

d) Ensure that all cables have been certified in accordance the relevant procedures.

e) Ensure adequate separation distances on high voltage cable connection chamber and terminations are as per Supplier's drawing.

f) Inspect tightness of bus-bar connections plus bracing from secondary winding to bus-bars of switchgear.

g) Measure the phase-to-phase and phase-to-earth insulation resistance for auxiliary circuits and both the MV and LV windings. The table below gives the test voltages and minimum acceptable values of insulation resistance.

TRANSFORMER

WINDING VOLTAGE

(V)

TEST VOLTAGE

(V)

MIN INSULATION RESISTANCE

(MΩ)

- Up to 1 kV

- Up to 4.6 kV

- Above 4.6 kV

1000 Vdc

2500 Vdc

5000 Vdc

10

150

200



Sheet 36 di 46


h) Carry out a power frequency voltage (pressure test) between the MV and LV

windings. The test should be carried out for one minute between each winding with the core and tank earthed.

Alternatively, a dc pressure test may be applied. Duration of this test shall be fifteen (15) minutes. The test voltages to be applied are given in the table below.

TRANSFORMER WINDING VOLTAGE

(V)

TEST VOLTAGE

AC (V)

MIN INSULATION

RESISTANCE (MΩ)

U

5000

10000

Note: Hi-pot test shall be carried out by supplier (only if original

certification records are not available from the manufacturer). i) Carry out the required testing of any protection and/or meter circuitry with cables

and bus ducts disconnected and in accordance with Supplier's commissioning instructions.

j) Check phase rotation of transformer secondary windings.

k) Check the operation of cooling fans (if fitted).


a) Pre-commissioning certification testing shall be recorded on Forms RS-E002 (MOD.ELE.FTC.021).

b) All supplementary certificates should be attached to Forms RS-E002 (MOD.ELE.FTC.021) for filing in the System Test Dossier.

c) Supplier test sheets shall be attached to Form RS-E002 (MOD.ELE.FTC.021) for inclusion in the system test dossier.

7.6 Neutral earthing resistors




c) Ensure all cable certification is complete as per relevant procedures.

d) Measure the insulation resistance of the resistor to earth with incoming and outgoing connections disconnected. Measure the value of neutral earthing resistor with resistor in cold state. Using temperature coefficient calculate resistance for temperature stated on the nameplate. Compare calculated and design resistance.

e) Measure resistance of frame earth path.



Sheet 37 di 46


f) Test the anti-condensation heater and circuits, where fitted.

g) If current transformers have been fitted, check that Supplier test certificates and magnetising curves are available.

h) Measure the equipment earth path resistance at the main earthing terminal to the general earth system.

i) Upon completion of tests, reconnect the incoming and outgoing cables.


a) Pre-commissioning certification testing shall be recorded on Forms RS-E011

(MOD.ELE.FTC.031).

b) Any supporting current transformer certificates should be attached to the relevant protection certificate.


7.7 MV & LV Motors




c) Ensure that all cables have been certified in accordance with the Cable Test Procedures. Check the phase sequence and polarity of all connections.

d) Measure the insulation resistance phase-to-phase if the windings can be separated and phase-to-earth. If the windings require drying out, reference shall be made to the guidance notes and typical drying out curves as detailed in Vendor's Instructions.

MOTOR VOLTAGE

(V)

TEST

VOLTAGE (V)

MIN INSULATION

RESISTANCE (MΩ)

- Up to 1 kV

- Up to 4.6 kV

- Above 4.6 kV

1000 Vdc

2500 Vdc

5000 Vdc

10

150

200

e) Measure insulation resistance of anti-condensation heater (if fitted).

f) Check motor cooling and lubrication.

g) If special motor protection devices (e.g. thermocouples) have been fitted, test their circuit continuity. (Insulation resistance tests should not be carried out across thermistor terminals or thermistor control units).

h) Verify that the starter cubicle has been tested in accordance with relevant Procedures (SWITCHGEAR).



Sheet 38 di 46


i) Verify that the water cooling, pressurization and purge systems have been tested and are available (if applicable).

j) Where applicable, remove earth strap on drive end of motor and measure non-drive end pedestal bearing insulation. If satisfactory, refit drive end earth strap.

k) Confirm that torque of motor terminations conforms to Supplier's Specifications.

l) Have the coupling broken to separate the motor from the driven unit or the belts removed from the belt-driven equipment. Ensure that the motor rotates freely and the rotor end play is within tolerance.

m) Start the motor to determine the direction of rotation and compare this with the required rotation of the driven unit.

n) Run the motor for about 30 minutes and check the bearings for undue temperature rise. Check for vibration. Tabulate results after 30 minutes to confirm temperature stabilizes. On DC motors check for armature sparking (if fitted).

o) Measure and record the line current of the free running motor (at no load).

7.7.2 Test Certificates a) Pre-commissioning certification testing shall be recorded on Forms RS-E003

(MOD.ELE.FTC.022).

b) Supplier test sheets shall be attached to Form RS-E003 (MOD.ELE.FTC.022) for inclusion in the system test dossier.

7.8 MV & LV Switchgear and Bus-bars




c) Check for correct voltage of trip/close supplies.

d) Prove correct operation of all mechanical and electrical interlocks (incoming feeder, outgoing feeder, all MCC cubicle, etc.).

e) Energise switchboard and check for correct bus-bar phase rotation.

7.8.2 Circuit Breakers Pre-Commissioning



c) Ensure manual trip and close is functional.

d) Ensure electrical trip and close is functional.

e) Ensure earthing switch is functional (if fitted).

f) Ensure that the appropriate requirements of Procedure for apparatus for use in hazardous areas have been complied with, if applicable.

g) Carry out insulation resistance tests before and after pressure test with circuit breaker both open and closed.

h) Carry out pressure tests as detailed on relevant Procedure and Supplier's instruction.



Sheet 39 di 46


i) Control Circuits - The following checks shall be undertaken. Check electrical closing and tripping from the following locations:

- local to breaker;

- local station;

- remote station (discrepancy switches);

- closing from dead bar and auto synchronizer contacts;

- tripping from protection trip relay.

Check control circuit operation for closing and tripping. Where coils are short-time rated, check the isolating contacts for operation. Check anti-pumping circuitry on circuit-breakers to ensure non-reclosure whilst keeping close push-button depressed.

Check breaker trip/close test facility in the isolated position.

Check alarm indications and status lamps at the following:

- local to breaker;

- local station;

- remote station.

Check circuit supervisions, i.e. closing circuit supervision for safety/energy schemes and trip circuit supervisions for circuit-breakers and latched contactors. Supervisory circuits are sensitive to control circuit resistances and tripping/closing coil resistances.

When commissioning a supervisory system it is essential to ensure that supervisory voltage drop across the supervised coil does not activate the coil. Some iron cored coils have a very low pick up voltage i.e. 12-20V for a 110Vdc control voltage.

j) Carry out required testing of any protection and/or meter circuitry in accordance with Supplier's Commissioning Instructions using primary and secondary injection methods as appropriate and if applicable.

7.8.3 Contactor Starter (MCC Cubicle) Pre-Commissioning



c) Ensure that the requirements of Procedure for apparatus for use in hazardous areas have been complied with, if applicable.

d) Function Check starter including remote control, annunciation and indicating instrument.

e) Tests and records the starter insulation resistance.

f) Carry out required testing of any protection and/or meter circuitry in accordance with the requirements of specifications and relevant procedures.

g) Setting of the thermal overboard protection relay.

h) Function check of the earth fault protection relay.



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7.8.4 Fuse Switches Pre-Commissioning



c) Measure the insulation resistance through the closed isolator (phase to phase and all phases to earth).

d) Carry out required testing of any protection and/or meter circuitry in accordance with the requirements of specifications and relevant procedures.

7.8.5 Testing of Protection Circuits

The following equipments may require testing of protection and/or meter circuitry by means of primary and/or secondary injection:

- Switchgear & Bus-bars

- Circuit Breakers

- Contactor Starter

- Fuse Switches

- Power Transformers

- Panels/Consoles

- Generator

Owing to both the variety of schemes and the diverse types of relays in use, no attempt has been made to produce a standard Testing Procedure. The following commissioning tests must be carried out in accordance with the relevant manufacturers commissioning documentation and with reference to the project "Power System Design - Protection Co-ordination Study documents", specification data sheet, etc. 1) Check that all factory checks and tests have been completed as par specification

requirement.

2) Check that all original of suppliers checks list and test records are available.

3) Individual items of protection have not been damaged by transport and handling. This is proved by Secondary injection Tests.

4) The correct items have been connected together, e.g. the correct set of Current Transformers have been connected to a given set of relay. This is provided by Primary Injection Tests.

5) All connections, panel wiring and intertrips are correct. This is provided by Function Tests.

6) The correct settings and/or adjustments have been applied according to the requirements of the specification, data sheet and Protection Co-ordination Study.

7.8.6 Voltmeter & Ammeter Testing

a) Check that each individual items have not been damaged by transport and handling.



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b) Any certificates generated by the requirements of electrical procedures (i.e. protection relay etc.) shall be attached to Form RS-E004 (MOD.ELE.FTC.023) for inclusion in the system test dossier.


7.9 DC Supply System – UPS & Battery Charger and Batteries




c) Measure the voltage at the terminal of each cell and compare with the recommended values. Record the results and ensure that a copy of the Check List remains with the batteries.

d) When all inspection and tests have been carried out, the batteries may be given their initial charge. This shall be carried out under the supervision of the Supplier's representative on site. The boost and float charge rates should be noted.

Under NO CIRCUMSTANCES WHATSOEVER are sealed cells to be boost charged.

e) Check the operation of all alarms.

f) Measure the level of output voltage ripple on load and check in the Supplier's data that this is within tolerance.

g) Check the operation of ESD trip and battery circuit breaker.

h) Carry out battery discharge test using a Procedure acceptable to the Supplier and record the results, including decay graphs, on test sheets (care must be taken not to damage batteries by excessive discharging).

i) Switch on the inverter and record the frequency, input and output voltage and current.

j) Transfer the load from the inverters via the static switch to mains by pass and from mains by pass back to the inverters via the static switch.


a) Pre-commissioning certification testing shall be recorded on Forms RS-E005, RS-E006 and RS-E012 (MOD.ELE.FTC.024, 25 and 32).

b) Any certificates generated by the requirements of electrical procedures (i.e. protection relay etc.) shall be attached to Forms RS-E005, RS-E006 and RS-E012 (MOD.ELE.FTC.024, 25 and 32) for inclusion in the system test dossier.

c) Supplier test sheets shall be attached to Forms RS-E005, RS-E006 and RS-E012 (MOD.ELE.FTC.024, 25 and 32) for inclusion in the system test dossier.



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7.10 Lighting & Small Power Distribution System


a) Test the voltage and polarity of each socket.

b) Check the operation of interlock on all sockets in hazardous areas.

c) Check the voltage drop at the further point of each circuit.

d) Carry out illumination tests. Illumination levels should comply with the specification requirements.

e) Test the operation of emergency lighting systems, paying particular attention to discharge times of battery-backed fittings.

f) Function check of each push-button including operation of interlock (where applicable) and indicating lamp.



b) Results of illumination level checks shall be recorded on Form RS-E007 (MOD.ELE.FTC.026).

c) Form RS-E007 (MOD.ELE.FTC.026) shall be endorsed to signify that the requirements of electrical procedure for apparatus for use in hazardous areas and procedure for junction box, if appropriate have been carried out satisfactorily.

7.11 Navigation AIDS


a) Ensure that all Site-installed cables have been certified in accordance with the relevant Electrical Procedure and test certificates completed.

b) If applicable, carry out testing of batteries and battery chargers in accordance with the Procedure for batteries and battery chargers.

c) Check correct operation of all control/synchronising circuits.

d) Check correct operations of all alarm circuits.



Form RS-E008 (MOD.ELE.FTC.027) requires endorsement to confirm that the requirements of electrical procedure for apparatus for use in hazardous areas, battery and battery charger have been carried out.

b) Supplier test sheets shall be attached to Form RS-E008 (MOD.ELE.FTC.027) for inclusion in the system test dossier.



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7.12 Electrical Equipment & Device (Heater, Panel, Junction Box, Push-Button

Station, Socket)


a) Confirm that all cable certification is complete.

b) Confirm that all electrical equipments are correct to latest revision of drawings.

c) Carry out function test of electrical equipments (for each equipment installed, i.e. metering and protection devices, ammeter, voltmeter indicating lamp, etc. refer to the electrical relevant procedures).


a) Pre-commissioning certification testing shall be recorded on form RS-E009 and RS-E010 (MOD.ELE.FTC.028 and 029).

b) Supplier test sheets shall be attached to Form RS-E009 and RS-E010 (MOD.ELE.FTC.028 and 029) for inclusion in the system test dossier.



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8. REFERENCE DOCUMENTS

8.1 Specification, Standards and Codes

Electrical installation check and test shall be carried out in accordance with the requirements of this procedure, the vendor’s documentation, the project electrical drawings and with the latest edition of the project specifications and codes:

8.2 Electrical Mechanical Completion Check Lists

MOD-ELE-FTC-001 Data sheet for duties and responsabilities of checks and tests of electrical installations

MOD-ELE-FTC-002 (CL-E001) Generator check list MOD-ELE-FTC-003 (CL-E002) Transformer check list MOD-ELE-FTC-004 (CL-E003) MV & LV Motors check list MOD-ELE-FTC-005 (CL-E004) MV & LV Switchgear and bus-bar check list MOD-ELE-FTC-006 (CL-E005) MV Cables test certificate MOD-ELE-FTC-007 (CL-E006) MV & LV Power and control cables check list MOD-ELE-FTC-008 (CL-E007) UPS & D.C. System check list MOD-ELE-FTC-009 (CL-E008) Batteries check list MOD-ELE-FTC-010 (CL-E009) Lighting & Small power check list

MOD-ELE-FTC-011 (CL-E010) Navigation aids check list

MOD-ELE-FTC-012 (CL-E011) Earthing bonding check list

MOD-ELE-FTC-013 (CL-E012) Heater check list MOD-ELE-FTC-014 (CL-E013) Electrical Equipment & Device check list MOD-ELE-FTC-015 Earthing system measurements MOD-ELE-FTC-016 Measurement of earth fault loop impedance MOD-ELE-FTC-017 (CL-E014) Electrical substation, etc check list MOD-ELE-FTC-018 (CL-E015) Cathodic protection system check list

MOD-ELE-FTC-019 (CL-E016) Cable Tray & Rack check list MOD-ELE-FTC-030 (CL-E017) Neutral earthing resistor check list



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8.3 Electrical Pre-Commissioning Record Sheet

MOD-ELE-FTC-020 (RS-E001) Generator pre-commissioning record sheet MOD-ELE-FTC-021 (RS-E002) Transformer pre-commissioning record sheet MOD-ELE-FTC-022 (RS-E003) MV & LV Motors pre-commissioning record sheet MOD-ELE-FTC-023 (RS-E004) MV & LV Switchgear pre-commissioning record sheet MOD-ELE-FTC-024 (RS-E005) D.C. System pre-commissioning record sheet MOD-ELE-FTC-025 (RS-E006) Batteries pre-commissioning record sheet MOD-ELE-FTC-026 (RS-E007) Lighting & Small Power pre-commissioning record sheet MOD-ELE-FTC-027 (RS-E008) Navigation Aids pre-commissioning record sheet MOD-ELE-FTC-028 (RS-E009) Heater pre-commissioning record sheet MOD-ELE-FTC-029 (RS-E010) Electrical Equipment pre-commissioning record sheet MOD-ELE-FTC-031 (RS-E011) Neutral earthing resistor pre-commissioning record sheet MOD-ELE-FTC-032 (RS-E012) Inverter ups pre-commissioning record sheet



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9 METHOD OF COMPANY STANDARS REQUEST / INFORMATIONS

For employees of Eni Exploration & Production Division:

• All documentation Company Standards, for ENI employees, is available on follow ENI intranet:

http://wwweandp.eni.it/TSServices/ITEM/Standards-/index.asp

• To request technical informations on this document write to Community of Pratics Electrical / Automation / Instrumentation:

[email protected]

For the outside companies:

• The outside Companies that in a contract with the contractor must use the Company standards, they may request a copy of the Company standard at the Development manager of the contract.

05221e06

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