KE01-A1-000-NC-E-PR-0001-000-C01

ORIGINATING COMPANY: NORTH CASPIAN CONSTRUCTORS

DOCUMENT NUMBER:

KE01-A1-000-NC-E-PR-0001-000PROJECT: MAIN WORKS CONSTRUCTIONKASHAGAN DEVELOPMENT EXPERIMENTAL PROGRAM

CONTRACT DESCRIPTION:

CONTRACT FOR THE MAIN WORKS CONSTRUCTION

AGIP KCO CONTRACT NO:

2004-0504

CONTRACTOR’S JOB NO:

HOLDS

N/ASHEET NO.1 OF 30

DOCUMENT TITLE:

PROCEDURE FOR ELECTRICAL INSTALLATION

CONTRACTOR’S DOCUMENT NUMBER:

C01 05.10.06 APPROVED FOR CONSTRUCTION

F.GURBUZ Y.Z.TÜFEKÇİ R.MCCORKLE P.MATTER

P02 21.09.06 REVISED AND RE-ISSUED FOR APPROVAL

F.GURBUZ Y.Z.TÜFEKÇİ R.MCCORKLE P.MATTER

P01 30.03.06 ISSUED FOR REVIEW F.GURBUZ Y.Z.TÜFEKÇİ R.MCCORKLE P.MATTER

REV DATE REASON FOR ISSUE PREPARED CHECKED APPROVED COMPANY

REVISION DESCRIPTION SHEET

ABSTRACT: This document describes procedures to be used for electrical works within the Kashagan Main Works Project.

KE01-A1-000-NC-E-PR-0001-000Rev. C01 – Date-05-10-2006

Page 2 of 30

Rev. Para. Revision Description

P01 ISSUED FOR REVIEW

P02 REVISED AND RE-ISSUED FOR APPROVAL

C01 APPROVED FOR CONSTRUCTION

Hold No.

Para. Description of Hold

TABLE OF CONTENTS


Page 3 of 30

1.0

PURPOSE.......................................................................................................................5

2.0 SCOPE......................................................................................................................5

3.0 ABBREVIATIONS.....................................................................................................5

4.0 REFERENCES..........................................................................................................6

5.0 CODES AND STANDARDS......................................................................................7

Industrial Codes and Standards...............................................................................7

Precedence.................................................................................................................8

6.0 DESIGN REQUIREMENTS.......................................................................................9

Design Life..................................................................................................................9

Design Temperature..................................................................................................9

Voltage and Frequency Requirements.....................................................................9

7.0 EQUIPMENT INSTALLATION................................................................................10

General.....................................................................................................................10

Transformers............................................................................................................11

Bus-Duct Systems...................................................................................................11

Metalclad Switchgear and Large Control Panels..................................................12

DCPS and UPS.........................................................................................................12

Cable Installation.....................................................................................................13

General..................................................................................................................13

Cable Separation..................................................................................................14

Cable Installation above Ground........................................................................15

Cable Installation Below Ground........................................................................17

Cable Termination....................................................................................................19

Cable Glands and Entries...................................................................................19

Cable Termination................................................................................................20

Cable and Core Identification.............................................................................21

Earthing and Lightning Protection.........................................................................22

Earthing System Installation...............................................................................22

Bonding.................................................................................................................23

Lightning Protection............................................................................................23

Lighting and Small Power Installation...................................................................23

Equipment Plates, Nameplates, Rating Plates and Labels..................................24


Page 4 of 30

8.0 INSPECTION, TESTING, PRE-COMMISSIONING AND COMMISSIONING..........25

Insulation Testing....................................................................................................26

Insulation Resistance Tests................................................................................26

High Voltage Withstand Tests.............................................................................26

Polarisation Index....................................................................................................27

Interpretation of Results......................................................................................27

Insulating Oil Tests..................................................................................................27

Bearing Insulation Tests.........................................................................................27

Conductivity and Earth Resistance tests..............................................................28

Conductivity Tests...............................................................................................28

Earth Resistance Tests.......................................................................................28

Equipment Wiring and Terminal Checks...............................................................28

Functional Tests......................................................................................................28

9.0 PRE-COMMISSIONING..........................................................................................29

SPARE PARTS AND SPECIAL TOOLS.......................................................................30

10.0 DOCUMENTATION...............................................................................................30


Page 5 of 30

1.0 PURPOSE

This procedure is prepared to set the requirements for electrical installation both for temporary

and permanent works.

2.0 SCOPE

Includes but not limited to for the Main Works Constraction Project, Kashagan Field

Development, Temporary contractor facilities and any work in the scope of project works.

3.0 ABBREVIATIONS

AC Alternating Current

Agip KCO - Kazakhstan North Caspian Operating Company

COMPANY is the party that initiates the project and ultimately pays for its

design and construction. The COMPANY will generally specify the

technical requirements. The COMPANY may also include an agent or

consultant authorised to act for, and on behalf of, the COMPANY.

CONTRACTOR is the party that carries out all or part of the design, engineering,

procurement, construction, commissioning or management of a project, or

operation or maintenance of a facility. The COMPANY may undertake all

or part of the duties of the Contractor

CB Circuit Breaker

CT Current Transformer

DC Direct Current

F&G Fire and Gas

HVAC Heating Ventilating & Air Conditioning

IEC International Electrotechnical Commission

HV High Voltage

HVSG High Voltage Switchgear

LV Low Voltage

LVSG Low Voltage Switchgear

MCB Miniature Circuit Breaker

MCCB Moulded Case Circuit Breaker

PE Protective Earthing

RCD Residual Current Device

RoK Republic of Kazakhstan

SCADA Supervisory Control and Data Acquisition

UPS Uninterrupted Power Supply


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4.0 REFERENCES

KE01-00-000-KD-E-SF-0020-000D01 PROJECT SPECIFICATION FORELECTRICAL INSTALLATION AND

TESTING

KE01-00-000-KD-E-ST-0001-000 D01 PROJECT SPECIFICATIONINDUCTION MOTORS

KE01-00-000-KD-E-ST-0003-000 D02 PROJECT SPECIFICATIONPOWER TRANSFORMERS

KE01-00-000-KD-E-ST-0005-000D01 PROJECT SPECIFICATIONINTEGRATED ELECTRICAL PROTECTION

AND CONTROL

KE01-00-000-KD-E-ST-0006-000D01 PROJECT SPECIFICATIONELECTRICAL REQUIREMENTS FOR

PACKAGE UNITS

KE01-00-000-KD-E-ST-0007-000 D04 PROJECT SPECIFICATIONELECTRICAL CABLES AND GLANDS

KE01-00-000-KD-E-ST-0008-000 D01 PROJECT SPECIFICATION ELECTRICAL TRACE HEATING

KE01-00-000-KD-E-ST-0009-000 D01 PROJECT SPECIFICATION ELECTRICAL BULK MATERIALS

KE01-00-900-KD-E-ST-0011-000D01 PROJECT SPECIFICATIONAC UNINTERRUPTIBLE POWER SUPPLIES

(ac UPSs)

KE01-00-900-KD-E-ST-0012-000D01 PROJECT SPECIFICATIONDC UNINTERRUPTIBLE POWER SUPPLIES

(dc UPSs)

KE01-00-000-KD-E-ST-0013-000 D01 PROJECT SPECIFICATIONSTATIONARY BATTERIES

KE01-00-000-KD-E-ST-0015-000D01 PROJECT SPECIFICATIONLOW VOLTAGE METAL

ENCLOSEDSWITCHGEAR AND MOTOR CONTROL CENTRES

KE01-00-000-KD-E-ST-0017-000 D01 PROJECT SPECIFICATIONSAFE AREA DISTRIBUTION BOARDS

KE01-00-000-KD-E-ST-0018-000 D01 PROJECT SPECIFICATIONPOWER BUSBARS

KE01-00-000-KD-E-YP-0001-000 D01 ELECTRICAL DESIGN CRITERIA

KE01-00-000-KD-E-YP-0002-000 D01 LIGHTING PHILOSOPHY

KE01-00-000-KD-E-YP-0003-000 D02 CABLE SIZING PHILOSOPHY

KE01-00-000-KD-E-YP-0004-000 D01 ELECTRICAL CONTROL PHILOSOPHY

KE01-00-945-KD-E-YP-0005-000 D01 EARTHING PHILOSOPHY

KE01-00-000-KD-E-YP-0006-000 D01 HAZARDOUS AREA CLASSIFICATION PHILOSOPHY

KE01-00-000-KD-E-YP-0007-000 B01 OVERALL ELECTRICAL PHILOSOPHY

KE01-00-000-KD-E-YP-0008-000 V01 ELECTRICAL INTERFACES PHILOSOPHY

KE01-00-000-KD-E-DS-0001-001 C01 Lighting Installation Standard (LS-12)

KE01-00-000-KD-E-DS-0002-001 C01 Lighting Installation Standard (LS-13)

KE01-00-000-KD-E-DS-0003-001 D01 Lighting Installation Standard (LS-14)









KE01-00-000-KD-E-DS-0012-001 D01 Power Installation Standard (PS-18)












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KE01-00-000-KD-E-DS-0029-001 D01 Earthing Installation Standard (ES-16)













KE01-A0-000-KD-E-DS-0001-001 D01 Lighting Installation Standard (LS-23)




KE01-A0-000-KD-E-DS-0005-001 D01 Power Installation Standard (PS-34)








KE01-A0-000-KD-E-DS-0013-001 D01 Earthing Installation Standard (ES-29)







5.0 CODES AND STANDARDS

Industrial Codes and Standards

The equipment and the installation shall be in compliance with the latest revisions of the

standards listed in document no. KE01.00.000.KD.Q.LS.0001.000. Contractor may advise

equivalent alternatives to satisfy the works which shall be identified and mutually agreed with

company. In case when any deviation is required from those standards, written permission shall

be requested from the company.

PUE Rules for Electrical InstallationVSN 59-88 Electrical Equipment in Residential and Public BuildingsSN 174-75 Guidelines for Design of Power Supply for Industrial PlantsRDS RK 4.04- 191-02 Guidelines for Design of Town and Village Electrical Supply Networks


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SNIP 3.05.06-85 Electrotechnical Devices18220f 07.12.2000g Regulations on Use of Electric PowerGOST 28668.1-91 Low Voltage Distribution and Control PackagesGOST 22789-94 Low Voltage Packages – General RequirementsRD 34.21.122-87 Design of Lightning Protection for Buildings & Structures

IEC-60050 International electrotechnical vocabulary.

IEC-60079 Electrical apparatus for explosive gas atmospheres

IEC-60287 Calculation of the continuous current rating of cables (100% load factor)

IEC-60364 Electrical installations of buildings

IEC-60445 Identification of equipment terminals and of terminations of certain designated conductors including general rules for alphanumerical systems

IEC-60446 Identification of conductors by colours or numerals.

IEC-60529 Degrees of protection provided by enclosures IEC 60840 Tests for power cable with extruded insulation for rated voltages above 30kV

IEC 60885 Electrical test methods for electrical cables

IEC 61035 Specification for conduit fittings for electrical installations

IEC 61084 Cable trunking and ducting systems for electrical installations.

Precedence

Where any conflict and/or contradiction between this procedure, the requisition, data sheets,

drawings, specifications, codes & standards or lack of clear definition, this will be identified by

CONTRACTOR in writing to the COMPANY immediately or within 30 days for

resolution/clarification prior to execution of works.

In general, the order of precedence shall be:

Contract

Data sheets

Project Specifications

Drawings

International/National Standards

Referenced Industry Codes & Standards e.g. IEC or other National Standards

In the event of any conflict arising between the referenced standards the more stringent shall be

applied.

Except for Republic of Kazakhstan Regulations, GOST’s and SNiP’s where the original

language version takes precedence, the English version shall take precedence should there be

any conflict between English & Russian versions of the applicable documents.

6.0 DESIGN REQUIREMENTS


Page 9 of 30

Design Life

Project design life shall be 40 years and all equipment shall be designed accordingly for normal

operating conditions.

Design Temperature

Design temperature for the equipments shall be as follows;

External -40 °C Min +40 °C Max

Internal -5 C Min +40 °C Max

Relative humidity % 85 Max

Voltage and Frequency Requirements

Electrical equipment shall be suitable to operate with voltage variations of ± 5% and AC

electrical equipment shall be suitable to operate with frequency variations of ± 5% rated values.

Normal operating conditions system voltage drops is limited by 5 %, under transients it will be

10 %.

Cable voltage drops shall be limited to the following values:

Main feeders: 1% at rated load

Motors: 4% at rated load (to motor terminals)

15% on motor starting (to motor terminals)

Process heater circuits: 5% at rated load

1% to heater panels

4% from panel to heater

Lighting circuits: 5% at rated load

2% to lighting distribution panels

3% for lighting branch circuits

Socket outlet circuits: 5% at rated load

2.5% to distribution panels

2.5% for branch circuits

7.0 ROLES AND RESPONSIBILITIES

Project Manager : has ultimate responsibility of compliance of work to, relevant methodologies,

standards, specifications listed, while assuring adequate organization resources to conduct the

work.

QA/QC Manager : Responsible for controlling and directing the activities complying with the

quality requirements given in the references. He reports to the Project Manager.


Page 10 of 30

HSE Manager: Responsible for the implementation of the HSE Plan and management system.

Supervisor: shall be responsible for Inspection of the electrical system to ensure quality and

confirm compliance with project documents and specifications. Timely delivery of the material to

site and ensure the work is progressing according to the schedule. Provide technical directions

and monitor "checkout test" associated with pre-commissioning. Evaluate shipping damage to

electrical equipment and recommend corrective action. He reports to construction manager.

Foreman: shall be responsible for site activities for the execution o the works. He shall organize

the site and ensure the site is ready for installation of material. He shall prepare daily reports for

the progress and manpower. He shall be responsible for maintaining good workmanship and

direct the craft installing the electrical systems. He shall manage his crew in a safe manner and

enforce all safety regulations. He reports to supervisor.

8.0 EQUIPMENT INSTALLATION

General

Utmost attention shall be given to the following during installation of the equipment;

Compatibility of the equipment to the environment

Ensure work carried out is of the highest quality

No damage on the installation material

Protection of fire-proofing

Using suitable tools for installation

Ensure minimum clearances for the installations are complied with

Ensure all unused entries are properly plugged according to the installation area code

No bare cable shall be present for the distribution systems

Equipment shall be installed in accordance with applicable standards and supplier’s

recommendations

All necessary precautions shall be taken to prevent damage to equipment during the

transportation the equipment from warehouse to site

Contractor is responsible to protect the equipment from site hazards, adverse weather and

loss of any parts during the construction period

Work in hazardous area shall be carried out in accordance with regulations.


Page 11 of 30

Loose components like commissioning spares/keys/operating tools to be documented and

identified and hand over.

Transformers

Transformer and associated fixing material shall be taken from Company warehouses. Prior to

transportation a visual inspection shall be made for any damage. Packing list and material shall

be compared at the warehouse; any deficiencies shall immediately be reported to the Company.

Transformer label shall be checked and verified against project drawings. Due care shall be

given to the kVA rating, primary and secondary voltage rating, altitude and winding conditions.

Any loose items delivered with the transformer like gauges, switches, marshalling boxes shall

be installed under the supervision of the supplier. The work shall be completed in accordance

with supplier instructions and shall be performed under his supervision.

If the transformer oil is supplied in drums, it will be stored in a clean and dry area. All measures

shall be taken to avoid contamination of the oil by moisture or dirt particles. Drum seals shall

only be broken immediately prior to the oil being tested and used to fill the transformer.

Prior to starting installation, all civil works shall be inspected, cable-bus duct entry position and

any embedded elements properly located.

Transformer shall be positioned and if necessary shall be aligned according to supplier

installation drawings. Transformer shall be earthed immediately after the installation is

completed.

Bus-Duct Systems

All field joints shall be torqued and ductored to ensure proper surface contact is made.

Where specified, bus-duct systems shall be installed between transformers and low voltage

switchgears. All fixing materials, support, elbows, terminals and couplings shall be included in

the package. Suitable tools and materials shall be provided as required for fixing and

installation. If required over-casting of epoxy insulation material for junctions shall be applied. All

connections torque values according to the supplier instructions, phase rotation and insulation

resistance shall be checked prior to over-casting. Installed and pending parts of bus duct

system shall be properly protected to avoid ingress of moisture and dust.

Metalclad Switchgear and Large Control Panels

Sections of the HV and LV Switchgear, generator control panels, large MCC and similar control

panels shall be assembled and connected at site.


Page 12 of 30

Switchgear shall be stored and preserved in a suitable controlled environment as defined in

supplier’s documentation. Space heaters may be temporarily energized from a reliable source

after permission is granted from the Company.

Prior to transportation of the switchgear an inspection shall be performed. Future use all

commissioning spares/operation tools/keys to be documented and stored properly. Installation

site should be clean and free of dust. Floor installation should be flat and level deviations

should be with in the manufacturer recommended tolerances.. All civil job, electrical job such as

lighting and small power system, HVAC duct and insulation job shall be completed.

Switchgear shall be positioned according to the project drawings and comply with the

clearances defined. The sections shall be positioned on the installation site in the desired order

of the assembly. Cover panels and parts shall be removed to facilitate access for switchgear

assembly. First section shall be positioned and secured to the floor. Position the second

section, secure to the floor and interconnect the two sections with the manufacturer

recommended bolts. Same manner shall be proceed for the other sections.

Earthing and phase bars of various sections shall be connected together via suitable nuts and

bolts. Assembly of the bars shall be done using torque wrenches as recommended by the

supplier. Bus-ducts shall be aligned, fixed and bolted to correct torque settings. Withdrawable

units shall be checked for alignment and correct operation.

Circuit identifications and labels shall be checked against the drawings and verified, all inter

cubicle bus wiring shall be completed. Base plates and cover panels shall be properly secured.

Equipotential connection shall be created for the doors by using yellow/green flexible cables.

All foreign objects (screws, wires, bolts, nuts, etc,) that might effect the operation of the

switchgear shall be removed and switchgear shall be vacuumed to remove any dust. An overall

insulation measurement and continuity test shall be carried out as recommended by the

supplier. A final check for the tightness of connections shall be made with a torque wrench,

earth continuity, mechanical locking of switchgears if there is any, and the electrical contacts

shall be lightly greased. All field joints shall be ductored with a micro ohmmeter to ensure

contact surface made or proper and within to trance.

DCPS and UPS

Prior to installation and/or transportation of the system, inspect the packing for any sign of

damage.

An inspection shall be carried out for the site installation location to verify;

Floor installation is completed and should be flat. Deviations should be within the

manufacturer recommended tolerances, fixing arrangements and cable entries are all

suitably completed.


Page 13 of 30

Enough room was provided for air intake and outlet

Environment temperature and humidity is within the specification requirements

No moisture, dust or corrosion

All finishing civil work, electrical work such as L&SP. HVAC duct and installation shall be

completed.

After all conditions stated above are met, system shall be unpacked and positioned to the

intended location. Units shall be fixed and bolted to the floor as recommended by the

manufacturer and unit shall be assembled accordingly. Batteries shall be delivered separately,

fully charged and ready for installation including interconnection link cables. The contractor shall

install links between battery cells and connect the external cables only when directed by the

company during precommissioning activity. All cable links and cables connections shall be

made secure and checked for tightness.

Cable Installation

GeneralAll rackway’s / ladder supporting systems to be completed fully and signed off prior to commencement of cables.

Cables shall be run on the cable trays or racks as the preferred method of cable installation,

however where defined in drawings or by agreement with the Company, cables may be installed

directly buried.

Cable routes and cable groups shall be strictly followed according to the contract drawings.

Where specific routes are not defined, routes shall be defined and proposed to the Company

approval by the contractor. Care should be given to select the shortest route for cable

installation.

Cables shall be pulled from cable drums and directly laid on the cable trays, racks or into the

trenches. If necessary cables shall be stored prior to laying in a heated environment at a

minimum temperature of 20 °C for a period of at least 24 hours.

All armoured and un-armoured cables up to 38 mm overall diameter shall be installed by hand

Larger diameter cables may be installed using suitable tools approved by the Company. All

armoured cables shall be laid with the help of rollers.

Utmost care shall be given while pulling the cables, not to exceed maximum tension levels

recommended by the manufacturer. Cables shall be laid in parallel formations as defined in the

construction drawings. Consideration shall be given at all times not to exceed the maximum

bending radius of the cables both during and after installation. Twisting, crossing and inter-

twinning of cables are not acceptable. Cable ends shall be protected by heat shrink end caps.


Page 14 of 30

Cables shall be tagged temporary after the installation, permanent labelling shall be done every

30 meters, includes direct buried cables. at every direction change and at both sides of every

cable transit.

Cables shall be laid without splice or joint as much as possible unless otherwise is stated in the

construction drawings. Where jointing is mandatory only Company approved joint kits shall be

used and Company approval shall be granted prior to joint. All joint points shall be indicated in

the respective drawings.

Cables shall be cut according to drum and pulling schedules, however the route length shall be

measured prior to cutting the cable.

Cable Separation

Power cables and signal cables shall be separated according to below-mentioned table to avoid

occurrence of Magnetic Disturbance. As per project specifications cables shall be installed in

accessible groups wherever possible.

Power Wiring Capacity Minimum Separation Between

Power Cables and Signal Cables

Max.

Voltage less

than:

Max.

Current less

than

Instrument

Category 1

Instrument

Category 2

Instrument

Category 3

125V 10 A 12” (300mm) 12” (300mm) 12” (300mm)

System 2250V 50 A 12” (300mm) 12” (300mm) 18” (450mm)

690V 200 A 12” (300mm) 12” (300mm) 24” (600mm)

5kV 800 A 12” (300mm) 24” (600mm) 48” (1200mm)

System 110kV 1000 A 12” (300mm) 24” (600mm) 60” (1500mm)

35kV 2000A 12” (300mm) 24” (600mm) 72” (1800mm)

System definitions are;

System 1 High voltage systems (above 1000V).

System 2Low voltage power supply and control cables for electrical systems

(1000V and below).

System 3 Instrumentation and Telecommunication systems.

Additionally System 3 is further categorized;

Category 1 Instrument power and control wiring (above 50V);

Includes a.c. and d.c. power supplies and control signals (including


Page 15 of 30

emergency shutdown circuits).

System 2

High level signal wiring (5V to 50V d.c.);

Includes digital signals, alarm signals, shutdown signals and high level

(e.g. 4-20mA) analogue signals.

System 3

Low level signal wiring (below 5V d.c.);

Includes temperature signals and low level analogue signals, e.g.

analyser measuring circuits.

Where power cables shall cross the instrument and telecom cables care shall be given to the

following:

Cables shall not touch each other, (300 mm separation)

Intersection shall be made with right angles,

For equipment entries and/or parallel runs of not more than 20 m, the minimum separation may

be considered as 300 mm.

Cable Installation above Ground

Cables shall be run on the cable trays or racks as the preferred method of cable installation.

Heavy duty cable trays of the type hot dipped, deep galvanized and silicon enriched shall be

installed. All racks and trays shall have ventilated covers up to a height of 2.5 m above grade.

Above 2.5 meter ventilation cover shall only be installed to protect cables from direct sun light.

Cables that shall be connected to electrical equipment shall be installed on trays, channel or

angle supports, fitted between the main rack and the equipment. In non-elevated substation

cable racks shall be suspended underneath the ceiling. In the elevated substation cable racks

shall be suspended underneath the floor. Cable racks and trays shall be bolted or clamped to

the structure, and single cables may be attached to the structure by cleats. Cables must not be

attached to access ladders or their supports. Welding shall not be permitted. Appropriate

mitigation measures shall be applied to prevent galvanic corrosion.

Single cables routed by the contractor, may be individually attached to structures with approved

cable cleats, but shall not be supported or attached to ladders.

Earthing continuity shall be provided throughout the route for the cable trays and ladders at the

splice plates and expansion joints where mechanical continuity is not satisfactory. All parts shall

be bonded together and to earth, at intervals specified in the contract drawings.

Where cable passes vertically through floor platforms, walkways substantial metallic plates up to

a height 150 mm above the floor level shall be provided as protection against mechanical

damage.


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Overhead cable entry points to the buildings shall be inclined with 10° below the horizontal axis

away from the entry to avoid water ingress into the building.

Following minimum clearances shall be provided as per project specification unless otherwise

stated in the approved contract drawings;

HV multicore cables up to 35kV - 1 cable diameter

HV Single core cables in trefoil– between trefoil groups

- 250mm

LV Single core cables in trefoil – between trefoil groups

- 100mm

LV power cable to any other LV power or control cable

- 100mm

LV power cable to any HV power cable -Separate cable rack or tray

LV motor cables -Single layer on tray touching

Lighting, small power cables, control cables, etc -Bunched – with maximum 100mm bunch diameter

Electrical power and control to Instruments -Refer to Cable Separation section

Minimum spacing between multiple layer ladder racks shall be 600 mm in vertical between rack

surfaces.

Following clearances shall be applied as per project specification unless otherwise stated in the

approved construction drawings;

Maintenance roads, for crane access 5.500mm

Operating areas, for truck access 4.300mm

Operating areas, over walkways, minor access ways and stairwells 2.200mm

Between cables and pipes 500mm

Between cables and oil/gas pipes 1.000mm

Cable entry penetrations shall be sealed to avoid ingress of moisture, dust and fire. Seals shall

have the same fire rating of the building.

All sharp edges and burrs from the cable racks and trays shall be removed after installation.

Cold galvanizing paint shall immediately be applied for repair purposes.

All sharp edges and bars are removed from cable ladder rack and tray following cutting on site.

Any damaged surfaces shall made good immediately with a proprietary cold galvanising paint.

The paint shall be subject to the approval of the company representative.


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All HV and LV multi-core power cables run above ground and having an overall diameter in

excess of 30mm shall be fixed with proprietary non-corrodible cable cleats. All other cables

shall be fixed with EVA coated stainless steel cable straps. Cable cleats shall be two holes

fixing, mechanically rated for the highest prospective short circuit fault level. Single core a.c

power cables shall be installed on ladder rack in trefoil formation and secured along their

complete length by heavy duty non-corrodible trefoil cleats with intermediate straps fitted

midway between the cleats. Cleats and straps shall be Type-Tested and have a certified cable

containment capability to a level in excess of the prospective short circuit levels. Maximum fixing

intervals shall be as follows;

Overall Diameter of Cable (mm) Spacing of Single Cleats or Straps (mm)Horizontal Run Vertical Run

< 20 900 225 20 2,000 600

Spacing of Trefoil Cleats (mm)Voltage Horizontal Run Flat Bend / Riser Vertical RunHV, LV 900 300 600

Where cable runs are inclined at up to 30O from horizontal, spacing shall be as for horizontal runs.

Where cable runs are inclined at more than 30O from horizontal, spacing shall be as for vertical runs.

Where horizontal runs are installed with rack or tray in the vertical plane, the spacing shall be as for vertical runs.

Where closer spacing are required to comply with short circuit fault ratings of cleats, the manufacturer’s recommended spacing shall be used.

Cable Installation Below Ground

Cable trench depths shall have the following depths unless otherwise stated in the contract

drawings and specifications ;

Cable rating up to 35 kV 1000mm

35 kV and above 1200mm

Width of the cable trenches shall not be less than 500mm unless otherwise mentioned in the

contract drawings.


Page 18 of 30

Direct buried cables shall have sand bedding and cover. Where cable routes intersect, there

shall be a vertical separation of at least 500mm of backfill material or sand between them. This

separation may be reduced to 150mm provided the cables are separated along the whole

intersection, plus 1 meter either side, by pipes or plates of concrete or other materials of similar

strength. Concrete tiles shall be laid above the cables in unpaved areas; however tiles may be

omitted where red colored concrete paving is placed above cable trenches. Where cables leave

the main trenches they may be run for short lengths in PVC ducting in suitable size. Cables

shall be in concrete encased ducts at road crossings. Cables installed underground in any

areas that may be subject to hydrocarbon contamination shall either be installed in concrete

encased ducts through the area or be lead sheathed for the whole of the route. However,

routing of 35kV and 110kV cables underground through areas of potential hydrocarbon

contamination shall be avoided.

Cables shall not be laid into the cable trenches unless the whole section is excavated and sand

bedding is completed. Prior to pulling cable, continuity test shall be performed on the drum.

Prior to laying cables into the trenches a visual inspection shall be made that the trench is

levelled, compacted and minimum 75 mm sand has been laid. Cables shall be laid with a slight

snaking to avoid possible stress during ground settlement.

Unless stated otherwise on the approved contract drawings, cables installed direct buried

underground shall maintain the following minimum clearances:

Any cable to any foundation or other structure - 600mm

Up to 35kV cable to gas pipelines - 2000mm

Up to 35kV cable to pipelines (other than gas), water ducts, sewerage pipes or drainage systems

- 1000mm

35kV cable to any other cable - 250mm

10kV or 6kV cable to any other 10kV, 6kV, LV power or any control cable

- 100mm

Single core cables in trefoil to any other cable - 250mm

LV power cable to any other LV power or control cable

- 100mm

Lighting, small power cables, etc - Bunched

Electrical power and control to Instruments -Refer to section Cable Separation


Page 19 of 30

After each layer of cables is in place, and before covering with sand, each cable shall be

visually inspected and subjected to a continuity and insulation test. Any cable proven defective

shall be reported to Company before installing the next layer of cables. All test data shall be

recorded by the Contractor, as installation progresses, and such test data shall be submitted to

the COMPANY for acceptance prior to ‘back-filling’ cable trench. A final 75mm layer of sand

shall be placed over the top layer of cables, followed by a row of correct width, suitably marked

cable tiles. The tiles shall cover the width of the cable run, with a minimum 50 mm overlap at

each side. A continuous line of proprietary plastic warning marker tape shall be installed along

the line of the cable trench, 300mm below the surface. The back fill material in cable trenches

shall be well compacted and the ground re-instated to its finished grade level. The back fill shall

be free from large stones or other injurious objects to a level at least 150 mm above the cable

protection tiles. Installed cables shall be fitted with corrosion resistant identification tags at 30m

intervals, at joints, at bends and either side of wall penetrations. All tags shall be suitable for

installation below ground. The routes of buried cables shall be identified by red concrete cable

markers set into the ground and projecting approximately 600mm above grade. The markers

shall be positioned at 50m intervals on straight runs and at points where the cable route

changes direction. The markers shall be placed directly above the underground cable

identification tags. Cable trenches shall be provided with single markers on the centreline of the

run. Similar markers suitably inscribed shall be used to indicate the position of any underground

joints.

Cable ducts shall be cleaned and inspected prior to installation, to ensure the absence of debris

and sharp objects, and temporarily sealed immediately after cable installation to prevent the

entry of such debris, or water. The ducts shall be permanently sealed as soon as all cables are

installed with easily removable material. French chalk shall be applied to the outer sheath of

cables before installation to prevent abrasion between cables and between cables and duct.

Cable Termination

Cable Glands and Entries

Compression type cable glands of the correct type and size shall be used for the cable

terminations. All cable glands used in plant areas shall be dual certified EExd IIC / EExe.

Industrial glands shall be used indoor in non-hazardous area buildings. Conductors shall be

terminated using approved pin crimp ferrules or compression lugs. Cable gland shrouds shall

not be installed and barrier type cable glands shall not be employed for power cable

termination.

The type and size of gland shall be in strict accordance with the construction drawings, data

sheets and schedules.


Page 20 of 30

Glands for multi-core power and control cables shall be manufactured from brass. Glands for

single core aluminum armored power cables shall be manufactured from aluminum. All glands

shall have an appropriate IP rating and utilize fiber washers between the gland body and the

gland plate to maintain the IP rating of the enclosure. Prior to installing cable glands into EExd

threaded entries, threads of the gland shall be lubricated with non toxic grease.

Hazardous area equipment shall in no case be drilled out and/or altered. Unused entries shall

be blinded with appropriate type plugs maintaining the same temperature rating of the

equipment. Where enclosures have clearance holes instead of threaded gland entries, cable

glands shall be secured by locknuts fitted with serrated star washers to ensure earth continuity.

Where the design of HV switchgear and control-gear necessitates the provision of an externally mounted core balance current transformer for earth fault protection, the following requirements shall be implemented:

a) All conductors shall pass through the current transformer.b) Insulated gland adaptors shall be fitted to the respective gland platesc) Earth tags shall be fitted between gland bodies and the insulated adaptorsd) Earth tags at each termination shall be bonded together and earthed by an insulated earth

cable passing back through the core balance current transformer prior to terminating on the switchboard earth bar.

e) Each gland plate shall be bonded with a protective conductor to the respective earth bar or stud.

Generally, cable entries to equipment in external locations shall be located on the underside of equipment. Where this is impracticable, side entry may be used provided the cables are installed with a downward slope. All cables shall be supported to avoid strain on either the cable gland or the equipment and at least 100mm of straight cable shall be left before a bend is formed.

Cable Termination

HV cable terminations above 6kV shall be of a stress relieving design. Power cable connections

to Generators, transformers and motors shall, generally, be affected via proprietary moulded,

separable, elbow/bushing connectors. Cable connections to HV switchgear and control-gear

shall be carried out using stress-relieving sleeves with trifurcating gloves, or heat shrink type

terminations. The manufacturer’s instructions regarding cable end preparation and termination

shall be followed exactly, employing any recommended special tools. It is particularly important

that the Manufacturers recommendation for the length of individual core terminations is

followed. The Contractor shall immediately notify COMPANY representatives if this requirement

is compromised by space limitations within the equipment terminal box. COMPANY

representatives will take responsibility for defining the required solution.


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Prior to fitting termination lugs, cables shall be inspected for strain free connections. Then

proprietary compression lugs shall be fitted for terminations. LV cables with conductor cross-

section up to and including 6mm2 shall be fitted with insulated pin crimp type ferrules and

terminated into SAK, or similar, type terminals, as supplied or approved by the COMPANY

representative. Cables with conductor cross-section larger than 6mm2 shall be fitted with

compression lugs to suit the equipment terminals. The shanks of compression lugs used for the

termination of cables in LV motor terminal boxes and other field-mounted equipment shall be

insulated with heat shrink sleeving to avoid the possibility of inadvertent contact between

adjacent un-insulated lugs. Where practical, an adequate length of cable tail shall be left at all

cable terminations to enable cores to be connected to any terminal by the longest route. Cable

tails shall be neatly looped or coiled and supported. Spare cores shall be marked as spare and

terminated in spare terminals, provided within the equipment, and earthed. Where insufficient

spare terminals are available, spare cores shall be connected directly to a convenient earth

point. Spare core length shall be maximized within the constraints imposed by the equipment.

Exceptions to this requirement, whereby only one conductor end is terminated due to potential

EMC constraints, will be defined in the construction drawings. Unless noted otherwise on

construction drawings, conductor earthing at one end only shall be at the field end.

For control cables, no more than two conductors shall be connected to any one terminal, one

incoming and one outgoing. Where multiple conductors are required to be terminated at the

same point, then the required number of terminals shall be interconnected by proprietary links.

The link shall not occupy the same terminal as the conductor.

The arrangement and connection of power cables within LV Distribution Boards shall provide

sufficient room to enable a clip-on ammeter to be used without stressing the cable.

Cable and Core Identification

Every cable shall have a unique identification number, as recorded in the construction drawings

and cable schedules. All cables shall be identified at their points of origin and destination and at

both sides of any wall or floor penetration. The DOT cable marking system shall be used.

Identification labels shall consist of user printable flame retardant heat shrink sleeves for cable

cores and smaller diameter cables, and polyamide strips for larger cables. Marker strips shall

have slotted ends to permit fixing to the cable by means of nylon ties. Each cable core shall be

uniquely identified at both ends by a core number or by phase color, as applicable, and as

shown on the construction drawings, schematic and connection diagrams. For power cables

where the core insulation color matches the corresponding phase color, no further marking is

necessary. However, where core insulation does not match the phase color, appropriately

colored sleeves shall be fitted at the termination point. Core identification shall be by proprietary

heat shrink ferrules suitable for thermal print inscription. Cable core identification on horizontally

terminated cores shall read from left to right, and on vertically terminated cores shall read from

bottom to top.


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Earthing and Lightning Protection

Earthing System Installation

The plant earth system for onshore plants shall take the form of a ring of insulated copper

conductors laid around the plant with sub-rings connected, as required, to the main ring and

with branch interconnections to equipment and structures. Exothermic fusion welded type joints

shall be used for underground connections and compression type crimps for above ground

connections. All underground connections shall be insulated with suitable insulation tape or

heat shrink insulation. Stainless steel rod electrodes shall be installed at selected points around

the ring to form a multi-point earthing system. The rods shall be driven directly into the ground

without excavation or drilling. Locations and depths of electrodes are indicated on the

construction drawings. The maximum value of resistance of individual earthing electrodes to the

general mass of earth shall not exceed 1 ohm. Rod type earth electrodes shall be spaced at

intervals required to comply with resistance values stated on drawing number

KE01-00-945-KD-E-YS-0001-001, “Earthing Methods Diagram”. If earth loop impedance tests

are unsatisfactory, the Contractor will be required to install additional lengths of electrodes until

the specified value of resistance is attained. Where necessary, buried earth ‘mats’ shall be

formed from stainless steel tapes. The electrodes shall be bonded by PVC insulated copper

cables to the earth mats and to the main earth bars located in Substations, within buildings and

on external steel plant structures. Disconnecting links shall be installed at earth bars to permit

periodic maintenance testing. Electrodes shall be connected by clamps. Earth electrodes shall

be installed via proprietary earth pits, as recorded on the construction drawings and earthing

layouts. Underground earthing conductors routed independently from cable rack or plant

structures, outside of a dedicated cable trench, shall be installed at a minimum depth of 600mm

below grade. Earthing systems within substations or electrical equipment rooms shall be

installed in accordance with the construction drawings. Where applicable, earth bus bars shall

be installed 600mm above floor level and adequately supported from the substation or electrical

room walls in accordance with the Standard Earthing Details.

Joints and tees between sections of copper bar shall be tinned and bolted; each joint shall have

a minimum of two bolts. Cable connections to earth bars shall be bolted via tinned lugs crimped

to earth cables; the earth bar shall be tinned at the point of connection.

The armour of all cables shall be earthed via the cable glands and gland plates. Cable armour

shall not be used as the principal earth conductor. Where necessary, power system earth

continuity shall be maintained via a separate earth core.


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Bonding

Every structure and item of plant equipment, including prefabricated steel buildings and pipe-

rack, shall be substantially and effectively connected to earth in the manner specified in the

construction drawings. Minimum conductor size shall be 6mm2 for earthing and bonding

connections and shall be arranged such that disconnection of an earth conductor from a piece

of equipment does not break the continuity of the earthing and bonding system. Two earth lugs

on to a single point connection is not acceptable. All non-current carrying metallic parts of

electrical equipment shall be connected directly to the main earth system.

The armour of cables in feeder circuits at LV distribution boards shall be bonded together and

directly connected to earth. Unless a conductive contact is established naturally (via bolts,

welds, etc), all exposed metalwork of electrical and non-electrical equipment shall be bonded to

the structure to ensure that the entire installation is an equipotential zone. Pipes entering or

leaving hazardous areas shall be bonded together and to a common local earth bar connected

to the main earth system. Pipe-work flanges and pipe to vessel, or equipment, connections,

where not electrically continuous, shall be provided with copper bonding straps unless cathodic

protection is installed.

All earthing studs on equipment shall be cleaned prior to connection of earth conductors. The

connection shall be secured by ‘locking nuts’ then coated with an approved anti-oxidant

corrosion inhibitor.

Instrument and control panel steelwork in control rooms or in plant areas shall be bonded in

accordance with the construction drawings. Particular care shall be taken to ensure that

instrument earth and power system earth systems remain isolated up to the common point of

connection.

Lightning Protection

The maximum earthing value shall in no case exceed 10 Ohms. Where practicable, lightning

protective systems shall utilize the same earth electrodes as used for power system earthing

installations but the interconnections from structures to earth electrodes shall be by separate

tapes or insulated cables.

Lighting and Small Power Installation

The precise location of the fixtures, switches and sockets shall be determined by the Contractor

according to the construction drawings.

Unless shown otherwise on the construction drawings the mounting height of luminaries and

accessories shall comply with the following, measured from the finished floor level, or working

platform, to the centre of the item:


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Switches for lights 1400mm

Socket outlets 500mm

Socket outlets above work tops. 1100mm

Bulkhead luminaires 2500mm

Emergency luminaries at exits 2000 - 2500mm

Distribution boards 1500mm

Luminaries shall be positioned so that areas or fixtures such as stairways, landings, and ladders

are adequately illuminated. In order to facilitate re-lamping, light fittings over walkways and

platforms shall be mounted not less than 2000mm and not more than 2200mm above the

walkway, or platform, and shall be mounted not less than 1000mm inside the edge of any such

platform or walkway. In the case of narrow platforms or walkways, less than 2000mm wide, the

luminaries shall be mounted on the centre line of the platform. The top handrails of walkways,

stairways and platforms shall not be obstructed by supports of stanchion type lighting fixtures.

In pump compounds, and other areas at ground level, luminaries shall not be mounted more

than 3250 mm above the level of the floor, unless otherwise specified on the construction

drawing.

The number of junction boxes used on lighting circuits shall be kept to a minimum. When

junction boxes are used they shall be located in easily accessible positions, in-board of platform

edges, and not more than 2200mm above the working floor level. All junction boxes shall be

fitted with permanent labels denoting circuit reference.

Luminaries and socket outlets shall be wired strictly in accordance with the circuits shown on

the construction drawings and Standard Detail drawings. Where two or more lighting cables are

run together they shall be fixed to cable tray, or run in trunking. Single cables may be fixed

direct to steelwork. All lighting fittings shall be labelled with the fitting and circuit references

shown on the construction drawings. Labels shall be fixed near lighting fittings but not on them.

Certified lighting and small power equipment shall not be modified, altered or drilled in any way,

neither shall terminals be added or substituted in marshalling and junction boxes.

Equipment Plates, Nameplates, Rating Plates and Labels

Manufacturer’s Equipment Plates, Nameplates and Rating Plates will be fitted to all equipment.

Additional Danger or Warning plates shall be fitted where necessary. All information shall be

given in dual language (Russian and English). Warning notices, cable route markers, cable

markers and wiring ferrules shall be installed in accordance with the contract documentation.

All electrical minor equipment, bulk materials and components, as listed below, shall be clearly

identified with labels supplied and fitted. The wording and character size of all labels shall be in

accordance with the contract documentation. Labels shall be provided for the following items:

Luminaries Junction boxes/marshalling boxes


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Control stations Motors Heaters Isolating switches Control switches Cable ladder rack and tray Cable Transit

Labels shall be of the engraved laminated plastic type, or approved equal and shall be dual

language, Russian/English. Identification labels shall comprise black characters on a white

background. Warning labels shall comprise black characters on a yellow background,

complying with the requirements of the relevant IEC Standard, and shall be fitted directly to all

items of electrical equipment.

Rotating machinery subject to automatic, remote, control shall be provided with a warning label

reading:

‘DANGER – THIS MACHINE LIABLE TO START AUTOMATICALLY’

Warning of electrical hazard shall be provided on equipment and component cover plates and

on any access doors not provided with interlocked isolators. Warning labels shall be fitted with

appropriate legends including:

‘WARNING – SUPPLIES MUST BE ISOLATED BEFORE REMOVING COVER’

‘WARNING – HEATER ENERGISED WHEN MOTOR STOPPED’

‘ISOLATE ELSEWHERE’

Labels shall be fixed to equipment or supporting steelwork with stainless steel screws and shall

not infringe hazardous area ‘Ex’ certification or IP rating of the respective enclosures. Self-

tapping screws shall not be employed.

8.0 INSPECTION, TESTING, PRE-COMMISSIONING AND COMMISSIONING

All necessary competent, certified personnel and tools, certified/calibrated test instrumentation

and test power supplies, to carry out inspection, testing and pre-commissioning testing activities

in accordance with this specification and as per the procedures and standards shall be

provided. In the specific case of a.c and d.c UPS systems a suitably rated load bank to

facilitate battery discharge and re-charge tests shall be provided.

Required permits / authorization for carry out test to be obtained prior to commencement of test.

A complete set of As-Built documentation for the installations prior to any commissioning

activities being undertaken shall be provided.


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All inspection and test results shall be recorded on the appropriate approved Inspection and

Test Record Sheets. All tests shall be performed under the supervision of Company

representative, unless otherwise stated by Company, record sheets shall be mutually signed.

The Contractor shall transfer all original Inspection & Test Record sheets in accordance with,

and as indicated in the project procedures.

The Suppliers of major electrical equipment will provide, within their IOM manuals, details for

installing, site testing and commissioning equipment within their scope of supply and will provide

representatives to assist during installation, site testing, commissioning and initial energisation

of the equipment. All items of electrical equipment will have been fully tested at the respective

Supplier’s works and complete test records will be supplied with the equipment.

The Contractor shall carry out standard tests of insulation, continuity, phase orientation and

correct operation, together with all other tests that may be deemed necessary to prove that the

electrical installation is satisfactory. Installations failing to pass such tests will be rejected and all

work necessary to bring the electrical installation to a satisfactory working condition shall be

carried out and tests shall be repeated.

Insulation Testing

Insulation tests shall be carried out during construction and at the pre-commissioning stage,

prior to the energisation of equipment or cables. The following two methods shall be used:

Insulation resistance testing, applicable to all electrical equipment including, but not

limited to, generators, transformers, switchgear, motors, UPS systems, distribution

boards, trace heating installations, lighting and small power installations, field cables,

earthing and bonding systems and all other items of electrical equipment. Where

equipment contains components, such as silicon diodes or transistors, or wiring, that is

susceptible to damage by over voltage, these items shall be disconnected prior to

commencing tests.

High voltage testing, applicable to switchgear rated at 400V and above and HV cables.

Test voltages shall be in accordance with the relevant IEC Standard or manufacture’s

recommendation and shall be specified in the equipment commissioning procedure.

Insulation Resistance Tests

Insulation resistance tests shall be conducted prior to executing high voltage tests. Insulation resistance shall be measured by applying a d.c test voltage from a ‘Megger’ insulation meter or equal. For correct comparison of test data, any subsequent insulation resistance tests should be carried out at the same voltage level as the initial test.

The measured resistance value is also dependent on the temperature of the insulation and shall be corrected as necessary. As a guide, the insulation resistance of windings reduces by approximately 50% for each 10C rise in temperature.


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High Voltage Withstand Tests

Prior to and on completion of conducting high voltage tests, insulation resistance tests shall have been carried out.

High voltage testing may be carried out by applying either an a.c. power frequency voltage, a very low frequency voltage (VLF) or a d.c. voltage, at a level above the operating voltage, in accordance with the relevant International Standards.Testing at power frequency is preferred and a.c test equipment must be capable of supplying the capacitive current requirement of the item under test. As such test equipment is bulky, and normally impractical for field use, d.c test equipment may be used for cables whereas a.c test equipment shall be used for switchgear. Cable tests shall record values of leakage current versus time.

High voltage a.c testing of major electrical equipment will have been conducted at the Supplier’s works to values specified in the relevant International Standards. As repeated high voltage testing may stress winding insulation such tests shall not be applied at site to generators, motors or transformers. If, however, for special reasons (e.g. when equipment has been partially assembled at site) such tests are considered to be necessary, they may be carried out after consultation and agreement with the COMPANY and the Supplier’s Site Representative but at a reduced voltage level corresponding to 70% of the factory test voltage.

Polarisation Index

Polarisation Index tests will be carried out on all HV motors. The test results will be compared with those values obtained during the Factory Acceptance Tests.

The Polarisation Index is the ratio of the value of insulation resistance measured after one minute to that measured after ten minutes, during continuous testing, at the appropriate voltage, i.e.: PI = R10 min/R1 min.

The Polarisation Index, being a ratio, is practically independent of winding temperature and test voltage. The ten minute measurement allows the capacitive current, the leakage current over the surface of the insulation and the dielectric absorption current to stabilise.

The Polarisation Index gives an indication of the condition of winding insulation, with regard to its dryness and cleanliness. The value will be lower for dirty, wet or chemically contaminated windings.

Interpretation of Results

Should values of insulation resistance or Polarisation Index fall below the minimum values specified, the equipment should not be energized nor subjected to high voltage testing. The equipment and windings should be heated and dried out prior to re-test.

Should a ‘flash-over’ occur during high voltage testing then the test shall be deemed to have failed. Appropriate remedial measures, such as cleaning, drying or, if necessary, repair should be adopted after which re-testing shall take place.

Insulating Oil Tests

High voltage withstand tests shall be carried out using a standard Foster oil test set, or equal, with 25mm diameter sphere head electrodes and a sphere gap of 2.5mm.

The minimum breakdown voltage shall be 30kV. The test sample shall be tested 6 times without breakdown using the same cell filling.


Page 28 of 30

Bearing Insulation Tests

Bearing Insulation tests shall be carried out on all HV motors.

The method of insulating bearings, as a means of controlling shaft current, depends upon the design and type of construction and the methods employed to support the bearings.

In the case of pedestal bearings, or sleeve bearings, where housings are completely insulated from the body of the machine, the insulation may be checked with the machine coupled and running at normal speed. This is to establish that an oil film in the bearing will prevent electrical contact between shaft and bearing. An ohm-meter applied across the insulation should indicate a resistance of >10k; values below this shall be investigated.

In the case of bearings having internally insulated ‘shells’ or having insulated shafts, measurements shall be carried out with the machine uncoupled and stationary. If, however, only one bearing is insulated verification is limited to the inspection of the Supplier’s QC documentation.

Where double insulation is applied to pedestal bearings, i.e. insulated around the bearing ‘shell’ and at the pedestal base, insulation resistance measurement at the ‘mid section’ with respect to earth will indicate if either insulation is bridged.

All tests shall be carried out in accordance with Supplier’s instructions.

Conductivity and Earth Resistance tests

Conductivity Tests

Conductivity tests shall be carried out on switchgear bus-bar connections, and switchgear earth system joints, in order to establish their tightness and condition. Conductivity testing shall be carried out with a “Ducter” (or equal) low-resistance test set having a 20A, d.c, output.

Test results shall be recorded across all connections and for identical connections the measured values shall not differ by more than 20% from each other.

Earth Resistance Tests

Earth resistance tests shall be conducted in accordance with the relevant International Standards.

All earth electrodes shall be tested by measurement of the resistance of the electrode against the mass of earth, using a purpose made test set.

On offshore installations, random continuity checks using a “Ducter” or similar low resistance ohmmeter shall be carried out to verify that equipment is effectively bonded to the structure.

Equipment Wiring and Terminal Checks

Electrical wiring shall be checked against the Supplier’s Schematic Diagrams and Diagrams of Connections, or against the Contractor’s Interconnection Diagrams, as applicable.The tightness of all terminals shall be verified.


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Functional Tests

Functional mechanical & electrical tests shall be carried out to demonstrate the correct operation of all electrical equipment and associated systems. This shall include primary and/or secondary current injection tests to check the protection and metering circuits. Particular attention shall be paid to equipment interfaces, where there is a greater likelihood of functional discrepancies.Where complex control or interlock systems are used, the Contractor shall demonstrate compliance with the design requirements using specific functional check-lists and system logic diagrams. Where such complex systems require the input of the Supplier’s site representative, for pre-commissioning activities, the Contractor may be required to provide assistance.

9.0 PRE-COMMISSIONING

The Contractor shall provide means of access to enable a complete visual inspection of the installation and the following visual checks shall be carried out in accordance with the Company’s approved Pre-Commissioning Check Lists. All results shall be recorded.

i. Removal and safe keeping of selected packing materials.

ii. Cleanliness of all equipment and components.

iii. Equipment identification plates, manufacturer’s nameplates and rating plate data comply with

the Drawings and the provision of cautionary or danger notices.

iv. Certified EEx (Ex) protection ‘certification labels’ are correct and comply with the design

documentation and Hazardous Area Certification Schedule.

v. Certified EEx (Ex) equipment enclosures and bulk materials comply with the manufacturer’s

specification, drawings and certification details.

vi. Configuration, alignment and tightness of fixing and holding down bolts. Integrity and

tightness of all electrical connections, terminations and cable glands.

vii. Operation of mechanical and key interlocks, safety shutters, access doors and locks. Provision

of padlocks and padlocking facilities.

viii. Correct degree of protection for equipment and materials. Provision, correct fitting and location

of gaskets and cable gland ‘O’ ring seals.

ix. Application of approved corrosion resistant greases. Oil levels and grease packing of machine

bearings is satisfactory.

x. Provision of earthing connections and effective earth bonding of equipment.

xi. Checking of fuse, MCCB and MCB ratings.

xii. Correct identification of equipment, cables and cable cores, cable ladder rack and cable tray.

xiii. Correctness of circuit details with Schematic, Wiring and Interconnection Diagrams.

xiv. Distribution board circuit schedules within the enclosures have been completed correctly.


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On completion of all inspection, testing and pre-commissioning activities, the Contractor shall assist the COMPANY in the commissioning of electrical installations as and when required. The Contractor shall not energise any electrical equipment without prior approval of the Company’s Site Representative and, where appropriate, the local RoK inspection authority.

Energisation of electrical equipment/systems will be done so under the strict control of the

“Permit to Work” system that will be in operation on the plant. The Contractor will be responsible

for obtaining such “Permit to Work” documents from the COMPANY representative or its

appointed representative prior to any work being carried out and such “Permit to Work”

documents will be renewed on a daily basis.

Spare Parts and Special Tools

The Contractor shall take due notice where applicable of any special instructions detailed in the manufacturers Manual for Erection and Testing.

All special tools supplied by equipment or material vendors for the installation, testing, commissioning and maintenance of equipment, including any lifting equipment, shall be returned to the COMPANY after commissioning.

Equipment Installation, Operation and Maintenance Manuals, which shall include a list of special tools, shall also be returned to the COMPANY after commissioning.

10.0 DOCUMENTATION

The Contractor shall, as part of the scope of the electrical installation contract, supply complete sets of ‘Red-Marked’ drawings, and any other related design documentation as defined in the Contract documents.

As-Built’ drawings shall comprise the Contractor’s construction issue drawings, or Supplier’s drawings, marked up to accurately reflect all site implemented modifications or revisions to the design for the completed electrical installation, as installed, connected, tested and commissioned.

The Contractor shall also supply ‘As-Built’ drawings recording all work carried out under the Contract but not covered in detail by the Company’s or Supplier’s documentation. Typically this shall include cable routing drawings above and below ground including any transits and rack numbers, supplementary lighting and small power circuit diagrams and any additional support steel details.

All ‘As-Built’ drawings and documentation shall be subject to the approval of the COMPANY representative.

One set of drawings shall be retained on site for an interim period whilst another set is used to revise the Master Drawings.

The Contractor will be required to complete all Inspection and Test Record sheets.

Documents

KE01-A1-000-NC-E-PR-0001-000-C01