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GS 112-1 ELECTRICAL ENGINEERING SPECIFICATION FOR MATERIALS AND WORKMANSHIP

February 1999

Copyright The British Petroleum Company p.l.c.

Copyright The British Petroleum Company p.l.c.


All rights reserved. The information contained in this document is subject to the terms and conditions of the agreement or contract under which the document was supplied to the recipient's organisation. None of the information contained in this document shall be disclosed outside the recipient's own organisation without the prior written permission of Manager, Standards, BP International Limited, unless the terms of such agreement or contract expressly allow.

BP GROUP RECOMMENDED PRACTICES AND SPECIFICATIONS FOR ENGINEERING Issue Date Doc. No.

February 1999

GS 112-1

Latest Amendment Date

Document Title

ELECTRICAL ENGINEERING SPECIFICATION FOR MATERIALS AND WORKMANSHIP


APPLICABILITY Regional Applicability: SCOPE AND PURPOSE This Specification details the minimum acceptable standard for materials and workmanship which are required in the execution of electrical works undertaken for, or on behalf of, British Petroleum and its associated companies Its purpose is to give information on acceptable installation and construction methods.

International

AMENDMENTS Amd Date Page(s) Description ___________________________________________________________________

CUSTODIAN (See Status List for Contact)

Electrical Engineering
Issued by:-

Engineering Practices Group, BP International Limited, Research & Engineering Centre Chertsey Road, Sunbury-on-Thames, Middlesex, TW16 7LN, UNITED KINGDOM Tel: +44 1932 76 4067 Fax: +44 1932 76 4077 Telex: 296041

CONTENTS Section Page

FOREWORD .......................................................................................................................iii 1. INTRODUCTION............................................................................................................. 1 1.1 Scope ................................................................................................................. 1 1.2 Quality Assurance ....................................................................................................... 1 2. DOCUMENTATION ........................................................................................................ 2 2.1 Construction Documents.............................................................................................. 2 2.2 As Installed Drawings .................................................................................................. 2 2.3 Construction Records Dossier...................................................................................... 2 2.4 System Test Dossiers................................................................................................... 3 3. GENERAL......................................................................................................................... 5 3.1 Contractors Responsibilities ......................................................................................... 5 3.2 Site and Equipment Tidiness and Cleanliness................................................................ 5 3.3 Tradesmen and Supervision ......................................................................................... 6 3.4` Identification .............................................................................................................. 6 * 3.5 Materials and Equipment........................................................................................... 6 3.6 Security and Safety Regulations ................................................................................... 6 * 3.7 Buildings, Structures and Plant ................................................................................. 7 3.8 Setting out Works........................................................................................................ 7 3.9 Temporary Power Installations..................................................................................... 8 3.10 Portable Handlamps, Electrical Appliances and Tools................................................. 8 3.11 Hand Tools and Aids ................................................................................................. 8 * 3.12 Electrolytic Corrosion ............................................................................................. 9 4. MATERIALS HANDLING AND STORAGE ............................................................... 10 5. EQUIPMENT IN HAZARDOUS AREAS ..................................................................... 11 6. CONSTRUCTION SITE POWER SUPPLIES.............................................................. 13 7. CABLES, WIRING AND INSTALLATION OF CABLES .......................................... 14 7.1 General ............................................................................................................... 14 7.2 Underground Cable Installation.................................................................................. 17 7.3 Cable Installed Above Ground (Onshore) Or Above Deck (Offshore)......................... 21 7.4 Cables and Wiring for Instrument Systems ................................................................. 31 7.5 Cable Records ........................................................................................................... 32 8. INSTALLATION OF ELECTRICAL EQUIPMENT ................................................... 33

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8.1 Switchgear ............................................................................................................... 33 8.2 Motors ............................................................................................................... 35 8.3 Transformers and Reactors ........................................................................................ 37 8.4 Batteries, Battery Chargers and Inverters ................................................................... 38 8.5 Electrical Surface Heating.......................................................................................... 39 8.6 Earthing and Bonding ................................................................................................ 39 8.7 Small Power and Lighting Systems ............................................................................ 40 8.8 Generator Packages ................................................................................................... 43 9. INSTALLATION, INSPECTION, TESTING AND COMMISSION........................... 44 9.1 General ............................................................................................................... 44 9.2 Installation ............................................................................................................... 44 9.3 Safety Precautions ..................................................................................................... 44 9.4 Inspection and Testing ............................................................................................... 45 9.5. Pre-Commissioning of Electrical Systems.................................................................. 45 9.6 Pre-acceptance Inspection and Testing....................................................................... 45 9.7 Energisation and Commissioning................................................................................ 46 APPENDIX A...................................................................................................................... 48 DEFINITIONS AND ABBREVIATIONS....................................................................... 48 APPENDIX B ...................................................................................................................... 49 LIST OF REFERENCED DOCUMENTS....................................................................... 49 APPENDIX C...................................................................................................................... 51 INSPECTION AND TEST PROCEDURE...................................................................... 51 APPENDIX D...................................................................................................................... 91 INFORMATION - HEALTH AND SAFETY.................................................................. 91

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FOREWORD Introduction to BP Group Recommended Practice and Specifications for Engineering The Introductory volume contains a series of documents that provide an introduction to the BP Group Recommended Practices and Specifications for Engineering (RPSEs). In particular, the General Foreword sets out the philosophy of the RPSEs. Other documents in the Introductory volume provide general guidance on using the RPSEs and background information to Engineering Standards in BP. There are also recommendations for specific definitions and requirements. Value of this Guidance for Specification This Guidance for Specification defines BPs minimum requirements for electrical engineering materials and workmanship using BPs knowledge and experience world-wide to ensure that electrical installations are carried out to a safe standard using materials of the required type and quality, and comply with good engineering practice commensurate with ease of installation, operation and maintenance. Application This Guidance for Specification is intended to guide the purchaser in the use or creation of a fit-for-purpose specification for enquiry or purchasing activity. Text in italics is Commentary. Commentary provides background information which supports the requirements of the Specification, and may discuss alternative options. It also gives guidance on the implementation of any Specification or Approval actions; specific actions are indicated by an asterisk (*) preceding a paragraph number. This document may refer to certain local, national or international regulations but the responsibility to ensure compliance with legislation and any other statutory requirements lies with the user. The user should adapt or supplement this document to ensure compliance for the specific application. Principle Changes from Previous Edition This document has been re-structured, revised and converted to the new Way Forward Style. (a) Various sections have now become sub-sections under new section headings. These new section headings are:Cables, Wiring and Installation of Cables Installation of Electrical Equipment Installation, Inspection, Testing and Commissioning

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Under the new section heading of Cables, Wiring and Installation of Cables are new sub-sections:Cable Transits Cable and Wiring for Instrument Systems Cable Records Under the new section heading of Installation of Electrical Equipment are new subsections:Transformers and Reactors Batteries, Battery Chargers and Invertors Electrical Surface Heating Generator Packages The new section heading Installation, Inspection, Testing and Commissioning incorporates the previously existing text from Inspection, Testing and Commissioning of the General section with new text on Installation, Safety Precautions, Precommissioning of Electrical Systems, Pre-acceptance Inspection and Testing and, Energisation and Commissioning. (b) The following other new sections have been added:Equipment in Hazardous Areas Construction Site Power Supplies Feedback and Further Information Users are invited to feed back any comments and to detail experiences in the application of BP RPSEs to assist in the process of their continuous improvement. For feedback and further information, please contact Engineering Practices Group, BP International or the Custodian. See Status List for Contacts.

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1.

INTRODUCTION 1.1 Scope This specification covers general standards of workmanship, material requirements and construction methods which are required in the execution of electrical works undertaken for, or on behalf of, British Petroleum and its associated companies. It additionally covers the minimum requirements for the installation, testing and commissioning of all electrical equipment and systems. Details of the various types of installation work likely to be encountered are included in this Specification, together with those of construction techniques required. In this connection due regard must be given to the extremes, widely differing, and adverse general climatic conditions that may be encountered, together with the environment local to any particular part of a plant or area. National and/or local regulations are frequently applicable and take the form of rules, codes of practice, standards etc. issued by the appropriate authority for the particular country, state or area concerned. It is essential that the Contractor ensures that easy access to all relevant documents for reference is available, since compliance with the above documents could be mandatory and any short-comings might lead to delays and could prejudice the subsequent granting of a plant operating licence. Consequently this Specification in no way replaces or supersedes the requirements contained in any national or local regulations that may be applicable, unless dispensation on any particular matter has been obtained in writing from the responsible authority. It is acknowledged that differences may occur between the requirements of the contract documents, of which this Specification forms part, and those of the particular authorities concerned, but in such cases the most stringent requirements must be complied with.
1.2 Quality Assurance Verification of the vendors quality system is normally part of the pre-qualification procedure, and is therefore not specified in the core text of this specification. If this is not the case, clauses should be inserted to require the vendor to operate and be prepared to demonstrate the quality system to the purchaser. The quality system should ensure that the technical and QA requirements specified in the enquiry and purchase documents are applied to all materials, equipment and services provided by sub-contractors and to any free issue materials Further suggestions may be found in the BP Group RPSEs Introductory Volume.

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2.

DOCUMENTATION 2.1 Construction Documents Site layout and construction of the installation shall be carried out in accordance with the approved drawings, standards, schedules, specifications and other documents with form an integral part of the Contract, e.g. (i) (ii) (iii) (iv) (v) (vi) Installation Block Diagrams Installation and Layout Drawings BP Standard Drawings e.g. Earthing, Line Heating, etc. Cable and Equipment Schedules Manufacturer's Drawings and Installation Instructions Electrical system protective relay setting schedules and characteristic curves, etc.

When the situation on site is such as to render any of the Contract Specifications inappropriate, e.g. where advantage can be taken of a change in circumstance to the benefit of the work from any aspect, full details should be brought to the notice of BP Site Management in order that appropriate action can be implemented. 2.2 As Installed Drawings The exact siting of equipment, cable routing, jointing and terminal connection details, together with any deviation from the drawing, shall be clearly marked on the construction drawings by the Contractor and submitted to BP site management on completion of each section of the work, or as otherwise directed. 2.3 2.3.1 Construction Records Dossier The parts of the dossier relevant to the electrical discipline will consist of all the information necessary to record the condition and as-built status of electrical installation; the results of testing will be included in the System Test Dossier, ref. 2.4. Suggested contents of the dossier are:(a) (b) An index of design and as-built drawing. Cable schedules showing installed length of cables.

2.3.2

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(c)

Cable Drumming schedules with manufacturers test certificates for each drum. Schedule of suppliers of certified bulk equipment e.g. cable glands, junction boxes, push button stations etc. with copies of approval certificates from certifying authorities, updated to include site purchases. Index of all tagged items by system showing purchase order number, manufacturer, hazardous area classification code (if any) and area classification of location. Index of relevant Engineering Queries in number order, identifying the system to which it applies together with a brief description. Copies of all Engineering Queries, including replies and all other attachments, filed by system number. Equipment preservation records as required by BP Group RP 32-2.

(d)

(e)

(f)

(g)

(h)

2.4 2.4.1

System Test Dossiers The parts of the test dossier relevant to the electrical discipline will consist of the results of all the tests carried out at site to show that a piece of equipment or circuit is ready for commissioning. Any results of tests carried out by vendors representatives at site will be included but NOT the results of vendors works tests, which will be held in vendor dossiers. An index of all the electrical equipment and cables to be tested shall be compiled and broken down into the system designations laid down in Project specifications/procedures. The system allocation of a piece of electrical equipment shall be decided by identifying the system in which it operates e.g. the drive motor for a closed drain pump will be located in the closed drain system. The cabling and power supply unit (starter, switch fuse etc.) for a piece of electrical equipment will be combined with the item of equipment for system allocation. Using the example of the close drain pump; located in the test dossier for the closed drain system will be the test sheets for the closed drain pump motor, its starter, and the cabling to the motor and push button units, even if the starter is part of a cubicle type switchboard.

2.4.2

2.4.3

2.4.4

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2.4.5

The final index shall list not only the piece of equipment and its associated cabling but also the numbers of all the test sheets and the date of completion of the test. The Contractors activities for the preparation of final documentation, namely, as built-drawings, fabrication and system test dossiers, and outstanding material lists, shall be carried out under the supervision of BP.

2.5

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3.

GENERAL 3.1 Contractors Responsibilities The Contractor will be expected to assume full responsibility for the completion of all works necessary to fulfil the specified functional requirements listed in the Contract Documents and Job Specification. The area and degree of responsibility vested in the Contractor for the protection and maintenance of electrical plant and equipment during construction and commissioning of the Works will be defined in the Contract Specification and implementation of these requirements shall be agreed with BP Site Management before work is commenced. In general the Contractor shall be responsible for:(a) The receipt, inspection and storage of all items of equipment supplied by BP. The supply of all other items of equipment as specified in the Contract Documents. The installation of all equipment, including any necessary support structures including fabrication, where necessary, of such supporting materials as specified in the Contract Documents. Bringing to the attention of BP any omissions from the Contract Documents of any items essential for the safe and correct functioning of any part of the specified equipment or system. The testing and pre-commissioning of all equipment and systems after installations. Maintenance of all installed equipment and systems until the works are formally accepted by, and control transferred to BP.

(b)

(c)

(d)

(e)

(f)

3.2

Site and Equipment Tidiness and Cleanliness The Contractor is to ensure that his work sites are kept in a clean and orderly fashion at all times and that unwanted scrap, waste materials, etc., are removed from site at appropriate intervals or as otherwise agreed or directed by BP Site Management. Upon completion of each part of the installation the Contractor shall ensure that every item of electrical equipment is internally and externally clean and free from extraneous objects.

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3.3

Tradesmen and Supervision Personnel engaged on the construction of electrical installations shall be fully qualified and competent tradesmen skilled in the particular field of work in which they are engaged. They will be required to operate under the general supervision of a suitably qualified and responsible electrical engineer, or supervisor, as required under the terms of the Contract.

3.4

Identification All cables, conductors, circuits and equipment, etc., shall be fitted with a permanent means of identification in accordance with the codes that have been established for the Works. Omissions shall be rectified, as the Works proceed, by the provision of an appropriate means of identification in compliance with, and/or an extension to, an established system, or by the introduction of an additional system in agreement with BP Site Management and compliance with the requirements of 2.2.

3.5

Materials and Equipment Materials and equipment supplied by the Contractor under the contract shall be new, unless otherwise agreed, and comply with Nationally recognised standards of the user country and BP Engineering Codes of Practice. Material and equipment manufactured to standards other than the above shall be approved in writing by BP and/or the appropriate authority in the user country.

3.6

Security and Safety Regulations All work shall be carried out in accordance with rules, regulations and instructions issued by BP Site Management. Unless otherwise stated the above shall be interpreted to include all National/Local rules, regulations, etc., as may be applicable, with particular attention to those concerning all aspects of safety. In some cases the Contract Works will be adjacent to, and/or within, existing plant operating areas under the control of an Operating Plant Company Management. Particular attention is drawn to the necessity of strict adherence to regulations and instructions applicable to such areas, these will include compliance with existing written "Permit-toWork" procedures. Serious consequences can arise due to accidental damage to and/or inadvertent operation of equipment associated with operating plant, or through interference; consequently every precaution shall be taken to prevent such occurrences. Should they take place, BP Site, or the Operating Plant Management shall be informed immediately. It is important that any related or immediate subsequent action necessary should only be undertaken on receipt of specific instructions from the BP Management unless the action needed is obvious and can be carried out safely, e.g. fighting a fire with the correct means.

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Written "Permit-to-Work" procedures may be introduced for any of the Contract Work areas should it be necessary to ensure safe working, and will be introduced immediately electrical testing and commissioning work requires equipment and cables to be energised. In the absence of a Clients Permit-to-Work System, the procedure contained in Project Departments Health and Safety at Work Advice and Information Manual shall apply. The actual requirements for each work area under a particular contract will be defined by BP Site Management, in conjunction with the Operating Plant Company Management when necessary, who will be responsible for any dispensation in requirements. Any dispensation must be obtained in writing. * 3.7 Buildings, Structures and Plant Equipment suspended or attached to any building, structure or plant, etc., must be installed strictly in accordance with the Contract instructions. When detailed instructions have not been included, no alteration shall be made to any building, structure or plant, etc., unless specifically authorised by BP Site Management. Inadvertent damage must be reported immediately to BP Site Management. 3.8 Setting out Works Care must be taken at all times to ensure that the finished work has a good appearance, and that, where appropriate, ready access is available to components. Thermal insulation and fireproofing materials, forming part of process lines, vessels, structures, etc., shall be left undisturbed unless specified otherwise by BP Inadvertent damage must be reported immediately to BP Site Management. Work carried out prior to the application of thermal insulation and fireproofing materials, shall allow adequate clearances, and the work must be fully protected against possible damage during the application of thermal insulation and fireproofing materials. All electrical equipment and installations shall be located and/or protected against the effects of heat that may be radiated or conducted from the process plant, and the likelihood of damage due to vibration, corrosion or chemical action. Care must be taken not to obstruct access to, and movement of, plant. When locating equipment, high fire risk areas must be avoided as far as is possible. Equipment should be located as far as possible to facilitate maintenance without the use of ladders or other temporary support structures.

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3.9

Temporary Power Installations Power distribution systems installed for the express purpose of providing temporary power for construction works shall be subject to the same standards of workmanship as permanent installations except where otherwise allowed for in the Contract or authorised by BP Site Management. There shall be no bare conductor overhead power supply and distribution systems of either a temporary or permanent nature in any work area. Overhead insulated conductor systems will only be permitted when unavoidable and require the written authorisation of BP Site Management. See section 7 of this Specification.

3.10

Portable Handlamps, Electrical Appliances and Tools Portable hand held lamps, electrical appliances and tools shall be supplied from single phase double wound transformers having the centre point of the utilisation voltage winding brought out and solidly earthed. Such transformers shall have an earthed metal screen between the windings. See Clause 6.5 Bench mounted equipment, heavy duty tools, etc., and when unavoidable, small portable electrical apparatus, may be supplied at voltages in excess of the above, i.e. from the standard medium voltage single phase and neutral supply, provided the equipment is of the double insulated type and/or the sub-circuit to which it is connected includes a current operated earth leakage protective device. The above equipment shall be maintained, inspected and tested at regular and appropriate intervals to ensure an entirely satisfactory condition.

3.11

Hand Tools and Aids A full range, and an adequate supply, of hand tools specifically designed for the purpose for which they are to be used, and for carrying out the work in the correct manner, shall always be available to all personnel engaged in the Contract Works. Materials and equipment to be supplied as part of the Contract Works shall include such special tools and aids as are necessary for the correct execution of the work. Materials and equipment supplied as a free issue to the Contract Works will normally include special tools and aids as are necessary unless otherwise specified. The Contractor shall ensure that the correct tools and aids are used for all work carried out.

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3.12

Electrolytic Corrosion Measures shall be adopted to minimise electrolytic corrosion. Examples with some alternatives are given below:(i) When apparatus of one metal, say aluminium, is to be mounted on a steel structure, stand-off washers shall be used. The bolts, washers, and nuts may be galvanised or cadmium plated. Cable glands, other than aluminium glands, for installation into aluminium enclosures, may be cadmium plated. Coatings of proprietary compounds, specially manufactured for the purpose, may be used between dissimilar metals, with the agreement of BP Site Management.

(ii)

(iii)

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4.

MATERIALS HANDLING AND STORAGE 4.1 The Contractor shall receive all items of equipment supplied by BP. Immediately on receipt, all equipment shall be inspected by the Contractor for damage during transit. All damage shall be notified in writing to the carrier, the supplier and BP for immediate action to avoid work schedule delays. The Contractor shall review the list of items of equipment to be supplied by BP and report immediately in writing to BP, the omission of any items necessary to complete the Works. The Contractor shall provide all other materials necessary to complete the works in accordance with the Contract Documents. The Contractor shall be entirely responsible for the safety, security and condition of all equipment and materials for the duration of the Contract. He shall keep all equipment and materials, before installation in safe storage and in environmental conditions suitable for the particular items of equipment where they will not be liable to damage deterioration or corrosion and, where applicable, in accordance with manufacturers recommendations. Any equipment broken or damaged in storage shall be repaired, to the satisfaction of BP, or replaced by the Contractor at his own cost. The Contractor shall be responsible for continuous monitoring and reporting of material usage, during installation, of those equipment items supplied by BP, and the Contractor shall advise BP in advance of any anticipated shortage in order to avoid delay in scheduled installation.

4.2

4.3

4.4

4.5

4.6

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5.

EQUIPMENT IN HAZARDOUS AREAS 5.1 The Contractor will be issued with drawings showing the hazardous area classification of the plant or installation. The Contractor shall ensure that all supervisory personnel are conversant with these drawings and fully understand the requirements for electrical apparatus in hazardous areas. All other personnel shall be fully qualified and competent tradesmen who have been trained in installation work in hazardous areas and, therefore, understand the characteristics of the types of protection of electrical equipment for use in such areas. The Contractor shall ensure that all electrical equipment supplied by BP for installation in hazardous areas is installed in the correct location in accordance with the contract drawings. Any ancillary equipment, e.g. cable glands, supplied by the Contractor shall be certified for use with the BP supplied equipment in order to maintain the characteristics of the type of hazardous area protection. Where relevant, the position of the electrical equipment in relation to other plant should be in accordance with the requirements of its certification and the associated Code of Practice, e.g. flameproof gaps on equipment with type of protection d should not be nearer to other plant than as specified. Where there is any conflict with these requirements the Contractor shall report immediately to BP for a decision regarding remedial action. All electrical equipment and ancillaries supplied by the Contractor for installation in hazardous areas shall be certified by a National Certifying Authority for use in the particular classified area, have the correct temperature classification and equipment group and be suitable for the particular environmental conditions, all as described in BS 5345. Equipment which has been manufactured and certified in a country other that the country of installation should be checked to ensure that the equipment has been tested at the voltage and frequency of use as otherwise the temperature rise may be excessive. Also the installation Codes of Practice in the country of manufacture and certification shall be checked to ensure that the certification is not related to an installation practice unacceptable in the country of use. In zone 1 hazardous areas only equipment of types of protection d, e and s, as defined in EN standard 50-014, shall be installed. In zone 2 hazardous areas only equipment of types of protection d, e, s N or n shall be used. The relevant specification for types of protection n is IEC Publication 79-13 and the general specification for types of protection N is BS 6941. Specifications for type N motors

5.2

5.3

5.4

5.5

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and type N luminaires are BS 5000 Part 16 and BS 4533, Section 102.51 respectively.

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6. *

CONSTRUCTION SITE POWER SUPPLIES 6.1 The Contractor shall produce for BP approval, an estimate of the total power requirements for construction, including if applicable, all temporary site accommodation and associated domestic services. When the Contract Documents place responsibility on the Contractor for providing construction site power supplies, this estimate shall be used for the purpose of either negotiating the provision of power supplies from an existing BP supply system or a power supply authority or providing temporary generating plant. When the Contract Document place responsibility on BP for the supply of construction power this estimate will be used by BP for the provision of supplies by one of the above methods. For the construction of offshore platforms, separate estimates of power supply requirements shall be provided for onshore construction and offshore construction. The power system for construction site power supplies shall be designed and installed in accordance with BP Group RP 12-1 and RP 12-19. In the UK the system and use of electricity shall also comply with BS CP 1017, the Guidance Note G524 published by the Health and Safety Executive and the IEE Wiring Regulations for Electrical Installations. Supplies to equipment from socket outlets shall comply with BP Group RP 12-17. 6.6 Any part of the construction supply electrical distribution system or any electrical equipment used for construction which may be energised or used after the plant or part of the plant has been commissioned and which may then be in a potentially hazardous area shall be certified for use in that area. This applies particularly in offshore situations where, due to space restrictions, modules are in close proximity to one another.

6.2

6.3

6.4

6.5

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7.

CABLES, WIRING AND INSTALLATION OF CABLES 7.1 7.1.1 General All cables, cable systems and wiring shall comply with:(a) (b) (c) (d) BP Group RP 12-13 BP Group RP 24-1 BP Group RP 24-2 BP Group GS 112-12

The clauses in this section of this document either make reference to, or are supplementary to, the requirements of the above. 7.1.2 The Contractor shall be responsible for ensuring that cables are installed in accordance with the Contract Drawings and cable schedules. Cables for each circuit shall be of the type and size specified for that circuit. This is of particular importance offshore where fire retardant or fire resistant cables are specified. No deviation shall be made from the cable routes shown on the Contract Drawings without BP Site Management approval. Where cable is installed overhead, however, the Contractor shall check the locations of cable tray, ladders and tracking shown on the drawings to ensure that no conflict exists between them and any other equipment, steelwork, piping, ducting etc., or that they do not cause any hazard to personnel, block access ways or prevent removal of equipment. Where problems arise BP Site management shall be consulted. Underground cable routes detailed in the Specification Documents and Drawings will have been selected to avoid areas likely to be subject to product contamination from spillage. Overhead cable routes will have be selected to avoid areas subject to both spillage and fire risk. Cable routes not detailed on contract drawings shall also comply with the above and be agreed with BP Site Management. Cables having an outer homogeneous corrosion protective outer sheath, e.g. PVC, which might be subject to deterioration at some point along its route, and thereby permit migration of flammable or corrosive substances along the interstices of the armouring, shall be treated to provide a visible drainage point near the termination at each end. The drainage point shall be made by cutting an annular ring from the outer plastic sheath, at a position so that any leakage that may occur does not create a hazard. The exposed armouring should be protected by a fire and corrosion resistant coating.

7.1.3

7.1.4

7.1.5

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7.1.6

Certain items of electrical plant and machinery are subject to movement and/or vibration during operation and subsequent maintenance, e.g. motors on slide rails, motor driven in-line pumps, motor driven agitators, etc. Connecting cables shall be so routed and/or of a type appropriate for the duty, e.g. mining type flexible armoured cable could be used for motors on slide rails, but the use of cables enclosed in flexible conduit is not normally permitted. The arrangement of the connection must permit freedom of equipment movement under all operating conditions, normal maintenance and adjustment without unduly stressing the cable and/or cable terminations, and easy replacement.

7.1.7

Storage and handling of cable before and during installation is to be carried out with due regard to manufacturers recommendations. Cable drums shall be rotated only in the direction indicated by drum markings and open ends of cable are to be effectively sealed immediately after cutting to prevent the ingress of moisture. Exposed cut ends of paper insulated cable shall be capped by plumbing. Other types shall be compounded and taped. At all times the utmost care is to be exercised to avoid damaging the protective sheathing of cable or of causing excessive bending or twisting which may result in bird caging of wire armour and/or damage to core insulation, sheaths, etc. The bending radius of a cable shall not be less than the manufacturers recommended minimum. Under no circumstances shall metal levers or tools be used in direct contact with cables during installation unless of a proprietary type specially designed for the purpose.

7.1.8 7.1.9

7.1.10

Cables shall be run in continuous unbroken lengths and joints will not be permitted unless the route length exceeds the maximum manufactured drum length, or jointing of the cable is otherwise specifically authorised by BP Site Management. When cable is supplied in drum lengths nominated for particular circuits it is the Contractor's responsibility to ensure that the cable is used for the nominated circuits.

7.1.11

Where cables pass through floors, or rise through covered trenches, they shall be provided with adequate mechanical protection in the form of metallic sleeves or kick plates projecting not less than 150 mm (6 in) above floor level. Kick plates shall be so positioned as not to constitute a trip hazard. Cables shall not be handled or installed when the ambient temperature is below 2C unless agreed with BP Site Management. In such

7.1.12

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circumstances handling and installation will only be permitted following an adequate period of storage at a relatively high temperature and provided the installation can be completed within a specified time. A procedure shall be agreed with BP Site Management, preferably approved by the cable manufacturer, and the work shall be carried out under the direct supervision of a competent person. * 7.1.13 Catenary support of cable will not be permitted unless all other methods of installation are impractical and then only with the specific authorisation of BP Site Management. For identification purposes cable having a protective outer sheath of PVC, polythene, or other special material shall carry distinctive markings as indicated in the Job Specification. The utmost care shall be exercised when installing such cables to ensure that they are correctly allocated to their specified duty. Unless otherwise specified single core cables shall be provided with an outer protective sheath, e.g., PVC, and if laid direct in the ground and/or if unsupported over any part of their entire length, shall include non-ferrous armouring. When single core cables are used for three phase circuits special attention shall be given to minimising the likelihood and effects of circulating currents in the lead sheaths and/or non-ferrous armouring, due to mutual induction. Insulated glands for cable terminations should be fitted at one end and must be assembled and tested strictly in accordance with the manufacturer's instructions. Each set of single core cables comprising a three phase circuit shall be run close together and under no circumstances shall ferrous metal be interposed between the single core cables. Trefoil formation shall be used for each three phase group of single core cables and this requirement will be relaxed only where it is impractical. The arrangements for clamping single core cables in three phase circuits requires special attention, particularly when they form part of an electrical network with a high prospective short circuit rating. Details of the clamping and bonding arrangements will generally be fully covered in the Job Specification, but irrespective of this the final arrangement shall be agreed with BP Site Management. Under no circumstances shall improvised devices be used for clamping cables in Trefoil formation; only those of an agreed type and materials obtained from agreed suppliers will be permitted. * 7.1.16 Unless otherwise specified, each cable shall be fitted with indestructible identification bands at each end, at 30 metre intervals over the entire route length, at all points where it enters or leaves ducts and buildings and at each change in direction.

7.1.14

7.1.15

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7.1.17

Cables shall be installed in accordance with manufacturers recommendations. The recommendations regarding minimum bending radius shall be strictly applied. It shall be the Contractors responsibility to obtain the cable manufacturers recommendations for the range of cables listed in the Contract cable schedules. Site testing of cable installations shall be carried out in accordance with BP Group RP 32-2 Site Inspection, Testing and Pre-Commission of New Plant and in accordance with Appendix C of this document. Underground Cable Installation Cable Installed Directly in the Ground Cables installed directly in the ground for the whole or part of the route should incorporate a lead sheath unless otherwise Specified by BP. For particular applications proven barrier materials other than lead may be permitted but must be agreed. Cables without barriers must be laid without deviation from the specified or agreed route, since this will have been selected as one unlikely to suffer contamination. If deviation is necessary for any reason authority must be obtained and the new route given written approval by BP Site Management.

7.1.18

7.2 7.2.1 * 7.2.1.1

7.2.1.2

Cables shall be surrounded by not less than 50 mm (2 in) of washed sand, loam or sifted soil and protected by suitably sized concrete or earthenware cable covers. Covers shall be of the standard interlocking type laid directly above the 50 mm (2 in) fill of screened material and shall extend to the full width of the trench giving an overlap of at least 50 mm (2 in) beyond the outer cables.

7.2.1.3

In temperature climates the minimum depth of cover required from cable to finished grade shall, unless otherwise stated in the Job Specification, be as follows:(i) (ii) Street lighting and telephone cables Power cables up to and including 1000 volts and control cables Power cables above 1000 volts 500mm

500mm 800mm

(iii)

If a pilot or control cable forms an integral part of a power circuit it shall be laid at the same depth and adjacent to the associated power cable.

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7.2.1.4

In areas where wet sand/soil is liable to frost action, cables shall be installed either below the frost level or, if installed above frost level the grade of bedding shall be such that less than 40% passes through a 0.1 mm sieve and less than 20% passes through a 0.2mm sieve. Attention shall then be paid to ensuring that the depth of excavation , before backfilling as detailed above for the initial bedding, is appropriately greater than the frost maximum penetration depth. Infilling of cable trenches shall be well compacted and the ground reinstated to its original grade and finish. The infill shall be free from large stones or other injurious objects to a level at least 150 mm (6 in) above the protection covers. The thermal conductivity of bedding and infill material for cable trenches and troughs must be established before use. Where thermal conductivity of the material is lower than anticipated and below the value on which cable ratings and grouping factors have been determined, as indicated in the Job Specification, action must be taken in agreement with Site Management on the corrective measures to be adopted. Any specific instructions included in the Job Specification and drawings in respect of special additives, and/or sand/cement mixes shall be strictly adhered to at all times.

7.2.1.5

7.2.1.6

Armoured cable shall be installed with the aid of specially constructed rollers. Cables up to 38 mm (1 1/2in) diameter shall be installed by hand, but larger cables may, with BP Site Management approval, be installed with the assistance of a suitable winch, having an adjustable tensioning device and indicator, operated by a trained and competent operator. Cable stockings shall be sized to the cable and fitted in a correct manner. Where recommended by the manufacturer pulling eyes shall be fitted to the cable at the time of manufacture. Unarmoured cable shall be installed by hand. Cable shall at no time be installed directly from a drum mounted on a moving vehicle. Under no circumstances is the maximum permitted tension for the type and size of cable to be exceeded.

7.2.1.7

Drum jacks, cable rollers and other equipment shall be of the correct type and size for each drum and cable laid. The equipment shall be kept in a sound condition and be used in the approved manner. Underground cable routes shall be identified by concrete cable markers set into the ground to project approximately 300 mm (12 in) above grade. The markers are to be positioned at 30 metre (100 ft.) intervals on straight runs and at points where the route changes direction. Cable

7.2.1.8

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trenches less than 1 metre wide shall be provided with single markers on the centre line of the run. Trenches wider than 1 metre shall be indicated by markers mounted on each side of the trench at the intervals specified. Similar markers suitable inscribed shall be used to indicate the position of underground joints. * 7.2.1.9 The installation of direct buried cables shall not be commenced until the entire route has been excavated and prepared ready to receive the cable. Where such procedure is impracticable a detailed programme of laying shall be agreed with BP Site Management. In all cases when cable is left exposed above ground it shall be coiled, suitable protected against damage, and this should include a temporary fence around the local area at an appropriate distance from the coiled cable. Alternatively such cable may be left on the drum which must be lowered from its jacks, firmly anchored and the immediate area fenced. 7.2.1.10 Accurate and detailed records of all buried cables are to be prepared in duplicate by the Contractor as each section of cable laying proceeds. A copy of these records shall be submitted to BP Site Management. Recorded information shall include dimensioned trench positions, duct and trench sections, indicating the circuits installed and the location of underground joints taken by measurement from fixed and permanent landmarks. This information will subsequently be transferred to permanent As Installed drawings by the Contractor or as otherwise detailed in the Job Specification. Cable Installed in Concrete Trenches (Including Troughs) The installation of cables in trenches or troughs shall comply with BP Group RP 12-13, Clauses 5.3.4, 5.3.5, 5.3.6. Relevant procedure included under Sub-Section 7.2.1, for installation of direct buried cable shall be adhered to insofar as it becomes equally applicable when the cable is installed in a prepared concrete trench. Before installing cable the concrete covers shall be removed and laid clear of the cable pulling area. The trenches shall then be cleared of all foreign material and left free of obstruction. When existing trenches are used to accommodate additional cables any fill shall be carefully removed to the level of the existing cables and new bedding prepared. 7.2.2.4 On completion of cable laying, trenches shall be back filled with clean sand and the covers replaced. Care shall be taken when replacing trench covers to ensure that they are not dropped and that they are properly positioned and seated. Responsibility for covers damaged or

7.2.2 7.2.2.1

7.2.2.2

7.2.2.3

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broken during cable laying operations shall rest entirely with the Contractor who shall replace them. Where trenches are located within plot limits of process areas or other locations subject to excessive spillage or washings the covers shall be effectively sealed or trenches floated over with a coloured weak cement mix as detailed in the Job Specification. 7.2.3 7.2.3.1 Cables Installed in Ducts Application and design of duct systems shall comply with the Job Specification and drawings. In general all ducts shall be haunched in concrete and be socket and spiggot type of earthenware or non-bituminous fibre. In special circumstances, e.g. railway crossings or where adequate depth of lay cannot be obtained, a single length of steel pipe shall be used. 7.2.3.2 For single runs or otherwise at the discretion of BP Site Management, manufactured earthenware bends of appropriate size and radius may be used having regard to overall diameter and the class of cables to be installed. When installing bends care shall be taken to ensure that the joints are fully engaged. The use of split ducting is prohibited except under special circumstances and with the approval of BP Site Management. In cases where the use of split ducting has been authorised all joints shall be correctly fitted and the ducts bound in an approved manner. If the ducts are to be haunched in concrete they shall be bound with an impervious tape to exclude ingress of the concrete. The overall length of ducts and pipe crossings shall extend at least 300 mm (12 in) beyond the limits of the area requiring ducts. Draw wires shall be installed in each duct. All ducting shall be temporarily sealed when not required for immediate use. Before cables are installed into ducts the duct line is to be proved clear of obstruction with the use of a wooden mandrel or by rodding. The procedures detailed under Sub-Section 7.2.1 - Cables Installed Direct in the Ground, shall be followed insofar as they are applicable to cables being installed in ducts.

7.2.3.3

7.2.3.4

7.2.3.5

7.2.3.6

7.2.3.7

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7.2.3.8

When ducts are allocated to specific circuits in the Job Specification or drawings these positions shall be strictly adhered to, otherwise duct banks shall be filled from the bottom upwards and spare ways left unobstructed at the top of the bank. Pilot and/or control cables shall not be installed together with a power cable in the same duct and in general each duct shall carry a single power cable. In cases where deviation from the practice is necessary the matter shall be referred to BP Site Management. Ducts shall be sealed at both ends immediately after installation of the cable and spare ducts shall be sealed with soft wood plugs, or other agreed material. Cable Installed Above Ground (Onshore) Or Above Deck (Offshore) General All above ground/deck cable installations shall comply with BP Group RP 12-13, Section.4. The material used for cable trays and ladder racks shall be selected from those listed in BP Group RP 12-13 Section 4. Unless already specified in the contract documents the Contractor shall obtain BP approval of the proposed material. Cables shall be allocated to racks in the particular grouping arrangement detailed in the Contract Specification and, where specified, the racks shall be colour coded. On minor cable routes involving both power and instrumentation cables where it is impractical to route more than one rack level, the instrumentation cables shall be installed on one side and power cables on the other. Care shall be taken to maintain the segregation distances between power and instrumentation cables specified in BP Group RP 30-8. Where due to space restrictions it is impractical to maintain these distances a segregation distance of 300 mm is adequate for all but very low signal level instrument action circuits but BP approval shall be obtained for all departures from the distances specified in BP Group RP 30-8. All cable cores shall be clearly, precisely and indelibly identified at each terminal, on point with individual number/letter combinations, using ferrules of the non-split cylindrical type.

7.2.3.9

7.3 7.3.1 7.3.1.1

7.3.1.2

7.3.1.3

7.3.1.4

7.3.1.5

7.3.1.6

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7.3.1.7

Where core numbers change, e.g. at connections between equipment of different manufacture, a system of double identification coding shall be used at the point of connection. For all multicore cables, other than power cables, the cable core identification shall be made up three parts: numbering from the terminal block these are:(a) (b) (c) the terminal number the core number the cable number

7.3.1.8

7.3.1.9

All cables shall be identified at each gland termination by their allocated number as indicated on the cable schedules, by the use of non-corodable identification tags. Similar tags shall be attached to the cables at either side of a transit unit or cable duct and at specified intervals over the entire length of cable. Where not specified the Contractor shall obtain BP agreement to the proposed tagging interval. The tags shall be fixed with EVA or PVC coated stainless steel ties. Cable ties shall be selected from those listed in BP Group RP 12-13 Clause 4.4.12. Where not specified, the Contractor shall obtain BP approval to his proposed material. Nylon 11 or 12 ties are preferred to the polypropylene type on the grounds of greater tensile strength.

7.3.1.10

7.3.1.11

Cables shall be securely cleated or tied to trays or ladders at the spacing specified in BP Group RP 12-13 clause 4.4.10, table 4. Any proposals to increase the spacing distances shall be subject to BP approval. Cables which leave main tray or ladder routes for connection to individual items of equipment shall be installed on tray, channel or angle supports fitted between the main cable run and the equipment. Electrical continuity shall be maintained between sections of cable tray or ladder by the use of flanged fish plates, and between the tray or ladder and the main structure, either through earthed support steelwork or by earthing cable connections to the main structure at each end of the tray or ladder run. Support Steelwork and Fixings The Contractor shall provide all supports necessary for mounting cable trays and cable ladders. Where possible these shall be of pre-fabricated

7.3.1.12

7.3.1.13

7.3.2 * 7.3.2.1

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PAGE 22

construction supplied by the tray or ladder manufacturer, to avoid onsite fabrication. In addition the Contractor shall provide, where necessary, all supports for such items as bus-ducting, control push button stations, socket outlets, lighting fittings, small power distributions boards etc. These shall also be of proprietary manufacture where possible; otherwise fabricated from steel channel, angle or tube. The Contractor shall provide such supports in accordance with Contract detail drawings, when provided, or alternatively obtain BP approval to his proposed mounting arrangements. 7.3.2.2 Site fabricated steel supports and brackets shall be properly fabricated and fitted. All drillings shall be made with minimum tolerances. All sharp edges shall be de-burred. The cable tray or ladder installation and support system shall be such that the maximum deflection between supports with maximum cable loading does not normally exceed 1/180 of the span. Any increase in designed deflection shall be agreed by BP. Normally all supports shall be made from steel in accordance with BS 4360 and shall be hot dipped galvanised to BS 729 or similar national standard. In particularly corrosive environments other support materials may be specified or considered but shall be subject to BP approval. All fixing bolts, nuts and washers, etc. shall be ISO metric threaded and of stainless steel. Shake proof spring washers shall be fitted to all bolted connections. When the fixing of electrical equipment, tray or trunking to fireproofed members cannot be avoided, any brackets required for such fixings shall be installed before the fireproofing material is applied. Consideration must be given to the likelihood of heat conduction through such fixings causing damage to the fireproofed member and appropriate safeguarding action taken in agreement with BP Site Management. Alternatively, and subject to the nature of the fireproofing, prefabricated clamping brackets may be accepted subject to approval by BP. * 7.3.2.7 Structural steel or pre-cast concrete members shall not be drilled for any reason unless specifically authorised on Contract Drawings or by BP Site Management. Fixing should be by means of clamping brackets. Under no circumstances shall welding or fixing operations be carried out on any process plant equipment, vessels, pipelines or structures

7.3.2.3

7.3.2.4

7.3.2.5

7.3.2.6

7.3.2.8

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PAGE 23

unless specifically indicated on the Contract Drawings or authorised by BP Site Management. Fixings to the above shall normally be made where brackets, etc. have already been provided or, when agreed by BP, by the use of purpose built clamps. 7.3.3. 7.3.3.1 Cable jointing and Termination Jointing and termination of cables shall comply with BP Group RP 1213, clause 4.6. All cable joints and terminations shall be carried out strictly in accordance with the cable manufacturers recommendations, with particular regard to the jointing or termination materials and procedure proposed. All jointing and termination of power cables shall be carried out by fully trained and competent tradesmen who have passed an approved course of instruction and training in such work for the operating voltage level involved. The Contractor shall be required to provide written confirmation of this or otherwise satisfy BP Site Management. Jointing and termination of high voltage cables shall be carried out or supervised by specialists, preferably from cable manufacturers. 7.3.3.4 Cable glands for termination at equipment in hazardous areas shall have component approval by a recognised certifying authority (e.g. BASEEFA, SIRA or equivalent body in other countries) for use with the type of cable and type of explosion proof equipment. The terminations for high voltage cables referred to in BP Group RP 12-13 Clause 4.6.4 shall incorporate voltage stress relief cones at voltages above 5kV. Prior to insulation of jointed conductors and earth continuity bonds, the joints shall be proved by resistance measurement to maintain the electrical ratings of the cable conductor, metal sheath (if applicable) and armouring. Glands entering enclosures where a single diaphragm or seal separates the enclosure from a hydrocarbon process shall be barrier types (i.e. pressure switches and solenoid valves etc.). Cable glands shall have ISO metric threads and shall be fitted with weather proof shrouds of PVC or other plastics material suitable for the environment.

7.3.3.2

7.3.3.3

7.3.3.5

7.3.3.6

7.3.3.7

7.3.3.8

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7.3.3.9

Where cables are terminated by glands into GRP enclosures having threaded entries and internal earth continuity plates, or metallic enclosures having clearance holes, a heavy gauge locknut and serrated washer shall be used. This is to guarantee the earth continuity between the gland body/cable armour and the enclosure. Serrated washers shall be deemed to be adequate to guarantee earth continuity when the glands are fitted to painted sheet steel enclosures. Brass earth tag washers may be used where serrated washers are not practical and a cable connection shall be made from the washer to the gland plate. The spare cores of control and instrumentation cables shall be terminated at both ends, in spare terminal ways or at earth terminals. Individual cores of cables up to and including 10mm2 shall be terminated on screw clamp/pressure plate type equipment terminals. All terminal blocks shall preferably be of Melamine insulating material. Raised insulated barriers shall be inserted between groups of terminals intended for wiring on different voltages, and between individual phases of a three phase supply. No more than two conductors shall be connected to any one terminal, i.e. one incoming and one outgoing conductor. If more than one conductor has to be terminated at the same point then several terminals shall be used and proprietary metal links used to interconnect the ways. The link shall not occupy the same place as the conductor. Terminals in marshalling boxes shall be arranged so that 10% spare ways shall be furnished, to allow for reasonable future modifications or additions. Cable Transits On on-shore installations, cables which pass from a pressurised enclosure, or through a fire wall leading directly from a safe area to a hazardous area, shall be fitted with approved proprietary cable transits or gland plates. On off-shore installations all bulkhead and deck penetrations by cables shall be carried out using agreed proprietary multi-cable transits. The Contractor shall provide the number of transit frames and tiers for each penetration position by reference to the schedule of cable transits. The Contractor shall determine the quantity (including spares) and

7.3.3.10

7.3.3.11

7.3.3.12 7.3.3.13

7.3.3.14

7.3.3.15

7.3.3.16

7.3.4 7.3.4.1

7.3.4.2

7.3.4.3.

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PAGE 25

provide and install the necessary transit insert blocks and frame accessories. 7.3.4.4 Transits shall be located in the positions indicated on the drawings. The Contractor shall be responsible for the cutting of all bulkhead and welding plates and the welding of all transit frames into position. If the Contractor can show valid reasons for the use of bulkhead or deck penetrations other than those indicated on the drawings then he shall obtain prior approval from BP Site Management before installation. Transits shall always be used where cables pass:(a) (b) (c) (d) 7.3.4.7 from a safe area to a hazardous area through blast walls through fire walls through walls, roofs and floors to the open

7.3.4.5

7.3.4.6

Care shall be taken to continue the trefoil formation of single core a.c. cables when passing through transits. Non-magnetic brass stayplates are required within the transits and each trefoil group shall pass through the same transit frame. Spare ways in transit frames shall be filled with blank filling blocks. A minimum of 25% spare ways shall be allowed in each penetration location. Cables passing through transits must be perpendicular to the transit for a minimum distance of 100mm on each side of the transit. The Contractor shall prepare drawings for the transits, to co-ordinate the positions of cables passing through and indicating the cable number, insert block and spare block sizes. The ways allocated for offshore cabling, as determined from the drawings and cable schedule, shall also be indicated. The clamping of the transit, after completing the onshore installation, shall be finger tight to allow any offshore installation to be made later and prevent the insert blocks premature loss of elasticity. All transits shall be identified by weatherproof labels on either side of their penetration. The labels shall preferably be fixed to adjacent racking and be easily readable from the deck below, with letters of at least 50mm height. Mineral Insulated Copper Sheath (MICS) Cable

7.3.4.8

7.3.4.9

7.3.4.10

7.3.4.11

7.3.4.12

7.3.5

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PAGE 26

7.3.5.1

MICS cable shall be installed and terminated by tradesmen who are trained and experienced in this class of work. The Contractor may be required to furnish written confirmation in this respect or otherwise satisfy BP Site Management accordingly. Relevant procedure included under Sub-Section 7.1 shall be adhered to insofar as it becomes equally applicable when routing and installing MICS cable. Cable that has become uneven, work hardened or otherwise unworkable or damaged during installation shall be replaced by the Contractor. The use of aluminium sheathed and/or aluminium conductor mineral insulated cable is normally prohibited. Its use for a particular installation, e.g. where no other type of cable is suitable, may be permitted, but written authority must be obtained from BP Site Management unless already covered in the Contract Documents. MICS cable with or without a protective sheath shall not be buried in the ground or installed in sand filled trenches. All circuits employing MICS cable except final sub-circuits of lighting installations shall be identified. The installation of MICS cable for trace heating application shall be carried out strictly in accordance with the cable makers instructions and the construction drawings. Single core MICS cables which are installed to form a three phase power circuit shall comply with requirements included under Clause 7.1.15. Restrictions are applied in the use of MICS cable and limitations on its use in the special situations detailed below shall be strictly adhered to:(a) MIC Cable shall not be used between discharge type lighting fittings and associated control equipment unless approved by BP Site Management and an appropriate surge suppressor has been correctly positioned in the circuit. When MICS Cable is specified, or its use for a.c. power circuits or d.c. circuits is agreed by BP Site Management, special consideration must be given if inductive load switching is involved, to the possible need for surge diverters in the circuit.

7.3.5.2

7.3.5.3

7.3.5.4

7.3.5.5

7.3.5.6

7.3.5.7

7.3.5.8

7.3.5.9

(b)

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PAGE 27

7.3.5.10

All cable, unless installed in trunking shall be straight and then saddled, in the manner described below. Straightening shall be carried out using a purpose made tool as supplied by the cable manufacturer for this purpose or by dressing the cables in situ with a hide or wooden mallet. Care shall be exercised in performing this operation to ensure that damage is not inflicted on either the cable sheath or outer protective sheath.

7.3.5.11

Saddling shall be carried out using manufactured saddles obtained from the cable maker or purpose made saddles made up from the cable maker or purpose made saddles made up for PVC coated aluminium or copper strip. The use of nylon or similar non metallic strip shall be restricted to horizontal runs where the saddle simply serves the function of holding the cable in position and not supporting it.

7.3.5.12

Bending and setting of cable is to be carried out in a neat manner with bends of a consistent radius and of all dimensions to ensure that the copper sheath does not wrinkle on the inner radius of the bend. The minimum radius of bends and sets shall be in accordance with the Manufacturers recommendations but shall not be less than six times the overall diameter of the cable.

7.3.5.13

Through joints shall not be used unless the route length exceeds the maximum manufactured cable length. Damaged cables may be repaired by through jointing only when a complete replacement is impractical, and then with the approval of BP Site Management. In safe areas, through joints shall comprise Jointing sleeves and the appropriate accessories supplied by the cable manufacturer specially for this purpose. After completion the joint shall be protected with a sleeve of similar material to the cable outer sheath. In hazardous areas through joints shall be effected by using adequately sized junction boxes, certified for the area of installation. Cable, glands, pot seals, sleeving, tools and all other accessories used together must be fully compatible and supplied by the same manufacturer. The mixing of components from different manufacturers is prohibited. Glands shall be of hexagon type and when applicable be certified for use in the hazardous area concerned. Glands of the knurled type are not acceptable.

7.3.5.14

7.3.5.15

7.3.5.16

7.3.5.17

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7.3.5.18

Terminations shall, whenever possible, be made using cold pot seals supplied by the cable manufacturer and care is to be taken in respect of the following procedures:(a) The pot is to be contained in the gland body and shall not protrude into the equipment. The pot is to be effectively screwed onto the cable sheath and its self cutting thread fully engaged, or in the case of wedge type fittings, these shall be correctly fitted in accordance with the manufacturers instructions. Copper swarf and surplus insulant is to be removed before sealing. The correct cold sealing compound is to be used and the pot filled in accordance with the manufacturers instructions. The sealing compound is to be fully compressed and the closing disc correctly crimped into position. Hot seals and those employing special sealing mediums shall be installed strictly in accordance with special procedure issued by the cable manufacturer. The manufacturers recommendations for excluding moisture from the cable immediately prior to making an end seal termination shall be rigidly observed.

(b)

(c)

(d)

(e)

(f)

(g)

7.3.5.19

At terminations, conductors are to be insulated with neoprene sleeving or where connections are made into high temperature enclosures e.g. tungsten fittings, etc. silicone rubber, or sleeving recommended by the cable manufacturer is to be used. In all cases except where positive earth continuity can be correctly maintained, e.g. via threaded entries of metallic enclosures, cable end seals with earth bonding tails must be used. The earth bonding tails must be properly terminated on earthed terminals provided for the purpose within the enclosures. Terminating glands clamped to nonthreaded entries by the use of locknuts are unacceptable for the purpose of maintaining earth continuity. The conductors of cables shall be terminated in a manner suitable for the terminal arrangement of the equipment concerned, and conductors of 10mm2 (0.015 in2 ) and above shall be fitted with compression lugs or alternatively cone grip lugs where space permits.

7.3.5.20

7.3.5.21

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7.3.6 7.3.6.1

Conduit Installations Conduit systems shall be designed and installed in compliance with appropriate regulations and codes of practice in force in the area of operation concerned. E.g. Installations within the UK shall comply with the IEE Regulations for Electrical Installations, 15th Edition. In countries which are not covered by national and/or local regulations, UK practice shall be applied.

7.3.6.2

Where a conduit system is to be installed wholly or in part in an area which is classified as hazardous, the installation shall, in addition to requirements under clause 7.3.6.1 also comply with the requirements of the current issue of the British Standard Code of Practice BS 5345 or the appropriate Code of the country concerned. Whenever possible conduit fittings shall be manufactured from malleable cast iron and for outdoor installations they shall be hot dipped galvanised and of weatherproof design. For plant installations, heavy gauge, hot dipped galvanised screwed steel conduit shall be used. The conduit shall be adequately sized to accommodate the total number of circuits involved without overcrowding and in no case shall conduit of less than 20mm bore be employed. Conduit for installations in hazardous areas shall be solid drawn, and fitted with Stopper Boxes as required. The use of welded seam conduit or flame retardant heavy gauge plastic conduit to BS 4607 Part 1 and BS 6099 Part 2 is acceptable for other areas.

7.3.6.3

7.3.6.4

7.3.6.5

The conduit system shall be electrically and mechanically continuous throughout and rigidly secured before wiring is commenced. An adequate number of draw-in boxes shall be installed to facilitate wiring without strain or damage to the cable. In all outdoor locations, and other areas where the formation of condensate may occur, conduit systems shall be provided with drain points. The conduit shall be installed in a manner which provides an adequate fall to ensure that the system drains to the drain points. Particular care shall be exercised in this connection to ensure that no equipment containing live parts is connected so that it can act as a drain point for all or part of the system.

7.3.6.6.

Conduit shall not be installed directly in the ground or in sand filled trenches.

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7.3.6.7

Flexible conduit will only be permitted when authorised by BP Site Management and then only when the use of flexible armoured cable is impractical. Conduit threads shell be cleanly cut to a finished length that leaves the minimum exposed length of thread when finally fitted. Threads shall be checked for correct size using an appropriate gauge. The leading edge and bore shall be made smooth. All exposed bare metal shall be cleaned and protected against corrosion using materials that are compatible with the original protective coating. Locknuts shall be used at all entries and be fully tight. The use of running couplers in installations in Zone 1 areas is prohibited and conduit unions shall be used. Bends and sets formed in conduit shall be made in the approved manner and without indentation or alteration of the conduit section. The bend radius shall be not less than that shown under the appropriate regulations referred to under 7.1.1. The type, grade or class of cable for conduit installation shall comply with requirements shown in the Job Specification. Wiring in conduit shall be looped from point to point and where joints are unavoidable they shall be made in junction boxes. The junction boxes shall be adequately sized and fitted with fixed connector blocks fully rated for the circuit requirement. In hazardous areas they shall be certified for use in the relevant area. Connections made into high temperature enclosures e.g. tungsten lighting fittings, etc., shall be made with silicone rubber insulated cable or other high temperature cable as may be agreed for the application concerned. Cables and Wiring for Instrument Systems Cables and wiring for instrument systems shall comply with BP Group RP 30-1. Cable glands shall be of the mechanical compression type Where used for terminating armoured and/or lead sheathed cables the gland shall include integral facilities for securing and bonding the armour and lead sheath. Where indicated on BP Standard Drawing No. S-1962 the glands shall be insulated from earth.

7.3.6.8

7.3.6.9

7.3.6.10

7.3.6.11

7.3.6.12

7.3.6.13

7.4 7.4.1

7.4.2

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7.5 7.5.1

Cable Records The Contractor shall prepare a cable drumming schedule which shall be kept up to date during the contract period. The cable drumming schedule shall be carefully prepared to minimise wastage of cables. The Contractor shall closely liaise with BP Site Management to ensure that, by forward planning of requirements, no delays are experienced in cable installation due to material shortage. Records shall be kept of all cable requests to BP. The Contractor shall maintain an up-to-date record of all cables installed by marking up a copy of the computer cable schedule to indicate where variations in length, size, number of conductors and destinations occur. This schedule shall be handed to BP Site Management at the end of the contract. The Contractor shall also institute a recording system (e.g. Kardex) to record actual lengths of cable removed from the drum, the drum reference and the purpose for which each length is used.

7.5.2

7.5.3

7.5.4 7.5.5

7.5.6

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8.

INSTALLATION OF ELECTRICAL EQUIPMENT 8.1 8.1.1. Switchgear In this Specification, the term switchgear includes high voltage and low voltage switchgear, motor control centres, relay panels, electrical control panels and main fused distribution boards but not small power and lighting sub-distribution boards. All switchgear supplied by the Contractor shall comply with BP Group RPs 12-6 and 12-7 for high voltage and low voltage switchgear respectively; also with BP Group GSs 112-8 and 112-9. The Contractor shall be responsible for familiarising himself with the vendors information regarding installation and testing requirements. It is recommended that the vendors representative should be present during installation, and particularly during all stages of positioning, alignment and levelling. Before any switchgear is installed, the Contractor shall ensure that all decking and supporting steelwork is completely installed, and is in accordance with the drawings. On offshore platforms mild steel plinths welded to the deck shall be provided, if required, to maintain switchboard rigidity and alignment. Particular care shall be taken when using jacks or lifting gear so as to avoid distorting or damaging equipment and only the vendor provided jacking and lifting parts shall be used. All panel sections shall be mounted in the correct sequence as shown on vendors and contract drawings and all circuit designation labels shall be checked for correct identification. The switchgear and motor control centre sections shall be tightly and rigidly bolted together. The manufacturers representative shall supervise and check the tightness of bolted connections within the equipment and ensure the tightness of all bus-bar connections, including correct alignment and connections of inter-connecting bus-bar sections between motor control centres and switchgear. The Contractor shall, where applicable, use only the special tools and equipment supplied by the Vendors and shall ensure that such tools are available in good condition for later use by others.

8.1.2

8.1.3

8.1.4

8.1.5

8.1.6

8.1.7

8.1.8.

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8.1.9

Switchboard sole plates, steel struts, or other mounting steelwork shall be installed within the tolerances specified by the manufacturers. If installed on a concrete surface the mounting steelwork shall be installed electrically clear of floor reinforcing metal work. floor screed below the switchboard and any truck run-out area shall be level within + or - 3mm over the whole area. All packing material and constraints shall be removed carefully and stored and the complete equipment thoroughly cleaned. The stored packing can be use for repacking on shipment offshore. The floor area in front of all withdrawable equipment shall be within the manufacturers recommended level tolerances to enable easy withdrawal and replacement. Withdrawable portions of the switchgear and motor control centres shall be checked for correct mating with the stationary portions and correct function of locking devices before the switchboard is commissioned. The Contractor shall be responsible for locating all minor equipment not otherwise located on the drawings e.g. Control Stations, Junction Boxes, etc. Local Control Stations shall always be mounted adjacent to their respective equipment. Final locations shall suit site conditions and be subject to approval of BP. All distribution boards shall be provided with an interior sub circuit identification schedule to indicate the equipment served. The schedule shall be completed by the Contractor prior to tow out. Where bus-ducting is issued, e.g. for connecting transformers to switchgear, the Contractor shall install it in accordance with the manufacturers recommendations, and strictly to the contract drawings with regard to route locations, support steelwork and if applicable offshore deck or bulkhead penetrations. Bus ducting will be any one of the following types, all of which will be supplied in bits for site assembly:(a) (b) (c) air insulated copper bar assemblies sleeved copper bar assemblies encapsulated copper bar assemblies

8.1.10

8.1.11

8.1.12

8.1.13

8.1.14

8.1.15

8.1.16

8.1.17

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All bus ducting systems should be supplied complete with butt right angled, tee and flexible inter-connecting kits and connection insulation kits as applicable. For encapsulated bus ducting, the manufacturer should also supply all support assemblies. 8.1.18 The Contractor shall be totally responsible for the installation of air insulated and sleeved copper bar types of bus ducting. The Contractor shall be responsible for the installation of encapsulated type bus ducting but under the supervision of the manufacturers representative. For encapsulated type bus ducting to be installed on offshore platforms the contractor shall interconnect (but NOT encapsulate interconnections) bus ducting onshore and shall ensure that the completed bus duct run is in proper alignment, free from any distortion along its length and does not impose any strain on connected terminals or equipment. After pre-commissioning tasks are completed, interconnections shall be loosened prior to tow-out. all bus duct

8.1.19

8.1.20

All bus-duct sections passing through deck or bulkhead penetrations and which require to be interconnected offshore shall be removed prior to tow-out, or else fully protected against damage, to the satisfaction of BP. After tow-out the Contractor shall:(a) (b) (d) install all interface connections tighten all bolted connections insulate, as applicable, all interconnections

For encapsulated type bus ducting, the manufacturers representative shall supervise these activities. Where bus ducting passes through A60 deck or bulkhead, certified seals shall be used, as shown on the drawings and fire resistant protection applied to the bus ducting above and below the penetration in accordance with the manufacturers detailed recommendations. 8.2 8.2.1. Motors All electric motors supplied by the Contractor shall comply with BP Group RP 12-11, unless otherwise agreed by BP. They should also comply with BP Group GSs 112-3 and 112-4 for high voltage motors and low voltage motors respectively.

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8.2.2

Motors supplied on packaged equipment will have been installed on the package and the package itself shall be installed in accordance with the manufacturers recommendations. The following requirements are intended primarily for motors on non-packaged equipment, but where relevant, are equally applicable to motors on packaged equipment. Baseplates shall be erected as part of the driven equipment and checked for level and location prior to the erection of machinery. Protective films on machined surfaces shall be cleaned off with the recommended solvents, either immediately prior to installation (e.g. mounting surfaces) or prior to commissioning (e.g. Motor shafts). Machinery shall be slung or lifted from the prescribed lifting positions or eyebolts fitted to the equipment. If no lifting points are provided, great care must be taken to prevent damage during lifting operations and the Contractor shall ensure that the equipment is lifted in the horizontal or upright position. Shims supplied with the equipment shall be used wherever possible for levelling that equipment. Shims shall be of similar size to the machined surfaces of the equipment footings. The maximum thickness of shim shall always be used to that the minimum number of shims are positioned under any one footing. Where separate bearing pedestals are supplied, these are to be positioned, levelled and lined up prior to the installation of other equipment. White metal bearings shall be checked to ensure adequate bedding using engineers blue or some other approved method of indication. The bedding shall be checked by the BP Representative. Coupling faces shall be truly parallel and level, checks being made with the shafts rotated to different positions. Coupling bolts or flexible connections shall be properly fitted without damage and all nuts must be tightened and locked before the equipment is run. If machines with grease lubricated bearings have been stored for a long period, the bearing grease shall be inspected and if deterioration has taken place, the bearings shall be thoroughly washed, dried and regreased using approved methods recommended by the manufacturer. Where oil lubricating systems are employed, the Contractor shall enquire that bearing oil rings, flow switches, pressure switches, pumps, etc. are fully operative prior to commissioning.

8.2.3

8.2.4

8.2.5

8.2.6

8.2.7

8.2.8

8.2.9

8.2.10

8.2.11

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8.2.12

Before connecting the supply to any motor, the Contractor shall ensure that the motor insulation resistance is not below the minimum value permitted by applicable standards or the manufacturers data. Motors with insulation resistance lower than the permitted minimum value shall first be dried out in accordance with the manufacturers instructions, and re-tested to ensure that resistances are satisfactory, The phase sequences for the connection of motors shall be confirmed on site and it shall be ensured that at least two cable core connections at the motor terminal box can be interchanged without having to make off the cable again. The requirement of correct rotation is particularly important on high voltage motors and low voltage motors rated 75 KW and above because of the difficulties involved in manipulating large cable cores at a later date, Care shall be exercised when insulation testing motors fitted with thermistor or thermocouple over-temperature protection. These devices are essentially low voltage or signal devices and if subjected to higher voltage they will be irreparably damaged. If motors with ball or roller bearings are left standing, particularly in conditions subject to vibration, before putting into service, they shall be turned over at regular intervals to avoid brinelling of the bearings. Transformers and Reactors Transformers and reactors supplied by the Contractor shall comply with BP Group RP 12-9 and BP Group GS 112-5. The Contractor shall ensure that all transformers and reactors are installed in the location shown on the drawings and in accordance with the manufacturers drawings and recommendations. Only the designated jacking and lifting points shall be used when the transformers are being put into position. Where there are separate lifting facilities for tank tops, cores and coils, these shall be removed or rendered unuseable during transport and erection. When bus-ducting is used for connections to transformers and reactor terminals, checks shall be made to ensure that the bus ducting connection can be made without imposing any stress on the bus-ducting copperwork or transformer terminal bushings, before the tank base is finally bolted or welded down.

8.2.13

8.2.14

8.2.15

8.2.16

8.3 8.3.1

8.3.2

8.3.3

8.3.4

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8.3.5

When correctly located and inspected, an insulation test shall be carried out and recorded between each phase and earth and, between HV and LV windings. On completion of the installation of all fittings and cables, etc., an insulation test of all windings and connections shall be made. Where applicable, the fluid level in transformers and colour of any breathing desiccants shall be checked and rectified where necessary. Where applicable, transformer oil or other liquid insulant shall be checked/tested in accordance with the manufacturers recommendations. Where applicable, any transformer tap changer must be securely padlocked in its required position. Batteries, Battery Chargers and Inverters Batteries, battery chargers and invertors, providing a source of:(a) (b) (c) (d) dc supplies for switchgear closing and tripping, instrumentation dc supplies of control systems secure static ac supplies for control systems dc supplies for other duties such as emergency lighting, emergency motor drives, hazard warning lights, etc.

8.3.6

8.3.7

8.3.8

8.3.9

8.4 8.4.1

Shall comply with BP Group RP 12-5 and BP Group GSs 112-10 and 112-11. 8.4.2 Installation and preparation of batteries for commissioning shall be carried out in accordance with manufacturers shall be carried out in accordance with manufacturers recommendations, which will vary with the type of battery and its delivered state of charge. When battery filling or handling is undertaken, every precaution shall be taken against the possible dangers of toxic fumes, heat and acid or alcali burns associated with battery electrolyte. Protective clothing shall be provided for the installation personnel by the Contractor and the area must be well ventilated. A quantity of neutralising solution shall be readily available when batteries are handled or commissioned. Batteries and charges shall not be left unattended whilst initial boost charging is being carried out.

8.4.3

8.4.4

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8.5 8.5.1

Electrical Surface Heating Electrical surface heating (ESH) equipment and systems shall comply with BP Group RP 12-15. The design of the ESH system will have been carried out by others. The Contractor shall be responsible for the installation of the equipment and system in accordance with the design specification and drawings, and the above Code of Practice. Earthing and Bonding The Contractor shall be responsible for installing earthing and bonding systems in accordance with BP Group RP 12-16. The earthing and bonding systems on offshore platforms shall also comply with the IEE Regulations for the Electrical and Electronic Equipment of Mobile and Fixed Offshore Installations Section 2. Where there is any conflict between these requirements and those in Clause 8.6.1 the Contractor shall consult BP for a decision. Earthing and bonding systems for electronic instrumentations, data collecting and data processing systems shall comply with BP Group RP 30-1, BP Group RP 30-8 Sect.4 and BP Standard Drawing No. S-1962. The Contractors responsibility shall include, but not be limited to:(a) (b) Earthing and bonding of power system neutral earthing Earthing and bonding of non-current carrying parts of electrical apparatus Earthing and bonding of process tanks and structures for lightning protection Earthing and bonding of process tanks, pipework and structures to disperse static charging Earthing and bonding to disperse any charging of structures, cranes, etc. by radio frequency induction from radio transmitting aerials and radar equipment Earthing and bonding of instrumentation equipment and cabling

8.5.2 8.5.3

8.6 8.6.1

8.6.2

8.6.3

8.6.4

(c)

(d)

(e)

(f)

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8.6.5

Protective screening around insulated conductors on cables emanating from a master station to outstations or field mounted instruments shall be earthed at the master station only and shall be insulated from the outstations or field mounted measuring devices. Where indicated on BP Standard Drawing No. S-1962, cable glands for instrumentation circuits shall be insulated from earth. Small Power and Lighting Systems Lighting and lighting installations shall comply with BP Group RP 1214. Where applicable they shall also comply with the IEE recommendations for the Electrical and Electronic Equipment of Mobile and Fixed Offshore Installations, Section 15. Also see section 6 regarding hazardous areas. Whenever possible, lighting luminaires and socket outlets shall be installed in locations shown on the contract drawings. Where necessary, the Contractor shall, by agreement with BP, relocate luminaires and socket outlets to avoid interference with other work or equipment. All elevations shown on drawings are in metres and are related to immediate floor or platform datum as defined on the contract drawings. Elevations are to the underside of the fittings. Light fitting heights shown on drawings may be nominal, and site adjustments may be necessary to clear local obstruction. However, all light fittings shall be positioned to provide safe access for lamp changing. All alterations shall be referred to BP for approval. All emergency hand lamps, socket outlets and junction boxes shall be mounted at a suitable height from floor or platform to facilitate ready access for use during maintenance, Socket outlets shall, wherever possible, be mounted 450mm above floor level. Final position and angles of floodlights shall be determined during construction. All floodlights shall be mounted on stirrups. The cable for connections to floodlights shall be of adequate length to permit the floodlight to be swivelled on its mounting through 360. Due account shall be taken of certification of fittings when determining final mounting positions. Control gear boxes shall be mounted adjacent to the fittings in a position easily accessible for maintenance and repair. For lighting circuits, all cabling shall be 2 core 2.5 mm2 PVC/SWA PVC except where contract drawings specifically states 2.5 mm2 PVC

8.6.6

8.7 8.7.1

8.7.2

8.7.3

8.7.4

8.7.5

8.7.6

8.7.7

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non-armoured cable or MICC 1.5 mm2 cable in specified areas or for specified services. 8.7.8 In non-hazardous areas lighting circuits shall be of the loop-in type with the lighting cable looping from one fitting to the next. The Contractor shall ensure that the continuity of the cable armour is maintained. In hazardous areas lighting circuits shall not be of the loop-in type. The installation shall be such that a complete lighting fitting can be removed and the integrity of the type of protection be maintained, e.g. by the insertion of a stopping plug in an EExe certified junction box, so that the remainder of the lighting circuit can be re-energised. Care shall be taken to ensure the correct polarities when wiring switches, socket outlets and lamp holders. The luminaries may be utilised on a temporary single phase power supply during the construction period, providing all necessary checks on cables and equipment have been made to the satisfaction of the Company prior to energisation. The number of fittings connected to any one final sub circuit shall be shown on the drawings. The Contractor shall however check that no area is totally without illumination upon supply failure of any one subcircuit. Each lighting sub-circuit shall be protected by a 15A MCB or 15A fuse at the distribution board. The maximum steady load (including control gear losses) on any lighting final sub-circuit shall not exceed 0.55 times the sub-circuit protective MCB rating or fuse rating. 8.7.14 Each lighting and small power distribution board shall be provided with an interior sub circuit identification and loading schedule which the Contractor shall complete prior to module tow out. Illumination levels shall be in accordance with the Chartered Institute of Building Services Engineers (CIBSE) Code for Interior Lighting 1984, taking into consideration all such limiting factors as Glare indices, Veiling reflections, etc. Typical illumination levels, applicable to offshore platforms, are as follows:Locations Illumination Level (LUX) Working Plane (m) On Working Plane

8.7.9

8.7.10

8.7.11

8.7.12

8.7.13

8.7.15

-Control room, Radio room Desk + Front Panel 500

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Back Panel -Generator rooms -Switchgear rooms -Battery room, Chargers, and Inverters room -Workshops - General - Workbench -Utility & Process areas -Walkways & Corridors -Exterior stairs and ladders -Laboratory -Offices -Stores -Kitchen - General - Serving Counter -Laundry -Cabins - General - Reading - Bathrooms -Dining Rooms -Rest room

150 200 150 100 300 500 150 50 100 500 500 150 200 500 300 50 200 100 200 150

Floor Floor Floor Floor Floor 0.9 Floor Floor Tread 0.9 0.75 Floor Floor 0.9 0.9 Floor 0.75 Floor Floor Floor

On offshore platforms sea perimeter lighting, an illumination level of 50 lux at the sea surface shall be achieved using floodlighting. 8.7.16 Following installation of the lighting systems, the Contractor shall, under night-time conditions:(a) take readings of illumination levels throughout the plant or platform with the normal lighting system energised. energise only the emergency lighting system to prove adequacy. Any areas not meeting design requirements shall be reported to BP. adjust orientation of floodlight fittings for maximum efficient use.

(b)

(c)

8.7.17

All areas shall have access to service with the use of a 15 metres cord for general purpose socket outlets and 30 metres cord for welding

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socket outlets. The quantity and location of socket outlets shall generally be as shown on the drawings. Socket outlets shall also be located adjacent to equipment requiring periodic inspection and maintenance, such as manway openings of vessels, towers and rotating machinery. 8.7.18 Anti-condensation heaters in all equipment (including instruments) shall be electrically fed from the nearest small power, trace heating or anticondensation heater distribution board. Generator Packages Generators and generator packages shall comply with BP Group GS 112-6. The Contractor shall install all Main, Emergency and, where specified, Standby Generators with their gas turbine or diesel engine drivers, and all equipment associated with these packages, in the locations shown on the drawings and in accordance with the manufacturers instructions. The Contractor shall install and terminate all interconnecting cables in accordance with the equipment suppliers drawings and contract drawings. Skilled supervision for the installation of generators and their ancillary equipments shall be provided by the manufacturer at the discretion of BP. The energisation of anti-condensation heaters, barring of rotors and all aspects of treatment during storage, installation and pre-commissioning periods shall be carried out in accordance with the manufacturers instructions and recommendations.

8.8 8.8.1

8.8.2

8.8.3

8.8.4

8.8.5

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9.

INSTALLATION, INSPECTION, TESTING AND COMMISSION 9.1 9.1.1 General The BP Site Electrical Engineer will be responsible for overseeing the Contractors work associated with the installation, inspection and testing of all electrically related equipment, circuits and systems in accordance with the following requirements of this section of the guidelines. The BP site Electrical Engineer will be responsible for agreeing the contractors installation, inspection and testing procedures. The Contractor shall be responsible for the provision of all necessary instruments, connections and other equipment including electrical supplies, also the requisite personnel whether the tests are undertaken at the works of the Contractors, or of the Sub-Contractor, or carried out at Site. All instruments used for commissioning shall be of an approved type and they shall have been calibrated against certified standards at regular and proper intervals. Their accuracy must be fully substantiated at the time of use. Installation The installation of electrical equipment and circuits will be checked for compliance with good engineering practice and the contractual requirements as detailed in:9.3 The latest revision of AFC Drawings and Schedules. Plant and Project Specifications. Equipment Specifications and Data Sheets. National Codes and Standards. BP Group RPSEs.

9.1.2

9.1.3

9.2

Safety Precautions Under no circumstances may any test be carried out in such a manner as to cause danger and all due safety precautions must be taken. No test should be undertaken until it has been confirmed that the equipment to be tested is properly isolated and has been effectively discharged. Areas where HV testing is to take place should be roped off prior to and during testing and cautionary notices should be displayed at all points of access. Similar precautions should be taken in all other instances where danger could arise, e.g. motor running tests.

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All equipment should be effectively discharged at the completion of testing; where necessary e.g. in the case of large cables and motors, the earth bond should be left on for 15 minutes or more. 9.4 9.4.1 Inspection and Testing The complete Works shall be subject to inspection and test for compliance with this specification, generally to BP Group RP 32-2 and Appendix C of this Specification. Electrical equipment and the electrical content of mechanical equipment packages will be inspected on receipt at site. Any remedial work carried out at site by either the fabricator or vendor to correct transit damage or faulty workmanship not previously detected will be supervised by the site Electrical Engineer. Pre-Commissioning of Electrical Systems Pre-commissioning inspection and tests shall be carried out by the Contractor on all electrical equipment under the supervision of, and to the satisfaction of, BP. The inspection and testing shall be carried out generally in accordance with Appendix C of this Specification. Inspection and testing of specialised equipment not included in the categories of Appendix C shall be carried out in accordance with procedures specified or agreed by BP. The results of all inspection and testing shall be recorded on data sheets as in Appendix C or an agreed variation. All data sheets of inspection and testing shall be signed and approved by BP. Pre-acceptance Inspection and Testing Prior to energising, 4 hr motor runs will be carried out by the Contractor. When a Contractor considers that the construction of an electrical system, circuit or parts thereof is complete and is of such a standard that pre-acceptance inspection and testing can commence, he shall advise BP accordingly. Unless a specific waiver is given by BP all inspection and tests which are to be recorded in the system test dossier shall be witnessed by a representative of BP. The Contractor must provide adequate notice of his intention to commence these activities so that BP has time to allocate an inspector.

9.4.2

9.5. 9..5.1

9.5.2

9.5.3

9.5.4

9.5.5

9.6 9.6.1

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The Contractor should maintain close liaison with BP so that inspection and testing may be carried out as work proceeds in order to avoid the need for disconnection of cables for testing purposes after the installation has been completed. Wherever possible final inspection and testing should be carried out immediately prior to acceptance by BP for energisation. Where this is not possible the Company may call for re-inspection and testing. * 9.6.2 Following the satisfactory completion of the inspection and testing of a system or circuit the Contractor shall complete the appropriate test certificate(s) and submit it to BP prior to, or together with, his formal notification that work on the system or circuit is complete. No work whatsoever shall be carried out on the system or circuit by the Contractor subsequent to this submission unless full details of such work are agreed in writing by BP. 9.7 9.7.1 Energisation and Commissioning When the electrical works or any section thereof, has been proved satisfactory and agreed to be such by BP, the Contractor will arrange for an attend upon BP during the commissioning of the completed works as agreed. Following submission of the formal notification that work is complete, arrangements will be made by BP to energise the system or circuit at a mutually convenient time. The energisation and commissioning of the system or circuit will be carried out by, and will be the responsibility of BP but the Contractor shall provide such assistance in these activities as is deemed necessary by BP. Under no circumstances may a circuit be energised or commissioned prior to its being inspected and tested and the relevant section of the system test dossier completed and approved. Prior to initial energising a work permit shall be obtained. Under no circumstances may any test be carried out on existing cables or equipment without the agreement and in the presence of a representative of BP. In certain instances, e.g. motors, special drives and systems, area lighting boards, control circuits, etc., BP may agree in writing to the Contractor assuming responsibility for the energisation from BP suppliers of the systems or circuits concerned. Such agreement will not be given until the Contractor has satisfied BP as to the adequacy of the precautions he intends to take to ensure the safety of the system and those working upon it. In such cases the Contractors shall implement

9.7.2

9.7.3

9.7.4

9.7.5

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an acceptable safe system of working, e.g. Permits to Work, etc., and submit to BP for approval. 9.7.6 If the results of the test and checks carried out after energisation are not satisfactory the system or circuit will be de-energised, locked off and handed back to the Contractor for correction. This, in some instances may be covered by a Punchlist detailing the remedial work required. In the event of electrical work being left in a de-energised or inoperable stage for any length of time prior to final acceptance, the Contractor shall arrange for, and/or, carry out any inspections, tests, operations, etc., as may be required by BP, to ensure that it is still in a satisfactory condition for re-energising and putting into operation. The above shall apply until such time as the Contractor is relieved from responsibility by the issue and acceptance of a handover certificate which may include provisos concerning minor items that remain to be completed. If the results of the energisation tests are satisfactory the system or circuit will be accepted by BP subject to any minor modifications specified by BP. Thereafter the circuit or system will become the responsibility of BP and no further work may be carried out on it without the prior approval of BP. Access to live metalwork or the energisation of sub circuits must thereafter have the express approval of BP by means of a permit to work system (see Appendix D),

9.7.7

9.7.8

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APPENDIX A DEFINITIONS AND ABBREVIATIONS Definitions Standardised definitions may be found in the BP Group RPSEs Introductory Volume. Manufacturer: the manufacturer of equipment/materials to which this Specification applies. a visual inspection of the equipment and the installed circuits and systems. routine tests normally carried out prior to energisation to ensure that the equipment, circuits and systems have been installed correctly and are safe to energise. energisation and the final tests and checks subsequent to energisation to ensure that each circuit and piece of equipment satisfactorily performs its required function.

Inspection:

Testing:

Commissioning:

Abbreviations AFC BASEEFA BS CIBSE EN ESH EVA GRP HV IEC IEE IP ISO LV MCB PVC SIRA SWA Approved for Construction British Approvals Service for Electrical Equipment Flammable Atmospheres British Standard Chartered Institute of Building Services Engineers European Standard Ethylene Vinyl Acetate Glass Reinforced Plastic High Voltage International Electrotechnical Commission The Institution of Electrical Engineers Institute of Petroleum International organisation for Standardisation Low voltage Miniature Circuit Breaker Polyvinyl Chloride

in

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APPENDIX B LIST OF REFERENCED DOCUMENTS A reference invokes the latest published issue or amendment unless stated otherwise. Reference standards may be replaced by equivalent standards that are internationally or otherwise recognised provided that it can be shown to the satisfaction of the purchasers professional engineer that they meet or exceed the requirements of the referenced standards. ISO 9001 Quality Systems - Model for Quality Assurance in Design/Development, Production, Installation and Servicing. Specification for Hot Dip Galvanized Coatings on Iron and Steel Articles. Specification for Weldable Structural Steels. Specification for Luminaires with Types of Protection N. Specification for Fittings and Components of Insulating Material. Rotating Electrical Machines with Type of Protection N. Code of Practice for Selection, Installation and Maintenance of Electrical Apparatus for Use in Potentially Explosive Atmospheres. Conduits for Electrical Installations. Part 2: Particular specifications. Distribution of Electricity on Construction and Building Sites

BS 729 BS 4360 BS 4533 Section 102.51 BS 4607: Part 1 BS 5000: Part 16 BS 5345

BS 6099

BS CP 1017

The Institution of Electrical Engineers (I.E.E.) Wiring Regulations for Electrical Installations, 15th Edition. The Institution of Electrical Engineers (I.E.E.) Regulations for the Electrical and Electronic Equipment of Mobile and Fixed Offshore Installations, Section 2. The Institution of Electrical Engineers (I.E.E.) Recommendations for the Electrical and Electronic Equipment of Mobile and Fixed Offshore Installations, Sections 6 and 15. Chartered Institute of Building Services Engineers (CIBSE) Code for Interior Lighting 1984 Health and Safety Executive (HSE) Guidance Note G524.

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BP Group RPSEs GS 112-4 GS 112-3 GS 112-5 GS 112-6 GS 112-9 GS 112-8 GS 112-12 GS 112-10 GS 112-12 RP 12-1 RP 12-5 RP 12-6 RP 12-7 RP 12-9 RP 12-11 RP 12-13 RP 12-14 RP 12-15 RP 12-16 RP 12-17 RP 12-19 RP 24-1 RP 24-2 RP 30-1 RP 30-8 RP 32-2 BP Standard Drawing:S-1962 High Voltage Induction Motors Low Voltage Induction Motors Transformers and Reactors. Electrical Requirements for A.C. Generators and Generation Packages High Voltage Switchgear and Control Gear Low Voltage Switchgear and Control Gear. D.C. Power Supplies Secure Static A.C. Power Supplies for Control Systems Requirements for Flame Retardant and Fire Resistant Cables Electrical Systems and Installations - General Electrical Systems and Installations - Power Supplies for Control Systems Electrical Systems and Installations - High Voltage Switchgear Electrical Systems and Installations - Low Voltage Switchgear Electrical Systems and Installations - Transformers and Reactors Electrical Systems and Installations - Motors Electrical Systems and Installations - Cables, Cable Systems and Wiring Electrical Systems and Installations - Lighting and Lighting Installations Electrical Systems and Installations - Electric Surface Heating Electrical Systems and Installations - Earthing and Bonding Electrical Systems and Installations - Supplies to Equipment via Socket Outlets Electrical Systems and Installations - Construction Site Power Supplies Fire Protection - Onshore Fire Protection - Offshore Instrumentation and Control - Design and Practice Instrumentation and Control - Electromagnetic Compatibility for Instrumentation and Control Systems Site Inspection, Testing and Pre-Commissioning of New Plant

Typical Earthing Diagram for Instrumentation Onshore

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APPENDIX C INSPECTION AND TEST PROCEDURE C.1 INTRODUCTION C.1.1 This section details the site inspection and testing procedures for the Electrical Discipline and includes standard forms which are to be used to accurately record the results of the inspection and tests and provide written evidence that all electrical equipment and systems comply with design parameters and function correctly. The procedures cover the inspection of electrical equipment prior to installation and the inspection and testing of installed equipment, circuits and systems before and after energisation and commissioning. Although the inspection and test procedures in this section are comprehensive, they may not necessarily cover all electrical equipment and systems included in the design. It is the responsibility of the BP site Electrical Engineer to agree all electrical inspections and tests and ensure that any further procedures, additional to those included in this document, are developed in order to give complete coverage and confirm that electrical systems in all respects are fit for energisation and service. It is also the responsibility of the BP Site Electrical Engineer to ensure that prior to construction a comprehensive component/equipment list and cable schedule is available against which all the required test certificates will be listed to give a concise cross reference for the completion of system testing. Where special electrical equipment and systems are provided, e.g. alternators, emergency generators, resistors, reactors, balanced current protection, synchronising and complex control circuits, invertors and public address systems, the supplier will be required to carry out final inspection and functional testing at site after installation. Such inspection and tests are to be recorded on test certificates prepared by the supplier and agreed by BP prior to use.

C.1.2

C.1.3

C.1.4

C.1.5

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C.2

INSPECTION AND TEST PROCEDURES C. 2.1 C. 2.2 C. 2.3 C. 2.4 C. 2.5 C. 2.6 C. 2.7 C. 2.8 C. 2.9 C. 2.10 C. 2.11 C. 2.12 C. 2.13 C. 2.14 C. 2.15 C. 2.16 C. 2.17 C. 2.18 C. 2.19 Procedure No. 1 - Power and Control Cables Procedure No. 2 - Switchboards and Busbars Procedure No. 3 - Circuit Breakers Procedure No. 4 - Contactor Breakers Procedure No. 5 - Fuse Switches Procedure No. 6 - Power Transformers Procedure No, 7 - Motors Procedure No.8 - Batteries and Battery Chargers Procedure No. 9 - Ininterruptable Power Supplies Procedure No 10 - Lighting and Small Power Distribution Procedure No. 11 - Neutral Earthing Resistors Procedure No. 12 - Trace Heating Tapes and Circuits Procedure No. 13 - Earthing Procedure No. 14 - Apparatus for use in Hazardous Areas Procedure No. 45 - Oil Insulation Tests Procedure no. 16 - Drying of Electrical Rotary Machinery Procedure No. 17 - Current Transformer Magnetising Curves Procedure No. 18 - Junction Boxes Procedure No. 19 - Testing of Protection and Meter Circuitry

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C. 2.1

Procedure no. 1 - Power and Control Cables The following inspection and test procedures are applicable to all cable sizes and types

C.2.1.1

Inspection (Post Installation) (a) Compare the cable size, type and numbering with the cable schedule paying particular attention to any special requirements. e.g. toxicity. Ensure that the core identification agrees with the connection diagrams and phase sequence. Ensure that the gland certificates meet the area classification requirements. 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 adaptors have been installed. Ensure that the gland plates for all single-core cables have been manufactured from non-magnetic materials. Where conductors have been terminated using crimped connections, ensure that the correct size and type of crimping lug has been used. Before making any measurement, the inspector should ensure that both ends of the cable have been disconnected and are clear of any metal. Inspect the earth connections. For HV cable, ensure that the cables have been glanded in accordance with the cable manufacturers instructions and in particular check that any stress relief measures have been incorporated. For MICC cable, the additional inspection as listed below should be carried out:(i) Check that the glanding is in accordance with the manufacturers instructions and that earth trails have been terminated at a suitable earthing terminal.

(b)

(c)

(d)

(e)

(f)

(g) (h)

(i)

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(ii)

Check that surge suppression voltage dependent resistors are correctly fitted where specified and that the correct type has been fitted.

(j)

Ensure the appropriate requirements of Procedures 15 and 19 are carried out if applicable.

C.2.1.2

Testing Before any cables are tested, all cleating, supports, backfilling of trenches etc. is to be completed. (a) Measure the insulation resistance of the cable and record on the relevant test certificate. The table below gives the test voltages and minimum acceptable values of insulation resistance. Where necessary measure the conductivity of the earth conductor. For LV and MV multicore cables, insulation resistance should be measured core to core, core to earth and screen to armour Record only the lowest figure obtained.

Cable Voltage (Working Range)

Test Voltage Minimum Insulation (Between conductor Resistance Meg-Ohms and to earth)

00/1000V 1900/3300V 3800/6600V 6350/11000 8700/15000 12700/22000 19000/33000

1000V 1000V 1000V 5000V 5000V 5000V 5000V

10 200 200 200 200 200 200

(b)

Apply a DC Test voltage (pressure test) between the conductors of each high voltage cable and the copper tape screen of each conductor, also between conductors. Record test voltage and duration of test, measure and record any leakage current.

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

CABLE GRADE

DC TEST VOLTAGE CONDUCTOR TO SHEATH

DURATION

CONDUCTOR TO SHEATH

1900/3300 3800/6600 6350/11000 19000/33000

7000 15000 25000 -

10000 20000 34000 75000

15 Mins 15 Mins 15 Mins 15 Mins

(Abstracted from BS 5467:1977 Table 17, BS 6346:1969 Table 20 and BS 6460:1969 Table 31). (c) Immediately after the above test, the insulation resistance between each conductor and its earthed copper screen shall be measured, as detailed in (a) above. The minimum acceptable value is as tabulated.

C.2.1.3

Test Certificates Forms E-1 and E-2 are to be used to record the results of the testing and require endorsement to confirm that all the requirements of this procedure, and procedures 14 and 18 if appropriate, have been carried out satisfactorily.

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C.2.2 C.2.2.1

Procedure No. 2 - Switchboard and Busbars Inspection (a) Pre-Installation (i) Ensure the equipment certificates meet the area classification requirements. Remove any temporary weatherproofing and silica gel drying agents from switchgear. Inspect the inside of the switchgear for cleanliness paying particular attention to the insulators. Compare the switchgear equipment with the equipment schedule, paying particular attention to the rating and any circuit changes. Ensure that the equipment meets Specification including weather, dust and vermin-proofing.

(ii)

(iii)

(iv)

(b)

Post Installation (i) Inspect the switchboard assembly for alignment, level, tightness of foundation bolts, and fixing in general. Ensure that all panel doors and gland plates are bonded to the switchboard structure. Ensure that all equipment installed in the switchboard is in good condition. Inspect the switchboard earth bar and earth cable for electrical and mechanical continuity. Inspect the busbar joints. Ensure the appropriate requirements of Procedure 14 are carried out if applicable.

(ii)

(iii)

(iv)

(v) (vi)

C.2.2.2

Testing (a) Prior to securely fitting the busbar covers, measure the insulation resistance of the busbars and control wiring. Where there are any busbar joints, a Ductor test must be carried out prior to fitting covers.

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(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. Ensure that all the Protection relays have been tested in accordance with the requirements of the appropriate test certificate, and vendors instructions. Measure the insulation resistance of the busbars and control wiring. This test should be carried out prior to the pressure test and before energising the switchboard. The minimum acceptable resistance together with the relevant test voltage, is given in the table below:-

(c)

(d)

Switchgear Voltage, KV

Test Voltage V

Min Insulation Resistance, Megohms

33 22 11 6.6 3.3 0.6 0.44 Control Wiring

5000 5000 5000 1000 1000 1000 1000 500

200 200 200 200 100 100 100 10

(These test levels are in accordance with BS 5405 and its predecessor BS CP 1008). (e) A power frequency voltage test (pressure test) on the main and auxilliary 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. All voltage transformers shall be disconnected by removal of primary and secondary fuses for duration of the test.

(ii)

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(iii)

One pole of the testing supply shall be connected to earth and to the frame of the assembly, for the phase to earth test.

The minimum acceptable test voltages are given in the table below. The tests should be carried out at a frequency of 25100HZ and full voltage should be applied for one minute.

EQUIPMENT VOLTAGE, KV

a.c TEST VOLTAGE, KV FOR 1 MINUTE .2 8.6 15.2 24 32 46 68

0.66 3.3 6.6 11 15 22 33

(Abstracted from BS 162, Table 12 and BS 5227 Table 6) (f) Upon completion of all tests, reconnect all cables and ensure that shorting links and fuses are replaced. As an alternative to the power frequency test, a high voltage d.c. test may be applied. BS 5227 does not contain any test voltages, only the comment that they are under consideration;. In the interim the test levels in BS 161 (Table 14) will be used:-

(g)

EQUIPMENT VOLTAGE, KV

a.c TEST VOLTAGE, KV FOR 15 MINUTES 1.5 7.5 15 25 32 45 66

0.66 3.3 6.6 11 15 22 33

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(h)

Carry out required testing of protection and/or meter circuitry in accordance with Procedure 19.

C.2.2.3

Test Certificates Form E-3 is to be used for recording the results of the testing and requires endorsement to confirm that all the requirements of this procedure, and Procedure 14 if appropriate, have been carried out satisfactorily. Originals of test certificates generated by implementing Procedure 19 must be attached to E-3 for filing in the System Test Dossier.

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C.2.3

Procedure No 3 - Circuit Breakers The following procedures are applicable to all circuit breakers in metal clad switchgear whether of the air-break, bulk oil, SF6 or vacuum type of circuit breaker. This procedure should be read in conjunction with Procedure 2.

C.2.3.1

Inspection (a) Pre-Installation Carry out the pre-installation checks of procedure 2. (b) Post-Installation (i) Carry out mechanical operation checks to ensure:(a) Correct alignment and connection of all busbar connections between fixed and moving portions of the circuit breaker and switchboard. Correct alignment and connection of all main and secondary plug and socket connections. Correct operation of busbar shutters and padlocking facilities. Correct fitting and operation of any special earthing facilities.

(b)

(c)

(d)

(ii)

Check operation of circuit breaker close and trip mechanism, manually and electrically. Ensure the appropriate requirements of Procedure 14 are carried out if applicable.

(iii)

C.2.3.2

Testing (i) Sample and test oil in oil circuit breakers before performing pressure test. Carry out insulation resistance tests before and after pressure test with circuit breaker both open and closed. Carry out pressure tests as detailed in Procedure 2.

(ii)

(iii)

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(iv)

Test Levels of insulation resistance and pressure test as given in Procedure 2. Carry out any required testing of protection and/or meter circuitry in accordance with Procedure 19.

(v)

C.2.3.3

Test Certificate Form E-4 is to be used for recording the results of the testing and requires endorsement to confirm that all the requirements of this procedure and Procedure 14 if appropriate have been carried out satisfactorily. Originals of test certificates generated by implementing Procedure 19 must be attached to E-4 for filing in the system Test Dossier.

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C.2.4 C.2.4.1

Procedure No. 4 - Contactor Starters Inspection (Post Installation) (a) Remove any transit packing and binding materials from the relays, contactor etc. Inspect the equipment in the compartment for damage during installation, and it is clean and any silica-gel etc. is removed. Compare the unit description with the Company schedules and Vendor drawing. Ensure that the isolator can be padlocked in the off position and that it is interlocked with the door. Inspect and check the operation of the isolator and any auxiliary switches. For plug-in starters test the operation of the withdrawal unit and alignment of main and auxiliary plugs. Test the mechanical operation of all contactors and relays and alignment of contacts. Compare the main and control fuse ratings with the schedules. Examine the internal wiring for security and ensure that it is not being caught or damaged by the door or drawout unit. Ensure that the door is earthed. Ensure that any ammeters and scales are correct/suitable. Ensure that the anti condensation heater, if fitted, is in the correct position, and that it is not too close to any internal cabling or heat sensitive devices. Examine flash barriers etc. Ensure the appropriate requirements of Procedure 14 are carried out if applicable.

(b)

(c)

(d)

(e)

(f)

(g)

(h) (i)

(j) (k) (l)

(m) (n)

C.2.4.2

Testing (a) Test the overload by primary or secondary injection and record the results on the relevant Test Certificate.

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This should agree (within tolerance) with the manufacturers curves. (b) Test the calibration of any ammeters by primary or secondary injection and record on Test Certificate. Test the overload for single phasing by passing 80% of full load current through two phases only and record on Test Certificate. Test and record the starter insulation resistance using:(i) 1000 volt test for main wiring - minimum value should be 10 megohms. 500 volt test for control wiring - minimum value should be 5 megohms.

(c)

(d)

(ii)

(e)

Carry out any required testing of protection and/or meter circuitry in accordance with Procedure 19.

C.2.4.3

Test Certificate Form E-5 is to be used for recording the results of the testing and requires endorsement to confirm the requirements of this procedure, and Procedure 14 if appropriate, have been carried out satisfactorily. Originals of test certificates generated by implementing Procedure 19 must be attached to E-5 for filing in the System Test Dossier.

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C.2.5 C.2.5.1

Procedure No 5 - Fuse Switches Inspection (Pre-Installation) (a) Note the nameplate ratings of the fuse switch, and any special instructions. Compare these ratings with those on the approved drawings. Remove any transit packing materials from the fuse switch (where fitted). Ensure that the fuse switch unit has been labelled correctly. Ensure that the interior of the unit has been cleansed and any silica-gel drying agents have been removed.

(b)

(c) (d)

C.2.5.2

Inspection (Post Installation) and Testing (a) Inspect the equipment in the fuse switch compartment for damage during installation. Inspect the mechanical operation of the fuse switch and any interlocks fitted in the fuse switch cubicle or cover. Inspect the equipment padlocking facility. Ensure the contact alignment of the fuse switch and the mechanical operation of the on-off indication. When operating handles are of the retractable type, ensure that they retract correctly. Check the ON-OFF operation of the indicator. Measure the insulation resistance through the closed isolator. Carry out any required testing or protection and/or meter circuitry in accordance with Procedure 19. Ensure the appropriate requirements of Procedure 14 are carried out if applicable.

(b)

(c)

(d)

(e) (f) (g)

(h)

C.2.5.3

Test Certificate Form E.6 is to be used for recording the results of the testing and requires endorsement to confirm that the requirements of this procedure, and Procedure 14 if appropriate, have been carried out satisfactorily.

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Originals of test certificates generated by implementing Procedure 19 must be attached to E-6 for filing in the System Test Dossier.

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C.2.6 C.2.6.1

Procedure No.6 - Power Transformers Inspection (Post-Installation) (a) Note the nameplate ratings of the transformers, and any special instructions concerning auxiliary apparatus. Compare these ratings with those on the approved drawings. Ensure certification meets the area requirements. Inspect the transformer and auxiliary equipment for alignment and tightness of foundation bolts and fixings in general. Inspect the boltings and the weatherproofing of terminal boxes. Inspect the padlocking facilities. Inspect the earthing bolts and the connections to the earthing grid. Inspect the bolting to the neutral connection. If neutral earthing resistors have been fitted, refer to Electrical Procedure No.11 for detailed requirements. Inspect the transformer breathing device and the condition of the moisture absorbing capsule (where fitted). Inspect the Gas Alarm device (where fitted). Inspect the pressure relief device (where fitted).

(b) (c)

(d) (e)

(f)

(g)

(h) (i) C.2.6.2 Testing (a) (b)

Test the alarm and trip circuits of the device. (i) Consult vendors instructions and if required measure the dielectric strength of the transformer oil. Two samples should be taken, one from the upper region of the tank, and the other from the bottom. If the transformers are supplied without oil, check each drum of oil supplied against the manufacturers specification, including insulation breakdown values. Check the oil level after filling. (Details of testing transformer oils are contained in Procedure 15). Link box oil shall be tested to Procedure 15 prior to final closing.

(ii)

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(c)

Ensure that all cables have been certified in accordance with the cable certificate. Measure the phase to phase, and phase to earth insulation resistance for both the HV and LV windings. The table below gives the test voltages and minimum acceptable values of insulation resistance.

(d)

TRANSFORMER WDG VOLTAGE

TEST VOLTAGE D.C

MINIMUM INSULATION RESISTANCE, MEGOHMS

25 110 440 3300 6600 11000 33000

250 250 500 1000 1000 1000 5000

10 10 50 150 150 150 200

(e)

Carry out a power frequency voltage (pressure) test between the HV and LV windings. The test should be carried out for one minute between each winding, with the core and tank earthed. Alternatively a d.c. pressure test may be applied. Duration of this test is to be 15 mins. The test voltages to be applied are given in the table below.

TRANSFORMER WDG VOLTAGE

TEST VOLTAGE DRY TYPE

TEST VOLTAGE OIL IMMERSED

A.C

D.C

A.C

D.C

3300 6600 11000 33000

600 11250 18750 -

5600 10600 17600 -

12000 16500 21000 52500

11300 15500 19800 49500

(Abstracted from BS171 Tables 9, 10 and 27.

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(f)

Carry out any required testing of protection and/or meter circuitry in accordance with Procedure 19.

C.2.6.3

Test Certificates Form E-7 is to be used for recording the results of the testing and requires endorsement to confirm that the requirements of this procedure have been carried out satisfactorily. All supplementary certificates should be attached to E-7 for filing in the system test dossier, namely E-13 for neutral earthing resistors if fitted (Procedure 11), E-16 for transformer and link box oil testing (Procedure 15) and certificates generated by implementing Procedure 19.

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C.2.7 C.2.7.1

Procedure No.7 - Motors Inspection (Post-Installation) (a) Note the nameplate rating of the motors and compare with those given in the approved drawing and motor schedule. Note any special instructions regarding auxiliary equipment. Ensure equipment certification meets the area classification requirements. Ensure that any shaft blocking or transit packing has been removed. Have the coupling broken to separate the motor from the driven unit or the belts removed from belt driven equipment. Ensure that the motor rotates freely and check that the end play of the rotor is within tolerances. Without dismantling the motor, inspect as far as possible, oil rings, oil levels, grease packing and bearings. Inspect for leakage. Inspect the paint finish of the motor for damage during installation. Any damaged areas are to be repainted. Inspect the weatherproofing and bolting of the connection boxes. This should not be dependent upon the application of paint, tape or plastic compounds. Inspect the stator winding connection and whether the system should be for star or delta connection. Inspect the earthing stud and the connection to the general earthing system, including those inside the connection box. After test ensure that all covers giving access to connections are fastened down. Ensure the appropriate requirements of Procedure 14 are carried out if applicable.

(b)

(c)

(d)

(e)

(f)

(g)

(h)

(i)

(j)

(k)

C.2.7.2

Testing (a) Ensure that all cables have been certified in accordance with the cable test procedures. Test the phase sequence and polarity of all connections.

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(b)

Measure the phase to frame resistance and phase to phase if the windings can be separated. A 5000V insulation tester should be used on HV motors. If the windings require drying out reference should be made to the guidance notes and typical drying out curve as detailed in Electrical Procedure No. 16. If special motor protective 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). Test the anti-condensation heater and circuit (where fitted). Start the motor to determine the direction of rotation and compare this with the required rotation of the driven unit. Run the motor for about 4 hours and check the bearings for undue temperature rise. Check for vibration. Measure and record the line current of the free running motor. Have the coupling reassembled and the alignment of the coupling and end play checked (or have the belts put back on if belt driven) after the 4 hours test. For HV motors measure the Polarisation Index (PI) and refer to the manufacturers documentation for acceptable levels. In the absence of the latter a figure of 1.7 should be the minimum acceptable level. For HV machines rated up to 10MW a high voltage a.c. test may be carried out at a voltage = 0.8 x (2 x M/c rated voltage + 1Kv), for 1 minute as specified in BS 4999: Part 60. This test may be replaced with a d.c test at a voltage to be agreed with the manufacturer, but which must NOT exceed 1.28 x (2 x m/c rated voltage + 1Kv.

(c)

(d) (e)

(f)

(g) (h)

(i)

(j)

NOTE:This test is NOT obligatory (k) Carry out any required testing of protection and/or meter circuitry in accordance with Procedure 19.

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C.2.7.3

Test Certificates Form E-8 is to be used for recording the results of the testing and requires endorsement to confirm that the requirements of this procedure and Procedure 14 if appropriate, have been carried out satisfactorily. If applicable the results of drying out motor windings, Procedure 16, are to be attached to Form E-8 for filing in the system test dossier, together with any certificates generated by implementing Procedure 19.

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C.2.8 C.2.8.1

Procedure No 8 - Batteries and Battery Charger Inspection (Post-Installation) (a) Note the nameplate rating of the equipment, and number, type and rating of the batteries supplied and compare with the ratings stated on the approved drawings for the equipment. Ensure that the equipment classification requirements. certificates meet the area

(b)

(c)

Inspect the chargers and battery stands for alignment, level, and tightness of foundation bolts and fixing. Inspect the earthing bolts and the connections to the earth system. Ensure that all site installed cables have been tested in accordance with the cable Test Certificate. Clean the interiors of all control panels, chargers etc. Remove any temporary silica-gel drying agents from the panels. Note the type, size and rating of all fuses and protective devices and compare with the values stated on the approved drawings. Inspect all batteries for cracks, damage and tightness and cleanliness of terminals and connections. Remove any transit bungs from the cells. Inspect all bolted connections between individual cells in a bank of batteries. Ensure that all battery terminals have been coated with vaseline or equivalent. Inspect the battery electrolyte level in all cells after filling.

(d)

(e)

(f)

(g)

(h) (i) (j)

(k) C.2.8.2 Testing

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 overvoltages.

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C.2.9

Procedure No. 9 - Uninterruptable Power Supplies This procedure is a preliminary to the inspection and test performed by the equipment vendor at site.

C.2.9.1

Inspection (Post-Installation) (a) Note the nameplate ratings of the equipment and any auxiliary apparatus and compare with the rating given on the approved drawings. Inspect the installed equipment for alignment, level, tightness of foundation bolts and fixings. Inspect the earthing bolts and the connection to the earthing system. Ensure that all site installed cables have been tested in accordance with the Electrical Procedure, and Test Certificates completed. Note the type, size and rating of all fuses and protective devices and compare with the values stated on the approved drawings. Clean the interiors of all control panels, inverters etc. Remove any temporary silica-gel drying agents from the panels.

(b)

(c)

(d)

(e)

(f)

C.2.9.2

Testing (a) Carry out testing of Batteries and Battery Charger in accordance with Procedure 8. Carry out all testing required on Form E-10 and sign off certificate. Ensure that all vendor site tests have been completed and all results recorded on vendor test sheets.

(b)

(c)

C.2.9.3

Test Certificate Form E-10 to be used for recording the results of the testing and requires endorsement to signify that the requirements of the procedure have been carried out satisfactorily. Certificates for Batteries and Battery Charger Tests, together with originals of Vendor Test Certificate should be attached to E-10 for filing in the system Test Dossier.

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C.2.10 C.2.10.1

Procedure No. 10 -Lighting and Small Power Distribution System Inspection (Post-Installation) (a) Ensure that the equipment meets the area classification requirements as laid down in the design specification and drawings. Note the siting of the lighting fittings, sockets, etc. and compare with the approved drawings. Note the distribution board circuit numbering and the fuse rating of the circuits and compare with the approved drawings. Test any safety features such as interlocks, padlocks and door switches. Ensure that the distribution board supply cable has been tested and relevant test certificate completed. Inspect the earthing busbar and cable earthing connections inside the distribution boards, and the earthing connections from individual items of equipment to the earthing grid where detailed on drawings. Inspect lighting fittings, sockets and switches for neatness, weather-proofness, glanding, internal connections and general good workmanship. As each sub-circuit from a distribution board is tested, complete a test tag and attach it to the sub-circuit control switch in a prominent position. All equipment in hazardous areas should be inspected in accordance with the requirements of Electrical Procedure No. 14. Carry out inspection of Junction Boxes in accordance with Electrical Procedure No. 18.

(b)

(c)

(d)

(e)

(f)

(g)

(h)

(i)

C.2.10.2

Testing (a) (b) Measure each outgoing circuit insulation resistance to earth. Test the voltage and polarity of each socket outlet and also the earth continuity.

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(c)

Carry out illumination tests. Illumination levels are to comply with the CIBS Code for interior lighting where no other statutory or contract illumination levels are specified. Carry out any required testing or protection and/or metering circuitry in accordance with Procedure 19.

(d)

C.2.10.3

Test Certificate Form E-11 is to be used for recording the results of the testing and require endorsement to signify that the requirements of this procedure, and Procedures 14 and 18 if appropriate, have been carried out satisfactorily. Originals of test certificates generated by implementing Procedure 19 must be attached to E-11 for filing in the System Test Dossier.

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C.2.11 C.11.1

Procedure No. 11 - Neutral Earthing Resistors Inspection (Post Installation) (a) Note the nameplate ratings of the neutral earth resistors (NERs) and compare with the approved drawings. Ensure the equipment certificates meet the area classification requirements. Remove any temporary weather proofing and any drying agents (e.g. silica-gel). Inspect the neutral earthing resistors for alignment, tightness of foundation bolts and fixings. Inspect the connections to the neutral earthing resistor. Inspect the frame earthing arrangement.

(b)

(c)

(d)

(e) (f) C.2.11.2 Testing (a)

Measure the insulation resistance of the resistor to earth with incoming and outgoing connections disconnected. Measure the value of the neutral earthing resistor. Test the anti-condensation heater and circuits where fitted. If current transformers have been fitted, check that Vendor test certificates and magnetising curves are available; if not carry out tests in accordance with Procedure 17. Measure the equipment earth path resistance at the main earthing terminal to the general earth system. Carry out required testing of protection and/or meter circuitry in accordance with procedure 19. Upon completion of tests, re-connect the incoming and outgoing cables.

(b) (c)

(d)

(e)

(f)

C.2.11.3

Test Certificate Form E-13 is to be used for recording the results of the testing and requires endorsement to confirm that the requirements of this procedure have been carried out satisfactorily. Any Supporting current transformer certificates (originals) generated by implementing

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Procedure 19 must be attached to E.13 for filing in the System Test Dossier.

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C.2.12 C.2.12.1

Procedure No 12 - Trace Heating Tapes and Circuits Inspection (Post-Installation) (a) (b) (c) Check that the tape type is correct to the drawing requirements. Check that the tape is of the correct length. Check that the circuit is correct for the voltage rating of the tape. Check that the fuse rating is correct for the total circuit loading. Check that the tape is installed correctly, especially with regard to removable items, e.g. valves etc. Check that the mounting of the junction boxes and thermostats is correct. Carry out inspection and tests detailed in Electrical Procedures nos 1, 14 and 18, as required.

(d) (e)

(f)

(g)

C.2.12.2

Testing (a) There is no BASEEFA requirement to carry out brine testing of CHEMELEX type tapes. However, it is recommended that an end-seal test in brine be carried out on all inaccessible tapes. Each tape shall be subject to an insulation resistance test when installation is complete. After all the tapes on a circuit are installed, the complete circuit shall have its insulation resistance tested and recorded. After completion of the thermal insulation, the circuit should have its insulation resistance re-checked (not recorded) to ensure no damage has occurred.

(b)

(c)

(d)

C.2.12.3

Test Certificates Forms E-14 and E-15 are to be used for recording the results of the testing, together with Form E-1 for cable testing in accordance with Procedure No.1 The forms require endorsement to confirm that the requirements of the procedure, and procedures 1, 14 and 18 as appropriate, have been carried out satisfactorily.

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C.2.13 C.2.13.1

Procedure No. 13 - Earthing Inspection (Post-Installation) (a) (b) Compare the earth connection type and size with the schedule. Where conductors have been terminated using crimped connections ensure that the correct size and type crimping lug has been used. Ensure all connections are tight and greased.

(c) C.2.13.2. Testing

Main Earthing Points (a) Each separate earthing point, which may consist of one or more electrodes, shall be tested with a standard earth test whenever practical. The resistance of each point must not exceed 10 ohms and may have to be below this to comply with (b) below. The resistance as measured from any part of the system to the main earth point should not normally exceed the values noted below and tests shall be carried out to confirm this:(i) (ii) (iii) C.2.13.3 Electrical Earthing Lightning Protection Static Bonding - 1ohm - 7 ohms - 10 ohms

(b)

Test Certificates There are no standard forms which make reference to this procedure; however Form E-21 should be used to record earth point tests.

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C.2.14 C.2.14.1

Procedure No. 14 - Apparatus for use in Hazardous Areas Inspection (Post-Installation) The following is a general inspection guide for all type of equipment used in hazardous areas, and form EC-1 is provided as guidance on the systematic method of record. The particular requirements for special equipment used in these locations will be listed individually hereafter and should be read in conjunction with BS 5345 or other appropriate national standards. (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. Ensure that there are no unauthorised modifications and that it carries correct circuit identification. Ensure that all bolts glands and stoppers are tight and that the condition of the enclose gaskets is satisfactory. 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. Ensure that cable and stopper box compound is correctly applied to avoid ingress of hydrocarbons. Inspect the equipment earthing for security and tightness. Ensure that there is no damage to any cables and that the equipment is adequately protected against corrosion, weather, vibration and other adverse factors. Ensure that the lamp rating and type are correct. Where guards are used, ensure that they are correctly located and that motor fans and couplings are not rubbing.

(b)

(c)

(d)

(e)

(f) (g)

(h) (i)

The following additional checks are required on special equipment as listed:(h) Ex d Flameproof Enclosure Ensure that:-

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(i)

Obstructions in the vicinity of the equipment do not impair the efficient operation of the equipment. All gaps are correct and free from corrosion, dirt and paint. The machined surface may be protected with one of the BP approved greases. The use of non hardening tape is to be avoided.

(ii)

(iii) (k)

All conduit runs are tight and free from corrosion.

Ex e Increased Safety Particular care should be taken on any equipment which uses an encapsulating material that there is no deterioration due to cracking, etc.

(l)

Ex N: Any hermetically-sealed or enclosed break devices should be examined for damage.

(m)

Ex i Intrinsically Safe: (i) All installations should be inspected to ensure that any cable screens are earthed in accordance with the relevant standard drawing. All diode safety barrier installations should be inspected to ensure that the correct type of barriers have 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 by repeated operation or vibration in a way which reduces the segregation afforded. The earth path resistance must be measured.

(ii)

(iii)

(iv)

(v)

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(n)

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. And 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.

C.2.14.2

Testing 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 of practice for the equipment and this should be complied with prior to final energisation of the circuit. Vendor dossiers must be examined to ensure that electrical components and equipment have been certified in compliance with BS 5345 or any other appropriate national standards and that relevant certificates are available e.g. BASEEFA. 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.

C.2.14.3

Test Certificates There is no specific standard form for recording that the requirements of the procedure have been implemented; Form E-21 should be used to record the results of any testing required by the standard, code of practice or BASEEFA certificate to demonstrate suitability for use in a hazardous area. The following 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, namely:Forms E-1, E-2, E-3, E-5, E-6, E-8, E-11, E.12, E-14, E-15.

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C.2.15 C.2.15.1

Procedure No. 15 - Oil Insulation Tests These tests are to be carried out using a standard test cell conforming to the requirement of BS 148:1972. Samples are to be taken from each drum before filling, or from the conservator (where fitted) and the top and bottom of the tank. NB: No tests are to be carried out on the oil in hermetically sealed transformers.

C.2.15.2

Mineral Insulating Oil The vessel containing the sample oil should be gently agitated and turned over several times to ensure even distribution of any impurities without forming air bubbles. The test shall be carried out six times on the same cell filling. The first test should be carried out within ten minutes of filling, For the five subsequent tests, the voltage is reapplied one minute after the disappearance of any bubbles that may have been formed, or five minutes if observation is not possible. The electric strength is the average of the six results obtained from the test.

C.2.15.3

Silicone Insulating Oil BS 148 does not apply to silicone insulating oils but may be used as a general guide in the absence of any official publication. A similar test procedure shall be followed as for mineral insulating oils except that only three samples shall be taken, each sample being tested only once and then discarded.

C.2.15.4

Test Certificate Form E-16 is to be used for recording the results of these tests.

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C.2.16 C.2.16.1

Procedure No.16 - Drying of Electrical Rotating Machinery Drying of Windings in Rotating Electrical Machinery The application of heat to the windings must be carefully controlled. The use of high intensity heat sources must be avoided at all times due to possible damage caused by local hot spots. Heat is to be applied gradually. The rate of temperature increase should not exceed 5 C/HR. Fresh clean air circulation shall be provided to remove humid air produced by the drying process. It is useful to construct a graph of the insulation resistance varying as function of time. This gives a clear picture of the drying process and an indication of the likely drying time. As a guide, readings should be taken every 30 minutes until the rate of change of insulation resistance dictates otherwise (see typical drying curve). The safest and most effective means of drying the winding of electrical drives is by utilising the anti-condensation heater circuits of the motor. If the motor is not equipped with anti-condensation heaters then one of the methods described below must be adopted.

C.2.16.2

Drying of Motors using Internal Heating Internal heating is obtained by circulating a low voltage AC or DC current through windings. The circulating current should not exceed 25% of the rated full load current and the allowable voltage is about 25% of the rated phase to phase voltage. If AC is used for drying larger squirrel cage induction motors, the rotor temperature shall be carefully monitored and it may be advisable to remove the rotor from the assembly if the temperature rise is too rapid. Wound rotors need not be removed, but the bandages of the windings shall be monitored for undue temperature increase. When using the current circulated method of drying windings, initial measurement of temperature shall be taken every 15 minutes during the first 3-5 hours to detect any undue temperature rises before damage occurs. For wound motors which are dried by current circulation, the drying current shall not be applied via the brushes as this would cause hot spots at the contact areas between the brushes and slip-rings or commutator.

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C.2.16.3

Drying of Motors using External Heating When drying motors using external heaters, the machinery should be covered with tarpaulin or similarly enclosed to promote a good heat distribution. The size of the heater used is dependent upon the machine frame and surrounding ambient conditions etc. As an approximate guide, the following relationship may be used:Heater size (KW) = Weight of M achine( kg ) 1000

C.2.16.4

R3

INSULATION RESISTANCE (MEG OHMS)

R2 R1
TIME (HOURS)

R1 - RESISTANCE OF WINDINGS AT START OF DRYING OUT PROCESS R2 - MINIMUM RESISTANCE OF WINDINGS (DUE TO VAPORISATION, ETC) R3 - FINAL RESISTANCE OF WINDINGS

C.2.16.5

Test Certificates There are no specific forms to be used for this procedure, but form E21 is to be used to record results. All results are to be recorded, retained with the graphs and attached to the motor test certificate, Form E-8.

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C.2.17 C.2.17.1

Procedure No. 17 - Current Transformer Magnetising Curve Inspection (Pre-Installation) Check the current transformers are the correct class, type and ratio for the duty called for on the project and vendor drawings; this will be given on the nameplate/label affixed to the current transformer. Inspect the fixing arrangements for the current transformers ensuring that they are securely fixed and will not be damaged during transportation. It should also be ensured that adequate protection is given to the current transformers from moving parts of switchgear and from likely damage during installation of cables into the switchgear.

C.2.17.2

Testing Testing to determine the magnetising characteristics of current transformers is invaribly carried out at the Vendors works after assembly, and Vendor test certification should be checked for completeness and accuracy. Therefore, it should not be necessary to carry out such testing at site unless doubt exists regarding the adequacy of Vendor testing or modification after initial assembly has invalidated the original vendor tests. If testing is considered necessary at site it is to be carried out in accordance with the procedure detailed below in C.2.17.3.

C.2.17.3

Test Procedure Before any testing commences, ensure primary circuit is open circuited; in most cases this can be achieved by disconnecting the outgoing/incoming cables and opening the breaker or switch. Protection must be put around any exposed primaries since dangerously high voltages will be produced during the testing period. The protective relay coils must then be disconnected from the current transformer; this can be achieved in most cases by the removal of the unit from its plug-in housing and the insertion of a test plug or by inserting insulated plugs between the current transformer and relay coil sliding contacts or simply by disconnection of wiring. Voltage is applied to the secondary of the current transformer by means of a variable voltage transformer or auto-transformer (primary at local mains voltage); it may be necessary in testing current transformers of ratings less than or equal to 1 ampere to have a step-up transformer in the test circuit to provide voltage above the local mains supply. An ammeter is connected in the test circuit; since the magnetising current will not be sinusoidal a moving iron ammeter should be used. The scale of the ammeter being graduated accordingly up to the secondary rating of the current transformer.

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The voltage applied should be slowly raised until the magnetising current can be seen to rise very rapidly for a small increase in voltage. This indicates the knee point or saturation level of the current transformer. The magnetising current should then be recorded for several levels of applied secondary voltage as the voltage is reduced to zero. In general the knee point level of the current transformer should be reached when the secondary voltage is raised until the magnetising current is equal to the rated secondary current. C.2.17.4 Test Certificate Form E-17 is to be used for recording the results of the testing, if carried out, and requires endorsement to confirm that all requirements of the procedure have been carried out satisfactorily.

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C.2.18 C.2.18.1

Procedure No. 18 - Junction Box Inspection Inspection (Post-Installation) (i) (ii) (iii) Ensure that the Junction Box location is correct to drawing. Check that the classification and I.P rating are to specification. Ensure that the Junction Box is adequately supported and identified. Ensure that the terminal type, size, fixing and identification are correct. Ensure that the earthing, internal and external, is correct. Ensure that the glands and accessories are correctly fitted and unused cable entries are plugged. Ensure that grease and gaskets are correctly installed, as required. Ensure that the box is correctly sealed. For hazardous area installations, procedure 15 must be followed.

(iv)

(v) (vi)

(vii)

(viii) (ix)

C.2.18.2

Testing No testing of Junction Boxes is carried out.

C.2.18.3

Test Certificates There is no specific standard form for recording that the requirements of the procedure have been implemented. The following forms, however, make reference to this procedure and require endorsement to confirm that the junction boxes and the standard of installation is suitable for the intended service, namely:Forms E-1, E-2, E-11, E-15.

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C.2.19 C.2.19.1

Procedure No. 19 - Testing of Protection and Meter Circuitry The equipment covered by the following procedures may require testing of protection and/or meter circuitry by means of primary and/or secondary injection, namely:Procedure 2 3 4 5 6 7 10 11 -Switchboards and busbars - Circuit Breakers - Contactor Starters - Fuse Switches - Power Transformers - Motors - Lighting and Small Power Distribution - Neutral Earthing Resistors

Owing to both the variety of schemes and the diverse types of relay in use, no attempt has been made to produce a detailed standard testing procedure. C.2.19.2 For each type of relay or meter tested, a test certificate is to be completed which shows clearly the portion of scheme and the specific part of the circuit tested, and records accurately the results of the testing carried out. Forms E-18 (Primary Injection Test Certificate), E-19 (Secondary Injection Test Certificate), E-20 (Voltmeter/Ammeter Secondary Injection Test Certificate) and continuation sheets if required, shall be completed for all protective and indication devices.

C.2.19.3

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C.3

TEST CERTIFICATE PROFORMAS Form No. E-1 E-2 E.3 E-4 E-5 E-6 E-7 E-8 E-9 E-10 E-11 E-13 E-14 E-15 E-16 E-17 E-18 E.19 E-20 E-21 EC-1 Test Certificate Description MV Cable Test Certificate High Voltage Test Certificate Switchboard & Busbars Test Certificate Circuit Breaker Test Certificate Contactor Starter Test Certificate Fuse Switch Test Certificate Power Transformer Test Certificate Electric Motor Test Certificate Batteries & Battery Charger Test Certificates (Sheet 1 and 2) U.P.S Test Certificate Lighting & Certificate. Small Power Distribution Test

Neutral Earthing Resistor Test Certificate Trace Heating Element Test Certificate Trace Heating Circuit Test Certificate Insulating Oil Test Certificate Current Transformer Magnetising Curve Primary Injection Test Certificate Secondary Injection Test Certificate Voltmeter-Ammeter Certificate Secondary Injection Test

General Test Certificate Check List of Electrical Equipment in Hazardous Areas

N.B. The procedure numbers shown on the following test sheets refer to the procedures as listed in this document only.

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APPENDIX D INFORMATION - HEALTH AND SAFETY PERMIT TO WORK SYSTEM - ELECTRICAL AND INSTRUMENTATION All work on equipment which has been handed over to the Operator will be carried out under the Operators permit system. When equipment has not been handed over, has been energised, and it becomes necessary to carry out testing, checking and adjustment, the work must be carried out under a Construction permit. An example of a typical permit, which may be adapted to suit local site conditions, is shown in Appendix D.1. PERMIT CONDITIONS The work must be carried out by competent electrical persons as required by statutory regulations and the Electrical Work Permit must be signed and issued only by an Authorised Electrical Engineer who is appointed by the person responsible for the equipment. This may be the RE or the main contractor but not both. A permit is required for electrical work on any high voltage (HV) plant or equipment, and main low voltage (LV) Plant or equipment where isolation has to be made at high voltage (e.g. the electrical system from the LV side of the HV/LV transformer to the LV switchboard bus bars including cabling and incoming switchgear. High voltage: Normally exceeding 1000 volts a.c. or 1500 volts d.c. between conductors, or 600 volts a.c. or 900 volts d.c. between conductors and earth. Low voltage: Normally exceeding 50 volts a.c. or 120 volts d.c., but not exceeding 1000 volts a.c. or 1500 volts d.c. between conductors, or 600 volts a.c. or 900 volts d.c. between any conductor and earth. The Authorised Electrical Engineer must make known to the competent persons which electrical equipment is dead, isolated and, where applicable, connected to earth and on which it is safe to work (e.g. earthing is not required for isolation of electrical equipment for the purpose of work on associated mechanical equipment). ISOLATION CERTIFICATE The purpose of an isolation certificate is to ensure the systematic and thorough isolation of any item of plant or equipment from sources of energy that might jeopardise the safety of anyone working upon the item. It also ensures that no de-isolation takes place until those involved with the work are clear and until it is safe for the plant or equipment. An example of a typical isolation certificate, which may be adopted to suit local site conditions, is shown in Appendix D.2.

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An isolation certificate must be used whenever the work to be performed requires more than one discipline, or is expected to extended beyond a shift change. The certificate must be displayed at the locking off point and will remain valid until the de-isolation is certified by the competent persons in the disciplines involved. Experience has shown a tendency for one discipline to carry out work on equipment which has been isolated for another. This presents the possibility of the equipment being energised when the official discipline has finished work but whilst the unofficial work is still in progress. Discipline engineers must ensure that permit work is carried out only under cover of an isolation certificate which has been issued specifically to them, regardless of any other certificates issued for the same equipment. No equipment must be energised until ALL the isolation certificates have been removed. For example, if a gang of fitters, a gang of electricians and a gang of instrument engineers are working on the same equipment during the same period then three isolation certificates should be displayed at the locking off point. As each gang finishes work their certificate should be removed and only when all three certificates have gone should the equipment be energised. A variation of this scheme is to have one isolation certificate with three tear-off sections at the bottom for use by mechanical, electrical and instrumentation disciplines. PROBLEM AREAS There will be some areas of work which cannot be clearly resolved into either the Operators or the Constructors permit system. These include:(a) Plant which is inside an operational area, which has not been handed over to the Operator since it is not yet acceptable, but which has been energised for operational requirements, e.g. MOVs, lighting switchboards, and Plant which is inside an operational area, is electrically complete, has not yet been handed over to the Operator, but has been energised to permit instrumentation precommissioning to proceed, e.g. Meter Banks, Surge Packages.

(b)

The problems can only be resolved on site but the following solutions are offered:1. Isolate the plant from the substation until such time that the plant is acceptable to the Operator. Ask the Operator to accept the plant in its incomplete state. Make the work subject to both the Operators and the Constructors permit systems. This will probably be the least attractive solution.

2. 3.

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ELECTRICAL WORK PERMIT Contractor Location Voltage Serial No.

APPENDIX D.1

Exact description of equipment on which .. work has to be done .. .. Brief description of work to be done .. .. Exact description of how the above .. equipment has been isolated and locked off .. from the supply .. Isolation Certificate No The equipment to be worked on has been .. earthed at the following points and danger .. notices posted .. Line diagram/sketch attached Yes No Delete as appropriate Issue I CERTIFY that the above safety precautions have been carried out and that the equipment listed is dead. It will NOT be made live until clearance is given by the recipient of this a permit. (time) .. (Signed) .(date) Receipt I ACCEPT RESPONSIBILITY for carrying out work on the equipment listed on this permit. No attempt will be made by me or by persons under my control to work on any other equipment. (Signed) ..(date). .(time) . Clearance I DECLARE that the work for which this permit was issued has been completed and that the equipment is ready for service. All persons under my control have been withdrawn and warned that it is no longer safe to work on the equipment (Signed)..(date).(time) . Cancellation This permit to work is hereby cancelled

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(Signed)(date)..(time).

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APPENDIX D.2 ELECTRICAL ISOLATION CERTIFICATE Contractor..Serial No. ISOLATE. EQUIPMENT NO (Here specify by name the equipment requiring isolation) A DETAILS OF WORK TO BE CARRIED OUT AUTHORISED BY.TIME.. DATE (M/C Authorised Person) METHOD OF ISOLATING ELECTRICAL SUPPLY .. SUPPLY IS NOW ISOLATED ..(M/C AUTHORISED PERSON) TIME. DATE. RECEIVED BYTIME. DATE. (Contractor's Competent Person-Supv.) RECEIVED ON THE JOB BY TIME DATE.. (Contractors Competent Person-Tradesman) WORK COMPLETED: SIGNED ..TIME. DATE.. (Contractors Competent Person-Tradesman) WORK COMPLETED: SIGNED ..TIME. DATE.. (Contractors Competent Person-Supv.) WORK HAS NOW BEEN COMPLETED AND ELECTRICAL RECONNECTION CAN NOW BE MADE AUTHORISED BY ..TIME. DATE.. (M/C) Authorised Person) STATE HERE ANY ADDITIONAL WORK CARRIED OUT ON ELECTRICAL CONNECTIONS/EQUIPMENT AT TIME OF, OR SUBSEQUENT TO ISOLATION (E.G. MOTOR DISCONNECTED/CONNECTED).. ... (Contractors Competent Person-Tradesman) TIMEDATE. ABOVE WORK NOW COMPLETED, CHECKED AND RECONNECTION OF SUPPLY CAN NOW BE MADE SIGNED (Contractors Competent Person-Tradesman) ... TIMEDATE.... ANY WORK CARRIED OUT UNDER (H) IS NOW COMPLETED AND CHECKED AND RECONNECTION OF SUPPLY CAN NOW BE MADE. (Contractors Competent Person-Supv) .. TIME.DATE ELECTRICAL SUPPLY RECONNECTED BY..

C D E F G

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(M/C AUTHORISED PERSON)

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