Projekt / Project: PKZ / PC

Termoelectrica del Sur BO1001

Termoelectrica de Warnes BO1000
Termoelectrica Entre Rios BO1002

Inhaltskennzeichen / Contents Code

Dept
DCC Doc. Class. Code.

Lieferant / Supplier

Siemens Dokumentennummer / Siemens Document Number: Index/ Rev Version

- -

Originator Document Number Seitenanzahl Format

Page Number

21054-607-10 1 of 29 A4
21055-607-10
21056-607-10
Dokumententitel / Document Title: Unid

HRSG ELECTRICAL & INSTRUMENTATION INSTALLATION

MANUAL
Handhabung / Handling
restricted
AL: ECCN:
Export Control Classification
N N

Änderungen / Changes:

0 2017-05-12 JVLU BDAR LFER First Issue

Rev. Date Prepared by Reviewed by Approved by Remarks
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Table of Contents
1 GENERAL ....................................................................................................................................................... 4
1.1 TERMS AND DEFINITIONS ............................................................................................................................ 4
1.2 REVISE, CHANGE, RELOCATE ..................................................................................................................... 6
1.3 DOCUMENT CONTROL................................................................................................................................ 6
1.4 MATERIAL HANDLING ................................................................................................................................. 7
1.5 INSPECTION & TEST PLAN (E&I INSTALLATION). .......................................................................................... 8
1.6 E&I INSTALLATION SEQUENCE .................................................................................................................... 9
1.7 PAINT & COATING...................................................................................................................................... 9
2 INSTRUMENT INSTALLATION ..................................................................................................................... 9
2.1 PROTECTION OF INSTRUMENTATION DURING CONSTRUCTION .................................................................... 10
2.2 ACCESSIBILITY AND READABILITY ............................................................................................................. 10
2.3 INSTALLATION OF LOCAL INSTRUMENTS (611) ........................................................................................... 10
2.4 INSTALLATION OF PRESSURE TRANSMITTERS ............................................................................................ 11
2.5 INSTALLATION OF TEMPERATURE TRANSMITTERS ...................................................................................... 11
2.6 INSTALLATION OF FLOW DEVICES (615) .................................................................................................... 12
2.7 INSTALLATION OF CONTROL VALVES (620) ............................................................................................... 12
2.8 INSTALLATION OF ATTEMPERATORS (621) ................................................................................................ 12
2.9 INSTALLATION OF ELECTRIC ACTUATORS (624)......................................................................................... 12
2.10 INSTALLATION OF LEVEL SWITCHES (614)................................................................................................. 13
2.11 INSTALLATION OF INSTRUMENT MECHANICAL PROVISIONS ......................................................................... 13
2.12 INSTRUMENT CONNECTIONS ..................................................................................................................... 14
2.13 TRAVEL STOPS, CAPS & PLUGS ............................................................................................................... 15
3 TESTING AND INSPECTION ....................................................................................................................... 15
3.1 INSPECTION & TESTING OF IMPULSE AND INSTRUMENT AIR TUBING AND THEIR PROCESS CONNECTIONS ..... 16
3.2 INSPECTION OF PRESSURE GAUGES......................................................................................................... 17
3.3 INSPECTION OF PRESSURE TRANSMITTERS AND THEIR MANIFOLDS ............................................................. 17
3.4 INSPECTION OF TEMPERATURE ELEMENT ASSEMBLIES .............................................................................. 18
3.5 TESTING AND INSPECTION OF FLOW DEVICES ........................................................................................... 18
3.6 TESTING AND INSPECTION OF CONTROL VALVES ....................................................................................... 18
3.7 TESTING AND INSPECTION OF ATTEMPERATORS ........................................................................................ 19
3.8 TESTING AND INSPECTION OF ELECTRIC ACTUATORS ................................................................................ 19
4 ELECTRICAL TECHNICAL REQUIREMENTS ........................................................................................... 20
4.1 LOCATION OF ELECTRICAL EQUIPMENT (634 &672) .................................................................................. 21
4.2 CABLE INSTALLATION, PULLING AND CONNECTION (671) ........................................................................... 21
4.3 CABLE MARKING ...................................................................................................................................... 23
4.4 CABLE LABELS......................................................................................................................................... 23
4.5 CABLES AND CABLE LABELS FIXATION ...................................................................................................... 23
4.6 CABLE LADDER INSTALLATION .................................................................................................................. 24
4.7 PANELS .................................................................................................................................................. 24
4.8 SUPPORTS .............................................................................................................................................. 24
4.9 CONDUITS ............................................................................................................................................... 25
4.10 EARTHING AND LIGHTNING PROTECTION.................................................................................................... 26
4.11 LIGHTING ................................................................................................................................................ 26
4.12 MOTORS ................................................................................................................................................. 26
5 INSPECTION AND TESTING....................................................................................................................... 27
5.1 GENERAL ................................................................................................................................................ 27
5.2 CABLE TESTS .......................................................................................................................................... 27
5.3 ELECTRICAL EQUIPMENT TESTS ................................................................................................................ 28
5.4 EARTHING TESTS ..................................................................................................................................... 28
5.5 MOTOR TESTS ........................................................................................................................................ 29
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Attachments
Attachment 1: Installation Check sheets for:

- Terminal Boxes
- Earthing System (above earth)
- Cabling Ladder & Conduit

Referenced Documents
2105x-607-26 Electrical and Instrumentation Installation Document List.

Notes
Revisions are indicated with a vertical line
Deleted items or text are indicated with strikethrough
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1 General
This E&I installation manual including all documents attached and or referenced herein, describe the
minimal requirements with regard to handling and installation of Electrical and Instrumentation
equipment including all mechanical provisions, all to be installed in the Heat Recovery Steam
Generators (HRSG) of Del Sur HRSG (21054), De Warnes (21055) and Entre Rios (21056)
projects located in Bolivia. For ease of reference the three projects combined are referred to as the
Bolivian projects. Where document numbers are used in this project the project number is shown as
2105x; this shall be read as 21054 + 21055 +21056. The Bolivian projects are comprised of a total of
22 id 8 for De Warnes and 6 for Entre Rios)

manual, drawings or guidelines, the most stringent requirement shall prevail.

The system international, SI-form of units shall be used except otherwise stated.

1.1 Terms and definitions

The following definitions are used throughout this installation manual:

OWNER : Ende Andina

CLIENT : Siemens IPPS
E&I : Electrical and Instrumentation
CONTRACTOR : Electrical and Instrumentation contractor executing the installation
works for the project
SUPPLIER : NEM Energy bv, Zoeterwoude, The Netherlands, hereafter
SUPPLIER
TA : Technical Advisor of SUPPLIER
IOM manual : Installation, Operation & Maintenance Manual

Based on the subcontract between CLIENT and SUPPLIER for this project SUPPLIER will not be
CONTRACTOR.

During the installation work a Technical Advisor (TA) will be provided by SUPPLIER for assisting the
installation works. As required this TA can give advice on the best and most expeditious method of
installation of the components. If required, documents will be explained.

This installation manual is based on experience with the installation of HRSG systems
and shall be followed by CONTRACTOR.

It shall be S objective to ensure that all materials supplied by SUPPLIER are assembled and
installed according to the drawings and other technical documentation as provided within this E&I
installation manual and other erection procedures and manuals as supplied by SUPPLIER.

This installation manual shall in no way relieve CONTRACTOR from his responsibility to comply with
the requirements of local and/or governmental authorities, project specifications, nor does it relieve
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CONTRACTOR
industrial practice.

Installation of equipment, cable ladder/tray, mounting frames/racks, electrical conduit, instrument

tubing, and associated supporting materials shall not block or limit the accessibility for operation,
service and maintenance nor result into safety hazards at all stage of the project.

Installation and testing of all equipment shall be carried out by qualified personnel.

The SUPPLIER will not accept any claims (back charges or warranty) if the instructions herein, or the
instructions of SUPPLIER or his personal are not followed.

The description of the installation steps does not always represent a definite timetable. Many
installation tasks have to be carried out in parallel and/or with specific time offsets, which can be
optimized by good co-ordination.

Installation of instruments, other electrical/electronic equipment, electrical/instrumentation and control

cabling should not start before finishing of all the main construction and welding activities on the
HRSG. After start of E&I installation work all main construction and welding made on the HRSG shall
be performed with additional protective measures like direct connection of return current clamp at the
welding part to limit/avoid damages due to stray currents, protective covers/welding blankets to avoid
damages due to hot metal parts/sparks.

Some equipment may be shipped with special provisions to protect the equipment and internals from
damage. Such provisions shall only be removed when necessary: just prior to installation.

During installation all electrical and Instrumentation equipment shall be closed and opened for cable
termination or testing purposes only. E&I equipment shall not be left open without supervision and for
prolonged time to allow dust, foreign particles (e.g. disc grinders, welding sparks etc.) moisture
entering the equipment which will result into premature failures. It will be CONTRACTORS
responsibility to keep the E&I equipment closed and clean at the inside.

CONTRACTOR shall consult equipment manufacturer drawings and installation documentation

(provided in this manual) to determine the extent of the work required, and shall adhere to any
requirement given in order to guarantee that all equipment will operate properly after completion of
works.

CLIENT / CONTRACTOR shall take upon himself the full responsibility for the care and provision of
tools and in general for all means used for the installation of E&I equipment, whether or not such
means have been recommended by, or commented on by the SUPPLIER, its technical advisor and/or
the manufacturer.

As the HRSG is operating at elevated flue gas and water/steam temperatures, all process part like
piping and flue gas ducts of the HRSG are subject to thermal expansion. During installation the
CONTRACTOR shall bear this in mind and install E&I equipment at sufficient distance from
expanding parts and sufficient length margins for connecting tubing/cabling to compensate for such
movements.
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1.2 Revise, change, relocate

All HRSG all have a uniform layout and instrument orientation as shown in the E&I installation
documents and the piping installation documents provided by SUPPLIER.
Changing location or orientation of E&I equipment relative to the location as shown on the
appropriate installation documents is only allowed during the erection of the first HRSG and only after
consultation with SUPPLIER.

After approval by SUPLLIER, CONTRACTOR shall mark-up any change on the latest revisions of the
installation drawings or documents and shall submit these drawings to SUPPLIER for the "As-built"
documents.
CONTRACTOR shall then use these marked-up drawings or documents for the erection of the
following HRSG , i.e. all HRSG s will have the same layout.

Any change after this will result in CONTRACTOR having to adapt the already built HRSG
comply to this layout requirement.

All indicated lengths, sizes and routes in the E&I installation documents are approximations and shall
be verified on location by CONTRACTOR prior to final cutting and installation of materials. Provided
detail hook-up drawings for instrumentation and electrical equipment are typical, generic drawings,
often containing more material than actually required during installation on site. Only in some minor
cases more lengths of material might be required, but this is in general covered by the overall surplus
of material included.

Additional information for installation and/or routing can be achieved from the 3D model of the HRSG
as made available by SUPPLIER to CLIENT.

1.3 Document Control

It shall be CLIENT'S objective to ensure that all correspondence, drawings and other technical
documentation at site are recorded, distributed and filed efficiently.

CLIENT shall ensure that CONTRACTOR is working with the latest revision of drawings and
documents.

All modifications shall be accurately recorded on the drawings by CLIENT / CONTRACTOR and
handed over as "AS BUILT" drawings to SUPPLIER.

CLIENT / CONTRACTOR shall document the inspection of material at the time of its receipt and the
operational check out of completed systems.

CLIENT / CONTRACTOR shall be responsible for the preparation of all other documents, drawings
and designs as required to execute the work.

The delivery of a complete set to SUPPLIER of marked-up "As built" drawings, clearly indicating all
changes, revisions, is part of CLIENT S scope.
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1.4 Material handling

Every effort shall be made to ensure that any item received will be handled and stored in such a way
as to minimize damage and corrosion.

E&I equipment and racks shall not be used as footholds, temporary supports or any other use that
might damage the functioning of the equipment.

1.4.1 Inspection of materials after receipt

The latest issue of the E&I reference documents shall be used to check/inspect all electrical and
instrumentation items directly after delivery at site.
Non-conformance can occur as a result of defective materials, equipment or workmanship. Any
defect or deviations from E&I reference documents shall be reported to SUPPLIER immediately.

All equipment shall be handled with sufficient care to prevent damage.

Care shall be taken that loose cable ends (interconnecting wiring) are properly tied or fastened within
the cabinets.

1.4.2 Storage of materials

All E&I equipment shall be stored and maintained during storage according suppliers instructions. In
general all instruments, control panels, terminal boxes and similar electronic and electrical equipment
shall be stored indoors at dry conditions at humidity and temperatures not exceeding manufacturer
specified values. Sensitive equipment like e.g. Computers shall be stored indoors in clean and air
conditioned rooms.

Control valves shall be sto

sealed.
05x -620-14-010-001.

Tubing may be stored outdoors on a rack however tubes shall be covered and protected to retain all
markings. Tube ends shall be kept tightly sealed and capped to prevent debris, sand, insects or other
animals from entering.

For materials such as cable ladders, cable trays, rack and conduit materials please refer to
manufacturer torage and Handling instructions as per referenced E&I Installation
document list.

Small items such as fittings, hand valves, bolts & screws etc. shall be kept boxed and stored indoors.

In general materials will be delivered in packages suitable for one year outside storage. When
opening this packages they may lose the ability to protect the materials outside properly.
Client/CONTRACTOR shall take this into consideration to guarantee proper storage for the materials
after the packages have been opened.
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1.4.3 Lifting of equipment & materials

Manufacturer's lifting lugs shall be used when provided. If lifting lugs are not present refer to
.

When lifting the equipment: slings shall have adequate protection to prevent marring of equipment
surfaces. Where necessary sling spreads shall be used to prevent crushing or damaging equipment.

1.5 Inspection & Test Plan (E&I installation).

For the E&I installation an Inspection and Test Plan (ITP) for site installation shall be made by the
CONTRACTOR. After Approval by CLIENT the CONTRACTOR is obliged to follow the instructions of
this ITP. Depending on the relation between CONTRACTOR and CLIENT and the organization of the
CONTRACTOR the ITP can be augmented or simplified (i.e. more/less hold-points or witness-points
for CLIENT). The ITP shall be issued to the SUPPLIER to fill in their witness and hold points.

owing important inspections need to be carried out:

(Regardless of the approved ITP).

a) Position of the E&I equipment and elevation with regard to the E&I plot plans (2105x -634-17
series)
b) Tubing routing including supports
c) Cable routing and proper fixation in the cable trays/ladders
d) Inspection on all Instrumentation welds and unions
e) Inspection of insulation & personnel protection
f) Pressure test of all tubing including manifolds
g) Loop checks of all instrumentation loops from instrument including the junction box
termination
h) Proper position of cables in applicable cable tray/ladder (segregation).

Note: From the above mentioned items a survey and or inspection report shall be made and

One co

The quality of the installation works is the responsibility of the CONTRACTOR

Detailed instructions for Commissioning for instruments/equipment and systems can be found in the
Commissioning Manual document 2105x-780-01.
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1.6 E&I Installation sequence

Recommended E&I installation sequence based on the experience of SUPPLIER:

Document review and equipment location check.

Earthing connections of (main) steel structures (directly after erection).
Installation of mounting racks/provisions for panels/instruments/junction boxes/cabinets
etc.
Installation of lighting poles provisions.
Installation of the main cable trays/ladders etc.
Installation of the secondary cable trays/ladders/conduit etc.
Installation of lighting/service outlets.
Installation of panels/junction boxes/instruments/sunshades/cabinets
Connection of impulse tubing.
Installation/connection of the electrical/instrument/earthing cables.
Installation of impulse/dosing/sample tubing.
Testing, Inspection and Acceptance procedures.

1.7 Paint & Coating

All plant equipment shall be suitably protected against damage and corrosion due to environmental
influences and installation works at all stages of installation.

Where galvanized steel is cut, drilled or damaged, the exposed steel surfaces shall be coated
immediately with high build zinc paint, with a dry film thickness of 90-110 micron.

Where painting and/or coating is damaged the damage shall be fixed immediately according
applicable painting system repair procedures.

2 Instrument Installation
mencing
per instrument type within this E&I
installation manual.

Location of instruments, mounting racks, junction boxes and process connections can be found in the
E&I plot plans document 2105x-634-17. The location on the E&I plot plan takes into account the
orientation of the instrument and sunshade with respect to the sun.

For piping isometrics refer to Erection Manual, document 2105x -730-01-001 & -002.

Hook-up details of the instruments can be found in document 2105x -627-27-001

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Special attention shall be paid to all instrumentation concerning:

Flow direction of valves and flow devices.
Location and accessibility of the hand wheels of all actuators as shown in the piping
isometrics and valve drawings.
Flow device pressure tap orientation, routing of flow device pressure tap piping and
location of condensation chambers and differential pressure instruments.
Pressure instrument locations.
Pressure indicator and thermometer dial orientations.
Orientation of displays.

All transmitters are factory pre-set, do not change transmitter settings unless instructed by SUPPLIER.

2.1 Protection of Instrumentation during Construction

Instruments and related equipment shall be protected against construction & site hazards, like
welding, grinding etc, and against adverse weather conditions during the construction period, i.e.
extensive use of large commercial quality polyethylene bags and fire proof blankets to cover control
valves, local instruments, panels, junction boxes, sunshades etc.

Do not leave internals of equipment open to the environment, seal/plug any opening to prevent moist
and dust from entering. Remove protective covers/plugs only when immediately replaced by cables &
glands or fittings etc.

2.2 Accessibility and Readability

All instruments shall be accessible for reading, testing or maintenance. With installation of the
instruments and rack access and readability of other equipment shall be taken into consideration, in
no way shall installation of the instrument or rack obstruct the access to and readability of other
equipment. CONTRACTOR shall verify this in situ. In case of access or readability issues SUPPLIER
shall be consulted.

Pressure gauges, thermometers and electronic level indicator displays shall be orientated in such a
way that their dials are visible from walkways.

Pressure transmitters will be installed with their display facing front, the instrument rack being the
back.

2.3 Installation of Local Instruments (611)

For relevant pressure gauge, thermometer and accessories documentation Pressure Gauges &
Thermometers .

For relevant thermowell documentation refer to .

Refer to the piping isometrics in the Erection manual, document 2105x-730-01-001&-002, for the
location of the local instruments.
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Orientation of pressure gauges shall be chosen

drainage or overspill of condensate, water or process fluids from adjacent plant equipment, or from
any foreign matter that could be detrimental to the functioning of the instrument.

2.4 Installation of Pressure Transmitters

For relevant pressure transmitter and accessories documentation ressure Transmitters &
Transmitter Accessories plus Instrument mechanical Hook- .
All parts necessary for the installation of the pressure transmitters and differential pressure
transmitters are supplied as loose items. Recommended is that the manifold, instrument and bracket
are pre-assembled before field installation on the racks.

HP feed water flow device shall be installed after pressure test and chemical cleaning of the piping
system. Installation of related pressure transmitter, its manifold, accessories, instrument rack and
tubing shall be installed in full except point 2 of the recommended installation sequence as found in
chapter 2.12 of this manual.

Refer to chapter 2.12 for all details regarding impulse tubing connections and installation.

All transmitters are factory pre-set; do not change transmitter settings unless instructed by SUPPLIER.

2.5 Installation of Temperature Transmitters

For relevant temperature assembly documentation refers to 2105x-613-13

Assemblies .

Most thermowells are already welded into the piping. Some of the thermowells are flanged/screwed.
Refer to the piping isometrics for exact installation location, documents (2105x-410 & 470 series) can
be found in the 05x-730-01.

Thermowells are provided with blind plugs to prevent dirt and moist from entering the thermowell, do
not remove blind plugs until temperature element is installed.

In case a blind plug is found missing: remove all dirt and moist from thermowell before installation of
temperature element.

Thermowells shall be internally clean before use and shall not contain debris or other foreign parts. If
the thermowell is not clean, the accuracy and the response time will be negatively influenced and
might result into non acceptable deviations.

The use of Lock-Tite. Teflon tape or any other related sealing to install the temperature assembly and
related extension is prohibited as each thermowell assembly is equipped with self-sealing conical
NPT thread. SUPPLIER shall be contacted in case the element cannot be spring loaded to the
bottom of the thermowell.

All transmitters are factory pre-set, do not change transmitter settings unless instructed by SUPPLIER.
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2.6 Installation of Flow devices (615)

For relevant flow device documentation refers to .

For steam flow services both pressure tappings shall be connected with condensing chambers, for
details on this condensing chamber, refer to documents 2105x-627-27-001.

For details on the installation of flow devices and condensing chambers: refer to the piping isometrics
provided in the 05x-730-01-001.

Orientation of the pressure tappings connected to the flow devices shall be as shown on the
dimensional outline drawings of the flow devices, documents 21045-615-14-124-001 to 005.
Orientation of the piping items connected to the pressure tappings shall be as shown on the piping
isometrics.

For details on installation of impulse tubing and connection to condensing chambers and differential
pressure instruments: - ng number 2105x-627-27-001.

2.7 Installation of Control Valves (620)

For relevant control valve documentation refers

For details on the installation of control valves: refer to the piping isometrics provided in the Erection
manual , document 2105x-730-01-001.

When valves are welded into the process line, the valve trim needs to be removed in order to prevent
damage to these trim parts. Due to the preheating and post weld heat-treat process, elastomeric
parts (O-rings, seal rings, packing and gaskets) might be damaged.

For removal of the trim please refer to detailed instructions by manufacturer in the IOM manual,
document 2105x-620-14-010-001.

Refer to chapter 2.12 for details regarding instrument air tubing connections and installation.

2.8 Installation of Attemperators (621)

For relevant Attemperator and .

For details on the installation of attemperators and their valves: refer to the piping isometrics provided
in the ual, document 2105x-730-01-001.

For Installation details regarding attemperator control valves please refer to chapter 2.9 and to
m s IOM manual, document 2105x-621-14-010-001.

2.9 Installation of Electric Actuators (624)

For relevant electric actuator documentation refer to . For relevant valve

documentation refer to documents 2105x-530-04-010-001&002&003, 2105x-531-04-010-001&002.
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For details on the installation of electric actuators and their valves: refer to the piping isometrics
provided in the 105x-730-01-001.

IMPORTANT:
All cable entries are supplied with plugs or caps. Do not remove until immediately replaced by IP65 or
better alternative. Under no circumstances shall these cable entries be left open to the environment.

For requirements on electrical connections, provisions, inspection and testing please refer to the
electrical part of this E&I installation manual chapter 4 and 5.

For Installation details regarding electric actuators please refer to manufactur

documents 2105x-530-04-010-001&002&003, 2105x-531-04-010-001&002.

All actuators are factory pre-set, do not change actuator settings unless instructed by TA or
SUPPLIER. Electric actuator setting see 2105x-624-13.

In case the electric actuator position on the valve has to be modified to meet applicable point of
installation manual operator and cable termination access then the limit switches shall be set again at
the require open and closed position. Same applies for the position transmitter if applicable (only for
Inching and control type valves).

IMPORTANT:
Modification of electric actuator torques settings should be avoided and only after written confirmation
with TA or SUPPLIER. Increased torque setting may result into mechanical damages of valve.

2.10 Installation of Level Switches (614)

For details regarding level switches please refer to documents 2105x-614-24-006-001, 2105x-614-
24-124-001 and 2105x-614-24-010-001.
Verify that after insulation the terminal box with cable entry are accessible and cooling by natural
circulation is possible to avoid overheating of the terminal box, electrical components and installed
gland/cabling. Personal protection when installed to protect for any remaining hot surface sections
shall allow natural ventilation/cooling of terminal box and gland/cabling.

2.11 Installation of Instrument Mechanical Provisions

For relevant instrument mechanical hook-up materials documentation and for relevant tubing
installation details refer to 2105x-627-27-001 series.

SUPPLIER installation guidelines as described in above mentioned documents shall be followed in

detail. No deviations are allowed unless approved / agreed upon by SUPPLIER. Refer to chapter 1.5
of this manual for recommended installation sequence.

Materials as provided by SUPPLIER shall be used for the hook-up of the instruments and instrument
pipe stand. Sufficient spares have been incorporated.

2.11.1 Tubing General

All instrument process connections and impulse-, and instrument air tubing shall be installed in
accordance with the relevant ASME requirements.
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It is recommended that both welds needed for installation of the reducer between the pressure
tapping and the impulse tubing are welded by the welder that installs the pressure tapping.

All tubing shall be properly supported and installed free from stress.

Recommended installation sequence of all tubing:

1. Installation of the (impulse) tubing from the instrument, actuator or sample/dosing skid
towards the main routing.
2. Installation of the (impulse) tubing from the process shut-off valves towards the main routing.
3. Installation of main tubing routing.

Special attention shall be paid to the continual sloping and the thermal expansion of the tubing and
also to the clearance to other piping or equipment to allow for installation of thermal insulation or
personnel protection where required.

Sliding tube clamps as provided by SUPPLIER shall be used to secure all tubing to their supports to
allow for movement caused by expansion/shrinkage of the tubing and/or piping and/or casing due to
temperature changes.

2.11.2 Installation of Impulse tubing

Tubing shall be sloped from the process connection all the way to the instrument.

Straight lengths of tubing covering a distance of 10 meters or more shall be installed with an
expansion loop as described and shown in the instrument mechanical hook-up typicals & drawings .

Sample and impulse tubing shall not be installed in direct vicinity of each other.

2.11.3 Installation of Instrument air tubing

Instrument air line as provided by SUPPLIER shall be used for the distribution of instrument air to
each individual instrument air consumer.

Connection to each instrument air consumer shall be as detailed in the instrument mechanical hook-
ups .

An expansion loop shall be installed close to the instrument air consumer to allow for movement of
the connected pneumatic equipment.

IMPORTANT:
Before connecting the instrument air tubing to the valve: clean and dry instrument air system. Refer to
chapter 3.1.4 for detailed instructions.

2.11.4 Installation of Instrument pipe stands and Tubing Supports

All instrument pipe stand shall be bolted or clamped to the existing steel work or structure. Damage to
coating of the steel or structure shall be repaired immediately. Racks and supports shall not be
welded to the structure.

Mounting of instrument pipe, supports and brackets shall be done carefully to avoid damage on civil
works, buildings and other equipment.

2.12 Instrument connections

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Tubing connectors are of the twin ferrule type compression fittings, installation instructions as
supplied by the manufacturer of these fittings shall be followed carefully.

High temp thread lubricants as provided by SUPPLIER shall be applied on all threaded connections.

Threaded connections shall not be seal welded especially not at the connections to the instruments
or instrument manifolds.

Flanged connections for attemperators and flow devices shall be installed with packing and bolts
according to pipe material specification 2105x-400-02-001.

2.13 Travel Stops, Caps & Plugs

In certain cases travel stops, plastic caps or plugs are used to prevent damage to or fouling of
vulnerable parts of instruments and related equipment.

Remove or release travel and shipping stops, caps or plugs only when necessary and only after
instrument has been installed or fitted.

3 Testing and inspection

Testing and inspection of all E&I equipment shall be completed prior to the initial start-up of the
HRSG, including, but not limited to, inspection of:

Alignment of instruments.
Operational check of each individual instrument.
Loop test of each instrument.
Continuity and other testing of instrument wiring and signal tubing
Testing of electrical, air and/or other utility supply systems to the instruments.
Complete operational check of all completed instrumentation and control systems.

All transmitters are factory pre-set, do not change transmitter settings unless instructed by SUPPLIER.
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Before testing:

Check whether all field instruments are in the correct location as shown on the E&I plot
plans, document 2105x-634-17 series.
Check whether visibility of indicating displays is satisfactory.
Check whether access is provided as required and called for by the design and
construction drawings.
Remove protective measures like travel stops.
Check all instruments, alarms, control valves, fittings, wiring, sealing, nameplates, tags,
wire identification, bolts/threads and associated devices to assure that they conform to E&I
documentation and information.

3.1 Inspection & Testing of Impulse and Instrument Air Tubing and their
Process Connections
Before hydro test of the piping systems, make sure the process shut-off valves to the tubing system
and connected instruments are closed. Impulse Tubing shall have a separate pressure test,
requirements as per ASME B31.3.

IMPORTANT:
Due to high pressures, there is a danger of tubing being blown out of the connectors/fittings when not
fitted properly. To minimize the risks involved, the checks shall be done on each fitting.

3.1.1 Inspection of Tubing and their Process Connections

a All tubing shall be disconnected and checked for continuity and correct identification by
pressurizing the system with dry air.
b Clean all tubing entirely from process connection up to instrument bodies. Blowing through
with dry air is adequate.
c Check all tubing for alignment and support and make sure that no strains are put on the
instruments, valves or dosing and sampling skids under either plant shutdown or operating
conditions and make sure that the tubing does not clash with other items.
d Check whether tubing for differential pressure instruments, steam sampling, instrument air
and dosing are connected to the proper instruments, valves, skids and process connections
as specified by the piping isometrics, 2105x-470 series, and Instrument mechanical hook-ups,
2105x-627-27-001.
e Check all process connections for proper welding and leak tightness.
f Check for adequate lubricant on the threads of all fittings.
g After checking the lubricant the tubing shall be reconnected and tightened according to
manufacturer's specification. Make sure all caps and plugs are installed or removed as
required for operation.
h Check all tube connectors and unions with gap inspection gauge to assure
that all fittings are sufficiently tightened. See documents 2105x-627-14-009-001 and 2105x-
627-14-010-003.

3.1.2 Testing Impulse Tubing and Process Connections

1 Impulse tubing shall be pressure tested according to the requirements of ASME. The pressure
testing is done with cold condensate, after the test the instruments and the impulse tubing
shall be carefully drained via the drain/vent connections.

2 For pressure and differential pressure transmitters the test pressure shall be applied to the
vent connection on the manifold block. All valves on the manifold shall be opened, drain
valves on (differential) pressure transmitter lines and the process block valves shall be closed.
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3 After pressure testing: check instrument manifold whether correct valves are opened and
closed as needed for operation. Make sure all caps and plugs are installed or removed as
required for operation.

3.1.3 Cleaning and Testing of Instrument Air Tubing

It is essential for the functioning of the pneumatic control valves that the instrument air system is free
from dirt and/or moisture.

Instrument air tubing shall be tested together with the instrument air piping. Be sure to disconnect the
instrument air tubing from the control valve/air regulator before testing. Under no circumstance shall
dirt or moist trapped in tubing or piping be allowed to enter the control valve/ air regulator.

Use clean, dry and oil free instrument air for cleaning and testing all instrument air tubing. Do not
pressure test the instrument air tubing and supply piping.

Following steps shall be carried out:

a Make sure instrument air tubing is disconnected from control valve air regulator.
b Make sure all hand valves on the instrument air manifold to the individual air consumers are
closed and drain and blow out the manifold with instrument air through the drain valve. Close
drain valve.
c Clean and blow down each individual instrument air tubing line with instrument air until
thoroughly clean by opening the one valve at a time at the instrument air manifold.
d Make sure all dirt and moisture is gone from the system before reconnecting the instrument air
tubing to the valve air regulator.
e After instrument air tubing is reconnected, pressurize the system and test all connections and
unions (also manifold connections) for leaks with a suitable commercial bubble fluid or soap
solution.

N.B.: Air-filters reducers shall be set at the right setting as indicated on the HRSG- Control Valve
datasheets 05x-620-13.

3.2 Inspection of Pressure Gauges

a Check all process connections for proper welding and leak tightness.
b Check for adequate lubricant on the threads of all fittings and bolts/nuts.
c Check for visible damage. Damaged instruments shall be replaced, not repaired.
d Check and adjust zero position if necessary and possible.
e Check pulsation dampening devices to be sure they are free of foreign matter and in working
condition.
f Make sure all caps and plugs are installed or removed as required for operation.
Do not disassemble liquid filled pressure gauges or gas filled thermometers.

3.3 Inspection of Pressure transmitters and their manifolds

a Check whether the plugs in the manifolds of the pressure transmitters have similar threads as
the openings in the manifolds and if they are properly tightened (in case of NPT: 2 or 3
threads are visible on the plug)
b Check whether manifolds and pressure transmitters are connected with the bolts as provided
by the manifold manufacturer and if all bolts are properly tightened.
c Check for adequate lubricant on the threads of all fittings and bolts/nuts.
d Check if all bonnet locking devices for the manifold valves are in place.
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e With parallel threads: check if the seal rings are properly installed and fittings properly
tightened.
f For differential pressure instruments in flow service check that the downstream tapping is
connected to the low pressure connection and that the upstream tapping is connected to the
high pressure connection. For steam flow services both tappings to be connected to a
condensation vessel.
g For differential pressure instruments in flue gas operation check whether high pressure side
of the instrument is connected to the flue gas and whether low pressure side of the instrument
is connected to the ambient pressure.
h Check instrument manifold whether correct valves are opened and closed tight as needed for
operation. Particularly check that the bypass valve is closed tight. Make sure all caps and
plugs are installed or removed as required for operation.
i Flush the seals and connected piping by removing the plug on de flush ring. Flush the process
piping connected to the capillary before installing the seals.

3.4 Inspection of Temperature Element Assemblies

a Check for adequate lubricant on the threads of all fittings and bolts/nuts.
b Check that the element is in contact with the bottom of the thermowell (pressed by spring).
c Check that the coupling of the extension is outside of pipe insulation.

3.5 Testing and Inspection of Flow Devices

Check that the flow device is installed as such that the flow through the flow device agrees with the
flow direction as indicated on the flow device body.

Check that pressure tappings are oriented as indicated in the dimensional outline drawings of the flow
devices, documents 2105x-615-14-124-001 u/i 005 .

Refer to chapter 3.1 for testing and inspection of the impulse tubing and to chapter 3.3 for testing and
inspection of the pressure instruments with their accessories.

3.6 Testing and Inspection of Control valves

Refer to valve installation, operation and maintenance manual for instructions
regarding the control valves. See document 2105x-620-14-010-001.

For hydrostatic testing and flushing of the piping system pipe spools are supplied.

It is essential for the functioning of the pneumatic control valves that the instrument air system is free
from dirt and moisture. If by accident dirt or moisture has entered the system, decommission the
instrument air system and clean and dry system and valves. Refer to valve installation,
operation and maintenance manual for instructions on how to clean and dry the valve and/or air
regulator. Refer to chapter 3.4 for cleaning and drying of instrument air system.

Check whether actuators with hand wheel are orientated as such that the handwheel readily
accessible in case of manual operation. If this is not the case consult with TA before adjusting the
orientation.

Check that the flow through the valve agrees with flow direction indicated on valve body.

Following checks to be made after hydrostatic test of the piping system is completed.
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a Spot-check control valve packing by service group for each manufacturer.

b Check each valve stem indicator for correct open and close position. Correct if necessary.
c Check that valves operate freely through the full length of the specified stroke.
d Check action of control valves to agree with valve action on air failure as shown on the control
valve data sheets. Failure on instrument signal shall be in the same direction as on air failure
unless otherwise specified on the control valve data sheets.
e The operations of all control valves with positioner may be checked without pressurized
pipeline. Check that the valve starts to move from open (or closed) position at a signal above
4 mA (for 4-20 mA signal) from positioner and reaches closed (or open) position at 20 mA.
f Suppliers approval is required before anyone may adjust the "settings" on actuator springs or
re-calibrate valve positioner.

3.7 Testing and Inspection of Attemperators

Mount the attemperator in a Tee piece with the nozzle posioned in the top quadrant of the pipe. The
nozzle orientation shall be facing the steam flow.

3.8 Testing and inspection of Electric Actuators

Check that actuators are installed with the hand wheel orientated as such its readily accessible in
case of manual operation and as indicated on the relevant piping isometrics. Change orientation if
necessary, but only after consultation with TA and approval of SUPPLIER.

Electric Actuators shall be tested and inspected as per Electrical requirements found in chapter 5 of
this document.

Check whether all bolts, nuts and supports are installed and secured and are in accordance with
manufacturer drawings.
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4 ELECTRICAL TECHNICAL REQUIREMENTS

All electrical materials glands, cable ties, markers. conduit fittings/clamp, fasteners etc, typically
packed in carton boxes shall be stored inside according referenced manufacturer instruction when
the outdoor packing is opened and site CONTRACTOR not able to restore the same quality of the
sealing as originally made.

Hot Dipped Galvanized channel profiles, standard steel profiles cable ladder and accessories like
cover, bends, T-pieces, can be stored outdoors free from the ground. Rain water shall be able to
drain from the Channel profiles, ladder components to avoid corrosion. Additional storage and
handling instruction can be found in the attached documents.

Stainless steel installation materials shall not be contaminated with carbon steel particles from disk
grinders and welding activities which result into the formation of rust. Contractor shall take all the
required measures to avoid contamination of stainless steel materials.

Protective measures are:

-Start with Stainless Steel installation materials installation when carbon steel activities are finished
-Site instruction to limit the spreading or carbon steel particles (welding blankets/covers/barriers)
-Cover SS items like boxes, instruments with SS manifold to avoid deposit of carbon steel particles
-Clean/remove carbon steel particles from SS materials regularly/ when noticed
-Limit contact surface between HDG/painted steel and use isolation pads/ring when indicated
-Use Stainless steel cutting tools only for stainless steel and not carbon steel

Materials as provided by SUPPLIER shall be used for the electrical mechanical provisions to hook-up
equipment like junction boxes, panels etc. Sufficient spare materials have been incorporated to cover
e.g. cutting losses.

Channel profiles Single and Back to Back will be used for multiple application e.g. for cable ladder,
conduit, racks etc. as per applicable typical installation drawings.

Single channel profile (41x41mm) and Back to Back channel profiles (e.g. 83x41mm) are provided
with default lenghts of 6 m.

Back to back channel profiles shall only be loaded between the stich or spot weldings weldings. No
loading foces shall be applied at the cutted ends of the back to back channel without stitch or spot
weldings.

Channel nuts for channel profiles shall be tighten according manufacturer recommendation. If no
specific instructions are given in the manufacturer documentation the following torque values can be
used:

Channel nut size Tightening Torque (Nm)

M6 12
M8 28
M10 55
M12 95

(*) use some light oil to lubricate thread of hot dipped galvanized channel nuts and bolts.

Too low or too high torque applied to the channel nuts will result into non proper fixation of the
connection with lower load bearing capacity than designed.
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Cables may be stored in the open, but shall be protected from direct solar radiation. The reels shall
be placed on open pallets or racks to keep them clear of the ground and allow circulation of air. The
pallets will also keep them clear of dirt and mud. Cable reels will be stored so that the cable is not
bearing weight, otherwise the insulation or strands may be damaged.

For cabling storage and handling see the applicable cable manufacturer documentation as
referenced to this manual.

4.1 Location of Electrical Equipment (634 &672)

Mounting position of all items; e.g. cable ladder, panel/boxes. as per applicable E&I plot plans
2105x-634-17-001&002 and cable ladder routing drawings 2105x-672-57-001&002. However, when
necessary, locations may only be repositioned with the prior approval of SUPPLIER.

4.2 Cable Installation, pulling and connection (671)

For handling, unwinding, pulling and fixing of cables and the making of all terminations shall be
strictly in accordance with the manufacturer's and SUPPLIER's instructions. For heavy cables, rollers
shall be used, when pulling cables in the ladder rack sections.

Pulling forces shall not exceed the maximum forces as specified in the attached manufacturer
documentation and instructions see documents 2105x-671-009-001 and 2105x-671-204-001&002

Special attention shall be paid when cutting the cable, from the manufacturer's reels/drums. Cable
shall be cut only from the reels/drums after verification of the actual required length. Indicated lengths
in SUPPLIER's cable list with document number 2105x-671-16 are estimated values. After cutting,
the remaining open cable end on the cable reel shall be protected by a plastic shrinked cap or similar
provisions, in order to avoid ingress of moisture and dirt.

Special care shall be taken to avoid nicking of cable or damage to cable sheath. Where cable sheath
is damaged it shall be reported to SUPPLIER and the method of repair or replacement shall be
mutual agreed upon.

The bending radius for cables shall not exceed the cable recommendation.

Where long vertical runs of cables are to be pulled, this shall be done by using cable sock supports
and steel wire rope to limit the tension on the cable. Where necessary, the cable sheath shall be
protected against damage from the action of the cable sock.

In general the nearest Instrumentation&Control or Electrical cable ladder shall be used. Cable
support provision from Instrument/Electrical Equipment to the nearest ladder shall be by means of
open Conduit system.

Cables shall be laid in straight runs, without crossing other cables, unless where leaving the
ladder/tray.
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4.2.1 Cable installation and fixation

Before fixation of cables is allowed in the trays/ladders the cable runs shall be verified to avoid
unnecessary crossing (cable dressing).
I&C cables will be grouped/bunched typical 3 to 10 cables in a bunch resulting in maximum 3 layers
of cables.

Fixation of the cables typical every 0.6m for vertical runs. For horizontal runs at least every 0.9m
distance.

Power cables to be grouped as single layer with approximately 3 to 5 cables per group.

No cable termination shall take place before the complete run of the cable has been grouped/dressed
and all unnecessary crossings have been removed.

Termination is only allowed after the cable dressing has been pro
QC representative.

At all termination of wires and cables, the insulation shall be neatly stripped without nicking the
strands of the conductors. Cable lugs for power cables shall be of adequate size. Cable glands or
clamps shall be fitted in all cases to prevent any stress being borne by the conductors or the
terminals. The sealing compound and sleeve used in terminations shall be selected to suit the service
temperature conditions under which the cable is to operate.

Unused cable entries of instruments and electrical equipment shall be properly sealed with plugs to
avoid entry of moisture and other particles.

Before final cutting and connection CONTRACTOR shall arrange and fixate all cabling on the cable
trays. All unnecessary crossings, bends over length etc. shall be corrected.

Cables shall be cut at sufficient length (loop) required for movement of the equipment, vibration and
for at least three new connections. Typically a small loop with diameter approx. 150mm with two
turns to be made at the Instrument/Electrical equipment

Excessive lengths at electrical equipment are not allowed. Only if specific indicated the cable shall be
coiled near the equipment to enable the removal of the equipment in case of maintenance without
disconnection.

Single and multi-core runs of cable shall enter equipment from below through weatherproof glands or
fitting suitable for appropriate size cable.

Stranded copper conductors shall be connected with proper crimping connectors (or ferrules).
Crimping tools shall be suitable for the crimps used and regular calibrated/checked according
manufacturer specified intervals.

Spare wires shall be isolated with isolation sleeve and fixed with ties to avoid any risk of connection
to live parts or other terminals which might result in unnecessary failures.
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4.3 Cable marking

The tag number system shall as per client specific coding system with project specific adaption.

The starting and destination points of all cables shall be marked with their associated cable numbers.
The cable numbers (cable labels) are to be affixed such that they are readily visible at all times.

In the case of cabinet connection the labels shall be affixed inside the cabinets approx. 5 - 10 cm
before the end of the cable jacket.

In the case of motor, apparatus or panel/box connections the labels are to be fastened approx.
10 - 15 cm before the lead-in into the component.

4.4 Cable labels

Per cable at least two sets of cable labels are to be provided, one set for each end of the cable.
Cable labeling will by others/Contractors due to plant uniformity.

Protective earth conductor will not have any cable identification markers.

4.5 Cables and Cable Labels fixation

The cable labels (markers) shall be fixed as follows:

- Prepare carrier strip with markers according to the cable number.
- Clean cable jacket.
- Put the cable label on the cable conduit with the markings in longitudinal direction and
tighten the ties.

All cable labels shall have the same orientation. Orientation in general for horizontal installation from
left to right and for vertical installation from bottom to top.

The use of plastic or stainless steel cable markers depends on the place of installation. For indoors
and inside panels/boxes locations plastic labels are recommended. For outdoors exposed to direct
solar radiation locations SS labels are required. Plastic cable ties shall only be used outdoors at
horizontal cable runs and only short vertical runs.

Supplied cable ties are suitable for outdoor used and solar radiation (UV) resistant. To be used for
horizontal and vertical fixation of supplied I&C cables. Number of cable ties supplied is more than
sufficient for NEM supplied I&C cabling on the HRSG mainly horizontal routed cable ladders.

Vertical cable ladders are provided by others and not included in NEM scope of supply
Different fixation method on these vertical cable ladder might be applicable/used.

For vertical runs Stainless steel ties shall be used typically every max 3m or less if local requirements
specifies shorter distance.

The orientation of the stainless steel ties (by others) shall be perpendicular to the run of the cables.
For fixation the slots in the ladder rungs shall be used. Stainless steel ties shall be tensioned and cut
with the proper cable ties cutting tools.
Diagonal fixation to e.g. cable ladder rungs with stainless steel ties is not allowed to avoid the risk of
damaged cable outer sheath.
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In case of stressed cable fixation with stainless steel ties an additional sleeve by means of a piece of
cable outer sheath has to be used to avoid the risk of damaging the cable.

4.6 Cable Ladder Installation

Before and during installation of the small bore ( 2") piping CLIENT shall check the planned cable
ladder routing. In case collisions or insufficient space the CLIENT shall inform SUPPLIER for
alternative routing of piping or cable ladders.

For routing of cable trays and ladders see referenced documents cable ladder plot plan.

Separate ladders will be assigned to each type of cable service as defined by the drawings. On the
HRSG only two cable service levels are applicable:
L1-I&C cabl
L2-Power cabling 230/400VAC

Both I&C cabling and power cabling will be installed on Hot Dip Galvanized cable ladder systems.

For stacked tray/ladders: I&C cable Ladder (L1) shall be at top and power cables at ladders (L2) and
located below the I&C cabling.

All cable ladder, being exposed to mechanical damage i.e. by welding sparks, sandblasting etc., shall
be adequately protected. Any damages shall be repaired immediately.

Sharp bends shall be avoided by using T-pieces and bending pieces.

By using standard galvanized supports with a maximum distance in accordance to the supplied
installation typical drawing a reliable and straight cable routing shall be achieved. Support span
distance typical not to exceed 2.5m.

The cable ladder shall be electrically continuous. This shall be achieved by cleaning the surfaces
before bolting together and by bonding with a copper conductor in case of interruptions.

Cable tray and ladders are not used for ground fault return path. Every electric powered equipment
(>60Volt) will be provided with a protective earth wire in the feeding power cable and connected to
the protective earth bar at the applicable panel/low voltage distribution board.

4.7 Panels

All panels/boxes shall be installed using SUPPLIER and manufacturer instructions.

During installation and termination the panels shall only be open to perform installation works and
testing. Immediately when finished the panels shall be closed to avoid dust/particles entering the
panels. Panels shall not left open unattended.

4.8 Supports

Supports shall be fabricated from materials as provided by SUPPLIER. For supporting and fixation
materials single and back to back channel profiles (Strut) are used. Only in exceptional cases where
clamping or bolting is not allowed/possible standard hot dipped galvanized steel profiles will be used
and welded to the main steel structure to provide the required support (e.g. round shape ducting or
stack supports).
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Supports shall be clamped or bolted to the existing steel work or structure. Damage to coating of
existing steel structure shall immediately be repaired.

Where galvanized, these should be fabricated from pre-galvanized material, and field welds wire
brushed and painted with galvanization paint.

4.9 Conduits

Conduits are fabricated for hot dip galvanized steel (HDG)..

Conduits shall be installed in such a way that moisture/water can leave the conduit.

Conduit shall be installed as per reference documents 2105x-670-37-001.

Conduit shall be installed with a limited amount (2) of bends (90Degr) or offsets to limit the stress
required during pulling of the cable. Minimum bending radius for conduit shall be followed as per
applicable international standard. A typical value is at least 5xDiameter of the conduit.

No long runs of conduits are foreseen on the HRSG. In general a cable ladder will be close to the
equipment will be installed for cable routing to Electrical and I&C Container supplied by others.

F /protection of the
applicable cables.

At all ends protective bushings shall be installed to protect cable from damage during installation.

Sharp edges shall be removed before installation of the conduit. Field routed conduit and its support
shall not limit access to any equipment and installed in such a way that it will not introduce any
hazards which may results into injuries during all stages of the plant.

Detailed typical installation drawings are included in the reference documents to inform the
CONTRACTOR about the required materials and fittings.

The Electrical Mechanical Provisions Reference lists document number 2105x-670-34-209-001 for
electrical and instrumentation is available to inform CONTRACTOR which typical installation detail
has to be used related with the tag number of the equipment. One piece of equipment may have
more than one installation typical drawing, this will be indicated in the Electrical Mechanical
Provisions Reference lists.

In general no grating cut outs shall be made. Only in exceptional cases when there are no alternative
routings possible a grating cut out at the supporting edge and only after SUPPLIER consult and
approval is allowed.

For equipment located on wide access platform a grating cutting already has been foreseen in the
design, to allow passing of conduit, pneumatic lines and Instrument tubing.

Use of grating kick plate is allowed for supporting of conduit, pneumatic lines and instrument tubing.

Top bar of handrail shall always be left free for at least 100mm due to safety regulations.
Any fixation of supports at hand rail to be made at the vertical posts only.
Fixation to handrail by means of clamping only. Clamps installed to handrail shall not results into any
hazards/risk of injuries.
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4.10 Earthing and lightning protection

CONTRACTOR shall install all material for the above ground earthing system according to the
referenced drawings. Location for steel structure earthing lugs see drawing to plant overall grounding
network by others see drawing 2105x-664-17.

Panels/boxes are provided with earthing boss/provision for connection to plant grounding system via
grounding bar by CONTRACTOR.

4.11 Lighting

Not included in NEM scope of supply.

4.12 Motors

Only electric motors are part of an Electric Actuator are provided by NEM. Connection and testing of
Electric Actuators and installation as per referenced documentation.
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5 Inspection and testing

5.1 General

This description gives general guidance for the field testing and inspection of electrical installations
and equipment.

As a general rule the requirements of the national and/or local regulations shall be adhered to, but if
these are less stringent than the requirements in this specification, the latter shall prevail.

For every piece of equipment the manufacturer recommendations according inspection and testing
shall be followed as a minimum requirement.

Throughout the specification the term 'test' includes resistance, insulation measurement, HV
insulation testing and/or functional testing. The term 'inspection' includes both physical examination
and where applicable testing trials.

5.2 Cable Tests

On site insulation resistance of cables shall be measured.

I&C cables (<60Volt) are only tested for continuity and isolation values by means of Ohm meter, and
not subject to any AC or DC insulation testing/measurement with elevated voltage levels

5.2.1 General notes

Insulation resistance measurements and insulation dielectric tests shall be carried out between each
phase to earth with the remaining phases/heaters and measurement etc. connected to earth.

The insulation condition of electrical equipment and cables can be tested in two ways:

5.2.2 Insulation resistance measurement

Insulation resistance measurement can be carried out by applying a DC-voltage from either the mega
ohm meter or a high-voltage insulation tester if a higher measuring voltage level is required. The test
voltage levels should not be higher than the peak value of the actual system voltage. Recommended
voltage levels are:

System voltage Test voltage

below 1000 V AC 500-V DC
1000V - 2.5 kV AC 1000 V DC
2.5 kV - 4.6 kV AC 2500-V DC
above 4.6 kV AC 5000-V DC

The measured insulation resistance will increase if the test is carried out at a lower voltage level.

For correct comparative interpretation of test data, consequent tests on electrical equipment shall
therefore be carried out at the same voltage level.

The megger check will be completed before a single terminal connection has been made-off.
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5.2.3 High-voltage insulation testing

High-Voltage testing can be carried out by applying AC or DC voltage. There are, however, distinct
differences in the nature of these tests.

For DC testing, the voltage distribution in non-homogenous insulation, such as electric windings, is
different from that under normal AC operating conditions and in addition the conditions for possible
flash-over are different.

For AC testing, high capacity test sets will be required for testing equipment with high capacitances,
such as cables. Each system therefore has its own field of application.

High-voltage pressure testing of cables on site with DC is fully acceptable because of the
homogenous insulation structure. These tests shall be carried out during inspection and testing.

High-pressure testing voltage levels shall be based on the designated voltage of the equipment and
not on the actual system voltage.

Duration: 3 minutes

Cable voltage Test Cable voltage Test

designation voltage designation voltage
kV - AC kV AC kV - AC kV - AC
0.75 insulation resis- -- --
0.6/1.0) tance test only -- --
1.9/3.3 7 8.7/15 30
3.0/3.0 10 10/10 30
3.8/6.6 13 13.7/22 44
6.0/6.0 18 15/15 45
6.35/11 22 19/33 65

NOTE: Cables and equipment shall be discharged after testing.

5.3 Electrical equipment tests

As repeated subjection to excessively high voltages may introduce weak points in the insulation of
windings, such tests shall not be applied at site to generators, motors or transformers.
If, however, for special reasons these tests are considered to be necessary, they shall be carried out
only with the manufacturer's approval.

5.4 Earthing tests

On completion of the installation the following tests shall be performed to certify that the earthing
system resistance is within specification.
Visual inspection
Tighten connections bolts/terminals
Earth resistance test (spot test point to point with Ohm meter)
Earthing grid resistance measurement
Marked up documentation for As Built
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5.5 Motor Tests

Insulation resistance testing of electric motors should include the determination of the polarization
index (for medium voltage motors).

This index is the ratio between the insulation resistance measured after one minute and that
measured after 10 minutes of continuous testing at the appropriate voltage.
Unlike the value of the insulation resistance, the polarization index is almost independent of the
winding temperature and of the test voltage. If the insulation level is already at values
e.g.>500MOhms (consult manufacturer data) the results of the polarization index are to be ignored.

Each motor is factory tested and shall undergo a test at Site. Insulation resistance shall be measured
on Low Voltage motors (up to 690VAC) using a mega ohm meter before motors are connected to
their supply conductors. The value of insulation resistance for LV-motors may be determined by a
single measurement.

Other commissioning requirements for motors are as follows:

Bearings are checked for proper lubrication, and where applicable, filled to the correct oil
level. Any sign of presence of water or other contaminants in the lubricant: the greaser oil
shall be replaced before the motor is energized.
Where applicable, drain plugs shall be removed or opened to remove water/condensate
and motors are checked for accumulation of water within the housing and drained if
necessary.
Each motor shall be checked for correct direction of rotation.
Space heaters are checked whether they are properly interlocked with the motor control
circuit.
 Name: HRSG E&I Installation Manual
Doc. nr.: 2105x-607-10
Revision: 0
Attachment: 1

Attachment 1

Installation Check Sheets for:

-Terminal boxes

-Earthing system (above earth)

-Cabling Ladder & Conduit

 Installation Check Sheet for
Terminal Boxes
1 Tag number :
2
3 Service / description :
4
general

5 Junction box drawing :

6 Wiring/connection diagram :
7
8 THE FOLLOWING WORKS/TEST HAVE BEEN COMPLETED/VERIFIED: witness
9 date contractor
10 check for additional supplier instructions
11
12 Visual and mechanical check
13 inspect for any damages
14 identification / nameplates / labeling / cable markers
15 location in accordance with drawing(s)
visual and mechanical check

16 installation / fixation / stability / accessibility (door)

17 shipping plugs / transport-storage preservation precautions removed
18 door seal / hinges / lock(s)
19 cables installed / supported / stress relieve
20 cables numbers as per drawing(s)
21 cable conductors finishing and termination
22 cables glands - tighten / conduit fittings - sealed
23 earthing / shielding connections installed as per drawings
24 cleaned and free from installation / termination works materials / particles
25 protective coating, galvanization / painting of mounting material
26
27
28
29
30 Testing
31 all terminals for wiring, protective earth wires shield termination made and tighten
32 continuity test (Instrumentation <60Volt) / Insulation (electrical >60Volt)
33 energyze and check junction box auxilliary system operation (if applicable e.g: lighting / heating / outlet)
testing

34 marked-up drawing(s)
35
36
37
38
39
40
41
42
remarks

43
44
45
46
47
48

- Contractor confirms that the above items are installed in accordance with the drawings, specifications and contract requirements.
- All documented evidence required to support this statement has been completed and approved.

name:

function:

date:

signature:

client: Siemens IPPS project: 2105x doc. no:

NEM INSTALLATION CHECK SHEET
 Installation Check Sheet for
Earthing System (above earth)
1 Inspected part of earthing system :
2
3 Drawing number(s) :
4
general

5
6
7
8 THE FOLLOWING WORKS/TEST HAVE BEEN COMPLETED/VERIFIED: witness
9 date contractor
10 check required earthing conductor size as per drawing(s)
11 Visual and mechanical check
12 main steel structure connections to plant earthing grid
13 isolated steel structures connections to earthing bar / plant earthing grid
14 cable trays / ladders earthing connection made to earthing bar / earthing grid
15 cable trays / ladders discontinuities interconnected
16 control panels / junction boxes connected to earthing bar (when required)
visual and mechanical check

17 electrical panels / low voltage distribution boards / motors to earthing bar / earthing grid
18 routing / conductor size and connections according drawing(s)
19 lugs / C-crimps compression properly made with suitable tools
20 earthing conductor fixation / supporting / protection
21 bolts / termination tighten
22
23
24
25
26
27
28
29
30
31
32
33 Testing
34 continuity check / resistance measurement of each made connection (indicative only)
testing

35 marked-up drawing(s)
36
37
38
39
40
41
42
remarks

43
44
45
46
47
48

- Contractor confirms that the above items are installed in accordance with the drawings, specifications and contract requirements.
- All documented evidence required to support this statement has been completed and approved.

name:

function:

date:

signature:

client: Siemens IPPS project: 2105x doc. no:

NEM INSTALLATION CHECK SHEET
 Installation Check Sheet for
Cabling Ladder & Conduit
1 Inspected part of Cable Tray, Ladder :
2 and Conduit
general

3 Drawing number(s) :
4
5 THE FOLLOWING WORKS/TEST HAVE BEEN COMPLETED/VERIFIED: witness
6 date contractor
7
8 Visual and mechanical check (pre-inspection; before installation of cabling)
9 routing according drawing(s)
10 identification / marking (if required for ladder)
11 sufficient supports for ladder/ conduit (rigid, no vibrations)
12 minimum installation height not exceeded and free access to equipment / manholes
13 fixation / couplings made (tighten)
14 bending radius
15 no sharp edges / protection sleeve / bushing installed
16
17 Visual and mechanical check (intermediate)
visual and mechanical check

18 cables grouping fixation and dressing (no crossing)

19 separation of Instrument-Control (<60Volt) / low voltage / medium voltage cabling
20
21 Visual and mechanical check (final)
22 routing and installation according drawing(s)
23 cabling according cable list
24 damaged cabling / ladder / conduit
25 sufficient supports ladder/ conduit (rigid, no vibrations)
26 minimum installation height not exceeded and free access to equipment / manhole
27 drain holes at low point available for conduit (if equipment below ladder)
28 no sharp edges / protection sleeve / bushing installed
29 separation of Instrument-Control (<60Volt) / low voltage / medium voltage cabling
30 identification / marking of cabling
31 bending radius of cabling
32 cables grouping fixation and dressing (no crossing)
33 cable tray /ladder cleaned free from debris
34 fixation of ladder covers with clamps
35 protective coating, galvanization / painting of mounting material
36
37 Testing (pre-inspection)
38 load and vibration test (manually, indicative only)
39
40 Testing (final)
testing

41 load and vibration test (manually, indicative only)

42 power and control cabling (>60Volt) insulation measurement at 500VDC (reports)
43 instrument and control cabling (<60Volt) continuity tested (reports)
44 marked-up drawings
45
46
remarks

47
48

- Contractor confirms that the above items are installed in accordance with the drawings, specifications and contract requirements.
- All documented evidence required to support this statement has been completed and approved.

name:

function:

date:

signature:

client: Siemens IPPS project: 2105x doc. no:

NEM INSTALLATION CHECK SHEET