RasGas Company Limited

Barzan Onshore Project

Revision Description (Form - 2)
The following summarizes revisions.
Item Description PRC PAA STR Remarks
*1 *2 *3
All Issued for As-Built a C/G

Justification or Impact if not adopted:

Legend:

*1 : PRC (Primary Reason for Change)

*2 : PAA (Primary Affected Area)
a. Design development incl. correction of wording and
P. Process
typographical error
U/O. Utility/Offsite
b. Industry/Vendor standard including non-conformance
OP Offplot
c. Safety/Operability/Maintainability
C/G. Common/General
d. Environmental/Health

e. COMPANY’s specific request

*3: STR (Subject to Risk Assessment)
YES : Risk Assessment is required.

D R A COMPANY Doc. No.

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JGC Doc. No.
S-B00-1380-008
Prev. Rev.
1
This Rev.
50
AS 1
 Job No. Company Doc. No. Rev.

0-5858-20 BF-S-B00-1380-008 50
Contractor Doc. No. Doc. Class

S-B00-1380-008 3
Page 1 of 21

RasGas Company Limited

Barzan Onshore Project

Project Specification for

Field Testing and Commissioning of Electrical Systems

Rev. Issue Date Purpose/ Description of Revision Prepared Reviewed Approved

50 Feb. 24 2015 Issued for As Built Y.Kusafuka T.Murakami J.Momma

1 Nov. 13, 2013 Issued for Construction Y.Kusafuka T.Murakami J.Momma
0 Mar. 16, 2009 Issued for Construction T. Tanaka K. Fukuzawa S. Onodera

A
Feb. 12, 2009 Issued for Approval T. Tanaka K. Fukuzawa S. Onodera

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CONTENTS
Page

1.0 SCOPE .......................................................................................................................................................... 4

2.0 REFERENCES.............................................................................................................................................. 4

3.0 GENERAL REQUIREMENTS ...................................................................................................................... 5

4.0 INSULATION TEST ...................................................................................................................................... 6

5.0 WIRE AND CABLE ....................................................................................................................................... 6

6.0 MOTORS ....................................................................................................................................................... 8

7.0 GENERATORS ........................................................................................................................................... 11

8.0 SWITCHGEAR AND MOTOR CONTROL EQUIPMENT.......................................................................... 11

9.0 RELAY AND PROTECTIVE DEVICES ...................................................................................................... 13

10.0 TRANSFORMERS ...................................................................................................................................... 14

11.0 UNINTERRUPTIBLE POWER SYSTEMS ................................................................................................ 16

12.0 BATTERY AND BATTERY CHARGER ..................................................................................................... 17

13.0 VARIABLE FREQUENCY DRIVES............................................................................................................ 17

14.0 POWER CAPACITOR BANK ..................................................................................................................... 18

15.0 HIGH / LOW RESISTANCE GROUNDING SYSTEM & SOLID GROUNDING SYSTEM ...................... 18

16.0 ALARMS ...................................................................................................................................................... 18

17.0 PACKAGED FACILITIES............................................................................................................................ 18

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18.0 LIGHTING AND RECEPTACLE SYSTEMS .............................................................................................. 19

19.0 GROUNDING .............................................................................................................................................. 19

20.0 BULK MATERIAL ........................................................................................................................................ 19

21.0 OPERATIONAL AND FUNCTIONAL TEST REQUIREMENTS ............................................................... 20

22.0 INSTALLATION........................................................................................................................................... 20

23.0 TEST REPORT FORM ............................................................................................................................... 20

24.0 TEST EQUIPMENT .................................................................................................................................... 20

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1.0 SCOPE

This specification specifies the general responsibilities and procedures for field testing and
commissioning prior to completely energizing an integrated electrical system for the RasGas Barzan
Onshore Project.

1.1 Contractor shall perform the following tests and calibrations:

a. Testing of all switchgear including all circuit breakers, instrument transformers, meters,
neutral grounding units, and other accessory devices.
b. Testing of all motor control centers including all starters, contactors, control transformers,
and meters.
c. Testing of all power distribution transformers including accessory equipment such as
primary disconnect switches and neutral grounding resistors.
d. Testing of metal enclosed busduct.
e. Testing of all cables.
f. Testing of ELICS, supervisory control equipment and circuits.
g. Testing of motors & generator.
h. The testing and calibration of synchronous motor control circuits and devices & VFD.
i. The calibration and setting of protective relays, static trip units, transducers, and electrical
alarm devices.
j. Testing of UPS and batteries and chargers.
k. Testing of lighting and grounding systems.
l. Operational and functional testing of all systems.
m. Verification of all fuses (power and control).

1.2 The following tests, inspections, calibrations and settings for the equipment shall be performed &
completed by a Vendor representative or under the supervision of the Vendor’s representative.
The Contractor shall assist the manufacturer's representative as required.

a. 132 kV and 33 kV Switchgear

b. High Voltage Transformers
c. Diesel Engine Generator Package
d. ELICS
e. UPS
f. 132KV Cable
g. Cathodic Protection
h. Electrical Heater Systems
i. VDF and associated Motor
j. Generator Package & Turbine Package

1.3 Test procedures, diagrams of connections, test and inspection sheets and safety precautions shall be
developed by CONTRACTOR and submitted to COMPANY for approval a minimum two (2) weeks
prior to any start of testing.

1.4 It shall be the responsible of the Contractor to test all electrical equipment regardless if it listed above.

2.0 REFERENCES

Codes and Industry Standards

All test, inspections, and calibrations which are performed shall be in accordance with specifications
of the International Electrotechnical Commission (IEC) and the specifications listed below. The
Contractor’s qualifications and test equipment, test equipment calibration, and safety precautions

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shall comply with the relevant standards of the IEC and specification listed below.

INTERNATIONAL ELECTRICAL TESTING ASSOCIATIONS

NETA STD ATS "ACCEPTANCE TESTING SPECIFICATIONS FOR ELECTRICAL POWER

DISTRIBUTION EQUIPMENT AND SYSTEMS"

3.0 GENERAL REQUIREMENTS

3.1 The testing and commissioning of electrical facilities required by this Specification shall be the
responsibility of CONTRACTOR. These requirements reflect only the minimum standards and
procedures to be followed before electrical facilities are placed in service or turned over to COMPANY
as being mechanically complete. It shall be the responsibility of the CONTRACTOR to make any
additional tests or commissioning checks necessary to provide a safe, reliable, and functionally sound
electrical installation.

3.2 CONTRACTOR shall obtain COMPANY approval to apply alternative testing methods from what is
described in this specification.

3.3 The testing and commissioning requirements shall be in accordance with the Vendor’s instructions or
under the supervision of the representative when equipment warranties could otherwise be voided.

3.4 Details of the procedures for testing and commissioning, including applicable tables and forms for
recording results, shall be developed by CONTRACTOR and submitted to COMPANY for approval.

3.5 All test equipment shall be provided by the Contractor and shall be subject to review by COMPANY.
Test equipment used by the Contractor shall comply with the following requirements for accuracy,
calibration and suitability for the intended testing.

a. 200 meg, 500 volt megohm tester.

b. AC ammeter with 0-15/30 ampere range with 0.5% accuracy.
c. AC voltmeter with 0-150/300/750 volt ranges and 1000 ohm per volt sensitivity.
d. Volt-ohm-milli ampere meter with multiple ranges, 1000 ohms per volt AC and 20,000 ohms
per volt DC.
e. Phase sequence meter.
f. Ground testing meter, direct reading, Associated Research Inc., "Vibraground" model or
Biddle Co., Earth Resistance Tester or equal.

3.6 COMPANY shall witness all tests and inspection functions and shall be notified 10 working days in
advance of the tests.

3.7 Prior to electrical testing, CONTRACTOR shall take necessary safety precautions, such as issuing
notices of intended testing, posting safety signs and barriers, and ensuring that necessary lockout and
tag procedures are followed. In addition to above, Person in charge of testing shall be completely
familiar with applicable Vendor’s instructions.

3.8 Test results shall equal or exceed the minimum values specified in this Specification or specified by the
Vendor. In the absence of specific data and subject to COMPANY approval, other acceptable
standards may be substituted to determine the acceptability of the test results.

3.9 COMPANY shall be advised immediately when equipment and facilities fail to meet established
testing standards or the intended function during testing and inspection. Equipment or material that
fails due to improper installation or handling shall be replaced. Replacement equipment and material
shall be new and identical to the replaced equipment. No additional cable splices will be allowed.

3.10 The specific commissioning requirements, including the commissioning team and the necessary
procedures for assuring the operability and proper functioning of the various systems and equipment,

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shall be developed by CONTRACTOR and submitted to COMPANY for approval.

3.11 The insulation resistance of transformers and motors shall be tested in accordance with the
requirements of this Specification and Vendor recommendations. The results shall be recorded and
forwarded to COMPANY with specific recommendations from Contractor to accept or reject the tested
equipment. For comparison Contractor shall submit equipment test results from the equipment Factory
Acceptance Test (FAT).

3.12 During construction Contractor shall perform periodic cleanup of indoor equipment especially substation
and electrical equipment within buildings. Periodic cleanup shall include dusting and vacuuming inside
equipment and switchgear. As part of the final commissioning responsibility, CONTRACTOR shall
thoroughly clean the areas, including dusting and vacuuming of equipment enclosures on both the
outside and inside, to ensure that the equipment is completely free of dust or other contaminants that
could affect performance and reliability.

4.0 INSULATION TEST

4.1 The ambient temperature and humidity shall be measured and recorded at the time of all insulation
tests.

4.2 Short time insulation resistance measurements shall be made with Megohmmeter testers,
(MEGGER). Resistance measurements shall be recorded after sixty seconds of applied voltage.
Test voltages shall conform to the following requirements.

a. Equipment rated 1000V or less shall be tested at 500V.

b. Equipment rated above 1000V and less than 4000V shall be tested at 2500V. Equipment rated
4000V and above shall be tested at 5000V.
c. Equipment rated above 5000V shall be tested at a voltage equal to 50 percent of the equipment
rating but not less than 5000V.

5.0 WIRE AND CABLE

5.1 Cables shall be visually inspected on the reels when received at the job site. Where damage to
metal-clad or shielded cables is indicated, preliminary insulation tests shall be performed in accordance
with the requirements of this Specification to determine if the cables are satisfactory and minimum
insulation values are met. For nonmetallic sheathed and unshielded cables, special testing
arrangements may be necessary to proof test cable insulation.

5.2 All cables shall be tagged. Tagging shall be in accordance with cable installation drawings.

5.3 Check cable sizes against applicable drawings and check for proper color coding for compliance with
job specifications.

5.4 Before being connected to equipment, installed wire and cable having all splices, potheads, stress
cones, and metallic insulation shielding complete shall be checked in accordance with the following
requirements:

a. Test for continuity of all conductors and, where applicable, continuity of metallic insulation shielding
to ground.
b. Test of insulation resistance of metal-clad and shielded medium-voltage wire and cable, using
high-potential DC in accordance with Vendor requirements. Tests on metal-clad cable having no
metallic insulation shielding shall be made between phase and metallic covering and between
phases. Tests on wire and cable having metallic insulation shielding shall be made between each
phase conductor and the metallic insulation shielding for that conductor.

5.5 Perform the following electrical tests after the cables have been installed and where applicable all

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splices have been completed. These tests shall be performed before backfilling and after backfilled
but before the cables are connected to the equipment.

a. Continuity test

b. Insulation resistance test on each conductor rated 600V or less. Measurements shall be made
between each phase conductor and between each phase conductor and ground. The conductor
shall be tested with a 500 volt megger. Insulation resistance for satisfactory power installations
shall not be lower than the values given by the following formula:

Minimum Insulation Resistance =

[ (Cable Voltage Rating / 1000) + 1 Megohm ] x 10

5.6 Metal-clad and shielded medium-voltage cables shall be tested using high-potential DC test equipment.
Other requirements of the test are as follows:

a. Maximum field test voltage shall be 80 percent of the factory test voltage.

b. Values of leakage current shall be measured and recorded at fixed increments of voltage between
zero and maximum field test voltage. A minimum of five and a maximum of ten voltage increments
shall be acceptable. Where breakdown of insulation is indicated during testing, the increments of
test voltage shall be reduced to enable a more accurate determination of the rate of rise of leakage
current versus test voltage.

c. The voltage at each test increment shall be sustained for a minimum of one minute before
recording the leakage current. The maximum field test voltage shall be sustained for at least five
minutes with the leakage current being recorded at the end of each one-minute period.

5.7 All shielded cables shall be tested for current leakage using a suitable DC high potential testing set.
The applied direct current voltage shall be 2.4 times the rated alternating voltage of the cables.

5.8 Tests results shall be recorded on the "DC High Potential Test Report". The cable shall be gradually
stressed to minimize harmful surge currents. High voltage ozone resistant, rubber type cable must be
capable of withstanding the following voltage stresses:

DC Maximum Test Voltage

100% 133%
Rated Circuit Voltage Insulation Level Insulation Level
Phase to Phase (Grounded Neutral) (Ungrounded Neutral)
2001 - 5000 Volts 25 kV 35 kV
5001 - 8000 Volts 35 kV 45 kV
8001 - 15000 Volts 55 kV 65 kV
15001 - 25000 Volts 80 kV 95 kV
25001 - 28000 Volts 85 kV 100 kV
28001 - 35000 Volts 100 kV 125 kV

The above shall apply to the following insulation:

Rubber type (EPR), Thermoplastic (XLPE); all with insulation shield.
Testing of 132kV High Voltage cables shall be carried out by the Vendor following Kahra-Maa

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requirements.

5.9 The following procedures shall apply for cable testing:

a. Leakage currents should be observed during voltage build-up. Faulty installations will
cause leakage values to steadily rise after thirty (30) seconds. After application of the initial
voltage, the voltage shall be raised uniformly to the test voltage in not less than 10 seconds
nor more than 60 seconds. (The test apparatus may, however, require a slightly longer time
to raise the voltage in some cases). Potheads and terminators isolated by switches from
other equipment may be stressed at the test voltage along with the cable.

b. Immediately upon reaching the test voltage, the time and current reading shall be noted
and recorded on the "DC High Potential Test Report." The test shall be for a 15 minute
duration for which current readings shall be made for the time intervals shown on the Test
Report.

c. After the test voltage has been reached, the current readings should show a decreasing
amount of current with time until a steady current flows toward the end of the test time.
If the current begins to increase during this time, the cable will be considered inadequate
and must be corrected or replaced.

d. If the test is interrupted before the required test interval is complete, the cable shall be
grounded for an interval at least equal to that time voltage was applied to the cable, before
a new test is begun.

e. After completing the test, the cable shall be grounded for a time interval at least equal to
the amount of time voltage was applied before the cable can be considered safe.

f. When cable testing includes existing "in-service" cables, the test voltage shall be reduced to
two times the rated cable voltage, plus 1000 volts. The test voltage shall be gradually
applied in maximum voltage steps of 5 kV. The voltage shall be held at each step for one
minute, and the stabilized leakage current recorded before increasing the voltage to the
next voltage level. The leakage current values shall be plotted on a graph during the test.
The curve development shall be observed and the test terminated if the curve approaches a
knee.

5.10 Short runs of cable (less than in meters) rated for service above 5000 volts and totally contained
within the switchgear building will be considered as satisfactorily installed if the meggered insulation
resistance using a DC hi-pot at maximum test voltage reads above the following minimum values:

Cable Size Grounded Neutral Ungrounded Neutral

2 2
16mm - 25mm 100 meg. 120 meg.
2 2
35mm - 50mm 80 meg. 100 meg.
2
120mm - 240mm2 60 meg. 80 meg.
2
250mm2 - 400 mm 40 meg. 60 meg.
2
500mm 30 meg. 40 meg.

6.0 MOTORS

6.1 All motors shall be subjected to an insulation test prior to connecting the machine terminals to the
motor feeder. A one minute "megger" reading taken at a machine temperature of 25C shall be
observed before energizing. The reading shall not be less than the Vendor’s recommendations. If

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the winding is not at a temperature of 25C, the observed one minute resistance shall be adjusted by
multiplying the observed value by the temperature co-efficient of insulation resistance (Kt25c) found
in the following table:

Winding Temperature

Deg.-C 0 5 10 15 20 25 30 35 40

Kt25c 0.19 0.25 0.36 0.50 0.70 1.0 1.50 2.00 2.50

6.2 Three phase machines with only three leads brought out shall have the insulation resistance
measured with all three leads connected together.

6.3 Three phase machines with all six leads brought out shall have the insulation resistance of each
phase measured separately with the other two phases grounded. The observed resistance of each
phase shall be divided by two to obtain a value, which after correction for temperature, can be
compared with the recommended minimum value of insulation resistance.

6.4 If the corrected insulation resistance is below the minimum value, the machine must be dried out, as
specified in section 6.9 below. It should be noted that for machines in good condition, insulation
resistance readings of 10 to 100 times the recommended minimum values.

6.5 The value of insulation resistance for low-voltage motors(less than 1.5kW) may be determined by a
single measurement.

6.6 The representative value of insulation resistance for medium voltage motors shall be determined by
the dielectric absorption ratio calculated from two megohmmeter readings taken during the same test.
The representative value of insulation resistance shall be the ratio of the 60 second reading to the 30
second reading. The minimum acceptable value is 1.5 for the 60 to 30 second ratio provided the 30
second readings equals or exceeds the requirement of Subparagraph 6.7.

6.7 For all voltage ratings, the minimum insulation resistance value shall be determined from the
following formula:

Rm = (kV + 1) x 10

Where
Rm = recommended minimum insulation resistance in megohms at 25C* of
the entire machine winding.
kV = rated machine potential in kilovolts.

6.8 Commissioning requirements for motors:

(a) Assure motors are designed for the area classification where they will be installed.

(b) Prior to energizing the machine, all foreign objects between the rotor and the stator field coils
should be removed. Voltage and Frequency on the nameplate of the machine must correspond
with the terminal line voltage and frequency.

(c) Exterior shall be inspected and spot painted where necessary.

(d) Check and tighten all hardware and connections.

(e) A check shall be made that bearings are properly lubricated, and where applicable, filled to
the correct oil level. If necessary because of the presence of water or other contaminants in the
lubricant, the grease or oil shall be replaced before the motor is energized. Only premium grade
synthetic grease compatible with Vendor supplied grease shall be used.

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(f) For sleeve bearing motors, a visual inspection shall be made of the rotation of the slinger
rings and the amount of lubricating oil being distributed when power is first applied to the motor.
This inspection should be made throughout the motor speed range where the motor operates in
conjunction with a variable frequency drive.

(g) Where applicable, drain plugs shall be removed and motors checked for accumulation of water
within the housing.

(h) Each motor shall be checked for correct direction of rotation.

(i) Motors shall be run unloaded with the coupling disconnected for a period of at least 2 hours
for low voltage motors and 4 hours for medium voltage motors. Rotors shall be manually
slow-rolled at least four complete revolutions prior to energizing the motor.

(j) During machine test-run, inspect for smoke, unusual noises, vibration and over-heating.
Operating conditions must be investigated and corrective action taken when the total
temperature (ambient plus rise) exceeds the values measured by resistance.

(k) Maximum acceptable unfiltered vibration limits shall be:

Hydrodynamic Journal Bearings

Anti-Friction Bearings
(Sleeve Or Pad)
On Bearing Housing, On Bearing Housing, On Shaft, Note(2)
Synchronous Speed Note(1) Note(1)
Peak-to-Peak
RMS RMS Displacement

Rev/m in. (mm) in. (mm) in. (mm)

≦3600 0.12 3.0 0.1 2.54 0.002 0.050
Notes:
(1) Axial Limit = 0.8 x Radial Limit.
(2) Excludes Shaft Run out.

All medium voltage motors vibration data shall be measured by Contractor and
witnessed by COMPANY.

(l) CONTRACTOR shall notify COMPANY three (3) days before no-load run testing
of each medium voltage motor.

(m) A check shall be made that space heaters are properly interlocked with the motor controller.

6.9 Motor Drying Out Process ( Refer to Section 6.4)

6.9.1 Machine windings shall be dried out by supplying heat from motor equipped heaters, from heat
pumps or by passing current through machine windings until a sufficiently high, rising insulation
resistance is obtained. When current is applied through the windings, it shall not exceed one-half the
nameplate rating.

6.9.2 The temperature maintained during the drying out process shall not exceed the following:

a. Class B Insulation
By a thermometer 90C
By resistance bridge or a thermal-sensitive resistor 110C
b. Class F Insulation
By a thermometer 115C
By a resistance bridge or a thermal-sensitive resistor 135C

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6.9.3 The applied voltage to produce drying current for synchronous and induction machines rated 6.6kV
and above shall not exceed 10% of the nameplate voltage and should not cause more than 50% of
nameplate full load current to pass through the windings. The voltage may be increased to 15% of
nameplate, after a low insulation resistance increases to 1/2 of the minimum value provided the
current flow is not increased.

6.9.4 To dry the motor winding; motor Vendor’s instructions and recommendations shall always be follow.

6.9.5 A period of 24 hours is usually sufficient for drying machines rated 450 to 1500kW.

7.0 GENERATORS

7.1 The services of a qualified representative of the Vendor having unit responsibility for the
engine/turbine-generator and auxiliary equipment shall be obtained to supervise and perform inspection,
testing, and commissioning requirements.

7.2 Function tests of engine/turbine-generator control, alarm, and protective equipment, including
switchboards and control boards, shall be made in accordance with the Vendor's recommendations.

7.3 Auxiliary equipment that is part of the engine/turbine-generator installation requires careful attention
during the commissioning process to ensure a reliable generation system. This includes review of the
following equipment:

a. Battery and connections.

b. Battery charger, including operation, DC voltage adjustments, metering, and local and
remote alarms.
c. Fuel system, including pump motors and controls, storage tank level controls, fuel leak
detection devices, and alarms.
d. Engine/turbine-generator heating where required.
e. Building motorized dampers and controls where required.

8.0 SWITCHGEAR AND MOTOR CONTROL EQUIPMENT

The services of a qualified Vendor representative shall be utilized for switchgear installation and
commissioning.

8.1 Following visual checked shall be made for switchgear:

a. Inspect individual circuit breakers for cleanliness, damage, loss of parts, alignment, and
for air insulated breakers the contact pressure shall be checked.
b. Contact alignment on all contactors and air insulated circuit breakers.
c. Verify that all fuse holders, fuses, and other protective devices are not damaged, and are of
the proper type, size and rating, in accordance with one-line diagrams.
d. Check clearance and tightness of all moving parts and remove wedges, ties and blocks
installed by the Vendor.
e. Check the bus bar rating, clearance and insulation of bus bars.
f. Verify correct VT and CT ratings and ratios per one-line diagrams.
g. Check for proper phase rotation R-Y-B, counting from: left to right, top to bottom, or front
to rear, when viewing from the front.
h. Verification of all fuses (power and control).

8.2 Before connecting cables to switchgear and motor control centers bus bars and, Bus Ducts shall
undergo a short time "megger" test. The results shall be recorder along with the humidity at time of
testing. A Ductor test will be made on all joints of bus bars and Bus Ducts.

8.3 The switchgear and motor control equipment shall be clean and dried before testing.

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8.4 Tests shall consist of megohmmeter measurements between each phase and ground and between
phases.

600 volts above

and below 601V to 15,000V 15,001 volts

15 meg. 100 meg. 200 meg.

(breakers in) (breakers out) (breakers open)

8.5 Prior to testing the following equipments shall be disconnected: lightning arrestors, capacitors,
potential transformers and secondary ground connections on current transformers.

8.6 Check nameplates against the one-line diagram for agreement with switchgear that will undergo
testing.

8.7 After completion of the wire and cable terminations, a final insulation measurement using a
megohmmeter shall be obtained for the entire system.

8.9 DC high potential test for AC switchgears shall be made in accordance with Vendor’s instructions or
recommendations.

8.10 Bolted bus joints, terminals, and other connections for each separate equipment installation shall be
checked for tightness and proper torque in accordance with the Vendor’s recommended torque values.
After bolts on outgoing feeder cables have been tested, the installation contractor shall insulate and
tape all connections on all switchgear and motor control equipment rated 415V and above.

8.11 Protective relays shall be set and tested in accordance with the requirements of the system coordination
studies and protective relay setting record. Where applicable, relays having an operating characteristic
that varies with time shall be tested at a minimum of three(3) points to verify conformance with the
Vendor’s data. The integrity of the circuitry between over-current relays and their associated current
transformers shall be verified.

8.12 Circuit protective devices that have adjustable settings, such as molded-case circuit breakers, shall be
set in accordance with the system coordination requirements.

8.13 Motor protection devices used by MCC’s to protect LV motors shall be individually checked to ensure
the proper settings and selections. Where fuses are used, their ampere rating and class shall be
checked for conformance with design requirements.

8.14 Other devices having variable timing characteristics, such as time-delay relays used in the automatic
restart of motor drivers, shall be set and tested in accordance with the intended control function.

8.15 Where the switchgear is arranged for a secondary selective system with automatic transfer scheme,
the transfer circuits shall be tested by simulated fault and under voltage conditions. Detailed
step-by-step procedure will be prepared by the CONTRACTOR for testing (a) secondary selective
system, (b) motor reacceleration scheme, (c) major package units. Testing of secondary selective
systems shall be as in BF-S-B00-1381-009 (Project Specification for Secondary Selective
Substations with Residual Voltage Based Automatic Transfer). The tests shall be witnessed by the
COMPANY's representative.

8.16 Electrical continuity check on all current, potential, and control circuits shall be performed and
witnessed by Company.

8.17 Operation Testing

-Verify that all control and protective devices trip their associated breakers and controllers.

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-Close and trip the breaker with its control switch.

-Manually trip the breaker.
-Close and trip the breaker from any remote control positions.
-Verify all permissive interlocks and shutdown contacts.
-Operate other auxiliary devices.

8.18 The following inspections and tests shall be performed on all MCC's prior to energizing.

a. Check circuit breakers, if used, for proper setting or verify the marked instantaneous and time
delay settings.
b. Check fuses, if used, for size and rating and compatibility with motor.
c. Inspect for damage, missing parts, and mechanical operation.
d. Check tightness of all connections.
e. Check, test and set overload relays for compatibility with motor.
f. Check contacts and adjust so that all "make" at the same time.
g. Check meter and relay system continuity.
h. Check current and potential transformers for proper ratio, size and polarity, in accordance
with one-line diagram.
i. All starters shall undergo a short megger test. All equipment from incoming to outgoing
cable must have a resistance to ground of at least 50 megohms.
j. Operate the starters for proper opening and closing from both remote and local stations, in
normal and test positions.

9.0 RELAY AND PROTECTIVE DEVICES

9.1 Check all relays for the following:

a. Loose terminals, holding lock screws.

b. Damage to resistors, wiring, indicators, and holding devices.

9.2 The relays shall undergo the following checks:

a. Differential relays - Test to verify the published differential characteristics by checking the
minimum operating current.

b. Undervoltage relays - Check for pickup and dropout voltage values, and time to operate.

c. Overvoltage relays - Check pickup and dropout values, time characteristics and any
operational function specified.

d. Directional elements - Check action of relay with either voltage or current. Check with high
current and minimum voltage required to cause effective closing. In applying time settings
to a directional overcurrent relay, arrange the test to include the time of both the directional
and overcurrent elements.

e. Instantaneous overcurrent relays and elements - Check minimum pickup current and
response.

f. Inverse time delay overcurrent relays and elements - Check pickup current and operating
time at the specified current values, at three points minimum. Make test with relay isolated
also with current transformers, meters and other burdens in the circuit, and note any
significant differences.

g. Check all fuse holders for damage or loose mounting.

h. Checks shall be made to confirm relays actually operate the circuit breakers.

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i. Relay test equipment shall include a variable source of current, a variable source of voltage,
a timer, ammeters and voltmeters to read both AC and DC, and switching arrangement to
permit test voltage or current to be applied at the same instant that the timer started.

j. All current transformer circuits shall be tested using primary and secondary current injection.
The proper operation of each protective relay, trip device, and meter shall be verified.

9.3 Relay settings and coordination curves shall be furnished to field personnel. The following
instructions apply for setting and programming relays:

a. All relays shall be set in accordance with the relay tabulations furnished.

b. Relays with time characteristics shall be tested at three points on the time coordination
curves to verify conformance with the manufacturer's data.

c. Protective relay settings and adjustments shall be made in accordance with manufacturers
applicable instruction booklets.

d. Circuit protective devices that have adjustable settings, such as molded-case circuit
breakers, shall be set in accordance with the system coordination requirements.

e. Thermal overload relays used for motor protection shall be individually checked to ensure
the proper element has been selected, installed and set for the motor nameplate full-load
current. Where fuses are used, their ampere rating and class shall be checked for
conformance with design requirements.

f. Other devices having variable timing characteristics, such as time-delay relay used in the
automatic restart of motor drivers, shall be set and tested in accordance with the intended
control function.

10.0 TRANSFORMERS

Testing and commissioning of transformers shall be carried out under the direction of the Vendor.

10.1 The insulation resistance of transformer windings shall be measured, using a megohmmeter, between
the following points:

a. Primary winding to ground.

b. Secondary winding to ground.
c. Primary to secondary winding.

10.2 Oil-filled transformers shall be visually inspected for leakage at fittings, bushings, and other externally
connected or gasket devices, such as oil temperature and level gages.

10.3 Control and protective equipment on transformers, such as shutdown and alarm devices, fault-pressure
relays, and forced-air cooling facilities, shall be checked for proper operation.

10.4 Tap changers shall be manually operated and set at the proper tap setting in accordance with the
load-flow or voltage profile studies.

10.5 Where liquid-filled transformers have been shipped by the manufacturer completely assembled, filled,
and factory tested, tanks shall not be opened for internal inspections unless specific conditions indicate
otherwise. When tanks must be opened, every precaution shall be taken to prevent the entrance of
water or other contaminants and, where applicable, to ensure proper repressuring of the tank with dry
air or inert gas as required.

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10.6 Insulating oil of oil-filled transformers shall be dielectrically tested at the following intervals.

a. Upon receipt of the transformer at the job-site.

b. Two (2) weeks prior to energization.
c. One (1) day prior to energization.

Test samples of oil must undergo a dielectric strength test The test sample must withstand the
following minimum voltage stress without an insulation breakdown when tested with a standard
testing device.

Oil 22,000 volts DC (Min. 40 MIL GAP.)

If the voltage causing a breakdown is less than the minimum value, the oil must be (dried) passed
through a suitable filter press until the minimum voltage stress can be sustained.

10.7 New oil shall be tested for dielectric strength with a standard testing device consisting of a test cup,
instrument, control and high voltage power supply prior to adding to a transformer.

10.8 Completely assembled, factory-sealed-tank transformers shipped with an insulating liquid

successfully passing the dielectric strength tests without filtering, may be put into service after
inspection if the cold coil insulation resistance between windings and between windings and ground
tests above the minimum values shown in the table below. In the event that the insulation resistance
value falls below the minimum acceptable value of the table below the transformer coils must be
dried.

Transformer Insulation Resistance Test Voltage

Transformer Coil Rating Minimum Minimum Insulation
Test Voltage Resistance in Megohms
0 - 600 Volts 1000 Volts DC 100
601 - 5000 Volts 2500 Volts DC 1000
5001 - 15000 Volts 5000 Volts DC 5000
15001 - 35000 Volts 5000 Volts DC 10000

10.9 In the event that drying is necessary the transformer coils will be heated to a temperature of 60-70C
for a period of 24 hours by circulating current through the windings. This may be accomplished by
short circuiting either windings (HV or LV) and impressing one to one-half percent of nameplate
voltage, (at normal frequency) across un-shorted windings. Current shall be limited to a maximum
fifteen (15.0) percent of the rated normal full load current by a rheostat in series with exciting winding.
As the maximum coil temperature is approached, the circulation current should be gradually reduced
until a steady temperature condition is reached within the 60-70C range.

10.10 The transformer tank and all fittings shall be inspected and tested for adequate sealing to prevent
leakage of insulating liquid, entrance of moisture and loss of inert gas protection before the
transformer is energized. During a leakage test the transformer tank shall not be subjected to a
pressure greater than the amount specified in the nameplate. If there is no nameplate pressure
specified, the Vendor shall be contacted to obtain a test pressure. A vacuum shall be pulled on the
tank and the dew point of the gas measured. A hot gas recirculation shall continue until Vendor’s
recommended values are reached. The liquid dielectric will be slowly pumped into the sealed
transformer until the correct liquid level is reached. Additional nitrogen shall be added to the tank until
the pressure correct tank pressure is reached. Joints, connections, and gaskets will be checked with
chalk dust to detect leaks.

10.11 Pressure gauge readings for sealed tank transformers shall be taken for two different temperatures,
differing over as wide a range as possible. Vendor’s design pressure requirements shall be checked.

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10.12 The following precautions should be taken before placing the transformer in service.

a. Check nameplate with the one-line diagram for agreement with application.
b. Check liquid level, oil leakage at fitting, bushings and other externally connected or
gasket devices, such as oil temperature and level gauges.
c. Check for correct phase rotation and polarity.
d. If provided, check and test current transformers for current transformer turns ratio (using
primary current injection), polarity and winding connections.
e. Perform ratio tests on the rated voltage connection and on all tap connections. Turns ratio
test results should not deviate more than one-half of one percent (0.5%) from calculated
ratio or adjacent coils.
f. When making primary-to-ground measurements, all secondary terminals and tanks must be
connected to ground. Primary terminals and case must be connected to ground when
making secondary-to-ground measurements. Primary and secondary terminals and case
shall be connected to ground when making neutral-to-ground measurements. Company’s
approval is required for deviations from these requirements.
g. If provided, check operation of temperature alarm and level alarm.
h. Perform polarity and phase relation tests on rated voltage connection.
i. If provided, check operation of cooling fan relay and circuit and fault pressure relay.
j. Check grounding of transformer.
k. Inspect high and low voltage bushings and lightning arrestors for cracks, chips, etc.
Remove all dust, dirt, or foreign matter and polish porcelain.
l. Tap changers shall be manually and electrically operated to check for correct operation
and set at the proper tap setting in accordance with the load flow or voltage profile studies.
Check the no-load tap changer to be sure it is in operating condition with the proper
settings.
m. Exterior shall be inspected and spot painted where necessary.
n. Check insulation measurement.

11.0 UNINTERRUPTIBLE POWER SYSTEMS

11.1 Testing and commissioning of UPS equipment shall be carried out under the direction of the Vendor.

11.2 The following field checks and tests shall be conducted:

(a) Check all connections for power and control.

(b) Check input AC battery charger voltage and Check output AC and DC voltage.

(c) Adjustment of the rectifier/charger for battery normal float and equalizing charge rates
including cell voltage.

(d) Verification that the operating load supplied by three-phase uninterruptible power system is
balanced between phases.

(e) Static load test to verify that the specified voltage regulation is maintained during both the
incoming power supply and battery supply modes of operation.

(f) Check the manual transfer of load from the uninterruptible power system to bypass and
return.

(g) Simulation of all alarm conditions.

11.3 The following test and inspections shall be performed on each UPS in addition to the Vendor’s
standard requirements.

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1. Synchronizing AC output, AC input and output.

2. No interruption during AC and DC switching.

3. Battery output voltage and charger operation, during AC input failure with rated UPS test
load connected to the output. The UPS test load shall be resistive load bank equal to the
rated kW output of the UPS unit. UPS operation shall be monitored and recorded until
minimum battery voltage is reached. Time of operation shall be recorded. This test shall be
performed one month after commissioning batteries.

12.0 BATTERY AND BATTERY CHARGER

12.1 The following precautions should be taken before placing the battery in service:

a. Check for leaks in sealed batteries.

b. Check the cell connections and wiring for continuity and polarity.
c. Check all protective devices for proper rating.
d. Check and record the battery output voltage.

12.2 Before energizing the battery charger, the battery should be connected across the output terminal in
such a manner that the positive battery terminal is connected to the positive terminal of the charger.

12.3 Place the battery and battery chargers into operation by following Vendor’s recommendations. All
battery banks should be given an eight (8) hour minimum equalizing charge. Check and record
battery cell voltage after equalizing charge.

12.4 Check all alarms, check functioning of ground fault location device by simulating ground faults.

12.5 Perform discharge test of batteries one month after commissioning batteries, using Vendor’s
recommended method, to confirm Ampere-Hour rating. Results shall be recorded cell by cell.

13.0 VARIABLE FREQUENCY DRIVES

Variable frequency drive shall be commissioned by in accordance with the Vendor’s procedures and
under the direction of a Vendor’s representatives. In addition to required Vendor’s testing the
following tests shall be carried out:

a. Check all connections for power and control.

b. Simulate all alarm conditions.

c. Inspect for mechanical damage.

d. Test all control circuits and interlock systems for proper operation and sequence.

e. Operation of VFD's with motor load connected.

f. Adjust all equipment parameters including: :

1. Ramp speed
2. Minimum operational speed
3. Maximum operational speed
4. Remote control signal follower
5. Speed avoidance

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14.0 POWER CAPACITOR BANK

Testing and commissioning of 6.6kV power capacitor bank shall be carried out under the
recommendation of the vendor.

14.1 The insulation resistance of the capacitor bank shall be measured between the terminals and the
container by using a megohmmeter. The criteria shall be not less than 1000 megohm.

14.2 Withstand voltage test shall be carried out between the terminals and the container. The test voltage
shall be AC 17.6kV (22kV x 80%), 1 minute.

14.3 Capacitance measurement test shall be carried out by applying AC 240V single phase for capacitor
bank. The current value of the capacitor shall be measured and compared with the factory data.

14.4 Sequence test shall be carried out by the latest schematic.

15.0 HIGH / LOW RESISTANCE GROUNDING SYSTEM & SOLID GROUNDING SYSTEM

15.1 The Contractor shall perform the following inspections and tests at the jobsite prior to energizing.

15.2 Test the high & low resistance grounding system as follows:

a. With switch on control panel to the normal position, intentionally ground system. (Warning:
de-energize circuit while ground is being installed, then transformer primary side is
energized by reduced test voltage.)
b. Check red lights for grounding fault on relay display and warning system operation.
c. Remove intentional ground (de-energize circuit prior to ground removal).
d. Return switch to normal position.
e. Press reset button to remove fault indications.

15.3 Test the solid grounding system as follows:

a. With switch on control panel to the normal position, intentionally ground system. (Warning:
de-energize circuit while ground is being installed, then transformer primary side is
energized by reduced test voltage.)
b. Check breaker trip of ACB / MCCB Incomer.
c. Remove intentional ground (de-energize circuit prior to ground removal).
d. Press reset button to remove fault indications.
e. Return breaker position to normal.

15.4 Test with test button

a. Press test button to simulate ground fault.

b. Observe alarms and red lights on display or trip breaker for proper operation.

15.5 Test for system capacitance charging current in accordance with manufacturers instructions.

16.0 ALARMS

Systems and circuits shall be individually checked by manually operating the initiating device for each
alarm condition.

17.0 PACKAGED FACILITIES

Packaged equipment shall be tested in accordance with the Vendor’s recommendations and
requirements. Contractor shall develop the required test forms and perform site testing to verify

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equipment integrity and operation.

18.0 LIGHTING AND RECEPTACLE SYSTEMS

17.1 Following inspections and tests shall be performed when all lighting system is completed.

a. Check lighting and lighting circuits to determine if all are operable.

b. Check that emergency lighting circuits are complete and operable by de-energizing normal
circuits and observing emergency lighting. The instant restart of all applicable lighting
fixtures shall be tested to ensure proper operation.

17.2 Contractor shall perform an illumination and area lighting levels survey to that measure lighting levels.
Measured illumination levels results shall be compared with design requirements to ensure the
installations conform with the requirements of BF-S-B00-1380-001 (Table 1) and Lighting Layout
drawings.
Light levels shall be checked two (2) hours after sunset to verify adequate lighting levels. Lighting
deficiencies shall be brought to COMPANY's attention and Contractor shall add additional fixtures
where required.

17.3 A functional check of lighting and receptacle systems shall be made. This check shall include polarity
and ground continuity tests of receptacle circuits.

17.4 Floodlight aiming shall be reviewed to ensure that the most effective illumination patterns are being
provided.

19.0 GROUNDING

Contractor shall perform the following ground inspections and tests:

a. Ground potential survey to performed, total ground grid integrity measured and equipment
grounding verified.

b. Check and tighten all hardware and connections. The continuity of underground insulated
ground conductors shall be verified.

c. The maximum allowed resistance between each ground rod and a test ground rod shall
not exceed 25 ohms for the individual rod. If the resistance is greater than 25 ohms, the
ground rod shall be removed, cleaned, re-installed, and re-tested.

d. The loop ground system shall be tested. The resistance to ground of the total system loop
with all ground rods connected and equipment grounding disconnected shall be less than 1
ohm. If necessary additional ground rods shall be added by Contractor to achieve total
ground potential of 1.0 ohm or less.

20.0 BULK MATERIAL

19.1 A check of seal fittings shall be made to ensure that each has been properly sealed with compound.
To facilitate this check, CONTRACTOR shall visually identify each seal fitting that has been filled with
compound.

19.2 Junction, pull, splice, and terminal boxes shall be reviewed for compatibility with the location
classification and the type and degree of moisture and corrosive agents that may be present.

19.3 The phase orientation and marking of all applicable cable buses and cable systems shall be checked.

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21.0 OPERATIONAL AND FUNCTIONAL TEST REQUIREMENTS

The CONTRACTOR, shall functionally test all systems including remote control devices and
interlocks to verify operation in accordance with the project schematic and wiring diagrams prior to
final energization.

22.0 INSTALLATION

Other checks or tests to be performed shall include:

a. Installation of all equipment identification nameplates, instruction plates, and circuit

directories.

b. Resistance measurements of grounding systems and connections for conformance with the
requirements of Section-18.0. Refer to IEEE Std 81 for methods of checking ground
resistance.

c. Tests to determine the proper functioning of all disconnect switches, circuit breakers, motor
control equipment, relays, programmable logic controllers, motors, motor-operated valves,
standby generator facilities, uninterruptible power systems, automatic transfer equipment,
batteries and battery chargers, lighting systems, and pressurization-heating-cooling systems,
including a complete check of all control, interlock, alarm, and sequence circuits.

All relays and control or equipment components that prove to be unpredictable in operation and could
affect the reliability of the facilities shall be repaired or replaced as necessary.

23.0 TEST REPORT FORM

The test report forms for motor test data and megger test data shall be used to record and report
applicable field test. Test forms for equipment which is tested by a third party or Vendor ‘s
representative shall be verified by Contractor prior to submission to Company. When furnished,
COMPANY test report forms shall be utilized for recording test results and re-submitted to
COMPANY for review and approval. The testing and inspection records shall contain the information
listed below. The reports shall be submitted to COMPANY on a weekly basis, unless agreed
otherwise. Repetitive-type tests such as, megohmmeter testing of motors or motor feeder and control
cables may be submitted on a single report. However, each test must be signed off.

a. Description of the inspection or test function, data performed and identification of the test
equipment used.
b. Applicable ratings, equipment tag numbers and location of the facilities.
c. Size, length and rating of cables; whether cables are shielded or unshielded; and
manufacturer's test values for medium and high voltage cables.
d. Ambient temperature and humidity where applicable to the particular test or
inspection function.
e. Minimum test values acceptable in compliance with project specifications.
f. Test results, including comments where necessary for clarification.
g. Details of any corrective action taken.
h. Results after corrective actions have been taken.
i. Signature of the tester, Installation contractor's representative and COMPANY's
representative.

24.0 TEST EQUIPMENT

All test equipment used by Contractor, Vendor representative, or third party shall have current

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calibration stickers on the test equipment and a complete record of the test equipment shall be
maintained by the Contractor.

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