Document Number PEC-QU-GDE-X-10874

Revision 0
Applicability All

Document Type Guideline

QUALITY CONTROL PROCEDURE

INSTALLATION OF SWITCHGEARS, MOTOR CONTROL
CENTERS AND BUS DUCTS

(GUIDELINE)

REVISION / APPROVAL HISTORY

0 Issued For Client Review

Rev. Date Description of Change Developer Reviewer Approver

Documented Information of approvals are retained in QMS

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CONTENTS
1.0 PURPOSE................................................................................................................................................... 3
2.0 SCOPE ........................................................................................................................................................ 3
3.0 DEFINITIONS / ABBREVIATIONS ............................................................................................................ 3
4.0 REFERENCES............................................................................................................................................ 4
5.0 RESPONSIBILITY & AUTHORITY ............................................................................................................ 4
6.0 DESCRIPTION OF ACTIVITIES................................................................................................................. 4
6.1 General Requirements ............................................................................................................................ 4
6.2 Equipment Inspection in Storage ............................................................................................................ 4
6.3 Equipment Installation ............................................................................................................................. 4
6.4 Equipment Inspection ............................................................................................................................. 5
6.5 Testing .................................................................................................................................................... 6
6.6 Inspection and Testing of Control, Metering and Protective Devices ..................................................... 7
6.7 Inspection and Testing of Circuit Breakers, Motor Starters, Fused Switch and Isolators ....................... 8
7.0 DOCUMENTED INFORMATION TO BE RETAINED (RECORDS) ........................................................... 8
7.1 List of Verifying Documents (ITR) ........................................................................................................... 8
8.0 APPENDICES ............................................................................................................................................. 9

Notes:

This document and referenced ITRs shall be applied to Construction/Inspection & Test activities carried out on
E&C Project Sites.

This document is based on widely used international codes, standards and good engineering practice that is
applied in Oil & Gas Projects and is intended to highlight the minimum tests and inspections that ensure quality
requirements are fulfilled within the scope of the document.

This document and referenced ITRs are generated to provide guidelines to Petrofac E&C Project teams
including their sub-contractors during preparation of project specific QCPs/ITRs and shall be customized to
meet specific requirements based on applicable project specifications and/or other statutory and regulatory
requirements. It may also be utilized at bidding/proposals stage.

In case of any conflict between this document and the Project specification, drawings and applicable codes, the
project specification shall take precedence over this QCP and applicable ITRs.

The referenced Inspection and Test Records (ITRs) are controlled independently. Therefore, the latest revision
of these ITRs, at the time of initiation, shall be utilized.

ITR number suffixed with letter “X” are classified as in-process Site/Field Quality Records and will not be part of
the Turnover System Process where as ITR number suffixed with letter “A” are part of the Turnover Process
and Turnover Records.

When filling ITRs do not leave any blanks. If an item/activity is not applicable, denote as N/A.

Use of Blanco, Tipp-ex etc. on ITR is forbidden.

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1.0 PURPOSE
1.1 The purpose of this procedure is to define the inspection and testing method, acceptance criteria for
the Installation of Switchgear, Motor Control Centers and Bus Ducts, the responsibility of
construction and Quality Control with regard to this procedure.

2.0 SCOPE
2.1 This Quality Control Procedure defines the Quality Control activities, the inspection and tests
pertaining to the Installation of Switchgear, Motor Control Centers and Bus Ducts.

2.2 This procedure covers work up to and including mechanical completion.

3.0 DEFINITIONS / ABBREVIATIONS

Company : Vedanta/Cairn Limited
PEC, E&C or Contractor : Petrofac Engineering & Construction
SC or Subcontractor : EDAC Engineering Limited
Project : Integrated Gas Surface For RDG Fields
QCP : Quality Control Procedure
ITP : Inspection & Test Plan
ITR : Inspection & Test Record
QC : Quality Control
PPE : Personal Protective Equipment
RFI : Request for Inspection
V : Volts
KV : Kilo Volts
DC : Direct Current
MV/HV : Medium Voltage/High Voltage
IP : Ingress Protection
U0 : Voltage between conductor and earth or metallic
screen
HSSE : Health, Safety, Security and Environment
IM&TE : Inspection, Measuring & Test Equipment
VT : Voltage Transformer
CT : Current Transformer
IR : Insulation Resistance
AC/DC : Alternating Current/Direct Current
MCC : Motor Control Center
GA : General Arrangement
SWGR : Switchgear
CMP : Construction Management Procedure

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4.0 REFERENCES
EDAC-PIC-E-ITP-003
EDAC-PIC-E-ITP-002
EDAC-PIC-E-ITP-001
: ITP-Installation of Switchgear and Motor Control Centers
and Bus Ducts
: ITP-Installation of Electrical Power & Control Cables
: ITP- Installation of Cable Tray/Ladder and Conduit System

EDAC-PIC-E-ITP-008 : ITP: Installation of Earthing & Lightning Protection System

5.0 RESPONSIBILITY & AUTHORITY

5.1 The SC Site Electrical Engineer/Supervisor shall be responsible for ensuring that Switchgears,
Motor Control Centers and Bus Ducts are installed to an acceptable standard of workmanship and
in accordance with applicable drawings and specifications as well as making request for inspection
(RFI) to Quality Department at each stage of work as per the applicable ITP requirements.

5.2 The Electrical QC Inspector/Site Supervisor shall be responsible as indicated on applicable ITP for
verifying that work carried out is complete, correct and meets the specified requirements.

5.3 The QC Engineer or his designee shall be responsible for ensuring that all inspections and tests
are witnessed based on approved ITP, recorded on applicable ITR listed in 7.1 and signed off.

5.4 The Site Electrician under the supervision of Electrical Supervisor shall conduct all tests and the test
shall be witnessed as per applicable ITP and results recorded by SC Electrical QC Inspector.

5.5 Hazardous Area Electrical inspection shall be carried out only by an Ex-Inspector.

6.0 DESCRIPTION OF ACTIVITIES

6.1 General Requirements

6.1.1 All material received at site shall be inspected upon receipt in accordance with Construction
Management Procedure for Material Receiving.
6.1.2 The test shall be recorded as defined herein and witnessed by Subcontractor, Petrofac and
Company as indicated in the ITP. Prior to issuing the report forms, the inspection items shall be
signed off by the concerned inspection personnel as indicated on the ITP No. EDAC-PIC-E-
ITP-003.

6.2 Equipment Inspection in Storage

6.2.1 When equipment is to be held in a storage area prior to installation, it shall be inspected for
mechanical damage. Particular attention should be paid to condition of instruments and
monitoring devices installed on the panel fascia’s.

6.2.2 Where equipment or equipment sections are sealed to prevent ingress of moisture or dust, this
shall not be disturbed unless physical damage is observed.

6.2.3 Where damage is observed, a thorough inspection shall take place and be reported based on
Material Receiving procedure.

6.2.4 All Switchgear shall be preserved as per manufacturer’s recommendations. Where applicable,
anti-condensate heaters shall be energized.

6.3 Equipment Installation

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6.3.1 Prior to installation checks shall be followed as in paragraph 6.2.

6.3.2 Verify that substation is ready for accepting panels. A dust free climate controlled equipment
room shall be maintained as per manufacturer’s recommendation.

6.3.3 House keeping with vacuum cleaner shall be carried out throughout the day as applicable to
remove dust from the equipment room.

6.3.4 Base plate, floor fixings etc. shall be checked for level and location and fixing Points checked
against their position on the respective panels.

6.3.5 Cable sleeves, floor opening and ducts shall be inspected to ensure correct line and location.

6.3.6 Before installing in position, panel sections shall be opened up and inspected for cleanliness
and to ensure no foreign bodies are present. Dust shall be removed using a vacuum cleaner or
rags as appropriate.

6.3.7 The panel section shall be inspected for mechanical damage and if required, IR checked to
ensure no direct connection to earth.

6.3.8 Installation shall be witnessed to ensure the equipment is vertical and fixing bolts tightened.
Where equipment consists of a number of panel sections, the assembly shall commence from
the centre section. Sections on either side of the centre shall be alternatively leveled and
shimmed as necessary.

6.3.9 The complete assembly shall be checked to ensure alignment and level after tightening of the
bolts as per torque values by manufacturer recommendation.

6.3.10 Bus ducts shall be installed as per GA drawing and manufactures instructions. Bus bar
arrangements and phase rotation shall be verified.

6.3.11 Flexible links shall be fitted at both sides of the bus ducts only after completion of all
inspection/test related to switchgear/MCC, bus duct and transformer.

6.3.12 Vendor Representative may be required at site to assist/advice.

6.4 Equipment Inspection

6.4.1 The equipment shall be inspected and checked against the relevant General arrangement
Drawing and layout drawing.

6.4.2 Doors and panels shall be checked to ensure proper opening and closure. Withdrawable units
shall be checked to ensure freedom of movement.

6.4.3 Fuse ratings, protection devices, indicators and ammeters shall be checked against the panel
schedule.

6.4.4 Current transformer/potential transformer ratios and rating shall be visually checked against
data sheet.

6.4.5 Busbar connections shall be inspected for correct phasing, rating, dimensions, tightness,
correct type of bolt/nut/washers, etc.

6.4.6 Visually check for correct phase sequence of busbars from left to right, top to bottom and front
to rear.

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6.4.7 All of the bus bar bolts shall be fastened using torque wrench by applying torque value
recommended by manufacturer. Each bolt shall be marked by a red permanent marker after
successful torquing.

6.4.8 Contact resistance of each bus bar joints shall be tested by using a low resistance ohm meter
(ductor tester). For identical connections, test results shall not differ by +/- 20% from each
other.

6.4.9 The mechanical operation of spring wound circuit breakers shall be checked.

6.4.10 The presence of all identifying and warning labels shall be verified.

6.4.11 All exposed bus bar joints shall be insulated with approved method/material.

6.4.12 All live parts shall be insulated and ensure sufficient clearance is maintained between phases
and phase to metal part/earth.

6.4.13 Bus ducts shall be inspected to ensure correct assembly, torquing of bus bar joints, supports,
IP rating, etc.

6.4.14 Flexible link connections shall be inspected and torque at manufacturer’s specified torque
value.

6.4.15 Earthing shall be checked to ensure it is as per the detail drawing and installed in accordance
with project specifications.

6.4.16 Inspection results shall be recorded on ITR-E-0501A/0502A/0510A as applicable.

6.5 Testing

6.5.1 The insulation resistance of the internal bus bars shall be checked as follows.

Note: Where applicable, ensure to remove fuses, eg: VT fuses.

a) The insulation resistance of each phase shall be checked after torque completed, with all
other phases and neutral tied together and earthed.
b) The test voltage and minimum insulation resistance shall be as recommended by
equipment manufacturer or as per applicable project specifications.
Below tables may be used as a guideline after consulting with manufacturer

Rated voltage (Volts) 251-600 3300 6600 11000 33000

Test Voltage (DC) 1000 5000 5000 5000 5000

Minimum IR value for groups of five panels shall be as follows

Voltage Rating LV SWGR LV MCC MV SWGR

M Ohms 100 100 >1000

c) Medium voltage equipment shall also be subjected to a "one minute" AC high voltage
withstand test. Applied voltages shall be as recommended by equipment manufacturer or
as per applicable NETA table.
Below table may be used as a guideline after consulting with manufacturer.
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*Test Voltage
Nominal Voltage
AC DC

3.3KV 10.0 13.5

6.6 KV 15.6 22.1
11 KV 20.4 28.8
33 KV 42.0 59.4

Note: *Always consult with equipment manufacturer, before applying test voltage and also
note that DC test voltage may be applied with permission from equipment manufacturer.

d) After completion of the high voltage test, the IR test on the equipment shall be repeated as
in Item 6.5.1 (a).
e) Bus ducts shall also be tested as detailed in 6.5.1 (a) & (b). where applicable MV/HV bus
duct shall be subject to a "one minute" AC high voltage withstand test as in 6.5.1(c).
f) Control transformer shall be tested as detailed in 6.5.1 (a) with test voltage and acceptance
criteria as per applicable project specification.
6.5.2 The tests shall be carried out as per approved ITP, and witnessed by Petrofac/Company and
results recorded on applicable ITRs listed in 7.1.
6.5.3 Earthing resistance and cable continuity shall be tested as per ITP for earthing.
6.6 Inspection and Testing of Control, Metering and Protective Devices

6.6.1 All energized and current injection tests shall be carried out by Vendor representative/pre-
commissioning team as per manufacturer’s testing procedure with assistance from
Subcontractor.

6.6.2 The current transformers/potential transformer connections shall be carefully checked with
respect to polarity/phase rotation for the applications.

6.6.3 CT’s shall be inspected to verify following and results recorded on ITR-E-503X.

a) Name plate details against drawings/data sheets.

b) Location against GA drawing, inspect physical and mechanical condition and ensure no
damages.
c) Mounting bolts are tightened/equipment secured.
d) Adequate clearances exist between bus bars and CTs.
e) Size of the CT wiring and terminal lugs are of correct type.
f) All required grounding and shorting connections are provided.
g) All required grounding and shorting connections are provided.
h) Correct connection of equipment with specification requirements.
i) The unit is free of dust and clean.
j) Identification tag correct.

6.6.4 VT’s shall be inspected to verify following and results recorded on ITR-E-504X.

a) Name plate details against drawings/data sheets.

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b) Location against GA drawing, inspect physical and mechanical condition and ensure no
damages.
c) Adequate clearances exist between primary and secondary circuit wiring.
d) Mounting bolts are tightened/equipment secured.
e) All required grounding connections are provided.
f) Correct connection of equipment with specification requirements.
g) Correct operation of withdrawal mechanism and grounding operation.
h) Primary and secondary fuse sizes are correct.
i) Appropriate lubrication on moving current carrying parts and on moving and sliding
surfaces.
j) The unit is free of dust and clean.
k) Identification tag correct.
6.6.5 Protective relays and metering devices shall be inspected to verify following and results to be
recorded on ITR-E-505X.

a) Name plate details against drawings/data sheets.

b) Location against GA drawing.
c) Mounting bolts are tightened/devices secured.
d) Inspect relays and cases for physical damage.
e) Inspect relay cover for correct gasket seal.
f) Clean cover glass, inspect shorting hardware, connection paddles, and knife switches.
g) Remove any foreign material from the case.
h) Check tightness of the connections.
i) Frame is grounded in accordance with manufacturer’s instructions.
j) The unit is free of dust and clean.
k) Identification tag correct.

6.7 Inspection and Testing of Circuit Breakers, Motor Starters, Fused Switch and Isolators

6.7.1 Name plate details shall be verified against data sheet.

6.7.2 Rating shall be checked against data sheets and load schedules.
6.7.3 Wiring shall be verified against applicable drawings/schematic.
6.7.4 Mechanical interlocks such as door interlocks shall be checked by actual opening and closing.
6.7.5 Operation of safety shutters shall be verified.
6.7.6 Operation of earthing shall be checked and confirmed.
6.7.7 Rack-in/rack-out operation shall be verified to ensure no obstructions.
6.7.8 Stab finger and contact with main bus bar shall be confirmed.
6.7.9 Inspection results shall be recorded on ITR-E-0509X.

7.0 DOCUMENTED INFORMATION TO BE RETAINED (RECORDS)

7.1 List of Verifying Documents (ITR)

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No. ITR No. Description QMS Reference No.

Inspection of Switchgears and Motor Control

1 ITR-E-0501A
Centers

2 ITR-E-0502A Ductor Test of Bus Bar Joints

3 ITR-E-0503X Inspection Record for Current Transformer

4 ITR-E-0504X Inspection Record for Voltage Transformer Nil

Inspection record for protection relays and

5 ITR-E-0505X
measuring/metering devices
Switchgear and Motor Control Centers Cubicle
6 ITR-E-0509X
Checks
Inspection and Testing of Metal Enclosed Bus
7 ITR-E-0510A
Ducts

8.0 APPENDICES
Nil

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