DEP 63100811_2015-02.pdf

DEP SPECIFICATION

FIELD COMMISSIONING OF ELECTRICAL INSTALLATIONS AND EQUIPMENT FOR GLOBAL APPLICATION le a s e r r o f t o N .l l e h S m o fr e s n e c li t u o h it w d e tt i m r e p g n i k r o w t e n r o n io t c u d o r p e r o N . s e i n a p m o C f o p u o r G ll e h S t h g ir y p o C

DEP 63.10.08.11-Gen. February 2015

DESIGN AND ENGINEERING PRACTICE

© 2015 Shell Group of companies All rights reserved. No part of this document may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior written permission of the copyright owner or Shell Global Solutions International BV.

DEP 63.10.08.11-Gen. February 2015 Page 2

PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions International B.V. (Shell GSI) and, in some cases, of other Shell Companies. These views are based on the experience acquired during involvement with the design, construction, operation and maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international, regional, national and industry standards. The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to Shell companies for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the quality of their work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will typically expect them to follow those design and engineering practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own respons bility, consult the Principal. The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three categories of users of DEPs can be distinguished: 1)

Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.

2)

Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of a Service Agreement or otherwise).

3)

Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these companies, that may issue DEPs or advise or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to t he user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in Shell GSI.

DEP 63.10.08.11-Gen. February 2015 Page 3 TABLE OF CONTENTS 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

INTRODUCTION ........................................................................................................5 SCOPE........................................................................................................................ 5 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 5 DEFINITIONS ............................................................................................................. 6 CROSS-REFERENCES ............................................................................................. 8 SUMMARY OF MAIN CHANGES ............................................................................... 8 COMMENTS ON THIS DEP ....................................................................................... 8 DUAL UNITS ............................................................................................................... 8 NON NORMATIVE TEXT (COMMENTARY) .............................................................. 8

2. 2.1 2.2

PROCEDURES, RESPONSIB ILITIES AND DOCUMENTATION ............................. 9 PROCEDURES AND RESPONSIBILITIES ................................................................ 9 DOCUMENTATION .................................................................................................. 10

3. 3.1 3.2 3.3 3.4 3.5 3.6

TESTING AND COMMISSIONING METHODS .......................................................11 INSULATION TESTING ............................................................................................ 11 CONDUCTIVITY AND EARTH (GROUND) RESISTANCE TESTS .........................12 WIRING AND TERMINAL CHECKS......................................................................... 12 FUNCTIONAL TESTS ..............................................................................................13 PHASING TESTS .....................................................................................................13 POST COMMISSIONING TESTS ............................................................................13

4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11

TESTING COMMISSIONING PROCEDURES ................................................13 GENERALAND ................................................................................................................. 13 HAZARDOUS (CLASSIFIED) AREA EQUIPMENT.................................................. 13 MOTORS .................................................................................................................. 14 GENERATORS .........................................................................................................15 TRANSFORMERS....................................................................................................19 BUS DUCT ................................................................................................................ 20 SWITCHGEAR.......................................................................................................... 20 MCCs AND SWITCHBOARDS .................................................................................21 PROTECTION........................................................................................................... 22 CABLES ....................................................................................................................23 VARIABLE SPEED DRIVE SYSTEMS (VSDS)/ ADJUSTABLE SPEED DRIVE SYSTEMS (ADSD) ...................................................................................................24 UNINTERRUPTIBLE POWER SUPPLY (UPS)........................................................25 EARTHING (GROUNDING) AND BONDING ...........................................................26

4.12. 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22

BUILDINGS ...............................................................................................................28 27 LIGHTING ................................................................................................................. ELECTRIC HEAT TRACING ....................................................................................28 ELECTRICAL PROCESS HEATERS .......................................................................29 CABLE SUPPORT SYSTEMS..................................................................................29 OVERHEAD POWER LINES AND OUTDOOR SWITCHYARDS ............................30 MISCELLANEOUS LOW VOLTAGE EQUIPMENT..................................................31 ELECTRICAL NETWORK MONITORING AND CONTROL (ENMC) SYSTEM COMMISSIONING ....................................................................................................31 INTEGRATED MOTOR CONTROL SYSTEM (IMCS) COMMISSIONING .............. 32

5.

REFERENCES .........................................................................................................33

DEP 63.10.08.11-Gen. February 2015 Page 4 APPENDICES APPENDIX A

INSPECTION AND TEST FORMS INDEX......................................................36

APPENDIX B

NOMOGRAM FOR TEMPERATURE CORRECTION ....................................39

APPENDIX C

TYPICAL CURVES FOR VA RIATION OF INSULATION RESISTANCES .... 40

APPENDIX D

GENERATOR SYNCHRONIZING SYSTEM TESTING ..................................41

APPENDIX E

RECOMMENDED TEST VOLTAGES FOR TESTING AND COMMISSIONING FOR NA APPL ICATIONS ................................................42

APPENDIX F

RECOMMENDED TEST VOLTAGES FOR COMMISSIONING FOR NON-NA APPL ICATIONS............................................................................... 45

APPENDIX G

RECOMMENDED INSULATION VAL UES FOR EQUIPMEN T OF NA APPL ICATIONS .............................................................................................. 48

APPENDIX H

RECOMMENDED INSULATION VALUES FOR EQUIPMENT OF NONNA APPL ICATIONS ........................................................................................49

APPENDIX I

TEST METHOD FOR EARTHING/ GROUNDING SYSTEM - ref er t o (4.13)................................................................................................................51

APPENDIX Ia

EARTH (GROUND) EL ECTRODE RESISTANCE .........................................52

APPENDIX Ib

EARTH ELECTRODE RESISTANCE USING CL AMP METERS .................. 54

APPENDIX J

EXAMPLES OF DELTA/STAR TRANSFORMER CONNECTION. ................ 55

APPENDIX K

TRANSFORMER OIL ...................................................................................... 56

APPENDIX L

VT AND CT FL ICK TESTS ............................................................................. 58

APPENDIX M

TORQUE VALUE OF B OLTS FOR NORTH AMERICAN A PPLICATION .... 59

DEP 63.10.08.11-Gen. February 2015 Page 5 1.

INTRODUCTION

1.1

SCOPE This DEP specifies requirements and gives recommendations for field commissioning of electrical installations and equipment for global application. It covers the pre-commissioning and commissioning of new electrical installations and equipment, or the re-commissioning of equipment following a major overhaul. This DEP is for global use and is harmonised with the Project Guide 14b (Commissioning and Start-up). Project Guide 14b has two major milestones applicable to electrical systems and equipment: •

Mechanical Completion (Handover 1), where systems and equipment are handed over having been tested in a de-energised state (for the electrical systems and equipment this means having tests done such as continuity and insulation resistance but without being initially energised).

•

Pre-Commissioning (Handover 2), where systems are handed over ready to be started up without the introduction of process hydrocarbons (for the electrical systems and equipment this means having tests done after initial energisation such as light run of motors, check of switchgear operation when energised). This then allows the commissioning and start-up team to operate systems by running pumps etc., run utility systems.

The corresponding inspection and test forms are in DEP 63.10.08.91-Gen. (Appendix A) provides an overview of the forms. Where activities are likely to be done outside the normal time frame (e.g., tests that have to be completed with equipment under load, which can only be done after commissioning of systems or even start-up of the plant), these are identified separately. The contents of DEP 63.10.08.14-Gen. (Field Commissioning and Testing of Electrical Systems and Equipment for North American Application) have been combined in this DEP. This is a revision of the DEP of the same number dated September 2011; see (1.5) regarding the changes. 1.2

DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorized by Shell GSI, the distribution of this DEP is confined to Shell companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated by them. Any authorized access to DEPs does not for that reason constitute an authorization to any documents, data or information to which the DEPs may refer. This DEP is intended for use in facilities related to oil and gas production, gas handling, oil refining, chemical processing, gasification, distribution and supply/marketing. Application in other facilities may also apply. When DEPs are applied, a Management of Change (MOC) process shall be implemented; this is of particular importance when existing facilities are to be modified. If national and/or local regulations exist in which some of the requirements could be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable with regards to the safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned, the objective being to obtain agreement to follow this DEP as closely as possible. In general, references to IEC standards do not apply to North American (NA) applications.

DEP 63.10.08.11-Gen. February 2015 Page 6 1.3

DEFINITIONS

1.3.1

General defin iti ons

The Contractor is the party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party that initiates the project and ultimately pays for it. The Principal may also include an agent or consultant authorized to act for, and on behalf of, the Principal. The word shall indicates a requirement. The word should indicates a recommendation. 1.3.2

Specific definitio ns Term

Definition

Au th or ized Electrical Pe rson

A Competent Electrical Person authorised by the Business Unit, to supervise or to carry out specified operations on high and low voltage electrical power systems and work on electrical equipment. The authorisation may include the authority to receive a sanction for test, issue and cancel limitations of access and perform the necessary safety procedures associated with such work or testing.

Certificate

Document issued by a recognised authority certifying that it has examined a certain type of apparatus and, if necessary, has tested it and concluded that the apparatus complies with the relevant standard for such apparatus.

Certifi cate of Conformity

Certificate stating that the electrical apparatus complies with the relevant standards for apparatus for potentially explosive atmospheres.

Declaration of compliance

Document issued by the Manufacturer declaring that the electrical apparatus complies with the requirements of IEC 60079-15.

Electrical Commissioning

Putting into service a piece of equipment or system AND demonstrating that the equipment or system is fit for the purpose for which it was intended. It is the last verification point prior to the official acceptance of that portion of the installation. Commissioning therefore consists of on-line functional, load and performance tests.

Electrical Precommissioning

Those activities which are carried out after equipment erection and prior to energizing and performance checks. Pre-commissioning is therefore concerned with the verification of the state of the equipment, quality of installation work and compliance with requirements and codes.

Electrical Technical Au th or it y

The discipline engineer appointed by the Principal responsible for all technical decisions associated with the work. The Electrical Technical Authority is responsible for technical integrity.

Electrical Ne twor k Monitoring and Control (ENMC) System

Computerized system which is dedicated to monitoring and controlling defined aspects of an electrical network.

GoCCMS

Construction and commissioning certification management system that enables the monitoring of the inspected, tested and commissioned status of individual tagged items of equipment, sub-systems or full plant systems.


Term

Definition

Inspection

Physical examination to determine the condition of a piece of equipment. This may involve sight, sound, smell and touch and may involve the opening of covers.

Integrate d Motor Control System

A system comprising control modules, central unit(s), a serial bus connecting the control modules to the central unit and a

(IMCS)

communication facility enabling connection of the central unit to a distributed control system (DCS) and/or a Supervisory Control and Data Acquisition System (SCADA).

Handover

Transfer of responsibility and/or ownership from one party to another. Also known as take-over or turnover . See Project Guide 14b.

1.3.3

Inverter

A converter for conversion from DC to AC.

Nomogram

Any graphic representation of numerical relationships.

Rectifier

A converter for conversion from AC to DC.

Test and Measurement

Verifying by means of instruments and tools the condition and the functioning of an item of equipment and to measure its parameters. (This may include re-calibration).

Abbreviations Term

Definition

AC

Alternating Current

ASD

Adjustable Speed Drive

ATEX

French ATmospheres EXplosives

AVR

Automatic Voltage Regulator

CT

Current Transformer

DC

Direct Current

DGA

Dissolved Gas Analysis

ETA

Electrical Technical Authority

FAT

Factory Acceptance Test

HOA

Hand/ Off/ Auto Switch

HV

High Voltage – IEC above 1000 V (NA above 38,000 V)

IEC

International Electrotechnical Commission

IR

Insulation Resistance

LV

Low Voltage (Voltage levels up to 1000 V)

MCC

Motor Control Center

MV

Medium Voltage (NA definition above 1000 V and less than or equal to 38,000 V)

NA

North America

PI

Polarization Index

RCU

Remote Control Unit

TTR

Transformer Turns Ratio

UPS

Uninterruptable Power Supply


Term

Definition

VLF

Very Low Frequency

VT

Voltage Transformer

VSDS

Variable Speed Drive System (same as ASD system)

1.4

CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section or clause number is shown in brackets ( ). Other documents referenced by this DEP are listed in (5).

1.5

SUMMARY OF MAIN CHANGES This DEP is a full revision of the DEP of the same number dated September 2011. The following are the main, non-editorial changes. Section/Clause

1.6

Change

General

Incorporation of text from DEP 63.10.08.14-Gen.

Appendix A

Removal of inspection and test forms.

COMMENTS ON THIS DEP Comments on this DEP may be submitted to the Administrator using one of the following options: Shell DEPs Online

(Users with access to Shell DEPs Online)

Enter the Shell DEPs Online system at https://www.shelldeps.com Select a DEP and then go to the details screen for that DEP. Click on the “Give feedback” link, fill in the online form and submit.

DEP Feedback System

(Users with access to

Enter comments directly in the DEP Feedback System which is accessible from the Technical

Shell Wide Web)

Standards Portal http://sww.shell.com/standards. Select “Submit DEP Feedback”, fill in the online form and submit.

DEP Standard Form

Use DEP Standard Form 00.00.05.80-Gen. to record feedback and email the form to the Administrator at [email protected].

(Other users)

Feedback that has been registered in the DEP Feedback System by using one of the above options will be reviewed by the DEP Custodian for potential improvements to the DEP. 1.7

DUAL UNITS This DEP contains both the International System (SI) units, as well as the corresponding US Customary (USC) units, which are given following the SI units in brackets. When agreed by the Principal, the indicated USC values/units may be used.

1.8

NON NORMATIVE TEXT (COMMENTARY) Text shown in italic style in this DEP indicates text that is non-normative and is provided as explanation or background information only. Non-normative text is normally indented slightly to the right of the relevant DEP clause.


PROCEDURES, RESPONSIBIL ITIES AND DOCUMENTATION

2.1

PROCEDURES AND RESPONSIBILITIES

2.1.1

General

1.

Testing and commissioning requirements shall be initially addressed at an early point in the design to ensure all testing requirements are identified, and the stage at which each test is best carried out is determined (i.e., FAT, pre-commissioning or commissioning). This ensures all tests are covered in the most cost effective manner and without unnecessary duplication. These requirements should form part of the Electrical Safety and Operability Review (SAFOP) review. Refer to section 2.1.2 of DEP 33.64.10.10-Gen., (section 2.3 of DEP 33.64.20.10-Gen. for NA applications).

2.1.2

2.

Electrical installations and equipment in plants engineered and/or erected by Contractors and, in general, any equipment which has been completed and is ready for operation, shall be subject to certain handover/turnover procedures agreed between the Contractor and the Principal before pre-commissioning.

3.

The handover procedures shall state clearly the relevant responsibilities of Contractor and Principal to provide an orderly transition during early pre-commissioning/early energisation and commissioning transitional period.

4.

The organization and execution of pre-commissioning and commissioning activities shall be the responsibility of the Contractor. Unless otherwise agreed by the Principal, complex electrical systems (e.g., switchgear, generators, AVRs, ASDs, UPSs) shall be rd commissioned with the assistance of the Manufacturer/Supplier or 3 party Contractor as appropriate. The extent and level of such assistance will be dependent on the experience and expertise of the site-commissioning teams.

5.

Hold/witness points shall be agreed between the Contractor and the Principal.

6.

Where site conditions prevent full performance tests (e.g., power output, temperature rise), agreement should be reached between the Principal and Contractor on the need for such tests at a later date.

7.

If applicable, the Principal should have internal procedures for equipment acceptance by Operations/Maintenance departments from Engineering/Construction departments.

Operation al Safety

1.

The necessity of safety precautions during work on electrical equipment cannot be over-emphasized. is drawn to DEP 80.64.10.10-Gen. on which local safety rules and practicesAttention shall be based.

2.

Electrical work shall be inspected for compliance with applicable codes by the Authority having jurisdiction or its delegate, in accordance with the laws of the jurisdiction. For example: a.

For projects in Alberta and British Columbia Canada, the electrical work shall be inspected for compliance using applicable safety codes as required by the Shell Quality Management Plan (Electrical Regulatory Management Plan (ERMP)) as approved by the Alberta Safety Codes Council and the British Columbia Safety Authority.

3.

Since it is likely that the whole electrical system cannot be energized at one time, the electrical system should be tested and commissioned in sub-systems of manageable size with physical controls of the boundaries e.g., application of padlocks. For safety reasons it is important to energize only a part of the electrical network that can be controlled so that neighbouring systems can be worked on safely.

4.

Work shall not continue nor equipment be energized until the appropriate documentation has been signed off by the Contractor and the Electrical Technical Authority or delegate.


2.1.3

The steps required to connect an electrical system, prior to its initial energizing, to an existing electrical network, shall be jointly agreed by the authorized electrical persons (Contractor and Electrical Technical Authority) responsible.

Protection against Explosion a nd Fire Hazards

1.

2.

Before starting field inspection, the Contractor shall provide documentation of the qualifications and competence of the personnel carrying out inspection of electrical equipment in hazardous (classified) areas, such as the CompEx or IECEx schemes. The requirements for competence of the personnel should be embedded in a Quality System compliant with DEP 82.00.10.10-Gen. and national legislation.

2.1.4 Flawless project delivery Analysis of past start-ups indicates a very strong correlation between successful, timely start-ups and the extent of start-up planning. Based on the lessons learnt from numerous projects and the common failure modes that occur during the commissioning, start-up and initial operating phases a Flawless Start-Up program has been developed and successfully applied in many projects. The recommendations for commissioning activities contained in this DEP are consistent with, and support a flawless start-up programme. 2.1.5

Maintenanc e management syst em data

1.

2.2

The Contractor shall provide to the Principal, in an electronic database, all relevant data and information associated with the electrical equipment installed. The format and content of the data shall be agreed in advance with the Principal. The data is intended to be used to populate the computerized maintenance management system with electrical equipment data.

DOCUMENTATION 1.

The Contractor shall complete the inspection contained in DEP Requisition/Datasheet 63.10.08.91-Gen. and listed in (Appendix A).

2.

The forms shall be pre-loaded with the data as recorded in the electrical equipment electronic database. As part of the commissioning procedures, this data shall be verified to be correct.

3.

Use may be made of the forms listed in (Appendix A), or forms generated directly from the database. In the latter case such forms shall contain, as a minimum, the same information as those contained in DEP Requisition/Datasheet 63.10.08.91-Gen.

4.

In order to align with the Shell Certification and Completion Management System (GoCCMS), the forms in requisition DEP 63.10.08.91-Gen. have been split to differentiate tests conducted during the Mechanical Completion (A tests) and during the pre-commissioning (B tests). If the test is to be performed during start-up, they are classified as C tests.

5.

In cases where differences are found to exist with the as-installed equipment, the commissioning forms shall be updated with correct information. The Contractor shall then upload any changes reported into the electronic database, having first checked that the changes do not invalidate any part of the design.

4.

For pre-commissioning and commissioning, 'Form 1 and Form 3' are applicable to all equipment; subsequent forms shall be used as required. It is recommended that vendor tests documentation be available on-site during the inspection and testing of

5. 6.

equipment. The Contractor may develop additional inspection forms for equipment not covered, or not fully covered in this DEP, only with agreement of the Principal. All deviations from requirements shall be documented on an "exception list" presented to those responsible for the installation work for their agreement and action. Any errors in the installation shall be corrected before installation is finally handed over.


The above documentation, including the updated electronic database, shall form part of the official handover of plant and equipment.

3.

TESTING AND COMMISSIONING METHODS

3.1

INSULATION TESTING

3.1.1

General 1. Insulation tests shall be performed at the pre-commissioning stage and prior to the energizing of equipment and cables.

2.

The two methods to be used are:

NOTE 1

3.

3.1.2

3.1.3

3.1.4

3.1.5

a.

Insulation Resistance (IR) testing for motors, generators, transformers, LV switchgear and all equipment other than those items susceptible to damage by over-voltage (e.g., electronic components);

b.

High potential AC (0.1 Hz [VLF] up to power system frequency) or DC testing 1 for MV (NA) and HV switchgear and MV (NA) and HV cables .

:

High potential DC tests should not be done on XLPE cables

Refer to (Appendix E) and (Appendix G) for recommended test voltages and insulation resistance values for NA applications. For other locations, use voltage and insulation

resistance values from (Appendix F) and (Appendix H). IR test s 1.

Perform IR testing by applying a DC voltage from an insulation tester at voltage levels given in (Appendix E) for NA applications and (Appendix F) for other locations.

2.

For correct comparative interpretation of test data, carry out subsequent IR tests at the same voltage level as the initial test.

3.

The measured resistance value is also dependent on the temperature of the insulation and shall be corrected with the use of the nomogram in (Appendix B).

4.

As a guide, the IR of windings reduces by approximately 50 % for each 10°C (20°F) rise in temperature.

Polarizatio n Index (PI)

1.

PI testing shall be performed on all motors rated above 1000V. The PI is the ratio between the insulation resistance measured after one minute and after 10 minutes of continuous testing at the appropriate voltage (PI = R 10 min / R 1 min).

2.

(Appendix C) shows typical curves for variations of insulation resistance and the values for the Polarisation Index.

Interpr etation of resul ts – IR and PI

1.

Where obtained IR or PI values fall below the minimum values given in (Appendix H), equipment should not be energized or subjected to high potential testing.

2.

Appropriate action should be taken to normalize the figures.

3.

Where 'flash-over' occurs during high potential testing, then the test shall be deemed to have failed and appropriate measures taken (e.g., cleaning, drying, repair) to eliminate the cause, following which a re-testing shall take place. The ETA or delegate should be made aware of test failures and approve re-testing.

High potential tests

1.

Before high potential tests are executed, insulation resistance tests shall be carried out. Refer to (3.1.2).


3.1.6

2.

High potential testing of electrical equipment, except LV cables, shall have been carried out at the Manufacturer's works with AC at voltage levels in accordance with the relevant DEP or International Standards.

3.

Repeated high potential pressure tests may introduce weak points in the insulation of windings, and therefore such tests shall no t 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 after consultation with the Manufacturer.

4.

Should 'flash-over' occur during high potential testing, then the test shall be deemed to have failed and appropriate measures taken (e.g., cleaning, drying, repair) to eliminate the cause, following which a re-testing shall take place.

5.

The ETA should be made aware of test failures and approve re-testing.

Bearing insulatio n tests

1.

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

2.

If the pedestal bearings or sleeve bearing housings are completely insulated from the body of the machine, the insulation may be checked with the machine coupled and running at normal speed to establish an oil film in the bearing which will prevent electrical contact between shaft and bearing. An ohmmeter applied across the insulation should indicate a resistance of > 10 kΩ or the Manufacturer’s/Supplier’s

3.

4.

recommendations. Values below 10 k Ω shall be investigated. If the bearings have internally insulated 'shells' or insulated shafts, carry out measurements with the machine uncoupled (and stopped). If, however, only one bearing is insulated (contrary to DEP requirements for motors and generators), verification is limited to the inspection of Manufacturer's/Supplier’s QC documentation. Where double insulation is applied to pedestal bearings, i.e., they are insulated around the bearing 'shell' and at the pedestal base, IR measurement of the 'mid-section' with respect to ground will indicate if either insulation is bridged.

3.2

CONDUCTIVITY AND EARTH (GROUND) RESISTANCE TESTS

3.2.1

Conductiv ity tests

1.

Conductivity tests shall be carried out on all field-made switchgear busbar connections and switchgear earth (ground) system joints and a sample of factory-tested joints with a high-current micro-ohmmeter test set in order to establish their tightness and condition.

2.

For identical connections, the measured values should not differ by more than 20 % from each other.

3.2.2

Earth (ground) resistance tests

3.2.2.1

General 1.

3.2.2.2

For values and method of earth resistance tests, see (4.13) and (Appendix Ia) and (Appendix Ib).

Earth (ground) electrodes 1.

All earth (ground) electrodes shall be tested by measuring the electrode resistance against the mass of earth, using a purpose-made test set as outlined in (Appendix Ia).

NOTE:

Verification of the connection of the earthing electrode to foundation earthing should be done as part of the civil scope of works.

3.3

WIRING AND TERMINAL CHECKS 1.

Electrical wiring shall be checked against the schematic diagrams. Factory-tested assemblies such as switchgear should require only sample checks; wiring done on site shall be checked.


3.4

The tightness of all field-made terminations shall be verified against Manufacturer torque specifications. For North American applications, refer to (Appendix M).

FUNCTIONAL TESTS 1.

Functional tests shall be performed to demonstrate the correct operation of complete systems.

2.

Refer to (2.1) about the need for testing to be considered at the design stages. These considerations shall include functional testing, especially of systems such as Load Shedding. It will be necessary to consider how satisfactory functional tests may be carried out without adversely affecting a running plant or disrupting the commissioning of another plant.

3.5

3.6

3.

The functional testing of safety-related systems, such as an auto start of diesel generation on supply failure, shall be mandatory.

4.

Attention should be paid to equipment interfaces, where there is a greater likelihood of functional impairment.

5.

In cases where complicated control and/or interlock systems are used, the Contractor shall demonstrate compliance with the design requirements by using special case-bycase functional check lists and system logic diagrams.

PHASING TESTS 1.

Confirmation of phase rotation for switchgear and generator operation shall be done using voltage indication units. ‘Phasing sticks’ shall not be used.

2.

For LV systems, phasing should not be done across main busbars but using a visible wiring check and test downstream/after the short-circuit protection (fuse/MCB) of the voltmeters.

POST COMMISSIONING TESTS If procedures require that the equipment be tested against operating conditions, for example motor load tests, then the tests may need to be performed during the start-up or even operational phase.

1.

These tests should be identified early in the preparation of the project commissioning planning and agreed by the Principal.

4.

TESTING AND COMMISSIONING PROCEDURES

4.1

GENERAL

4.2

1.

All items of electrical equipment (except bulk ordered equipment) shall be inspected and tested in accordance with the relevant DEP, this DEP and the Inspection and Testing Forms in DEP 63.10.08.91-Gen.

2.

All electrical equipment tags shall be verified for compliance with the relevant drawings and specifications, i.e., equipment nameplates, etc.

HAZARDOUS (CLASSIFIED) AREA EQUIPMENT Refer to DEP 63.10.08.91-Gen., Form 4 and applicable equipment forms.

4.2.1

Installation

1.

All items of electrical equipment installed in a hazardous (classified) area shall be subject to an initial detailed inspection in accordance with IEC 60079-14 / IEC 60079-17 and information recorded on the above forms.


For North American application, all items of electrical equipment installed in a hazardous (classified) area shall be subject to inspection in accordance with NFPA 70, CSA C22.1, IEEE 45, API RP 14F (or API RP 14FZ) where applicable, and information recorded on the above forms.

3.

Bulk ordered material such as light fittings, junction boxes and RCUs/HOAs should be divided into circuits or sub-packages (as dictated by the installation programme) such that they may be inspected as they are completed and before access from temporary scaffolding or similar constraints are removed.

4.

Once a circuit or sub-package is inspected, it should have readily identifiable labels or tags attached to clearly mark what has or has not been inspected. Any subsequent installation work on that circuit or package requires that the additional works should be inspected and the tie-in points should be re-inspected.

5.

During final inspection, one Form 1 per plant area is sufficient for each 'bulk material' type. A sample inspection of the installation may be undertaken to prove that no deterioration or interference has taken place since the sub-package inspections.

6.

The testing Contractor shall ensure that cable connections and terminations have been made according to specifications and by qualified personnel.

7.

Purged and pressurized enclosures shall be inspected to verify proper operation of purge and pressurization systems and alarms.

4.2.2

Certification 1. Certificates shall be examined to ensure that the equipment and installation is in compliance with the certification requirements.

4.2.3

Ex / Hazardou s Area Classif icati ons Register

1.

The Ex register / Hazardous Area Classifications register (see deliverables in DEP 33.64.10.10-Gen., Appendix 7 and DEP 33.64.20.10-Gen., Appendix 1) shall be completed in order to provide the verification dossier for compliance of the installation with the relevant standards.

4.3

MOTORS

4.3.1

General Refer to DEP 63.10.08.91-Gen., Forms 1, 3, 23, 24, 25, 26. The scopeforms. of motor testing depends upon the motor type and size indicated on the inspection

4.3.2

Insulation tests

1.

Typically, final motor insulation resistance testing is completed with the feeder cable attached. Where acceptable insulation resistance test values cannot be achieved or where capacitors and surge arresters are connected in the motor terminal box, the motor and feeder should be disconnected and testing completed on the individual components. Appropriate test voltages and pass criteria are shown in (Appendix E) and (Appendix G) for NA applications with values for other locations in (Appendix F) and (Appendix H).

2.

Unless otherwise specified, polarization index testing test duration shall be ten minutes.

3.

If specified, HV and MV (NA) motors shall be subjected to high-potential tests (DC).

4.

Insulation resistance tests shall be performed on the exciter and field winding of synchronous motors, including the exciter solid state components.

DEP 63.10.08.11-Gen. February 2015 Page 15 4.3.3

Vibration tests

1.

a.

point x axis - side of bearing housing at shaft height

b.

point y axis - top of bearing housing

c.

point z axis - axial of bearing housing at shaft height

2.

The measurements shall be performed with an instrument conforming to ISO 2954 (10-1000 Hz frequency range). With the motor at normal operating temperature, the vibration velocity shall not exceed 2.8 mm/s (0.11 in/s) RMS, or 4 mm/s (0.16 in/s) PEAK, in any direction.

3.

For bearings fitted with proximity probes, the unfiltered peak-to-peak value of vibration (including shaft 'run-out') at any load between no load and full load, shall not exceed the following values:

4.

5. 4.3.4

Motor vibration shall be measured in a tri-axial direction, i.e.:

a.

50 µm (0.002 in) for two-pole motors

b.

60 µm (0.0024 in) for four-pole motors

c.

75 µm (0.003 in) for six-pole or higher motors

For North American application, the vibration limits in API 541, Figure 1 and Figure 2, shall be used for MV induction motors and the API 546 for MV synchronous machines. For LV motors, the vibration limits shall be in accordance to IEEE 841. For motors with active magnetic bearings (AMB), testing and commissioning shall conform to Manufacturer’s requirements.

Bearing temperature rise tests

1.

Motors shall be operated at no load for at least 1 hour after the bearing temperatures have stabilized. The no load run shall demonstrate that bearing operation is without excessive noise. Stable temperature is defined as a change of not more than 1°C (2°F) in 30 minutes.

2.

Bearing temperature rise limits shall be as given in DEP 33.66.05.31-Gen. for IEC induction motors, DEP 33.65.11.31-Gen. for IC synchronous motors, DEP 33.65.11.34-Gen. for NA synchronous motors, DEP 33.66.05.36-Gen. for NA API 541 motors, and DEP 33.66.05.37-Gen. for NA API 547 motors.

4.3.5

Synchron ous moto rs 1. Insulation resistance tests should be performed on the exciter and motor field. This includes the exciter solid state components.

4.4

GENERATORS Refer to DEP 63.10.08.91-Gen., Forms 1, 3, 29, 30 and 31.

4.4.1

4.4.1.1

Base load generators / Main power genera tors

1.

A detailed commissioning plan shall be developed before generator tests commence. Details of the test plan shall be agreed between the Principal, Contractor and Manufacturer/Supplier.

2.

The following tests should be performed in order to prove the satisfactory performance of the generator, governor, automatic voltage regulator (AVR) and synchronizing/protection systems.

Pre-commissioning checks (prior to running) 1.

All electrical pre-commissioning work shall have been satisfactorily completed, i.e., all possible tests shall have been carried out, prior to the equipment being run and energised.

DEP 63.10.08.11-Gen. February 2015 Page 16 2. 4.4.1.2

Pre-synchronising checks (generator running, no-load)

4.4.1.2.1

Open circuit tests 1.

4.4.1.2.2

Verify the excitation system and generator characteristics by gradually increasing excitation and plotting generator-output voltage against excitation current. Generator / busbar phase rotation

1.

4.4.1.2.3

Verify phase rotation of generator / busbar by means of an LV phase rotation meter connected as shown in (Appendix D), to generator VTs, the VTs being fed either from the busbars (test 1) or the generator (test 2). Synchronising circuit checks

1.

During the above test 1, verify in-phase indication on all of above devices and verify synchronising relay operating parameters and close command.

2.

During the above test 2, verify that operation of the synchroscope, voltmeter, auto and check synchronising relays follows the 'beat frequency', i.e., the difference between generator and network frequency and voltage.

3.

As a last check, verify, using the capacitive voltage indication on generator breaker, that the synchronising relay 'close' command coincides with the in-phase condition when comparing the generator output with a capacitive voltage indicator, measuring the busbar voltage. This will require a phasing out instrument from the same Vendor who supplied the capacitive voltage indication unit.

4.4.1.2.4

4.4.1.3

Protection relays should be tested in accordance with (4.9); however some tests may only be possible with the generator running. See (4.4.1.2.4).

Protection tests 1.

In the absence of suitable 3-phase primary injection test sets, differential relay in-zone operation and out-of-zone stability may be verified by using the generator as a current source.

2.

Differential relay stability check includes the following steps: a.

A 3-phase short circuit shall be applied at a suitable point outside of the differential protection zone.

b.

The generator shall subsequently be run up to speed and excited.

c.

The generator excitation shall be adjusted from zero to a low figure so that no more than full load current may flow. Refer to Manufacturer's test data.

3.

For a Differential Relay Sensitivity Check, a 3-phase short circuit is applied at a suitable point inside the differential protection zone. Proceed further as for the stability check.

4.

Other items of protection and indication equipment may also be verified at this time if not already done by primary current injection, e.g., overcurrent, neutral displacement, negative sequence relays.

5.

For the overspeed check, operation of mechanical and electronic overspeed trip devices shall be verified.

Synchronizing and operational checks (generator running, loaded)

4.4.1.3.1

Synchronize to grid 1.

4.4.1.3.2

The network to which the generator will be initially synchronized should be configured so that the risk of a disturbance to normal plant operations is minimized. Function tests

1.

The following function tests shall be confirmed: a.

auto and manual synchronizing;


4.4.1.3.3

b.

control of power factor over full range of power generation;

c.

control of load;

d.

'bumpless' change-over from Auto AVR to Manual and vice versa;

e.

change-over of AVR from power factor to voltage control (when changing from coupled to 'island operation')

Dynamic tests Refer to DEP 63.10.08.91-Gen., Form 30. 1.

Dynamic tests shall comprise: a.

active load rejection,

b.

reactive load acceptance,

c.

active load sharing,

d.

reactive load sharing,

e.

’Island' proving tests, if applicable.

2.

Test of load rejection/acceptance should be at 100 % of generator rating if suitable active load blocks are available.

3.

The following parameters shall be measured on a suitable recorder:

4.

5.

a.

generator voltage/time,

b.

current/time,

c.

speed (or frequency)/time.

The test acceptance criteria shall be: a.

no tripping of any protection device;

b.

no parameter shall exceed 80 % of the difference between nominal value and trip set points;

c.

transient response shall be within the Manufacturer/Supplier design parameters.

Governor tests a.

Measure load acceptance and rejection: transient response by the switching IN and OUT of active load blocks.

b.

Measure droop settings in "island condition": speed change between zero and full load.

c.

Active load sharing: verify that the load is shared equally (or for different ratings, pro rata) between the generator being commissioned and all other combinations of generators. Verify that the load continues to be shared during changes in total load.

d.

Verify that electrical load variations are within agreed limits during the changeover of fuels.

6. AVR tests a.

Transient response. Measure the recovery of generator voltage during the reactive load acceptance and the load rejection tests to verify that it is within the limits of time and terminal voltage.

b.

Voltage droop*. Verify that voltage droop is proportional to reactive load or is according to design.


4.4.1.3.4

4.4.1.4

4.4.1.5

d.

Current boost*: (for AVRs whose supply is derived from their own terminal voltage), it shall be verified from design data, that generator terminal voltage is sufficiently maintained to allow operation of protective devices in the event of a short circuit.

e.

For items marked *, factory test results are acceptable.

f.

'Block load' values shall be such as to demonstrate the equipment's compliance with its design.

g.

AVR Under and Over excitation (UEL and OEL) limiters shall be checked.

1.

The operation of the Reverse Power relay shall be verified by decreasing the governor setting at minimum load.

2.

The operation of the Field Failure relay shall be verified by decreasing the excitation at minimum load.

Load tests 1.

Load tests shall be performed as agreed between Contractor and Principal and will normally follow satisfactory completion of all the above tests and the completion of construction and testing of the various systems and sub-systems peripheral to the generator and prime mover.

2.

The final tests should be a series of load tests culminating in a protracted run, under design conditions, at maximum power output to demonstrate that the generator, prime mover and all auxiliary equipment meet the designed performance levels while running continuously at full rated load.

Utility/Grid compliance tests Tests shall be performed as agreed with the public utility/local grid company. These may include operation at extremes of real and reactive power, tests at reduced voltage of auxiliary supplies, momentary interruption of supply to auxiliaries, etc. See also (4.4.3).

Black start generators 1.

4.4.2

Reactive load sharing. Verify the ability of the generator being commissioned to run at the same power factor as parallel connected generators. Also verify that the power factor remains equal during changes in reactive load.

Protection tests

1.

4.4.1.6

c.

Where black start capability is required, a suitable commissioning procedure that function tests the system shall be developed and executed.

Emergency and standby genera tors

1.

Where relevant, the tests described in (4.4.1.1) through (4.4.1.5) shall be carried out (DEP 63.10.08.91-Gen. Form 31). The testing methods and procedures shall be subject to agreement between the Principal and the Contractor.

2.

Generators of the 'automatic start on mains failure' type shall be tested to start and supply the load on loss of voltage and should include the associated switchgear as a complete unit.

3.

Additional tests shall be carried out to prove that the unit functions as intended, including the number of successive starting attempts.

4.

Where an emergency generator system is designed to withstand severe accident conditions of fire, explosion and strong vibration, this capability shall be verifiable from tests and inspection. These performance requirements are application specific and the standards to be followed shall be defined in the equipment specification.


Addit ional tests

1.

If confirmed by the Principal, additional tests shall be performed.

2.

These may include operation outside (DEP) standard operating limits of voltage and frequency, additional testing of excitation and governor systems, prolonged interruption of supply to auxiliaries and cascade control of voltage and power in systems with power generation at multiple voltage levels. The tests are intended to demonstrate the capabilities of systems rather than of the single major components.

4.5

3.

During testing, the configurations of the network should be kept as similar as possible to the operational configuration.

4.

The requirement for the additional tests shall be confirmed by the Principal.

TRANSFORMERS Refer to DEP 63.10.08.91-Gen., Forms 1, 3 and 9.

4.5.1

Oil-filled power transform ers

4.5.1.1

General 1.

Windings of transformers shall not normally be subjected to high potential testing. Refer to (Appendix E) and (Appendix G) for NA test voltages and acceptable insulation resistance values. For other locations, use (Appendix F) and (Appendix H). rd

Power transformers are typically tested by a 3 party Contractor.

2.

Test results shall be reviewed and accepted by the ETA. Tests that are typically done rd by a 3 party Contractor include: a.

Power factor using a Doble (or equivalent) test set

b.

Transformer Turns Ratio (TTR) test

3.

SFRA (Sweep Frequency Response Analysis) should be performed on large (> 25 MVA) power transformers and compared to the factory SFRA signature which also serves as the baseline signature for future reference/analysis.

4.

After initial energisation of a power transformer, it should be put on no-load ‘soak’ for a few hours (e.g., overnight) before being put on load.

5.

Before parallel operation of the transformer is attempted, 'phasing-out' operations shall be carried out to verify that the two supplies are “in-phase”. Refer to (Appendix D). Refer to (Appendix J) for examples of Delta/Star Transformer connections.

4.5.1.2

Transformer oil 1.

Liquid levels shall be verified that they are correct. For transformers with nitrogen or other dry gas blanket, verify that a positive pressure (in accordance with the Manufacturer/Supplier data) is maintained.

2.

If this cannot be verified, transformer oil in grid intake, generator step-up, VSDS, captive motor duty and/or large (> 25 MVA) power transformers, shall be conditioned prior to use to confirm that the transformer windings and oil are free from moisture.

3.

An oil sample should be taken from conservator type transformers and sealed transformers with a rating over 3000 kVA and laboratory-tested in accordance with ASTM D923. Refer to (Appendix K). Tests should include: a.

Visual Examination

b.

Dissolved Gas Analysis (DGA)

c.

Liquid Power Factor

d.

Dielectric Strength


4.5.2

4.6

e.

Acid Neutralization Number

f.

Interfacial Tension

g.

Colour

h.

PPM Water

4.

The minimum withstand voltage shall be 30 kV (27 kV for NA applications).

5.

For transformers with auto on-load tap changers, an oil sample should also be taken from the tap-changer compartment and laboratory-tested.

Dry type transfor mers

1.

Testing of dry type transformers other than air-cooled, dry type LV transformers for lighting and small power shall be in accordance with Manufacturer/Supplier recommendations.

2.

Air-cooled, dry type LV transformers for lighting and small power transformers should have insulation-resistance tests performed winding-to-winding and each winding-toground for 1-minute duration, prior to energisation.

BUS DUCT Refer to DEP 63.10.08.91-Gen., Form 11.

1.

Bus duct shall be inspected, tested and commissioned in accordance with the test form.

2.

Functionally test the bus duct heaters to ensure they are working properly. Verify that the amp meter shows current flow through the heater circuits to ensure that it is continuous and operating.

3.

Check that the bus duct enclosure has adequate drainage to prevent the accumulation of moisture.

4.

Check that wall/floor penetrations are properly installed.

5.

Testing of bus duct will primarily consist of insulation resistance tests. (Appendix E) and (Appendix G) show proper test voltages and insulation resistance values for NA applications. For other locations, see (Appendix F) and (Appendix H).

4.7

SWITCHGEAR

4.7.1

Air insul ated switc hgear Refer to DEP 63.10.08.91-Gen., Forms 5, 6, 7 and 19.

4.7.1.1

4.7.1.2

Conductivity tests 1.

After assembly and alignment, switchgear busbar joints shall be tightened to the Manufacturer's recommended torque settings. After correct installation, busbar joints shall be insulated in accordance with the Manufacturer's instructions.

2.

All torqued connections shall be marked to: a.

Indicate that they have been properly torqued;

b.

Show if torque bolts/nuts have been disturbed after the fact.

3.

Switchboard 'droppers' shall be considered as part of the busbar system.

4.

Conductivity tests shall be performed between adjacent, cubicle spouts (See 3.2.1).

5.

The measured values shall be interpreted on a comparative basis and according to the Manufacturer’s statements regarding expected variation in conductance.

Insulation tests 1.

MV (NA) and HV switchgear components (busbars, contactors and circuit breakers) shall be subjected to high-potential tests at the pre-commissioning stage.


4.7.1.3

4.7.2

2.

In general high potential tests are carried out with DC. Refer to (Appendix E) for test voltages and durations for NA applications. For applications outside NA, the test voltage shall be limited to 70 % of the peak value of the relevant AC voltage levels given in IEC 62271.

3.

For HV cast, resin-insulated switchgear, the Manufacturer shall recommend appropriate testing methods.

4.

LV switchgear components (busbars, contactors and switches) shall be subjected to IR tests at the pre-commissioning stage.

Functional tests 1.

All draw out switching devices shall be checked for free movement and correct alignment.

2.

In addition to all checks as given in the appropriate test forms, a full check shall be performed to demonstrate that all features of the switchboard function as intended.

3.

For complex installations, the Contractor shall develop specific, functional check–lists, based upon control schematic diagrams, to demonstrate compliance with the design requirements.

4.

Function checks shall be witnessed by an ETA (or designate).

Gas ins ulated swi tch gear (GIS)

1.

4.7.3

Requirements for Gas Insulated Switchgear (GIS) shall be obtained from the Manufacturer/Supplier. Commissioning of this type of switchgear shall normally be carried out by or under the supervision of the Manufacturer/Supplier.

Swit ches (AIS) Refer to DEP 63.10.08.91-Gen., Forms 19, 20 and 21.

1.

Switches shall be inspected, tested and commissioned fully in accordance with the specific test forms.

2.

The tests are designed to confirm the performance of the switch, including: a.

Operation of the mechanical operator, space heaters and control devices;

b.

Blade alignment, wipe and lubricated according to the Manufacturer’s/Supplier’s requirements;

c. d.

Contact resistance across switch blade and fuse holder (if applicable); Insulation resistance tests phase to phase and phase to ground shall be measured and recorded.

3.

For fused switches, fuse resistance should be included.

4.

In addition to all checks as given on the appropriate test forms, a full function test should be carried out to demonstrate that all features of the switch function as intended/designed.

4.8

MCCs AND SWITCHBOARDS

4.8.1

General Refer to DEP 63.10.08.91-Gen., Forms 13, 14, 15 and 16.

1.

MCCs and switchboards shall be inspected, tested and commissioned fully in

2.

accordance with the specific test forms. Closing of busbar compartments should be witnessed by the ETA.


Conductiv ity tests

1.

4.8.3

4.8.4

a.

Indicate that they have been properly torqued;

b.

Show if torque bolts/nuts have been disturbed after the fact.

2.

Random checks shall be carried out to verify compliance with factory torque figures.

3.

An MCC vertical bus shall be considered part of the bus bar system.

4.

The measured values shall be interpreted on a comparative basis.

Insulation tests

1.

Components (bus bars, starters and circuit breakers) shall be subjected to insulation resistance tests.

2.

Refer to (Appendix E) for NA test voltages and durations. (Appendix F) should be references for locations other than NA.

Function al tests

1.

4.9

All bolts and nuts in the power current carrying circuits shall have been tightened with a torque wrench to the factory recommended figures before conductivity tests are performed. All torqued connections shall be marked to

In addition to all checks as given in the appropriate test forms, a full check shall be performed to demonstrate that all features of the motor control centre/switchboard function as intended/designed.

PROTECTION Refer to DEP 63.10.08.91-Gen., Forms 33, 34, 35, 36 and 37.

4.9.1

Protection testing general

1.

Relays shall be tested and commissioned in accordance with the Manufacturer's instructions. Use should be made of the standard test forms in this DEP; but where these prove to be inadequate, e.g., for multi-function microprocessor-based relays, specific forms may be developed.

2.

The use of digitally controlled test sets which can be configured to self-document the test results and avoid the need to generate project-specific forms is recommended. Such information may also then be extracted in a digital form and may be more easily uploaded into record systems.

3.

All relay operations; indications and logic schemes shall be checked and results recorded on test forms.

4.

CT and VT polarity may be proven by flick tests – refer to (Appendix L).

5.

All CT ratios shall be verified by primary current injection. CT connections once proven by primary injection should not be removed without being retested. Break-in to CT circuits should subsequently only be made at test links provided for the purpose.

6.

All protection relays shall be tested by means of primary current injection at (wherever possible) the normal settings to verify their operating parameters. Where it is impractical to use a primary injection test set, relays may be tested by secondary injection, subject to the approval of the Electrical Technical Authority.

7.

Relay testing shall include verification of the operation of the switching device's tripping mechanism and all alarms and intertrips.

8.

Overload relays of Ex'e' motors shall be tested to verify that the tripping time of a 'warm' relay is less than the tE time shown on the motor rating plate when a current equivalent to the motor starting current is injected.

9.

Motor restart relays and systems shall be tested to verify that their settings are as recommended by a "motor restart/re-acceleration" study.

DEP 63.10.08.11-Gen. February 2015 Page 23 10. For generators and generator/transformer combinations, use may be made of the generator as a current source. 11. After each test, it shall be verified that the actual relay setting is in accordance with the setting as laid down in the overall protection scheme of the power system. 12. The last test date shall be indicated on the relay, and a download of the settings file for numeric relays shall be performed. This shall be identified as the “as-built” record of the relay settings and shall form part of the documentation at hand over of the installation. 13. An approved software change procedure should be in place prior to testing to control Management of Change for software changes. 4.9.2

4.9.3

4.9.4

Protection test equipment

1.

Equipment used to test relays shall have sufficient capability to drive the relay loads.

2.

Electro-mechanical relays generally have non-linear impedance characteristics and may impose high burden on the test set.

3.

Use of test sets with inadequate drive capacity can lead to significant timing errors and invalidate the test results. For these reasons current source secondary test sets with sufficient burden handling capability shall be used.

4.

If the test set is to be used with all relays at a facility, then it shall be rated to meet the

5.

higher load demands of existing protection relays as well. Test equipment shall be calibrated by an authorized test laboratory and be capable of providing accurate test current and voltages applicable for the devices under test.

6.

A current calibration certificate shall be in force.

Electro nic relays

1.

Care shall be taken that electronic relay components are touched only under controlled conditions, i.e., in a workshop equipped with anti-static facilities.

2.

Electronic relays shall be removed or short circuited during IR tests on connected circuits.

Communications

1.

Testing of communication are proven at a Factory Integration Test and before equipment is delivered to site; site tests shall prove all communications in links disturbed since the factory test (e.g., by disconnection).

2.

This testing shall be performed either: a.

between intelligent devices and, board mounted interface units, or;

b.

between DCS or ENMC and the protection relays / switchboard interface units (where fitted)

4.10

CABLES

4.10.1

General Refer to DEP 63.10.08.91-Gen., Forms 48, 49, 51, 53, 54, 55 and 56.

1.

Cables shall be inspected for a complete installation before electrical testing.

2.

Cables that are not terminated and have exposed ends shall be sealed against moisture ingress. Heat tracing cable ends shall be kept sealed under all circumstances to prevent moisture ingress which may destroy the temperature regulating characteristic of the cable.

3.

A shield-continuity test shall be performed on each power cable using a micro-ohm meter. For MV shielded cable, proper routing of shield drain conductors through CTs shall be verified.


4.10.2

4.11

4.

Underground cables should be tested prior to cable trench back-filling. MV (NA) and HV cables may be tested only after terminations are completed, which generally is after trenches are backfilled. In this case, sheath integrity testing can be carried out after first fill (normally sand) of trench has been completed, provided all cable through joints are completed.

5.

Testing of all power cables shall be performed while isolated from both supply and load circuits. This shall include phase allocation verified by continuity checks on cable cores.

6.

For power cables connected to an ASD/VSDS, insulation resistance shall be tested before final termination, but after all lugs, termination kits and other preparations are complete.

7.

If completed tests indicate that a conductor or cable has been damaged, the Contractor shall notify the ETA immediately and the conductors shall not be terminated.

8.

For NA applications refer to (Appendix E) and (Appendix G) for values of test voltage, method and acceptable insulation resistance values. For other locations refer to (Appendix F) and (Appendix H).

Cable joint s and termination s

1.

QA hold and witness points shall be provided for supervisor inspection via an agreed

2.

Inspection and Test plan. Jointers / terminators shall provide valid certificates of competence for the specific joint / termination.

3.

The first work of a jointer / terminator at site shall be checked (destructive inspection) by a Vendor supervisor; subsequently the first 10 field joints / terminations shall be inspected.

4.

The jointer / terminator shall sign their name on the completed joint / termination worksheet for traceability and ownership of the completed work, for recording by the Contractor.

VARIABLE SPEED DRIVE SYSTEMS (VSDS)/ ADJUSTABLE SPEED DRIVE SYSTEMS (ADSD) Refer to DEP 63.10.08.91-Gen., Forms 17.

4.11.1

4.11.2

General

1.

VSDS/ASDS and, if appropriate excitation controls, shall be commissioned fully in accordance with the Manufacturer's instructions. For complex equipment, the Manufacturer’s representatives will normally be used to supervise or undertake the commissioning activities.

2.

All protection devices which perform a trip, alarm or control function shall be functionally tested up to and including the operation of the final 'device'.

3.

On completion of commissioning, a list of all equipment set points and parameters shall be recorded and attached to the relevant equipment records in the electrical equipment database.

Testing

1.

The testing of large variable speed drives should form part of the purchase requisition due to difficulty, cost andin complexity of testing. The tests should to be performed on-site should be included this protocol. Reference be made to DEP 33.66.05.33-Gen. for more guidance on testing of VSD/ASD systems. (DEP 33.66.05.32-Gen. for NA applications).


Testing of smaller VSD/ASD systems (typically those not covered DEP 33.66.05.33-Gen. or DEP 33.66.05.32-Gen. for NA) should follow Manufacturer’s recommendations.

3.

Testing of smaller VSD/ASD systems shall include as a minimum: a.

setting of site-specific parameters

b.

full load trials, including auto-restart and voltage dip ride through

c.

full load noise tests throughout the speed range

d.

full load vibration tests throughout the speed range

4.12.

UNINTERRUPTIBLE POWER SUPPLY (UPS)

4.12.1

General

4.12.2

by the

1.

UPS shall be commissioned fully in accordance with the Manufacturer's instructions. For complex equipment, the Manufacturer’s representatives will normally be used to supervise or undertake the commissioning activities.

2.

All protection devices which perform a trip, alarm or control function shall be functionally tested up to and including the operation of the final 'device'.

3.

On completion of commissioning, a list of all equipment set points and parameters shall be recorded and attached to the relevant equipment records in the electrical equipment database.

AC UPS Refer to DEP 63.10.08.91-Gen., Form 39.

4.12.3

1.

The inspection, testing and commissioning procedure shall follow the Manufacturer's instructions.

2.

The procedure shall include tests designed to confirm the static and dynamic performance of the equipment, including: a.

rectifier float charge voltage level

b.

rectifier boost charge voltage level

c.

operation of Inverter and By-pass in synchronism

d.

transfer of load from Inverter to By-pass and return

e.

when the rectifier is switched off, the battery accepts load and the UPS output remains within limits

f.

oscilloscope checks on the equipment's output waveform

DC UPS Refer to DEP 63.10.08.91-Gen., Form 40.

1.

4.12.4

The inspection, testing and commissioning procedure shall follow the specific test form. These tests are designed to confirm the performance of the equipment, including: a.

rectifier float charge voltage level;

b.

rectifier boost/equalize charge voltage levels;

c.

when the rectifier is switched off, the battery accepts load and the UPS output remains within limits.

Batteries Refer to DEP 63.10.08.91-Gen., Form 41.

1.

The tests are designed to confirm the performance of the battery, including:

DEP 63.10.08.11-Gen. February 2015 Page 26 a.

battery cell voltage and specific gravity measurements

b.

internal resistance and inter-cell resistance;

c.

battery discharge capacity test

2.

For flooded cell batteries, add cell temperature.

3.

Outside NA, an acceptance test of the battery capacity shall be performed in accordance with IEEE 450, IEEE 1106, IEEE 1188 or IEC 62040-3 to determine that the battery and installation meets design specifications.

4.13

EARTHING (GROUNDING) AND BONDING

4.13.1

General Refer to DEP 63.10.08.91-Gen., Forms 58, 59, 60, 61. The test numbers mentioned below are illustrated in (Appendix I). The drawing shows typical plant installation details and the appropriate test methods to be used for each installation.

1. 4.13.2

Measurements should be taken during normal ground moisture.

Electrical system earthin g (groundi ng)

1.

For bonding connections to the plant earth (ground) grid or connections between plant earth (ground) grids, a clamp-on meter should be used to determine earth (ground) loop resistance (refer to Appendix Ib)

4.13.3

2.

Test 1: For earth (ground) electrodes the earth (ground) loop resistance should be measured against the overall impedance of the plant earth (ground) grid with one of the earth (ground) cables disconnected (n-1). The resistance shall not exceed 4 Ω.

3.

If there is a suspect reading, a more accurate resistance test should be done using the potential fall test shown in (Appendix Ia).

4.

Test 2, Test 3: All earth (ground) connections between the electrode, the supply neutral and the plant earth loop shall be tested for continuity.

5.

Test 4: All earth (ground) connections between switchboards, transformers and the substation earth (ground) bar shall be tested for continuity.

6.

The earth (ground) loop impedance of all power and convenience outlets shall be measured using an appropriate 'earth (ground) loop tester'.

7.

Where protection is by fuses, the impedances measured should allow a maximum 0.4 second disconnection time for portable equipment and a maximum of 5 seconds for fixed installations.

8.

Tests on lighting and small power circuits shall be performed on each circuit at a point furthest from supply point. Where the circuit has short spurs only with limited numbers of fittings from the main circuit route, it is not necessary to test individual spurs. Where there are significant numbers of junction boxes in spur circuits, then this test shall be repeated from ends of spur circuits as well as at the end of the main circuit.

9.

Where protection is by earth leakage circuit breakers/ground fault circuit interrupters, the test currents and operating times shall be as determined by the circuit breaker characteristics.

Instrument earth (ground) (if prov ided) There may be a separate telecom and/or instrument earth (ground) system with their own earth (ground) bars within FARs/CCRs, with a connection (inside the FAR/CCR) to the electrical earth (ground) bar, with NO connection to a separate external earth (ground) electrode.

1.

Test 5, Test 6: All earth (ground) connections, between the instrument earth (ground) bar and the electrical earth (ground) bar, shall be tested for continuity.


Equipment external earth (ground )

4.13.4.1 Process plant non-electrical equipment 1.

For bonding connections to the plant earth (ground) grid or connections between plant earth (ground) grids, a clamp-on meter should be used to determine earth (ground) loop resistance, refer to (Appendix Ib).

2.

Test 7: Sample measurements shall be taken (5 % of the total) to verify the continuity of the equipment's external earthing (grounding) cable (with the cable disconnected from the equipment) and any adjacent earthing (grounding) cable (also disconnected from its equipment).

4.13.4.2 Process plant electrical equipment, (motors, heaters, etc.)

4.13.5

4.14

1.

Test 8: Measurements shall be made on the earth (ground) return path of all electrical equipment having an external earth (ground) connection.

2.

Measurements shall be made with the equipment in operational condition and all cables connected. The earth (ground) return impedance shall be measured between the body of the equipment and the substation earth (ground) bar, using a conductivity meter and a calibrated cable.

3.

Results shall be evaluated on a comparative basis to identify any abnormal readings.

4.

Earth (ground) loop impedance shall be such as to allow the protective device to

5.

operate before damage to the cable occurs. For motor circuits with earth (ground) leakage protection, this calculation shall be based upon operation of the fuse or mcb protection.

Earth (ground) for light ning and static disch arge

1.

Test 9: For earth (ground) electrodes the earth (ground) loop resistance should be measured against the overall impedance of the plant earth (ground) grid with one of the earth (ground) cables disconnected (n-1). The resistance shall not exceed 10 Ω.

2.

Test 10: All earth (ground) connections between the electrode and the plant earth (ground) grid shall be verified for continuity.

BUILDINGS See DEP 63.10.08.91-Gen., Forms 1, 3, 63 and various other forms as needed.

1.

Plant buildings and non-plant buildings (i.e., offices, warehouses, gatehouses, workshops, etc.) shall be treated in the same manner as plant equipment and be subject to pre-commissioning and commissioning procedures.

2.

The Contractor shall have knowledge of the relevant local regulations applying to the country of the installation and conform to these requirements. Where there are no specific local regulations, then the Contractor shall propose and obtain agreement of the Principal of the testing programme to be followed.

3.

The scope of the pre-commissioning and commissioning activities covers all electrical equipment and systems, including the following: a.

Purge systems;

b.

Lighting shall include normal, emergency and escape lighting systems. Refer to (4.15) and DEP 63.10.08.91-Gen., Form 44;

c.

Switchboards and associated transformers (DEP 63.10.08.91-Gen., Form 43);

d.

Earthing (grounding) systems, refer to (4.13);

e.

Convenience outlets, refer toDEP 63.10.08.91-Gen., Form 44);

f.

HVAC electrical equipment;

DEP 63.10.08.11-Gen. February 2015 Page 28 g.

Power cables, lighting circuits and receptacle circuit conductors, Refer to (4.11) and DEP 63.10.08.91-Gen., Form 48.

h.

Miscellaneous electrical equipment:

4.15

LIGHTING

4.15.1

General

i.

Uninterruptible power supplies (DEP 63.10.08.91-Gen., Forms 39 and 40);

ii.

Automatic transfer/bypass switches (DEP 63.10.08.91-Gen., Form 21);

iii.

Battery systems (DEP 63.10.08.91-Gen., Forms 40 and 41).

Refer to DEP 63.10.08.91-Gen., Forms 43 and 44.

4.15.2

1.

For hazardous area lighting, 100 % checks shall be made as described in (4.1.1).

2.

One Inspection (DEP 63.10.08.91-Gen., Form 1, 3 or 4) per equipment type and per area shall be completed.

3.

For lighting in unclassified areas, spot checks on 5 % (minimum) of the total shall be made. If any faults are found, the inspection shall be suspended and the Installation Contractor asked to check the entire installation and correct any faults found. Inspection may then be restarted with a fresh 5 % sample, and if necessary, the cycle repeated.

4.

The activities shall include a record of measured illumination levels. Luxmeter readings shall be taken at the working plane or 1 m above the floor level in a horizontal plane and entered on a suitable plot or building plan.

5.

The illumination levels shall be as specified in Appendix 4 of DEP 33.64.10.10-Gen., Section 4.15.1 of DEP 33.64.20.10-Gen. or as specified by the Principal.

Emergency and escape light ing

1. 4.15.3

Navigation and obstru ction light ing

1.

4.16

The operation and autonomy time of all Emergency and Escape lighting systems shall be verified by testing.

Correct operation of navigation and obstruction lighting and audible warning systems shall be tested as per regulatory requirements.

ELECTRIC HEAT TRACING Refer to DEP 63.10.08.91-Gen., Form 65.

1.

Testing of all electric heat tracing cables shall be carried out while isolated from the power supply circuits. Heat tracing cable ends shall be kept sealed under all circumstances to prevent moisture ingress.

2.

Insulation resistance test for heat tracing cables shall be conducted (phase to braid) for the following situations: a.

When the cables are received at the job site before installation.

b.

After the cables are installed, but before insulation is applied.

c.

After insulation is applied.

3.

Insulation resistance test voltages for heat tracing cable shall be in accordance with (Appendix E) for NA and (Appendix G) for other locations.

4.

Control panels shall be inspected to verify that they are complete with all components installed. Controllers shall be programmed with design parameters.


4.17

5.

Skin effect heat tracing systems shall be tested in accordance with the Manufacturer’s/Supplier’s instructions. Heat tube and connecting conductor test results shall be recorded.

6.

In addition to all checks as given in the appropriate inspection and test form, a full check shall be performed to demonstrate that all features of the control system function as intended.

7.

Transformers, panel boards and associated power systems should be tested in accordance with (4.20).

8.

Insulation systems are a critical part of the heat tracing system. Proper insulation methods should be verified.

9.

The monitoring system of heat tracing systems on safety critical elements shall be tested and when possible, demonstrated to achieve the correct operating temperature.

ELECTRICAL PROCESS HEATERS Refer to DEP 63.10.08.91-Gen., Form 66.

1.

The Contractor / Manufacturer shall submit a test plan detailing all such tests and showing required interfaces with third parties, for approval by the Principal. Refer to DEP 33.68.30.33-Gen.

2.

The following electrical tests shall be carried out: a.

Insulation test of heaters to earth with a 500 V DC insulation resistance tester;

b.

Continuity to be tested on each phase of the heater.

3.

In addition to all checks as given in the appropriate inspection and test form, a full check shall be performed to confirm operation of the control and protection system.

4.

The power control assembly should be tested in accordance with (4.20).

5.

A full load test of the heater in its service condition shall be carried out to confirm the design output. In addition, interfaces to other connected systems shall be tested with particular emphasis on control, protection and alarm systems.

4.18

CABLE SUPPORT SYSTEMS

4.18.1

Cable tr ay

1.

Refer to DEP 63.10.08.91-Gen., Form 55. Cable tray systems inspections for proper materials and installation shall include:

a.

Cable tray size and material

b.

Cable tray supports

c.

Hold downs and anchoring

d.

Cable tray grounding

e.

Expansion joints

f.

Bonding jumpers

g.

Cable tray covers where applicable

h.

Cable tray separation shall be provided for the following situations: i. ii.

Between instrument trays and power trays From hot services

iii.

Vertical spacing between cable trays

iv.

Stainless steel cable trays and galvanised steel.

DEP 63.10.08.11-Gen. February 2015 Page 30 i. 4.18.2

Proper tagging

Abovegro und condu it Refer to DEP 63.10.08.91-Gen., Form 53.

1.

2.

4.18.3

Conduit systems inspection for proper materials and installation shall include: a.

Conduit supports

b.

Proper bend radius

c.

Conduit grounding

d.

Expansion fittings

e.

Bonding jumpers

f.

Seals and drains

g.

Proper tagging

Conduit separation shall be provided for the following situations: a.

Between instrument conduits

b.

From hot services

Underground condu it (duct banks) Refer to DEP 63.10.08.91-Gen., Form 54.

1.

Underground conduit systems shall be inspected before and after concrete pour or backfill.

2.

Prior to concrete pour or backfill the following shall be verified/inspected:

3. 4.18.4

Location, elevation and forming

b.

Conduit size and type

c.

Conduit spacing

d.

Conduit stub ups

e.

Proper bend radius

After concrete is poured or backfilled, coverage and stub ups shall be verified.

Electri cal manho les Refer to DEP 63.10.08.91-Gen., Form 56.

1.

4.19

a.

Electrical manholes shall be inspected before and after concrete pour or backfill. Prior to concrete pour or backfill, the following shall be inspected: a.

Proper opening sizes

b.

Conduit window locations

c.

Grounding

d.

Conduit sizes and type

e.

Sump or drain

OVERHEAD POWER LINES AND OUTDOOR SWITCHYARDS

1.

Refer to DEP 63.10.08.91-Gen., Form 67. Inspection criteria and responsibility shall be clearly defined at the time of contract award. Measurements and inspections include:

a.

conductor tension (during and after pulling)

b.

conductor sag (temperature corrected);

DEP 63.10.08.11-Gen. February 2015 Page 31 c.

conductor to ground clearance (temperature corrected) at critical points (e.g., road crossings)

d.

resistance across line compression joints and termination fittings

e.

structural alignment (poles in line and upright)

f.

resistance to earth (ground) of static earth wires, guys, structures, lightning arrestors, etc.

g.

Installation of large orange signs at grade (where overhead power lines cross roadways) in both directions warning of Overhea d Power Lin es .

It is common practice for the Contractor responsible for erection of the overhead power lines to also carry out the inspection required during erection.

4.20

2.

The Contractor shall be required to submit to the Principal for approval a procedure for stringing/tensioning the line.

3.

Prior to energisation, the entire line and associated equipment shall be checked visually and the insulation resistance of the line recorded. It is often not possible to arrange for high potential testing of the line and in this case, insulation resistance measurements may be made using a 5 kV insulation tester.

MISCELLANEOUS LOW VOLTAGE EQUIPMENT Refer to DEP 63.10.08.91-Gen., Forms 43, 44 and 45. LV equipment includes transformers, panel boards, receptacles and control panels, etc.

1.

4.21

LV equipment should be inspected for proper installation which includes: a.

Proper mounting and support.

b.

Proper grounding to cases and to the earth (ground) grid.

c.

Properly installed conduit and/or cable terminations to the enclosure.

d.

Proper wire terminations.

2.

Low voltage equipment should be checked for proper connection per the one-line diagrams, schematic diagrams and wiring diagrams. This can also include Manufacturer/Supplier drawings. Cable types and sizes should be verified. The equipment should also be verified for proper voltage levels and short circuit capabilities, as applicable.

3.

Wire terminations to equipment should be checked for tightness. a.

Connections of power cables should be checked with a calibrated torque wrench, refer to (Appendix M).

b.

A simple pull test of the wire will determine that the wire is properly terminated on a terminal block in a control panel.

4.

Verify that panel boards have complete and accurate schedules at the panel board.

5.

Testing of low voltage equipment will primarily consist of insulation resistance tests. (Appendix E) and (Appendix G) show proper test voltages and insulation resistance values for NA applications. For other locations, use (Appendix F) and (Appendix H).

6.

Function checks of the equipment should be carried out as is applicable for the type of equipment.

ELECTRICAL NETWORK MONITORING AND CONTROL (ENMC) SYSTEM COMMISSIONING 1.

DEP 33.64.10.32-Gen. shall serve as guidance on commissioning of EMNC systems.

2.

In principle, the inter-operation of the components forming the systems shall be proven during Factory Acceptance Testing before erection at site. The site-specific tests shall

DEP 63.10.08.11-Gen. February 2015 Page 32 demonstrate the site installed communication wiring or fibre optic components are operating correctly, and then confirm that the systems are communicating correctly. 3.

4.22

Thereafter, the system DEP 33.64.10.32-Gen.

testing

shall

follow

recommendations

given

in

INTEGRATED MOTOR CONTROL SYSTEM (IMCS) COMMISSIONING 1. 2.

DEP 33.67.01.31-Gen. shall serve as guidance on commissioning of IMCS systems. The switchgear assembly including the IMCS shall be subjected to a full routine test before erection at site. The site-specific tests shall demonstrate the site installed communication wiring or fibre optic components are operating correctly, and then confirm that the systems are communicating correctly.

3.

Thereafter, the system DEP 33.67.01.31-Gen.

testing

shall

follow

recommendations

given

in


REFERENCES

In this DEP, reference is made to the following publications: NOTES:

1. Unless specifically designated by date, the latest edition of each publication shall be used, together with any amendments/supplements/revisions thereto. 2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell Wide Web) at http://sww.shell.com/standards/.

SHELL STANDARDS

Global technical standards index

DEP 00.00.05.05-Gen.

DEP feedback form

DEP 00.00.05.80-Gen.

Electrical engineering design

DEP 33.64.10.10-Gen.

Electrical network monitoring and control system for industrial networks

DEP 33.64.10.32-Gen.

Electrical engineering design for North American application

DEP 33.64.20.10-Gen.

Synchronous AC machines (amendments/supplements to IEC 60034-1)

DEP 33.65.11.31-Gen.

Synchronous AC machines for North American application (amendments/supplements to API 546)

DEP 33.65.11.34-Gen.

Electrical machines - Cage-induction types (amendments/supplements to IEC 60034-1 and IEC 60034-14)

DEP 33.66.05.31-Gen.

AC electrical adjustable speed drive systems - Rated 375 KW and larger for North American application (amendments to IEEE STD 1566:2005)

DEP 33.66.05.32-Gen.

AC electrical variable speed drive systems

DEP 33.66.05.33-Gen.

MV induction motors for North American application (amendments/supplements to API 541)

DEP 33.66.05.36-Gen.

General-Purpose Form-Wound Squirrel Cage Induction Motors – 250 Horsepower and Larger for North American Application (Amendments/Supplements to API 547)

DEP 33.66.05.37-Gen.

Low voltage switchgear and controlgear assemblies (amendments/supplements to IEC 61439)

DEP 33.67.01.31-Gen.

Electrical process heaters

DEP 33.68.30.33-Gen.

Field Commissioning and Testing of Electrical Systems and Equipment for North American Application withdrawn

DEP 63.10.08.14-Gen.

Field commissioning and testing of electrical systems and equipment (Inspection and Test Forms)

DEP 63.10.08.91-Gen.

Electrical safety rules

DEP 80.64.10.10-Gen.

Static electricity

DEP 80.64.10.11-Gen.

Project Guide 14b: Commissioning and Start up

PG 14b

https://eu015sp.shell.com/sites/IPMS/Lists/IPMS%20Images/Standards%20and%20Guides.htm

GoCCMS - Certification and Completions Management System

GoCCMS

http://sww.go-ccms.shell.com/Userlogin.aspx

AMERICAN STA NDARDS

Design, Installation, and Maintenance of Electrical Systems for Fixed and Floating Offshore Petroleum Facilities for Unclassified and Class 1, Division 1 and Division 2 Locations

API RP 14F


Recommended Practice for Design and Installation of Electrical Systems for Fixed and Floating Offshore Petroleum Facilities for Unclassified and Class I, Zone 0, Zone 1 and Zone 2 Locations

API RP 14FZ

Electrical installations in petroleum processing plants

API RP 540

Form-Wound Squirrel-Cage Induction Motors—500 Horsepower and Larger

API STD 541

Brushless Synchronous Machines - 500 kVA and Larger

API STD 546

General-purpose Form-wound Squirrel Cage Induction Motors 250 Horsepower and Larger

API STD 547

Standard test method for dielectric breakdown voltage of insulating liquids using disk electrodes

ASTM D877

Standard practice for sampling electrical insulating liquids - reinstated

ASTM D923

Standard test method for water in insulating liquids by Coulometric Karl Fischer titration

ASTM D1533

Standard test method for dielectric breakdown voltage of insulating oils of petroleum srcin using VDE electrodes

ASTM D1816

Standard test method for analysis of gases dissolved in electrical

ASTM D3612

insulating oil by gas chromatography Recommended Practice for Electrical Installations on Shipboard

IEEE 45

Guide for Field Testing of Shielded Power Cable Systems Using Very Low Frequency (VLF) (less than 1 Hz)

IEEE 400.2

Recommended practice for maintenance, testing, and replacements of vented lead-acid batteries for stationary applications

IEEE 450

Petroleum and Chemical Industry—Premium- Efficiency, Severe-Duty, Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors— Up to and Including 370 kW (500 hp)

IEEE 841

Recommended practice for electrical impedance, induction, and skin effect heating of pipelines and vessels

IEEE 844

Recommended Practice for Installation, Maintenance, Testing, and

IEEE 1106

Replacement of Vented Nickel-Cadmium Batteries for Stationary Applications Recommended Practice for Maintenance, Testing, and Replacement of Valve-Regulated Lead-Acid (VRLA) Batteries for Stationary Applications

IEEE 1188

National Electrical Code

NFPA 70

Standard for Purged and Pressurized Enclosure for Electrical Equipment

NFPA 496

CANADIAN STANDARDS

Canadian Electrical Code

CSA C22.1

INTERNATIONAL STANDARDS

Rotating Electrical Machines - Part 1:Rating and performance Rotating Electrical Machines - Part 5: Degrees of protection provided by the integral design of rotating electrical machines (IP code)

IEC 60034-1 IEC 60034-5

Rotating Electrical Machines - Part 16: Excitation Systems for Synchronous Machines - Section 3: Dynamic Performance - Edition 1

IEC 60034-16-3


International Electrotechnical Vocabulary

IEC 60050

Explosive atmospheres – Part 14: Electrical installations design, selection and erection

IEC 60079-14

Explosive atmospheres - Part 17: Electrical installations inspection and maintenance

IEC 60079-17

Insulating Liquids - Determination Frequency - Test Method – Editionof2 the Breakdown Voltage at Power

IEC 60156

Mineral Insulating Oils in Electrical Equipment – Supervision and Maintenance Guidance

IEC 60422

Power cables with extruded insulation and their accessories for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) – Part 1: Cables for rated voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um = 3,6 kV)

IEC 60502-1

Classification of Degrees of Protection Provided by Enclosures

IEC 60529

Power cables with extruded insulation and their accessories for rated voltages above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) – Test methods and requirements

IEC 60840

Uninterruptible power systems (UPS) – Part 3: Method of specifying the performance and test requirements

IEC 62040-3

High-voltage switchgear and controlgear – Part 1: Common specifications

IEC 62271-1

Mechanical vibration of rotating and reciprocating machinery Requirements for instruments for measuring vibration severity

ISO 2954

DEP 63.10.08.11-Gen. February 2015 Page 36 APPENDIX A

INSPECTION AND TEST FORMS INDEX

This list refers to DEP 63.10.08.91-Gen. which is a requisition for inspection and test forms. The form numbers listed in column 1 correspond to form numbers accessed within DEP 63.10.08.91-Gen. In column 2: MC means that the form has a Mechanical Completion test part. PC means that the form has a Pre-Commissioning test part. CM means that the form has a Commissioning test part. Form

Form Form Form Form

Test Part

1 2 3 4

- MC - MC - MC

Title of form General Electrical Equipment Receiving Checklist Inspection and Testing - Insulation Resistance Inspection of Electrical Equipment Inspection of Certified and Hazardous Area Equipment Switchgear

Form 5

- MC- PC

Form 6

- MC- PC

Form 7 Form 8

- MC- PC

Inspection and Testing of Switchgear Inspection and Testing of Medium Voltage Power Circuit Breaker and Cubicles Inspection and Testing of Low Voltage Power Circuit Breaker and Cubicles Future Transformers

Form 9 Form 10

- MC- PC

Inspection and Testing of Liquid-Immersed Power Transformers Future

Form 11 Form 12

- MC

Bus Duct Inspection and Testing of Bus Ducts Future

Form 13 Form 14

- MC- PC - MC- PC

Form 15

- MC- PC

Form 16

- MC- PC

Form 17 Form 18

- MC- PC

Motor Control Inspection and Testing of Medium-Voltage MCC Line-Ups Inspection and Testing of Medium-Voltage Motor Starters

Inspection and Testing of Low-Voltage MCC Line-Ups and Switchracks Inspection and Testing of Low-Voltage Motor Starters, Circuit Breakers and Switches Inspection and Testing of Low Voltage Adjustable Speed Drives Future

Form 19

- MC

Switches Inspection and Testing of Medium-Voltage Metal Enclosed Air Switches

Form 20

- MC

Inspection and Testing of Low-Voltage Disconnect Switches


Form

Test Part

Title of form

Form 21 Form 22

- MC

Inspection and Testing of Automatic Transfer Switches (ATS) Future Motors

Form 23

- MC- PC

Form Form Form Form Form

- MC- PC - MC- PC

24 25 26 27 28

Inspection and Testing of Medium Voltage Induction Motors Inspection and Testing of Medium Voltage Synchronous Motors Inspection and Testing of Low Voltage Induction Motors Inspection and Testing - Dielectric Absorption Future Future Generators

Form 29

- MC- PC

Form 30

- CM

Form 31 Form 32

- CM

Inspection and Testing of Synchronous Generators and Control Panels Synchronous and Dynamic Testing of Synchronous Generators Inspection and Testing of Black Start/Emergency Generators Future Relays, Current Transform ers and Potential Transformers

Inspection and Testing of Current Transformers (Single Ratio) Inspection and Testing of Current Transformers (Multi Ratio)

Form 33

- MC

Form 34

- MC

Form 35

- MC

Inspection and Testing of Voltage (Potential) Transformers Inspection and Testing of relay with Overcurrent and

Form 36

- MC

Form 37

- MC

Undervoltage Function Future - New Inspection and Testing of relay with Differential Function AC UPS, DC UPS and Bat ter ies

Form Form Form Form

39 40 41 42

- MC- PC - MC- PC - MC- PC

Inspection and Testing of Uninterruptible Power Supply (AC UPS) Inspection and Testing of Battery Chargers (DC UPS) Inspection and Testing of Batteries and Battery Racks Future Misc. Low Voltage E quip ment

Form 43 Form 44

- MC- PC - MC- PC

Form 45 Form 46 Form 47

- MC- PC

Inspection and Testing of Low Voltage Panelboards and Associated Transformers Inspection and Testing of Lighting and Receptacles Inspection and Testing of Control Panels and Control Wiring Future Future


Form

Test Part

Title of form

Form 48

- MC- PC

Wire and Cable Inspection and Testing of Low-Voltage Cable and Wire

Form 49

- MC- PC

Inspection and Testing of Medium-Voltage Cable and Wire

Form 50 Form 51 Form 52

- MC

Inspection and Testing - DC High Potential Inspection and Testing of Direct Buried Cable Future

53 54 55 56 57

- MC - MC - MC - MC

Conduit and Cable T ray Inspection of Aboveground Conduit Systems Inspection of Underground Conduit Systems (Ductbanks) Inspection of Cable Tray Systems Inspection of Electrical Manholes Future

Form 58 Form 59

- MC - MC

Form 60

- MC

Form 61 Form 62

- MC

Form Form Form Form Form

Earthing/Grounding Inspection and Testing of Earthing/Grounding Systems Inspection and Testing of Earthing/Grounding Electrodes Inspection and Testing of High Resistance Grounding Equipment

Inspection and Testing of Low Resistance Grounding Equipment Future Substa tion Build ings

Inspection of Power Distribution/Substation Buildings (Including Transformer Yard) Future

Form 63 Form 64

- MC

Form 65

- MC- PC

Heat Tracing Systems Inspection and Testing of Electric Heat Tracing Systems

Form 66

- MC- PC

Inspection and Testing of Electric Heater (including control unit)

Form 67 Form 68

- MC- PC

Overhea d Lines Inspection and Testing of Overhead Power Lines Future

DEP 63.10.08.11-Gen. February 2015 Page 39 APPENDIX B

NOMOGRAM FOR TEMPERATURE CORRECTION

Example:

Measured resistance: 100 MΩ

Temperature at measurement: 20 °C (1000-6600 V) Corrected resistance: 70 MΩ


APPENDIX C

TYPICAL CURVES FOR VARIA TION OF INSUL ATION RESIST ANCES

Change in one-minute and ten-minute insulation resistance during the drying process of a class B insulated alternating current armature winding. Initial winding temperature 25 °C (77 F). Final winding temperature 75 °C (167 F). °

°


APPENDIX D

NOTES:

GENERATOR SYNCHRONIZING SYSTEM TESTING

1.

Test 1, verify in-phase indication of synchroscope, check sync and voltmeter.

2.

Using a phase rotating meter (A), verify identical phase rotation for tests 1 and 2.

3.

Test 2 with generator energised, verify that synchroscope, voltmeter, auto and check sync relays follow the 'beat frequency'.

DEP 63.10.08.11-Gen. February 2015 Page 42 APPENDIX E

E.1

CABLES 1.

E.1.1

E.1.2

RECOMMENDED TEST VOL TAGES FOR TESTING AND COMMISSIONING FOR NA APPLICATIONS

Carry out insulation resistance tests and high potential tests between each phase and ground with the remaining phases connected to ground and loads disconnected.

Insulation resistance tests System Voltag e

Test Voltage (DC)

LV up to 1kV

1000

MV up to 5 kV

2500

MV 5 kV and above

5000


1.

DC test voltages are applied to discover gross problems such as incorrectly installed accessories or mechanical damage. a.

New cables – DC Testing Maximum DC Field Test Voltages, kV

Rated Voltage kV

NOTE:

100 % Insulation Level


5

28

36

8

36

44

15

56

64

25

80

96

35

100

124

When older cables or other types/classes of cables or accessories are connected to the system, voltages lower than those shown m ay be necessary.

b.

New cables – AC Testing AC Tes t Vo lt age, k V

Rated Voltage kV

Conductor Size AW G or kcmil



5

8 - 1000

18

23

5

1001 - 3000

28

28

8

6 - 1000

23

28

8

1001 - 3000

35

35

15

2 - 1000

35

44

15

1001 - 3000

44

44

25

1 - 3000

52

64

35

1/0 - 3000

69

84

DEP 63.10.08.11-Gen. February 2015 Page 43 E.1.3

Partial dis charg e test Partial Discharge Requirements f or Semicon ducti ng Coating and Tape D esigns Only Rated Circui t Volt age Phase – to – Phase Volts

E.1.4

Minimum Partial Discharge Extinction Level, KV 100 %Level Insulation

133 %Level Insulation

2001 – 5000

4

5

5001 – 8000

6

8

8001 - 15000

11

15

VLF test VLF Te sting Levels 0.1 Hz Test Volt age (rms)

E.1.5

System Voltage Phase – to – Phase

Proof Phase – to – Ground

(kV) (rms)

(kV) (rms)

5

10

15

22

25

33

35

47

Heat tracing insul ation resistance tests Cable Type

DC Test Voltage, V

Self regulation

2500

MI

1000

Flexible pad heaters

500

E.2

MOTORS, GENERATORS, TRANSFORMERS (COIL WOUND EQUIPMENT)

E.2.1

Insulation resistance tests

1. E.3

Use values given in (E.1.1).

SWITCHGEAR 1.

High potential tests and insulation tests on bus bar systems shall be performed between each phase and ground with the remaining phases connected to ground (voltage transformers and load disconnected).

2.

High potential tests and insulation resistance tests on circuit breakers and contactors may be carried out together with or separately from the bus bar and shall be carried out with the breaker/contactor closed, with loads disconnected.

DEP 63.10.08.11-Gen. February 2015 Page 44 E.3.1

High potential test volt ages Type of Switchgear

Rated Maximum Voltage (kV) (rms)

Low-Voltage Power Circuit Breaker

Maximum Test Voltage kV AC

DC

.254/.508/.635

1.6

2.3

4.76

14

20

8.25

27

37

15

27

37

27

45

Note 1

38

60

Note 1

Switchgear

Metal-Clad Switchgear

NOTE 1:

E.3.2

Insulation resistance test voltages

1. E.4


NON-SEGREGATED BUS DUCT 1.

E.5.1

High potential tests on capacitor units shall exclude the cable and be performed between each phase to ground with the remaining phases connected to earth.


1. E.5


CAPACITORS 1.

E.4.1

The Manufacturer/Supplier should be contacted for recommendations before applying DC withstand tests.

Insulation resistance tests and high potential tests shall be performed between each phase and ground with the remaining phases connected to ground and loads disconnected.

High potential test volt ages Type of Bus

Rated Voltage (kV)

Nonsegregated Phase

E.5.2


1.


Maximum Test Voltage kV

.254/.508/.635

AC 1.6

DC 2.3

4.76

14.2

20

15

27

37

25.8

45

63

38

60

-


APPENDIX F

F.1

CABLES 1.

F.1.1

F.1.2

RECOMMENDED TEST VOL TAGES FOR COMM ISSIONING FOR NON-NA APPL ICATIONS

Insulation resistance tests and high potential tests shall be carried out between each phase and earth with the remaining phases connected to earth and loads

disconnected. Insulation resistance tests System Voltage

Test Voltage

LV 50 V - 1 kV

500 V (DC)

HV up to 4.6 kV

2500 V (DC)

HV above 4.6 kV

5000 V (DC)


1.

New Paper Insulated Cables

Duration: 3 minutes

2.

Cable Volt age De signatio n kV (AC) UO/U (Um )

Test Voltage kV (DC)

< 1.0

IR test only

1.8/3 (3.6)

10

3.6/6 (7.2)

15

6/10 (12)

25

8.7/15 (17.5)

35

12/20 (24)

50

18/30 (36)

70

New polymeric (e.g., cross linked polyethylene (XLPE) insulated cables

Duration: 15 minutes

Cable Volt age De signatio n kV (AC) UO/U (Um)

Test Voltage kV (AC)

< 1.0

IR test only

1.8/3 (3.6)

7kV DC

3.6/6 (7.2)

7.2

6/10 (12)

12

8.7/15 (17.5)

17.5

12/20 (24)

24

18/30 (36)

36

NOTE 1:

If VLF is used, the test voltage is 3 x UO


Cables specifically manufactured for unearthed systems, i.e. Uo = U, shall be tested at the value given above for U o. e.g., cable type 3/3 (3.6) should be tested at 11 kV. Uo is the rated power-frequency voltage between conductor and earth or metallic screen, for which the cable is designed. U is the rated power frequency voltage between conductors, for which the cable is designed. Um is the maximum value of the 'highest system voltage' for which the equipment may be used.

4. F.1.3

DC sheath integrit y test

1.

F.2 F.2.1

F.3

F.3.1

For AC test, the frequency is chosen between 0.1 Hz (VLF) up to power system frequency. (Refer to IEEE 400.2, IEC 60502-1, IEC 60502-2, IEC 60840).

After installation, all the sheaths shall be tested for one minute at a voltage level according to the thickness of the sheath of the cable as follows: a.

Extruded PVC or polyethylene: 4 kV DC per mm of thickness with a maximum of 10 kV DC

b.

The minimum average thickness shall be used to calculate the voltage test.

MOTORS, GENERATORS, TRANSFORMERS (COIL WOUND EQUIPMENT) Insulation resistance tests System Voltage

Test Voltage

LV below 1 kV

500 V (DC)

HV up to 4.6 kV

2500 V (DC)

HV above 4.6 kV

5000 V (DC)

SWITCHGEAR 1.

High potential tests and insulation tests on busbar systems shall be performed between each phase and earth with the remaining phases connected to earth (voltage transformers and load disconnected).

2.

High potential tests and insulation resistance tests on circuit breakers and contactors may be carried out together with or separately from the busbar and shall be carried out with the breaker/contactor closed, with loads disconnected.

High potential test voltages Duration: 1 minute

Max System Voltage kV

3.6

7.2

12

17.5

24

36

Test Volt age kV (DC )

10

20

28

38

50

70

DEP 63.10.08.11-Gen. February 2015 Page 47 F.3.2

F.4

Insulation resistance test voltages Test Voltage

LV systems

500 V (DC)

HV systems up to 4.6 kV

2500 V (DC)

HV systems above 4.6 kV

5000 V (DC)

CAPACITORS 1.

F.4.1

System Voltage

High potential tests on capacitor units shall exclude the cable and be carried out between each phase to earth with the remaining phases connected to earth.

High potential tests (commiss ionin g only) Duration 10 s, after stabilisation of charge current. Highest System Voltage kV (AC)

1.0

3.6

7.2

12

17.5

Test Volt age kV (DC)

1.0*

10

20

28

38

1*: LV capacitor banks and cables shall not be HV tested, but insulation resistance tests shall be carried out. F.4.2


1.

Use values given in (F.3.2).

DEP 63.10.08.11-Gen. February 2015 Page 48 APPENDIX G

RECOMMENDED INSULATION VAL UES FOR EQUIPMENT OF NA APPL ICATIONS

Equipment type G.1 Switc MCCs hgear, Cable, Bu s Duct , Switches,

Minimum f or acceptance at commissioning

Insulation (MResistance Ω)

Nominal Rating of Cable in Volts -

600V

100

-

5000V

1000

-

8000V

2000

-

15000V

5000

-

25000V

20000

-

35000V

100000

G.2 Motors and G enera tors

-

Insulation Resistance above 1 kV

100 MΩ

-

Insulation Resistance below 1 kV

5 MΩ

-

PI

G.3 Transformers

2 Liquid Filled (MΩ)

Dry (MΩ)

Transformer Coil Rating Type in Volts

NOTES:

-

0 – 600V

100

500

-

601 – 5000

1000

5000

-

Greater than 5000

5000

25000

1. These values are considered the lowest acceptable to allow energization of new equipment. Corrective action shall be taken where lower values are found. 2. The above figures are to be used, unless local regulations are more stringent, in which case the latter shall prevail. 3. IR to be measured with load disconnected. 4. Test results are dependent on the temperature of the insulating material and the humidity of the surrounding environment at the time of the test. 5. Insulation-resistance test data may be used to establish a trending pattern. Deviations from the baseline information permit evaluation of the insulation. 6. Minimum insulation resistance values are given for 25 °C (77 °F) equipment temperature; apply corrections for differing temperatures. See (Appendix C).

DEP 63.10.08.11-Gen. February 2015 Page 49 APPENDIX H

RECOMMENDED INSULATION VAL UES FOR EQUIPMENT OF NON-NA APPL ICATIONS Minimum fo r acceptance at commissioning

H.1

Switchgear Insulation resistance: HV bus LV bus LV wiring

200 MΩ 20 MΩ 5 MΩ (NOTE 2)

H.2

Cables Insulation resistance: HV and LV

•

minimum length 100 m (NOTE 3)

H.3 H.3.1

Motor s and generators Polarization Index: LV and HV machines Class B and F

2.0 (6)

(NOTES 6 and 8)

H.3.2

Insulation resistance (at 25 °C) LV and HV machines:

10(kV+1) MΩ

(NOTES 4, 5, and 7)

H.4 H.4.1 H.4.2

Power transformers (max. 36 kV) OIL IMMERSED Insulation resistance:

75 MΩ

DRY TYPE Insulation resistance: HV side:

100 MΩ

LV side:

10 MΩ

H.5 H.5.1

Equipment and compon ents FIXED INSTALLATIONS Insulation resistance:

H.5.2 H.5.2.1

MOVABLE EQUIPMENT Hand Tools Insulation resistance Class I: Class II: Class III:

H.5.2.2

Distribution equipment (cables, distribution boards, transformers) Insulation resistance: NOTES:

5 kΩ/volt

2 MΩ 7 MΩ 2 MΩ

5 MΩ

1. These values are considered the lowest acceptable to allow energisation of existing equipment. Corrective action shall be taken where lower values are found. 2. The above figures are to be used unless local regulations are more stringent in which case the latter shall prevail. 3. IR to be measured with load disconnected. Example: Required value for maintenance (MΩ) is kV rating of cable/length in km. 4. Minimum insulation resistance values are given for 25 °C (77 °F) equipment temperature; apply corrections for differing temperatures.

DEP 63.10.08.11-Gen. February 2015 Page 50 5. For machines < 10 MVA energisation is possible if IR or PI is above the minimum given. 6. PI values below those given may be accepted if IR is > 100(kV+1) MΩ. 7. For test method and voltage see (Appendix F) 8. PI measurements on insulation class 'F' machines with IR in the GΩ range may be difficult to obtain due to meter scale compression.


APPENDIX I

TEST METHOD FOR EARTHING/GROUNDING SYSTEM - refer t o (4.13)

DEP 63.10.08.11-Gen. February 2015 Page 52 APPENDIX Ia

EARTH (GROUND) ELECTRODE RESIST ANCE

1

An alternating current of a steady value is passed between the earth electrode T and an auxiliary earth electrode T1 placed at such a distance from T that the resistance areas of the two electrodes do not overlap.

2

A second auxiliary earth electrode T2, which may be a metal spike driven into the ground, is then inserted half-way between T and T 1 and the voltage drop between T and T2 is measured.

3

The resistance of the earth electrodes is then the voltage between T and T2, divided by the current flowing between T and T 1, provided that there is no overlap of the resistance areas.

4

To check that the resistance of the earth electrodes is a true value, two further readings are taken with the second auxiliary electrode T 2 moved 6 m (20 ft) further from and 6 m (20 ft) nearer to T, respectively.

5

If the three results are substantially in agreement, the mean of the three readings is taken as the resistance of the earth electrode T. If there is no such agreement the tests are repeated with the distance between T and T 1 increased.

6

The test is made either with current at power frequency, in which case the resistance of the voltmeter used must be high (of the order of 200 Ω per volt), or with alternating current from an earth tester comprising a hand-driven generator, a rectifier (where necessary), and a direct-reading ohmmeter.

7

If the tests are made at power frequency the source of the current used for the test is isolated from the mains supply (e.g., by a double-wound transformer), and in any event the earth electrode T under test is disconnected from all sources of supply other than that used for testing.

Measurement of earth electrode resistance T

-

earth electrode under test, disconnected from all other sources of supply.

DEP 63.10.08.11-Gen. February 2015 Page 53 T1 -

auxiliary earth electrode.

T2 -

second auxiliary earth electrode.

X

-

alternative position of T2 for check measurement.

Y

-

further alternative position of T2 for check measurement.

DEP 63.10.08.11-Gen. February 2015 Page 54 APPENDIX Ib

EARTH ELECTRODE RESISTANCE USING CLAMP METERS

Earth/Ground clamp meters should have:

measurement of bonding of skid to plant earth/ground grid

Self-calibration Overload protection

measurement of earth/ground electrode against the impedance of the plant earth/ground grid

AC current measurement > 10 A

ski d

plant earth/ground grid

loop impedance Zb via bonding connections and plant earth/ground grid

Earthing/grounding impedance Zr of earth/ground rod against plant earth/ground grid impedance

Earthing / grounding electrode with inspection pit

DEP 63.10.08.11-Gen. February 2015 Page 55 APPENDIX J

EXAMPLES OF DELTA /STAR TRANSFORMER CONNECTION

DEP 63.10.08.11-Gen. February 2015 Page 56 APPENDIX K

K.1

TRANSFORMER OIL

OIL CONDITIONING AND SAMPLING 1.

The dielectric strength of the oil shall be tested before it is used to fill or top up the transformer.

2.

For the filling of the transformer, an oil filter/heater pump unit shall be used. The

3.

transformer shall be filled from the bottom drain valve and air released at the top. Heated oil shall be circulated/filtered for at least 48 h, after which the oil shall be tested. If the test result is unsatisfactory, the oil shall be circulated/filtered until a satisfactory test result is obtained. WARNING: Transformers rated < 66 kV are unlikely to be rated to withstand full vacuum; therefore care shall be taken before connection of any oil treatment equipment. Management of change shall be used to confirm that safe operation can take place.

K.2

K.3

K.4

5.

It is important that the sample valve be first thoroughly cleaned externally and then wiped with a clean material reasonably free from fibre, followed by a similar material soaked in oil.

6.

Finally, the valve should be flushed by draining off a sufficient quantity of oil to ensure that the sample obtained is representative of the oil at the bottom of the tank.

7.

Stoppered glass sampling bottles are recommended. They shall be absolutely clean and dry and should be rinsed with the first sample drawn.

8.

Tests should be carried out as soon as possible after drawing a sample.

ELECTRIC STRENGTH/DIELECTRIC BREAKDOWN VOLTAGE TESTING 1.

Tests shall be carried out using equipment with a gap of 2.5 mm (0.01 in) between electrodes.

2.

Each sample shall be tested 6 times to breakdown voltage level using equipment and methods in accordance with IEC 60156 and IEC 60422 (ASTM D877 or ASTM D1816 for NA applications).

3.

The electric strength of the oil shall be the arithmetic mean of the 6 tests and shall not be lower than 30 kV (27kV for NA applications).

TEST FOR MOISTURE 1.

If the oil sample fails the electric strength test, it may be due to moisture content, which may be simply tested by means of the 'crackle test' (whereby a metal rod is heated to a dull redness and lowered into the oil sample and stirred. Audible crackling will occur during the stirring if moisture is present in unacceptable quantities), or by means of the Coulometric Karl Fischer Titration test method per ASTM D1533.

2.

A typical specification value for new oil, as received from the Manufacturer/Supplier, is a maximum of 35 ppm.

DISSOLVED GAS ANALYSIS (DGA) 1.

For new installations it is recommended to carry out DGA testing using a specialist Contractor to provide baseline data for future reference.

2.

During evaluation of existing units if the inspection of the samples indicates deterioration of the oil or if the oil sample fails the dielectric breakdown voltage test, DGA should be applied to investigate the root cause of the deterioration.

3.

For NA applications, the DGA should be performed in accordance with ASTM D3612.

DEP 63.10.08.11-Gen. February 2015 Page 57 K.5

K.6

ACIDITY NEUTRALIZATION NUMBER 1.

Suggested acidity limits are as follows:

1.

< 0.5 mg KOH/g (< 500 ppm KOH)

-

No action necessary if oil is satisfactory in other respects.

2.

≥ 0.5 < 1.0 mg KOH/g

-

Increase testing frequency and filter oil.

3.

(≥ 500 < 1000 ppm KOH) ≥ 1.0 mg KOH/g (≥ 1000 ppm KOH)

-

Change oil; if condition is serious and is combined with heavy sludging then further treatment of the windings and core may necessary.

INSPECTION OF SAMPLES 1.

K.7

The colour of transformer oil is indicative of the condition of the oil. In new transformers, the acceptable colour range, (typically light amber) shall be compared against Manufacturer data sheets.

SLUDGING 1.

If severe sludging is present, then hot oil cleaning of the windings and core may be required.

DEP 63.10.08.11-Gen. February 2015 Page 58 APPENDIX L

VT AND CT FLICK TESTS

VT Flick test

V 6V

CT Flick test P2

S2

A

6V

P1

S1

1.

Applying lead with arrow causes kick of voltmeter in forward direction.

2.

Removal of lead causes kick in backward (negative direction).

3.

DC current should only be momentarily applied.


APPENDIX M

TORQUE VAL UE OF BOL TS FOR NORTH AMERICA N APPLICATION

NOTE:

This appendix is presented in USC units only

This Appendix contains stress area, proof load, clamp load and assembly torques (dry and lubricated) for threaded fasteners ranging in thread size from #4 to 4-½ in. nominal Unified thread size. Data is provided for grade 2, grade 5, grade 8 and grade 9 fasteners.

Grade Images

The following images have been provided for reference:

Grade 2

Grade 5

Grade 8

1.

The following table provides torque and stress information for threads.

2.

Values are determined using the following equations: • Clamp load = 75 % * Proof * stress area. •

Torque is R * D * T where: o

R = .200 (dry) or .150 (lubricated),

o

D = Nominal diameter (in), and

o

T = Desired clamp load (lbs).

“Lubricated” includes lubricants, lubrizing plating, and hardened washers. Ass emb ly Tor qu e Nominal Size or Basic of Major Diameter Thread

Stress Area in

2

Grade

Proof Load

ksi

lbs

Clamp Load in*lb

Dry in*lb

Lubricated

ft*lb

# 4-40

0.1120

.0060

2

55

248

5

4

# 4-40

0.1120

.0060

5

85

384

8

6

# 4-40

0.1120

.0060

8

120

542

12

9

# 4-48

0.1120

.0066

2

55

272

6

5

# 4-48

0.1120

.0066

5

85

421

9

7

# 4-48

0.1120

.0066

8

120

594

13

10

# 6-32

0.1380

.0091

2

55

374

10

7

# 6-32

0.1380

.0091

5

85

579

15

11

# 6-32

0.1380

.0091

8

120

817

22

18

# 6-40

0.1380

.0101

2

55

418

11

8

# 6-40

0.1380

.0101

5

85

646

17

13

# 6-40

0.1380

.0101

8

120

912

25

18

# 8-32

0.1640

.0140

2

55

577

18

14

Dry ft*lb

Lubricated


Ass emb ly Tor qu e Nominal Size or Basic Major Diameter of Thread

Stress Area

# 8-32

0.1640

.0140

5

85

893

29

21

# 8-32

0.1640

.0140

8

120

1260

41

31

# 8-36

0.1640

.0147

2

55

607

19

14

# 8-36

0.1640

.0147

5

85

938

30

23

# 8-36

0.1640

.0147

8

120

1325

43

32

#10-24

0.1900

.0175

2

55

723

27

20

#10-24

0.1900

.0175

5

85

1117

42

31

#10-24

0.1900

.0175

8

120

1577

59

44

#10-32

0.1900

.0200

2

55

824

31

23

#10-32

0.1900

.0200

5

85

1274

48

36

#10-32

0.1900

.0200

8

120

1799

68

51

¼-20 ¼-20

0.2500 0.2500

.0318 .0318

2 5

55 85

723 1117

65 101

49 76

¼-20

0.2500

.0318

8

120

1577

143

107

¼-20

0.2500

.0318

9

145

3460

173

129

¼-28

0.2500

.0364

2

55

824

75

56

¼-28

0.2500

.0364

5

85

1274

115

86

¼-28

0.2500

.0364

8

120

1799

163

122

¼-28

0.2500

.0364

9

145

3955

197

148

5/16-18

0.3125

.0524

2

55

2162

11

8

5/16-18

0.3125

.0524

5

85

3342

17

13

5/16-18 5/16-18

0.3125 0.3125

.0524 .0524

8 9

120 145

4718 5701

24 29

18 22

5/16-24

0.3125

.0581

2

55

2395

11

8

5/16-24

0.3125

.0581

5

85

3701

19

14

5/16-24

0.3125

.0581

8

120

5225

27

20

5/16-24

0.3125

.0581

9

145

6314

32

24

⅜-16

0.3750

.0775

2

55

3196

19

14

⅜-16

0.3750

.0775

5

85

4939

30

23

⅜-16

0.3750

.0775

8

120

6974

43

32

⅜-16

0.3750

.0775

9

145

8427

52

39

⅜-24

0.3750

.0878

2

55

3622

22

16

⅜-24

0.3750

.0878

5

85

5599

34

26

⅜-24

0.3750

.0878

8

120

7904

49

37

⅜-24

0.3750

.0878

9

145

9551

59

44

7/16-14

0.4375

.1063

2

55

4385

31

23

in

2

Grade

Proof Load

ksi

lbs

Clamp Load in*lb

Dry in*lb

Lubricated

ft*lb

Dry

Lubricated

ft*lb



Stress Area

7/16-14

0.4375

.1063

5

85

6777

49

37

7/16-14

0.4375

.1063

8

120

9567

69

52

7/16-14

0.4375

.1063

9

145

11561

84

63

7/16-20

0.4375

.1187

2

55

4897

35

26

7/16-20

0.4375

.1187

5

85

7568

55

41

7/16-20

0.4375

.1187

8

120

10684

77

58

7/16-20

0.4375

.1187

9

145

12910

94

70

½-13

0.5000

.1419

2

55

5853

48

36

½-13

0.5000

.1419

5

85

9046

75

56

½-13

0.5000

.1419

8

120

12770

106

79

½-13

0.5000

.1419

9

145

15431

128

96

½-20 ½-20

0.5000 0.5000

.1600 .1600

2 5

55 85

6598 10197

54 84

41 63

½-20

0.5000

.1600

8

120

14395

120

90

½-20

0.5000

.1600

9

145

17394

144

108

9/16-12

0.5625

.1819

2

55

7505

70

52

9/16-12

0.5625

.1819

5

85

11598

108

81

9/16-12

0.5625

.1819

8

120

16375

150

110

9/16-12

0.5625

.1819

9

145

19786

185

139

9/16-18

0.5625

.2030

2

55

8372

78

58

9/16-18

0.5625

.2030

5

85

12940

121

90

9/16-18 9/16-18

0.5625 0.5625

.2030 .2030

8 9

120 145

18268 22074

171 206

128 155

⅝-11

0.6250

.2260

2

55

9322

97

72

⅝-11

0.6250

.2260

5

85

14407

150

112

⅝-11

0.6250

.2260

8

120

20340

211

158

⅝-11

0.6250

.2260

9

145

24577

256

192

⅝-18

0.6250

.2560

2

55

10558

109

82

⅝-18

0.6250

.2560

5

85

16317

169

127

⅝-18

0.6250

.2560

8

120

23036

239

179

⅝-18

0.6250

.2560

9

145

27835

289

217

¾-10

0.7500

.3345

2

55

13796

175

130

¾-10

0.7500

.3345

5

85

21321

266

199

¾-10

0.7500

.3345

8

120

30101

376

282

¾-10

0.7500

.3345

9

145

36372

454

340

¾-16

0.7500

.3730

2

55

15384

192

144

in

2

Grade

Proof Load

ksi

lbs

Clamp Load in*lb

Dry in*lb

Lubricated

ft*lb

Dry

Lubricated

ft*lb



Stress Area

¾-16

0.7500

.3730

5

85

23776

297

222

¾-16

0.7500

.3730

8

120

33566

419

314

in

2

Grade

Proof Load

ksi

lbs

Clamp Load in*lb

Dry in*lb

Lubricated

ft*lb

Dry

Lubricated

ft*lb

¾-16

0.7500

.3730

9

145

40559

506

380

⅞-9

0.8750

.4617

2

33

13796

170

125

⅞-9

0.8750

.4617

5

85

21321

266

199

⅞-9

0.8750

.4617

8

120

30101

376

282

⅞-9

0.8750

.4617

9

145

36372

454

340

⅞-14

0.8750

.5095

2

33

15384

192

144

⅞-14

0.8750

.5095

5

85

23776

297

222

⅞-14

0.8750

.5095

8

120

33566

419

314

⅞-14

0.8750

.5095

9

145

40559

506

380

1-8 1-8

1.0000 1.0000

.6057 .6057

2 5

33 85

14992 38616

249 643

187 482

1-8

1.0000

.6057

8

120

54517

908

681

1-8

1.0000

.6057

9

145

65874

1097

823

1-12

1.0000

.6630

2

33

16410

273

205

1-12

1.0000

.6630

5

85

42268

704

528

1-12

1.0000

.6630

8

120

59673

994

745

1-12

1.0000

.6630

9

145

72105

1201

901

1 ⅛-7

1.1250

.7633

2

33

18891

354

265

1 ⅛-7

1.1250

.7633

5

74

42361

794

595

1 ⅛-7 1 ⅛-7

1.1250 1.1250

.7633 .7633

8 9

120 145

68694 83066

1288 1556

966 1167

1 ⅛-12

1.1250

.8557

2

33

21179

397

297

1 ⅛-12

1.1250

.8557

5

74

47492

890

667

1 ⅛-12

1.1250

.8557

8

120

77014

1444

1083

1 ⅛-12

1.1250

.8557

9

145

93059

1477

1308

1 ¼-7

1.2500

.9691

2

33

23985

499

374

1 ¼-7

1.2500

.9691

5

74

53785

1120

840

1 ¼-7

1.2500

.9691

8

120

87220

1817

1362

1 1/4-7

1.2500

.9691

9

145

105391

2195

1646

1 ¼-12

1.2500

1.0729

2

33

26555

553

414

1 ¼-12

1.2500

1.0729

5

74

59548

1240

930

1 ¼-12

1.2500

1.0729

8

120

96565

2011

1508

1 ¼-12

1.2500

1.0729

9

145

116682

2430

1823

1 ⅜-6

1.3750

1.1549

2

33

28583

655

491



Stress Area

1 ⅜-6

1.3750

1.1549

5

74

64096

1468

1101

1 ⅜-6

1.3750

1.1549

8

120

103939

2381

1786

1 ⅜-6

1.3750

1.1549

9

145

125593

2878

2158

1 ⅜-12

1.3750

1.3147

2

33

32539

745

559

1 ⅜-12

1.3750

1.3147

5

74

72966

1672

1254

1 ⅜-12

1.3750

1.3147

8

120

118324

2711

2033

1 ⅜-12

1.3750

1.3147

9

145

142974

3276

2457

1 ½-6

1.5000

1.4053

2

33

34780

869

652

1 ½-6

1.5000

1.4053

5

74

77891

1949

1462

1 ½-6

1.5000

1.4053

8

120

126472

3161

2371

1 ½-6

1.5000

1.4053

9

145

152821

3820

2865

1 ½-12 1 ½-12

1.5000 1.5000

1.5810 1.5810

2 5

33 74

39130 87746

978 2193

733 1645

1 ½-12

1.5000

1.5810

8

120

142292

3557

2667

1 ½-12

1.5000

1.5810

9

145

171936

4298

3223

1 ¾-5

1.7500

1.8995

2

33

47011

1371

1028

1 ¾-5

1.7500

1.8995

5

74

105420

3074

2306

1 ¾-5

1.7500

1.8995

8

120

170951

4986

3739

2-4.5

2.0000

2.4982

2

33

61831

2061

1545

2-4.5

2.0000

2.4982

5

74

138651

4621

3466

2-4.5

2.0000

2.4982

8

120

224840

7497

5621

2 ¼-4.5 2 ¼-4.5

2.2500 2.2500

3.2477 3.2477

2 5

33 74

80380 180246

3014 6759

2260 5069

2 ¼-4.5

2.2500

3.2477

8

120

292292

10960

8220

2 ½-4

2.5000

3.9988

2

33

98971

4213

3092

2 ½-4

2.5000

3.9988

5

74

221935

9247

6935

2 ½-4

2.5000

3.9988

8

120

359894

14995

11246

2 ¾-4

2.7500

4.9340

2

33

122166

5597

4197

2 ¾-4

2.7500

4.9340

5

74

273837

12550

9413

2 ¾-4

2.7500

4.9340

8

120

444061

20352

15264

3-4

3.0000

5.9674

2

33

147692

7384

5538

3-4

3.0000

5.9674

5

74

331189

16559

12419

3-4

3.0000

5.9674

8

120

537063

26853

20139

3 ¼-4

3.2500

7.0989

2

33

175698

9516

7137

3 ¼-4

3.2500

7.0989

5

74

393989

21341

16005

3 ¼-4

3.2500

7.0989

8

120

638901

34607

25955

in

2

Grade

Proof Load

ksi

lbs

Clamp Load in*lb

Dry in*lb

Lubricated

ft*lb

Dry

Lubricated

ft*lb



Stress Area

3 ½-4

3.5000

8.3286

2

33

206133

12024

9018

3 ½-4

3.5000

8.3286

5

74

462238

26963

20222

3 ½-4

3.5000

8.3286

8

120

749575

43725

32793

3 ¾-4

3.7500

9.6565

2

33

238998

14937

11203

3 ¾-4

3.7500

9.6565

5

74

535935

33495

25121

3 ¾-4

3.7500

9.6565

8

120

869085

54317

40738

4-4

4.0000

11.0826

2

33

274293

18286

13714

4-4

4.0000

11.0826

5

74

615082

41005

30754

4-4

4.0000

11.0826

8

120

997430

66495

49871

4 ¼-4

4.2500

12.6068

2

33

312018

22101

16575

4 ¼-4

4.2500

12.6068

5

74

699677

49560

37170

4 ¼-4 4 ½-4

4.2500 4.5000

12.6068 14.2292

8 2

120 33

1134611 352172

80368 26212

60276 19809

4 ½-4

4.5000

14.2292

5

74

789720

59229

44421

4 ½-4

4.5000

14.2292

8

120

1280628

96047

72035

in

2

Grade

Proof Load

ksi

lbs

Clamp Load in*lb

Dry in*lb

Lubricated

ft*lb

Dry

Lubricated

ft*lb

DEP 63100811_2015-02.pdf

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