Method of Statement for MV&LV Switchgears PROJECT NAME
: Khabat Thermal Power Plant Units 1&2
DOCUMENT NO.
: KP-00+++-CY712-B7204
TITLE
: Method of Statement for MV&LV Switchgears
OWNER
: Ministry of Electricity (MOE) of Kurdistan Regional Government
A
11.08.2015
Rev. No.
DATE
TOTAL 12 PAGES (Including Cover)
Purpose ☐ For Information ☒ For Review ☐ For Approval ☐ For Construction ☐ As-Built
For Review PREPARED DESCRIPTION
CHECKED
REVIEWED
APPROVED
GAMA POWER SYSTEMS ENG &CONTRACTING,INC.
Owner
Ministry of Electricity (MOE) of Kurdistan Regional Government Contractor
POSCO ENGINEERING & CONSTRUCTION CO., LTD. Main Subcontractor
GAMA POWER SYSTEMS ENGINEERING & CONTRACTING,INC.
KHABAT TPP UNITS 1&2
Method Statement for
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Contents 1. PURPOSE ................................................................................................................................. 8 2.DEFINITIONS .............................................................................................................................. 8 3. REFERENCES ........................................................................................................................... 8 4.SCOPE .......................................................................................................................................... 8 5. RESPONSIBILITIES .......................................................................................................... 8 6.PREREQUISITES and PRECAUTIONS……………………………………………………….9 7. PROCEDURES………………………………………………………………………………..10 8.ACCEPTANCE CRITERIA……………………………………………………………………11 9.EXHIBITS……………………………………………………………………………………11
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Method Statement for
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1. Purpose This procedure provides a safe, standardized approach for the initial inspection, checkout, Commissioning testing and data documentation of MV & LV SWITCHGEAR. The use of different testing equipment may result in performing slightly different steps. 2. Definitions
Project : Company : Construction : Supplier (Manufacturer/Vendor) : The supplier (Manufacturer/Vendor) is the party that manufacturers or supplies equipment and services to perform the duties specified by the Company or Contractor. The word SHALL indicate a requirement. The word SHOULD indicate recommendation.
3. References Electrical Single-Line Diagrams. Electrical Schematic Diagrams. Electrical Three Line Diagrams. Grounding Notes, Symbols, and Details. Vendor’s Instruction Manual and Associated Drawings. Electrical Equipment Installation Procedure. Lock out and Tag-out Procedure. IEC 62271-200 AC metal-enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 52 Kv IEC 60694 Common specifications for high-voltage switchgear and controlgear standards IEC 60060-1 High voltage test techniques- Part 1: General definitions and test requirements.
4. SCOPE This procedure is applicable to the Project Site and covers MV & LV Switchgear , CONTRACTOR has Commissioning responsibility. This procedure applies to insulation resistance, high potential test, contact resistance.
5. RESPONSIBILITIES Participate in and provide input to Safety Task Analysis Risk Reduction Talk (STARRT)/Job Hazard Analysis. Provide HSE coverage for Pre-commissioning activities and walk downs.
Cable tray supervisor shall be ensuring that work area facilities are safe prior to cable tray work activities. Personel Protection Equipment have to be used by workers Our staff has the responsibility to check if workers are wearing the proper PPE at site.
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If a worker is not working proper to the HSE rules; supervisor will stop him. Related Personnel Project Manager; directs and coordinates the work execution and the administration of the worksso as to ensure to compliance with the established schedule ,budgets and quality requirements. Construction Manager, manage the activity of construction personnel ,to ensure that the construction and installation work is in accordance with the established construction schedule . QC Department;responsible controlling and directing the activities complying with the quality requirements given in the references and reports to the Project Manager. Administering and approving project inspection and test plan. Reporting quality problems to the Project Manager Commissioning Manager Has overall responsibility for Commissioning test program. Commissioning Electrical Field Engineer Has responsibility for detailed checkout insulation resistance, high potential test and contact resistance test of MV & LV Switchgear. Coordinates with discipline engineers, operations, and test performers to accomplish testing and completes the data record (Exhibit 1). The testing engineer performing this procedure shall ultimately be responsible for all evolutions. . 6. PREREQUISITES and PRECAUTIONS a.
b.
Prerequisites i.
For Pre-Commissioning activities, equipment to be tested is under jurisdictional control of the organization responsible for performing the testing.
ii.
Verify that test equipments used for recording data is calibrated within their calibration interval.
iii.
Verify that the equipment is correct (per data sheets, specifications, etc.) and installed in accordance with project design documents and vendor manuals/drawings. Review system/component punch list.
iv.
Review the vendor’s instruction manual(s) for special precautions or limitations specific to the equipment/system’s components. Note and observe the vendor's precautions and limits.
Precautions i.
Areas under test must be clean and free of loose debris and only authorized personnel must be permitted in test areas.
ii.
Systems (complete or partial) or equipment under initial test where high energy will be introduced for the first time must be physically walked down to ensure unauthorized personnel are removed from test areas. As required, personnel may be stationed at
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designated locations to keep test areas free of unauthorized personnel. Emergency egress routes must be identified and verified clear of obstructions. iii.
Equipment Lockout and Tag out (LOTO) requirements in support of this activity must be implemented in accordance with the Lockout and Tag out Procedure.
iv.
A pre-test briefing incorporating STARRT/JHA must be conducted. Discuss test performance and expected results with involved personnel. Personal Protection Equipment (PPE) identified in the STARRT/JHA is required to be worn during performance of this test
v.
Special attention must be provided for protection of personnel and equipment. Ensure precautions such as barriers, flagging, danger signs, horns, area restrictions, etc., are used to protect personnel and equipment.
vi.
Immediately terminate testing if any unusual noises, smoke, or anomalies occur, or if design limits that may compromise the safety of personnel or equipment are exceeded. Immediately notify the Pre-commissioning Manager depending on type of test and the site HSE representative (if applicable) of such occurrences.
vii.
Assure adequate access is provided to all required areas during the test. Where permanent access is not provided, scaffolding or a man lift must be provided in accordance with job site procedures.
viii.
Establish appropriate level of communication between test and control room personnel.
ix.
The Switchgear shall be proved dead &earthed and made safe prior to starting testing.
7.
PROCEDURES
NOTE: The vendor’s instruction manual takes precedence over this procedure in the event of conflicts. Detailed equipment testing procedures and parameters shall be according to the vendor’s manuals. a. Pre-Commissioning Insulation Resistance Testing i.
Select the tester for the dc output voltage of test equipment as 5000V for MV switchgear and 1000V for LV switchgear. Record the test voltage on the MV & LV Switchgear Commissioning Test Data Record, Exhibit 1.
ii.
Determine the Acceptance Criteria. If no Vendor Criteria is provided refer to Acceptance Criteria.
iii.
Connect the tester in accordance with the test equipment (megger) manufacturer's instructions.
iv.
Record the temperature and humidity on the MV & LV Switchgear Commissioning Test Data Record, Exhibit 1. This information would be used to correct to a standard temperature for comparison of data taken at different times.
v.
For MV & LV Switchgear, test each bus with respect to ground (U-N, V-N, and W-N).
vi.
Discharge the insulation resistance tester.
vii.
Disconnect the tester leads using rubber gloves if test leads are not adequately insulated.
viii.
Discharge the component to ground.
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b. Commissioning High Potential Test i.
De-energize, discharge, and safety tag the equipment to be tested, as necessary. Record the equipment number on the MV & LV Switchgear Pre-Commissioning Test Data Record, Exhibit 1.
ii.
Determine test voltage, duration, and voltage steps to be used according to manufacturer’s manual, Exhibits or Attachments of this procedure.
iii.
Ground all equipment, cables, and conductors not under test that are in contact with the cable under test or that can become energized by a flashover.
iv.
Voltage transformers, and certain other items (e.g. transformers and cables), must be disconnected from the system section to be tested.
v.
Make short-circuit and earth the current transformers on the secondary side.
vi.
Screening components must be fitted if system parts have to be disconnected for testing.
vii.
Before performing High Potential Test As a precautionary measure, a megger reading shall be made by applying 5000 V dc between the test terminals to ensure that the switchgear is free from gross defects as a result of damage during installation and that no inadvertent grounds have been left. The megger readings shall be recorded on the MV & LV Switchgear Commissioning Test Data Record, Exhibit 1.
viii.
Position the test instrument inside the test area, keeping the high voltage lead between the test instrument and the switchgear being tested.
ix.
Connect the test set in accordance with the manufacturer's instructions. Connect each phase conductor of the main circuit in turn to the high-voltage terminal of the test supply, with the other phase conductors connected to earth.
x.
Set the ammeter to its highest range.
xi.
Set the voltage to its lowest range.
xii.
Gradually increase the test voltage to 18 kV in accordance with IEC 60694 Standard. At 15, 30 60 seconds record test voltage and leakage current on MV & LV Switchgear Commissioning Test Data Record, Exhibit 1. Remain at 18 kV ac for 60 seconds.
NOTE: As long as the plotted curve of leakage current versus voltage is linear for each step, the insulation system is in good condition. At some value of step voltage, if the leakage current begins to increase noticeably, an increase in the slope of the curve will be noticed, If the test is continued beyond this test voltage, the leakage current will increase even more rapidly and immediate breakdown may occur in the switchgear insulation. As a result whenever this noticeably current leakage will occur, urgently decrease test voltage value. NOTE: If switchgear insulation failure should occur, as indicated by the rapidly increasing ammeter reading, secure the test voltage immediately. xiii.
Repeat step 6.2.10, correcting any abnormalities, until the maximum test voltage is reached. A retest should not be started until the switchgear under test has been grounded for a period at least four times the duration of the previous test.
xiv.
Measure leakage current every minute and record data on the MV & LV Switchgear Commissioning Test Data Record, Exhibit 1.
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xv.
Reduce test voltage continuously, but not abruptly.
xvi.
Turn off the test instrument and allow the voltage to decay for at least the minimum time in accordance with the test instrument instructions.
NOTE: The test apparatus may store a dangerous charge unless it is grounded unless it is grounded after the test. xvii.
Ground the switchgear (use a discharge rod) and allow the ground to remain in place for a period of at least 3 to 5 minutes.
xviii.
Remove the test lead connections.
xix.
Restore the switchgear to its as-found condition or ground it and move on to the next conductor. Use proper torque values on terminations as required.
xx.
Upon test completion remove all grounds installed for testing and restore all switchgear.
c.
d.
Commissioning Contact Resistance Test
i.
Ensure that all electronic circuits and equipment should be disconnected before testing otherwise damage may occur.
ii.
Verify enclosures or frames are grounded to station ground. Temporarily ground if necessary.
iii.
Remove all external equipment that may affect contact resistance readings (e.g. capacitors, lightning arresters, brush rigging, etc.)
iv.
Discharge the component to ground.
v.
Remove all visible surface dust and moisture from the component in test when practical.
vi.
Make certain the line is de-energized on both sides of the bus-bar.
vii.
Ground the bus-bar on both sides and ground the test equipment.
viii.
Ensure that measuring distances specified on bus bars are as short as possible, in order to locate poor contact points as quickly as possible. Measuring points are located between neighboring branches, in order to ensure direct comparability.
ix.
Define the allowable voltage drop. At each coupling point and conductor connection, manufacturer’s specifications for allowable voltage drops shall be used as test criteria.
x.
Use earthing switches primarily as feeder in case of bad readings caused by using earthing switches for measuring and feeding at the same time.
xi.
When using earthing switches, disconnect the link and reconnect after taking the measurement.
xii.
Feed a constant DC 100 A and measure the voltage drop specified points.
xiii.
Make a record of the readings and the test conditions.
Restoration
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i.
Verify that temporary alterations made during the performance of this test have been restored.
ii.
Verify that temporary test device has been removed, and all system connections and permanent equipment are replaced and secured. De-energize the control circuit(s), and leave devices in a position compatible with the de-energized state of the control circuit.
iii.
Verify that equipment and system(s) affected by this procedure are restored to conditions as specified by the person responsible for the system(s).
iv.
Verify that applicable Data Records have been completed.
ACCEPTANCE CRITERIA For Acceptance Criteria, if Vendor Criteria is provided, that shall be regarded. Unless vendor criteria are provided, insulation resistance shall not be less than 10 Mohm. For High Potential test, if leakage current asymmetry between phases is higher than 20% at a full test voltage, this proves low quality of terminations and joints. For Contact Resistance test, due to the fact that contact resistance test depends on the type of connection and these will differ by equipment and manufacturer. There is no standard or code which specifies minimum contact resistance. As a result, manufacturer or vendor criteria shall be regarded. In case there is no even manufacturer recommendation and criteria, the difference of measured resistance between each phase must be not more 20 %.
9.
EXHIBITS 1— MV & LV Switchgear Commissioning Test Data Record 2--- LV&MV CIRCUIT BREAKER / CONTACTOR AND FUSED SWITCH DATA RECORD
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EXHIBIT 1 MV & LV SWITHGEAR COMMISSIONING TEST DATA RECORD Project No:
Area/Unit:
Project Title:
System/Sub System:
Equipment Desc..:
Equipment Tag No:
Type:
Serial Number:
Manufacturer:
Rated Voltage:
Cross Section of Busbar: Temperature:
Length of Busbar: Humidty:
INSULATION RESISTANCE U-N Before HIPOT
V-N After HIPOT
Before HIPOT
W-N After HIPOT
Before HIPOT
After HIPOT
HIGH POTENTIAL TEST PHASE U Leakage Test Voltage Current
Duration
PHASE V Leakage Test Voltage Current
PHASE W Leakage Test Voltage Current
15 sec.. 30 sec.. 60 sec.. 120 sec..
BUSBAR CONTACT RESISTANCE TEST Applied Current: L1
L2
L3
Measured Contact Resistance:
REMARKS
MANUFACTURER
TYPE
TEST EQUIPMENT SERIAL NUMBER
EXPIRY DATE OF CERTIFICATE
SIGNATURES Test Performed By
Checked and Approved By
Accepted By
Job Title Name Date Signature
INSPECTION OF SWITCHBOARD BUSBAR CONTINUITY (INCLUDING INCOMING AND SECTIONALIZER UNITS) Circuit designation From
To
Busbar conductivity L1
L2
L3
N
E
Ducter #
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EXHIBIT 2 LV&MV CIRCUIT BREAKER / CONTACTOR AND FUSED SWITCH DATA RECORD SHEET_1_ OF ___
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EQUIPMENT IDENTIFICATION FACILITY/PROJECT
UNIT
SYSTEM NAME/NUMBER
JOB NO. EQUIPEMT NAME/NUMBER
PREREQUISTIES COMPLETE AND SAFETY PRECAUTIONS READ AND COMPLIED WITH: NAMEPLATE DATA MANUFACTURER MAX VOLTAGE
TEST ENGINEER DATE _____________________/________
MODEL FREQUENCY
SERIAL No.
INTERRUPT CAPACITY
CIRCUIT BREAKER/CONTACTOR STARTER AND FUSED SWITCH CHECKS Items to be Checked
N/A N/A OK
For All LV and MV Circuit Breakers and Contactors 1
Control circuit I.R. Mohm.
2
Main circuit I.R. Mohm.
3
Check Phase Rotation
4
Protection settings verified with latest project setting schedule.
5
Check door, isolator and padlock operations are correct.
7
Earth fault protection testing complete. ( If available )
8
Cubicle function checked and wiring correct to Schematic Dwg No.
9
Prove operation of remote stop / start (DCS). ( If DCS is ready )
10
Remote annunciation correct (DCS). ( If DCS is ready )
All MV Circuit Breakers and Contactors and LV Incomer Circuit Breakers 11
Check for Mechanical damage.
12
Check alignment into switchboard
13
Check Manual Charge and Close
14
15
Check contact resistance of the circuit breaker/contact Resistance Injecting 100A DC. L1: ……….ohm L2: ………..ohm L3:………… ohm Check operation of charging motor and charge time.
16
Check control operation of tripping / closing circuit.
17
Check operation of position indicators.
18
Check operation of cubicle carriage switches.
19
Check operation of circuit breaker auxiliary contacts.
20
Confirm that circuit breaker cannot be racked in or out when closed.
21
Test all isolation and circuit earthing. Measure Eath Loop Impedance: ......... ohm
Punch List
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22
Ensure breaker “manual close” is properly guarded.
23
With Circuit Breaker in “Test” position Check manual closing.
25
Check the circuit breaker trips for manual operation ,all protection relays and operation of local breaker control switch.
26
Check the circuit breaker trip by operation of local mechanical push button
Check the circuit breaker trips for manual operation , all protection relays and operation of local breaker control switch. Check the circuit breaker trip by operation of local mechanical push button
24
Check closing by operating the local breaker control switch.
27
Ensure circuit breaker cannot close , if lockout relay has been tripped. With Circuit Breaker in “Service” position Check manual closing.
28 29 30 31 32
Check closing by operating the local breaker control switch.
C
Ensure circuit breaker cannot close , if lockout relay has been tripped.
BREAKER/CONTACTOR CHECKS TEST ENGINEER DATE _____________________/________
GROUNDING COMPLETE? Check Anti-pumping System ( If available )
OK
N/A
Check Limit Switch ( If available )
OK
N/A
POLE 1
POLE 2
POLE 3
SPRING CHARGE TIME CONTACT OPEN TIME CONTACT CLOSE TIME
TEST ENGINEER (PRINT/SIGN) EMPLOYER ENGINEER (PRINT/SIGN)
DATE DATE
