Electric QAQC Procedure

DOC. NO.
HRED-PROC-EC-002
PT. HUTAMA ELECTRICAL
PAGE 1 OF 34
REKSA ENERGI QA/QC
REV. 0
DUA PROCEDURE
DOC. TITLE : ELECTRICAL QA/QC PROCEDURE
CLIENT : PT. GRESIK POWER INDONESIA
CONTRACTOR : PT. HUTAMA REKSA ENERGI DUA
PROJECT TITLE : SUPERHEATER PROJECT
LOCATION : GRESIK, JAWA TIMUR
NO DATE PAGE DESCRIPTION PREP'D CHK'D APP'D
0 February 11, ALL Issued for Bid
2010
Doc. No. BPK-PROC-EC-002
PT. BAHARU PENTA
ELECTRICAL QA/QC PROCEDURE Page No. 2 of 34
KENCANA Date February 10, 2010
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CONTENTS
Section Sheet No.
1. SCOPE OF WORK......................................................................................................4
2. REFERENCE...............................................................................................................4
3. SAFETY PROCEDURE.................................................................................................4
3.1. General Procedure.........................................................................................4
3.2. Power Distribution Transformer.....................................................................5
3.3. Switchgear and control center.......................................................................5
3.4. Cables...........................................................................................................6
3.5. Motor............................................................................................................6
4. INSPECTION AND TESTS..........................................................................................6
4.1. Purpose.........................................................................................................6
4.2. Power and Distribution Transformer..............................................................6
4.3. 13.8 kV and 4.16 kV Switchgear....................................................................7
4.4. Electric Motors............................................................................................13
4.5. Cables.........................................................................................................14
4.6. Grounding System.......................................................................................15
4.7. Lighting Installation....................................................................................16
4.8. Power Generators........................................................................................16
4.9. Miscellaneous..............................................................................................18
5. TESTING METHOD..................................................................................................21
5.1. Insulation Resistance Test...........................................................................21
5.2. High-Voltage Test.......................................................................................22
5.3. Grounding Resistance Test..........................................................................22
5.4. Grounding Continuity Test...........................................................................22
5.5. Electrical Continuity Test.............................................................................22
5.6. Polarity Test................................................................................................23
5.7. Dielectric Strength test................................................................................23
5.8. Interlocks and Control Test.........................................................................24
5.9. Primary Injection Test.................................................................................24
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5.10. Protective Relay Test...................................................................................25
5.11. Polarization Index.......................................................................................25
5.12. Lighting Transformer / Panel / Circuit Test / Illumination Level..................26
5.13. Electrical Distribution System phase Rotation Check and Polarity Test........27
5.14. Running Test of Motor Uncoupled...............................................................27
6. ACCEPTANCE CRITERIA..........................................................................................28
6.1. Insulation Resistance..................................................................................28
6.2. High voltage Tests......................................................................................29
6.3. Grounding Resistance..................................................................................31
6.4. Dielectric Strength.......................................................................................32
6.5. Polarization Index.......................................................................................32
7. APPENDIXES...........................................................................................................32
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1. SCOPE OF WORK
This specification covers the procedures for final inspection and testing prior to
commissioning of electrical equipment and installations for Steam Superheater Project, PT.
Gresik Power Indonesia.
2. REFERENCE
The following documents shall form a part of the requirement of this specification
1. NETA
3. SAFETY PROCEDURE
3.1.General Procedure
3.1.1. Whenever inspection and test are to be performed on electrical facilities, safety should be
the primary consideration at all time. To assure the safety of testing and construction
personnel, assume that;
1). Wiring is incorrect
2). Motors are connected to run in reverse
3). Phases are different across a bus-tie breaker
4). Everything needs checking
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3.1.2. Use rubber gloves when working on electrical equipment rated above 240 Volts. Always
wear shoes with good electrical insulating properties, i.e. with rubber soles.
3.1.3. Safety assurance during the testing of electrical system cannot be overemphasized.
Whenever possible, all power sources must be isolated by opening and withdrawing the
breakers. Tag all breaker and padlock switches if necessary. Never use a spark-generating
instrument in a hazardous area. Or a safety precaution shall be taken before using such an
instrument. Safety and/or clearance certificate from authorized person(s) is required.
3.1.4. Authorized person must be kept away from test work. Rope of the area if necessary. Erect
warning signs. Plan ahead and think before acting. One good way to avoid trouble is to
write down the sequence before proceeding with a complex or hazardous inspection or
test.
3.1.5. Safety and/or clearance certificate from authorized person(s) is required before working on
any electrical installation to be worked on is in connection with the existing installation.
3.2.Power Distribution Transformer
3.2.1. Remember that certain test equipment such as Insulation Tester and dielectric test sets
can cause painful, if not lethal, shocks. Be careful when working with transformers; low voltages
applied to the secondary windings can produce lethal voltages at the primary terminals.
3.2.2. Remember that open-circuit secondary windings of current transformers can produce
extremely high voltage if their primaries are excites.
3.2.3. All secondary of current transformer shall be short circuited whenever their loads are
removed. For example, an ammeter may be required for calibration. The current transformer to
which the ammeter is connected shall be short-circuited when the ammeter is removed.
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3.3.Switchgear and control center
3.3.1 When working any one circuit, be sure to positively identify the specific source breaker(s)
and the lock it open and tag it. In case of draw out or vertical lifts type gear, removed
the breaker from its operation position. Make sure that personal working on the
equipment is familiar with the test procedures. Make sure they verify that the breaker is
locked open.
3.3.2 Serious accident may result from improper switchgear operation. If switchgear cannot be
mounted in a rack, or switched on, it must not be forced.
3.3.3 It should also be remembered that secondary selective substation allow electrical power
to be maintained at all plant loads, while individual system elements are de-energized for
inspection or test.
3.4.Cables
3.4.1 Established that the circuit is dead by testing it with a high voltage detector (glow stick);
or in the case of 460 Volts or 230 Volts, use a voltage tester.
3.4.2 Make sure that the glow stick, voltmeter or voltage tester is in working order by checking
it against a live cables or test devices both before and after the circuit check.
3.4.3 In addition to this test, the source circuit breaker shall be opened, tagged and pas
locked. Only after these precautions have been taken can the testing and checking of
circuit begin.
3.4.4 When along cable is impressed with voltage and a Insulation Tester is used during tests,
the cable can still give a painful shock after the source is removed. Before allowing
personnel to work on the cable, the cable must be discharged by connecting an insulated
wire to ground.
3.5.Motor
3.5.1 Before any work is done on a motor, ensure that the motor controller has been
disconnected, tagged and padlocked if provision for that exists. If possible, ground the
motor feeder.
3.5.2 If it is necessary to remove a motor for repair, always remember to reconnect the ground
to the motor frame when reinstalling. Make sure that the makers of power cables and
motor leads are marked correctly.
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4. INSPECTION AND TESTS
4.1. Purpose
The inspection and tests described in this specification shall be carried out at the
appropriate time both during and after the installation or erection of the electrical facilities.
At the beginning of the electrical inspection and tests, the Test equipment List (Appendix -
2) shall be filled in by the inspection engineer.
4.2. Power and Distribution Transformer
4.2.1 The following shall be checked, inspected, or tested:
1 The rating on the nameplate is correct.
2 The design meets the area classification where the transformer is installed.
3 The bushing seals are satisfactory.
4 The oil level is correct and there is no leakage.
5 The valves and pipe plugs are correct and tight.
6 The cables and connections are correct and firm
7 The cable and bells are tight.
8 The gland mounting plate is suitable for magnetic flux.
9 The terminal box seals are satisfactory.
10 The bolting and gaskets are tight and satisfactory.
11 Test the alarm and trip circuits of the gas relay.
12 The connected protective relays and pressure relief devices are correctly adjusted.
13 Check the continuity of the tap setting switch.
14 The bolting, clamping, etc. of the neutral connection is complete and firm.
15 Check the continuity of the equipment grounding connection.
16 The polarity of the terminals and the phase sequence are correct.
17 Ratio check for each tap.
18 Measure the insulation resistance of the high and low-tension windings between
phase and ground.
19 Measure the dielectric strength of the insulation oil. For new transformer, the oil shall
withstand 30KV on breakdown test.
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20 Check all auxiliary devices such as oil level gauges, pressure gauges, temperature
gauges etc. Calibrate each and check the switch operations.
21 Check, restore released pressure as specified. Return all conditions to normal and
conduct Insulation Tester test with the opposite winding to be grounded.
The following reading shall be applied:
Min. Acceptance
System Volts Insulation Tester Volts
value in Mega Ohms
4.16 KV 2,500 V 10
13.8 KV 5,000 V 25
34.5 KV 10,000 V 100
Record all readings and name plate data
4.3. 13.8 kV and 4.16 kV Switchgear
4.3.1 Procedure for Checking 13.8 KV and 4.16 KV Switchgear
Pre-requisite
1 Remove all potential transformer fuses to eliminate any possibility of feedbacks into
other circuits.
2 Insulation Testing and hi pot testing
3 Verify all PT fuses removed.
4 Short out and ground all secondary CT’s.
5 Verify equipment under test is grounded.
6 Barricade the test area and post high voltage sings as required. Post a man at any
exposed ends of equipment under test.
7 Check and record temperature and humidity for calculating reading compensation.
8 All protective relays to be calibrated with secondary injection with a relay tester.
Record on the approved forms.
B. Checkout
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1. Check incoming buses from their source to establish proper phasing.
2. Check all electrical/mechanical connections for proper tightness. Special attention
should be devoted to the shipping splices.
3. Micro ohm the bus splices and cable connections with size #4/0 (95 mm2) and larger.
See micro ohm procedure. Make comprehensive record indicating locations of splices
along with ohm value.
4. Check for proper grounding connections.
5. Ratio and polarity check on potential transformer
See transformers ratio and polarity checking procedure.
6. Ratio, polarity and saturation check on current transformers.
See transformers ratio and polarity checking procedure.
7. Current circuit point check will be conducted by light bulb test.
Firstly, provide circuit as the Inserting test plug into the relay in the CT circuit and
inject current through light bulb to the stud on the test plug (as which circuit consider
firstly to check) and verify proper voltage against the ground at each terminal point
associate with CT Circuit being checked, after that, continued to other phase with
proper stud on the test plug. To make sure just have one point ground in the circuit,
remove the ground connection and verify the light bulb off (i.e.; no additional
grounding present).
After verifying all circuits restore circuits to normal.
8. Potential circuit point to point, check will be conducted same as No. 7 but secondary
fuses to be take out before commence of check.
9. Check 120 Volts AC and DC power circuits for continuity.
10. Using a primary current injection test set, inject sufficient input current into circuit to
achieve operation of Device 51, 51G and 07.
11. Insulation resistance test
Apply insulation test voltage between each bus with other buses grounded.
Insulation Tester Min. Acceptance Value

Bus Volts Times
Volts in Mega Ohms

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4.16 KV 2500 Up to Saturation 10
After all readings acceptable, conduct a high pot test. See hi-pot test procedure. The
following values will apply:
Min. Acceptance
Bus Volts Hi-pot Volts Times Leakage Current Value
in mille Amps
5 KV per min. Hold

4.16 KV/12.5 KV DC or 6.24 KV AC
1 min. 20.5
13.8 KV DC or 20.7 KV 5 KV per min.
41.4 KV AC Hold 1 min. 25
34.5 KV DC or 43.1 KV 5 KV per min.
86.3 KV AC Hold 1 min. 25
Repeat step a. same results should be obtained. Records results on form
4.3.2 Checkout of 13.8 KV & 4.16 KV Switchgear Cubicles
A. Prerequisites
1. Circuit breaker must be checked according to the manufacturers recommended
procedures. All pertinent records shall be made.
2. All electrical and mechanical bolts, fasteners etc. to be checked for tightness.
3. Check the moving parts. This should be done with dead bus including racking-
mechanism, shutters, relays, mechanical interlocks, latches, switches etc.
4. Check rating of fuses, breakers, lamps etc. and compare to the drawings for
record.
5. Micro ohm all power circuit breaker contacts, cable connection, bus disconnects
etc. and record on appropriate from.
6. Check cables for proper identifications, termination and markings.
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Conduct continuity check of one conductor in each cable to verify opposite end
identification.
7. Check control circuit insulation resistance with 500 Volt insulation tester.
8. Insulation test.
Prerequisites
a) Short out and ground all secondary CT’s
b) Verify potential transformer fuses removed.
c) Verify equipment to be tested is grounded.
d) Barricade the test area and post high voltage signs as required. Post a man at
any expose ends of equipment.
9. Mechanical check circuit breaker according to manufacturer’s instructions.
Checkout
a) Insulation Test circuit on load side terminals (load cable to be tested separately).
The following values shall apply
Insulation Test Min. Acceptance in Mega

Bus Volts Times
Volts Ohms
4.16 KV 2500 Up to saturation 10
b) Power VAC circuit breakers will be hi-potted using the manufacturers testing set.
Record the results on appropriate.
c) Measure the primary contact closed by using a micro ohmmeter.
The resistance reading shall be less than 100 micro ohms. Record the results.
B. Function Checkout
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1. Step-1 will consist of impressing a closure signal on the control circuit and
observing a breaker trip, green light – off, red light on.
2. Step-2 will consist of impressing a trip signal on the control circuit and observing a
breaker trip, green light-on, red light off.
With breaker in the open position do the following:
a) Insert closing fuses to observe the motor cranking stored energy springs.
b) Insert trip fuses and observe green light at the switchgear only.
c) Check D.C. voltage polarity at fuses, relays, control switch lamps etc. Verify
with drawings.
d) Do step-1 with local control switch and observe the operation.
e) Do step-2 with local control switch and observe the operation.
f) Repeat step-1 and sequentially trip by manipulating each 50/51, 50GR and
other protective relay contacts.
g) Do step-1 with remote control and observe no operation.
h) Actuate TOC switch
i) Check control voltage polarity at various terminal points and remote
station.
j) Test chain of permissive series contacts by closing all contacts successively.
The final contact closure will produce step-1. Each contact should be tested as final
contact to prove series circuit.
k) Use same procedure as in item “J” to test any series trip circuit. Observe step-
2. Normally trip circuits have more than one parallel contacts.
l) Energize and set any timing relays.
m) Checks annunciate alarms by functional operation of relays and breakers to
prove alarm contacts.
n) Check all heaters and circuitry
o) Using primary injection with high current test set check each 50/51, 50G, 87
and any other pertinent relays.
4.3.3 Checkout of 480 Switchgear
A. Prerequisites
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1. Remove all potential transformer fuses to eliminate any feedbacks into other
circuits.
2. Insulation Test:
a) Verify all potential circuit open
b) Short out and ground all secondary CT
c) Verify equipment undergoing test is properly grounded
d) Barricade the test area and post high voltage signs as necessary. Post a man at
any exposed ends of equipment under test.
e) Check and record temperature and humidity.
B. Checkout
1. Check incoming buses from their source to establish proper phase of bus.
2. Check all mechanical and electrical connections for tightness.
Special attention to be given for shipping splices
3. Micro ohm all bus splices and cables #4/0 (95 mm2) or larger.
Make a record of the location of splices along with ohm values.
4. Check grounding connection from switchgear to ground grid.
5. Check ratio and polarity to potential transformers, see procedure.
6. Check ratio and polarity to current transformers, see procedure.
7. Conduct point-to-point check of potential circuit as outlined in 13.8 KV switchgear.
8. Conduct point-to-point check of current circuit as outlined in 13.8 KV switchgear.
9. Check 120 Volt AC & DC power circuits for continuity.
10. Insulation Resistance Test.
Apply insulation test voltage between each bus and ground with other buses
grounded.
The following values shall apply:

Insulation Testing Min. Acceptance Value
Bus Voltage Times
Volts in Mega Ohm
480 1000 Up to saturation 3.0
Record the readings on form.
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4.3.4. Checkout of 480 Volt Switchgear Cubicles
1. 480 Volt switchgear operates only from local control.
Energize the control circuit and observe the correct indicating lights. Closure the
breaker and observe motor charging action, indicating lights.
2. Trip the breaker and check the indicating lights.
3. Check the breaker permissive interlocks to 13.8 KV breaker and tiebreaker.
4.3.5. Checkout of Motor Control Centers Power Panels etc.
(1) Micro Ohm feeder, bus connection and cables #4/0 (95 mm2) and larger and make
records.
(2) Check buses for proper phasing.
(3) Visually verify breaker trip settings.
(4) Check cables for proper termination. Check one conductor in each cable.
(5) Check each starter and breaker as follows:
a) Verify breaker, starter, overloads and control transformer size to match the load
requirements.
b) Check all mechanical and electrical connections for tightness.
c) Use an independent source of power for function checks the control circuit.
d) With a current test set, check calibration of breaker tripping points. Records the
results.
e) With a current test set, check calibration of overload protection. Record result.
(6) Check Starter racking/latching devices
4.4. Electric Motors
The following shall be checked, inspected, or tested:
(1) The rating on the nameplate is correct.
(2) The design meets the area classification
(3) The shaft blocking devices for transport is removed.
(4) The coupling alignment and rotor endplay are satisfactory.
(5) Rotate the motor by hand.
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(6) The bearings, greases packing, grade and quality of grease, oil level, and oil rings
are in good condition.
(7) The bolting weatherproofing of the terminal box is complete and tight. The terminal
connections are correct and tight.
(8) Test the anti condensation heater.
(9) The cable and bells and glands are complete and tight.
(10) The continuity of the equipment grounding connection.
(11) The components of the cooling system are in good condition.
(12) Conduit Insulation check with the following reading:
Min. Acceptance value in

System Volts Insulation Test Volts
Mega Ohm
480 V 1000 0.5
4.16 KV up to 15 KV 5000 4.5
13.8 KV 5000 13.5
(13) Polarization index for motors having capacity more than
1.100 KW.
(14) Run the motor uncoupled and check the bearings for overheating.
(15) The direction of rotation is correct.
(16) Measure the ampere and vibration during the uncoupled run.
(17) Stop the motor and reassemble the coupling.
(18) The push-button station is correctly installed.
(19) Measure the insulation resistance.
(20) Record all value, secure and make ready for service
4.5. Cables
(1) The cable trench is clean and free from any foreign objects.
(2) The size and installation agree with the approved drawings
(3) The circuit indication and terminal numbering are correct and firm
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(4) The cable end bells, oil or compound levels are satisfactory and there is no leakage.
(5) The cable route markers are correct
(6) The cable end seals are complete and tight.
(7) The cable glands are complete and tight
(8) The clamps and connections of the single-conductor cables are tight and suitable for
magnetic flux.
(9) The cable terminations and connections are correct and tight.
(10) The cable is protected against mechanical damage.
(11) The cable tray is correctly rigid and grounded.
(12) Apply insulation test voltage between ground and conductor under test.
Prerequisites
a. Barricade test area and post high voltage signs as necessary.
Post a man at any exposed ends.
b. Separate each conductor and ground all conductors except the one under test.
The following value shall be applied:

Min. Acceptance
Insulation
Cable Rated Volts Time Value in Mega
Tester Volts
Ohms
600 V 1000 Up to saturation 0.5
5 KV 2500 Up to saturation 4.5
(13) In addition to a insulation test, 5KV & 15 KV cables will have a hi-pot test/see hi-pot
procedure. The following value shall be applied.
Max. Acceptance
Cable Rated Volts Hi pot Volts Times Leakage Current in
Mega Ohm
5 KV 14.4 KV DC 5 KV steps 1 min. hold 3.2
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max. 15 min.
5 KV steps 1 min. hold

15 KV 36 KV DC
max. 15 min. 2.7
5 KV steps 1 min. hold

35 KV 87.5 KV DC
max. 15 min. 5.8
4.6. Grounding System
The inspection shall be carried out as follows:
(1) The grounding joints are complete and tight. The underground joints should be
spot-checked before they are backfilled.
(2) Measure the grounding resistance of each electrode
(3) Measure the grounding resistance of each grounding system.
(4) Check the grounding continuity of the grounding system.
(5) The size of the cables and installation agree with the approved drawings and latest
revision.
(6) The installation of the electrodes is satisfactory.
(7) Check the protective measures that have been taken against mechanical damage
to the system.
4.7. Lighting Installation
(1) The enclosure for area classification.
(2) The numbers and location of the equipment are correct.
(3) The distribution panel circuit numbering and loading are correct. The switch ratings
and the fuse ratings are correct.
(4) The weatherproofing of the cable glands is satisfactory.
(5) The feeder cable size is correct.
(6) The operation and setting of the time switches, photo electric cells, magnetic control
switches, etc. are satisfactory.
(7) Check the insulation resistance of each circuit.
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(8) The lighting circuit connection is correct for circuit numbering/identification.
(9) Measure the voltage at each socket
4.8. Power Generators
4.8.1. Check Generator Power Terminals for:
a) Correct phase sequence for generator rotation (refer to vendor drawings).
b) Correct physical connections to switchgear bus.
c) Proper termination. Check tightness of mechanical bolting of generator main leads and
buses with micro ohmmeter.
d) Record with location drawings.
e) Insulation resistance.
Prerequisites
Disconnect surge arrestors, capacitors, potential transformers and neutral ground resistor.
(1) Conduct a polarization. Index test. The P.I. should be at least-2
(2) If the P.I. acceptable, conduct a hi-pot test with the following value apply.
Max. Acceptance
Gen. Volts Hi - pot Volts Times Leakage Current in
Micro Ohm
2 KV step 2 min. hold at

5 KV Max. 30KV DC
each step. 100
Record all readings on appropriate form.
4.8.2. Generator Potential Circuits
Use vendor’s drawings and conduct the following checks:
a) Ratio and polarity of each transformer.
b) Proper phase connections to primary and secondary of each transformer.
c) Conduct point-to-point check as outlined in 13.8 KV switchgear procedures.
d) Insulation resistance check with 500 V Insulation Tester.
e) Determine the proper place and ground circuit.
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4.8.3. Excitation System
a) Use vendor’s drawings and conduct the inspection to see that voltage regulator exciter
and their components are properly wired.
b) Use vendor’s instruction manuals to conduct an Insulation Tester check on
recommended parts. Max. Insulation Tester volts 500 V.
4.8.4. Generator Control Circuits
Use vendor’s drawings and conduct the following checks
a) Controls in local panel
b) Controls in remote panel
c) Controls in switchgear
4.8.5. Check Generator Ground Circuit Cables and Connections
4.8.6. Energized Phasing Check
If all of prior checks are found acceptable, return all connections, covers, calibrated relay
etc. in service and leave either the primary generator leads on the generator or leads on
the generator “Y” points disconnected.
Simulate certain permissive interlock to close the circuit breaker. Close the circuit breaker
to energize generator bus duct and generator PT Cubicle. Conduct phasing checks of
generator PT circuits to switchgear bus PT circuits. At this time a selection of the
synchronizing circuit will indicate an in phase conditions on the synchronous scope.
4.8.7. If all checks complete, de energize and reconnect generator main leads
Remove all jumpers used to simulate interlocks in the switchgear.
4.8.8. Record all nameplate data
4.9. Miscellaneous
4.9.1. Batteries and Battery Chargers
(1) The rating on the nameplate of the charger is correct, check the battery case for
crack or damage.
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(2) The battery rating, voltage, and ampere-hours are correct.
(3) The connected loads agree with the approved drawings, fuses, relays etc. are
correct.
(4) The protective devices for battery charge, i.e. fuses, relay, etc. are correct.
(5) The cable connections and inter-cell connections are correct and tight.
(6) The exhaust, ventilation, and drainage facilities of the battery rooms are in good
condition.
(7) The equipment grounding is complete
(8) The batteries are completely charged and electrolyte level is correct.
(9) Check charging current and voltage, adjust if necessary.
4.9.2. Relays and Control Devices
The following shall be checked:
(1) The rating and range area in accordance with setting data. Whether the ratings of
the current and potential transformers are adequate.
(2) All blocking materials are removed.
(3) Adjust the relays and devices to the correct duty point per the setting data.
(4) Operation is satisfactory.
4.9.3. Fire Alarm System
The following shall be checked and tested:
(2) Operation of the manual fire alarm station and fire detectors, and that the main and
auxiliary control panels are satisfactory.
4.9.4. FM 200 Control Panel
Use vendor’s drawings and conduct the following check and test:
(1) The installation of the panel(s) is satisfactory
(2) Check the name plate (s) and components in the panel as per vendor drawings.
(3) Confirm panel grounding
(4) Check power supply and energize the panel.
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(5) Remove release solenoids from cylinders tentatively and check the function by using
“smoke spray” or other simulation means.
(6) Record the result and restore the release solenoids.
4.9.5. CCTV System
Use vendor drawing and conduct following check and test:
(1) Check all the components of CCTV system are correctly installed in the location as per
construction drawing(s).
(An encoder, a camera, a decoder, monitor, etc.)
(2) Check installation is properly being done.
(3) Check nameplate, any physical damage and loss of component as per vendor drawings.
(4) Check availability of power supply.
(5) Switch on the power source and confirm energizing by indicating lamp.
(6) Select the camera installed at field by camera switcher. And check operation of the
camera and video quality on monitor screen.
(7) Check following Encoder/Decoder functions:
a. Tilting up/down
b. Pan left/right
c. Auto Scan
d. Camera on/off
e. Zoom in/out
f. Focus near/far
4.9.6. Cathodic Protection System
Use construction drawings and vendor drawings and conduct following check and test.
4.9.6.1.General
(1) Check all the components are installed at correct location as per construction
drawing (s).
(2) Check any damage or loss of material as per vendor drawing.
(3) Confirm all the wirings are completed.
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4.9.6.2.Impressed Current System
(1) Measure insulation resistance of power/control circuit of Transformer Rectifier
(T/R) except solid state circuit/component (s)
(2) Remove out put wiring and energize T/R
(3) Check out put voltage and confirm increase/decrease function.
(4) Repeat the above for all T/R installed.
(5) De-energize T/R.
(6) Disconnect anodes at J/B and measure installed anode resistance to suitable
ground (nearest Test Station).
(7) Measure the natural potential between structure and soil at all test location and
bond stations with bond disconnected.
(8) Restore all removed connection (s)
(9) Energize each T/R and record output voltage and current at stepwise increase of
output.
(10) Adjust T/R output and confirm specified potential vs. reference is attained.
(11) Record all T/R settings and output Volts/Amps.
(12) Check potential fully at all designated test locations noting following information
a. T/R setting/output Volts & Amps.
b. Anode current
c. Pipe to soil potentials
d. Tank base potentials
4.9.6.3.Sacrificial Anode System
(1) Check visually, where it is possible sacrificial anodes are installed as per
construction drawings.
(2) Check and record structure to electrolyte potentials using portable silver/silver
chloride reference electrode.
5. TESTING METHOD
5.1. Insulation Resistance Test
5.1.1 The insulation resistance shall be measured with an appropriate Insulation Tester.
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5.1.2. Voltage supplied by the Insulation Tester shall be as follows unless otherwise specified
elsewhere;
(1) Circuits rated at 240 V: 500V
(2) Circuits rated at 600 V: 1000 V
(3) Circuits rated at 4.16 KV to 15 KV: 5000 V
(4) Circuits rated at above 15 KV: 10000 V
5.1.3. Voltage shall be applied until the pointer remains steady.
5.1.4. Charged energy shall be discharged after taking a reading.
5.1.5. Complete an insulation resistance test data sheet.
5.2. High-Voltage Test
This test shall be applied to switchgear, transformer, and cables. The switchgear and cable
shall be tested separately, with the circuit breaker open, as shown in the following
procedure:
(2) If the insulation resistance measured is satisfactory connect the high voltage test
equipment.
Make sure that the voltage adjustment knob is on minimum position.
(3) Increase the voltage gradually to the required value. Refer to Subsection 6.2 for
the voltage to be applied.
(4) Read the voltage and leakage current when the voltage steadies at the required
voltage.
(5) Maintain the voltage for the time specified in subsection 6.2
(6) Reduce the applied voltage down to zero, and discharge any residual voltage.
(7) Measure the insulation resistance as before.
(8) Complete a high-voltage test data sheet for every test.
5.3. Grounding Resistance Test
5.3.1. Grounding resistance shall be measured with a grounding tester.
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5.3.2. Grounding resistance shall be measured at each separate grounding well.
5.3.3. Complete a grounding resistance test data sheet for every test.
5.4. Grounding Continuity Test
Before backfilling ground wiring, make a visual check of the underground connections.
Measure the electrical continuity with a circuit tester, according to the following sequence:
(1) Disconnect one grounding live as shown in figure. 4. Check continuity between
disconnected grounding wire and any nearby grounding wire.
(2) Continue the item (1) above for all grounding termination including grounding rods.
(3) Record the result.
5.5. Electrical Continuity Test
Check electrical continuity with a circuit tester, according to the following procedure:
(1) Connect the conductor and metal sheath (it not applicable, any nearby grounded
metal) at one end of the cable with a wire clip.
(2) Attach the circuit tester to the same conductor and metal sheath (or nearby grounded
metal), as shown in the figure.
(3) Using the same procedure, check the electrical continuity between all of the
conductors.
(4) Complete a cable test data sheet for every test.
5.6. Polarity Test
This test shall be applied to power transformer, according to the following procedure:
(1) Be sure secondary neutral is disconnected.
(2) Connect primary terminal “C” and secondary terminal “C”.
(3) Connect a temporary dia. 3 200 V power source to the primary side the transformer
and switch it on.
(4) Measure the voltage between each terminal as follows:
A–a : V
A–b : V
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B–b : V
B–a : V
If the following vector diagram is obtained, the winding is correctly arranged.
(5) Complete a power transformer polarity test data sheet for every test.
Note, alternatively, three phase transformer turn ratio checker may be utilized to
check the polarity
5.7. Dielectric Strength test
This test shall be applied to electrical insulation oil. Each sample shall be tested according
to the following procedure:
(1) Make the Testing connection.
The testing vessel and electrodes shall be cleaned, dried, and then rinsed with a
little of the equipment to be tested.
Take a sample of the insulating oil from the transformer, etc. Do not uncork the
sample until it is the temperature of the test area.
(2) Maintain the ambient temperature during the test at 15-35 0C
(3) Fill the testing vessel with the sample and wait approximately 3 minutes, until the
oil bubbles have disappeared.
(4) Increase the test voltage by 3 kV per second until a breakdown occurs.
(5) Repeat the procedure five times while the sample is in the testing vessel and
record results. (Stir the sample before making the each succeeding test and wait
another 3 minutes).
(6) Complete an insulation oil test data sheet for every test.
The breakdown voltage of the insulating oil shall be determined by calculating the
arithmetical average of the four breakdown voltages recorded (the first breakdown
voltages recorded are not used in the calculation).
5.8. Interlocks and Control Test
With the switchgear control power energized, each circuit breaker position shall be
checked, and then checked again in the operating position, according to the following
procedure:
(1) Close the circuit breaker and trip it from the control switch and remote control panel.
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(2) Mechanically trip each electrically operated circuit breaker.
(3) Test the lockout device in the closing circuit for proper operation by simulating
conditions in which lockout would occur.
(4) Complete a sequence test data sheet for every test.
5.9. Primary Injection Test
5.9.1 Switchgear
This test shall be carried out for all ct circuit.
This test method shall be in accordance with manufacture’s instruction.
5.9.2. ACB, MCCB, Thermal Overload Heater
This test shall be carried out for all 480 V ACB’S MCCB’S and thermal overload relays, all
other main breakers, for each phase to confirm tripping functions.
5.10. Protective Relay Test
5.10.1. Inverse-Time Relay Calibration and Test
(1) Using a relay tester with a third harmonic filter, set the relay in accordance with
the relay setting list.
(2) Connect one relay unit to the relay tester.
(3) The minimum pickup current input to the relay and the calibration of the relay
shall be tested as follows:
a. Rotate the armature disk by hand to the midpoint of its full travel. Mark a
red target line between the disk and a stationary part.
b. Increase the input current to the set tap value and monitor the armature
disk to determine when it starts to rotate.
c. If the disk does not start rotating at the set tap current, increase the
current slightly.
d. Check that when the disk stops, the red lines coincide. If not, adjust the
tension in the spring accordingly.
(4) Operational Test
a. Set the input current at 300% of the set tap value.
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b. Set the cycle counter and input the 300% current through the relay coil.
Measure the duration of operation.
c. Repeat the procedure with a 600% tap current.
(5) Complete the relay-setting list for every item of test data.
5.10.2 Instantaneous Relay Test
(1) Set the relay in accordance with the relay-setting list.
(2) Set the input current at the tap value and confirm that there is current
between the relay and pickup.
(3) Complete the relay-setting list for every item of test data.
5.11. Polarization Index
For motors and generators of 1100 KW and Larger, take reading at one minute and 10
minutes intervals to determine the polarization index.
The index shall be obtained by following:
 minutes reading (in Mega Ohms) or 1 minute reading (mA)
 minute reading (in Mega Ohms) or 10 minutes reading (mA)
5.12. Lighting Transformer / Panel / Circuit Test / Illumination Level
5.12.1. Transformer
(1) Make sure the transformer in not energized.
(2) Make sure all the connections are correct and properly marked, for instance with
color tapes.
(3) Make sure transformer body is grounded as per drawing.
(4) Make sure the secondary neutral is connected the neutral terminal in the lighting
panel
(5) Measure insulation resistance on primary and secondary windings against the
grounding.
5.12.2 Lighting Panel
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(1) Make sure the panel is not energized.
(2) Make sure the panel is grounded as per drawing
(3) Make sure all connections are secure.
(4) Make sure all neutral wires are color coded with white.
(5) Make sure all grounding wires are color coded with green.
(6) If the panel is fed from transformer, make sure the neutral terminal is bonded to the
grounding terminal or panel casing.
If the panel is fed from transformer, make sure the neutral terminal is insulated from
the grounding and no bonding between the neutral and the grounding terminals.
(7) Disconnect transformer neutral wire; switch the main breaker off, measure insulation
resistance on each bus bar against the grounding. Record the result, reconnect the
transformer neutral wire.
5.12.3 Lighting Circuit
After satisfactory insulation resistance value has been obtained, the lighting circuit shall be
tested according to the following procedure:
(1) Turn off all the branch circuit up to the lighting panel.
(2) Energize the distribution circuit up to the lighting panel
(3) Check the voltage between all phases, and between each phase and the neutral
conductor, at the buses to the lighting panel.
(4) Turn on one branch circuit switch and check that the illuminated lighting is in
accordance with the lighting drawing.
(5) Test each earth leakage breaker by pushing test button.
(6) Complete a lighting circuit test data sheet.
5.12.4 Illumination Level
(1) Switch on all lighting fixtures
(2) Measure illumination levels by using color corrected photometer and record the
result.
(3) Walk through the illuminated area to confirm all the area or spots for operation and
maintenance are well illuminated.
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5.13. Electrical Distribution System phase Rotation Check and Polarity Test.
Before energizing the electrical panel by permanent power, phase rotation and polarity
shall be checked at each panel to be energized by using the temporary low voltage power.
Further testing procedure shall be submitted for each case at site.
5.14. Running Test of Motor Uncoupled
All test and inspections of the motor, such as visual inspection, insulation resistance
measurements, and sequence checks, shall be completed before performing a motor no-
load running test. A copy of all the related test records for the motor shall be ready to
present before starter being energized. The related records may include,
(1) Cable resistance, continuity
(2) Primary injection report
(3) Function test report.
(4) Motor maintenance data such as Insulation Tester data & grease conditions
Other checks to be performed are as follows:
(1) Check that the motor can be easily turned by hand.
(2) Ensure that the coupling is correctly aligned and the motor is fixed to its
foundation
(3) Using the starter, energize each motor to check that is rotates in the direction
indicated by the rotation arrow. If direction is not correct, reverse the
connection leads at the motor, if practicable. Run the motor uncoupled at least
2 hours and until the motor temperature reaches the saturation point.
(4) Check the vibration, noise, and bearing and body temperature. Use a
Thermometer to check and record the bearing temperature. Defective bearings
will be discovered by their being noisy or by their overheating.
(5) Continue to run the motor for minimum two (2) hours and until temperature
saturates.
(6) Complete a motor uncoupled run test data sheet for every test.
6. ACCEPTANCE CRITERIA
Unless otherwise specified in approved individual testing procedure for electrical
apparatus, following acceptance criteria shall be applied.
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6.1. Insulation Resistance
6.1.1 In the case of electrical wiring up to 600 volts AC or up to 750 volts DC, the individual
electrical wiring, which can be isolated by switching devices such as circuit breakers,
cutouts, disconnecting switches, oil cutouts, and oil switches, shall not fall below the
following minimum insulation resistance values between each conductor and the ground
with other phase conductors being grounded,
Voltage Minimum
Between Insulation
Conductors Voltage to Ground Resistance
Up to 300 volts Voltage to ground (for grounded 0.1 Mega Ohm
Circuit, voltage between conductors
And ground or a circuit conductor
That is grounded, for ungrounded
Circuits, the largest other circuit
Conductor) is below 150 volts.
Up to 300 volts Other than above 0.2 Mega Ohm
Over 300 volts 0.4 Mega Ohm
6.1.2 Electrical wiring up to 600 volts for AC or up to 750 volts for DC, shall be insulated
integrally so that the leakage current from the conductor insulation to ground, per
conductor, does not exceed ½, 000 of maximum capacity of the conductor.
6.2. High Voltage Test
6.2.1. Cables
Cables used for circuits having an AC voltage over 600 volts or a DC voltage over 750 volts
shall be subjected to the following high-voltage test. The test voltage shall be applied
between conductors, and between each conductor and ground, with other phase
conductors being grounded.
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(1) An AC voltage be applied for 5 minutes between the circuit and ground, as follows:
Maximum utilization voltage Test Voltage
a. 601 – 7,000 volts Max. Utilization
Voltage x 1.5 (V)
b. 7,001 – 60,000 volts Max. Utilization
Voltage x 1.25 (V)
(min. 10,500 volts)
c. An AC system having an Max. Utilization
essentially solid grounded voltage x 0.92 (V)
neutral and voltage of
7,001 – 15,000 volts
(2) A DC test voltage may be applied for 15 minutes to cables used only for circuits, as
follows:
Maximum utilization Voltages Test Voltage
a. 601 – 7,000 volts Max. Utilization
Voltage x 1.5 x 2 (V)
b. 7,001 – 60,000 volts Max. Utilization
Voltage x 1.25 x 2 (V)
(min. 21,000 volts)
c. An AC system having an Max. Utilization
essentially solid grounded voltage x 0.92 x 2 (V)
neutral and voltage of
7,001 – 15,000 volts
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6.2.2. Switches, Circuit – Breakers, Power Capacitors, Induction Voltage Regulators, Instrument
Transformer, Bus bars, and Bus ducts
An AC voltage shall be applied for 10 minutes, between each conductor and ground, with
other conductors being grounded.
Maximum Utilization Voltage Test Voltage
a. Up to 7,000 volts Max. Utilization
Voltage x 1.5 (V)
(min. 500 volts)
b. over 7,001 Max. Utilization
Voltage x 1.5 (V)
(min. 10,500 volts)
c. An AC system having an essentially an Max. Utilization
essentially solid grounded neutral and Voltage x 0.92 (V)
voltage of 7,001 – 15,000 volts
6.2.3 Others
Electric circuit having an AC voltage over 600 volts or a DC voltage over 750 volts other
than described in subsection 6.2.1. thru 6.2.4. shall be tested in accordance with
subsection 6.2.1. (1).
Notes:
(1) The maximum utilization voltage is defined as the highest line-to-line voltage that
occurs at any time temporary voltage variations due to the sudden disconnection of
large loads, but excluded those due to faults conditions.
(2) The maximum utilization voltage may be computed by multiplying the nominal system
voltage and the factor given below:
Nominal System Voltage Multiplying Factor
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Up to and including 1,000 volts 1.15
Over 1,000 volts 1.1
(3) The nominal system voltage is defined as the line-to-line voltage for which the system
is designated and installed. This is the voltage by which a system is generally known,
and is not necessarily the same as the rated voltage of every piece of apparatus
connected to that system. An electrical system is defined as an individual electrical
system in which all the conductors and apparatus are electrically connected and
operate at a common voltage. The term includes all the conductors and apparatus.
6.3. Grounding Resistance
Grounding resistance shall be as follows:
(1) A grounding electrodes 2.5 ohms
(2) Instrument grounding 5 ohms
6.4. Dielectric Strength
The insulation oil shall have a minimum breakdown voltage of 30 KV AC.
6.5. Polarization Index
The polarization index is as follows:
= 10 minutes reading = 2.0
1 minutes reading
7. APPENDIXES
The following appendixes shall form a part of this specification:
Appendix-1 Summarized List of Test items and form sheet no.
Appendix-2 Test Equipment List
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DOC. NO.

DOC. TITLE : ELECTRICAL QA/QC PROCEDURE

CLIENT : PT. GRESIK POWER INDONESIA

CONTRACTOR : PT. HUTAMA REKSA ENERGI DUA

PROJECT TITLE : SUPERHEATER PROJECT

LOCATION : GRESIK, JAWA TIMUR

NO DATE PAGE DESCRIPTION PREP'D CHK'D APP'D

0 February 11, ALL Issued for Bid

Section Sheet No.

3.1. General Procedure.........................................................................................4

3.2. Power Distribution Transformer.....................................................................5

3.3. Switchgear and control center.......................................................................5

4. INSPECTION AND TESTS..........................................................................................6

4.2. Power and Distribution Transformer..............................................................6

4.3. 13.8 kV and 4.16 kV Switchgear....................................................................7

4.4. Electric Motors............................................................................................13

4.6. Grounding System.......................................................................................15

4.7. Lighting Installation....................................................................................16

4.8. Power Generators........................................................................................16

5.1. Insulation Resistance Test...........................................................................21

5.2. High-Voltage Test.......................................................................................22

5.3. Grounding Resistance Test..........................................................................22

5.4. Grounding Continuity Test...........................................................................22

5.5. Electrical Continuity Test.............................................................................22

5.6. Polarity Test................................................................................................23

5.7. Dielectric Strength test................................................................................23

5.8. Interlocks and Control Test.........................................................................24

5.9. Primary Injection Test.................................................................................24

5.10. Protective Relay Test...................................................................................25

5.11. Polarization Index.......................................................................................25

5.12. Lighting Transformer / Panel / Circuit Test / Illumination Level..................26

5.14. Running Test of Motor Uncoupled...............................................................27

6.1. Insulation Resistance..................................................................................28

6.2. High voltage Tests......................................................................................29

6.3. Grounding Resistance..................................................................................31

6.4. Dielectric Strength.......................................................................................32

6.5. Polarization Index.......................................................................................32

Gresik Power Indonesia.

personnel, assume that;

1). Wiring is incorrect

2). Motors are connected to run in reverse

3). Phases are different across a bus-tie breaker

4). Everything needs checking

instrument. Safety and/or clearance certificate from authorized person(s) is required.

any electrical installation to be worked on is in connection with the existing installation.

3.2.Power Distribution Transformer

extremely high voltage if their primaries are excites.

3.3.Switchgear and control center

mounted in a rack, or switched on, it must not be forced.

or in the case of 460 Volts or 230 Volts, use a voltage tester.

motor leads are marked correctly.

4. INSPECTION AND TESTS

2) shall be filled in by the inspection engineer.

4.2. Power and Distribution Transformer

4.2.1 The following shall be checked, inspected, or tested:

1 The rating on the nameplate is correct.

3 The bushing seals are satisfactory.

4 The oil level is correct and there is no leakage.

5 The valves and pipe plugs are correct and tight.

6 The cables and connections are correct and firm