ES-14-902-02

Testing and Commissioning of Electrical and Instrumentation Installations

ES-14-902-02

Version No. 4.0 Page 1 of 21

Document last modified: 16 July 2009. PDF Created: 22 January 2010.

This is a Controlled Document that complies with CSBP Limited formatting and Quality Control guidelines. Please check that this is the latest available version before use.

Title: TESTING AND COMMISSIONING OF ELECTRICAL AND INSTRUMENTATION INSTALLATIONS

Number: ES-14-902-02

Owner: Simon Orton

Authoriser: David Zacher

Version Details: Changed Document Authoriser.

Deleted Reference to GM-11-031-31 Special Permits in line with close out of old Work Permit system by Ray Chittenden.

TABLE OF CONTENTS 1. SCOPE .....................................................................................................................................................3

2. PURPOSE................................................................................................................................................3

3. DEFINITION OF TERMS.....................................................................................................................3 3.1 CONTRACTOR/VENDOR.................................................................................................................3 3.2 SUBCONTRACTOR...........................................................................................................................3 3.3 SUPERINTENDENT...........................................................................................................................3 3.4 CSBP....................................................................................................................................................3 3.5 WORKS ...............................................................................................................................................3

4. STANDARDS ..........................................................................................................................................4

5. GENERAL...............................................................................................................................................6

6. SAFETY...................................................................................................................................................7

7. TEST PROCEDURES............................................................................................................................7 7.1 SWITCHGEAR ...................................................................................................................................7 7.2 RELAYS, PROTECTIVE DEVICES AND METERING.................................................................10 7.3 MOTOR CONTROL CENTRES.......................................................................................................11 7.4 TRANSFORMERS............................................................................................................................12 7.5 MOTORS...........................................................................................................................................13 7.6 CABLES ............................................................................................................................................14 7.7 CONTROL EQUIPMENT.................................................................................................................15 7.8 BATTERIES AND BATTERY CHARGERS ...................................................................................16 7.9 EARTHING AND LIGHTNING PROTECTION .............................................................................16 7.10 LIGHTING AND SMALL POWER CIRCUITS..........................................................................16 7.11 FUNCTIONAL TESTS.................................................................................................................17 7.12 HAZARDOUS LOCATIONS.......................................................................................................18


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7.13 PROGRAMMABLE CONTROLLERS........................................................................................18

8. TEST RECORDS..................................................................................................................................20

9. HANDOVER .........................................................................................................................................21

10. RECORDS MANAGEMENT .........................................................................................................21 10.1 AS-BUILT DRAWINGS ..............................................................................................................21 10.2 ENGINEERING PROJECT FILES ..............................................................................................21


ES-14-902-02



1. SCOPE This Standard details the requirements for testing and commissioning of all electrical and instrument equipment and works performed for and /or by CSBP.

The Standard assumes that all equipment items have been inspected and tested for compliance with relevant standards, at their place of manufacture immediately prior to transport to CSBP.

2. PURPOSE

To ensure all electrical and instrument equipment installed at CSBP can be operated safely without danger to personnel or equipment, and that equipment and its performance is in accordance with:

Contract drawings and documentation.

Standards and codes specified in this Standard.

Statutory Regulations.

Manufacturers requirements.

3. DEFINITION OF TERMS

3.1 CONTRACTOR/VENDOR

The company that provides the equipment and services needed.

3.2 SUBCONTRACTOR

A third party to be employed by the Contractor/Vendor, who has been approved by the Superintendent.

3.3 SUPERINTENDENT

CSBP Limited, or authorised representative. For internal works the Superintendent shall be the Responsible Officer.

3.4 CSBP

CSBP Limited.

3.5 WORKS

The scope of works that a Contractor is or may be required to execute under an agreement including variations and remedial work.


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4. STANDARDS

The Contractor shall perform the Works in accordance with this Standard, the latest issue of reference standards and Contractor regulations for on-site work. Should there be a conflict between the Works, Statutory Requirements and the Standards, the Contractor shall notify the Superintendent in writing for resolution. In general, the most stringent requirements prevail.

CSBP Engineering Standards

ES-14-101-02 Drawing Management ES-14-101-03 Drawing Preparation ES-14-101-04 Drawing Numbering ES-14-101-06 Equipment Numbering System ES-14-102-09 Labels and Signs: Plant and Equipment ES-14-102-12 Protective Coatings ES-14-701-01 Electrical/Instrument Preferred Equipment ES-14-702-01 Materials and Workmanship for Instrumentation Installations ES-14-902-01 ES-14-902-05

Materials and Workmanship for Electrical Installations Electrical Rotating Machine Repairs

ES-14-903-07 3 Phase Isolators (Field Mounted) for 415/440V Induction Motors ES-14-903-12 Electric Motors ES-14-903-19 Lighting CSBP Guide Manuals

GM-KS-101-01 Isolation of 132 kV Switchboard GM-10-020-04 Contractors Site Instructions GM-11-031-51 Work Permit System GM-11-032-02 Access to Switch Rooms GM-11-032-03 High Voltage Isolation and Earthing GM-11-035-02 Basic Safety Rules GM-11-038-06 Portable Electrical Equipment CSBP Procedures

DP-05-010-01 Calibration and Maintenance of Process Control Measuring Equipment in Kwinana Works

EP-08-030-05 Engineering Project Files EP-08-030-38 Engineering Project Handover CSBP Forms

PF1004 Instrument Service Calibration Sheet SF0958 CSBP Handover Certificate


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CSBP Commissioning Test Reports

SF0942 E01 Cables SF0943 E02 Earthing Systems SF0944 E03 Equipment Bus Insulation/Resistance SF0945 E04 HV Circuit Breaker SF0946 E05 O/C E/F Relay Calibration Record SF0947 E06 Current Transformers SF0948 E07 415 V Motor Starter SF0949 E08 Transformer SF0950 E09 Electric Motor Standard Association of Australia

AS1026 Electrical Cables - Impregnated Paper Insulated - Working Voltages up to and including 33 kV.

AS1076 Code of Practice for Selection, Installation and Maintenance of Electrical Apparatus and associated equipment for use in Explosive Atmospheres (other than mining applications).

AS1125 Conductors in Insulated Electric Cables and Flexible Cords AS1429.1 Electric Cables - Polymeric Insulated for Working Voltages 1.9/3.3 kV up

to and including 19/33 kV. AS1680 Interior Lighting AS1747 Reeling, Trailing and Feeder Cables used for Mining - Repair and Testing AS1767 Insulating Liquids AS1768 Lightning Protection AS1931 High Voltage Test Techniques AS2191 Stationery Batteries of the Lead - Acid Plante Positive Plate Type AS2373 Electric Cables for Control and Protection Circuits AS2430.1 Classification of Hazardous Areas - Explosive Gas Atmospheres AS2625 Rotating and Reciprocating Machinery - Mechanical Vibration - Parts 1

and 2. AS3000 Electrical Installations (AS/NZ Wiring Rules) AS3008.1 Electrical Installations - Selection of Cable for Alternating Voltages up to

and including 0.6/1 kV AS3116 Approval and Test Specification - Electrical Cables - Elastomer Insulated

for Working Voltages up to and including 0.6/1 kV AS3147 Approval and Test Specification - Electric Cables - Thermoplastic

Insulated for Working Voltages up to and including 0.6/1 kV AS3198 Approval and Test Specification - Electric Cables - XLPE Insulated - For

Working Voltage up to and including 0.6/1 kV


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AS3439 Low Voltage Switchgear and Control gear Assemblies AS3912.1 Quality Assurance Requirements for Measuring Equipment Other Engineering Standards and Publications

ESAA Guide to Working on Cables and Ancillary Equipment under Induced Voltage Conditions

BS6739 Code of Practice for Instrumentation in Process Control Systems: Installation Design and Practice

5. GENERAL Inspections and tests shall verify continuity, insulation integrity, polarity, turns ratio, calibration, adjustments, protective devices and relay settings, motor rotation, run-in operation and functional activation of all electrical equipment, devices and controls.

All tests shall be performed using certified instruments in accordance with AS3912.1 and CSBP Procedure Calibration and Maintenance of Process Control Measuring Equipment (DP-05-010-01)

All electrical equipment such as transformers, switchgear, motor control centres, motors, hardware, etc., shall be inspected for proper location, adequate fastening in place, proper connections, correct rating, marking and labelling and shall be tested as appropriate for continuity, earthing, protection, operation and run-in.

All power and control cabling shall be tested, as applicable for open and short circuits, continuity and leakage.

Electrical single line and schematic drawings shall be used to reference initial tests and progress shall be illustrated by diagram colour-out. Upon completion of testing of all individual units in a system, the entire system shall be tested to ensure proper operation. Similar procedures shall be adopted with pre-operational testing to programmable logic controllers and process measurement and control instrumentation.

Access procedures shall be adhered to during the testing of each specific circuit or item of equipment.

All tests shall be recorded on CSBP test sheets. Refer to Section 8.0 for details.

Actual connections shall be compared with schematic and elementary wiring diagrams and errors shall be rectified as appropriate either by reconnection or by revision of the diagrams.

Required drawing changes shall be recorded and incorporated in as-built drawings. Refer to Section 10.0 for details.

The Superintendent shall be given agreed, adequate notice of intention to commence testing procedures. The testing program shall be approved as nominated in the relevant contract or in the absence of any contract, by agreement with the Superintendent. The clearance procedures in force in the plant concerned shall apply.


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6. SAFETY All equipment used by the Contractor shall be properly maintained and operated in accordance with any safety regulations applicable to that equipment.

In carrying out the Works the Contractor shall strictly comply with applicable CSBPs site regulations, which include:

GM-KS-101-01 Isolation of 132 kV Switchboard GM-10-020-04 Contractors Site Instructions GM-11-032-02 Access To Switchrooms . GM-11-032-03 High Voltage Isolation and Earthing GM-11-035-02 Basic Safety Rules GM-11-038-06 Portable Electrical Equipment. GM-11-031-51 Work Permit System

7. TEST PROCEDURES

7.1 SWITCHGEAR

Physical inspection of switchgear assemblies shall include the checking of:

a. Line-up of switchboard for level, vertical alignment and continuity of level between panels. b. Tightness of busbar connection bolts against correct torque settings. c. Tightness of cable and wire terminations against torque setting for HV. d. All bushings, to make sure they are clean and free from damage. e. All cable terminations, to make sure they are in accordance with termination diagrams at

the equipment external termination points. f. Possible physical damage to components. g. Operation of door handles, mechanical interlocks, and the like and freedom of operation of

electrical switches. h. Earthing connections i. Equipment for the presence of foreign bodies such as swarf, filings and other debris. j. Remove all fuses and links and open all link terminals, except for CT link terminals, which

shall be left closed. These shall be progressively replaced/closed, over the course of the commissioning process. At each de-isolation point, the voltage/current to/from the point of isolation shall be proved correct prior to the de-isolation taking place.

Inspect individual circuit breakers for damage or missing parts. Slow close to check alignment and contact pressure.

Check clearance, tightness of bolts and operation of all moving parts and remove wedges, ties and blocks installed by manufacturer.


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For on-load isolators, check fuse rating, if applicable.

For all circuit breakers, fill or top up oil chambers after testing oil as for transformers.

For gas filled circuit breakers, check and fill if required.

Check line-up and ease of operation of each circuit breaker carriage for insertion and withdrawal, and raising and lowering in each of the operating, test and earthing positions, ensuring proper main and auxiliary contact alignment, shutter operation and functioning of interlocks. Check manual closing and tripping of circuit breaker.

Check phasing of incoming and outgoing circuits to ensure continuity of each phase colour within the switchboard.

Make an electrical continuity check of all current, potential and control circuits. Refer to wiring diagrams and compare the diagrams with actual connections. Correct diagrams and /or connections as required. Carry out ductor tests on busbars and primary switching devices.

Check all protective devices are of proper type, size and rating in accordance with single line diagrams and /or metering and protection diagrams.

Verify that instrument transformers are the proper type and rating. Make ratio and polarity checks of the transformers in accordance with nameplate data.

See Section 7.2 for relay and protective device inspection and testing. Check that each relay will trip the circuit breaker concerned.

Test direct trip breakers with high current supply to verify the marked instantaneous and time delay settings with tabulations furnished.

Before connecting incoming and outgoing cables, the switchgear shall undergo a one-minute duration megger test. All circuits, busbar and connections shall display the following minimum resistance:

600 Volts and less 6.6 kV and 11 kV 11 kV and up 1 kV megger 5 kV megger 5 kV megger 2.0 megohms 50 megohms 200 megohms (BREAKERS IN) (BREAKERS OUT) (BREAKERS OUT)

DC High voltage pressure test of HV Busbars (rated volts x 2 plus 2 kV). The voltage shall be applied gradually over a 30 second period and maintained for a further 60 seconds without failure. Extreme care must be exercised to ensure that all relevant CTs are effectively shorted out and grounded during the test and all PTs disconnected from the bus. Immediately after the test all temporary CT shorting devices will be removed.


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Injection test all CTs at sufficient voltage/current to determine the magnetisation curve and identify the knee point voltage. Submit to the Superintendent a graph of the magnetisation curve with the knee point voltage value clearly identified on the graph.

Primary injection-test all CTs to confirm ratio. Verify that each CT ratio and magnetisation characteristic is in accordance with the CT nameplate.

Note: Where primary injection current exceeds the range of the test equipment multiple primary turns on the CT may be employed for the test.

Check tripping battery for electrolyte level. Switch on trickle charge using a temporary supply source if necessary. Check battery voltage. Switch on tripping supply to switchboard.

With the breaker in the test position, make the following tests:

a. Close and trip the breaker by using its control switch. b. Manually trip breaker. c. Close the trip breaker from remote location if remote control exists. d. Automatic transfer to secondary selective systems shall be tested by simulated power

failure and under-voltage conditions. e. Check-test and operate all other auxiliary devices. f. Check main panel labels against installed cables and confirm each panel is connected to

correct destination.

Pre-operational testing of switchgear involves also the pre-operational testing of the supply circuit breaker and the intervening power transformer, if any. Test and prove inter-tripping and pilot wire protection.

Feeder circuit breakers outgoing from the switchgear are to be tested in conjunction with the equipment fed.


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7.2 RELAYS, PROTECTIVE DEVICES AND METERING

Check all relays for the following:

a. Loose terminals, holding and locking screws. b. Damage to coil, resistors, wiring, indicator targets and holding devices. c. Foreign material in magnet gaps. d. Any cause for sluggish action. e. Disc run back time (should not exceed 12 sec for full travel). Protection relays shall be tested at sufficient points to verify their correct operation. A minimum of three (3) tests shall be performed to cover the operating range of the relay. At completion of these tests the relay shall be set to the recommended setting, as per the protection study report and a final test conducted at the setting.

Use the manufacturers instructions to set, adjust and calibrate protective relays.

Protection relays shall undergo the following checks:

a. Differential Relays

Test to verify the published differential characteristics by checking the minimum operating current in each restraint coil.

Primary injection test the CTs as a complete system to prove correct CT ratios, CT polarity and phasing is correct and connection to any interposing phasing CTs are correct.

b. Undervoltage Relays

Check for pick-up and dropout values, time characteristics and any operational function specified.

c. Directional Elements

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

d. Instantaneous Overcurrent Relays and Elements

Check minimum pick-up current and response at three (3) different settings.

e. Time Delay overcurrent Relays and Elements

Check pick-up current and operating times at a minimum of three operating points.


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f. Primary Injection Testing Testing shall be carried out on all protective relays and each relay shall be proved to operate in accordance with the manufacturers data and in line with the requirements of the system protected.

Any relay test equipment should include a variable source of current, a variable source of voltage, a timer, ammeters and voltmeters to read both AC and DC and switching arrangement to permit test voltage or current to be applied at the same instant that the timer is started. In this way, the time required for the contacts to close after operating power has been applied can be determined and adjusted when needed. CT ratio, burden, polarity, and DC resistance shall be checked against the respective drawings.

Check labels fixed near each instrument or protection relay for correct data.

The correct operation of panel meters, including watt-hour meters and hour run counters shall be established using appropriate voltage and current injection methods. Watt-hour meters wattmeters or transducers shall be tested against a reference instrument with known and calibrated error.

Out of calibration units shall be returned to the Supplier for recalibration, and not used until satisfactorily calibrated.

7.3 MOTOR CONTROL CENTRES

For each starter module:

a. Check alignment and operation of main isolating switches and correct adjustment where necessary.

b. Check thermal overloads and fuses, if used, for size and rating. c. Check arc boxes and replace if broken. d. Check tightness of all connections and particularly connections to the thermal overloads. e. Check motor overload rating and thermistor operating resistance. Set all protection relays

in accordance with drawings. Set motor overload to motor full load current. f. Checks contacts, and if possible, adjust so that all make at the same time. g. Check current and potential transformers for proper ratio, size and polarity, in accordance

with Single Line Diagrams. h. Check meter and relay system continuity. i. Check continuity of control systems. Refer to wiring diagrams and operate with actual

connections. j. Remove all fuses and links and open all link terminals, except for CT link terminals, which

shall be left closed. These shall be progressively replaced/closed over the course of the commissioning process. At each de-isolation point, the voltage/current to/from the point of isolation shall be proved correct prior to the de-isolation-taking place.


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All starters shall undergo a megger test. All equipment from incoming to outgoing cable must have a resistance of at least 1,000 ohms per rated volt with a minimum allowable for any starter of 1 megohms regardless of rated voltage.

Operate the starter for proper opening and closing from both remote and local stations.

Check main panel labels against installed cables and confirm each drive connected to correct starter.

The MCC shall undergo a one-minute megger test, and the main busbars shall be subjected to a ductor test. MCC busbars shall also undergo a high voltage pressure test, as described in Section 7.1.

Check cabinet penetrations for rust and enclosures for presence of foreign bodies such as swarf, filings and other debris.

For MCCs installed outdoors, check correct operation of busbar chamber, anti-condensation space heaters.

Check phasing of incoming and outgoing circuits to ensure continuity of each phase colour within the switchboard, and between the switchboard and feeder power distribution panel.

Pre-operational testing of the motor control centre involves also the pre-operational testing of the supply circuit breaker in the feeder power distribution panel. Check this remote circuit breaker is ready for closing on power and operates properly.

7.4 TRANSFORMERS

Carry out the following physical inspection and tests:

a. Inspect bushings for chips or cracks. b. Check any damage to tank, fins and the like. c. Check cooling fan mountings and general condition. d. Check cooling fan control panels. e. Check tap changer for proper movement. Leave set at nominal ratio unless otherwise

directed by the Superintendent. f. Check operation of temperature and pressure indicators and trip/alarm relays. g. Inspect all gaskets and fittings for oil leakage. h. Check oil level and gas pressure in sealed transformers. i. Check nameplate data against transformer data sheets and single line diagrams. j. Check Denso tape fitted to all termination boxes. k. Check fitment of flexible connectors in LV termination box.

Perform dielectric strength tests on all oils. If oil has been stored for more than six months, a water content test is required. All sampling and tests shall be in accordance with AS 1767. The test samples must withstand a minimum of 30 kV and have water content of less than 35 mg/kg. Oils that fail these tests shall be refurbished as applicable.


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Coils submerged in oil that satisfy the dielectric strength test and are in factory sealed tanks, can be put into service if insulation resistance exceeds 300 Megohms between windings and ground and other windings. A check of megger readings against manufacturers test certificate shall be made.

Coils submerged in oil that fail the strength tests and coils shipped without insulating oil must undergo out-of-liquid megger tests. The megger readings should be in excess of 300 Megohms.

If the windings fail the megger test they shall be dried out and retested.

Drying should be continued until four consistently high resistance values are obtained covering at least four consecutive measurements over a period of at least 16 hours of the drying time.

If the internal heat method is used for drying, it shall be carried out as follows:

a. Short circuit secondary windings. b. Impress voltage of 0.5-1.5% rated voltage on primary windings. c. Limit drying current to one-fifth the normal winding current.

d. Maintain coil temperature at 60 to 70C by adjusting coil current. e. The megger test is to be made at a coil temperature of 60 to 70C. f. Check transformer ratio on all taps.

Check phasing of primary and secondary circuits to ensure continuity of phase colours across the transformer.

Perform ratio test to confirm winding connections and transformer ratios.

7.5 MOTORS

Record nameplate data and compare with motor data sheet entries.

On totally enclosed machines open drain hole. Replace porous drain plugs.

Measure insulation resistance using 500V megger for 415V motors and 5 kV megger for 6.6 kV motors. Apply test for one minute. The megger readings should not be substantially lower than values shown on Manufacturers test certificates. If certificates are not available the following shall be considered as minimum acceptable values:

750kV and Below (at Ambient Temperature) 415V 6600V

1.5 megohm 50 megohm

For motors 200kW or above, a polarisation index measurement shall be made. The index should be above 1.5. For 415V motors a 500V megger shall be used, for 6.6 kV motors a 5 kV megger shall be used.


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Motors that fail insulation tests must be dried out. The coil temperature must not exceed the following values:

Insulation Temperature Class A 60C Class B 80C Class E 75C Class F 100C

Drying should be continued, until four consistently high resistance values are obtained. Readings should be taken at four-hour intervals.

During the half-hour acceptance run with load disconnected, check and record motor temperature, speed, current, rotation and vibration. Measure the insulation resistance on completion of the run.

Frequency of large motor starts shall be maintained within the allowable limits.

Before energising slip ring motors check rotor resistance grading and record the connection layout of the resistors. Check that sequence and timing of rotor resistance contactors correspond to the drawings and that rotor resistance is successively reduced.

On motors fitted with condensation heaters and /or winding temperature detectors, measure the resistance of the winding temperature detectors and megger the heaters.

For motors fitted with motor protection relays, carry out relay calibration checks in accordance with the appropriate test sheet.

Check that all terminated boxes have Denso tape applied.

Ensure that the armouring or screening of cables run from a VSD to a motor is positively earthed at both the motor and the VSD to prevent radiation of electromagnetic energy.

7.6 CABLES

Visually inspect accessible cables to confirm insulation integrity and that cable route and separation between power and control cables are in accordance with design.

Visually inspect that correct type and size of cables have been used, also inspect for correct cable and wire numbering.

Check terminations for correct glanding, earthing and terminations.

Ensure that glands are appropriately protected against corrosion.

Ensure that cable earth conductors do not pass through any toroidal CTs fitted to the cable.

For HV XLPE cables, the Superintendent or deputy, shall visually inspect the first cut back of the semi-conducting sheath and verify that the method employed does not cut into the XLPE insulation.


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All cables must be meggered and HV cables shall be further tested at HV AC for 15 minutes.

The test voltages to be used for all cables are as follows:

Megger / DC AC 50 Hz Cable Rating Test Voltage Test Voltage Phase to Earth Test Voltage Phase To Phase

0.11 kV 500V N/A N/A 0.6 / 1 kV 1000V N/A N/A

3.8 / 6.6 kV 5 kV 4.2 kV 7.2 6.35 / 11 kV 5 kV 7 kV 12 12.7 / 22 kV 5 kV 14 kV 24

Testing of trailing cables is to be carried out in accordance with procedures outlined in AS1747.

7.7 CONTROL EQUIPMENT In all control cabinets, relay panels, lighting and power panels, junction boxes and field mounted devices:

a. Check all terminals for proper connections. b. Check all enclosures for loose wires, tools and components. c. Check for proper identification of wires, terminals, terminal boxes, instruments, control

switches, electrical relays and the like. d. Check for proper fuse ratings of all control circuits using drawings and schematic diagrams.

Also check for burned-out fuses. e. Check all switches and push-buttons for completeness of movement, installation,

adjustment, rating and labelling. f. Make sure that enclosures are equipped with drain and breather fittings if specified, and

inspect all boxes for any moisture collection. g. Check for proper bundling of wires. h. Check all wires terminated for being free of unintentional earth connections. i. Check for proper sequence of connections as per schematic diagrams. j. Check for proper earthing of enclosures and screen and drain wires in cables. k. Check for proper sealing of conduit connections, cable glands and other penetrations. l. Check that all spare conductors are identified and terminated, or neatly laced back with

sufficient length in the duct. m. Check cable polarities, cable sizes and cable types against drawings. n. Check polarity of all static devices such as diodes. o. Check circuit cards and /or drawings that are required to be left in the enclosures.


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p. Check that all relay coils are suitable for the designed operating voltage and that the relays are fitted with the required number of contacts; the contacts are free of oxidisation and that armature is free to operate.

q. Check that Denso tape is applied to all junction boxes/enclosures.

7.8 BATTERIES AND BATTERY CHARGERS

Carry out the following checks:

a. Check battery case for cracks or damage. b. Check battery terminals for tightness and general appearance. c. Check protective devices. d. Compare battery and charger polarity. e. Check charging current and voltage. Adjust if necessary. Carry out tests on each battery in accordance with the appropriate sections of AS2191.

7.9 EARTHING AND LIGHTNING PROTECTION

The earthing system shall be checked to ensure that all parts of steel structures, motor frames, switchgear, trays, conduits and other electrical equipment are earthed in accordance with the drawings and the relevant standards.

Check that the Control and Computer System earthing systems are adequate and effectively separated.

Check that earthing connections and layouts are in accordance with relevant drawings.

Check that all connections to the main earth are clearly identified.

With the use of an earth-testing meter determine the earth resistances of individual earth stakes and the combined earth resistance of the main earth grid. The same tests shall be applied to the lightning earth grid.

Check all earthing bars, earth neutral links and test connections following testing.

After completion of individual earth tests the overall earthing/lightning resistance will be measured.

7.10 LIGHTING AND SMALL POWER CIRCUITS

Carry out the following tests on the circuits and equipment:

a. Test each individual circuit with a continuity tester to ascertain that the wiring and connections are correct.

b. Check all power outlets for correct polarity and correct operation of earth leakage protection equipment.


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c. Test for correct functioning of all Earth Leakage Protection Devices.

d. Check for earth continuity.

e. Check for correct cable marking.

When all lighting system tests have been completed satisfactorily, the system shall be energised and functional tests shall be executed. Check that floodlights and all other directional fittings direct light into the specified areas. Check illumination levels.

Check the correct functioning of Emergency Lighting Packs. The burning time of Emergency Lighting shall be recorded.

Check that all Lighting and Power Distribution Boards are fitted with correct, complete and legible Circuit Schedules.

Check minimum clearance of 1.2 metres is maintained in front of distribution boards.

7.11 FUNCTIONAL TESTS

At the conclusion of the foregoing component tests, the system as a whole shall be tested for correct function by applying or simulating all possible inputs, and observing that the appropriate response or output is obtained.

Particular attention is to be given to the response to:

a. Electrical protection trips and alarms

b. Mechanical protection trips and alarms (limits, pressure, temperature, etc.)

c. Local control operations (MCC, etc.)

d. Field control operations (emergency stops, pullwires, etc.)

e. Remote control selection and operation

Functions checked should include:

a. Correct tripping

b. Local trip and alarm indications

c. Remote trip and alarm indications

d. Local metering and control indications

e. Remote metering and control indications

f. Satisfactory on-load operation

g. Achievement of guaranteed performance levels


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7.12 HAZARDOUS LOCATIONS

During testing of electrical equipment using energy sources (eg. megger) within a defined hazardous area, the test leads shall be applied to the cables outside the hazardous area and the system whilst under test shall comply with the hazardous area requirements.

7.13 PROGRAMMABLE CONTROLLERS

Programmable controllers (PLC) are used in a variety of applications in industry including batch control, motor control, process logic or interlocking and as a direct replacement or substitute for conventional analog electronic instruments and distributed control systems.

Consequently, all pertinent documents including flow sheets, piping and instrument diagrams, Loop drawings, cable schedule, hook-up drawings, location drawings and I/O address schedules shall be available at all times for point to point wiring checks, complete Loop checks and system checks.

Visual inspection for programmable controllers should verify that:

a. All modules listed in the reference documents are fitted.

b. The chassis and modules have not been subjected to physical damage. Ensure that all Dual In-line Pin (DIP) mode select switches and configuration links on the chassis, processor modules and I/O modules have been set correctly in accordance with the reference documents and manufacturers recommendations.

Check that all I/O modules have been correctly labelled with their complete reference addresses.

Confirm that all inter-connector cables have been installed in accordance with the reference documents.

Check that all I/O cabling to field devices and the field devices themselves are installed and comply with the reference documents.

Verify that the supply to all field devices and I/O is isolated.

Remove all fuses on the field side of interposing relays and D.C. supply for inputs.

Switch on the AC power supply to the processor and I/O power supply modules and verify that the DC output voltages are correct. Check that all power status indicators are correctly illuminated. Also check that the processor back up battery is fitted, healthy and that the battery age is within acceptable limits.

Load the programme into the processor and verify that all I/O can be correctly addressed and that no fault indicators are illuminated.

Switch on the DC supply for digital output interposing relays. Force each output on individually and verify that:


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a. The indicating LED on the output module illuminates.

b. The corresponding interposing relay is energised.

c. The indicating LED on the interposing relay board illuminates.

For each of the analog outputs connect a 5 digit digital meter of 0.01% accuracy to the output terminals and verify the cards calibration and operation.

For each of the analog inputs, connect the 5 digit meter to the input terminals with an analog supply and verify the inputs calibration and operation.

Verify that all communication cables are run with adequate clearance from power cables and in appropriate conduit to ensure shielding against stray electric or magnetic fields.

Verify all communications between PLCs, PLC and Computer, PLC and motor controller and PLC and operator interfaces.

Switch on the DC supply to the input field devices and prove, using the PLC programmer, that each field device when operated:

a. Illuminates the LED on the relevant digital input card.

b. Indicates the relevant state in the PLC data tables.

Switch on the power supplies to the analog input devices and check the readings obtained. Where possible, manually operate the analog devices and verify their operation.

Instrumentation

Before start-up of a new installation, the completed instrumentation and control equipment installed shall be fully tested to ensure it is in proper working order. Accordingly, approved for construction drawings, appropriate test and calibration instruments certified to AS3912.1 and in accordance with CSBP Procedure Calibration and Maintenance of Process Control Measuring Equipment (DP-05-010-01), and the relevant manufacturers instruction manuals shall be utilised.

Pre-operational checks such as the removal of shipping stops and other initial procedures detailed in the manufacturers instruction manual shall be carried out. Electronic instrumentation shall be energised for twenty-four (24) hours before testing.

Documentation required in addition to that generally described in Section 7.13 shall include a schedule of calibration data by tag number for all installed instrument hardware and a schedule of bench sets for all pneumatic control valves.

The correct installation of all field instrumentation shall be verified by visual inspection with reference to the relevant location drawings and hook-up drawings.

Check that the correct supplies, both pneumatic and electric have been provided.

The calibration of all instruments shall be checked in both upscale and downscale directions and their as left condition be within the limits of accuracy stated by the manufacturer. All calibration


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records shall be entered into the designated Instrument Service Calibration Sheet (PF1004). An approved calibration sticker, signed and dated shall be placed in an accessible but protected area of the device.

Digital input devices such as temperature, pressure, flow, level switches etc., shall be checked for correct installation with reference to the relevant location and hook-up drawings and tested at their operating points. A continuity test circuit shall be connected across the contacts to ensure correct operation.

Solenoid valves shall be similarly checked with respect to their installed state. A flywheel diode shall be installed across either the solenoid valve or the PLC/DCS output. The operation of each valve shall be checked, by operating a test switch and observing that the changeover action is correct. Electrical and manual reset, override and time delay features shall be checked as specified by the manufacturer. Tight shut-off shall be verified when required by a bubble test at the stated design shut-off pressure.

Control valves may be calibrated to the nominated bench set in the workshop. Their correct installation shall be checked against the relevant piping and instrument, hook-up and location drawings. Particular attention should be paid to the quality of the instrument air supply and the indicated header pressure.

Loop testing shall be carried out to ensure that all instrumentation components in the Loop are in full operational order when connected together and are in a state ready for plant commissioning.

Loop testing of remote loops will generally require at least two people with suitable means of communication. The use of portable radios should take into account the published RF immunity of all components in the Loop and adjacent instrumentation. The Superintendent shall witness final Loop tests and they shall include the stroking of all final control devices from the relevant controller.

Alarms and trips associated with the instruments installed shall be set and tested as part of the above procedure and their functional correctness recorded on the Instrument Service Sheet.

8. TEST RECORDS All tests shall be recorded on Commissioning Test Reports listed in Section 4.0. These represent the minimum standard of test reporting required.

Test Record Sheets shall be developed as required for specific tests. The Superintendent shall approve them after consultation with the Engineering and Maintenance Support Managers prior to being put to use.

Where a Contractor carries out pre-operational testing, and the Contractor has an established system of Test Record Sheets, they may use them if approved by the Superintendent.

Note: CSBP shall have the opportunity to witness all tests carried out by the Contractor. Witnessing by CSBP is at CSBPs discretion and does not constitute approval of the test results.


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9. HANDOVER

All electrical, electronic and process instrumentation including programmable logic controllers and final control elements shall be complete and demonstrated to be working to the satisfaction of the plant manager prior to the hand-over and acceptance certificates being prepared.

Handover of as-built drawings, data sheets, check lists, test results, operating and maintenance instruction manuals, quality assurance / quality control reports etc. that are prepared during the design, construction and commissioning of the plant, together with the transfer of responsibility to the business unit shall be in accordance with CSBP Engineering Procedure Engineering Project Handover (EP-08-030-38).

The final Handover Certificate (SF0958) shall be issued and signed only when all electrical systems and circuits, control loops and individual instrument systems have been demonstrated to work satisfactorily and have been accepted by the plant manager.

If, at the moment of final acceptance, certain items are, for unforeseeable reasons still pending, they shall be individually listed as exceptions to the final Handover Certificate (SF0958) and agreement shall be marked and noted concerning the method of completing the exceptions and the time for its completion.

10. RECORDS MANAGEMENT

10.1 AS-BUILT DRAWINGS

On completion of installation, testing and commissioning activities, drawings shall be upgraded to reflect any as-built design deviations. Responsibility for this shall be specified in the Works.

Drawings recording the as-built details shall be prepared/revised, numbered, approved and handed over in accordance with CSBP Engineering Standards:

ES-14-101-02 Drawing Management

ES-14-101-03 Drawing Preparation

ES-14-101-04 Drawing Numbering

10.2 ENGINEERING PROJECT FILES

On completion of the project and Handover to the Business Unit, all relevant hard-copy documentation shall be archived in the designated work area in numbered project files in accordance with CSBP Engineering Procedure Engineering Project Files (EP-08-030-05).

Records in electronic format (such as drawings and JDE data) shall be stored in the appropriate database and designated work area.

ES-14-902-02

Documents

Transcript of ES-14-902-02