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1.0 PURPOSE The purpose of this document is to ensure safe, high quality and consistent installation of the electrical system at the Escravos Produced Water Disposal facility.
2.0 SCOPE This Electrical work procedure covers all onshore electrical construction activities, Installation, inspection and testing of electrical system on Main deck, Cellar deck, Jacket and Bridge of the Escravos Produced Water Disposal facility. The overviews of work are as follows: Unboxing and Sorting of Lighting Accessories Cable drum testing Fabrication and Installation of Cable Tray Supports Fabrication and Installation of Cable Tray Earth Bonding Junction Box Installation Bridge Conduit Installation and Wiring Fabrication and Installation of Stanchion / Pendant Light support Installation of Plant Lighting Systems Transformers Installation and Termination Electric Motors Installation and Termination MV, LV Power and Control Cable Pulling Cable Glanding and Termination Cable Tagging and Core Identification Testing (Meggering and Continuity) Mechanical Completion Checks
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3.0 REFERENCE All construction work, installation and testing shall be carried out in accordance with good engineering practice and shall satisfy all statutory requirements of the National and/or local authorities in which the installations will be located.
The following Standards and requirements shall form an integral part of the electrical construction work, Installation, inspection and testing in the Escravos Produced Water Disposal facility:
API RP 14F Recommended Practice for Design and Installation of Electrical System for Offshore Production Platforms ASTM A123 Specification for Zinc (Hot- Galvanized) Coating on Product Fabricated from Rolled, Pressed, and Forged Steel Shaped Plates, Bars, and Strip ASTM A386 Specification for Zinc-Coating (Hot-Dip) on Assembled Steel Products IEEE 45 Recommended Practice for Electric Installation on Shipboard NPFA National Electrical Code 70 NPFA Lightning Protection Code 78
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5.0 RESPONSIBILITIES ! Electrical Team Lead Shall ensure proper implementation of this procedure. He shall coordinate the activities of the Electrical Engineer who leads the Electrical team.
! Electrical Engineer The Electrical Engineer shall be responsible for the following: Verifying all activities relevant to installation and testing of field mounted Equipment and Lighting accessories. Verifying the availability of the materials required for installation. Preparation and submission of as-built drawings and resolving all technical problems that may arise during installation activities. He is also responsible for coordinating with the QA / QC Engineer for resolving technical queries.
! Electrical Supervisor Shall lead the Electrical activities at construction stage; carry out all inspection required; issue the relevant report or checklist and coordinate with the QA / QC Inspector and the Electrical Engineer.
! Quality Control Inspector Shall monitor the proper implementation of the project procedures and specifications. Shall also be responsible for conducting of tests on cables and instruments during delivery and before installation; responsible for all final inspection activities; rectify all punch list items and sign off all finished works.
! Electrical Technician Electrical Technicians shall be responsible for Installing all Electrical equipment and lighting. Coordinating with the Electrical Supervisor, QA/QC Engineer and Electrical Engineer in electrical installation and in resolving technical issues. !"#$%&'" )$'*+#,* -%.,$ )$'/,#. 0'1#'2 !3,$45 6,$&7#," 8727.,* 9:,&$'3 ;74,$7% 8727.,* <!)-=>
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6.0 PROCEDURE 6.1 Receiving and Inspection of Electrical Equipment / Material Upon receipt of electrical materials the QC Inspector and warehouse personnel shall inspect visually the materials and equipment for possible defects, physical damages or missing part. The conformance of the electrical equipment to specifications, hazardous area classification and mechanical certification shall be verified. The provision in the following documents shall form the basis for all the inspection required. Quality Assurance/Quality Control Inspection and Test Plan Manufacturers data and technical manuals Electrical equipment shall be visually inspected for possible damage and defects during handling and shipment. However, for MV / LV Switchgear panels in the MCC, high voltage test on the panel should have been carried out as part of the manufacturers scope in accordance with the relevant CNLs or international Standards; all relevant documents duly signed. 6.2 Pre-Installation Test and Inspection Tests shall be carried out on cables and wires at delivery and before installation and the QC inspector shall perform these test. 6.2.1 Test on Cables The order of test shall be Insulation Resistance Test for " Low Voltage Power Cable (LV) " Low Voltage Control Cable (LV) " Medium Voltage Cable (MV) Continuity Test for " Low Voltage Power Cable (LV) " Low Voltage Control Cable (LV) Medium Voltage Test for Medium Voltage Cable (HV) !"#$%&'" )$'*+#,* -%.,$ )$'/,#. 0'1#'2 !3,$45 6,$&7#," 8727.,* 9:,&$'3 ;74,$7% 8727.,* <!)-=>
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Test equipment to be used are as follows Megger Tester 1000V or 5000V Fluke Multi-tester Hi-Pot Tester 6.3 Electrical Equipment Storage and Preservation Material storage shall comply with the material Control Procedure provided for this project. 6.3.1 The Electrical equipment shall be stored where appropriate in accordance with vendor advice. On receiving the motors, it shall be stored in a dry and clean shelter position, which is free from vibration and rapid change in temperature. The motor shall be covered completely with tarpaulins to prevent ingress of dust or moisture until such a time installation is complete. Where the motor is fitted with anti-condensation heater. With the client approval, a suitable power supply shall be made available; the heater shall be switched on throughout the storage period, particularly where the storage period is likely to be prolonged. Warning notice shall be attached to this effect. 6.4 Calibration All test equipment shall be calibrated in accordance with calibration control procedure and shall be traceable to the applicable standards.
7.0 ELECTRICAL EQUIPMENT INSTALLATION 7.1 Cable tray Supports Fabrication and Installation Structural welders shall carry out fabrication of cable tray support. These Cable tray supports shall be installed on horizontal base plate unless otherwise field adjustments are required. The cable tray supports shall be fastened with bolts and nuts and angular iron for bracing wherever possible for !"#$%&'" )$'*+#,* -%.,$ )$'/,#. 0'1#'2 !3,$45 6,$&7#," 8727.,* 9:,&$'3 ;74,$7% 8727.,* <!)-=>
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reinforcement. Cable tray support shall provide strength and safe working capacity (SWL) sufficient to meet the load requirement of the cables to be laid on top cable trays. The cable tray support material shall agree with the EPWD project specification. Special consideration will be given to center-supported systems considering eccentric loading. 7.2 Paint Touch-up for Cable Tray Support Paint touch-up for cable tray support shall be done with zinc- rich galvanizing materials that meet the required specification. Cable trays that have a Hot-dip galvanized coating shall be re-touched after fabrication i.e. after cutting and drilling since the coating gets damaged over time. Other protective coatings that are cut or damaged must be touched up with compatible coatings. 7.3 Cable Trays Installation Cable tray shall be installed in conformance with NEC A318 and standards set forth in NEMA VE-1 and VE-2 as well that provided by the project (PWD-D017-ELE-DTL- NET-000- 90005 Electrical Installation Details (Power & Control) Offshore Consideration shall be given to loads associated with future cable additions or any other loads to the cable tray system or cable tray support system. Cable tray cut section shall be treated to remove sharp edges, which could cause damage to cables and cause injury to personnel. Insulation separators and insulated fitting materials shall be used to prevent contact corrosion due to the use of SS-316 in combination with steel supports. Cable tray hardware (nuts, bolts and washers..) to be used !"#$%&'" )$'*+#,* -%.,$ )$'/,#. 0'1#'2 !3,$45 6,$&7#," 8727.,* 9:,&$'3 ;74,$7% 8727.,* <!)-=>
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during the installation shall be of 316 stainless steel materials. Where cable trays are linked together, splice plate connectors/hinges shall be used to bolt them and cable tray shall be grounded according to EPWD Grounding specification. The linking points shall be bonded together using a dedicated bond wires, and bonding wires shall have a good surface contacts. Competent and qualified persons familiar with standards electrical construction practices, electrical equipment shall perform the work. 7.4 Cable Pulling. Prior to cable installation, cable path shall be examined to ensure that all areas are free of hazards that may cause damage during cable installation. All cables shall be pulled from the top of the drum and in the direction indicated on the drum according to vendors recommendation. Sufficient cables rollers and side roller (when required) shall be used when pulling cable in position. This will reduce the effort required and ensure the cable outer sheath is not damaged. The minimum bending radius of the cable shall be maintained to prevent damage to the cable After pulling of cables, temporary identification tags shall be attached. Permanent tags shall be attached at the end of termination activities. Correct power and control cable size and type shall be pulled. After pulling, the cable end shall be sealed to prevent moisture ingress
7.5 Cable Glanding Proper sizes of cable gland suitable for the cable shall be used to match the appropriate cable. Any unused cable entry hole shall be plugged. While glanding power cables, it shall be ensured that the loads of the cables are not coming on the glands. Close attention shall be paid to the cable glanding and sealing arrangements on all electrical equipment. 7.6 Cable Termination Termination (wiring connection) shall be done as per specification, wiring drawings and/or manufacturers instruction. Core shall be terminated with pin crimps or cable lugs. These shall be installed with crimping / compression tools and shall be tightened to manufacturers recommended torques. Each lug shall correctly match the cross-sectional area of the conductor and shall be crimped on with the correct compression tools and dies. Power cables and control cables shall be anchored to the cable tray by using cable ties (tie wraps). Sufficient length of cable for connection shall be coiled near the equipment side. Certified HV/MV jointer shall perform all MV cable termination and joints where required. 7.7 Cable Tagging and Core Identification Each cable shall be correctly tagged as per project specification and standards for suitable identification. Identification numbers for power and control cables shall read from terminals outwards Identification shall be in the form of captive o ring ferrule of appropriate diameter engraved or indelibly printed with the cable number, the core number and the terminal number. Wire maker shall be provided for cable wires/cores for power !"#$%&'" )$'*+#,* -%.,$ )$'/,#. 0'1#'2 !3,$45 6,$&7#," 8727.,* 9:,&$'3 ;74,$7% 8727.,* <!)-=>
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cables and control cables. 7.8 Grounding System All metallic enclosures of equipment, cable trays, cable tray structural supports, vessels, skids, structural steel supports etc. as found in bridge, main deck, cellar deck and jacket shall be grounded by connection to the common Earth Grid. The Earthing System / Pattern shall be in accordance with the approved drawings. All Earthing cables shall be PVC covered. 7.9 Electric Motor Electric motors shall be erected or installed in full accordance with the manufacturer instructions and project specification with regards to foundation, alignment, shimming etc. Before electrical hook-up of the electric motor, the Electrical Equipment Field Inspection report form shall be filled, signed and duly approved by all relevant parties. The terminations shall be in correct Phase-Sequence arrangement and marked L1, L2 & L3 at each end. The metal casing of the electric motors shall be earthed using the specified wire size according to project spec.
lLem 8esulL 1 2 3 4 3 6 7 8 9 SlgnaLure uaLe !"#$%&'&( *+ ,"-."# !"/0'12.'3"/ ,"-."# 4! !56 !"/0'12.'3"/ CommenLs/AcLlon (where appllcable) ower, conLrol cable 220 volLs and above, lnsulaLlon LesL accepLable for phase Lo earLh (L1-L, L2-L, L3-L) core Lo core (L1-L2, L1-L3,L2-L3) nC1L: Lnsure any elecLronlc componenLs are dlsconnecLed from clrculL before performlng lnsulaLlon LesL. lnLerface cables marked and sealed off ln Lhe spllce end and colled correcLly and ln accordance wlLh colllng AfLer LermlnaLlon make sure LhaL all cuLLlngs and debrls are cleared away. CorrecL Lype of glands flLLed correcLly and LlghLened, and correcL l washer flLLed. (where Check boxes for each llne numbeer Lo be marked wlLh Ck or nA Cable accordlng Lo daLa on cable schedule (slze and Lype) Labellng, numberlng and core ferrullng correcL. 8endlng radlus, cleaLlng and supporL accordlng Lo speclflcaLlon. 1ermlnaLlon correcL and LlghL and no core damage. Spare cores earLhed and LlghL. ConLlnulLy ln all cores, screen, earLh and armour. AccepLable value 0.2 ohm. Sub-SysLem uescrlpLlon uaLe rlnLed urawlng 8eference unlque lu lLem/1ag no. ro[ecL name: Sub-SysLem no 7%&.'13.8% !97!: ;,<!7=>,7 767!?,@!A6 !A*67 @5B?A66A?@<5
lLem 8esulL 1 2 3 4 3 6 7 8 9 10 SlgnaLure uaLe !"#$%&'&( *+ ,"-."# !"/0'12.'3"/ ,"-."# 4! !56 !"/0'12.'3"/ CommenLs/AcLlon (where appllcable) Check boxes for each llne numbeer Lo be marked wlLh Ck or nA CorrecL [uncLlon box lnsLalled accordlng Lo enclosure classlflcaLlon and are classlflcaLlon, and ln accordance wlLh locaLlon drawlng Labellng, numberlng and ferrule correcL. !uncLlon box mechanlcally sound, solldly and correcLly mounLed. 1ermlnal blocks are of correcL Lype correcLly mounLed, mechanlcally sound and clearly maarked. 8arrlers flLLed where requlred and all connecLlons LlghL. LarLhlng bondlng and colorlng correcL. lnsLrumenL screens segregaLed from elecLrlcal earLh. no Lop enLry cables unless auLhorlzed. Spare enLrles plugged. Cland plaLe correcLly lnsLalled and draln plug lnsLalled where appllcable SufflclenL access for lncomlng cables LqulpmenL locaLed correcLly Lo allow access for malnLenance. Lx & l raLlng as per daLa sheeL, correcLly malnLalned by use of plugs, glands, seals. Check LhaL preservaLlon and mechanlcal proLecLlon ls ln accordance wlLh pro[ecL speclflcaLlon and any dlsLurbed preservaLlon replaced. urawlng 8eference ro[ecL name: Sub-SysLem no Sub-SysLem uescrlpLlon uaLe rlnLed 7%&.'13.8% unlque lu lLem/1ag no. !97!:;977<=767!<,>!?6 >5;<?66?<>@5; 7%&.'13.8% A2/.'3"/ *"B
lLem 8esulL 1 2 3 4 3 6 7 8 9 10 11 12 13 14 13 Lnsure all flxLures as per CA drawlng and as bullL where appllcable. PlghllghLe Lo show all checked equlpmenL ALLach a copy of LlghLlng ClrculL Slngle llne dlagram PlghllghLed Lo show all lnspecLed cables LlghLs 8oxes and SwlLches SlgnaLure uaLe CommenLs/AcLlon (where appllcable) !"#$%&'&( *+ ,"-."# !"/0'12.'3"/ ,"-."# 4! !56 !"/0'12.'3"/ Spare holes plugged wlLh correcL raLed plug and l washer. (where appllcable) All nuLs, bolLs and washers flLLed and accordlng Lo spec lnLernal earLhlng correcL. SufflclenL access for lncomlng cables LlghLlng lnsLallaLlon lnsLalled wlLh sufflclenL access for malnLenance Check core conLlnulLy and clrculL polarlLy of each clrculL and supply. Max accepLable value: 0.2 Chm Check lnsulaLlon reslsLance from dlsL. 8oard for compleLe clrculL aL 300vdc, llve conducLor Lo earLh neuLral Lo earLh, mlnlmum accepLable value 2 Mohms 1ermlnaLlons correcL and LlghL !uncLlon box gaskeL flLLed Lo lld cover Check boxes for each llne numbeer Lo be marked wlLh Ck or nA All equlpmenL lnsLalled accordlng Lo drawlng, speclflcaLlon and area classlflcaLlon, lncludlng all [uncLlon boxes. All Lag numbers correcL, securely aLLached and readable. All equlpmenL undamaged and correcLly mounLed. LlghL flxLures sealed and clean CorrecL Lype of glands flLLed and LlghLened, l washer flLLed.(where appllcable) Sub-SysLem uescrlpLlon uaLe rlnLed urawlng 8eference unlque lu lLem/1ag no. ro[ecL name: Sub-SysLem no 7%&.'13.8% !97!: ;,<!7=>,7 767!?,@!A6 6@B9?@5B @5C?A66A?@<5