R1111-Prc-El-00-001 Electrical Inspectio and Test Plan PDF

ELECTRICAL INSPECTION AND TEST PLAN
NO. R1111-PRC-EL-00-001
Rev. 0
PAGE: 2 / 34
Revisions report:
Revision No
0A
0
002/AR 11/11
Revision Description
Issued For Approval
Final Issue
04/10
NO. R1111-PRC-EL-00-001
Rev. 0
PAGE: 3 / 34
TABLE OF CONTENTS
1
SCOPE .......................................................................................................................................4
DEFINITIONS .........................................................................................................................4
INVOLVEMENT LEGEND AND DEFINITIONS ...............................................................4
MATRIX OF INSPECTIONS ACTIVITIES............................................................................4
ITP LIST ....................................................................................................................................5
ATTACHMENT ...................................................................................................................... 12
002/AR 11/11
04/10

1
NO. R1111-PRC-EL-00-001
Rev. 0
PAGE: 4 / 34
SCOPE
The scope of this Quality Control Plan (QCP) is to define the Electrical Installation ,Testing Activities in
accordance with KHARTOUM-MADANI 12"PIPELINE Project.
2
DEFINITIONS
For the purpose of this document the following definitions shall apply:
Client / Owner
Sudanese Petroleum Pipelines Company (SPPC)
Engineering Company
Engineering Procurement & Project Management (EPPM)
Contractor
PCC Contractor
Project
12 NPS Multi Product Pipeline from Khartoum to Madani State
Vendor / Supplier
The party(s) which manufactures and/or supplies equipment,

materials, technical Documents/drawings and services to
perform the duties specified
INVOLVEMENT LEGEND AND DEFINITIONS

H - Mandatory Hold Point For Inspection by full witness of activities .the activities cannot
proceed without witness
W - Witness: Company to be notified in advance prior to starting activity .If company does not
attend activity can proceed
S Surveillance Inspection of activities, random check to verify compliance with Project specs.
R Review: Verification of compliance with specifications by review of documentations.
MATRIX OF INSPECTIONS ACTIVITIES

Activity N
Process Description
Quality Inspection Activities
Specification/ Procedure Reference
Involvements
Report Forms
002/AR 11/11
04/10

5
ITP LIST
EL 01 :
Electrical Cables
EL 02 :
Earthing & Lightning
EL 03 :
Cathodic Protection
EL 04 :
Lighting
EL 05 :
Electrical Equipements
EL 06 :
Electrical Motors
002/AR 11/11
NO. R1111-PRC-EL-00-001
Rev. 0
PAGE: 5 / 34
04/10
NO. R1111-PRC-EL-00-001
Rev.
0
PAGE: 6 / 34
ITP N EL 01
TITLE: Electrical Cables
Activity
No
1
Process Description
Trench
Quality Inspection Activity
Survey and check the trench depth and soft sand

bedding
Specification/ Procedure
Reference
Electrical Standard Details
Inspection and Acceptance
Quality
Subcontractor Contractor Owner Records

W
EL 01-01
EL 01-02
EL 01-03
S/R
EL 01-04
Gable dressing and marking, check for physical

2
Cable verification during/after

laying
damage after laying
Gheck cable size and rating
Gable installation, glanding, earthing,

identification of termination
Hi-pot test on MV cables
Megger test for MV cables
Gable tray installation
Gheck installation details and layout drawings
002/AR 11/11
As per electrical standard

details
As per electrical standard
details
04/10
NO. R1111-PRC-EL-00-001
Rev.
0
PAGE: 7 / 34
ITP N EL 02
TITLE: Earthing & Lightning
Activity
No
Process Description
Installation inspection
for earthing
Installation of Earthing Electrodes & Bus bar
Check correctness of cable size and of the depth
Lightning protection installation checked
Reference
Quality
Subcontractor Contractor Owner Records
EL 02-01
EL 02-02
Earth resistance for

2
earth electrodes and
Earth resistance testing
grid checked
002/AR 11/11
04/10
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Rev.
0
PAGE: 8 / 34
ITP N EL 03
TITLE: Cathodic Protection
Activity
N
Process Description
Installation of anodes
Installation of anode
2
junction box/Test
Points
002/AR 11/11
Visual inspection
Visual inspection
Testing
Reference
Quality
Subcontractor
Contractor
Owner
Records
EL 03-01
S/R
EL 03-02
04/10
NO. R1111-PRC-EL-00-001
Rev.
0
PAGE: 9 / 34
ITP N EL 04
TITLE: Lighting
Activity
N
002/AR 11/11
Process Description
Lighting & Area lighting

System
Earthing connections completed
Base plates, fixings, support fixed as per detailed

drawing
Installation of lighting poles and fixtures
Orientation and alignment correct
Flood, road and column light, installation
Reference

Subcontractor Contractor
Quality
Owner
Records
EL 04-01
Electrical Standard
Details
04/10
NO. R1111-PRC-EL-00-001
Rev.
0
PAGE: 10 / 34
ITP N EL 05
TITLE: Electrical Equipements
Activity
N
1
Process Description
Power Transformers
Reference
Quality
Subcontractor
Contractor
Owner
Records
Installation Inspection
EL 05-01
Generator
EL 05-02
Switchgear
EL 05-03
Distribution Boards
EL 05-04
UPS & DC Power Supply
EL 05-05
002/AR 11/11
04/10
NO. R1111-PRC-EL-00-001
Rev.
0
PAGE: 11 / 34
ITP N EL 06
TITLE: Electrical motors
Activity
N
Process Description
Quality
Reference
Subcontractor
Contractor
Owner
Records
EL 06-01
Name plate, equipment classification

and IP rating check
Motors Installation
Earthing completed and checked against

design requirements
Gland completed, spare entries plugged

cable termination are correct
002/AR 11/11
04/10
NO. R1111-PRC-EL-00-001
Rev. 0
PAGE: 12 / 34
ATTACHMENT
EL 01-01 :
Trench Release For Cables Installation
EL 01-02 :
Cables Installation Report
EL 01-03 :
MV Pressure Test Report
EL 01-04 :
Cables Tray Installation Report
EL 02-01 :
Earthing System Inspection Report
EL 02-02 :
Earth resistance Test Report
EL 03-01 :
Anode Installation Inspection Report
EL 03-02 :
Junction boxes & Test Points Installation Inspection Report
EL 04-01 :
Lighting & Small Power Socket Installation Report
EL 05-01 :
Transformer Installation Inspection Report
EL 05-02 :
Generator Installation Inspection Report
EL 05-03 :
Switchgear Installation Inspection Report
EL 05-04 :
Distribution Boards Installation Inspection Report
EL 05-05 :
Batteries & UPS Installation Inspection Report
EL 06-01 :
Electrical Motor Installation Inspection Report
002/AR 11/11
04/10
Trench Release For Cables Installation

EL 01-01
Location/System
Description
Trench/Line No
Drawing No
No
Items to be Checked
Location Of Trench As per Drawing.
Trench Depth As Per Drawing.
Trench Depth As Per Drawing.
Soil Compaction ( If Applicable).
5
6
Results
Cleanliness ( Free Of Stone, Debris, Sharp edge,

Foreign Materials..)
Sand-bed as Required
Note:
Date
Name
Company
Visa
Inspection Performed
by
Date
Name
Compan
y
Visa
Inspection Accepted by
Remarks
Cbles Installation Report

EL 01-02
Item
Description of check
Results
01
Cable is the correct type and size. As per the drawings
02
Cable glands/constant force springs are the correct type, and correctly fitted.
03
Ensure IP sealing washers & serrated washers are fitted to gland, where required
04
On single core cables, ensure that cables are earthed as shown on the contract
electrical drawings & ensure correct type of glands are fitted
05
Ensure bending radius is within the manufacturers recommendations
06
Confirm cable route and segregation are correct including verification of destination
07
Inspect cable markers throughout length, transit and end

Inspect there are no damage to cores, termination chamber layout is satisfactory,
08
core identification marker is correct and crimped satisfactory cable terminated as per
latest revision of drawing
09
Confirm spare cores and screens are terminated as per drawings
10
Inspect earth bonding is correct to design drawing
11
Ensure protective measures (Kick Plates) are fitted correctly
12
Inspect continuity and IR test of the cables
Cable N
From
To
Core to
Core
Core to
Screen
Core to
Armour
Continuity
Sub System
N
Cable N
From
To
Core to
Core
Core to
Screen
Core to
Armour
Continuity Sub System

N
TEST EQUIPMENT DETAILS:

MANUFACTURER
MODEL N.
Inspection Performed by
Date
Name
Company
Visa
SERIAL N.
Date
Name
Company
Visa

EL 01-03
A.
INDENT/CONTRACT N:
LOCATION:
SYSTEM/DUTY:
MANUFACTURER:
N OF CORES:
SIZE:
N OF RUNS:
CONSTRUCTION:
RATING:
COLOUR:
Sl. N
Description of check sheet
Cable is correct type & size as per cable schedule.
Cable glands are correct type and installed correctly.
Ensure IP sealing washers are fitted to gland where required.
Check earth bonding is correct to design drawings.
5.
Confirm cable route and segregation are correct.
Check cable bending radius is within the
manufacturers recommendation.
Check cable markers are correct through transits and each end.
Confirm the mechanical protection is fitted as required.
Carry out HV pressure test and record the results.
10
Reconnect all cores and confirm correct phasing.
11
Confirm correct termination and fit of terminal box cover.
Remarks/Comments:
Status
Initial/Sign.

EL 01-03
MV Pressure Test Results
Insulation Resistance (IR) Test (before J-IV pressure test) use 5000V Megger DC.
Between conductors
L1 - L2, L3, E Screen
IR - M
J-IV Pressure Test (DC voltage applied) = (
kV) Refer to manufacturer's specification for cable.
Record leakage current on page 3

Between conductors
Leakage mA (maximum)
Duration Mins
Insulation Resistance (IR) Test (after J-IV pressure test) use 5000V Megger DC.
Between conductors
IR - M
Note: Ensure after completing J-IV Pressure tests all cores are discharged to earth for a minimum of 1 5 minutes.
Test Equipments Used
Manufacturer/Tag N
Remarks/Comments:
Model N
Serial N
Calibration Due Date

EL 01-03
Test Duration
Leakage Current (Micro-Ampere)

L1 - L2, L3, G
L2 - L3, L1, G
L3 - L1, L2, G
30 sec.
1 min.
2 min.
3 min.
4 min.
5 min.
6 min.
7 min.
8 min.
9 min.
10 min.
11 min.
12 min.
13 min.
14 min.
15 min.
Date
Name
Company
Visa
Date
Name
Company
Visa
Remarks
Cables Tray Installation Report

EL 01-04
Equipment Tag N:
Manufacturer:
Location:
Report N:
Item
1
Inspection Activities
Tray/rack conduits and fittings are checked for quality and
conformance to specification
All cable tray supports secured
Fabrication cuts will be painted as specification
Acc.
Sharp edge of cable tray rack/conduits to be file and painted to protect the
cable
Expansion joints fitted where specified
Earth installation and continuity satisfactory
Gables tray supported at correct intervals
No excess pressure on cable tray supports
Entry points to building and field end made good
10
Gable tray/rack/conduits installed as per design and layout drawing
11
Pull ropes are installed to facilitate cable pulling where applicable
12
Gable tray/ladder labelled in accordance with contract drawings
Remarks:
Date
Name
Company
Visa
Date
Name
Company
Visa
Rej.
Earthing System Inspection Report

EL 02-01
Equipment Tag N:
Manufacturer:
Location:
Report N:
Item
1
2
Inspection Activities
Acc.
Buried conductors and earth rods are located in accordance with the design
Conductors installed without protection are sheathed (yellow/green)
The continuity of the protective conductors (PE), equipotential conductors
and other conductors which form part of the earthing system has been
verified
5
6
Conductors rising from the floor or ground are protected by means of a

conduit section
Buries joints of conductors are protected against damp with a bitumen of
similar compound
Air terminations and down conductors for lighting protection comply with
the design
Transformer neutrals are correctly earthed
Terminals and earth bus-bars are correctly installed
Metal sheets and cable armouring are earthed
10
Bus-bar joints or conductor fixing bolts are well tightened
11
Protection against corrosion has been provided and is complete or made

good where necessary
Date
Name
Company
Visa
Date
Name
Company
Visa
Rej.
Earth resistance Test Report

EL 02-02
Equipment Tag N:
Manufacturer:
Location:
Report N:
Earth Pit N/Ref.
Earth Resistance (Ohms)
Remarks
Earth Grid Ref.
Earth Resistance (Ohms)
Remarks
Details of Test Instrument Used:

Instrument
Manufacturer
Material/Serial Number
Date
Name
Company
Visa
Certificate Number
Date
Name
Company
Visa
Anode Installation Inspection Report

EL 03-01
Equipment Tag N:
Manufacturer:
Location:
Type:
Type of Check
S.N
Yes
Check Equipment is De-Energised condition
Check the Anode bed is levelled and compact
Check Anode is installed as per drawing.
Check Anode cable is properly connected.
5
6
Date
Name
Company
Visa
No
Cable testing completed before sand filling the cable trenches/tank

foundation
After back filling put the Anode Marker at the designated place.
Inspection Performed
by
Date
Name
Company
Visa
Remarks
Junction boxes & Test Points Installation Inspection Report

EL 03-02
Equipment Tag N:
Manufacturer:
Location:
Type:
S.N
N J.B & T.P
Type
External Visual
Inspection
Internal Visual
Inspection
Above Ground
Cables &
Termintion
1
2
3
4
5
6
7
8
9
10
11
12
Date
Name
Company
Visa
Date
Name
Company
Visa
Remarks
Lighting & Small Power Socket Installation Report

EL 04-01
Equipment Tag N:
Manufacturer:
Location:
Type:
Item
Verify equipment is suitable for IP rating
Verify name plate ratings etc. are correct against design data sheet or design documents
Visually inspect equipment for external damage
Check equipment fixings and mountings are secure
Check interior for damage, cleanliness and remove packing
Check earthing conforms to project specifications
Check all connections are correct, tight and cable markings are fitted
Check all equipment carries the correct circuit identification
Confirm there is no internal damage to the equipment
10
Confirm equipment has been installed in a maintainable position
11
Confirm correct lamp rating where fitted
12
Confirm glasses or covers are not cracked or broken
13
Confirm correct location and height against layout drawings
14
Confirm covers can be removed easily
15
Confirm outlet cannot be energized whilst the plug is removed
Results
Item
Results
16
Flood, road and column light, installation orientation and alignment correct
17
Confirm all cables have been glanded correctly and to manufactures requirements
Remarks/Observations:
Date
Name
Company
Visa
Date
Name
Company
Visa
Transformer Installation Inspection Report

EL 05-01
Equipment Tag N:
Manufacturer:
Location:
Type:
Serial N:
Item
Inspect the transformer for mechanical damage
Verify name plate ratings etc. are correct against design data sheet or design documents
Inspect foundation fixing details and plinth level
Check transformer assembly as per General Arrangement Drawing
Check interior for damage, cleanliness and remove packing
Inspect all bushings, radiator fins, joints for leakage
Inspect and ensure cleanliness of all marshalling boxes, junction boxes, etc.
10
11
Check polarity of transformer terminals
12
Inspect bolting and gaskets, and that weatherproofing of all marshalling boxes, junction boxes,
etc and ensure that requirements of relevant specifications are met
13
Operation check of protective devices
14
Buchholz rely
15
Pressure relief device
Results
Item
16
Oil level gauge
17
Oil temperature indicator
Results
Date
Name
Company
Visa
Date
Name
Company
Visa
Generator Installation Inspection Report

EL 05-02
Equipment Tag N:
Manufacturer:
Location:
Type:
Serial N:
Item
Confirm that the equipment is supplied in accordance with the data sheet
Orientation and alignment correct
Auxilliary item installed
Fuel oil system charged
Lube oil system charged
Control panel installed
System free from leak and spillages.
10
11
Ensure direction of rotation is clearly marked
12
Operation check of protective devices
13
Generator stator coil
14
15
Generator rotor winding and rotary rectifier coil

Generator AC armature winding
Results
Item
16
Results
armature winding
Date
Name
Company
Visa
Date
Name
Company
Visa
Switchgear Installation Inspection Report

EL 05-03
Equipment Tag N:
Manufacturer:
Location:
Type:
Serial N:
Item
Results
Ensure that pre-commissioning checks have been carried out and the relevant Construction
Test sheet completed
Manufacturer's Test Sheets are available
Current Transformer test satisfactory
Voltage Transformer test satisfactory
Circuit Breaker test satisfactory
Busbar ducter test satisfactory
Check all trip signals to the LV Switchgear
Close Bus-section switches and check outputs.
10
11
Armature winding
Date
Name
Company
Visa
Date
Name
Company
Visa
Distribution Boards Installation Inspection Report

EL 05-04
Equipment Tag N:
Manufacturer:
Location:
Type:
Item
Results
Inspect DB for mechanical damage
Check DB nameplate details
Inspect DB for cleanliness and to ensure correct connections
Check safety features like separation sheets, door, isolator and padlock operations
Inspect to ensure that the weatherproofing is in accordance with the relevant specifications
Check wiring and ferruling in accordance with wiring/schematic diagrams
Check rating of MCCBs, MCBs, ELCB and fuse
Check operation of ELCB
Check earthing connections inside the DBs
10
Inspect cable gland for suitability and tightness
Date
Name
Company
Visa
Date
Name
Company
Visa
Batteries & UPS Installation Inspection Report

EL 05-05
Equipment Tag N:
Manufacturer:
Location:
Type:
Item
Check all equipment is suitable for area
Verify equipment is suitable for IP rating & is supplied as per the data sheet
Verify name plate details against data sheet
Visually inspect equipment for external damage
Check equipment fixings and mountings are secure
Check inside of the equipment is clean, dry and silica gel etc. has been removed
Check all doors can be opened and are not obstructed
Internally inspect the Inverter for damage
Check outgoing distribution is complete and correctly identified
10
Ensure outgoing isolators / MCB s are isolated
11
Confirm main isolator is lockable
12
Check all equipment carries the correct circuit identification
13
On completion of all cable glanding confirm spare entries are correctly plugged
14
Check gaskets and seals are not damaged
15
Check all bolts are correct and none are missing
16
Verify nameplate details against data sheet..
Results
Item
17
Visual inspect equipment for external damage.
18
Check equipment fixings and mountings are secure.
19
Inspect for alignment and secure fixings.
20
Check all terminals and links are secured identified. And clean.
21
Check all bolts are correct and none are missing.
Results
Date
Name
Company
Visa
Date
Name
Company
Visa
Electrical Motor Installation Inspection Report

EL 06-01
Equipment Tag N:
Manufacturer:
Location:
Type:
Item
Results
Inspect motor for mechanical damage.
Ensure that name plate details conform to design data.
Inspect terminal box fixing bolts.
Rotate rotor by hand and check free movement.
Ensure all control and aux. wiring connection done as per IFC drawing.
Check the cable earth wire or armour earth connections inside the terminal box.
Ensure earthing of motor done and connected to main grounding system.
Ensure all cable glands are secured.
Ensure that all cables identify correctly and terminated as per drawing.
10
Check the motor coupling is tight
11
Check that spare cable entries are plugged
Date
Name
Company
Visa
Date
Name
Company
Visa

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ELECTRICAL INSPECTION AND TEST PLAN

ELECTRICAL INSPECTION AND TEST PLAN

INVOLVEMENT LEGEND AND DEFINITIONS ...............................................................4

MATRIX OF INSPECTIONS ACTIVITIES............................................................................4

ITP LIST ....................................................................................................................................5

ELECTRICAL INSPECTION AND TEST PLAN

Sudanese Petroleum Pipelines Company (SPPC)

Engineering Procurement & Project Management (EPPM)

12 NPS Multi Product Pipeline from Khartoum to Madani State

The party(s) which manufactures and/or supplies equipment,

INVOLVEMENT LEGEND AND DEFINITIONS

MATRIX OF INSPECTIONS ACTIVITIES

ELECTRICAL INSPECTION AND TEST PLAN

Earthing & Lightning

ELECTRICAL INSPECTION AND TEST PLAN

Quality Inspection Activity

Survey and check the trench depth and soft sand

Inspection and Acceptance

Subcontractor Contractor Owner Records

Gable dressing and marking, check for physical

Cable verification during/after

damage after laying

Gheck cable size and rating

Electrical Standard Details

Gable installation, glanding, earthing,

Hi-pot test on MV cables

Megger test for MV cables

Gable tray installation

Gheck installation details and layout drawings

As per electrical standard

ELECTRICAL INSPECTION AND TEST PLAN

Quality Inspection Activity

Installation of Earthing Electrodes & Bus bar

Check correctness of cable size and of the depth

Lightning protection installation checked

Inspection and Acceptance

Subcontractor Contractor Owner Records

Electrical Standard Details

Electrical Standard Details

Earth resistance for

earth electrodes and

Earth resistance testing

ELECTRICAL INSPECTION AND TEST PLAN

Quality Inspection Activity

Electrical Standard Details

Electrical Standard Details

Inspection and Acceptance

ELECTRICAL INSPECTION AND TEST PLAN

Lighting & Area lighting

Quality Inspection Activity

Earthing connections completed

Base plates, fixings, support fixed as per detailed

Installation of lighting poles and fixtures

Orientation and alignment correct

Flood, road and column light, installation

Inspection and Acceptance

ELECTRICAL INSPECTION AND TEST PLAN

Quality Inspection Activity

Inspection and Acceptance

Electrical Standard Details

Electrical Standard Details

Electrical Standard Details