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MINISTRY OF ELECTRICITY General Directorate For Gas DIBIS Tender

Power Plant Project 2011

Republic of Iraq
Ministry of Electricity

DIBIS 2xSGT5-PAC 2000E


Dual fuel + Heavy Fuel Oil

Section-VI-Chapter 3

Annex 04

TESTS AND INSPECTIONS

TOTAL PAGES: 17
Including this page

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Table of Contents

1. Tests and Inspections................................................................................................................................4


1.1 General Tests and Inspections...........................................................................................................4
1.2 Materials...........................................................................................................................................4
1.3 Castings.............................................................................................................................................5
1.4 Forgings............................................................................................................................................5
1.5 Welding.............................................................................................................................................5
1.6 Non-destructive testing....................................................................................................................6
2. Tests in Manufacturers Works..................................................................................................................7
2.1 Tests on mechanical systems and equipment...................................................................................7
2.1.1 General.....................................................................................................................................7
2.1.2 Pipework...................................................................................................................................7
2.1.3 Structural steelwork..................................................................................................................8
2.1.4 Vertical site welded storage tanks.............................................................................................8
2.1.5 Castings, forgings and wrought products..................................................................................9
2.1.6 Pressure vessels........................................................................................................................9
2.1.7 Valves........................................................................................................................................9
2.1.8 Pumps.......................................................................................................................................9
2.1.9 Motor driven auxiliaries............................................................................................................9
2.1.10 Cranes.....................................................................................................................................10
2.2 Electrical systems............................................................................................................................10
2.2.1 General...................................................................................................................................10
2.2.2 Auxiliary Services: General.....................................................................................................10
2.2.3 Auxiliary Services transformers...............................................................................................11
Type test.................................................................................................................................................11
Routine Tests..........................................................................................................................................11
2.2.4 Distribution Board...................................................................................................................11
2.2.5 Low voltage AC Distribution Board..........................................................................................12
2.2.6 DC supplies equipment...........................................................................................................12
2.2.7 Protection equipment.............................................................................................................13
2.2.8 Control systems.......................................................................................................................13
3. Site Tests.................................................................................................................................................14

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3.1 Open cycle plant.............................................................................................................................14
3.2 Switchgear and ancillary equipment...............................................................................................14
3.3 Transformers...................................................................................................................................14
3.4 Battery equipment..........................................................................................................................15
3.5 Cabling............................................................................................................................................15
3.6 Test equipment...............................................................................................................................15
3.7 Generator.......................................................................................................................................16
3.8 Excitation system............................................................................................................................16
3.9 Control and instrumentation..........................................................................................................16
3.10 Main connections...........................................................................................................................17
3.11 Earthing and lightning protection systems......................................................................................17
3.12 Lighting and small power................................................................................................................17

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1. Tests and Inspections

1.1 General Tests and Inspections

Tests and inspections shall include electrical, mechanical, hydraulic or any other tests to ensure that the plant
being supplied complies with the requirements of the Specification and with the standards as applicable to
the plant.

Tests shall be conducted in accordance with the specified standards. For equipment not covered by such test
standards nor specifically mentioned in the specification, the test procedure shall be agreed between MoE
and/or the Owners Engineer and the Contractor.

All important forgings are to be jointly examined at the manufacturers factory by MoE and/or the Owners
Engineer and by representatives of the manufacturer during forging and heat treatment.

An approved method of radiographic or other non-destructive testing is to be used for proving all welding
associated with pressure vessels. The Contractor shall supply suitable test pieces of all materials as required
by MoE and/or the Owners Engineer.

Control, instrumentation and plant control system will be subject to Factory Acceptance Tests (FAT), which
will be carried out at the Contractors works. These tests will be carried out after the Contractor has
completed all his integrated system testing in the Works and consists of General System Testing and
Performance Testing.

In addition to particular inspections and tests specified herein, MoE and/or the Owners Engineer reserves
the right to carry out any such other inspections and tests, as he may deem necessary to ensure that the works
complies with the requirements of the specification .

All site welding and testing of mechanical, civil/structural and electrical systems connecting to the GE
supplied equipment must meet GEs recommendations. Furthermore, all testing on GEs supplied scope will
be by the contractor under GEs on site technical direction.

1.2 Materials

All materials must be supplied in accordance with the EN Group of Standards and Specifications or
equivalent with written agreement of MoE and/or the Owners Engineer. The Contractor shall indicate the
generic material type(s) being processed i.e. 1 per cent Cr steel, 2 per cent Cr. steel, 9 per cent Cr. steel,
stainless steel, etc, and the nature of the work, i.e. forging, casting, fabrication work, etc.

The Contractor shall provide test pieces as required by MoE and/or the Owners Engineer to enable him to
confirm the quality of the material supplied under the Contract. Such test pieces shall be prepared and
supplied free of charge and any cost of the tests shall be borne by the Contractor.

If any test piece fails to comply with the requirements of the appropriate specifications for the material in
question, MoE and/or the Owners Engineer may reject the whole of the material represented by that test

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piece; the Contractors or subcontractors designers and metallurgists will be consulted before any material is
so rejected.

If MoE and/or the Owners Engineer is furnished with certified particulars of tests which have been carried
out for the
Contractor by the suppliers of material, he may, at his own discretion, dispense with the previously
mentioned tests.

1.3 Castings

Castings where defined below for specific components or equipment shall be examined by Magnetic Testing
(or penetrant testing for non-magnetic castings) and Ultrasonic Testing using established procedures and
acceptance standards which have been approved by the contractor and submitted.

Weld repairs may be made at the foundry prior to final heat treatment without the permission of MoE and/or
the Owners Engineer but records and maps showing the excavation sizes and defect types shall be submitted
prior to commencement of repairs. Major repairs are defined as excavations >20 per cent of the wall
thickness or >25 mm deep, or >65 cm2, or which result in leakage on hydrostatic test. All other repairs are
classed as minor repairs.

Major weld repairs shall not be made after rough machining without the prior written agreement of MoE
and/or the Owners Engineer. Requests to repair after rough machining shall be accompanied by the weld
repair procedure, the supporting procedure qualification report and a map indicating the defect types and the
dimensions of the excavations. Minor repairs after rough machining shall be report to MoE and/or the
Owners Engineer.

1.4 Forgings

Forgings shall be supplied in compliance with the applicable standards and specifications except where
modified elsewhere in this document.

Forgings as defined below for specific components or equipment shall be examined by ultrasonic testing
after rough machining. Bores, fillets and changes of section shall be examined by magnetic testing (penetrant
testing for non-magnetic materials).

1.5 Welding

All fabrication welding and, where agreed in writing by MoE and/or the Owners Engineer, repair welding
must be carried out using written and qualified procedures, welders and operators except where modified
and agreed in writing with MoE and/or the Owners Engineer.

At least 8 weeks prior to commencing fabrication the Contractor shall, except where otherwise agreed by
MoE and/or the Owners Engineer, submit for review four copies in the English language of:

Welding procedures together with the relevant procedure qualification records.


Non destructive testing procedures.
Heat treatment procedures.

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Welding procedures and welders' qualifications shall be in accordance with the latest revision of BS EN 288
and BS EN 287 respectively or equivalent ASME Standards.

The welding procedures submitted shall include all of the details required by BS EN 288, both essential and
non-essential variables for the particular welding process(es) together with a detailed sketch of the weld
joint.

The Contractor shall maintain for review, or if requested shall submit to MoE and/or the Owners Engineer
documentary evidence of the competency of all welders employed on the Contract. Where documentary
evidence does not exist welders' qualification tests will be required by MoE and/or the Owners Engineer. If
in the opinion of MoE and/or the Owners Engineer the welders are not carrying out the work in a suitable
manner the Engineer reserves the right to call for samples of welding for examination and test. The
Contractor shall bear all costs for carrying out such tests.

For the purposes of identification, the welders name and/or check number shall be retained by the Contractor
as part of the Quality Assurance System. These documents shall be made
available for review by MoE and/or the Owners Engineer.

In no case whatsoever will stamping or hammering of alloy material be allowed.

Welding consumables e.g. electrodes, filler wires, flux and shielding gas shall deposit weld metal that has
mechanical properties at least equal to the minimum values required for the parent material.

All consumables shall deposit weld metal of similar composition as used in the procedure and welders'
qualification tests.

The Contractors welding plant and ancillary equipment shall be in accordance with the appropriate parts of
EN 60974 and shall be maintained in good working order.

Permanent backing rings are not permitted and temporary backing rings shall only be used as allowed by the
relevant approved welding procedure.

All surfaces for welding shall be clean and free from paint, oil, grease, rust, scale or other material
detrimental to welding. All butt weld preparations shall be completed by machining, grinding, machine or
manual flame cutting with subsequent grinding.

The use of temporary attachments welded to components shall be avoided where possible. If used, the
attachments shall be removed flush with the base metal after they have served their purpose and the area of
attachment shall be examined by the method specified for permanent fillet welds in the system.

The carbon contents shall not exceed 0.25 per cent for carbon and carbon-manganese steels which are to be
welded unless otherwise approved in writing by MoE and/or the Owners Engineer.

Where post weld heat treatment is required by the fabrication specification the heat treatment charts showing
temperature time shall be retained by the Contractor. The charts shall indicate the heating and cooling rates,
holding temperature and time and shall clearly identify the component(s) or weld(s) heat treated.

Sufficient thermocouples shall be in contact with the furnace load to ensure adequate heat treatment.
Attachment shall be by capacitor discharge method unless otherwise agreed by MoE and/or the Owners
Engineer.

Welding in the fabrication shop or at Site shall be done under the supervision of a qualified welding engineer.

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1.6 Non-destructive testing

NDT of castings, wrought products and weldments shall be carried out in accordance with the appropriate
Euro Norme except where otherwise specified by MoE and/or the Owners Engineer.

The techniques of ultrasonic, radiographic, magnetic particle, liquid penetrant and leak detection methods
applicable to all the principle items of plant shall be to the approval of MoE and/or the Owners Engineer.

Dye penetrant examination shall not be used on ferritic materials.

NDT operators shall be qualified in accordance with an agreed nationally accredited scheme such as the
Personnel Certification in Non-destructive testing (PCN) scheme and shall be certificated to level II or higher
of that system. Alternative NDT qualifications equivalent to NDT level II may be submitted to MoE and/or
the Owners Engineer for approval. Where in-house qualification systems are employed these will be subject
to quality audit by MoE and/or the Owners Engineer.

The Contractor shall submit a document relating the weld procedure, weld finish, acceptable criteria and the
extent and method of non-destructive testing for each weld or group of welds.

The Contractor shall institute and maintain a record of all approved non-destructive tests and these records
shall be readily available for verification by MoE and/or the Owners Engineer.

Where requested the welding, heat treatment and manufacturing procedures shall be submitted .

2. Tests in Manufacturers Works

2.1 Tests on mechanical systems and equipment

2.1.1 General

The tests shall be arranged to represent working conditions as closely as possible.

Type tests when called for shall be made on equipment which has previously passed its routine tests.

Where type tests have been carried out under previous contracts on equipment similar in all essential respects
to the equipment included in the Contract, MoE and/or the Owners Engineer may waive the type tests on
production of complete test records relating to the equipment concerned.

2.1.2 Pipework

The supply, fabrication and erection of all pipe work shall comply with the requirements of EN 13480 or
ANSI B31.1.

All butt welds shall be full penetration welds with complete fusion between weld runs and base metal.
The following tests shall be carried out on welds (both shop and Site).

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a. 100 per cent visual examination of all welds to the requirements of the application standard.

b. At least 10 per cent ultrasonic or radiographic and surface flow examination on all pipe butt welds
and branch welds to the acceptance criteria of the applicable standard.

c. At least 10 per cent magnetic particle examination of all fillet welds.

d. Hydrostatic test to the requirements of the applicable code.

Weld defect acceptance levels shall be in accordance with the applicable standard except that lack of root
fusion or incomplete root penetrant will not be permitted.

2.1.3 Structural steelwork

Welding and inspection in both shop and site shall be in accordance with Section 5 of BCSA publication No
203/93 - National Structural Steelwork Specification for Building Construction, or AWS D1.1 except as
modified by Section 9 of the Contract Specification.

Where only partial inspection is required the location of the joints selected for testing shall be agreed by
MoE and/or the Owners Engineer.

Should any of these welds prove to be defective on inspection, the number of welds to be tested in that
system shall be twice that originally required. Should any of the second increment welds prove to be
defective, then all the welds in that system shall be tested.

Weld defect acceptance levels shall be in accordance with Table 2 of BCSA document No 203/94 or AWS
D1.1 as appropriate.

2.1.4 Vertical site welded storage tanks

The storage tanks and associated valves and pipework shall be designed, manufactured and tested in
compliance with API 650 and associated specifications. The Contractor shall recognize during material
selection and testing the limitations imposed by site and service conditions. Welding process during shop
and site fabrication and erection shall be limited to MMA (SMAW), SAW, TIG (GTAW), MIG (GMAW)
(excluding short-circuiting mode), and FCAW (excluding self-shielded). For the purposes of welding this
component weld procedures, welders, weld operators and non-destructive test operators may be qualified in
accordance with ASME/ASTM Codes.

Where required by Code, surface crack detection shall be made by magnetic testing on ferrite materials. All
branch welds including reinforcement plates and load bearing fillet welds shall be examined by magnetic
testing. Penetrant testing may be applied to non-magnetic materials only.

Spot radiographic examination may be applied in accordance with the Code subject to, as a minimum, all
intersections of welds shall be included with a minimum weld length of 75 mm from the intersection and are
in addition to the requirements specified in Figure 6.1 for vertical and horizontal joints. In addition where
circular openings and reinforcement plates are located within the allowable dimensions specified in the Code
the weld joint seam shall be subject to 100 radiographic examination for a distance of 1.5 times the opening
diameter from each point of intersection.

MoE and/or the Owners Engineer may determine the locations for spot welds and shall select from welds
completed by all welders equally. Radiographs shall be produced, interpreted and presented to MoE and/or

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the Owners Engineer within 24 hours of completing the weld. MoE and/or the Owners Engineer reserves
the right to request additional radiographs at no additional cost.

On completion of erection the tank shall be subject to a water test to a static head determined by the design.

2.1.5 Castings, forgings and wrought products

All castings, forgings and wrought products shall be subjected by the manufacturer to chemical analysis,
material tests and inspections in accordance with the appropriate BS except where otherwise agreed by MoE
and/or the Owners Engineer. Inspection should be scheduled in order to detect defects as early as possible,
to avoid unnecessary delay in manufacture and delivery of the plant. In case of a rejection influencing the
delivery time, written and certified notice must be given in due time to MoE and/or the Owners Engineer.

MoE and/or theOwners Engineer reserves the right to examine and witness acceptance tests, prior to and
following weld repairs and subsequent post weld heat treatment, mechanical tests etc, at the material
suppliers works.

Weld repair procedures are subject to approval of the Engineer.

2.1.6 Pressure vessels

All pressure vessels shall be designed, fabricated and tested in accordance with PD 5500 or ASME section
VIII. MoE and/or the Owners Engineer reserves the right to verify or witness any activity required by the
Specification.

2.1.7 Valves

All castings and forgings shall comply with the requirements of this Specification and BS 759 or BS 6759 as
applicable to the service of the valves. All valves shall be subject to hydraulic test at 1.5 times the PN rating
of the valve. In addition valves supplied with butt weld ends shall be subject to radiographic or ultrasonic
examination for a length of 75 mm from the prepared weld tip and magnetic particle examination of the weld
tip profile.

2.1.8 Pumps

All castings and forgings shall comply with the requirements of this Specification. In addition the radii,
changes in section and butt weld ends of the castings shall be subject to magnetic particle and radiographic
or ultrasonic examination unless otherwise agreed by MoE and/or the Owners Engineer.
Castings shall be subject to hydraulic test at 1.5 times the design pressure.

Pump rotors shall be subject to ultrasonic examination in the rough machined condition and magnetic
particle or dye penetrating examination in the final machined condition unless otherwise agreed by MoE
and/or the Owners Engineer.

Dynamic balance shall be carried out on the completed rotor and performance tests carried out on the
completed pumps to the requirements of BS EN ISO 9906 and BS EN ISO 5198 as appropriate.

Pumps shall be factory tested with their contact motors.

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2.1.9 Motor driven auxiliaries

All motor driven auxiliaries shall be run at 20 per cent overspeed for two minutes.

2.1.10 Cranes

Electric overhead travelling cranes shall be designed, manufactured and tested in accordance with BS 466
and BS 2573 or equivalent internationally recognized standards.

Electrical tests on the cranes in manufacturer's works shall include:

a. thyristor and rectifier assembly


b. control gear and wiring
c. Contactors
d. motors.

2.2 Electrical systems

2.1.1 General

The equipment provided is subject to inspection and tests by MoE and/or the Owners Engineer during the
course of manufacture and on completion in order to ensure compliance with this Specification. The
Contractor shall give MoE and/or the Owners Engineer a list of the tests to be conducted for each system
one (1) month after the purchase order has been placed and at least 14 days notice of materials for inspection
or test. For tests of long duration at least one months notice shall be given.

The Contractor shall provide to MoE and/or the Owners Engineer as soon as practicable after tests have
been witnessed three copies of the relevant test certificates. These shall contain details of each test
performed. Records, results and calculations of all electrical tests shall be provided.

All tests shall be carried out in the presence of MoE and/or the Owners Engineer unless otherwise agreed in
writing. All instruments used shall have valid calibration certificates, and calibration data shall be made
available to MoE and/or the Owners Engineer on demand. All the inspection, measuring and test equipment
required for inspections and tests shall be provided by the Contractor.
The Contractor shall provide type test certificates for identical or essentially similar equipment which
satisfies MoE and/or the Owners Engineer. Such certified results shall be presented to MoE and/or the
Owners Engineer for consideration no later than six months after the Contract date.

Six copies of test certificates detailing all the works tests performed shall be issued by the Contractor to MoE
and/or the Owners Engineer within two months of completion of works tests on each item of plant or
equipment.

2.1.2 Auxiliary Services: General

All tests shall be carried out in accordance with the latest edition of the applicable standards.

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The Contractor shall supply the type test certificates as required by applicable standards, such as:

a. Impulse voltage tests;


b. Sound level test;
c. Temperature rise tests;
d. Short-circuit with stand test.
e. Other tests

Where Type test certificate is not available the Contractor shall get the test done and offer for test witness.

The routine tests shall be carried out by the Contractor as required by applicable standard, such as::

a. Measurement of winding resistance ;


b. Voltage ratio measurement and check of polarity;
c. Measurement of load losses and short-circuit voltage;
d. Measurement of no-load losses current;
e. Separate source voltage with stand test:
f. Measurement of partial discharge

2.1.3 Auxiliary Services transformers


Type test:

The Contractor shall supply the type test certificates as required by applicable IEC standards, such as:
a. Impulse voltage test;
b. Sound level test;
c. Temperature rise test;
d. Short-circuit withstand test.

Routine Tests:

The contractor shall carry out routine tests as required by the applicable IEC standards, such as -
a. Measurement of winding resistance;
b. Voltage ratio measurement and check of polarity;
c. Measurement of load losses and short- circuit voltage;
d. Measurement of no-load losses and current;
e. Separate source voltage withstand test;
f. Measurement of partial discharges.

2.1.4 Distribution Board

All tests on the Distribution Board and the various components shall be carried out in accordance with
the latest edition of applicable IEC Stantdards.

Type tests

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The Contractor shall supply the following type test certificates:

a. Verification of temperature-rise limits;


b. Verification of the dielectric properties;
c. Verification of the short-circuit strength;
d. Verification of the continuity of the protective device;
e. Verification of the clearance and creepage distances;
f. Verification of mechanical operation;
g. Verification of degree of protection.

Routine test

The following routine test shall be carried out by the Contractor:

a. Inspections of the equipment, including inspection of wiring, and if necessary, electric operation test;
b. Dielectric test;
c. Checking of protective measures and electrical continuity of the protective circuit.

2.1.5 Low voltage AC Distribution Board

All tests on the Distribution Board and the various components shall be carried out in accordance with
the latest edition of applicable IEC Stantdards.

Type tests
The Contractor shall supply the following type test certificates:

h. Verification of temperature-rise limits;


i. Verification of the dielectric properties;
j. Verification of the short-circuit strength;
k. Verification of the continuity of the protective device;
l. Verification of the clearance and creepage distances;
m. Verification of mechanical operation;
n. Verification of degree of protection.

Routine test
The following routine test shall be carried out by the Contractor:

a. Inspections of the equipment, including inspection of wiring, and if necessary, electric operation test;
b. Dielectric test;
c. Checking of protective measures and electrical continuity of the protective circuit.

2.1.6 DC supplies equipment


Performance tests. One battery shall be subjected to the emergency discharge and recharge time
requirements of the Specification. Voltage/time, current/time and specific gravity/time curves shall be plotted
throughout the recharge period.

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The automatic and manual voltage control system and alarm and indication functions of the chargers.
regulation, efficiency shall be demonstrated to the satisfaction of MoE and/or the Owners Engineer.

2.1.7 Protection equipment

All relays shall be subjected to routine tests at the manufacturer's works to confirm that
they comply with the claimed performance and design limits.

For measuring relays (ie relays which have a defined setting of the input and/or characteristic quantity
subjected to accuracy requirements, eg current, time, etc) these routine tests shall include as a minimum the
following:

a. Measurement of the assigned error(s) under reference conditions, ie measuring


accuracy and operating time characteristics.

b. Measurement of the resetting ratios.

c. Dielectric tests as specified in Clause 6 of IEC 60255-5, the test voltage being 2 kV rms. All
normally open output contacts of all relays shall withstand a test voltage of 1 kV rms.

For all-or-nothing relays, the routine tests shall include a check of relay operation and resetting, together
with the dielectric tests described above.

Unless otherwise agreed with MoE and/or the Owners Engineer, all unit protection schemes using either
biased differential, current balance or voltage balance principles shall be subjected to heavy current con
junctive tests using the actual current transformer windings which will be used in service. Tests shall be
made to prove operating sensitivity, time of operation and to demonstrate stability of the protection under the
worst transient external fault conditions. Tests will only be waived if the manufacturer is able to produce type
test results for an identical scheme. In this case it will be sufficient to prove that individual component
characteristics are identical, eg current transformers are of the same design, have the same magnetization
characteristics, knee-point voltage and secondary resistance.

Each circulating current protection scheme designed must fulfil the following routine testing requirements:

a. Each current transformer, which must be of the low reactance type, shall beindividually tested
for turns ratio, secondary winding resistance and excitation characteristic up to a secondary
voltage equal to 120 per cent of the knee-point voltage.

b. The VA consumption at operation of current operated relays shall be measured and shall not
exceed the maximum value declared by the manufacturer.

c. The operating current of voltage relays shall be measured and shall not exceed the maximum
value declared by the manufacturer.

2.1.8 Control systems

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3. For each separate control system, the correct operation of all inputs,
outputs, control functions, monitoring functions, operator display
systems, printing systems and all associated systems shall be tested to a
test specification which shall be approved by MoE and/or the Owners
Engineer in advance of the factory acceptance testing. The factory
acceptance testing shall be witnessed by MoE and/or the Owners
Engineer.Site Tests

3.1 Open cycle plant

The Contractor shall carry out, under GEs TA directions, the performance tests. .

For details, reference the requirements specified in Section IV, Chapter 4 of these specifications and to
Section IV, Chapter 3 Annex 06, Extracts from GE Contract, Section 16 (Performance Testing).

3.2 Switchgear and ancillary equipment

Tests before completion.

These shall comprise Site testing to demonstrate complete satisfactory operation of the equipment after
transport and installation generally in line with the routine tests as per applicable standard in the
manufacturer's works.

Commissioning and setting to work.

This shall include the tests recommended by the equipment manufacturer and shall include the following:

a. The checking of all connections, and conductivity testing of bus bar joints.
b. The checking and ringing through of all small wiring and multicore cables connected to the
equipment.
c. Dielectric testing of all primary circuits on the equipment.
d. Insulation resistance measurement of all secondary circuits on the equipment.
e. Primary injection of all protective and metering circuits to check satisfactory operation.
f. The checking for satisfactory adjustment and operation of all circuit breakers, switches, and
mechanical and electrical interlocks.
g. Secondary injection tests on relays and instruments to check operating characteristics.
h. Tests to check the magnetism curve, polarity and resistance of current transformers.
i. Final setting of all protection.
j. Secondary injection of voltage transformer circuits.
k. Phasing tests prior to making live.
l. On-load checks of protection, indicating and metering circuits.

3.3 Transformers

Tests before completion.

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This shall include the tests recommended by the equipment manufacturer and shall include the following

a. Insulation resistance of core and windings at not less than 2000 V dc.
b. Insulation resistance of auxiliary wiring.
c. Proving of manual and electrical operation of each device.
d. Operation of equipment in accordance with the overall control scheme.

Commissioning and setting to work. This shall include:

e. Ratio and no-load current at reduced voltages on all tappings. Vector relationship at reduced voltage.

3.4 Battery equipment

Tests before completion.

This shall include the tests recommended by the equipment manufacturer and shall include the following
after erection of the batteries/chargers and switchboards:
a. The checking of all connections.
b. 500 V insulation testing of all primary and secondary circuits.
c. Primary injection of all protection and indication circuits.
d. The checking for satisfactory adjustment and operation of all circuit breakers,
e. switches and mechanical and electrical interlocks.

Dummy loads if required for testing shall be provided by the Contractor.

3.5 Cabling

Routine insulation tests shall be made and recorded on all cables, joints and sealing ends etc.

HV dc tests at 4Uo shall be made between conductors and between conductors and sheath on cables
operating between 3.3 kV and 33 kV.

1000 V insulation tests shall similarly be made on LV power cables and dc power supplies cables.

500 V insulation tests shall be applied between all cores and earth on all multicore cables.

On terminations with insulated glands (single core cables) a 1000 V insulation test shall be carried out
between armour and/or sheath and earth.

3.6 Test equipment

The Contractor shall provide all the necessary instrumentation, vibration and balancing equipment, recorders,
sensors etc with experienced test engineers and staff to carry out these tests.
Six copies of test certificates for all the site tests shall be issued by the Contractor to MoE and/or the
Owners Engineer.

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The Contractor shall submit his Site test proposals and programme to MoE and/or the Owners Engineer for
approval 3 months before site tests are due to commence. The following tests shall be included in the tests to
be carried out.
Continuity tests shall be carried out on all earthing systems to ensure that the resistance to earth of all earthed
equipment does not exceed 0.5 ohms.

For the GT performance tests, GE will provide test equipment using a combination of permanent station
Instruments and precision test instruments supplied by GE on a temporary basis. These instruments will be
installed and commissioned by the contractor under GEs on site technical direction.

3.7 Generator

The Contractor shall perform checks and tests under GE technical direction as required and recommended by
GE.

3.8 Excitation system

The Contractor shall perform checks and tests as required and recommended by GE.

Tests shall be carried out on each machine to demonstrate that the equipment performs correctly and as
specified, and that stability margins are adequate.

A commissioning test programme for the completely assembled excitation equipment shall be agreed with
and approved by the Engineer:

3.9 Control and instrumentation

Installation and commissioning shall be generally in accordance with BS 6739.

Test documents shall be produced and shall include check lists to be witnessed by MoE and/or the Owners
Engineer. These test documents shall contain agreed acceptance criteria.

The Contractor shall record the results of all calibration checks and loop tests on suitable check sheets such
as those examples given in BS 6739.

Commissioning will in general be achieved in the following stages:

a. Calibration and performance tests prior to operation.

This shall include:

i. Calibration of total loop where possible.


ii. Performance check using simulated input/output conditions.
iii. Sequence and interlock equipment proving.
iv. Control loop functions using simulated conditions.

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v. Software testing.
vi. Redundancy tests.
vii. Data communications checks.

b. Cold plant interface tests:

These shall be carried out with equipment connected to the main plant and shall as far as possible
demonstrate that plant may be controlled safely and to specification.

c. Hot plant performance tests:

These shall be carried out in conjunction with the main plant in operation. They shall include on-line
tests to demonstrate that all control and plant monitoring equipment are within specification in an
operating environment. Tests may also involve co-operation during any required plant performance
guarantee testing.

3.10 Main connections

After erection at Site the main connections shall be subject to dielectric, conductivity and temperature rise
tests to prove compliance with the specified requirements.

3.11 Earthing and lightning protection systems

Each electrode shall be tested before being connected to the underground copper grid
earthing system. Continuity tests shall be carried out on all earthing systems and lightning protection
systems to ensure that connections are mechanically sound and the resistance to earth of all equipment and
terminations does not exceed the
design value.

3.12 Lighting and small power

After completion and before being energized the installation shall be inspected and tested. All tests required
by Part 7 of BS 7671.shall be carried out.

After energization, the operation of all lighting and small power circuits and devices shall be demonstrated,
including the automatic and emergency circuits.

Illumination levels for all normal and emergency systems shall be measured.

The Electrical Installation Certificate in Appendix 6 of BS 7671 shall be completed in its entirety and issued
to MoE and/or the Owner Engineer.

END OF SECTION IV, CHAPTER 3, ANNEX 04

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