Procedure for installation & Testing of Electrical Equipments

Procedure for installation & Testing of Electrical Equipments

1.0	PURPOSE
	1.1	The purpose of this procedure is to provide the minimum requirements for the installation of Electrical equipments, cable laying and termination for the Project”.
2.0	SCOPE
	2.1	The scope of this procedure covers the Installation and Testing of Electrical equipments, cable laying and termination for the Project
3.0	REFERENCES
4.0	DEFINITIONS
	4.1	Company         –
	4.2	Contractor        –
5.0	ABBREVIATIONS
	5.1	CLIENT	-	Kuwait Oil Company.
	5.2	PD	-	Project Director
	5.3	QR	-	Quality Representative
	5.4	QAM	-	QA/QC Manager
	5.5	PM	-	Project Manager
	5.6	DO	-	Director of Operations
	5.7	EE	-	Electrical Engineer
	5.8	MOV	-	Motor Operated Valve
	5.9	NEMA	-	National Electrical Manufacturers Association
	5.10	IEC	-	International Electro technical commission
	5.11	XLPE	-	Cross linked polyethylene
6.0	PROCEDURE
	6.1	Explosion proof DB
	6.1.1	The Distribution Board shall be, EEX’d’type and the certified for the use in Zone II, II B T3 application.
	6.1.2	Flame proof DB shall be suitable for 440V, 50Hz, 3 phase, 4 wire power system and it shall have fault level rating not less than 10MVA symmetrical.
	6.1.3	DB shall be suitable for the service in an ambient temperature of 55oC.
	6.1.4	The ingress protection of enclosure shall be of minimum IP 55.
	6.1.5	The foundation , alignment and orientation shall be checked with approved drawings
	6.1.6	The incoming feeder circuit breaker shall be 4 pole MCCB types with variable thermal and magnetic type releases.
	6.1.7	Circuit breaker shall be provided with external trip free externally operating handle. Handle shall be lockable in ‘off’ position.
	6.1.7	Circuit breakers shall have minimum 14kA interrupting capacity and rated for 600 volts.
	6.1.8	Cable entry shall be from below. All the cable shall be terminated with explosion proof cable gland and shroud.
	6.1.9	Engraved nameplates shall be provided on DB components to identify all circuit breakers, contactors, relays, switches, indicating lights and other devices.
	6.1.10	Name plate shall be fabricated with Three-ply urea plastic approximately 2.5mm thick, 38 mm wide and 102 mm long with black lettering on white background. Engraving shall be 5mm standard block style characters.
	6.2          MOV Actuator
	6.2.1	MOV Actuators used in zone 1 and zone 2, hazardous areas shall be flame proof certified Ex ’d’ suitable for group IIB and temperature class T3.
	6.2.2	The motor shall be suitable for 440 V AC, 3 Phase, 50 Hz power supply.
	6.2.3	The motor shall be of high torque – low inertia, single speed squirrel cage type with life time pre lubricated bearings.
	6.2.4	Motor windings shall have minimum class F insulation with a temperature rise limited to class B in accordance with BS 2757.
	6.2.5	Motor shall be protected against loss of one or more phases by a single phasing prevention.
	6.2.6	An integral local / off / remote switch shall be provided where remote operation is specified for facilitating transfer control between the remote systems and the integral push buttons.
	6.2.7	Local position indicator shall be provided for continuous display of the valve position form fully “open” to fully “closed”.
	6.2.8	The actuator assembly shall include all necessary limit switches and torque switches required for normal travel operation and indication purposes, to suit the control and indication requirement specified in the data sheet / P & ID.
	6.2.9	The position limit switch shall be adjustable over the full range of valve travel.
	6.2.10	The gear box shall be of robust construction and be an integral part of the actuator. The out put characteristics shall match the requirements of the particular service both for speed and torque requirements.
	6.2.11	A hand wheel shall be provided for manual operation under all operating condition, independent of the motor.
	6.2.12	The terminal box shall be separately sealed and shall provide adequate room for the necessary terminals, which shall be angled to assist making of connections at the facility.
	6.2.13	All cable entries shall be provided with suitable certified flame proof glands as specified in the data sheet.
	6.2.14	All metallic casings of the actuator shall be provide with electrical continuity, and internal and external studs shall be provided for terminating the earthing cable.
	6.3           Cable Laying
	6.3.1	Cables shall be laid in excavated trenches/trays as per the Instrument main cable trench/tray layout drawings, Instrument cable schedule, Instrument cable drum schedule and CLIENT Specifications CLIENT-E-008, CLIENT-E-023.
	6.3.2	The correct permit to work shall be obtained prior to excavation. In plant areas, excavations shall be carried out by hand. Underground facilities detection using suitable equipment/slit trenching shall be carried out prior to excavation.
	6.3.3	Trenches shall be cleaned of all foreign materials before laying the cables. The dimensions of the trenches shall be checked against the approved drawings and recorded in Attachment No.3.
	6.3.4	Sand bedding of 75 mm shall be provided before laying the cable as per the trench layout drawing.
	6.3.5	Cable shall be tested on cable drums using a suitable megger and recorded in Attachment No.5 & Attachment No.6
	6.3.6	Cable rollers shall be placed at suitable locations, to avoid bends so that smooth laying of cables with out damaging the outer sheath.
	6.3.7	Cables shall be spaced at a minimum of 3000 mm distance from other services, e.g., Pipes or as approved by CLIENT.
	6.3.8	Where cables enter buildings, pass under roads, bunds and similar obstructions, they shall be installed in 150mm ducts. At each duct bank, 20% spare ducts shall be provided, with a minimum of two spare ducts for future use. All duct ends, including spare ducts shall be sealed with suitable sealant.
	6.3.9	Voltage grade separation shall be maintained while installing cables in ducts. No ducts shall have more than 40% of its cross-sectional area filled.
	6.3.10	Non corrosive cable markers with preprinted characters shall be fixed to cables at both ends and every 30 meters along the route. The number of each cable shall correspond to the number allocated in the cable schedule
	6.3.11	Where cables surface from below ground, they shall be protected by substantial galvanized steel pipes which shall extend from 150mm below ground level to a minimum of 150mm above ground level to provide mechanical protection of cables. Pipes shall be sized to have 60% of area unused.
	6.3.12	The cables shall be laid on and also covered by 100 mm layers of clean sand and then concrete cable tiles laid 100mm above the cables. The cable tiles shall overlap the cables on the extreme outside.
	6.3.13	Cables passing through duct banks shall be sealed and protected
	6.3.14	Spare holes in duct banks and cable entry to the control room shall be sealed
	6.3.15	Cable inspection during the laying and after laying shall be offered to CLIENT.
	6.3.16	Cables shall be tested and results approved before backfilling takes place. Cable ends shall be sealed to prevent ingress until ends are made up.
	6.3.17	The first 100mm of backfill shall be of soft sand, well compacted and level. Excavated non contaminated sand and soil, free from gatch and stones, shall be used for backfill over concrete cable tiles. The backfill shall be firmly compacted in layers up to the grade level.
	6.3.18	Route markers inscribed in Arabic and English shall be provided to identify all trenches and shall be installed at every 30 meters along the route and at changes of direction.
	6.3.19	Cable rising from below ground shall be provided with protection sleeve 100 mm from grade level and sealed.
	6.4	Cable laying in trays/ladders
	6.4.1	Cables above ground shall be installed as follows: Where cables run above grade, they shall be securely fixed and suitably supported. Heavy duty hot dip galvanized steel cable racks or trays and shall be bonded for electrical continuity & earthed.  Structural support should twice - 200% of cable weight
	6.4.2	Cable racks and trays shall be attached to steel supporting structures of buildings, platforms and pipe ways and purpose provided support steelworks. They shall not be supported from process piping.
	6.4.3	Cables shall be laid as per the cable schedule and shall be tied to trays or ladders at intervals of 350mm. On horizontal runs where the cables are supported throughout the length or where a number of small cables tied together in bunch, these spacing may be increased. Trays / ladders shall be bonded to safety earth.
	6.4.4	Cables shall be laid with sufficient slack to prevent stress.
	6.4.5	Cables shall be laid not more than two layers deep in any tray or ladder racking.
	6.4.6	The minimum permissible bending radius shall be observed.
	6.5	Cable Terminations
	6.5.1	All cable termination and joints shall be done as per CLIENT standard 381/020 clause 14.12
	6.5.2	Jointing and termination shall be in accordance with the specified phase rotation.
	6.5.3	Cable conductors shall be fitted with correctly sized ferrules or lugs.
	6.5.4	Cable gland shall be of correct size to match the appropriate cable. All glands shall be properly earthed as per the earthing layout. The gland shall be covered with PVC shroud.
	6.5.5	Glanding and termination shall be carried out as per the approved cable termination drawings. All terminations shall be made with approved tools. Where screw down terminals are used, crimped pin or spade connection with retaining lips shall be used. Sufficient slack shall be left neatly at the terminal to remake the connection.
	6.6	Cable testing
	6.6.1	After completion of cable installation, they shall be tested for continuity of core and insulation resistance using a suitable and certified megger and recorded in Attachment No.5 & Attachment No.6.
	6..2	Cable connections to the equipments shall be disconnected prior to dielectric tests and discharged to earth after the test to ensure safety from accumulated charge.
	6.7	Earthing
	6.7.1	All non-current carrying metal components of electrical installations and power consuming equipment shall be connected to earthing system as per standard CLIENT-E-024 and approved earthing layout drawings.
	6.7.2	Where electrical apparatus is required to be bonded to an earthing system, any cable used for such purpose shall be sized to carry out the total fault current.
	6.7.3	Earthing conductors shall be provided with an over all protective covering with green or green with yellow stripes PVC.
	6.7.4	Earthing cables shall only be terminated above ground with correctly sized crimped lugs by using correct sized and approved crimping tool.
	6.7.5	Lugs, bolts, nuts, washers, screws, clamps, cleats and other items which come in direct contact with copper earth bars, tapes and cables etc. shall be non ferrous and manufactured from brass, bronze or other suitable conducting materials which will not cause electrolytic corrosion. Connection between copper and galvanized structures shall additionally be tinned.
	6.7.6	Earthing conductors shall be continuous lengths. If joining becomes absolutely necessary, they will be joined by fusion welding with the prior approval.
	6.7.7	The position of all earthing connections shall be visible and easily accessible.
	6.7.8	Maximum earth resistance shall be 4 ohms as per CLIENT Standard 381/020. Sufficient number of earth electrodes shall be provided to achieve this value.
	6.7.9	Earth electrode shall comprise of solid copper earth rod, phosphor bronze couplers, steel driving tip, steel driving head, conductor clamp, and concrete inspection pit.
	6.7.10	Earth electrode shall be driven in to the ground with out excavation or drilling. A concrete inspection pit with cover shall be provided as per the relevant drawing.
7.0	HSE
	7.1	Supervisor shall ensure that all necessary health and safety procedures during the excavation, cable laying, and backfilling.
	7.2	Equipments shall be checked periodically and maintained in good conditions
	7.3	All relevant safety requirements of CLIENT Fire & safety regulations and CLIENT’s HSE requirements shall be strictly followed.
8.0	Attachments
	8.1	Attachment  No. 1			Inspection Check list for Explosion proof DB installation
	8.2	Attachment  No. 2			Inspection check list for MOV Actuator installation
	8.3	Attachment  No. 3			Inspection check list for direct buried cables
	8.4	Attachment  No. 4			Inspection checklist for Cable installation in Trays & Conduit
	8.5	Attachment  No. 5			Insulation resistance test report for Power Cables
	8.6	Attachment  No. 6			Insulation resistance test report for control cables