bp standard gs 112-1 elec spec for materials & workmanship

GS 112-1

ELECTRICAL ENGINEERINGSPECIFICATION FOR MATERIALS

AND WORKMANSHIP

February 1999

Copyright © The British Petroleum Company p.l.c.

Copyright © The British Petroleum Company p.l.c.All rights reserved. The information contained in this document is subject to the terms andconditions of the agreement or contract under which the document was supplied to therecipient's organisation. None of the information contained in this document shall bedisclosed outside the recipient's own organisation without the prior written permission ofManager, Standards, BP International Limited, unless the terms of such agreement orcontract expressly allow.

BP GROUP RECOMMENDED PRACTICES AND SPECIFICATIONS FOR ENGINEERING

Issue Date February 1999Doc. No. GS 112-1 Latest Amendment Date

Document Title

ELECTRICAL ENGINEERING SPECIFICATIONFOR MATERIALS AND WORKMANSHIP

APPLICABILITYRegional Applicability: International

SCOPE AND PURPOSE

This Specification details the minimum acceptable standard for materials and workmanshipwhich are required in the execution of electrical works undertaken for, or on behalf of,British Petroleum and it’s associated companies

It’s purpose is to give information on acceptable installation and construction methods.

AMENDMENTSAmd Date Page(s) Description___________________________________________________________________

CUSTODIAN (See Status List for Contact)

Electrical EngineeringIssued by:-

Engineering Practices Group, BP International Limited, Research & Engineering CentreChertsey Road, Sunbury-on-Thames, Middlesex, TW16 7LN, UNITED KINGDOM

Tel: +44 1932 76 4067 Fax: +44 1932 76 4077 Telex: 296041

GS 112-1ELECTRICAL ENGINEERING -SPECIFICATION

FOR MATERIALS AND WORKMANSHIPPAGE i

CONTENTS

Section Page

FOREWORD .......................................................................................................................iii

1. INTRODUCTION .............................................................................................................1

1.1 Scope .................................................................................................................11.2 Quality Assurance.......................................................................................................1

2. DOCUMENTATION ........................................................................................................2

2.1 Construction Documents..............................................................................................22.2 As Installed Drawings..................................................................................................22.3 Construction Records Dossier......................................................................................22.4 System Test Dossiers...................................................................................................3

3. GENERAL.........................................................................................................................5

3.1 Contractors Responsibilities.........................................................................................53.2 Site and Equipment Tidiness and Cleanliness................................................................53.3 Tradesmen and Supervision.........................................................................................63.4` Identification..............................................................................................................6* 3.5 Materials and Equipment...........................................................................................63.6 Security and Safety Regulations...................................................................................6* 3.7 Buildings, Structures and Plant.................................................................................73.8 Setting out Works........................................................................................................73.9 Temporary Power Installations.....................................................................................83.10 Portable Handlamps, Electrical Appliances and Tools.................................................83.11 Hand Tools and Aids.................................................................................................8* 3.12 Electrolytic Corrosion.............................................................................................9

4. MATERIALS HANDLING AND STORAGE ............................................................... 10

5. EQUIPMENT IN HAZARDOUS AREAS ..................................................................... 11

6. CONSTRUCTION SITE POWER SUPPLIES.............................................................. 13

7. CABLES, WIRING AND INSTALLATION OF CABLES .......................................... 14

7.1 General ............................................................................................................... 147.2 Underground Cable Installation.................................................................................. 177.3 Cable Installed Above Ground (Onshore) Or Above Deck (Offshore)......................... 217.4 Cables and Wiring for Instrument Systems................................................................. 317.5 Cable Records........................................................................................................... 32

8. INSTALLATION OF ELECTRICAL EQUIPMENT ................................................... 33


FOR MATERIALS AND WORKMANSHIPPAGE ii

8.1 Switchgear............................................................................................................... 338.2 Motors ............................................................................................................... 358.3 Transformers and Reactors........................................................................................ 378.4 Batteries, Battery Chargers and Inverters ................................................................... 388.5 Electrical Surface Heating.......................................................................................... 398.6 Earthing and Bonding................................................................................................ 398.7 Small Power and Lighting Systems............................................................................ 408.8 Generator Packages ................................................................................................... 43

9. INSTALLATION, INSPECTION, TESTING AND COMMISSION........................... 44

9.1 General ............................................................................................................... 449.2 Installation ............................................................................................................... 449.3 Safety Precautions..................................................................................................... 449.4 Inspection and Testing............................................................................................... 459.5. Pre-Commissioning of Electrical Systems.................................................................. 459.6 Pre-acceptance Inspection and Testing....................................................................... 459.7 Energisation and Commissioning................................................................................ 46

APPENDIX A ...................................................................................................................... 48

DEFINITIONS AND ABBREVIATIONS....................................................................... 48

APPENDIX B ...................................................................................................................... 49

LIST OF REFERENCED DOCUMENTS....................................................................... 49

APPENDIX C ...................................................................................................................... 51

INSPECTION AND TEST PROCEDURE...................................................................... 51

APPENDIX D ...................................................................................................................... 91

INFORMATION - HEALTH AND SAFETY.................................................................. 91


FOR MATERIALS AND WORKMANSHIPPAGE iii

FOREWORD

Introduction to BP Group Recommended Practice and Specifications for Engineering

The Introductory volume contains a series of documents that provide an introduction to the BPGroup Recommended Practices and Specifications for Engineering (RPSEs). In particular, the‘General Foreword’ sets out the philosophy of the RPSEs. Other documents in theIntroductory volume provide general guidance on using the RPSEs and backgroundinformation to Engineering Standards in BP. There are also recommendations for specificdefinitions and requirements.

Value of this Guidance for Specification

This Guidance for Specification defines BP’s minimum requirements for electrical engineeringmaterials and workmanship using BP’s knowledge and experience world-wide to ensure thatelectrical installations are carried out to a safe standard using materials of the required type andquality, and comply with good engineering practice commensurate with ease of installation,operation and maintenance.

Application

This Guidance for Specification is intended to guide the purchaser in the use or creation of afit-for-purpose specification for enquiry or purchasing activity.

Text in italics is Commentary. Commentary provides background information which supportsthe requirements of the Specification, and may discuss alternative options. It also givesguidance on the implementation of any ‘Specification’ or ‘Approval’ actions; specific actionsare indicated by an asterisk (*) preceding a paragraph number.

This document may refer to certain local, national or international regulations but theresponsibili ty to ensure compliance with legislation and any other statutory requirements lieswith the user. The user should adapt or supplement this document to ensure compliance for thespecific application.

Principle Changes from Previous Edition

This document has been re-structured, revised and converted to the new ‘Way Forward’ Style.

(a) Various sections have now become sub-sections under new section headings. Thesenew section headings are:-

Cables, Wiring and Installation of CablesInstallation of Electrical EquipmentInstallation, Inspection, Testing and Commissioning


FOR MATERIALS AND WORKMANSHIPPAGE iv

Under the new section heading of ‘Cables, Wiring and Installation of Cables’ are newsub-sections:-

Cable TransitsCable and Wiring for Instrument SystemsCable Records

Under the new section heading of ‘I nstallation of Electrical Equipment’ are new sub-sections:-

Transformers and ReactorsBatteries, Battery Chargers and InvertorsElectrical Surface HeatingGenerator Packages

The new section heading ‘ Installation, Inspection, Testing and Commissioning’incorporates the previously existing text from ‘Inspection, Testing and Commissioning’of the ‘General’ section with new text on Installation, Safety Precautions, Pre-commissioning of Electrical Systems, Pre-acceptance Inspection and Testing and,Energisation and Commissioning.

(b) The following other new sections have been added:-

Equipment in Hazardous AreasConstruction Site Power Supplies

Feedback and Further Information

Users are invited to feed back any comments and to detail experiences in the application of BPRPSEs to assist in the process of their continuous improvement.

For feedback and further information, please contact Engineering Practices Group, BPInternational or the Custodian. See Status List for Contacts.


FOR MATERIALS AND WORKMANSHIPPAGE 1

1. INTRODUCTION

1.1 Scope

This specification covers general standards of workmanship, materialrequirements and construction methods which are required in theexecution of electrical works undertaken for, or on behalf of, BritishPetroleum and it’s associated companies.

It additionally covers the minimum requirements for the installation,testing and commissioning of all electrical equipment and systems.

Details of the various types of installation work likely to be encounteredare included in this Specification, together with those of constructiontechniques required. In this connection due regard must be given to theextremes, widely diff ering, and adverse general climatic conditions thatmay be encountered, together with the environment local to anyparticular part of a plant or area.

National and/or local regulations are frequently applicable and take theform of rules, codes of practice, standards etc. issued by the appropriateauthority for the particular country, state or area concerned. It isessential that the Contractor ensures that easy access to all relevantdocuments for reference is available, since compliance with the abovedocuments could be mandatory and any short-comings might lead todelays and could prejudice the subsequent granting of a plant operatinglicence. Consequently this Specification in no way replaces orsupersedes the requirements contained in any national or localregulations that may be applicable, unless dispensation on any particularmatter has been obtained in writing from the responsible authority. It isacknowledged that differences may occur between the requirements ofthe contract documents, of which this Specification forms part, andthose of the particular authorities concerned, but in such cases the moststringent requirements must be complied with.

1.2 Quality Assurance

Verification of the vendor’s quality system is normally part of the pre-qualificationprocedure, and is therefore not specified in the core text of this specification. If thisis not the case, clauses should be inserted to require the vendor to operate and beprepared to demonstrate the quality system to the purchaser. The quality systemshould ensure that the technical and QA requirements specified in the enquiry andpurchase documents are applied to all materials, equipment and services providedby sub-contractors and to any free issue materials

Further suggestions may be found in the BP Group RPSEs Introductory Volume.



2. DOCUMENTATION

2.1 Construction Documents

Site layout and construction of the installation shall be carried out inaccordance with the approved drawings, standards, schedules,specifications and other documents with form an integral part of theContract, e.g.

(i) Installation Block Diagrams

(ii) Installation and Layout Drawings

(iii) BP Standard Drawings e.g. Earthing, Line Heating, etc.

(iv) Cable and Equipment Schedules

(v) Manufacturer's Drawings and Installation Instructions

(vi) Electrical system protective relay setting schedules andcharacteristic curves, etc.

When the situation on site is such as to render any of the ContractSpecifications inappropriate, e.g. where advantage can be taken of achange in circumstance to the benefit of the work from any aspect, fulldetails should be brought to the notice of BP Site Management in orderthat appropriate action can be implemented.

2.2 As Installed Drawings

The exact siting of equipment, cable routing, jointing and terminalconnection details, together with any deviation from the drawing, shallbe clearly marked on the construction drawings by the Contractor andsubmitted to BP site management on completion of each section of thework, or as otherwise directed.

2.3 Construction Records Dossier

2.3.1 The parts of the dossier relevant to the electrical discipline will consistof all the information necessary to record the condition and as-builtstatus of electrical installation; the results of testing will be included inthe System Test Dossier, ref. 2.4.

2.3.2 Suggested contents of the dossier are:-

(a) An index of design and as-built drawing.

(b) Cable schedules showing installed length of cables.



(c) Cable Drumming schedules with manufacturer’s test certifi catesfor each drum.

(d) Schedule of suppliers of certified bulk equipment e.g. cableglands, junction boxes, push button stations etc. with copies ofapproval certificates from certifying authorities, updated toinclude site purchases.

(e) Index of all tagged items by system showing purchase ordernumber, manufacturer, hazardous area classification code (ifany) and area classification of location.

(f) Index of relevant Engineering Queries in number order,identifying the system to which it applies together with a briefdescription.

(g) Copies of all Engineering Queries, including replies and all otherattachments, filed by system number.

(h) Equipment preservation records as required by BP Group RP32-2.

2.4 System Test Dossiers

2.4.1 The parts of the test dossier relevant to the electrical discipline willconsist of the results of all the tests carried out at site to show that apiece of equipment or circuit is ready for commissioning. Any resultsof tests carried out by vendor’s representatives at site will be includedbut NOT the results of vendor’s works tests, which will be held invendor dossiers.

2.4.2 An index of all the electrical equipment and cables to be tested shall becompiled and broken down into the system designations laid down inProject specifications/procedures.

2.4.3 The system allocation of a piece of electrical equipment shall be decidedby identifying the system in which it operates e.g. the drive motor for aclosed drain pump will be located in the closed drain system.

2.4.4 The cabling and power supply unit (starter, switch fuse etc.) for a pieceof electrical equipment will be combined with the item of equipment forsystem allocation. Using the example of the close drain pump; locatedin the test dossier for the closed drain system will be the test sheets forthe closed drain pump motor, its starter, and the cabling to the motorand push button units, even if the starter is part of a cubicle typeswitchboard.



2.4.5 The final index shall list not only the piece of equipment and itsassociated cabling but also the numbers of all the test sheets and thedate of completion of the test.

2.5 The Contractors activities for the preparation of final documentation,namely, as built-drawings, fabrication and system test dossiers, andoutstanding material lists, shall be carried out under the supervision ofBP.



3. GENERAL

3.1 Contractors Responsibilities

The Contractor will be expected to assume full responsibility for thecompletion of all works necessary to fulfil the specified functionalrequirements listed in the Contract Documents and Job Specification.

The area and degree of responsibility vested in the Contractor for theprotection and maintenance of electrical plant and equipment duringconstruction and commissioning of the Works will be defined in theContract Specification and implementation of these requirements shallbe agreed with BP Site Management before work is commenced.

In general the Contractor shall be responsible for:-

(a) The receipt, inspection and storage of all items of equipmentsupplied by BP.

(b) The supply of all other items of equipment as specified in theContract Documents.

(c) The installation of all equipment, including any necessarysupport structures including fabrication, where necessary, ofsuch supporting materials as specified in the ContractDocuments.

(d) Bringing to the attention of BP any omissions from the ContractDocuments of any items essential for the safe and correctfunctioning of any part of the specified equipment or system.

(e) The testing and pre-commissioning of all equipment and systemsafter installations.

(f) Maintenance of all installed equipment and systems until theworks are formally accepted by, and control transferred to BP.

3.2 Site and Equipment Tidiness and Cleanliness

The Contractor is to ensure that his work sites are kept in a clean andorderly fashion at all times and that unwanted scrap, waste materials,etc., are removed from site at appropriate intervals or as otherwiseagreed or directed by BP Site Management.

Upon completion of each part of the installation the Contractor shallensure that every item of electrical equipment is internally andexternally clean and free from extraneous objects.



3.3 Tradesmen and Supervision

Personnel engaged on the construction of electrical installations shall befully qualifi ed and competent tradesmen skill ed in the particular field ofwork in which they are engaged. They will be required to operateunder the general supervision of a suitably qualified and responsibleelectrical engineer, or supervisor, as required under the terms of theContract.

3.4 Identification

All cables, conductors, circuits and equipment, etc., shall be fitted witha permanent means of identification in accordance with the codes thathave been established for the Works. Omissions shall be rectified, asthe Works proceed, by the provision of an appropriate means ofidentification in compliance with, and/or an extension to, an establishedsystem, or by the introduction of an additional system in agreement withBP Site Management and compliance with the requirements of 2.2.

* 3.5 Materials and Equipment

Materials and equipment supplied by the Contractor under the contractshall be new, unless otherwise agreed, and comply with Nationallyrecognised standards of the user country and BP Engineering Codes ofPractice. Material and equipment manufactured to standards other thanthe above shall be approved in writing by BP and/or the appropriateauthority in the user country.

3.6 Security and Safety Regulations

All work shall be carried out in accordance with rules, regulations andinstructions issued by BP Site Management. Unless otherwise statedthe above shall be interpreted to include all National/Local rules,regulations, etc., as may be applicable, with particular attention to thoseconcerning all aspects of safety.

In some cases the Contract Works will be adjacent to, and/or within,existing plant operating areas under the control of an Operating PlantCompany Management. Particular attention is drawn to the necessityof strict adherence to regulations and instructions applicable to suchareas, these will i nclude compliance with existing written "Permit-to-Work" procedures.

Serious consequences can arise due to accidental damage to and/orinadvertent operation of equipment associated with operating plant, orthrough interference; consequently every precaution shall be taken toprevent such occurrences. Should they take place, BP Site, or theOperating Plant Management shall be informed immediately. It isimportant that any related or immediate subsequent action necessaryshould only be undertaken on receipt of specific instructions from theBP Management unless the action needed is obvious and can be carriedout safely, e.g. fighting a fire with the correct means.



Written "Permit-to-Work" procedures may be introduced for any of theContract Work areas should it be necessary to ensure safe working, andwill be introduced immediately electrical testing and commissioningwork requires equipment and cables to be energised.

In the absence of a Client’s ‘Permit-to-Work’ System, the procedurecontained in Project Department’s Health and Safety at Work Adviceand Information Manual shall apply.

The actual requirements for each work area under a particular contractwill be defined by BP Site Management, in conjunction with theOperating Plant Company Management when necessary, who will beresponsible for any dispensation in requirements. Any dispensationmust be obtained in writing.

* 3.7 Buildings, Structures and Plant

Equipment suspended or attached to any building, structure or plant,etc., must be installed strictly in accordance with the Contractinstructions. When detailed instructions have not been included, noalteration shall be made to any building, structure or plant, etc., unlessspecifically authorised by BP Site Management. Inadvertent damagemust be reported immediately to BP Site Management.

3.8 Setting out Works

Care must be taken at all times to ensure that the finished work has agood appearance, and that, where appropriate, ready access is availableto components.

Thermal insulation and fireproofing materials, forming part of processlines, vessels, structures, etc., shall be left undisturbed unless specifiedotherwise by BP Inadvertent damage must be reported immediately toBP Site Management.

Work carried out prior to the application of thermal insulation andfireproofing materials, shall allow adequate clearances, and the workmust be fully protected against possible damage during the applicationof thermal insulation and fireproofing materials.

All electrical equipment and installations shall be located and/orprotected against the effects of heat that may be radiated or conductedfrom the process plant, and the likelihood of damage due to vibration,corrosion or chemical action.

Care must be taken not to obstruct access to, and movement of, plant.When locating equipment, high fire risk areas must be avoided as far asis possible. Equipment should be located as far as possible to facilitatemaintenance without the use of ladders or other temporary supportstructures.



3.9 Temporary Power Installations

Power distribution systems installed for the express purpose ofproviding temporary power for construction works shall be subject tothe same standards of workmanship as permanent installations exceptwhere otherwise allowed for in the Contract or authorised by BP SiteManagement.

There shall be no bare conductor overhead power supply anddistribution systems of either a temporary or permanent nature in anywork area. Overhead insulated conductor systems will only bepermitted when unavoidable and require the written authorisation of BPSite Management.

See section 7 of this Specification.

3.10 Portable Handlamps, Electrical Appliances and Tools

Portable hand held lamps, electrical appliances and tools shall besupplied from single phase double wound transformers having thecentre point of the utilisation voltage winding brought out and solidlyearthed. Such transformers shall have an earthed metal screen betweenthe windings. See Clause 6.5

Bench mounted equipment, heavy duty tools, etc., and whenunavoidable, small portable electrical apparatus, may be supplied atvoltages in excess of the above, i.e. from the standard medium voltagesingle phase and neutral supply, provided the equipment is of the doubleinsulated type and/or the sub-circuit to which it is connected includes acurrent operated earth leakage protective device.

The above equipment shall be maintained, inspected and tested atregular and appropriate intervals to ensure an entirely satisfactorycondition.

3.11 Hand Tools and Aids

A full range, and an adequate supply, of hand tools specifically designedfor the purpose for which they are to be used, and for carrying out thework in the correct manner, shall always be available to all personnelengaged in the Contract Works.

Materials and equipment to be supplied as part of the Contract Worksshall include such special tools and aids as are necessary for the correctexecution of the work. Materials and equipment supplied as a free issueto the Contract Works will normally include special tools and aids asare necessary unless otherwise specified.

The Contractor shall ensure that the correct tools and aids are used forall work carried out.



* 3.12 Electrolytic Corrosion

Measures shall be adopted to minimise electrolytic corrosion.Examples with some alternatives are given below:-

(i) When apparatus of one metal, say aluminium, is to be mountedon a steel structure, stand-off washers shall be used. The bolts,washers, and nuts may be galvanised or cadmium plated.

(ii) Cable glands, other than aluminium glands, for installation intoaluminium enclosures, may be cadmium plated.

(iii) Coatings of proprietary compounds, specially manufactured forthe purpose, may be used between dissimilar metals, with theagreement of BP Site Management.



4. MATERIALS HANDLING AND STORAGE

4.1 The Contractor shall receive all items of equipment supplied by BP.Immediately on receipt, all equipment shall be inspected by theContractor for damage during transit. All damage shall be notified inwriting to the carrier, the supplier and BP for immediate action to avoidwork schedule delays.

4.2 The Contractor shall review the list of items of equipment to besupplied by BP and report immediately in writing to BP, the omission ofany items necessary to complete the Works.

4.3 The Contractor shall provide all other materials necessary to completethe works in accordance with the Contract Documents.

4.4 The Contractor shall be entirely responsible for the safety, security andcondition of all equipment and materials for the duration of theContract. He shall keep all equipment and materials, before installationin safe storage and in environmental conditions suitable for theparticular items of equipment where they will not be liable to damagedeterioration or corrosion and, where applicable, in accordance withmanufacturer’s recommendations.

4.5 Any equipment broken or damaged in storage shall be repaired, to thesatisfaction of BP, or replaced by the Contractor at his own cost.

4.6 The Contractor shall be responsible for continuous monitoring andreporting of material usage, during installation, of those equipmentitems supplied by BP, and the Contractor shall advise BP in advance ofany anticipated shortage in order to avoid delay in scheduledinstallation.



5. EQUIPMENT IN HAZARDOUS AREAS

5.1 The Contractor will be issued with drawings showing the hazardousarea classification of the plant or installation.

5.2 The Contractor shall ensure that all supervisory personnel areconversant with these drawings and fully understand the requirementsfor electrical apparatus in hazardous areas. All other personnel shall befully qualified and competent tradesmen who have been trained ininstallation work in hazardous areas and, therefore, understand thecharacteristics of the types of protection of electrical equipment for usein such areas.

5.3 The Contractor shall ensure that all electrical equipment supplied by BPfor installation in hazardous areas is installed in the correct location inaccordance with the contract drawings. Any ancill ary equipment, e.g.cable glands, supplied by the Contractor shall be certified for use withthe BP supplied equipment in order to maintain the characteristics ofthe type of hazardous area protection. Where relevant, the position ofthe electrical equipment in relation to other plant should be inaccordance with the requirements of its certification and the associatedCode of Practice, e.g. flameproof gaps on equipment with type ofprotection ‘d’ should not be nearer to other plant than as specified.Where there is any conflict with these requirements the Contractor shallreport immediately to BP for a decision regarding remedial action.

5.4 All electrical equipment and ancill aries supplied by the Contractor forinstallation in hazardous areas shall be certified by a National CertifyingAuthority for use in the particular classified area, have the correcttemperature classification and equipment group and be suitable for theparticular environmental conditions, all as described in BS 5345.Equipment which has been manufactured and certified in a countryother that the country of installation should be checked to ensure thatthe equipment has been tested at the voltage and frequency of use asotherwise the temperature rise may be excessive. Also the installationCodes of Practice in the country of manufacture and certification shallbe checked to ensure that the certification is not related to aninstallation practice unacceptable in the country of use.

5.5 In zone 1 hazardous areas only equipment of types of protection ‘d’, ‘e’and ‘s’, as defined in EN standard 50-014, shall be installed.

In zone 2 hazardous areas only equipment of types of protection ‘d’,‘e’, ‘s’ ‘N ’ or ‘n’ shall be used. The relevant specification for types ofprotection ‘n’ is IEC Publication 79-13 and the general specification fortypes of protection ‘N’ is BS 6941. Specifications for type ‘N’ motors



and type ‘N’ luminaires are BS 5000 Part 16 and BS 4533, Section102.51 respectively.



6. CONSTRUCTION SITE POWER SUPPLIES

* 6.1 The Contractor shall produce for BP approval, an estimate of the totalpower requirements for construction, including if applicable, alltemporary site accommodation and associated domestic services.

6.2 When the Contract Documents place responsibili ty on the Contractorfor providing construction site power supplies, this estimate shall beused for the purpose of either negotiating the provision of powersupplies from an existing BP supply system or a power supply authorityor providing temporary generating plant.

6.3 When the Contract Document place responsibili ty on BP for the supplyof construction power this estimate will be used by BP for the provisionof supplies by one of the above methods.

6.4 For the construction of offshore platforms, separate estimates of powersupply requirements shall be provided for onshore construction andoffshore construction.

6.5 The power system for construction site power supplies shall bedesigned and installed in accordance with BP Group RP 12-1 and RP12-19.

In the UK the system and use of electricity shall also comply with BSCP 1017, the Guidance Note G524 published by the Health and SafetyExecutive and the IEE Wiring Regulations for Electrical Installations.Supplies to equipment from socket outlets shall comply with BP GroupRP 12-17.

6.6 Any part of the construction supply electrical distribution system or anyelectrical equipment used for construction which may be energised orused after the plant or part of the plant has been commissioned andwhich may then be in a potentially hazardous area shall be certified foruse in that area.

This applies particularly in offshore situations where, due to spacerestrictions, modules are in close proximity to one another.



7. CABLES, WIRING AND INSTALLATION OF CABLES

7.1 General

7.1.1 All cables, cable systems and wiring shall comply with:-

(a) BP Group RP 12-13(b) BP Group RP 24-1(c) BP Group RP 24-2(d) BP Group GS 112-12

The clauses in this section of this document either make reference to, orare supplementary to, the requirements of the above.

7.1.2 The Contractor shall be responsible for ensuring that cables are installedin accordance with the Contract Drawings and cable schedules. Cablesfor each circuit shall be of the type and size specified for that circuit.This is of particular importance offshore where fire retardant or fireresistant cables are specified.

* 7.1.3 No deviation shall be made from the cable routes shown on theContract Drawings without BP Site Management approval. Wherecable is installed overhead, however, the Contractor shall check thelocations of cable tray, ladders and tracking shown on the drawings toensure that no conflict exists between them and any other equipment,steelwork, piping, ducting etc., or that they do not cause any hazard topersonnel, block access ways or prevent removal of equipment. Whereproblems arise BP Site management shall be consulted.

* 7.1.4 Underground cable routes detailed in the Specification Documents andDrawings will have been selected to avoid areas likely to be subject toproduct contamination from spill age. Overhead cable routes will havebe selected to avoid areas subject to both spill age and fire risk. Cableroutes not detailed on contract drawings shall also comply with theabove and be agreed with BP Site Management.

7.1.5 Cables having an outer homogeneous corrosion protective outer sheath,e.g. PVC, which might be subject to deterioration at some point alongits route, and thereby permit migration of flammable or corrosivesubstances along the interstices of the armouring, shall be treated toprovide a visible drainage point near the termination at each end. Thedrainage point shall be made by cutting an annular ring from the outerplastic sheath, at a position so that any leakage that may occur does notcreate a hazard. The exposed armouring should be protected by a fireand corrosion resistant coating.



7.1.6 Certain items of electrical plant and machinery are subject to movementand/or vibration during operation and subsequent maintenance, e.g.motors on slide rails, motor driven in-line pumps, motor drivenagitators, etc. Connecting cables shall be so routed and/or of a typeappropriate for the duty, e.g. mining type flexible armoured cable couldbe used for motors on slide rails, but the use of cables enclosed inflexible conduit is not normally permitted.

The arrangement of the connection must permit freedom of equipmentmovement under all operating conditions, normal maintenance andadjustment without unduly stressing the cable and/or cable terminations,and easy replacement.

7.1.7 Storage and handling of cable before and during installation is to becarried out with due regard to manufacturer’s recommendations. Cabledrums shall be rotated only in the direction indicated by drum markingsand open ends of cable are to be effectively sealed immediately aftercutting to prevent the ingress of moisture.

7.1.8 Exposed cut ends of paper insulated cable shall be capped by plumbing.Other types shall be compounded and taped.

7.1.9 At all times the utmost care is to be exercised to avoid damaging theprotective sheathing of cable or of causing excessive bending ortwisting which may result in bird caging of wire armour and/or damageto core insulation, sheaths, etc. The bending radius of a cable shall notbe less than the manufacturers recommended minimum.

Under no circumstances shall metal levers or tools be used in directcontact with cables during installation unless of a proprietary typespecially designed for the purpose.

* 7.1.10 Cables shall be run in continuous unbroken lengths and joints will notbe permitted unless the route length exceeds the maximummanufactured drum length, or jointing of the cable is otherwisespecifically authorised by BP Site Management.

When cable is supplied in drum lengths nominated for particular circuitsit is the Contractor's responsibility to ensure that the cable is used forthe nominated circuits.

7.1.11 Where cables pass through floors, or rise through covered trenches,they shall be provided with adequate mechanical protection in the formof metallic sleeves or kick plates projecting not less than 150 mm (6 in)above floor level. Kick plates shall be so positioned as not to constitutea trip hazard.

* 7.1.12 Cables shall not be handled or installed when the ambient temperature isbelow 2°C unless agreed with BP Site Management. In such



circumstances handling and installation will only be permitted followingan adequate period of storage at a relatively high temperature andprovided the installation can be completed within a specified time. Aprocedure shall be agreed with BP Site Management, preferablyapproved by the cable manufacturer, and the work shall be carried outunder the direct supervision of a competent person.

* 7.1.13 Catenary support of cable will not be permitted unless all other methodsof installation are impractical and then only with the specificauthorisation of BP Site Management.

7.1.14 For identification purposes cable having a protective outer sheath ofPVC, polythene, or other special material shall carry distinctivemarkings as indicated in the Job Specification. The utmost care shall beexercised when installing such cables to ensure that they are correctlyallocated to their specified duty.

* 7.1.15 Unless otherwise specified single core cables shall be provided with anouter protective sheath, e.g., PVC, and if laid direct in the groundand/or if unsupported over any part of their entire length, shall includenon-ferrous armouring. When single core cables are used for threephase circuits special attention shall be given to minimising thelikelihood and effects of circulating currents in the lead sheaths and/ornon-ferrous armouring, due to mutual induction. Insulated glands forcable terminations should be fitted at one end and must be assembledand tested strictly in accordance with the manufacturer's instructions.Each set of single core cables comprising a three phase circuit shall berun close together and under no circumstances shall ferrous metal beinterposed between the single core cables. Trefoil formation shall beused for each three phase group of single core cables and thisrequirement will be relaxed only where it is impractical.

The arrangements for clamping single core cables in three phase circuitsrequires special attention, particularly when they form part of anelectrical network with a high prospective short circuit rating. Detailsof the clamping and bonding arrangements will generally be fullycovered in the Job Specification, but irrespective of this the finalarrangement shall be agreed with BP Site Management. Under nocircumstances shall improvised devices be used for clamping cables inTrefoil formation; only those of an agreed type and materials obtainedfrom agreed suppliers will be permitted.

* 7.1.16 Unless otherwise specified, each cable shall be fitted with indestructibleidentification bands at each end, at 30 metre intervals over the entireroute length, at all points where it enters or leaves ducts and buildingsand at each change in direction.



7.1.17 Cables shall be installed in accordance with manufacturersrecommendations. The recommendations regarding minimum bendingradius shall be strictly applied. It shall be the Contractor’s responsibili tyto obtain the cable manufacturer’s recommendations for the range ofcables listed in the Contract cable schedules.

7.1.18 Site testing of cable installations shall be carried out in accordance withBP Group RP 32-2 Site Inspection, Testing and Pre-Commission ofNew Plant and in accordance with Appendix C of this document.

7.2 Underground Cable Installation

7.2.1 Cable Installed Directly in the Ground

* 7.2.1.1 Cables installed directly in the ground for the whole or part of the routeshould incorporate a lead sheath unless otherwise Specified by BP. Forparticular applications proven barrier materials other than lead may bepermitted but must be agreed.

Cables without barriers must be laid without deviation from thespecifi ed or agreed route, since this will have been selected as oneunlikely to suffer contamination. If deviation is necessary for anyreason authority must be obtained and the new route given writtenapproval by BP Site Management.

7.2.1.2 Cables shall be surrounded by not less than 50 mm (2 in) of washedsand, loam or sifted soil and protected by suitably sized concrete orearthenware cable covers.

Covers shall be of the standard interlocking type laid directly above the50 mm (2 in) fil l of screened material and shall extend to the full widthof the trench giving an overlap of at least 50 mm (2 in) beyond theouter cables.

7.2.1.3 In temperature climates the minimum depth of cover required fromcable to finished grade shall, unless otherwise stated in the JobSpecification, be as follows:-

(i) Street lighting and telephone cables 500mm

(ii) Power cables up to and including 1000 volts andcontrol cables 500mm

(iii) Power cables above 1000 volts 800mm

If a pilot or control cable forms an integral part of a power circuit itshall be laid at the same depth and adjacent to the associated powercable.



7.2.1.4 In areas where wet sand/soil is liable to frost action, cables shall beinstalled either below the frost level or, if installed above frost level thegrade of bedding shall be such that less than 40% passes through a 0.1mm sieve and less than 20% passes through a 0.2mm sieve. Attentionshall then be paid to ensuring that the depth of excavation , beforebackfilling as detailed above for the initial bedding, is appropriatelygreater than the frost maximum penetration depth.

7.2.1.5 Infilling of cable trenches shall be well compacted and the ground re-instated to its original grade and finish. The infill shall be free fromlarge stones or other injurious objects to a level at least 150 mm (6 in)above the protection covers.

The thermal conductivity of bedding and infill material for cabletrenches and troughs must be established before use. Where thermalconductivity of the material is lower than anticipated and below thevalue on which cable ratings and grouping factors have beendetermined, as indicated in the Job Specification, action must be takenin agreement with Site Management on the corrective measures to beadopted.

Any specific instructions included in the Job Specification and drawingsin respect of special additives, and/or sand/cement mixes shall be strictlyadhered to at all times.

* 7.2.1.6 Armoured cable shall be installed with the aid of specially constructedrollers. Cables up to 38 mm (1 1/2in) diameter shall be installed byhand, but larger cables may, with BP Site Management approval, beinstalled with the assistance of a suitable winch, having an adjustabletensioning device and indicator, operated by a trained and competentoperator. Cable stockings shall be sized to the cable and fitted in acorrect manner. Where recommended by the manufacturer pulling eyesshall be fitted to the cable at the time of manufacture. Unarmouredcable shall be installed by hand.

Cable shall at no time be installed directly from a drum mounted on amoving vehicle.

Under no circumstances is the maximum permitted tension for the typeand size of cable to be exceeded.

7.2.1.7 Drum jacks, cable rollers and other equipment shall be of the correcttype and size for each drum and cable laid. The equipment shall be keptin a sound condition and be used in the approved manner.

7.2.1.8 Underground cable routes shall be identified by concrete cable markersset into the ground to project approximately 300 mm (12 in) abovegrade. The markers are to be positioned at 30 metre (100 ft.) intervalson straight runs and at points where the route changes direction. Cable



trenches less than 1 metre wide shall be provided with single markerson the centre line of the run. Trenches wider than 1 metre shall beindicated by markers mounted on each side of the trench at the intervalsspecifi ed. Similar markers suitable inscribed shall be used to indicatethe position of underground joints.

* 7.2.1.9 The installation of direct buried cables shall not be commenced until theentire route has been excavated and prepared ready to receive the cable.Where such procedure is impracticable a detailed programme of layingshall be agreed with BP Site Management.

In all cases when cable is left exposed above ground it shall be coiled,suitable protected against damage, and this should include a temporaryfence around the local area at an appropriate distance from the coiledcable. Alternatively such cable may be left on the drum which must belowered from its jacks, firmly anchored and the immediate area fenced.

7.2.1.10 Accurate and detailed records of all buried cables are to be prepared induplicate by the Contractor as each section of cable laying proceeds. Acopy of these records shall be submitted to BP Site Management.Recorded information shall include dimensioned trench positions, ductand trench sections, indicating the circuits installed and the location ofunderground joints taken by measurement from fixed and permanentlandmarks. This information will subsequently be transferred topermanent “As Installed” drawings by the Contractor or as otherwisedetailed in the Job Specification.

7.2.2 Cable Installed in Concrete Trenches (Including Troughs)

7.2.2.1 The installation of cables in trenches or troughs shall comply with BPGroup RP 12-13, Clauses 5.3.4, 5.3.5, 5.3.6.

7.2.2.2 Relevant procedure included under Sub-Section 7.2.1, for installation ofdirect buried cable shall be adhered to insofar as it becomes equallyapplicable when the cable is installed in a prepared concrete trench.

7.2.2.3 Before installi ng cable the concrete covers shall be removed and laidclear of the cable pulli ng area. The trenches shall then be cleared of allforeign material and left free of obstruction.

When existing trenches are used to accommodate additional cables anyfil l shall be carefully removed to the level of the existing cables and newbedding prepared.

7.2.2.4 On completion of cable laying, trenches shall be back fill ed with cleansand and the covers replaced. Care shall be taken when replacingtrench covers to ensure that they are not dropped and that they areproperly positioned and seated. Responsibili ty for covers damaged or



broken during cable laying operations shall rest entirely with theContractor who shall replace them.

Where trenches are located within plot limits of process areas or otherlocations subject to excessive spillage or washings the covers shall beeffectively sealed or trenches floated over with a coloured weak cementmix as detailed in the Job Specification.

7.2.3 Cables Installed in Ducts

7.2.3.1 Application and design of duct systems shall comply with the JobSpecification and drawings.

In general all ducts shall be haunched in concrete and be socket andspiggot type of earthenware or non-bituminous fibre.

In special circumstances, e.g. railway crossings or where adequatedepth of lay cannot be obtained, a single length of steel pipe shall beused.

7.2.3.2 For single runs or otherwise at the discretion of BP Site Management,manufactured earthenware bends of appropriate size and radius may beused having regard to overall diameter and the class of cables to beinstalled. When installing bends care shall be taken to ensure that thejoints are fully engaged.

7.2.3.3 The use of split ducting is prohibited except under specialcircumstances and with the approval of BP Site Management. In caseswhere the use of split ducting has been authorised all joints shall becorrectly fitted and the ducts bound in an approved manner. If theducts are to be haunched in concrete they shall be bound with animpervious tape to exclude ingress of the concrete.

7.2.3.4 The overall length of ducts and pipe crossings shall extend at least 300mm (12 in) beyond the limits of the area requiring ducts. Draw wiresshall be installed in each duct.

7.2.3.5 All ducting shall be temporarily sealed when not required for immediateuse.

7.2.3.6 Before cables are installed into ducts the duct line is to be proved clearof obstruction with the use of a wooden mandrel or by rodding.

7.2.3.7 The procedures detailed under Sub-Section 7.2.1 - Cables InstalledDirect in the Ground, shall be followed insofar as they are applicable tocables being installed in ducts.



7.2.3.8 When ducts are allocated to specific circuits in the Job Specification ordrawings these positions shall be strictly adhered to, otherwise ductbanks shall be filled from the bottom upwards and spare ways leftunobstructed at the top of the bank. Pilot and/or control cables shallnot be installed together with a power cable in the same duct and ingeneral each duct shall carry a single power cable. In cases wheredeviation from the practice is necessary the matter shall be referred toBP Site Management.

7.2.3.9 Ducts shall be sealed at both ends immediately after installation of thecable and spare ducts shall be sealed with soft wood plugs, or otheragreed material.

7.3 Cable Installed Above Ground (Onshore) Or Above Deck(Offshore)

7.3.1 General

7.3.1.1 All above ground/deck cable installations shall comply with BP GroupRP 12-13, Section.4.

* 7.3.1.2 The material used for cable trays and ladder racks shall be selected fromthose listed in BP Group RP 12-13 Section 4. Unless already specifiedin the contract documents the Contractor shall obtain BP approval ofthe proposed material.

7.3.1.3 Cables shall be allocated to racks in the particular groupingarrangement detailed in the Contract Specification and, where specified,the racks shall be colour coded.

7.3.1.4 On minor cable routes involving both power and instrumentation cableswhere it is impractical to route more than one rack level, theinstrumentation cables shall be installed on one side and power cableson the other.

* 7.3.1.5 Care shall be taken to maintain the segregation distances betweenpower and instrumentation cables specified in BP Group RP 30-8.Where due to space restrictions it is impractical to maintain thesedistances a segregation distance of 300 mm is adequate for all but verylow signal level instrument action circuits but BP approval shall beobtained for all departures from the distances specified in BP Group RP30-8.

7.3.1.6 All cable cores shall be clearly, precisely and indelibly identified at eachterminal, on point with individual number/letter combinations, usingferrules of the non-split cylindrical type.



7.3.1.7 Where core numbers change, e.g. at connections between equipment ofdifferent manufacture, a system of double identification coding shall beused at the point of connection.

7.3.1.8 For all multicore cables, other than power cables, the cable coreidentifi cation shall be made up three parts: numbering from the terminalblock these are:-

(a) the terminal number

(b) the core number

(c) the cable number

* 7.3.1.9 All cables shall be identified at each gland termination by their allocatednumber as indicated on the cable schedules, by the use of non-corodableidentifi cation tags. Similar tags shall be attached to the cables at eitherside of a transit unit or cable duct and at specified intervals over theentire length of cable. Where not specified the Contractor shall obtainBP agreement to the proposed tagging interval. The tags shall be fixedwith EVA or PVC coated stainless steel ties.

7.3.1.10 Cable ties shall be selected from those listed in BP Group RP 12-13Clause 4.4.12. Where not specified, the Contractor shall obtain BPapproval to his proposed material.

Nylon 11 or 12 ties are preferred to the polypropylene type on thegrounds of greater tensile strength.

* 7.3.1.11 Cables shall be securely cleated or tied to trays or ladders at the spacingspecified in BP Group RP 12-13 clause 4.4.10, table 4. Any proposalsto increase the spacing distances shall be subject to BP approval.

7.3.1.12 Cables which leave main tray or ladder routes for connection toindividual items of equipment shall be installed on tray, channel or anglesupports fitted between the main cable run and the equipment.

7.3.1.13 Electrical continuity shall be maintained between sections of cable trayor ladder by the use of flanged fish plates, and between the tray orladder and the main structure, either through earthed support steelworkor by earthing cable connections to the main structure at each end ofthe tray or ladder run.

7.3.2 Support Steelwork and Fixings

* 7.3.2.1 The Contractor shall provide all supports necessary for mounting cabletrays and cable ladders. Where possible these shall be of pre-fabricated



construction supplied by the tray or ladder manufacturer, to avoid on-site fabrication.

In addition the Contractor shall provide, where necessary, all supportsfor such items as bus-ducting, control push button stations, socketoutlets, lighting fittings, small power distributions boards etc. Theseshall also be of proprietary manufacture where possible; otherwisefabricated from steel channel, angle or tube.

The Contractor shall provide such supports in accordance withContract detail drawings, when provided, or alternatively obtain BPapproval to his proposed mounting arrangements.

7.3.2.2 Site fabricated steel supports and brackets shall be properly fabricatedand fitted. All drilli ngs shall be made with minimum tolerances. Allsharp edges shall be de-burred.

* 7.3.2.3 The cable tray or ladder installation and support system shall be suchthat the maximum deflection between supports with maximum cableloading does not normally exceed 1/180 of the span. Any increase indesigned deflection shall be agreed by BP.

* 7.3.2.4 Normally all supports shall be made from steel in accordance with BS4360 and shall be hot dipped galvanised to BS 729 or similar nationalstandard. In particularly corrosive environments other supportmaterials may be specified or considered but shall be subject to BPapproval.

7.3.2.5 All fixing bolts, nuts and washers, etc. shall be ISO metric threaded andof stainless steel. Shake proof spring washers shall be fitted to allbolted connections.

* 7.3.2.6 When the fixing of electrical equipment, tray or trunking to fireproofedmembers cannot be avoided, any brackets required for such fixings shallbe installed before the fireproofing material is applied. Considerationmust be given to the likelihood of heat conduction through such fixingscausing damage to the fireproofed member and appropriatesafeguarding action taken in agreement with BP Site Management.

Alternatively, and subject to the nature of the fireproofing,prefabricated clamping brackets may be accepted subject to approval byBP.

* 7.3.2.7 Structural steel or pre-cast concrete members shall not be drill ed forany reason unless specifically authorised on Contract Drawings or byBP Site Management. Fixing should be by means of clamping brackets.

* 7.3.2.8 Under no circumstances shall welding or fixing operations be carriedout on any process plant equipment, vessels, pipelines or structures



unless specifically indicated on the Contract Drawings or authorised byBP Site Management.

Fixings to the above shall normally be made where brackets, etc. havealready been provided or, when agreed by BP, by the use of purposebuilt clamps.

7.3.3. Cable jointing and Termination

7.3.3.1 Jointing and termination of cables shall comply with BP Group RP 12-13, clause 4.6.

7.3.3.2 All cable joints and terminations shall be carried out strictly inaccordance with the cable manufacturers’ recommendations, withparticular regard to the jointing or termination materials and procedureproposed.

7.3.3.3 All jointing and termination of power cables shall be carried out by fullytrained and competent tradesmen who have passed an approved courseof instruction and training in such work for the operating voltage levelinvolved. The Contractor shall be required to provide writtenconfirmation of this or otherwise satisfy BP Site Management.

Jointing and termination of high voltage cables shall be carried out orsupervised by specialists, preferably from cable manufacturers.

7.3.3.4 Cable glands for termination at equipment in hazardous areas shall havecomponent approval by a recognised certifying authority (e.g.BASEEFA, SIRA or equivalent body in other countries) for use withthe type of cable and type of explosion proof equipment.

7.3.3.5 The terminations for high voltage cables referred to in BP Group RP12-13 Clause 4.6.4 shall incorporate voltage stress relief cones atvoltages above 5kV.

7.3.3.6 Prior to insulation of jointed conductors and earth continuity bonds, thejoints shall be proved by resistance measurement to maintain theelectrical ratings of the cable conductor, metal sheath (if applicable) andarmouring.

7.3.3.7 Glands entering enclosures where a single diaphragm or seal separatesthe enclosure from a hydrocarbon process shall be barrier types (i.e.pressure switches and solenoid valves etc.).

7.3.3.8 Cable glands shall have ISO metric threads and shall be fitted withweather proof shrouds of PVC or other plastics material suitable for theenvironment.



7.3.3.9 Where cables are terminated by glands into GRP enclosures havingthreaded entries and internal earth continuity plates, or metallicenclosures having clearance holes, a heavy gauge locknut and serratedwasher shall be used. This is to guarantee the earth continuity betweenthe gland body/cable armour and the enclosure. Serrated washers shallbe deemed to be adequate to guarantee earth continuity when theglands are fitted to painted sheet steel enclosures. Brass earth tagwashers may be used where serrated washers are not practical and acable connection shall be made from the washer to the gland plate.

7.3.3.10 The spare cores of control and instrumentation cables shall beterminated at both ends, in spare terminal ways or at earth terminals.

7.3.3.11 Individual cores of cables up to and including 10mm2 shall beterminated on screw clamp/pressure plate type equipment terminals.

7.3.3.12 All terminal blocks shall preferably be of Melamine insulating material.

7.3.3.13 Raised insulated barriers shall be inserted between groups of terminalsintended for wiring on different voltages, and between individual phasesof a three phase supply.

7.3.3.14 No more than two conductors shall be connected to any one terminal,i.e. one incoming and one outgoing conductor.

7.3.3.15 If more than one conductor has to be terminated at the same point thenseveral terminals shall be used and proprietary metal links used tointerconnect the ways. The link shall not occupy the same place as theconductor.

7.3.3.16 Terminals in marshalling boxes shall be arranged so that 10% spareways shall be furnished, to allow for reasonable future modifications oradditions.

7.3.4 Cable Transits

7.3.4.1 On on-shore installations, cables which pass from a pressurisedenclosure, or through a fire wall leading directly from a safe area to ahazardous area, shall be fitted with approved proprietary cable transitsor gland plates.

7.3.4.2 On off-shore installations all bulkhead and deck penetrations by cablesshall be carried out using agreed proprietary multi-cable transits.

7.3.4.3. The Contractor shall provide the number of transit frames and tiers foreach penetration position by reference to the schedule of cable transits.The Contractor shall determine the quantity (including spares) and



provide and install the necessary transit insert blocks and frameaccessories.

7.3.4.4 Transits shall be located in the positions indicated on the drawings. TheContractor shall be responsible for the cutting of all bulkhead andwelding plates and the welding of all transit frames into position.

* 7.3.4.5 If the Contractor can show valid reasons for the use of bulkhead ordeck penetrations other than those indicated on the drawings then heshall obtain prior approval from BP Site Management beforeinstallation.

7.3.4.6 Transits shall always be used where cables pass:-

(a) from a safe area to a hazardous area(b) through blast walls(c) through fire walls(d) through walls, roofs and floors to the open

7.3.4.7 Care shall be taken to continue the trefoil formation of single core a.c.cables when passing through transits. Non-magnetic brass stayplatesare required within the transits and each trefoil group shall pass throughthe same transit frame.

7.3.4.8 Spare ways in transit frames shall be filled with blank filling blocks. Aminimum of 25% spare ways shall be allowed in each penetrationlocation.

7.3.4.9 Cables passing through transits must be perpendicular to the transit fora minimum distance of 100mm on each side of the transit.

7.3.4.10 The Contractor shall prepare drawings for the transits, to co-ordinatethe positions of cables passing through and indicating the cable number,insert block and spare block sizes. The ways allocated for offshorecabling, as determined from the drawings and cable schedule, shall alsobe indicated.

7.3.4.11 The clamping of the transit, after completing the onshore installation,shall be ‘finger tight’ to allow any offshore installation to be made laterand prevent the insert blocks premature loss of elasticity.

7.3.4.12 All transits shall be identified by weatherproof labels on either side oftheir penetration. The labels shall preferably be fixed to adjacentracking and be easily readable from the deck below, with letters of atleast 50mm height.

7.3.5 Mineral Insulated Copper Sheath (MICS) Cable



7.3.5.1 MICS cable shall be installed and terminated by tradesmen who aretrained and experienced in this class of work. The Contractor may berequired to furnish written confirmation in this respect or otherwisesatisfy BP Site Management accordingly.

7.3.5.2 Relevant procedure included under Sub-Section 7.1 shall be adhered toinsofar as it becomes equally applicable when routing and installingMICS cable.

7.3.5.3 Cable that has become uneven, work hardened or otherwiseunworkable or damaged during installation shall be replaced by theContractor.

* 7.3.5.4 The use of aluminium sheathed and/or aluminium conductor mineralinsulated cable is normally prohibited. It’s use for a particularinstallation, e.g. where no other type of cable is suitable, may bepermitted, but written authority must be obtained from BP SiteManagement unless already covered in the Contract Documents.

7.3.5.5 MICS cable with or without a protective sheath shall not be buried inthe ground or installed in sand filled trenches.

7.3.5.6 All circuits employing MICS cable except final sub-circuits of lightinginstallations shall be identified.

7.3.5.7 The installation of MICS cable for trace heating application shall becarried out strictly in accordance with the cable makers instructions andthe construction drawings.

7.3.5.8 Single core MICS cables which are installed to form a three phasepower circuit shall comply with requirements included under Clause7.1.15.

* 7.3.5.9 Restrictions are applied in the use of MICS cable and limitations on it’suse in the special situations detailed below shall be strictly adhered to:-

(a) MIC Cable shall not be used between discharge type lightingfittings and associated control equipment unless approved by BPSite Management and an appropriate surge suppressor has beencorrectly positioned in the circuit.

(b) When MICS Cable is specified, or its use for a.c. power circuitsor d.c. circuits is agreed by BP Site Management, specialconsideration must be given if inductive load switching isinvolved, to the possible need for surge diverters in the circuit.



7.3.5.10 All cable, unless installed in trunking shall be straight and then saddled,in the manner described below.

Straightening shall be carried out using a purpose made tool as suppliedby the cable manufacturer for this purpose or by dressing the cables insitu with a hide or wooden mallet. Care shall be exercised inperforming this operation to ensure that damage is not inflicted oneither the cable sheath or outer protective sheath.

7.3.5.11 Saddling shall be carried out using manufactured saddles obtained fromthe cable maker or purpose made saddles made up from the cable makeror purpose made saddles made up for PVC coated aluminium or copperstrip.

The use of nylon or similar non metallic strip shall be restricted tohorizontal runs where the saddle simply serves the function of holdingthe cable in position and not supporting it.

7.3.5.12 Bending and setting of cable is to be carried out in a neat manner withbends of a consistent radius and of all dimensions to ensure that thecopper sheath does not wrinkle on the inner radius of the bend.

The minimum radius of bends and sets shall be in accordance with theManufacturers recommendations but shall not be less than six times theoverall diameter of the cable.

* 7.3.5.13 Through joints shall not be used unless the route length exceeds themaximum manufactured cable length. Damaged cables may be repairedby through jointing only when a complete replacement is impractical,and then with the approval of BP Site Management.

7.3.5.14 In safe areas, through joints shall comprise Jointing sleeves and theappropriate accessories supplied by the cable manufacturer specially forthis purpose. After completion the joint shall be protected with a sleeveof similar material to the cable outer sheath.

7.3.5.15 In hazardous areas through joints shall be effected by using adequatelysized junction boxes, certified for the area of installation.

7.3.5.16 Cable, glands, pot seals, sleeving, tools and all other accessories usedtogether must be fully compatible and supplied by the samemanufacturer. The mixing of components from different manufacturersis prohibited.

7.3.5.17 Glands shall be of hexagon type and when applicable be certified for usein the hazardous area concerned. Glands of the knurled type are notacceptable.



7.3.5.18 Terminations shall, whenever possible, be made using cold pot sealssupplied by the cable manufacturer and care is to be taken in respect ofthe following procedures:-

(a) The pot is to be contained in the gland body and shall notprotrude into the equipment.

(b) The pot is to be effectively screwed onto the cable sheath and itsself cutting thread fully engaged, or in the case of wedge typefittings, these shall be correctly fitted in accordance with themanufacturer’s instructions.

(c) Copper swarf and surplus insulant is to be removed beforesealing.

(d) The correct cold sealing compound is to be used and the potfilled in accordance with the manufacturer’s instructions.

(e) The sealing compound is to be fully compressed and the closingdisc correctly crimped into position.

(f) Hot seals and those employing special sealing mediums shall beinstalled strictly in accordance with special procedure issued bythe cable manufacturer.

(g) The manufacturer’s recommendations for excluding moisturefrom the cable immediately prior to making an end sealtermination shall be rigidly observed.

7.3.5.19 At terminations, conductors are to be insulated with neoprene sleevingor where connections are made into high temperature enclosures e.g.tungsten fittings, etc. silicone rubber, or sleeving recommended by thecable manufacturer is to be used.

7.3.5.20 In all cases except where positive earth continuity can be correctlymaintained, e.g. via threaded entries of metallic enclosures, cable endseals with earth bonding tails must be used. The earth bonding tailsmust be properly terminated on earthed terminals provided for thepurpose within the enclosures. Terminating glands clamped to non-threaded entries by the use of locknuts are unacceptable for the purposeof maintaining earth continuity.

7.3.5.21 The conductors of cables shall be terminated in a manner suitable forthe terminal arrangement of the equipment concerned, and conductorsof 10mm2 (0.015 in2 ) and above shall be fitted with compression lugsor alternatively cone grip lugs where space permits.



7.3.6 Conduit Installations

7.3.6.1 Conduit systems shall be designed and installed in compliance withappropriate regulations and codes of practice in force in the area ofoperation concerned. E.g. Installations within the UK shall complywith the IEE Regulations for Electrical Installations, 15th Edition.

In countries which are not covered by national and/or local regulations,UK practice shall be applied.

7.3.6.2 Where a conduit system is to be installed wholly or in part in an areawhich is classified as hazardous, the installation shall, in addition torequirements under clause 7.3.6.1 also comply with the requirements ofthe current issue of the British Standard Code of Practice BS 5345 orthe appropriate Code of the country concerned.

7.3.6.3 Whenever possible conduit fittings shall be manufactured frommalleable cast iron and for outdoor installations they shall be hot dippedgalvanised and of weatherproof design.

7.3.6.4 For plant installations, heavy gauge, hot dipped galvanised screwedsteel conduit shall be used. The conduit shall be adequately sized toaccommodate the total number of circuits involved withoutovercrowding and in no case shall conduit of less than 20mm bore beemployed.

Conduit for installations in hazardous areas shall be solid drawn, andfitted with Stopper Boxes as required. The use of welded seam conduitor flame retardant heavy gauge plastic conduit to BS 4607 Part 1 andBS 6099 Part 2 is acceptable for other areas.

7.3.6.5 The conduit system shall be electrically and mechanically continuousthroughout and rigidly secured before wiring is commenced.

An adequate number of draw-in boxes shall be installed to facili tatewiring without strain or damage to the cable.

In all outdoor locations, and other area’s where the formation ofcondensate may occur, conduit systems shall be provided with drainpoints. The conduit shall be installed in a manner which provides anadequate fall to ensure that the system drains to the drain points.Particular care shall be exercised in this connection to ensure that noequipment containing live parts is connected so that it can act as a drainpoint for all or part of the system.

7.3.6.6. Conduit shall not be installed directly in the ground or in sand fill edtrenches.



* 7.3.6.7 Flexible conduit will only be permitted when authorised by BP SiteManagement and then only when the use of flexible armoured cable isimpractical.

7.3.6.8 Conduit threads shell be cleanly cut to a finished length that leaves theminimum exposed length of thread when finally fi tted. Threads shall bechecked for correct size using an appropriate gauge. The leading edgeand bore shall be made smooth. All exposed bare metal shall be cleanedand protected against corrosion using materials that are compatible withthe original protective coating.

7.3.6.9 Locknuts shall be used at all entries and be fully tight. The use ofrunning couplers in installations in Zone 1 areas is prohibited andconduit unions shall be used.

7.3.6.10 Bends and sets formed in conduit shall be made in the approved mannerand without indentation or alteration of the conduit section. The bendradius shall be not less than that shown under the appropriateregulations referred to under 7.1.1.

7.3.6.11 The type, grade or class of cable for conduit installation shall complywith requirements shown in the Job Specification.

7.3.6.12 Wiring in conduit shall be looped from point to point and where jointsare unavoidable they shall be made in junction boxes. The junctionboxes shall be adequately sized and fitted with fixed connector blocksfully rated for the circuit requirement. In hazardous areas they shall becertified for use in the relevant area.

7.3.6.13 Connections made into high temperature enclosures e.g. tungstenlighting fittings, etc., shall be made with sili cone rubber insulated cableor other high temperature cable as may be agreed for the applicationconcerned.

7.4 Cables and Wiring for Instrument Systems

7.4.1 Cables and wiring for instrument systems shall comply with BP GroupRP 30-1.

7.4.2 Cable glands shall be of the mechanical compression type Where usedfor terminating armoured and/or lead sheathed cables the gland shallinclude integral facili ties for securing and bonding the armour and leadsheath. Where indicated on BP Standard Drawing No. S-1962 theglands shall be insulated from earth.



7.5 Cable Records

7.5.1 The Contractor shall prepare a cable drumming schedule which shall bekept up to date during the contract period.

7.5.2 The cable drumming schedule shall be carefully prepared to minimisewastage of cables.

7.5.3 The Contractor shall closely liaise with BP Site Management to ensurethat, by forward planning of requirements, no delays are experienced incable installation due to material shortage.

7.5.4 Records shall be kept of all cable requests to BP.

7.5.5 The Contractor shall maintain an up-to-date record of all cablesinstalled by marking up a copy of the computer cable schedule toindicate where variations in length, size, number of conductors anddestinations occur. This schedule shall be handed to BP SiteManagement at the end of the contract.

7.5.6 The Contractor shall also institute a recording system (e.g. Kardex) torecord actual lengths of cable removed from the drum, the drumreference and the purpose for which each length is used.



8. INSTALLATION OF ELECTRICAL EQUIPMENT

8.1 Switchgear

8.1.1. In this Specification, the term switchgear includes high voltage and lowvoltage switchgear, motor control centres, relay panels, electricalcontrol panels and main fused distribution boards but not small powerand lighting sub-distribution boards.

8.1.2 All switchgear supplied by the Contractor shall comply with BP GroupRPs 12-6 and 12-7 for high voltage and low voltage switchgearrespectively; also with BP Group GSs 112-8 and 112-9.

8.1.3 The Contractor shall be responsible for familiarising himself with thevendor’s information regarding installation and testing requirements. Itis recommended that the vendor’s representative should be presentduring installation, and particularly during all stages of positioning,alignment and levelling.

8.1.4 Before any switchgear is installed, the Contractor shall ensure that alldecking and supporting steelwork is completely installed, and is inaccordance with the drawings. On offshore platforms mild steel plinthswelded to the deck shall be provided, if required, to maintainswitchboard rigidity and alignment.

8.1.5 Particular care shall be taken when using jacks or lifting gear so as toavoid distorting or damaging equipment and only the vendor providedjacking and lifting parts shall be used.

8.1.6 All panel sections shall be mounted in the correct sequence as shown onvendor’s and contract drawings and all circuit designation labels shall bechecked for correct identification. The switchgear and motor controlcentre sections shall be tightly and rigidly bolted together.

8.1.7 The manufacturer’s representative shall supervise and check thetightness of bolted connections within the equipment and ensure thetightness of all bus-bar connections, including correct alignment andconnections of inter-connecting bus-bar sections between motor controlcentres and switchgear.

8.1.8. The Contractor shall, where applicable, use only the special tools andequipment supplied by the Vendors and shall ensure that such tools areavailable in good condition for later use by others.



8.1.9 Switchboard sole plates, steel struts, or other mounting steelwork shallbe installed within the tolerances specified by the manufacturers.

8.1.10 If installed on a concrete surface the mounting steelwork shall beinstalled electrically clear of floor reinforcing metal work. floor screedbelow the switchboard and any truck run-out area shall be level within+ or - 3mm over the whole area.

8.1.11 All packing material and constraints shall be removed carefully andstored and the complete equipment thoroughly cleaned. The storedpacking can be use for repacking on shipment offshore.

8.1.12 The floor area in front of all withdrawable equipment shall be within themanufacturer’s recommended level tolerances to enable easywithdrawal and replacement.

8.1.13 Withdrawable portions of the switchgear and motor control centresshall be checked for correct mating with the stationary portions andcorrect function of locking devices before the switchboard iscommissioned.

* 8.1.14 The Contractor shall be responsible for locating all minor equipment nototherwise located on the drawings e.g. Control Stations, JunctionBoxes, etc. Local Control Stations shall always be mounted adjacent totheir respective equipment. Final locations shall suit site conditions andbe subject to approval of BP.

8.1.15 All distribution boards shall be provided with an interior sub circuitidentification schedule to indicate the equipment served. The scheduleshall be completed by the Contractor prior to tow out.

8.1.16 Where bus-ducting is issued, e.g. for connecting transformers toswitchgear, the Contractor shall install it in accordance with themanufacturer’s recommendations, and strictly to the contract drawingswith regard to route locations, support steelwork and if applicableoffshore deck or bulkhead penetrations.

8.1.17 Bus ducting will be any one of the following types, all of which will besupplied in bits for site assembly:-

(a) air insulated copper bar assemblies

(b) sleeved copper bar assemblies

(c) encapsulated copper bar assemblies



All bus ducting systems should be supplied complete with butt rightangled, tee and flexible inter-connecting kits and connection insulationkits as applicable. For encapsulated bus ducting, the manufacturershould also supply all support assemblies.

8.1.18 The Contractor shall be totally responsible for the installation of airinsulated and sleeved copper bar types of bus ducting.

8.1.19 The Contractor shall be responsible for the installation of encapsulatedtype bus ducting but under the supervision of the manufacturer’srepresentative.

8.1.20 For encapsulated type bus ducting to be installed on offshore platformsthe contractor shall interconnect (but NOT encapsulateinterconnections) bus ducting onshore and shall ensure that thecompleted bus duct run is in proper alignment, free from any distortionalong its length and does not impose any strain on connected terminalsor equipment.

After pre-commissioning tasks are completed, all bus ductinterconnections shall be loosened prior to tow-out.

All bus-duct sections passing through deck or bulkhead penetrationsand which require to be interconnected offshore shall be removed priorto tow-out, or else fully protected against damage, to the satisfaction ofBP.

After tow-out the Contractor shall:-

(a) install all interface connections

(b) tighten all bolted connections

(d) insulate, as applicable, all interconnections

For encapsulated type bus ducting, the manufacturer’s representativeshall supervise these activities.

Where bus ducting passes through A60 deck or bulkhead, certified sealsshall be used, as shown on the drawings and fire resistant protectionapplied to the bus ducting above and below the penetration inaccordance with the manufacturer’s detailed recommendations.

8.2 Motors

8.2.1. All electric motors supplied by the Contractor shall comply with BPGroup RP 12-11, unless otherwise agreed by BP. They should alsocomply with BP Group GSs 112-3 and 112-4 for high voltage motorsand low voltage motors respectively.



8.2.2 Motors supplied on ‘packaged’ equipment will have been installed onthe package and the package itself shall be installed in accordance withthe manufacturer’s recommendations. The following requirements areintended primarily for motors on non-packaged equipment, but whererelevant, are equally applicable to motors on packaged equipment.

8.2.3 Baseplates shall be erected as part of the driven equipment and checkedfor level and location prior to the erection of machinery.

8.2.4 Protective films on machined surfaces shall be cleaned off with therecommended solvents, either immediately prior to installation (e.g.mounting surfaces) or prior to commissioning (e.g. Motor shafts).

8.2.5 Machinery shall be slung or lifted from the prescribed lifting positionsor eyebolts fitted to the equipment. If no lifting points are provided,great care must be taken to prevent damage during lifting operationsand the Contractor shall ensure that the equipment is lifted in thehorizontal or upright position.

8.2.6 Shims supplied with the equipment shall be used wherever possible forlevelling that equipment. Shims shall be of similar size to the machinedsurfaces of the equipment footings. The maximum thickness of shimshall always be used to that the minimum number of shims arepositioned under any one footing.

8.2.7 Where separate bearing pedestals are supplied, these are to bepositioned, levelled and lined up prior to the installation of otherequipment.

8.2.8 White metal bearings shall be checked to ensure adequate bedding usingengineer’s blue or some other approved method of indication. Thebedding shall be checked by the BP Representative.

8.2.9 Coupling faces shall be truly parallel and level, checks being made withthe shafts rotated to different positions. Coupling bolts or flexibleconnections shall be properly fitted without damage and all nuts mustbe tightened and locked before the equipment is run.

8.2.10 If machines with grease lubricated bearings have been stored for a longperiod, the bearing grease shall be inspected and if deterioration hastaken place, the bearings shall be thoroughly washed, dried andregreased using approved methods recommended by the manufacturer.

8.2.11 Where oil lubricating systems are employed, the Contractor shallenquire that bearing oil rings, flow switches, pressure switches, pumps,etc. are fully operative prior to commissioning.



8.2.12 Before connecting the supply to any motor, the Contractor shall ensurethat the motor insulation resistance is not below the minimum valuepermitted by applicable standards or the manufacturers data. Motorswith insulation resistance lower than the permitted minimum value shallfirst be dried out in accordance with the manufacturers instructions, andre-tested to ensure that resistances are satisfactory,

8.2.13 The phase sequences for the connection of motors shall be confirmedon site and it shall be ensured that at least two cable core connections atthe motor terminal box can be interchanged without having to make offthe cable again.

8.2.14 The requirement of correct rotation is particularly important on highvoltage motors and low voltage motors rated 75 KW and abovebecause of the difficulties involved in manipulating large cable cores ata later date,

8.2.15 Care shall be exercised when insulation testing motors fitted withthermistor or thermocouple over-temperature protection. Thesedevices are essentially low voltage or signal devices and if subjected tohigher voltage they will be irreparably damaged.

8.2.16 If motors with ball or roller bearings are left standing, particularly inconditions subject to vibration, before putting into service, they shall beturned over at regular intervals to avoid brinelling of the bearings.

8.3 Transformers and Reactors

8.3.1 Transformers and reactors supplied by the Contractor shall comply withBP Group RP 12-9 and BP Group GS 112-5.

8.3.2 The Contractor shall ensure that all transformers and reactors areinstalled in the location shown on the drawings and in accordance withthe manufacturers drawings and recommendations.

8.3.3 Only the designated jacking and lifting points shall be used when thetransformers are being put into position. Where there are separatelif ting facili ties for tank tops, cores and coils, these shall be removed orrendered unuseable during transport and erection.

8.3.4 When bus-ducting is used for connections to transformers and reactorterminals, checks shall be made to ensure that the bus ductingconnection can be made without imposing any stress on the bus-ductingcopperwork or transformer terminal bushings, before the tank base isfinally bolted or welded down.



8.3.5 When correctly located and inspected, an insulation test shall be carriedout and recorded between each phase and earth and, between HV andLV windings.

8.3.6 On completion of the installation of all fittings and cables, etc., aninsulation test of all windings and connections shall be made.

8.3.7 Where applicable, the fluid level in transformers and colour of anybreathing desiccants shall be checked and rectified where necessary.

8.3.8 Where applicable, transformer oil or other liquid insulant shall bechecked/tested in accordance with the manufacturer’srecommendations.

8.3.9 Where applicable, any transformer tap changer must be securelypadlocked in its required position.

8.4 Batteries, Battery Chargers and Inverters

8.4.1 Batteries, battery chargers and invertors, providing a source of:-

(a) dc supplies for switchgear closing and tripping, instrumentation

(b) dc supplies of control systems

(c) secure static ac supplies for control systems

(d) dc supplies for other duties such as emergency lighting,emergency motor drives, hazard warning lights, etc.

Shall comply with BP Group RP 12-5 and BP Group GSs 112-10 and112-11.

8.4.2 Installation and preparation of batteries for commissioning shall becarried out in accordance with manufacturer’s shall be carried out inaccordance with manufacturer’s recommendations, which will vary withthe type of battery and its delivered state of charge.

8.4.3 When battery filli ng or handling is undertaken, every precaution shall betaken against the possible dangers of toxic fumes, heat and acid or alcaliburns associated with battery electrolyte. Protective clothing shall beprovided for the installation personnel by the Contractor and the areamust be well ventilated. A quantity of neutralising solution shall bereadily available when batteries are handled or commissioned.

8.4.4 Batteries and charges shall not be left unattended whilst initial boostcharging is being carried out.



8.5 Electrical Surface Heating

8.5.1 Electrical surface heating (ESH) equipment and systems shall complywith BP Group RP 12-15.

8.5.2 The design of the ESH system will have been carried out by others.

8.5.3 The Contractor shall be responsible for the installation of the equipmentand system in accordance with the design specification and drawings,and the above Code of Practice.

8.6 Earthing and Bonding

8.6.1 The Contractor shall be responsible for installi ng earthing and bondingsystems in accordance with BP Group RP 12-16.

8.6.2 The earthing and bonding systems on offshore platforms shall alsocomply with the IEE Regulations for the Electrical and ElectronicEquipment of Mobile and Fixed Offshore Installations Section 2.Where there is any conflict between these requirements and those inClause 8.6.1 the Contractor shall consult BP for a decision.

8.6.3 Earthing and bonding systems for electronic instrumentations, datacollecting and data processing systems shall comply with BP Group RP30-1, BP Group RP 30-8 Sect.4 and BP Standard Drawing No. S-1962.

8.6.4 The Contractors responsibility shall include, but not be limited to:-

(a) Earthing and bonding of power system neutral earthing

(b) Earthing and bonding of non-current carrying parts of electricalapparatus

(c) Earthing and bonding of process tanks and structures forlightning protection

(d) Earthing and bonding of process tanks, pipework and structuresto disperse static charging

(e) Earthing and bonding to disperse any charging of structures,cranes, etc. by radio frequency induction from radio transmittingaerials and radar equipment

(f) Earthing and bonding of instrumentation equipment and cabling



8.6.5 Protective screening around insulated conductors on cables emanatingfrom a master station to outstations or field mounted instruments shallbe earthed at the master station only and shall be insulated from theoutstations or field mounted measuring devices.

8.6.6 Where indicated on BP Standard Drawing No. S-1962, cable glands forinstrumentation circuits shall be insulated from earth.

8.7 Small Power and Lighting Systems

8.7.1 Lighting and lighting installations shall comply with BP Group RP 12-14. Where applicable they shall also comply with the IEErecommendations for the Electrical and Electronic Equipment of Mobileand Fixed Offshore Installations, Section 15. Also see section 6regarding hazardous areas.

8.7.2 Whenever possible, lighting luminaires and socket outlets shall beinstalled in locations shown on the contract drawings. Wherenecessary, the Contractor shall, by agreement with BP, relocateluminaires and socket outlets to avoid interference with other work orequipment.

8.7.3 All elevations shown on drawings are in metres and are related toimmediate floor or platform datum as defined on the contract drawings.Elevations are to the underside of the fittings.

* 8.7.4 Light fitting heights shown on drawings may be nominal, and siteadjustments may be necessary to clear local obstruction. However, alllight fittings shall be positioned to provide safe access for lampchanging. All alterations shall be referred to BP for approval.

8.7.5 All emergency hand lamps, socket outlets and junction boxes shall bemounted at a suitable height from floor or platform to facili tate readyaccess for use during maintenance, Socket outlets shall, whereverpossible, be mounted 450mm above floor level.

8.7.6 Final position and angles of floodlights shall be determined duringconstruction. All fl oodlights shall be mounted on stirrups. The cablefor connections to floodlights shall be of adequate length to permit thefloodlight to be swivelled on its mounting through 360°. Due accountshall be taken of certifi cation of fi ttings when determining finalmounting positions. Control gear boxes shall be mounted adjacent tothe fittings in a position easily accessible for maintenance and repair.

8.7.7 For lighting circuits, all cabling shall be 2 core 2.5 mm2 PVC/SWAPVC except where contract drawings specifically states 2.5 mm2 PVC



non-armoured cable or MICC 1.5 mm2 cable in specified areas or forspecified services.

8.7.8 In non-hazardous areas lighting circuits shall be of the loop-in type withthe lighting cable looping from one fitting to the next. The Contractorshall ensure that the continuity of the cable armour is maintained.

8.7.9 In hazardous areas lighting circuits shall not be of the loop-in type. Theinstallation shall be such that a complete lighting fitting can be removedand the integrity of the type of protection be maintained, e.g. by theinsertion of a stopping plug in an EExe certified junction box, so thatthe remainder of the lighting circuit can be re-energised.

8.7.10 Care shall be taken to ensure the correct polarities when wiringswitches, socket outlets and lamp holders.

8.7.11 The luminaries may be utili sed on a temporary single phase powersupply during the construction period, providing all necessary checkson cables and equipment have been made to the satisfaction of theCompany prior to energisation.

8.7.12 The number of fittings connected to any one final sub circuit shall beshown on the drawings. The Contractor shall however check that noarea is totally without illumination upon supply failure of any one sub-circuit.

8.7.13 Each lighting sub-circuit shall be protected by a 15A MCB or 15A fuseat the distribution board.

The maximum steady load (including control gear losses) on anylighting final sub-circuit shall not exceed 0.55 times the sub-circuitprotective MCB rating or fuse rating.

8.7.14 Each lighting and small power distribution board shall be provided withan interior sub circuit identification and loading schedule which theContractor shall complete prior to module tow out.

8.7.15 Illumination levels shall be in accordance with the Chartered Institute ofBuilding Services Engineers (CIBSE) Code for Interior Lighting 1984,taking into consideration all such limiting factors as Glare indices,Veili ng reflections, etc. Typical ill umination levels, applicable tooffshore platforms, are as follows:-

Locations IlluminationLevel (LUX)

WorkingPlane (m)

-Control room, Radio roomDesk + Front Panel 500 On Working Plane



Back Panel 150 Floor

-Generator rooms 200 Floor

-Switchgear rooms 150 Floor

-Battery room,Chargers, and Inverters room

100 Floor

-Workshops - General- Workbench

300500

Floor0.9

-Utility & Process areas 150 Floor

-Walkways & Corridors 50 Floor

-Exterior stairs and ladders 100 Tread

-Laboratory 500 0.9

-Offices-Stores

500150

0.75Floor

-Kitchen - General- Serving Counter

200500

Floor0.9

-Laundry-Cabins - General

- Reading- Bathrooms

-Dining Rooms

30050200100200

0.9Floor0.75FloorFloor

-Rest room 150 Floor

On offshore platforms sea perimeter lighting, an illumination level of 50lux at the sea surface shall be achieved using floodlighting.

8.7.16 Following installation of the lighting systems, the Contractor shall,under night-time conditions:-

(a) take readings of illumination levels throughout the plant orplatform with the normal lighting system energised.

(b) energise only the emergency lighting system to prove adequacy.Any areas not meeting design requirements shall be reported toBP.

(c) adjust orientation of floodlight fittings for maximum efficientuse.

8.7.17 All areas shall have access to service with the use of a 15 metres cordfor general purpose socket outlets and 30 metres cord for welding



socket outlets. The quantity and location of socket outlets shallgenerally be as shown on the drawings. Socket outlets shall also belocated adjacent to equipment requiring periodic inspection andmaintenance, such as manway openings of vessels, towers and rotatingmachinery.

8.7.18 Anti-condensation heaters in all equipment (including instruments) shallbe electrically fed from the nearest small power, trace heating or anti-condensation heater distribution board.

8.8 Generator Packages

8.8.1 Generators and generator packages shall comply with BP Group GS112-6.

8.8.2 The Contractor shall install all Main, Emergency and, where specified,Standby Generators with their gas turbine or diesel engine drivers, andall equipment associated with these ‘packages’, in the locations shownon the drawings and in accordance with the manufacturers instructions.

8.8.3 The Contractor shall install and terminate all interconnecting cables inaccordance with the equipment suppliers drawings and contractdrawings.

8.8.4 Skill ed supervision for the installation of generators and their ancill aryequipments shall be provided by the manufacturer at the discretion ofBP.

8.8.5 The energisation of anti-condensation heaters, barring of rotors and allaspects of treatment during storage, installation and pre-commissioningperiods shall be carried out in accordance with the manufacturer’sinstructions and recommendations.



9. INSTALLATION, INSPECTION, TESTING AND COMMISSION

9.1 General

9.1.1 The BP Site Electrical Engineer will be responsible for overseeing theContractors work associated with the installation, inspection and testingof all electrically related equipment, circuits and systems in accordancewith the following requirements of this section of the guidelines.

9.1.2 The BP site Electrical Engineer will be responsible for agreeing thecontractors installation, inspection and testing procedures.

9.1.3 The Contractor shall be responsible for the provision of all necessaryinstruments, connections and other equipment including electricalsupplies, also the requisite personnel whether the tests are undertakenat the works of the Contractors, or of the Sub-Contractor, or carriedout at Site. All instruments used for commissioning shall be of anapproved type and they shall have been calibrated against certifiedstandards at regular and proper intervals. Their accuracy must be fullysubstantiated at the time of use.

9.2 Installation

The installation of electrical equipment and circuits will be checked forcompliance with good engineering practice and the contractualrequirements as detailed in:-

- The latest revision of AFC Drawings and Schedules.- Plant and Project Specifications.- Equipment Specifications and Data Sheets.- National Codes and Standards.- BP Group RPSEs.

9.3 Safety Precautions

Under no circumstances may any test be carried out in such a manner asto cause danger and all due safety precautions must be taken.

No test should be undertaken until it has been confirmed that theequipment to be tested is properly isolated and has been effectivelydischarged.

Areas where HV testing is to take place should be roped off prior toand during testing and cautionary notices should be displayed at allpoints of access. Similar precautions should be taken in all otherinstances where danger could arise, e.g. motor running tests.



All equipment should be effectively discharged at the completion oftesting; where necessary e.g. in the case of large cables and motors, theearth bond should be left on for 15 minutes or more.

9.4 Inspection and Testing

9.4.1 The complete Works shall be subject to inspection and test forcompliance with this specification, generally to BP Group RP 32-2 andAppendix C of this Specification.

9.4.2 Electrical equipment and the electrical content of mechanical equipmentpackages will be inspected on receipt at site. Any remedial work carriedout at site by either the fabricator or vendor to correct transit damageor faulty workmanship not previously detected will be supervised by thesite Electrical Engineer.

9.5. Pre-Commissioning of Electrical Systems

9..5.1 Pre-commissioning inspection and tests shall be carried out by theContractor on all electrical equipment under the supervision of, and tothe satisfaction of, BP.

9.5.2 The inspection and testing shall be carried out generally in accordancewith Appendix C of this Specification.

9.5.3 Inspection and testing of specialised equipment not included in thecategories of Appendix C shall be carried out in accordance withprocedures specified or agreed by BP.

9.5.4 The results of all inspection and testing shall be recorded on data sheetsas in Appendix C or an agreed variation.

* 9.5.5 All data sheets of inspection and testing shall be signed and approved byBP.

9.6 Pre-acceptance Inspection and Testing

9.6.1 Prior to energising, 4 hr motor runs will be carried out by theContractor. When a Contractor considers that the construction of anelectrical system, circuit or parts thereof is complete and is of such astandard that pre-acceptance inspection and testing can commence, heshall advise BP accordingly. Unless a specific waiver is given by BP allinspection and tests which are to be recorded in the system test dossiershall be witnessed by a representative of BP. The Contractor mustprovide adequate notice of his intention to commence these activities sothat BP has time to allocate an inspector.



The Contractor should maintain close liaison with BP so that inspectionand testing may be carried out as work proceeds in order to avoid theneed for disconnection of cables for testing purposes after theinstallation has been completed.

Wherever possible final inspection and testing should be carried outimmediately prior to acceptance by BP for energisation. Where this isnot possible the Company may call for re-inspection and testing.

* 9.6.2 Following the satisfactory completion of the inspection and testing of asystem or circuit the Contractor shall complete the appropriate testcertificate(s) and submit it to BP prior to, or together with, his formalnotification that work on the system or circuit is complete.

No work whatsoever shall be carried out on the system or circuit by theContractor subsequent to this submission unless full details of suchwork are agreed in writing by BP.

9.7 Energisation and Commissioning

9.7.1 When the electrical works or any section thereof, has been provedsatisfactory and agreed to be such by BP, the Contractor will arrangefor an attend upon BP during the commissioning of the completedworks as agreed.

9.7.2 Following submission of the formal notification that work is complete,arrangements will be made by BP to energise the system or circuit at amutually convenient time. The energisation and commissioning of thesystem or circuit will be carried out by, and will be the responsibility ofBP but the Contractor shall provide such assistance in these activities asis deemed necessary by BP.

9.7.3 Under no circumstances may a circuit be energised or commissionedprior to its being inspected and tested and the relevant section of thesystem test dossier completed and approved. Prior to initial energisinga work permit shall be obtained.

* 9.7.4 Under no circumstances may any test be carried out on existing cablesor equipment without the agreement and in the presence of arepresentative of BP.

* 9.7.5 In certain instances, e.g. motors, special drives and systems, arealighting boards, control circuits, etc., BP may agree in writing to theContractor assuming responsibility for the energisation from BPsuppliers of the systems or circuits concerned. Such agreement will notbe given until the Contractor has satisfied BP as to the adequacy of theprecautions he intends to take to ensure the safety of the system andthose working upon it. In such cases the Contractors shall implement



an acceptable safe system of working, e.g. Permits to Work, etc., andsubmit to BP for approval.

9.7.6 If the results of the test and checks carried out after energisation are notsatisfactory the system or circuit will be de-energised, locked off andhanded back to the Contractor for correction. This, in some instancesmay be covered by a Punchlist detailing the remedial work required.

9.7.7 In the event of electrical work being left in a de-energised or inoperablestage for any length of time prior to final acceptance, the Contractorshall arrange for, and/or, carry out any inspections, tests, operations,etc., as may be required by BP, to ensure that it is still in a satisfactorycondition for re-energising and putting into operation. The above shallapply until such time as the Contractor is relieved from responsibility bythe issue and acceptance of a ‘handover certificate’ which may includeprovisos concerning minor items that remain to be completed.

* 9.7.8 If the results of the energisation tests are satisfactory the system orcircuit will be accepted by BP subject to any minor modificationsspecified by BP. Thereafter the circuit or system will become theresponsibility of BP and no further work may be carried out on itwithout the prior approval of BP. Access to live metalwork or theenergisation of sub circuits must thereafter have the express approval ofBP by means of a permit to work system (see Appendix D),



APPENDIX A

DEFINITIONS AND ABBREVIATIONS

Definitions

Standardised definitions may be found in the BP Group RPSEs Introductory Volume.

Manufacturer: the manufacturer of equipment/materials to which thisSpecification applies.

Inspection: a visual inspection of the equipment and the installed circuitsand systems.

Testing: routine tests normally carried out prior to energisation to ensurethat the equipment, circuits and systems have been installedcorrectly and are safe to energise.

Commissioning: energisation and the final tests and checks subsequent toenergisation to ensure that each circuit and piece of equipmentsatisfactorily performs it’s required function.

Abbreviations

AFC Approved for ConstructionBASEEFA British Approvals Service for Electrical Equipment in

Flammable AtmospheresBS British StandardCIBSE Chartered Institute of Building Services EngineersEN European StandardESHEVA Ethylene Vinyl AcetateGRP Glass Reinforced PlasticHV High VoltageIEC International Electrotechnical CommissionIEE The Institution of Electrical EngineersIP Institute of PetroleumISO International organisation for StandardisationLV Low voltageMCB Miniature Circuit BreakerPVC Polyvinyl ChlorideSIRASWA



APPENDIX B

LIST OF REFERENCED DOCUMENTS

A reference invokes the latest published issue or amendment unless stated otherwise.

Reference standards may be replaced by equivalent standards that are internationally orotherwise recognised provided that it can be shown to the satisfaction of the purchaser’sprofessional engineer that they meet or exceed the requirements of the referenced standards.

ISO 9001 Quality Systems - Model for Quality Assurance inDesign/Development, Production, Installation and Servicing.

BS 729 Specification for Hot Dip Galvanized Coatings on Iron andSteel Articles.

BS 4360 Specification for Weldable Structural Steels.BS 4533 Section 102.51 Specification for Luminaires with Types of Protection ‘N’.BS 4607: Part 1 Specification for Fittings and Components of Insulating

Material.BS 5000: Part 16 Rotating Electrical Machines with Type of Protection ‘N’.BS 5345 Code of Practice for Selection, Installation and Maintenance of

Electrical Apparatus for Use in Potentially ExplosiveAtmospheres.

BS 6099 Conduits for Electrical Installations. Part 2: Particularspecifications.

BS CP 1017 Distribution of Electricity on Construction and Building Sites

The Institution of Electrical Engineers (I.E.E.)Wiring Regulations for Electrical Installations, 15th Edition.

The Institution of Electrical Engineers (I.E.E.)Regulations for the Electrical and Electronic Equipment ofMobile and Fixed Offshore Installations, Section 2.

The Institution of Electrical Engineers (I.E.E.)Recommendations for the Electrical and Electronic Equipmentof Mobile and Fixed Offshore Installations, Sections 6 and 15.

Chartered Institute of Building Services Engineers (CIBSE)Code for Interior Lighting 1984

Health and Safety Executive (HSE)Guidance Note G524.



BP Group RPSEs

GS 112-4 High Voltage Induction MotorsGS 112-3 Low Voltage Induction MotorsGS 112-5 Transformers and Reactors.GS 112-6 Electrical Requirements for A.C. Generators and Generation

PackagesGS 112-9 High Voltage Switchgear and Control GearGS 112-8 Low Voltage Switchgear and Control Gear.GS 112-12 D.C. Power SuppliesGS 112-10 Secure Static A.C. Power Supplies for Control SystemsGS 112-12 Requirements for Flame Retardant and Fire Resistant CablesRP 12-1 Electrical Systems and Installations - GeneralRP 12-5 Electrical Systems and Installations - Power Supplies for

Control SystemsRP 12-6 Electrical Systems and Installations - High Voltage SwitchgearRP 12-7 Electrical Systems and Installations - Low Voltage SwitchgearRP 12-9 Electrical Systems and Installations - Transformers and

ReactorsRP 12-11 Electrical Systems and Installations - MotorsRP 12-13 Electrical Systems and Installations - Cables, Cable Systems

and WiringRP 12-14 Electrical Systems and Installations - Lighting and Lighting

InstallationsRP 12-15 Electrical Systems and Installations - Electric Surface HeatingRP 12-16 Electrical Systems and Installations - Earthing and BondingRP 12-17 Electrical Systems and Installations - Supplies to Equipment via

Socket OutletsRP 12-19 Electrical Systems and Installations - Construction Site Power

SuppliesRP 24-1 Fire Protection - OnshoreRP 24-2 Fire Protection - OffshoreRP 30-1 Instrumentation and Control - Design and PracticeRP 30-8 Instrumentation and Control - Electromagnetic Compatibility

for Instrumentation and Control SystemsRP 32-2 Site Inspection, Testing and Pre-Commissioning of New Plant

BP Standard Drawing:-S-1962 Typical Earthing Diagram for Instrumentation Onshore



APPENDIX C

INSPECTION AND TEST PROCEDURE

C.1 INTRODUCTION

C.1.1 This section details the site inspection and testing procedures for theElectrical Discipline and includes standard forms which are to be usedto accurately record the results of the inspection and tests and providewritten evidence that all electrical equipment and systems comply withdesign parameters and function correctly.

C.1.2 The procedures cover the inspection of electrical equipment prior toinstallation and the inspection and testing of installed equipment,circuits and systems before and after energisation and commissioning.

C.1.3 Although the inspection and test procedures in this section arecomprehensive, they may not necessarily cover all electrical equipmentand systems included in the design. It is the responsibility of the BP siteElectrical Engineer to agree all electrical inspections and tests andensure that any further procedures, additional to those included in thisdocument, are developed in order to give complete coverage andconfirm that electrical systems in all respects are fit for energisation andservice.

C.1.4 It is also the responsibility of the BP Site Electrical Engineer to ensurethat prior to construction a comprehensive component/equipment listand cable schedule is available against which all the required testcertificates will be listed to give a concise cross reference for thecompletion of system testing.

* C.1.5 Where special electrical equipment and systems are provided, e.g.alternators, emergency generators, resistors, reactors, balanced currentprotection, synchronising and complex control circuits, invertors andpublic address systems, the supplier will be required to carry out finalinspection and functional testing at site after installation. Suchinspection and tests are to be recorded on test certificates prepared bythe supplier and agreed by BP prior to use.



C.2 INSPECTION AND TEST PROCEDURES

C. 2.1 Procedure No. 1 - Power and Control Cables

C. 2.2 Procedure No. 2 - Switchboards and Busbars

C. 2.3 Procedure No. 3 - Circuit Breakers

C. 2.4 Procedure No. 4 - Contactor Breakers

C. 2.5 Procedure No. 5 - Fuse Switches

C. 2.6 Procedure No. 6 - Power Transformers

C. 2.7 Procedure No, 7 - Motors

C. 2.8 Procedure No.8 - Batteries and Battery Chargers

C. 2.9 Procedure No. 9 - Ininterruptable Power Supplies

C. 2.10 Procedure No 10 - Lighting and Small Power Distribution

C. 2.11 Procedure No. 11 - Neutral Earthing Resistors

C. 2.12 Procedure No. 12 - Trace Heating Tapes and Circuits

C. 2.13 Procedure No. 13 - Earthing

C. 2.14 Procedure No. 14 - Apparatus for use in Hazardous Areas

C. 2.15 Procedure No. 45 - Oil Insulation Tests

C. 2.16 Procedure no. 16 - Drying of Electrical Rotary Machinery

C. 2.17 Procedure No. 17 - Current Transformer Magnetising Curves

C. 2.18 Procedure No. 18 - Junction Boxes

C. 2.19 Procedure No. 19 - Testing of Protection and Meter Circuitry



C. 2.1 Procedure no. 1 - Power and Control Cables

The following inspection and test procedures are applicable to all cablesizes and types

C.2.1.1 Inspection (Post Installation)

(a) Compare the cable size, type and numbering with the cableschedule paying particular attention to any special requirements.e.g. toxicity. Ensure that the core identification agrees with theconnection diagrams and phase sequence.

(b) Ensure that the gland certificates meet the area classificationrequirements.

(c) Inspect the cable glands for tightness and good workmanship.Ensure that the correct type of gland has been used for the sizeand type of cable installed, and that, where specified, insulatinggland adaptors have been installed.

(d) Ensure that the gland plates for all single-core cables have beenmanufactured from non-magnetic materials.

(e) Where conductors have been terminated using crimpedconnections, ensure that the correct size and type of crimpinglug has been used.

(f) Before making any measurement, the inspector should ensurethat both ends of the cable have been disconnected and are clearof any metal.

(g) Inspect the earth connections.

(h) For HV cable, ensure that the cables have been glanded inaccordance with the cable manufacturers’ instructions and inparticular check that any stress relief measures have beenincorporated.

(i) For MICC cable, the additional inspection as listed belowshould be carried out:-

(i) Check that the glanding is in accordance with themanufacturers’ instructions and that earth trails havebeen terminated at a suitable earthing terminal.



(ii) Check that surge suppression voltage dependentresistors are correctly fitted where specified and that thecorrect type has been fitted.

(j) Ensure the appropriate requirements of Procedures 15 and 19are carried out if applicable.

C.2.1.2 Testing

Before any cables are tested, all cleating, supports, backfilling oftrenches etc. is to be completed.

(a) Measure the insulation resistance of the cable and record on therelevant test certificate. The table below gives the test voltagesand minimum acceptable values of insulation resistance. Wherenecessary measure the conductivity of the earth conductor.

For LV and MV multicore cables, insulation resistance shouldbe measured core to core, core to earth and screen to armourRecord only the lowest figure obtained.

Cable Voltage(Working Range)

Test Voltage(Between conductorand to earth)

Minimum InsulationResistance Meg-Ohms

00/1000V 1000V 101900/3300V 1000V 2003800/6600V 1000V 2006350/11000 5000V 2008700/15000 5000V 200

12700/22000 5000V 20019000/33000 5000V 200

(b) Apply a DC Test voltage (pressure test) between the conductorsof each high voltage cable and the copper tape screen of eachconductor, also between conductors. Record test voltage andduration of test, measure and record any leakage current.



Each cable shall be discharged after the above tests and theconductors earthed until the cable is put into service. The testvoltage and duration are as tubulated below:-

CABLE GRADE DC TEST VOLTAGE DURATION

CONDUCTORTO

SHEATH

CONDUCTORTO

SHEATH

1900/3300 7000 10000 15 Mins3800/6600 15000 20000 15 Mins

6350/11000 25000 34000 15 Mins19000/33000 - 75000 15 Mins

(Abstracted from BS 5467:1977 Table 17, BS 6346:1969 Table20 and BS 6460:1969 Table 31).

(c) Immediately after the above test, the insulation resistancebetween each conductor and its earthed copper screen shall bemeasured, as detailed in (a) above. The minimum acceptablevalue is as tabulated.

C.2.1.3 Test Certificates

Forms E-1 and E-2 are to be used to record the results of the testingand require endorsement to confirm that all the requirements of thisprocedure, and procedures 14 and 18 if appropriate, have been carriedout satisfactorily.



C.2.2 Procedure No. 2 - Switchboard and Busbars

C.2.2.1 Inspection

(a) Pre-Installation

(i) Ensure the equipment certificates meet the areaclassification requirements.

(ii) Remove any temporary weatherproofing and silica geldrying agents from switchgear. Inspect the inside of theswitchgear for cleanliness paying particular attention tothe insulators.

(iii) Compare the switchgear equipment with the equipmentschedule, paying particular attention to the rating andany circuit changes.

(iv) Ensure that the equipment meets Specification includingweather, dust and vermin-proofing.

(b) Post Installation

(i) Inspect the switchboard assembly for alignment, level,tightness of foundation bolts, and fixing in general.

(ii) Ensure that all panel doors and gland plates are bondedto the switchboard structure.

(iii) Ensure that all equipment installed in the switchboard isin good condition.

(iv) Inspect the switchboard earth bar and earth cable forelectrical and mechanical continuity.

(v) Inspect the busbar joints.

(vi) Ensure the appropriate requirements of Procedure 14 arecarried out if applicable.

C.2.2.2 Testing

(a) Prior to securely fitting the busbar covers, measure theinsulation resistance of the busbars and control wiring. Wherethere are any busbar joints, a Ductor test must be carried outprior to fitting covers.



(b) Test the switchboard earth system for electrical and mechanicalcontinuity. Measure the earth path resistance at the earth bar tothe general earth system.

(c) Ensure that all the Protection relays have been tested inaccordance with the requirements of the appropriate testcertificate, and vendors instructions.

(d) Measure the insulation resistance of the busbars and controlwiring. This test should be carried out prior to the pressure testand before energising the switchboard. The minimumacceptable resistance together with the relevant test voltage, isgiven in the table below:-

SwitchgearVoltage, KV

Test VoltageV

Min InsulationResistance, Megohms

33 5000 20022 5000 20011 5000 2006.6 1000 2003.3 1000 1000.6 1000 1000.44 1000 100Control Wiring 500 10

(These test levels are in accordance with BS 5405 and itspredecessor BS CP 1008).

(e) A power frequency voltage test (pressure test) on the main andauxilli ary circuits shall be carried out between phases and phaseto earth. The following conditions must be adhered to for thetests:-

(i) All current transformers secondaries will be shortcircuited for the test.

(ii) All voltage transformers shall be disconnected byremoval of primary and secondary fuses for duration ofthe test.



(iii) One pole of the testing supply shall be connected toearth and to the frame of the assembly, for the phase toearth test.

The minimum acceptable test voltages are given in the tablebelow. The tests should be carried out at a frequency of 25-100HZ and full voltage should be applied for one minute.

EQUIPMENT VOLTAGE, KV a.c TEST VOLTAGE, KVFOR 1 MINUTE

0.66 .23.3 8.66.6 15.2

11 2415 3222 4633 68

(Abstracted from BS 162, Table 12 and BS 5227 Table 6)

(f) Upon completion of all tests, reconnect all cables andensure that shorting links and fuses are replaced.

(g) As an alternative to the power frequency test, a highvoltage d.c. test may be applied. BS 5227 does notcontain any test voltages, only the comment that they are‘under consideration;. In the interim the test levels inBS 161 (Table 14) will be used:-

EQUIPMENT VOLTAGE, KV a.c TEST VOLTAGE, KVFOR 15 MINUTES

0.66 1.53.3 7.56.6 15

11 2515 3222 4533 66



(h) Carry out required testing of protection and/or metercircuitry in accordance with Procedure 19.


Form E-3 is to be used for recording the results of the testing andrequires endorsement to confirm that all the requirements of thisprocedure, and Procedure 14 if appropriate, have been carried outsatisfactorily.

Originals of test certificates generated by implementing Procedure 19must be attached to E-3 for filing in the System Test Dossier.



C.2.3 Procedure No 3 - Circuit Breakers

The following procedures are applicable to all circuit breakers in metalclad switchgear whether of the air-break, bulk oil, SF6 or vacuum typeof circuit breaker.

This procedure should be read in conjunction with Procedure 2.

C.2.3.1 Inspection

(a) Pre-Installation

Carry out the pre-installation checks of procedure 2.

(b) Post-Installation

(i) Carry out mechanical operation checks to ensure:-

(a) Correct alignment and connection of all busbarconnections between fixed and moving portionsof the circuit breaker and switchboard.

(b) Correct alignment and connection of all main andsecondary plug and socket connections.

(c) Correct operation of busbar shutters andpadlocking facilities.

(d) Correct fitting and operation of any specialearthing facilities.

(ii) Check operation of circuit breaker close and tripmechanism, manually and electrically.

(iii) Ensure the appropriate requirements of Procedure 14 arecarried out if applicable.

C.2.3.2 Testing

(i) Sample and test oil in oil circuit breakers before performingpressure test.

(ii) Carry out insulation resistance tests before and after pressuretest with circuit breaker both open and closed.

(iii) Carry out pressure tests as detailed in Procedure 2.



(iv) Test Levels of insulation resistance and pressure test as given inProcedure 2.

(v) Carry out any required testing of protection and/or metercircuitry in accordance with Procedure 19.

C.2.3.3 Test Certificate

Form E-4 is to be used for recording the results of the testing andrequires endorsement to confirm that all the requirements of thisprocedure and Procedure 14 if appropriate have been carried outsatisfactorily.

Originals of test certificates generated by implementing Procedure 19must be attached to E-4 for filing in the system Test Dossier.



C.2.4 Procedure No. 4 - Contactor Starters

C.2.4.1 Inspection (Post Installation)

(a) Remove any transit packing and binding materials from therelays, contactor etc.

(b) Inspect the equipment in the compartment for damage duringinstallation, and it is clean and any silica-gel etc. is removed.

(c) Compare the unit description with the Company schedules andVendor drawing.

(d) Ensure that the isolator can be padlocked in the off position andthat it is interlocked with the door.

(e) Inspect and check the operation of the isolator and any auxiliaryswitches.

(f) For plug-in starters test the operation of the withdrawal unit andalignment of main and auxiliary plugs.

(g) Test the mechanical operation of all contactors and relays andalignment of contacts.

(h) Compare the main and control fuse ratings with the schedules.

(i) Examine the internal wiring for security and ensure that it is notbeing caught or damaged by the door or drawout unit.

(j) Ensure that the door is earthed.

(k) Ensure that any ammeters and scales are correct/suitable.

(l) Ensure that the anti condensation heater, if fitted, is in thecorrect position, and that it is not too close to any internalcabling or heat sensitive devices.

(m) Examine flash barriers etc.

(n) Ensure the appropriate requirements of Procedure 14 are carriedout if applicable.

C.2.4.2 Testing

(a) Test the overload by primary or secondary injection and recordthe results on the relevant Test Certificate.



This should agree (within tolerance) with the manufacturerscurves.

(b) Test the calibration of any ammeters by primary or secondaryinjection and record on Test Certificate.

(c) Test the overload for single phasing by passing 80% of full loadcurrent through two phases only and record on Test Certificate.

(d) Test and record the starter insulation resistance using:-

(i) 1000 volt test for main wiring - minimum value shouldbe 10 megohms.

(ii) 500 volt test for control wiring - minimum value shouldbe 5 megohms.

(e) Carry out any required testing of protection and/or metercircuitry in accordance with Procedure 19.


Form E-5 is to be used for recording the results of the testing andrequires endorsement to confirm the requirements of this procedure,and Procedure 14 if appropriate, have been carried out satisfactorily.




C.2.5 Procedure No 5 - Fuse Switches

C.2.5.1 Inspection (Pre-Installation)

(a) Note the nameplate ratings of the fuse switch, and any specialinstructions. Compare these ratings with those on the approveddrawings.

(b) Remove any transit packing materials from the fuse switch(where fitted).

(c) Ensure that the fuse switch unit has been labelled correctly.

(d) Ensure that the interior of the unit has been cleansed and anysilica-gel drying agents have been removed.

C.2.5.2 Inspection (Post Installation) and Testing

(a) Inspect the equipment in the fuse switch compartment fordamage during installation.

(b) Inspect the mechanical operation of the fuse switch and anyinterlocks fitted in the fuse switch cubicle or cover. Inspect theequipment padlocking facility.

(c) Ensure the contact alignment of the fuse switch and themechanical operation of the on-off indication.

(d) When operating handles are of the retractable type, ensure thatthey retract correctly.

(e) Check the ON-OFF operation of the indicator.

(f) Measure the insulation resistance through the closed isolator.

(g) Carry out any required testing or protection and/or metercircuitry in accordance with Procedure 19.

(h) Ensure the appropriate requirements of Procedure 14 are carriedout if applicable.


Form E.6 is to be used for recording the results of the testing andrequires endorsement to confirm that the requirements of thisprocedure, and Procedure 14 if appropriate, have been carried outsatisfactorily.



C.2.6 Procedure No.6 - Power Transformers

C.2.6.1 Inspection (Post-Installation)

(a) Note the nameplate ratings of the transformers, and any specialinstructions concerning auxiliary apparatus. Compare theseratings with those on the approved drawings.

(b) Ensure certification meets the area requirements.

(c) Inspect the transformer and auxiliary equipment for alignmentand tightness of foundation bolts and fixings in general. Inspectthe boltings and the weatherproofing of terminal boxes.

(d) Inspect the padlocking facilities.

(e) Inspect the earthing bolts and the connections to the earthinggrid.

(f) Inspect the bolting to the neutral connection. If neutral earthingresistors have been fitted, refer to Electrical Procedure No.11for detailed requirements.

(g) Inspect the transformer breathing device and the condition ofthe moisture absorbing capsule (where fitted).

(h) Inspect the Gas Alarm device (where fitted).

(i) Inspect the pressure relief device (where fitted).

C.2.6.2 Testing

(a) Test the alarm and trip circuits of the device.

(b) (i) Consult vendors instructions and if required measure thedielectric strength of the transformer oil. Two samplesshould be taken, one from the upper region of the tank,and the other from the bottom. If the transformers aresupplied without oil, check each drum of oil suppliedagainst the manufacturer’s specification, includinginsulation breakdown values. Check the oil level afterfilling. (Details of testing transformer oils are containedin Procedure 15).

(ii) Link box oil shall be tested to Procedure 15 prior to finalclosing.



(c) Ensure that all cables have been certified in accordance with thecable certificate.

(d) Measure the phase to phase, and phase to earth insulationresistance for both the HV and LV windings. The table belowgives the test voltages and minimum acceptable values ofinsulation resistance.

TRANSFORMER WDGVOLTAGE

TESTVOLTAGED.C

MINIMUMINSULATIONRESISTANCE,MEGOHMS

25110440

33006600

1100033000

250250500

1000100010005000

101050

150150150200

(e) Carry out a power frequency voltage (pressure) test between theHV and LV windings. The test should be carried out for oneminute between each winding, with the core and tank earthed.Alternatively a d.c. pressure test may be applied. Duration ofthis test is to be 15 mins. The test voltages to be applied aregiven in the table below.

TRANSFORMERWDGVOLTAGE

TEST VOLTAGEDRY TYPE

TEST VOLTAGEOIL IMMERSED

A.C D.C A.C D.C

33006600

1100033000

600 560011250 1060018750 17600

- -

12000 1130016500 1550021000 1980052500 49500

(Abstracted from BS171 Tables 9, 10 and 27.



(f) Carry out any required testing of protection and/or metercircuitry in accordance with Procedure 19.


Form E-7 is to be used for recording the results of the testing andrequires endorsement to confirm that the requirements of this procedurehave been carried out satisfactorily.

All supplementary certificates should be attached to E-7 for filing in thesystem test dossier, namely E-13 for neutral earthing resistors if fitted(Procedure 11), E-16 for transformer and link box oil testing(Procedure 15) and certificates generated by implementing Procedure19.



C.2.7 Procedure No.7 - Motors


(a) Note the nameplate rating of the motors and compare withthose given in the approved drawing and motor schedule. Noteany special instructions regarding auxiliary equipment.

(b) Ensure equipment certification meets the area classificationrequirements.

(c) Ensure that any shaft blocking or transit packing has beenremoved.

(d) Have the coupling broken to separate the motor from the drivenunit or the belts removed from belt driven equipment. Ensurethat the motor rotates freely and check that the end play of therotor is within tolerances.

(e) Without dismantling the motor, inspect as far as possible, oilrings, oil levels, grease packing and bearings. Inspect forleakage.

(f) Inspect the paint finish of the motor for damage duringinstallation. Any damaged areas are to be repainted.

(g) Inspect the weatherproofing and bolting of the connectionboxes. This should not be dependent upon the application ofpaint, tape or plastic compounds.

(h) Inspect the stator winding connection and whether the systemshould be for star or delta connection.

(i) Inspect the earthing stud and the connection to the generalearthing system, including those inside the connection box.

(j) After test ensure that all covers giving access to connections arefastened down.

(k) Ensure the appropriate requirements of Procedure 14 are carriedout if applicable.

C.2.7.2 Testing

(a) Ensure that all cables have been certified in accordance with thecable test procedures. Test the phase sequence and polarity ofall connections.



(b) Measure the phase to frame resistance and phase to phase if thewindings can be separated. A 5000V insulation tester should beused on HV motors. If the windings require drying outreference should be made to the guidance notes and typicaldrying out curve as detailed in Electrical Procedure No. 16.

(c) If special motor protective devices (e.g. thermocouples) havebeen fitted, test their circuit continuity. (Insulation resistancetests should not be carried out across thermistor terminals orthermistor control units).

(d) Test the anti-condensation heater and circuit (where fitted).

(e) Start the motor to determine the direction of rotation andcompare this with the required rotation of the driven unit.

(f) Run the motor for about 4 hours and check the bearings forundue temperature rise. Check for vibration.

(g) Measure and record the line current of the free running motor.

(h) Have the coupling reassembled and the alignment of thecoupling and end play checked (or have the belts put back on ifbelt driven) after the 4 hours test.

(i) For HV motors measure the Polarisation Index (PI) and refer tothe manufacturers’ documentation for acceptable levels. In theabsence of the latter a figure of 1.7 should be the minimumacceptable level.

(j) For HV machines rated up to 10MW a high voltage a.c. testmay be carried out at a voltage = 0.8 x (2 x M/c rated voltage +1Kv), for 1 minute as specified in BS 4999: Part 60.

This test may be replaced with a d.c test at a voltage to beagreed with the manufacturer, but which must NOT exceed 1.28x (2 x m/c rated voltage + 1Kv.

NOTE:This test is NOT obligatory

(k) Carry out any required testing of protection and/or metercircuitry in accordance with Procedure 19.




Form E-8 is to be used for recording the results of the testing andrequires endorsement to confirm that the requirements of this procedureand Procedure 14 if appropriate, have been carried out satisfactorily. Ifapplicable the results of drying out motor windings, Procedure 16, areto be attached to Form E-8 for filing in the system test dossier, togetherwith any certificates generated by implementing Procedure 19.



C.2.8 Procedure No 8 - Batteries and Battery Charger


(a) Note the nameplate rating of the equipment, and number, typeand rating of the batteries supplied and compare with the ratingsstated on the approved drawings for the equipment.

(b) Ensure that the equipment certificates meet the areaclassification requirements.

(c) Inspect the chargers and battery stands for alignment, level, andtightness of foundation bolts and fixing.

(d) Inspect the earthing bolts and the connections to the earthsystem.

(e) Ensure that all site installed cables have been tested inaccordance with the cable Test Certificate.

(f) Clean the interiors of all control panels, chargers etc. Removeany temporary silica-gel drying agents from the panels.

(g) Note the type, size and rating of all fuses and protective devicesand compare with the values stated on the approved drawings.

(h) Inspect all batteries for cracks, damage and tightness andcleanliness of terminals and connections.

(i) Remove any transit bungs from the cells.

(j) Inspect all bolted connections between individual cells in a bankof batteries. Ensure that all battery terminals have been coatedwith vaseline or equivalent.

(k) Inspect the battery electrolyte level in all cells after filling.

C.2.8.2 Testing

Measure the earth path resistance at the main earthing terminal. Notethat special care must be taken when making tests on electronicequipment due to its susceptibility to damage by overvoltages.



C.2.9 Procedure No. 9 - Uninterruptable Power Supplies

This procedure is a preliminary to the inspection and test performed bythe equipment vendor at site.


(a) Note the nameplate ratings of the equipment and any auxiliaryapparatus and compare with the rating given on the approveddrawings.

(b) Inspect the installed equipment for alignment, level, tightness offoundation bolts and fixings.

(c) Inspect the earthing bolts and the connection to the earthingsystem.

(d) Ensure that all site installed cables have been tested inaccordance with the Electrical Procedure, and Test Certificatescompleted.

(e) Note the type, size and rating of all fuses and protective devicesand compare with the values stated on the approved drawings.

(f) Clean the interiors of all control panels, inverters etc. Removeany temporary silica-gel drying agents from the panels.

C.2.9.2 Testing

(a) Carry out testing of Batteries and Battery Charger inaccordance with Procedure 8.

(b) Carry out all testing required on Form E-10 and sign offcertificate.

(c) Ensure that all vendor site tests have been completed and allresults recorded on vendor test sheets.


Form E-10 to be used for recording the results of the testing andrequires endorsement to signify that the requirements of the procedurehave been carried out satisfactorily.

Certificates for Batteries and Battery Charger Tests, together withoriginals of Vendor Test Certificate should be attached to E-10 forfiling in the system Test Dossier.



C.2.10 Procedure No. 10 -Lighting and Small Power Distribution System


(a) Ensure that the equipment meets the area classificationrequirements as laid down in the design specification anddrawings.

(b) Note the siting of the lighting fittings, sockets, etc. and comparewith the approved drawings.

(c) Note the distribution board circuit numbering and the fuse ratingof the circuits and compare with the approved drawings. Testany safety features such as interlocks, padlocks and doorswitches.

(d) Ensure that the distribution board supply cable has been testedand relevant test certificate completed.

(e) Inspect the earthing busbar and cable earthing connectionsinside the distribution boards, and the earthing connections fromindividual items of equipment to the earthing grid where detailedon drawings.

(f) Inspect lighting fittings, sockets and switches for neatness,weather-proofness, glanding, internal connections and generalgood workmanship.

(g) As each sub-circuit from a distribution board is tested, completea test tag and attach it to the sub-circuit control switch in aprominent position.

(h) All equipment in hazardous areas should be inspected inaccordance with the requirements of Electrical Procedure No.14.

(i) Carry out inspection of Junction Boxes in accordance withElectrical Procedure No. 18.

C.2.10.2 Testing

(a) Measure each outgoing circuit insulation resistance to earth.

(b) Test the voltage and polarity of each socket outlet and also theearth continuity.



(c) Carry out illumination tests. Illumination levels are to complywith the CIBS Code for interior lighting where no otherstatutory or contract illumination levels are specified.

(d) Carry out any required testing or protection and/or meteringcircuitry in accordance with Procedure 19.


Form E-11 is to be used for recording the results of the testing andrequire endorsement to signify that the requirements of this procedure,and Procedures 14 and 18 if appropriate, have been carried outsatisfactorily.




C.2.11 Procedure No. 11 - Neutral Earthing Resistors

C.11.1 Inspection (Post Installation)

(a) Note the nameplate ratings of the neutral earth resistors(NER’s) and compare with the approved drawings.

(b) Ensure the equipment certificates meet the area classificationrequirements.

(c) Remove any temporary weather proofing and any drying agents(e.g. silica-gel).

(d) Inspect the neutral earthing resistors for alignment, tightness offoundation bolts and fixings.

(e) Inspect the connections to the neutral earthing resistor.

(f) Inspect the frame earthing arrangement.

C.2.11.2 Testing

(a) Measure the insulation resistance of the resistor to earth withincoming and outgoing connections disconnected. Measure thevalue of the neutral earthing resistor.

(b) Test the anti-condensation heater and circuits where fitted.

(c) If current transformers have been fitted, check that Vendor testcertificates and magnetising curves are available; if not carry outtests in accordance with Procedure 17.

(d) Measure the equipment earth path resistance at the mainearthing terminal to the general earth system.

(e) Carry out required testing of protection and/or meter circuitry inaccordance with procedure 19.

(f) Upon completion of tests, re-connect the incoming andoutgoing cables.


Form E-13 is to be used for recording the results of the testing andrequires endorsement to confirm that the requirements of this procedurehave been carried out satisfactorily. Any Supporting currenttransformer certificates (originals) generated by implementing



Procedure 19 must be attached to E.13 for filing in the System TestDossier.



C.2.12 Procedure No 12 - Trace Heating Tapes and Circuits


(a) Check that the tape type is correct to the drawing requirements.

(b) Check that the tape is of the correct length.

(c) Check that the circuit is correct for the voltage rating of thetape.

(d) Check that the fuse rating is correct for the total circuit loading.

(e) Check that the tape is installed correctly, especially with regardto removable items, e.g. valves etc.

(f) Check that the mounting of the junction boxes and thermostatsis correct.

(g) Carry out inspection and tests detailed in Electrical Proceduresno’s 1, 14 and 18, as required.

C.2.12.2 Testing

(a) There is no BASEEFA requirement to carry out brine testing of‘CHEMELEX’ type tapes. However, it is recommended that anend-seal test in brine be carried out on all inaccessible tapes.

(b) Each tape shall be subject to an insulation resistance test wheninstallation is complete.

(c) After all the tapes on a circuit are installed, the complete circuitshall have its insulation resistance tested and recorded.

(d) After completion of the thermal insulation, the circuit shouldhave its insulation resistance re-checked (not recorded) toensure no damage has occurred.


Forms E-14 and E-15 are to be used for recording the results of thetesting, together with Form E-1 for cable testing in accordance withProcedure No.1 The forms require endorsement to confirm that therequirements of the procedure, and procedures 1, 14 and 18 asappropriate, have been carried out satisfactorily.



C.2.13 Procedure No. 13 - Earthing


(a) Compare the earth connection type and size with the schedule.

(b) Where conductors have been terminated using crimpedconnections ensure that the correct size and type crimping lughas been used.

(c) Ensure all connections are tight and greased.

C.2.13.2. Testing

Main Earthing Points

(a) Each separate earthing point, which may consist of one or moreelectrodes, shall be tested with a standard earth test wheneverpractical. The resistance of each point must not exceed 10ohms and may have to be below this to comply with (b) below.

(b) The resistance as measured from any part of the system to themain earth point should not normally exceed the values notedbelow and tests shall be carried out to confirm this:-

(i) Electrical Earthing - 1ohm

(ii) Lightning Protection - 7 ohms

(iii) Static Bonding - 10 ohms


There are no standard forms which make reference to this procedure;however Form E-21 should be used to record earth point tests.



C.2.14 Procedure No. 14 - Apparatus for use in Hazardous Areas


The following is a general inspection guide for all type of equipmentused in hazardous areas, and form EC-1 is provided as guidance on thesystematic method of record. The particular requirements for specialequipment used in these locations will be listed individually hereafterand should be read in conjunction with BS 5345 or other appropriatenational standards.

(a) Ensure that the apparatus is appropriate to the areaclassification, the surface temperature class is correct, theapparatus group is correct and that any special conditions on thecertificate have been followed.

(b) Ensure that there are no unauthorised modifications and that itcarries correct circuit identification.

(c) Ensure that all bolts glands and stoppers are tight and that thecondition of the enclose gaskets is satisfactory.

(d) Inspect the interior of the equipment for dust or dirtaccumulation and ensure that all electrical connections are tight.A check should also be made that the electrical protection isadequate for the drive rating.

(e) Ensure that cable and stopper box compound is correctlyapplied to avoid ingress of hydrocarbons.

(f) Inspect the equipment earthing for security and tightness.

(g) Ensure that there is no damage to any cables and that theequipment is adequately protected against corrosion, weather,vibration and other adverse factors.

(h) Ensure that the lamp rating and type are correct.

(i) Where guards are used, ensure that they are correctly locatedand that motor fans and couplings are not rubbing.

The following additional checks are required on special equipment aslisted:-

(h) Ex ‘d’ Flameproof Enclosure

Ensure that:-



(i) Obstructions in the vicinity of the equipment do notimpair the efficient operation of the equipment.

(ii) All gaps are correct and free from corrosion, dirt andpaint.

The machined surface may be protected with one of theBP approved greases. The use of non hardening tape isto be avoided.

(iii) All conduit runs are tight and free from corrosion.

(k) Ex ‘e’ Increased Safety

Particular care should be taken on any equipment which uses anencapsulating material that there is no deterioration due tocracking, etc.

(l) Ex ‘N’:

Any hermetically-sealed or enclosed break devices should beexamined for damage.

(m) Ex ‘i’ Intrinsically Safe:

(i) All installations should be inspected to ensure that anycable screens are earthed in accordance with the relevantstandard drawing.

(ii) All diode safety barrier installations should be inspectedto ensure that the correct type of barriers have beenfitted and that they remain firmly fixed to the barrierearth bar.

(iii) Boxes containing diode safety barriers and junctionboxes should be inspected to ensure that they do notcontain wiring other than that specified in thedocumentation for the intrinsically safe system.

(iv) All installations should be inspected to ensure that relaysand similar devices which act as safety barriers betweencircuits have not become damaged by repeated operationor vibration in a way which reduces the segregationafforded.

(v) The earth path resistance must be measured.



(n) General

The particular earthing requirements of any of the aboveequipment must be clarified with reference to the specific codeof practice for the equipment. And it is also recommended thatwhere there is any ambiguity in the interpretation of therequirements, reference should be made to the relevant code ofpractice.

C.2.14.2 Testing

The diversity of equipment and special components which are containedin a particular type of apparatus does not permit a generalisation of thetesting required to demonstrate suitabili ty for service in a hazardousarea. Special requirements for testing may be contained in the standardor specific code of practice for the equipment and this should becomplied with prior to final energisation of the circuit.

Vendor dossiers must be examined to ensure that electrical componentsand equipment have been certified in compliance with BS 5345 or anyother appropriate national standards and that relevant certificates areavailable e.g. BASEEFA. Such certificates must also be examined todetermine whether the validity of the certificate is subject to specificinstallation instructions and further testing after installation, e.g. testingof cables for intrinsically safe apparatus.


There is no specific standard form for recording that the requirementsof the procedure have been implemented; Form E-21 should be used torecord the results of any testing required by the standard, code ofpractice or BASEEFA certifi cate to demonstrate suitabili ty for use in ahazardous area.

The following forms however make reference to this procedure andrequire endorsement to signify that the equipment and the standard ofinstallation is suitable for use in hazardous areas, namely:-

Forms E-1, E-2, E-3, E-5, E-6, E-8, E-11, E.12, E-14, E-15.



C.2.15 Procedure No. 15 - Oil Insulation Tests

C.2.15.1 These tests are to be carried out using a standard test cell conformingto the requirement of BS 148:1972.

Samples are to be taken from each drum before filli ng, or from theconservator (where fitted) and the top and bottom of the tank.

NB: No tests are to be carried out on the oil in hermetically sealedtransformers.

C.2.15.2 Mineral Insulating Oil

The vessel containing the sample oil should be gently agitated andturned over several times to ensure even distribution of any impuritieswithout forming air bubbles. The test shall be carried out six times onthe same cell filli ng. The first test should be carried out within tenminutes of filli ng, For the five subsequent tests, the voltage is re-applied one minute after the disappearance of any bubbles that mayhave been formed, or five minutes if observation is not possible. Theelectric strength is the average of the six results obtained from the test.

C.2.15.3 Silicone Insulating Oil

BS 148 does not apply to sili cone insulating oils but may be used as ageneral guide in the absence of any offi cial publication. A similar testprocedure shall be followed as for mineral insulating oils except thatonly three samples shall be taken, each sample being tested only onceand then discarded.


Form E-16 is to be used for recording the results of these tests.



C.2.16 Procedure No.16 - Drying of Electrical Rotating Machinery

C.2.16.1 Drying of Windings in Rotating Electrical Machinery

The application of heat to the windings must be carefully controlled.The use of high intensity heat sources must be avoided at all times dueto possible damage caused by local hot spots. Heat is to be appliedgradually. The rate of temperature increase should not exceed 5 C/HR.Fresh clean air circulation shall be provided to remove humid airproduced by the drying process.

It is useful to construct a graph of the insulation resistance varying asfunction of time. This gives a clear picture of the drying process and anindication of the likely drying time. As a guide, readings should betaken every 30 minutes until the rate of change of insulation resistancedictates otherwise (see typical drying curve).

The safest and most effective means of drying the winding of electricaldrives is by utilising the anti-condensation heater circuits of the motor.If the motor is not equipped with anti-condensation heaters then one ofthe methods described below must be adopted.

C.2.16.2 Drying of Motors using Internal Heating

Internal heating is obtained by circulating a low voltage AC or DCcurrent through windings. The circulating current should not exceed25% of the rated full load current and the allowable voltage is about 2-5% of the rated phase to phase voltage.

If AC is used for drying larger squirrel cage induction motors, the rotortemperature shall be carefully monitored and it may be advisable toremove the rotor from the assembly if the temperature rise is too rapid.Wound rotors need not be removed, but the bandages of the windingsshall be monitored for undue temperature increase.

When using the current circulated method of drying windings, initialmeasurement of temperature shall be taken every 15 minutes during thefirst 3-5 hours to detect any undue temperature rises before damageoccurs.

For wound motors which are dried by current circulation, the dryingcurrent shall not be applied via the brushes as this would cause hotspots at the contact areas between the brushes and slip-rings orcommutator.



C.2.16.3 Drying of Motors using External Heating

When drying motors using external heaters, the machinery should becovered with tarpaulin or similarly enclosed to promote a good heatdistribution.

The size of the heater used is dependent upon the machine frame andsurrounding ambient conditions etc. As an approximate guide, thefollowing relationship may be used:-

Heater size (KW) = Weight of Machine kg( )

1000

C.2.16.4

R3

R2

R1

TIME (HOURS)

INSULATIONRESISTANCE(MEG OHMS)

R1 - RESISTANCE OF WINDINGS AT START OF DRYING OUT PROCESS

R2 - MINIMUM RESISTANCE OF WINDINGS (DUE TO VAPORISATION,ETC)

R3 - FINAL RESISTANCE OF WINDINGS


There are no specific forms to be used for this procedure, but form E-21 is to be used to record results. All results are to be recorded,retained with the graphs and attached to the motor test certificate, FormE-8.



C.2.17 Procedure No. 17 - Current Transformer Magnetising Curve

C.2.17.1 Inspection (Pre-Installation)

Check the current transformers are the correct class, type and ratio forthe duty called for on the project and vendor drawings; this will begiven on the nameplate/label affixed to the current transformer.

Inspect the fixing arrangements for the current transformers ensuringthat they are securely fixed and will not be damaged duringtransportation. It should also be ensured that adequate protection isgiven to the current transformers from moving parts of switchgear andfrom likely damage during installation of cables into the switchgear.

C.2.17.2 Testing

Testing to determine the magnetising characteristics of currenttransformers is invaribly carried out at the Vendor’s works afterassembly, and Vendor test certification should be checked forcompleteness and accuracy.

Therefore, it should not be necessary to carry out such testing at siteunless doubt exists regarding the adequacy of Vendor testing ormodification after initial assembly has invalidated the original vendortests.

If testing is considered necessary at site it is to be carried out inaccordance with the procedure detailed below in C.2.17.3.

C.2.17.3 Test Procedure

Before any testing commences, ensure primary circuit is open circuited;in most cases this can be achieved by disconnecting theoutgoing/incoming cables and opening the breaker or switch.Protection must be put around any exposed primaries since dangerouslyhigh voltages will be produced during the testing period.

The protective relay coils must then be disconnected from the currenttransformer; this can be achieved in most cases by the removal of theunit from its plug-in housing and the insertion of a test plug or byinserting insulated plugs between the current transformer and relay coilsliding contacts or simply by disconnection of wiring.

Voltage is applied to the secondary of the current transformer by meansof a variable voltage transformer or auto-transformer (primary at localmains voltage); it may be necessary in testing current transformers ofratings less than or equal to 1 ampere to have a step-up transformer inthe test circuit to provide voltage above the local mains supply. Anammeter is connected in the test circuit; since the magnetising currentwill not be sinusoidal a moving iron ammeter should be used. The scaleof the ammeter being graduated accordingly up to the secondary ratingof the current transformer.



The voltage applied should be slowly raised until the magnetisingcurrent can be seen to rise very rapidly for a small increase in voltage.This indicates the ‘knee point’ or ‘saturation level’ of the currenttransformer. The magnetising current should then be recorded forseveral levels of applied secondary voltage as the voltage is reduced tozero. In general the ‘knee point’ level of the current transformer shouldbe reached when the secondary voltage is raised until the magnetisingcurrent is equal to the rated secondary current.


Form E-17 is to be used for recording the results of the testing, ifcarried out, and requires endorsement to confirm that all requirementsof the procedure have been carried out satisfactorily.



C.2.18 Procedure No. 18 - Junction Box Inspection


(i) Ensure that the Junction Box location is correct to drawing.

(ii) Check that the classification and I.P rating are to specification.

(iii) Ensure that the Junction Box is adequately supported andidentified.

(iv) Ensure that the terminal type, size, fixing and identification arecorrect.

(v) Ensure that the earthing, internal and external, is correct.

(vi) Ensure that the glands and accessories are correctly fitted andunused cable entries are plugged.

(vii) Ensure that grease and gaskets are correctly installed, asrequired.

(viii) Ensure that the box is correctly sealed.

(ix) For hazardous area installations, procedure 15 must befollowed.

C.2.18.2 Testing

No testing of Junction Boxes is carried out.


There is no specific standard form for recording that the requirementsof the procedure have been implemented.

The following forms, however, make reference to this procedure andrequire endorsement to confirm that the junction boxes and the standardof installation is suitable for the intended service, namely:-

Forms E-1, E-2, E-11, E-15.



C.2.19 Procedure No. 19 - Testing of Protection and Meter Circuitry

C.2.19.1 The equipment covered by the following procedures may require testingof protection and/or meter circuitry by means of primary and/orsecondary injection, namely:-

Procedure 2 -Switchboards and busbars3 - Circuit Breakers4 - Contactor Starters5 - Fuse Switches6 - Power Transformers7 - Motors10 - Lighting and Small Power Distribution11 - Neutral Earthing Resistors

Owing to both the variety of schemes and the diverse types of relay inuse, no attempt has been made to produce a detailed standard testingprocedure.

C.2.19.2 For each type of relay or meter tested, a test certificate is to becompleted which shows clearly the portion of scheme and the specificpart of the circuit tested, and records accurately the results of thetesting carried out.

C.2.19.3 Forms E-18 (Primary Injection Test Certificate), E-19 (SecondaryInjection Test Certificate), E-20 (Voltmeter/Ammeter SecondaryInjection Test Certificate) and continuation sheets if required, shall becompleted for all protective and indication devices.



C.3 TEST CERTIFICATE PROFORMA’S

Form No. Test Certificate Description

E-1 MV Cable Test Certificate

E-2 High Voltage Test Certificate

E.3 Switchboard & Busbars Test Certificate

E-4 Circuit Breaker Test Certificate

E-5 Contactor Starter Test Certificate

E-6 Fuse Switch Test Certificate

E-7 Power Transformer Test Certificate

E-8 Electric Motor Test Certificate

E-9 Batteries & Battery Charger Test Certificates (Sheet1 and 2)

E-10 U.P.S Test Certificate

E-11 Lighting & Small Power Distribution TestCertificate.

E-13 Neutral Earthing Resistor Test Certificate

E-14 Trace Heating Element Test Certificate

E-15 Trace Heating Circuit Test Certificate

E-16 Insulating Oil Test Certificate

E-17 Current Transformer Magnetising Curve

E-18 Primary Injection Test Certificate

E.19 Secondary Injection Test Certificate

E-20 Voltmeter-Ammeter Secondary Injection TestCertificate

E-21 General Test Certificate

EC-1 Check List of Electrical Equipment in HazardousAreas

N.B. The procedure numbers shown on the following test sheets referto the procedures as listed in this document only.



APPENDIX D

INFORMATION - HEALTH AND SAFETY

PERMIT TO WORK SYSTEM - ELECTRICAL AND INSTRUMENTATION

All work on equipment which has been handed over to the Operator will be carried out underthe Operator’s permit system. When equipment has not been handed over, has been energised,and it becomes necessary to carry out testing, checking and adjustment, the work must becarried out under a Construction permit. An example of a typical permit, which may beadapted to suit local site conditions, is shown in Appendix D.1.

PERMIT CONDITIONS

The work must be carried out by competent electrical persons as required by statutoryregulations and the Electrical Work Permit must be signed and issued only by an AuthorisedElectrical Engineer who is appointed by the person responsible for the equipment. This maybe the RE or the main contractor but not both.

A permit is required for electrical work on any high voltage (HV) plant or equipment, andmain low voltage (LV) Plant or equipment where isolation has to be made at high voltage (e.g.the electrical system from the LV side of the HV/LV transformer to the LV switchboard busbars including cabling and incoming switchgear.

High voltage: Normally exceeding 1000 volts a.c. or 1500 volts d.c. between conductors, or600 volts a.c. or 900 volts d.c. between conductors and earth.

Low voltage: Normally exceeding 50 volts a.c. or 120 volts d.c., but not exceeding 1000volts a.c. or 1500 volts d.c. between conductors, or 600 volts a.c. or 900 volts d.c. betweenany conductor and earth.

The Authorised Electrical Engineer must make known to the competent persons whichelectrical equipment is dead, isolated and, where applicable, connected to earth and on whichit is safe to work (e.g. earthing is not required for isolation of electrical equipment for thepurpose of work on associated mechanical equipment).

ISOLATION CERTIFICATE

The purpose of an isolation certificate is to ensure the systematic and thorough isolation of anyitem of plant or equipment from sources of energy that might jeopardise the safety of anyoneworking upon the item. It also ensures that no de-isolation takes place until those involvedwith the work are clear and until it is safe for the plant or equipment.

An example of a typical isolation certificate, which may be adopted to suit local siteconditions, is shown in Appendix D.2.



An isolation certificate must be used whenever the work to be performed requires more thanone discipline, or is expected to extended beyond a shift change. The certificate must bedisplayed at the locking off point and will remain valid until the de-isolation is certified by thecompetent persons in the disciplines involved.

Experience has shown a tendency for one discipline to carry out work on equipment which hasbeen isolated for another. This presents the possibility of the equipment being energised whenthe ‘official’ discipline has finished work but whilst the ‘unofficial’ work is still in progress.

Discipline engineers must ensure that permit work is carried out only under cover of anisolation certificate which has been issued specifically to them, regardless of any othercertificates issued for the same equipment.

No equipment must be energised until ALL the isolation certificates have been removed. Forexample, if a gang of fitters, a gang of electricians and a gang of instrument engineers areworking on the same equipment during the same period then three isolation certificates shouldbe displayed at the locking off point. As each gang finishes work their certificate should beremoved and only when all three certificates have gone should the equipment be energised.

A variation of this scheme is to have one isolation certificate with three tear-off sections at thebottom for use by mechanical, electrical and instrumentation disciplines.

PROBLEM AREAS

There will be some areas of work which cannot be clearly resolved into either the Operator’sor the Constructor’s permit system. These include:-

(a) Plant which is inside an operational area, which has not been handed over to theOperator since it is not yet acceptable, but which has been energised for operationalrequirements, e.g. MOV’s, lighting switchboards, and

(b) Plant which is inside an operational area, is electrically complete, has not yet beenhanded over to the Operator, but has been energised to permit instrumentation pre-commissioning to proceed, e.g. Meter Banks, Surge Packages.

The problems can only be resolved on site but the following solutions are offered:-

1. Isolate the plant from the substation until such time that the plant is acceptable to theOperator.

2. Ask the Operator to accept the plant in its incomplete state.

3. Make the work subject to both the Operator’s and the Constructor’s permit systems.This will probably be the least attractive solution.



ELECTRICAL WORK PERMIT APPENDIX D.1

Contractor………………………………

Serial No.…………………………………

Location………………………………

Voltage…………………………………

Exact description of equipment on whichwork has to be done

……………………………………………..……………………………………………..……………………………………………..

Brief description of work to be done ……………………………………………..……………………………………………..

Exact description of how the aboveequipment has been isolated and locked offfrom the supply

……………………………………………..……………………………………………..……………………………………………..

Isolation Certificate NoThe equipment to be worked on has beenearthed at the following points and ‘danger’notices posted

……………………………………………..……………………………………………..……………………………………………..

Line diagram/sketch attached Yes No Delete as appropriateIssueI CERTIFY that the above safety precautions have been carried out and that the equipment

listed is dead. It will NOT be made live untila permit.

(Signed) .……………………………(date) …

clearance is given by the recipient of this

……………………(time) …………………..

ReceiptI ACCEPT RESPONSIBILITY for carrying oNo attempt will be made by me or by personsequipment.

(Signed) …………………………..(date)….

ut work on the equipment listed on this permit. under my control to work on any other

…………………….(time) ………………….

ClearanceI DECLARE that the work for which this perthe equipment is ready for service. All person

warned that it is no longer safe to work on the

(Signed)…………………………..…(date)…

mit was issued has been completed and thats under my control have been withdrawn and equipment

…………………….(time) ………………….

Cancellation This permit to work is hereby cancelled



(Signed)………………………………(date)……….……………….(time)………………….



APPENDIX D.2ELECTRICAL ISOLATION CERTIFICATE

Contractor……………………………………………..Serial No…………………………….

ISOLATE……………………………………………. EQUIPMENT NO……………………(Here specify by name the equipment requiring isolation)

A DETAILS OF WORK TO BE CARRIED OUT…………………………………………………………………………………………………………………………………AUTHORISED BY…………………………………….TIME……….. DATE………(M/C Authorised Person)

B METHOD OF ISOLATING ELECTRICAL SUPPLY ………………………………..…………………………………………………………………………………………SUPPLY IS NOW ISOLATED ……………………..…(M/C AUTHORISEDPERSON)

TIME………. DATE……….C RECEIVED BY…………………………………………TIME………. DATE……….

(Contractor's Competent Person-Supv.)D RECEIVED ON THE JOB BY …………………………TIME……… DATE………..

(Contractor’s Competent Person-Tradesman)E WORK COMPLETED: SIGNED …………………..TIME………. DATE………..

(Contractor’s Competent Person-Tradesman)F WORK COMPLETED: SIGNED …………………..TIME………. DATE………..

(Contractor’s Competent Person-Supv.)G WORK HAS NOW BEEN COMPLETED AND ELECTRICAL RECONNECTION

CAN NOW BE MADEAUTHORISED BY ……………………………………..TIME……….DATE………..(M/C) Authorised Person)

H STATE HERE ANY ADDITIONAL WORK CARRIED OUT ON ELECTRICALCONNECTIONS/EQUIPMENT AT TIME OF, OR SUBSEQUENT TO ISOLATION(E.G. MOTORDISCONNECTED/CONNECTED)……………………………………………………..……………………………………………………………….…………………………..(Contractors Competent Person-Tradesman)

TIME…………DATE……….ABOVE WORK NOW COMPLETED, CHECKED AND RECONNECTION OFSUPPLY CAN NOW BE MADESIGNED (Contractor’s Competent Person-Tradesman) ……………………………...

TIME…………DATE…..…..J ANY WORK CARRIED OUT UNDER (H) IS NOW COMPLETED AND

CHECKED AND RECONNECTION OF SUPPLY CAN NOW BE MADE.(Contractor’s Competent Person-Supv) ………………………………………………..

TIME………….DATE………K ELECTRICAL SUPPLY RECONNECTED BY…………………………………..……



(M/C AUTHORISED PERSON)