Saudi Aramco Pre-Commissioning Forms, P-005 and P-006, Medium and High Voltage Cables
The Saudi Aramco Pre-Commissioning Forms, P-005, and P-006, Medium and High Voltage Cables (Figures 27 and 28), respectively, provide a field installation check list for medium and high voltage cable installations. The pre-commissioning form has a broad check list of visual and mechanical inspections, as well as the listed electrical tests that are required for medium and high voltage cable installations. Space is also provided on the form for test data.
WORK AID 4 (Cont'd)
FORM # P-005 (7/94) SHT 1 of 4
Saudi Aramco Pre-Commissioning Form Medium Voltage Cables
Equipment Type: User Reference:
Equipment No.: Description:
BI/JO NO.: Plant No./Location
Ref. Drawings: & Documents Manufacturer:
Model No.: Serial:
Commissioning Date:
Field Installation Checklist
Visual and Mechanical Inspection
YES NO
1. Check cable reel assignments and cutting schedules.
2. Check cable pulling schedule for direction of pull and method of pulling in conduit for medium voltage cable.
3. Check arrows on cable reels for direction for pulling off reel.
4. Check for correct cable test voltages, minimum pulling temperature and type of pulling compound.
5. Inspect cables for jacket damage.
6. The conductors are identified as per specification and drawings.
7. Cable ends sealed after cutting.
8. All water and debris must be removed from underground conduit before pulling cable.
9. Cable supports and spacing as per specifications and drawings.
11. Conduits clean, stub-ups protected, open ends plugged, damage during construction repaired.
12. Field bend radius correct per specification and codes. Bends free of deformities.
13. Expansion joints as shown on drawings.
NOTE: This non-mandatory form may be used as the starting point to assemble a pre-commissioning checklist. Entries should be revised, added and deleted and approval adjusted to reflect the needs of the Project Acceptance Committee.
SAPMT INSPECTION OTHER DEPT. OPERATIONS
APPROVALS Signature &
Date
Saudi Aramco Pre-Commissioning Form, P-005, Medium Voltage Cables Figure 27
WORK AID 4 (Cont'd)
FORM # P-005 (7/94) SHT 2 of 4
Saudi Aramco Pre-Commissioning Form Medium Voltage Cables
Equipment Type: User Reference:
Equipment No.: Description:
BI/JO NO.: Plant No./Location
Ref. Drawings: & Documents Manufacturer:
Model No.: Serial:
Commissioning Date:
Visual and Mechanical Inspection (Continued)
YES NO
14. Spacing between instrument and power conduit and/or cables as per specifications.
15. Spacing from hot pipes and from hot surfaces maintained.
16. Proper fittings are installed with threads fully engaged, proper sealing compound is used, there are no wrench cuts, conduit ends have bushings and covers installed.
17. Seals and drains are installed per drawings.
18. Aluminum, PVC or PVC coated conduits are installed where specified on drawings.
19. Flexible conduit is installed with proper bending radius and with standard fittings.
20. Metal junction boxes leveled and supported per drawings with proper hubs, locknuts and bushings installed.
21. Seals poured.
Electrical Test
YES NO
1. Cables on reels must be isolated and
2. Prepare installed cables for test by ensuring the circuit is de-energized, remove any
temporary grounds and disconnect cable from equipment. If equipment cannot be
disconnected, a reduced voltage should be used for the test.
NOTE: This non-mandatory form may be used as the starting point to assemble a pre-commissioning checklist. Entries should be revised, added and deleted and approval adjusted to reflect the needs of the Project Acceptance Committee.
SAPMT INSPECTION OTHER DEPT. OPERATIONS
APPROVALS Signature &
Date
Saudi Aramco Pre-Commissioning Form, P-005, Medium Voltage Cables Figure 27 (Cont'd)
WORK AID 4 (Cont'd)
FORM # P-005 (7/94) SHT 3 of 4
Saudi Aramco Pre-Commissioning Form Medium Voltage Cables
Equipment Type: User Reference:
Equipment No.: Description:
BI/JO NO.: Plant No./Location
Ref. Drawings: & Documents Manufacturer:
Model No.: Serial:
Commissioning Date:
Electrical Test (Continued)
YES NO
3. Insulate cable cores from ground.
4. Erect safety barriers and post safety man at cable end remote from the test equipment.
5. Check the insulation resistance of the cable using a megger tester. The test voltage should be 5000 volts for 5000 volt and above cables.
Measure the insulation resistance of each core and any metallic armor or sheath grounded at one end only.
6. Each cable shall be high potential tested as follows: each core to ground, with the shield, other cores and any metallic armor or sheath grounded at one end only.
7. For commissioning new cables, the final D.C.
test voltage is the 80% test voltage in the tables below.
8. For commissioning new cables that are spliced to old cables, and for testing old cables, the final D.C. test voltage shall be determined by the proponent of the cables, and should not exceed the 65% test voltage in the tables below (40% of these values is recommended after 5 years). A voltage equal to 2X operating voltage + 2 kV is recommended for extremely old cables with low megger readings.
9. The D.C. high voltage shall be applied in a minimum of four steps (each step approximately equal to the rated rms voltage of the cable) of one (1) minute duration each except for the final test voltage which shall be maintained for fifteen (15) minutes.
NOTE: This non-mandatory form may be used as the starting point to assemble a pre-commissioning checklist. Entries should be revised, added and deleted and approval adjusted to reflect the needs of the Project Acceptance Committee.
SAPMT INSPECTION OTHER DEPT. OPERATIONS
APPROVALS Signature & Date
Saudi Aramco Pre-Commissioning Form, P-005, Medium Voltage Cables Figure 27 (Cont'd)
WORK AID 4 (Cont'd)
FORM # P-005 (7/94) SHT 4 of 4
Saudi Aramco Pre-Commissioning Form Medium Voltage Cables
Equipment Type: User Reference:
Equipment No.: Description:
BI/JO NO.: Plant No./Location
Ref. Drawings: & Documents Manufacturer:
Model No.: Serial:
Commissioning Date:
Electrical Test (Continued)
YES NO
10. On completion of tests the cable shall be left with all cores and shields grounded for one hour to allow the residual charge to dissipate.
XLPE OR EPR CABLES MANUFACTURED TO AEIC CS5 OR CS6 AND 15-SAMSS-502 Rated Voltage Insulation
XLPE OR EPR CABLES MANUFACTURED TO IEC-502 AND 15-SAMSS-502 Rated Voltage Insulation
NOTES: 80% and 65% refer to percentages of the factory test voltages specified in AEIC CS5 and CS6. AEIC CS5 and CS6 permit testing at the 65% test voltage “at anytime during the period of the guarantee.” Test values for cables older than 5 years are listed in the 40% column.
NOTE: This non-mandatory form may be used as the starting point to assemble a pre-commissioning checklist. Entries should be revised, added and deleted and approval adjusted to reflect the needs of the Project Acceptance Committee.
SAPMT INSPECTION OTHER DEPT. OPERATIONS
APPROVALS Signature & Date
Saudi Aramco Pre-Commissioning Form, P-005, Medium Voltage Cables Figure 27 (Cont'd)
WORK AID 4 (Cont'd)
FORM # P-006 (7/94) SHT 1 of 4
Saudi Aramco Pre-Commissioning Form High Voltage Cables
Equipment Type: User Reference:
Equipment No.: Description:
BI/JO NO.: Plant No./Location
Ref. Drawings: & Documents Manufacturer:
Model No.: Serial:
Commissioning Date:
Field Installation Checklist Visual and Mechanical Inspection
YES NO
1. Check cable reel assignments and cutting schedules.
2. Check cable pulling schedule for direction of pull and method of pulling.
3. Check arrows on high voltage cable reels for direction for pulling off reel.
4. Check for correct cable test voltages, minimum pulling temperature and type of pulling compound if applicable.
5. Inspect cables for jacket damage.
6. The conductors are identified as per specification and drawings.
7. Cable ends sealed after cutting.
8. Cable support and spacing as per specifications and drawings.
9. Cable supports are adjacent to terminal fittings.
10. Field bend radius correct per specification and codes. Bends free of deformities.
12. Spacing between instrument and power conduit and/or cables as per specifications.
13. Spacing from hot pipes and from hot surfaces maintained.
NOTE: This non-mandatory form may be used as the starting point to assemble a pre-commissioning checklist. Entries should be revised, added and deleted and approval adjusted to reflect the needs of the Project Acceptance Committee.
SAPMT INSPECTION OTHER DEPT. OPERATIONS
APPROVALS Signature & Date
Saudi Aramco Pre-Commissioning Form, P-006, High Voltage Cables Figure 28
WORK AID 4 (Cont'd)
FORM # P-006 (7/94) SHT 2 of 4
Saudi Aramco Pre-Commissioning Form High Voltage Cables
Equipment Type: User Reference:
Equipment No.: Description:
BI/JO NO.: Plant No./Location
Ref. Drawings: & Documents Manufacturer:
Model No.: Serial:
Commissioning Date:
Visual and Mechanical Inspection (Continued)
YES NO
14. Proper fittings are installed with threads fully engaged, proper sealing compound is used, there are no wrench cuts, conduit ends have bushings and covers installed.
15. Seals and drains are installed per drawings.
16. Aluminum, PVC or PVC coated conduits are installed where specified on drawings.
17. Metal junction boxes leveled and supported per drawings with proper hubs, locknuts and bushings installed.
18. Seals poured.
Electrical Tests
YES NO
1. Cables on reels must be isolated and meggered before unreeling.
2. Prepare installed cables for test by ensuring the circuit is de-energized, remove any temporary grounds and disconnect cable from equipment.
3. Insulate cable cores from ground.
4. Erect safety barriers and post safety man at cable end remote from the test equipment.
5. Check the insulation resistance of the cable using a megger tester. The test voltage should be 5000 volts. Measure the
6. Each cable shall be high potential tested as follows: each core to ground, with the shield, other cores and any metallic armor or sheath grounded at one end only.
NOTE: This non-mandatory form may be used as the starting point to assemble a pre-commissioning checklist. Entries should be revised, added and deleted and approval adjusted to reflect the needs of the Project Acceptance Committee.
SAPMT INSPECTION OTHER DEPT. OPERATIONS
APPROVALS Signature & Date
Saudi Aramco Pre-Commissioning Form, P-006, High Voltage Cables Figure 28 (Cont'd)
WORK AID 4 (Cont'd)
FORM # P-006 (7/94) SHT 3 of 4
Saudi Aramco Pre-Commissioning Form High Voltage Cables
Equipment Type: User Reference:
Equipment No.: Description:
BI/JO NO.: Plant No./Location
Ref. Drawings: & Documents Manufacturer:
Model No.: Serial:
Commissioning Date:
Electrical Tests (Continued)
YES NO
7. For commissioning new cables, the final D.C. test voltage is the 80% test voltage in the tables below.
8. For commissioning new cables that are spliced to old cables, and for testing old cables, the final D.C. test voltage shall be determined by the proponent of the cables, and should not exceed the 65% test voltage in the tables below (40% of these values is recommended after 5 years). A voltage equal to 2X operating voltage + 2 kV is recommended for very old cables with low megger readings.
9. The D.C. high voltage shall be applied such that the rate of increase of the test voltages should be approximately uniform and should be no more than 100 percent in 10 second nor less than 100 percent in 60 seconds. The final (max) test voltage shall be held for fifteen (15) minutes.
10. On completion of tests the cable shall be left with all cores and shields grounded for one hour to allow the residual charge to dissipate.
D.C. TEST VOLTAGES - EPR AND XLPE CABLES (ICEA/AEIC TESTS) Cable
Rating (kV)
Insulation Thickness MM/Mils
Max. D.C. Test Voltage (kV)
100% 80% 75% 65%
69 EPR 16.51/650 240 192 180 156
69 XLP 16.51/650 240 192 180 156
115 20.32/800 300 240 225 195
NOTE: At any time during installation, a dc proof test may be made at a voltage not exceeding 75% of the dc test voltage specified in the above table applied for 5 consecutive minutes. After installation and before the cable is placed in regular service, a high voltage dc test may be made at 80% of the dc test voltage specified for fifteen consecutive minutes. The cable may be tested after placing in service any time within the first 5 years at 65% of the dc test voltage. Very old cables are tested at 1/2 the 80% values.
NOTE: This non-mandatory form may be used as the starting point to assemble a pre-commissioning checklist. Entries should be revised, added and deleted and approval adjusted to reflect the needs of the Project Acceptance Committee.
SAPMT INSPECTION OTHER DEPT. OPERATIONS
APPROVALS Signature & Date
Saudi Aramco Pre-Commissioning Form, P-006, High Voltage Cables Figure 28 (Cont'd)
WORK AID 4 (Cont'd)
FORM # P-006 (7/94) SHT 4 of 4
Saudi Aramco Pre-Commissioning Form High Voltage Cables
Equipment Type: User Reference:
Equipment No.: Description:
BI/JO NO.: Plant No./Location
Ref. Drawings: & Documents Manufacturer:
Model No.: Serial:
Commissioning Date:
HIGH VOLTAGE CABLE TEST RECORD
B.I. or W.O. No. Cable No. Voltage Rating
Plant Size & Type
High Potential Test (D.C.) Test Voltage
Micro Amps Phase Megohms
kV Phase 1 to 2
15 Sec Test Voltage (Megger)
30 Sec 500/1000/2500/5000 Volt
45 Sec
1 Min General Data:
2 Min
3 Min Temp.Deg.F/
C
4 Min % Rel. Hum.
5 Min Insul Thick.
6 Min Cable Test
7 Min Voltage
8 Min 9 Min 10 Min
14 Min 15 Min
NOTE: This non-mandatory form may be used as the starting point to assemble a pre-commissioning checklist. Entries should be revised, added and deleted and approval adjusted to reflect the needs of the Project Acceptance Committee.
SAPMT INSPECTION OTHER DEPT. OPERATIONS
APPROVALS Signature & Date
Saudi Aramco Pre-Commissioning Form, P-006, High Voltage Cables Figure 28 (Cont'd)
WORK AID 4 (Cont'd)
Information, Formulas, and Tables for Use in Evaluating the Results of Insulation Resistance (Megger) Tests
Medium/High Voltage cables (5 kV and above) must be tested as follows:
(a) New installations of cable and splices must be 5 kV insulation resistance (megger) tested after installation. The 5 kV megger must be performed prior to commissioning but prior to backfill in the case of direct buried cables.
(b) New cables to be spliced to existing cables must be megger tested prior to splicing as in (a) above. After splicing (but prior to backfill in the case of direct buried cables), the new and existing cable combination must be 5 kV megger tested.
The integrity of the overall sheath or jacket of cables that are rated 35 kV and higher must be tested by conducting a 5 kV megger test between the cable insulation metallic shield and ground. Direct buried cables must be tested and accepted prior to backfill of the cable trench.
The results of all commissioning megger tests that are performed on cable that is rated 5 kV and above must be documented on the appropriate Saudi Aramco pre-commissioning form.
The following are the types of megger tests that can be conducted:
• Short time or spot reading
• Time resistance
• Dielectric Absorption Ratio
When the dielectric absorption ratio megger test is performed, the polarization index can be determined through use of the following equation, which provides readings of resistance:
Figure 29 provides insulation conditions for 60/30 second ratio results and for 10/1 minute ratio results.
WORK AID 4 (Cont'd)
Insulation
Condition 60/30 - Second
Ratio 10/1 - Minute Ratio (Polarization Index)
Dielectric Absorption Ratio Chart Figure 29
Information, Formulas, and Tables for Use in Evaluating the Results of DC Hi-Pot Tests Medium/High Voltage cables (5 kV and above) must be dc hi-pot tested as follows:
(a) New installations of cable and splices must be dc hi-pot tested after installation. The dc hi-pot test should be conducted after the megger test. The dc hi-pot test must be performed prior to commissioning but prior to backfill in the case of direct buried cables. The voltage levels of the dc hi-pot test are specified in 15-SAMSS-502 and 15-SAMSS-503.
(b) New cables to be spliced to existing cables must be dc hi-pot tested prior to splicing as in (a) above. After splicing (but prior to backfill in the case of direct buried cables), the new and existing cable combination may be dc hi-pot tested. The dc hi-pot test voltage should be equal to or lower than the values specified under (c) below, as determined by the Proponent of the cable.
c) Maximum dc hi-pot test voltages for old cables:
• Cables up to 5 years old: 65% values, applicable AEIC standards.
• Cables above 5 years old: 40% values, applicable AEIC standards.
WORK AID 4 (Cont'd)
The results of all dc hi-pot tests that are performed for commissioning on cable that is rated 5 kV and above must be documented on the appropriate Saudi Aramco pre-commissioning form.
The dc hi-pot test should be secured if one of the following situation occurs:
• The duration of the test has expired
• A rapid rise in leakage current occurs
• The polarization index < 1
The following are the characteristics of a satisfactory dc hi-pot test:
• The leakage current gets smaller over time.
• The polarization index > 1.
• The leakage current increases on a straight line as voltage is increased. No "knee" is noticeable in the leakage current curve.
Figure 30 shows a failure forecast table that is used with dc hi-pot test results to predict when a cable failure could occur.
ELASTOMERIC (EPR) FAILURE FORECAST FROM DC HIGH POTENTIAL TESTING
DC Test Potential at Start of Current Runaway
(% of AC rms Voltage) Estimated Failure Time (Years)
200 0.0
300 0.5
500 2.0
800 Over 6
Table of Elastomeric (EPR) Cable Failure Forecast Figure 30
WORK AID 4 (Cont'd)
An example of dc hi-pot test data is shown in Figure 31. Figure 31 shows both good and bad insulation test data.
Use Word 6.0c or later to
view Macintosh picture.
Example of DC Hi-Pot Test (Good and Bad Cable Insulation) Figure 31
WORK AID 4 (Cont'd)
Evaluating the Cable Tensionometer (Strain Gage) and Pulling Devices
The following are the inspections and checks that should be performed during the evaluation of the cable tensionometer (strain gage) and pulling devices evaluation:
• Check that the proper cable pulling hardware is provided.
• Check the actual conduit or cable tray bend radii to ensure conformity to the original pulling tension calculations.
• Check the cable reel assignments and cutting schedules.
• Check the minimum and maximum pulling specifications (e.g., tensions).
• Check the arrows on the cable reels for the direction to pull the cable off of the reel.
• Inspect the cable for jacket damage.
• Ensure that all water and debris are removed from underground conduit prior to the cable pull.
Point-to-Point Verification of Cables
The following are the inspections and checks that should be performed during the point-to-point verification of a cable installation:
• Verify that circuit separation is maintained between the cable and any other cables in the run.
• Verify the clearance between the cable and process piping or other process facilities.
• If a raceway (e.g., cable tray or conduit) is used for the installation, verify that the cable is correctly installed in the raceway.
• Verify that the cable supports and fasteners are installed correctly and that there is no cable damage.
WORK AID 4 (Cont'd)
Figure 32 shows Saudi Aramco and industry splices and terminations installation requirements.
General
requirements Compression-type connectors are the preferred method for splicing or terminating cable conductor ends. Compression (crimped) type connectors must be used for terminating stranded conductors.
All compression connectors must be tinned copper and must have a manufacturer's reference compression die number and conductor size printed or stamped on the connector.
The metallic composition of the crimp connector and the metallic composition of the cable conductor should be similar.
The use of solder lugs is prohibited.
Cable terminators that rely on inwardly protruding flat springs (tines) for grounding the metallic sheath or armor are prohibited.
Armored cable (unless specifically designated as Type AC per NEC Article 333) must be manufactured to IEC 502 and must have galvanized steel wire armor or galvanized double steel tape armor. For installation and application purposes, the cable is considered to be equivalent to type MC (metal clad) cable, except suitable armored cable terminators (glands) must be used to terminate and ground the armor.
Type MC cable and armored cable must be permitted to be installed exposed where it is not subject to damage by vehicular traffic or similar hazards. Other types of cable must not be installed exposed above
ground, and must be installed in cable trays, conduit, or, where flexibility is required, in flexible conduit.
To prevent water from entering the end of the cable, heat shrinkable boots
To prevent water from entering the end of the cable, heat shrinkable boots