GENERAL SPECIFICATION
GS EP EXP 105
Precommissioning execution
03 09/05 New test sheets (ELEC,INST,TEL,PIP) 02 09/03 Change of Group name and logo 01 04/03 Rev. 00 with subsea specification
00 01/01 First issue
Contents
1. Scope ...4
2. Reference documents...4
3. Precommissioning activities...5
3.1 Preamble ...5 3.2 General requirements ...6 3.3 Scope of work ...74. Electrical precommissioning ...13
4.1 Introduction ...13 4.2 Precommissioning checks ...13 4.3 Precommissioning tests...155. Instrument precommissioning...31
5.1 Introduction ...31 5.2 Precommissioning checks ...31 5.3 Precommissioning tests...345.4 Test Sheets master forms...37
6. Telecommunications precommissioning...37
6.1 Introduction ...37 6.2 Precommissioning checks ...37 6.3 Precommissioning tests...407. Mechanical precommissioning ...40
7.1 Introduction ...40 7.2 Precommissioning checks ...41 7.3 Precommissioning tests...468. Sub-sea precommissioning ...58
8.1 Introduction ...58Appendix 1 Piping and vessels Flushing ,Cleaning and Chemical Cleaning
specifications
Appendix 2 Electrical “Check List” master forms
Appendix 3 Electrical “Test Sheet” master forms
Appendix 4 Instrument “Check List” master forms
Appendix 5 Instrument “Test Sheet” master forms
Appendix 6 Telecom “Check List” master forms
Appendix 7 Telecom “Test Sheet” Masters forms
Appendix 8 Mechanical “Check List” master forms
Appendix 9 Mechanical “Test Sheet” master forms
Appendix 10 Subsea “Check List” master forms
Appendix 11 Subsea “Test Sheet” master forms
1. Scope
2. Reference documents
The reference documents listed below form an integral part of this General Specification. Unless otherwise stipulated, the applicable version of these documents, including relevant appendices and supplements, is the latest revision published at the EFFECTIVE DATE of the CONTRACT.
Standards
Reference Title
IEC 60034 Rotating Electrical machines
IEC 60060 High-voltage test techniques
IEC 60071 Insulation co-ordination
IEC 60076 Power Transformers
IEC 60156 Insulating liquids – Determination of the break down voltage at
power frequency. Test method.
IEC 60364-4-41 Electrical installation of building - Protection for safety - Protection
against electric shock
IEC 60502-2 Power cables with extruded insulation for rated voltage from 1 kV
up to 30 kV.
IEC 60599 Mineral oil – impregnated electrical equipment in service. Guide to
the interpretation of dissolved and free gases
IEC 62271 High voltage switchgear and controlgear
IEC 60694 Common specification For HV switchgears and controlgear
standards Professional Documents Reference Title API standard 598 API 527 Regulations Reference Title Not applicable
Codes Reference Title ANSI B 147.1 Other documents Reference Title Not applicable
Total General Specifications
Reference Title
GS EP EXP 101 Rev4 Precommissioning and Commissioning Specification
GS EP EXP 103 Rev4 Precommissioning and Commissioning Technical Preparation
GS EP EXP 107 Rev3 Commissioning execution
GS EP SPS 001 Rev1 Design philosophy and requirements for subsea stations
GS EP PLR 401 Rev2 Installation of submarine pipelines
GS EP PLR 407 Rev1 Load-out of submarine cables, umbilicals and flexible pipes
GS EP PLR 408 Rev1 Transportation of submarine cables, umbilicals and flexible pipes
GS EP PLR 409 Rev1 Installation of submarine cables, umbilicals and flexible pipes
GS EP PLR 501 Rev2 Hydrostatic testing of pipelines
GS EP PLR 502 Rev1 Precommissioning of submarine gas pipelines
GS EP SPS 023 Rev2 Cleaning and Flushing of hydraulic systems
3. Precommissioning activities
3.1 Preamble
The present specification GS EP EXP 105 provides the basic information, procedures and support documents required to carry out on site precommissioning activities in a planned, safe, and efficient manner.
However the enclosed documentation is not intended to be fully comprehensive, hence it shall be used in conjunction with appropriate technical specifications and MANUFACTURERs' instructions.
The GS EP EXP 105 “Precommissioning execution” will also be read in conjunction with the:
• GS EP EXP 101 “Precommissioning and Commissioning Specification”, which gives, in
particular, the definition, rationale, and key principles of precommissioning, thus allowing an easier approach to anyone having to execute these activities.
• GS EP EXP 103 “Precommissioning and Commissioning Technical Preparation”, which covers all tasks to be completed prior to the actual start on site of precommissioning and commissioning execution.
The omission from this specification of any item essential for the correct achievement of precommissioning shall be brought to the attention of the COMPANY by the CONTRACTOR, and any deviation the CONTRACTOR may wish to make to this specification shall be submitted to the COMPANY for approval, which shall have to be received in writing before any deviation is implemented.
3.2 General requirements
3.2.1 References
The CONTRACTOR shall comply with Project and/or COMPANY specifications referenced in the contractual documentation.
3.2.2 Standards and Codes
The Standards and Codes applicable to precommissioning shall be those referenced in the Project or COMPANY specifications.
3.2.3 Provision of equipment
All facilities, services, tools, test equipment and consumables required to carry out and complete the precommissioning are within the CONTRACTOR's scope of supply unless stated otherwise in the contractual documentation.
In particular, all workshop and portable calibration facilities shall be provided by CONTRACTOR. Calibration certificates shall be made available by the CONTRACTOR for all items of test equipment, and specifications for the maintenance and calibration of test equipment shall be adhered to.
3.2.4 Safety
The CONTRACTOR shall only use competent and experienced personnel to carry out the precommissioning in each discipline.
Before commencement of any precommissioning test, it must be established that the equipment is de-energized and all necessary safety precautions have been taken.
Before commencing pressure testing of pipework and valves, cleaning, blowing of piping or vessels, the concerned area shall be suitably cordoned off and warning notices posted.
During the completion of construction and precommissioning activities the CONTRACTOR shall be responsible for implementing the Safety Procedures and Work Permit System applied on Site.
The CONTRACTOR shall comply with all Safety regulations of the country, and all Safety requirements of the contract.
The CONTRACTOR will be responsible for its internal safety organisation and control.
3.2.5 Organisation
3.2.5.1 The CONTRACTOR shall organise, prepare, carry out, and report the
A subsystem is a subdivision of the installation, being either process or utility, including the various equipment required for that subsystem to operate, which performs a given operational function (see document GS EP EXP 103 for more details regarding systems and subsystems delimitation rules).
3.2.5.2 The CONTRACTOR shall carry out the precommissioning activities in accordance with
a subsystems precommissioning sequence. This sequence will have been established prior to the beginning of precommissioning operations (see document GS EP EXP 103 for more details).
3.2.5.3 Unless stated otherwise in the Contractual documentation, the transfer of responsibility
from the CONTRACTOR to commissioning, will take place on a subsystem basis, commissioning designating here the Party in charge of the commissioning activities of that subsystem.
It is a transfer of the responsibility for operation, maintenance and safety of the related equipment, the accepting Party being thereafter responsible for all consequences resulting from miss-operation. On the other hand, it does not relieve the CONTRACTOR and the other parties from their contractual obligations.
The transfer for a given subsystem will be formalised by the signature by the CONTRACTOR and the commissioning of the "Ready for Commissioning Certificate" and of the mutually agreed "Ready for Commissioning Punch List" of that subsystem.
The transfer for a given subsystem will take place when the subsystem has reached the "Ready for Commissioning" status, i.e. when:
• All precommissioning operations on that subsystem are complete, with the possible exception of a reasonable number of punch list items
• No punch list item affects the operation, safety, and/or the commissioning activities of the subsystem
• The subsystem area is clean, free from debris, tools, and extraneous material which would impede operation or cause an unsafe condition
• The painting, insulation, fire proofing are complete enough so that there is no excessive amount of scaffolding left, nor an excessive number of painters, insulators still working, in the subsystem area
• The Precommissioning Dossier has been compiled, submitted to
COMPANY/Commissioning and approved (see § 3.3.9).
3.3 Scope of work
3.3.1 Equipment to precommission
The CONTRACTOR shall thoroughly perform the precommissioning of all subsystems and equipment, or pieces of equipment, either purchased as individual items, or as part of a VENDOR'S package, or as part of a COMPANY supplied item, of all facilities defined in the contract.
This scope of work consists of:
• Static/de-energized tests of equipment items
• Specific operations, such as the pipes and vessels flushing and cleaning.
The scope of work shall be performed in accordance with the procedures, and by using the support documents, given in:
• Chapter 4 (electrical precommissioning) • Chapter 5 (Instrument precommissioning)
• Chapter 6 (telecommunications precommissioning) • Chapter 7(mechanical precommissioning)
• Chapter 8 (sub-sea precommissioning) of the present specification.
3.3.2 Precommissioning technical preparation
The CONTRACTOR shall perform the precommissioning technical preparation activities, including especially:
• The issuing of the precommissioning planning and progress calculation method. Both shall be submitted to COMPANY for approval
• The preparation of the checks lists (refer to paragraph 3.3.3) and of the Test Sheets (refer to paragraph 3.3.4)
• The preparation of the Precommissioning Dossiers (refer to paragraph 3.3.9). A typical dossier will be prepared as an example and submitted to COMPANY for approval
• The updating of the Status Index (refer to paragraph 3.3.5) according to last issues of documents
• The gathering of required Engineering and VENDORS documentation
• The preparation of tools, test equipment, consumables, and all facilities and services required for precommissioning activities.
3.3.3 Conformity checks 3.3.3.1 Check Lists
The CONTRACTOR shall perform conformity checks of equipment items as per Check Lists available in the present specification.
The Check Lists define the exact scope of work that shall be systematically performed on every equipment item, and they also constitute the support documents used to record the checks. The Check Lists provided in the specification are typical for each type of equipment item, and numbered accordingly. The Check Lists are regrouped by discipline and included in the chapter relating to the concerned discipline.
Where checks lists have an associated continuation sheet, these define all the tag numbers or cable numbers relating to the Check List items detailed on sheet 1 Check List. Any requirement for additional checks such as insulation and continuity tests shall be recorded on this continuation sheet. These tests relate mainly to cables and trace heat tape.
In the event that Check Lists are omitted for any item of equipment, the CONTRACTOR shall inform the COMPANY, review the requirements and issue a new Check List for COMPANY's approval.
3.3.3.2 Preparation
All Check Lists, grouped by subsystem, shall be prepared by the CONTRACTOR at the precommissioning preparation phase, by:
• Indicating the subsystem number and description
• Recording the tag numbers of the items of equipment corresponding to the type of the Check List in the appropriate columns. If required, several continuation sheets will be used until every item of equipment of the relevant type belonging to that subsystem is listed
• Marking the number of continuation sheets.
3.3.3.3 Execution
The Check Lists shall be used as working documents by the CONTRACTOR's Engineer performing the checks. While the Engineer physically checks an item of equipment, he will initial each check of the list when it is satisfactory, and he will do so for every item of equipment listed on the Check List.
Any check which is not satisfactory shall be treated in the following manner:
• If possible, the defect shall be immediately corrected by CONTRACTOR. The Engineer who has identified the defect shall ensure that it is properly corrected.
• If CONTRACTOR cannot correct the defect immediately, CONTRACTOR shall report it to the COMPANY, include it in the Punch List, and take all necessary actions to have this item cleared.
• If the remedial work does not fall in the CONTRACTOR's Scope (for example; defect on equipment free issued by COMPANY), CONTRACTOR shall report it to the COMPANY and include it in the Punch List. COMPANY will take action to have this item cleared, with assistance from the CONTRACTOR, as required.
Once all checks of the Check List have been performed on all items of equipment listed on the Check List, the Check List will be transmitted to the CONTRACTOR Supervisor in charge of the concerned discipline, who will date and sign in the appropriate boxes.
The Check Lists will not be signed by the CONTRACTOR nor filed in the precommissioning dossier until all checks have been performed satisfactorily.
A spare sign box is provided at the bottom of each check sheet to be used at the discretion of COMPANY or CONTRACTOR.
3.3.4 Static tests 3.3.4.1 Test Sheets
The CONTRACTOR shall perform static/de-energized tests of items of equipment in accordance with the test procedures given in the present specification.
The results of the tests shall be reported on Test Sheets, the master forms of which, typical for each type of component requiring testing and numbered accordingly, are available in the
present specification, regrouped by discipline and included in the chapter relating to the concerned discipline.
In the event that Test Sheets are omitted for any item of equipment, the CONTRACTOR shall inform the COMPANY, review the requirements, and issue a new Test Sheet for COMPANY's approval.
3.3.4.2 Preparation
All Test Sheets, grouped by subsystem, shall be prepared by the CONTRACTOR at the precommissioning preparation phase, by filling-in the heading of the Test Sheets.
There shall be one Test Sheet for each item of equipment to be tested.
3.3.4.3 Execution
Prior to any test being carried out, it shall be the CONTRACTOR's responsibility to verify that all construction work is completed and all connections properly made and that the associated checks have been successfully completed according to the Check List.
The CONTRACTOR shall ensure that the work site is clean with adequate access and that all test equipment and tooling is available to properly carry out the test. CONTRACTOR shall ensure that testing is performed in a safe and secure manner.
For any test to be witnessed by COMPANY, Commissioning, Certifying Authorities, or other, the CONTRACTOR shall give adequate notice to the Parties concerned.
The tests will then be carried out by the CONTRACTOR in accordance with the specification technical procedures and reported on the Test Sheets.
If a test cannot be completed, or does not give satisfactory results because of any defect, the CONTRACTOR shall treat the defect in the same manner as that defined in Section 3.3.3.3 (Check Lists).
The defect shall be indicated on the Test Sheet and reported on the Punch List if it cannot be corrected immediately.
The test shall be repeated until successfully completed.
A spare sign box is provided at the bottom of each Test Sheet to be used at the discretion of COMPANY or CONTRACTOR.
3.3.4.4 Specific Operations
Specific precommissioning operations, such as cleaning of vessels and piping, or filling of batteries with electrolyte, shall be performed exactly as Tests, in accordance with procedures included in the present specification, and reported on adequate Test Sheets.
3.3.5 Status Index
The Status Index is the list of all equipment subject to one or several precommissioning operations. This list, arranged per subsystem, discipline and type of equipment, is created from the various Engineering and VENDORS equipment lists (instrument list, cables list, piping list, etc.).
The Status Index indicates for each item of equipment (pressure gauges, electrical cables, pumps, etc.) the corresponding precommissioning tasks, i.e. checks, and tests when applicable,
by showing the reference number of the task report document, i.e. Check Lists and Test Sheets numbers. The Status Index is therefore a summary of the precommissioning scope of work. The CONTRACTOR shall keep the Status Index updated during the precommissioning activities, by recording the completion dates of each Check List and Test Sheet.
The CONTRACTOR shall maintain and operate the necessary computer equipment and personnel to process continuously the Status Index database.
3.3.6 Case of packages 3.3.6.1 General rule
Unless stated otherwise in the Contract, the packages shall be precommissioned by the CONTRACTOR in accordance with the same procedures as those applied on field equipment, i.e. every item of equipment of the packages shall be checked for conformity with the relevant Check Lists, and every item of the equipment of the packages that can be subject to a precommissioning test shall be tested, and the tests reported on relevant Test Sheets.
Sub-sea production system equipment (SPS) can be considered as packaged equipment and will be fully pre-commissioned at the VENDOR’S premises prior to transportation. The relevant check and test records will be completed and included in the pre-commissioning dossier at this time. See chapter 8 for further details.
Sub-sea control system equipment, the SCU, SPCU and HPU will be completely pre-commissioned and pre-commissioned after installation on the offshore platform or vessel.
Sub-sea umbilical and flowlines equipment (UFL) can also be considered as packaged equipment and will be pre-commissioned at the VENDORS premises prior to transportation offshore. The relevant check and test records will be completed and included in the pre-commissioning dossier at this time. Further pre-pre-commissioning will take place offshore for the UFL equipment. See chapter 8 for further details.
In no case shall equipment warranty be invalidated. Therefore, VENDORS instructions shall
be followed by the CONTRACTOR, and VENDORS representatives shall be mobilised by the CONTRACTOR, upon COMPANY's approval, for assistance during critical precommissioning activities, unless it is formally stated by the VENDORS that such an assistance is not required.
3.3.6.2 Exceptions
A reduced precommissioning scope of work will be performed by the CONTRACTOR on the packages, which will have been thoroughly tested, prior to the precommissioning phase on site, at the MANUFACTURER’s.
The only packages to which the reduced scope applies are specifically listed as such in the contract.
The reduced scope shall be the following:
• A single package Check List shall be performed, instead of various equipment Check Lists. This Check List, named C-ZX-01, is available in chapter 8, Mechanical Precommissioning, of the specification.
• The precommissioning Tests will be limited to: - Electrical: insulation and continuity Tests
- Instrument: calibration, and cables continuity tests between the item of equipment and the marshalling cabinet in the Technical or Control Room, of all equipment related to safety: alarm and shutdown devices, safety valves
- Mechanical/Piping: alignment of all equipment and flushing of all piping reinstated on site by the CONTRACTOR.
3.3.7 Punch Lists
While the precommissioning checks and tests are being performed, all discrepancies, damaged or missing equipment, malfunctions, missing documents, etc., shall be recorded by the CONTRACTOR in the subsystem punch lists, if the situation was not able to be corrected immediately. These lists shall be kept updated during the precommissioning operations, so as to have a precise status of each subsystem at the Ready for Commissioning stage (by which time there should be few punch list items yet to clear, and of minor importance).
There will be one punch list by subsystem, subdivided by discipline.
The CONTRACTOR shall comply to the Punch List Co-ordination Procedure issued by commissioning or COMPANY.
3.3.8 Drawings up-dating
During the precommissioning phase it shall be the CONTRACTOR's responsibility to keep the following drawings up-dated:
• P&ID's
• Electrical and instrument TSLD's • One line diagrams
• Connection diagrams • Interlocks logic diagrams
so as to obtain at the completion of the precommissioning of each subsystem a set of (marked-up) "as precommissioned" drawings, taking into account all modifications implemented on site or deviations from construction drawings.
In the same way, the CONTRACTOR shall amend any document as required by a modification carried out during the precommissioning e.g. equipment data sheets in case of set points modifications, etc.
3.3.9 Precommissioning dossier
The CONTRACTOR shall compile all documentation pertaining to the precommissioning operations in a specific "Precommissioning Dossier", arranged by subsystem, which shall contain all the information required to demonstrate to the commissioning and COMPANY that the subsystem has reached the "Ready for Commissioning" status.
Its contents will be the following:
• Ready for Commissioning Certificate • Punch list
• Status Index • Check Lists • Test Sheets • As-built drawings by discipline • VENDOR'S reports
• Specific procedures and tests • List of modifications.
4. Electrical precommissioning
4.1 Introduction
The precommissioning of electrical equipment shall be carried out in accordance with the rules given in chapter 3 of this specification.
The present chapter provides additional information and support documents, specific to the Electrical Discipline:
• Electrical Check Lists specificities • Check Lists Master Forms
• Precommissioning Tests Procedures • Test Sheets Master Forms.
4.2 Precommissioning checks
4.2.1 Check lists index
Type of equipment Check list reference Nb of sheet
List C-PX-00 1 Generator C-PX-01 1 Power Transformer C-PX-02 1 HV switchboard/MCC C-PX-04 1 LV switchboard/MCC C-PX-05 1 Bus duct C-PX-07 1 HV cables C-PX-08 1
LV Power cables and control cables C-PX-09 1
Multicore Instrument cables C-PX-10 1
HV motor C-PX-12 1
LV motor C-PX-13 1
Type of equipment Check list reference Nb of sheet LV distribution board/Control panel/Console C-PX-15 1 Charger/Inverter C-PX-16 1 Batteries C-PX-17 1 Lighting circuits C-PX-18 1
Power Socket outlets C-PX-19 1
Electrical heater C-PX-20 1
Neutral earth resistor C-PX-21 1
Trace heating C-PX-22 1
Control station C-PX-23 1
Local Isolator C-PX-24 1
Navigation aids C-PX-25 1
Earthing system C-PX-26 1
Miscellaneous electrical equipment C-PX-27 1
Cable racking C-PX-30 1
Junction box/Marshalling box C-PX-31 1
4.2.2 Procedures 4.2.2.1 General case
CONTRACTOR will carry out equipment checks, and fill-in relevant Check Lists forms, as per the rules given in chapter 3, paragraph 3.3.3, except in the following cases, where specific rules apply.
4.2.2.2 Exceptions
Case of packages with simplified precommissioning scope of work: refer to chapter 3, paragraph 3.3.6.2.
4.2.2.3 Case of CP-X-10 - Multicore instrument cables 4.2.2.3.1 Field cables
Field cables are clearly allocated to one system or sub-system.
4.2.2.3.2 Multicore cables
For Multicore cables two cases must be considered:
• Case 1: Multicore cables allocated to a system or sub-system They will be part of the corresponding system or sub-system.
This is often the case for packages. It is also the case for some systems, for example gas detection system.
In this case Multicore (Multipairs) cables shall be treated in the same way as field cables. • Case 2: Multicore cables with cores allocated to two or more systems
These cables will be gathered in a Multicore cable system (including the Junction boxes). The Status Index of this system will clearly indicate the system corresponding to the different cores (pairs).
4.2.2.4 Case of C-PX-31 – Junction box /Marshalling box
The same rule as defined for multicore cables shall apply.
Junction boxes shall be checked after final assembly, meaning when all checks and tests of the cables connected to them are completed.
4.2.2.5 Electrical checks
Record check results as required on the relevant check-list forms.
4.2.3 Check lists master forms
Refer to Appendix 2.
4.3 Precommissioning tests
4.3.1 Test Sheets index
Type of equipment Test Sheet reference Nb of sheet
List of test sheet forms T-PX-00 1
General purpose Test Sheet T-PX- 1
Generator T-PX-01 1 HV transformer T-PX-02 1 Auxiliary LV transformer T-PX-03 1 HV switchboard/ MCC T-PX-04 1 LV switchboard / MCC T-PX-05 1 Bus duct T-PX-07 1 HV cables T-PX-08 1 LV power cables T-PX-09 1 Multicore cables T-PX-10 1 HV motor T-PX-12 1 LV motor T-PX-13 1 DC motor T-PX-14 1
Distribution boards/ Control panel/Console
T-PX-15 1
Type of equipment Test Sheet reference Nb of sheet
Batteries T-PX-17 1
Lighting circuits and convenience sockets outlets circuits
T-PX-18 1
Power Socket outlets T-PX-19 1
Heaters T-PX-20 1
Neutral earth resistors T-PX-21 1
Trace heating T-PX-22 1
Control station T-PX-23 1
Navigation aids T-PX-25 1
Earthing system T-PX-26 1
4.3.2 Test procedures
4.3.2.1 Test voltages and frequency
The project procedures and Test Sheets shall take into account the project voltages and frequency.
The power frequency dielectric test voltages shall be based on the following IEC recommendations and shall be adjusted to take into account the fact that some equipment has already been subjected to factory tests.
In no case the test voltage shall exceed the value indicated in the equipment VENDOR
maintenance manual.
• IEC 60034 for Rotating Electrical machines
• IEC 60060 – High Voltage test techniques
• IEC 60071 - Insulation co-ordination
• IEC 60076 for Electrical Transformers
• IEC 60502-2 for HV cables
• IEC 62271 and IEC 60694 for HV and LV switchgears
4.3.2.2 Test methods
4.3.2.2.1 Insulation Resistance (IR) tests
IR testing shall be carried out by applying a D.C. voltage from an insulation tester at voltage levels given in this specification.
4.3.2.2.2 High voltage tests
Before high voltage tests are executed, insulation resistance tests shall be carried out.
High-voltage testing of electrical equipment, except LV cables, shall have been carried out at the Manufacturer's works with A.C. at voltage levels in accordance with the IEC.
Repeated high voltage tests may introduce weak points in the insulation of windings, and therefore such tests shall not be applied at site to generators, motors or transformers.
The HV tests at full voltage shall not be repeated two times. If however for special reasons these tests are considered to be remade a second time, they shall be carried out only after consultation with the Manufacturer and with a test voltage of 80 % of the initial full test voltage.
4.3.2.2.3 Polarisation Index (PI)
The polarisation Index is the ratio between the insulation resistance measured after a time period of 10 minutes over the initial insulation resistance (PI = R 10 min / R 1 min).
The minimum acceptable Polarisation Index shall be 2.5.
The PI obtained gives an indication of the condition of the winding insulation with regard to its dryness and cleanness. PI will be lower for a dirty, wet or chemically contaminated winding insulation.
4.3.2.2.4 Test procedures
Prior of any test, relevant Project Specifications and MANUFACTURER's Test Procedures shall be adhered to.
The CONTRACTOR shall carry out tests as laid down on the Test Sheet.
If the obtained IR or PI values fall below the minimum values, then the equipment should not be energised or subjected to high voltage testing.
Appropriate action should be taken, e.g. drying, to normalise the figures.
In case of 'flash-over' during high voltage testing appropriate measures shall be taken (e.g. cleaning, drying, repair) to eliminate the cause. Re-testing shall be performed after repair.
In the event that any of the tests fails to meet the specification requirements, it will be necessary for the CONTRACTOR to list any discrepancies and to present them to the COMPANY Engineer.
The Test Sheet will be completed, signed and dated, and presented to the COMPANY Engineer for approval.
Copies of the Test Sheet will be issued to the Certifying Authority if required. The original shall be inserted in the Ready for Commissioning dossier.
4.3.2.3 Generators - Test Sheet T-PX-01
The CONTRACTOR shall carry out the insulation resistance tests on the generator windings, the exciter windings, the generator space heater, the bearing pedestal insulation (if practical), and record the data obtained.
The following Megohmmeter shall be used: • 5000 V for HV windings
• 1000V for LV windings
The minimum acceptable insulation resistance value shall be: ¾ HV generator windings - 150 Megohms
¾ LV generator windings - 100 Megohms ¾ Exciter windings - 10 Megohms
• Anti-condensation heaters - 10 Megohms • Bearing Insulation - 1 Megohm.
If the pedestal bearings or sleeve bearing housings are completely insulated from the generator frame, the insulation may be checked with the machine coupled and running at the commissioning stage.
In the other cases refer to manufacturer procedure.
4.3.2.4 Power transformers - Test Sheet T-PX-02 -
Neutral earthing resistors shall be disconnected from the neutral point before starting tests. They shall be tested separately in accordance with section 4.3.2.21.
HV earthing transformers shall be tested in accordance with the requirements of HV Transformers Test Sheet and Neutral Earthing Resistors Test Sheet (section 4.3.2.4)
4.3.2.4.1 Insulation resistance tests
Insulation résistance shall be measured between:
• Primary windings and secondary windings connected to earth • Secondary windings and primary windings connected to earth.
A 5000 V Megohmmeter shall be used for testing the HVwindings, andHV/LV windings insulation. A 1000 V Megohmmeter shall be used for the LV windings.
The minimum acceptable insulation resistance values shall be: • HV windings - 150 Megohms
• LV windings - 100 Megohms
• Primary / secondary – 150 Megohms • .
CONTRACTOR shall carry out an insulation resistance test on auxiliary wiring, if any, with a 500 V Megohmmeter. Minimum acceptable value is 10 Me ohms
4.3.2.4.2 Oil breakdown tests
A sample of the transformer tank insulating oil shall be drawn off from the tank and tested in accordance with the requirements of:
¾ IEC 60599 Mineral oil – impregnated electrical equipment in service. Guide to the
¾ IEC 60156 Insulating liquids – Determination of the break down voltage at power frequency. Test method. ".
4.3.2.5 LV transformer - Test Sheet T-PX-03
Insulation résistance shall be measured between the primary windings and earth, the secondary windings and earth and between primary and secondary windings.
A 1000 V Megohmmeter shall be used for the tests and the minimum acceptable insulation resistance values shall be 100 Megohms.
4.3.2.6 HV switchboard - Test Sheet T-PX-04
Precautions should be taken to prevent circuit breakers and selectors being operated without the knowledge of the Test Engineer.
4.3.2.6.1 HV Tests:
Before testing, the switchgear framework shall be connected to earth and control circuits, including Static type protection relays shall be protected according manufacturer instructions. Voltage transformers shall be isolated and tested separately.
On control circuits, all earth connections as shown on the wiring diagrams shall be disconnected before the application of the test voltage and reconnected when the test is completed.
All incoming and outgoing isolating switches shall be open.
High voltage test of the main circuit shall be carried out on each phase with the remaining two phases connected to earth (voltage transformers and load disconnected).
For the test, the reference pole of the testing supply is connected to the same earth as the frame of the equipment under test. Test voltage for the duration of one minute shall be as indicated in IEC 60694.
.
4.3.2.6.2 Insulation Resistance Tests:
The insulation resistance shall be measured before the HV test is carried out and measured again after the HV test is completed to ensure that the initial resistance has not been altered appreciably.
The connections used for the insulation resistance tests shall be similar to the ones used on the high voltage test.
Insulation resistance test shall be performed on busbars alone, busbars and circuit breakers, voltage transformers, anti-condensation heaters and signalling, control and breakers rearming motor wiring.
A 5000 V Megohmmeter shall be used for testing the HV bus bar, and a 500 V Megohmmeter shall be used for auxiliary wiring (heater, control, signalling, rearming motors).
The minimum acceptable insulation values shall be: ¾ HV switchgear – 200 Megohms
¾ Control and Auxiliary wiring Circuits - 10 Megohms.
4.3.2.6.3 Voltage Transformer (VT) and current transformer (CT)
Insulation resistance measurement shall be performed on each voltage transformer. A 5000 V Megohmmeter shall be used for primary wirings testing (secondary wiring earthed), and a 500 V Megohmmeter shall be used for secondary wirings (primary wiring earthed). Minimum acceptable insulation values shall be:
¾ Primary wirings - 150 Megohms ¾ Secondary wirings - 10 Megohms.
• If current transformers are installed, a polarity test with the use of battery flick test shall be performed.
4.3.2.7 LV switchboard - Test Sheet T-PX-05
Precautions should be taken to prevent the circuit breakers and selectors being operated without the knowledge of the Test Engineer.
4.3.2.7.1 HV test
Before testing, the switchgear framework shall be connected to earth and control circuits, including Static type protection relays shall be protected according manufacturer instructions. Voltage transformers shall be isolated and tested separately.
On control circuits, all earth connections as shown on the wiring diagrams shall be disconnected before the application of the test voltage and reconnected when the test is completed.
All incoming and outgoing isolating switches shall be open.
HV test of the main power circuit shall be carried out on each phase with the remaining two phases connected to earth. For the test, the reference pole of the testing supply is connected to the same earth as the frame of the equipment under test.
Test voltage for the duration of one minute shall be as indicated in IEC 60694
4.3.2.7.2 Insulation resistance tests:
The insulation resistance of the switchgear should be measured before the HV test is carried out and again after the HV test is completed to ensure that the initial resistance has not been altered appreciably.
The connection used for the insulation resistance tests shall be similar to the ones used on the high voltage testing. A 1000 V Megohmmeter (500 V for control circuits) shall be used for testing and the minimum insulation resistance value shall be:
¾ LV switchgear - 100 Megohms
¾ Signalling, Control circuits - 10 Megohms. ¾ Anti condensation heating circuit -10 Megohms.
4.3.2.7.3 Voltage Transformer (if any) and current transformer
Insulation resistance measurement shall be performed on each voltage transformer. A 500 V Megohmmeter shall be used. Minimum acceptable insulation value shall be 10 Megohms.
• If current transformers are installed, a polarity test with the use of battery flick test shall be performed.
4.3.2.8 Bus duct - Test Sheet T-PX-07
An HV test as described in 5.3.2.5.1 and in 5.3.2.4.1 shall be performed.
Bus duct shall be disconnected at both ends (i.e. transformer and switchboard).
The insulation resistance test shall be carried out using a 5000 V Megohmmeter for HV bus duct and 1000 V for LV. The test shall be carried out between each phase with the other two phases and frame bonded together and earthed (three tests). Minimum acceptable value shall be 200 Megohms for HV and 100 Megohms for LV.
If space heater is installed, a 500 V Megohmmeter shall be used for testing its insulation resistance, the minimum value shall be 10 Megohms.
Bus bar and space heater continuity shall be check with ohmmeter
4.3.2.9 HV cables - Test Sheet T-PX-08
The CONTRACTOR shall carry out all the tests with the cable ends glanded and terminated but not connected.
One sheet will be used for each cable (Trefoil configuration is considered as one cable).
On completion of all tests, HV terminations shall be tightened to torque setting specified by Vendor documentation and recorded on the test sheet.
Note: Where cables are terminated using "Elastimold" type terminations, an "Elastimold" "dead
end plug" must be fitted during IR (Insulation resistance) and HV tests.
4.3.2.9.1 HV test
The HV test shall be carried out by the CONTRACTOR on all HV cables. It shall be applied as follows:
¾ Single Core Cables: between the conductor and the armour, the armour being solidly connected to earth.
¾ Three Core Cables: between each conductor and the remaining conductors and armour, which shall be connected together and to earth (three tests per cable), and, between conductors (three tests per cable). In case of HV cable with screen, these HV tests shall be performed with the screen connected to the armour.
The test voltage shall be gradually increased to test value and maintained for fifteen minutes. The leakage current measured should not exceed one milliamp.
Voltage shall be held at each increment to allow the capacitive charging current to stabilise.
4.3.2.9.2 Insulation test (before and after HV test)
The insulation resistance tests should be carried out using a 5000 V Megohmmeter, the test configuration being as for the HV test. The insulation resistance should be at least 150 Megohms.
4.3.2.10 LV power cables - Test Sheet T-PX-09
The CONTRACTOR shall carry out all the tests with the cable ends glanded and prepared but not connected. Core and armour continuity checking shall be performed. The insulation resistance tests will be carried out using a 1000 V Megger for LV power cables.
The minimum acceptable value shall be: • LV cables above 240V - 50 Megohms • 240 V and below - 10 Megohms.
• LV lighting and trace heating cables shall not be considered in this chapter.
4.3.2.11 Multicore cables - Test Sheet T-PX-10
This Test Sheet is to be used for all Instrument, Fire and Gas and Telecommunications multicore cables, with the exception of special purpose cables for data highways/data links with the Supervisory Computer/Distributed Control Systems (DCS), which shall be tested by the Commissioning Engineer and/or the VENDOR.
Test Sheet and Check List shall be completed by Sub-System as detailed by the Status Index. Test and Check Sheet shall be numbered consecutively where more than one sheet is required. For example:
• C-PX-10 sht 1 to 4 • T-PX-10 sht 1 to 6.
The CONTRACTOR shall carry out and record all data for the insulation resistance with the cable ends glanded and prepared but not connected. On completion of the tests the cable shall be connected.
For the allocation of the different cores in the different system the procedure defined for Check List C-PX-10 will be followed (see 4.2.2).
Control station multicore cables shall not be considered in this chapter.
4.3.2.11.1 Insulation test
Insulation resistance tests shall be carried out using a 500 V Megohmmeter and the minimum recorded value shall be 10 Megohms.
4.3.2.11.2 Continuity checking
Continuity tests shall be carried out for each core. Continuity tests shall cover the whole cable circuit as indicated on the trouble-shooting diagrams, from the initial point (generally control room marshalling cabinets) to the final element on the field, e.g. I/P converter, transmitter, solenoid, etc., irrespective of the multicore sub-system limits.
4.3.2.12 HV motor - Test Sheet T-PX-12
The HV test shall only be carried out at the request of the COMPANY Engineer and under his supervision.
The CONTRACTOR shall carry out the insulation resistance tests on the motor windings, motor heater, and bearing pedestal insulation and record the data obtained. Each winding will be
tested to earth using a 5000 V Megohmmeter with the remaining windings, and frame connected together and to earth.
The insulation resistance of the motor heater will be tested using a 500 V Megohmmeter.
If the pedestal bearings or sleeve bearing housings are completely insulated from the motor frame, the insulation may be checked with the machine coupled and running at the commissioning stage.
In the other cases refer to manufacturer procedure. The minimum acceptable insulation values shall be :
• Stator Windings: 150 Megohms
• Anti-condensation Heater: 10 Megohms • Bearing Insulation: 1 Megohm.
4.3.2.13 LV motor - Test Sheet T-PX-13
The CONTRACTOR shall carry out the insulation resistance tests on the motor windings, and space heater.
The windings shall be tested using a 1000 V Megohmmeter. The heater shall be tested using a 500 V Megohmmeter. The minimum acceptable insulation value shall be :
• Motor Winding: 100 Megohms • Heater : 10 Megohms
4.3.2.14 DC motors - Test Sheet T-PX-14
The CONTRACTOR shall carry out the insulation resistance tests on the motor windings, and the motor heater..
The motor field and armature windings shall be tested using a 1000 V Megohmmeter , each winding shall be tested with the remaining windings, and frame connected together and earthed. (In some instances it may be impractical to test/earth each phase winding separately). Motor heater shall be tested under 500 V only.
The minimum acceptable insulation value shall be : • Shunt Field: 10 Megohms
• Armature: 10 Megohms
• Series Field/Compounding: 10 Megohms • Heater Winding: 10 Megohms.
Brushes:
The spring tension on the dc motor commutator brushes shall be checked in accordance with the MANUFACTURER’s recommendations.
4.3.2.15 Distribution boards/Control panels / Consoles - Test Sheet T-PX-15
The CONTRACTOR shall carry out the insulation resistance tests on all distribution board, control panel or console, main circuits and also any control wiring.
All incoming and outgoing isolating switches shall be open
The insulation resistance test on the main circuit shall be carried out between phase and earth and phase to phase using a 1000 V Megohmmeter. The minimum acceptable resistance value shall be 50 Megohms.
4.3.2.16 The control wiring and apparatus (voltmeter etc...) shall be tested using a 500 V Megohmmeter Minimum resistance value shall be 10 Me ohms.Charger/Inverter - Test Sheet T-PX-16
All tests required by the MANUFACTURER’s documentation shall only be carried out by the CONTRACTOR in accordance with the MANUFACTURER’s standard test procedures and under the supervision of the MANUFACTURER’s representative.
.
The Test Sheet shall be used as a front sheet to record test results.
4.3.2.17 Batteries - Test Sheet T-PX-17
All tests required by the MANUFACTURER’s documentation shall only be carried out by the CONTRACTOR in accordance with the MANUFACTURER’s standard test procedures and under the supervision of the SUPPLIER’s representative.
Test Sheet shall be numbered consecutively where more than one sheet is required
4.3.2.18 Lighting circuits and convenience sockets outlets circuits - Test Sheet T-PX-18 -
Tests on the lighting installation shall be carried out by the CONTRACTOR on one circuit basis (cables and luminaires, cables and sockets).
The circuit insulation resistance test shall be carried out using a 500 V Megohmmeter, insulation resistance being measured between each phase and earth.
Important: Do not use megohmmeter across phases
The minimum acceptable insulation resistance value for the circuit will be 10 Megohms .
4.3.2.19 Socket outlets - Test Sheet T-PX-19
For power socket outlets the individual sockets shall be tested using a 1000 V Megohmmeter and the insulation resistance recorded.
The minimum acceptable value shall be 100 Megohms.
4.3.2.20 Heaters - Test Sheet T-PX-20 - Associated Check List C-PX-20
The CONTRACTOR shall carry out the insulation resistance tests on heater using a 1000 V Megohmmeter, measuring each phase to the other ones connected to earth
4.3.2.21 Neutral earth resistors - Test Sheet T-PX-21
The NER terminals shall be disconnected from the transformer or generator neutral point and from earth
Surge diverters shall be tested in accordance with the MANUFACTURER’s recommendations. A 1000 V Megohmmeter should be used for testing the resistor elements.
The minimum acceptable insulation resistance values shall be: ¾ HV Distribution - 150 Megohms
¾ LV and Lighting and Small Power Distribution - 100 Megohms.
HV earthing transformers shall be tested in accordance with the requirements of HV Transformers Test Sheet (section 4.3.2.4) and Neutral Earthing Resistors Test Sheet. In all cases, test voltages shall be in accordance with the MANUFACTURER’s recommendations .
4.3.2.22 Trace heating - Test Sheet T-PX-22
Tests on the Trace Heating installation shall be carried out by the CONTRACTOR on a circuit basis (Supply cable, tape, junction boxes)..
All tests required shall only be carried out by the CONTRACTOR under the supervision of the MANUFACTURER’s representative.
Before the insulation is applied to the pipe, the tape shall be tested for continuity and an insulation resistance test shall be carried out using a 500 V Megohmmeter(minimum acceptable value - 10 Megohms regardless of length).
After the pipe insulation has been installed, the continuity and insulation resistance test shall be repeated to ensure the tape has not been damaged.
In hazardous areas the resistance to earth in megohms must not be less than: L
750
(Where L = Length of the Heater in Metres)
4.3.2.23 Control stations - Test Sheet T-PX-23
Tests on the control stations including its multicore cable shall be carried out by the CONTRACTOR.
The circuit insulation resistance test shall be carried out using a 500 V Megohmmeter, insulation resistance being measured between each phase and earth.
.
The minimum acceptable value will be 50 Megohms.
The on/off tests of the control station shall be carried out with the continuity test from the MCC .
4.3.2.24 Navigation aids - Test Sheet T-PX-25
All tests required by the MANUFACTURER’s documentation shall only be carried out by the CONTRACTOR in accordance with the MANUFACTURER’s standard test procedures and under the supervision of the MANUFACTURER’s representative.
Batteries shall be tested in accordance with 5.3.2.15
The Test Sheet shall be used as a front sheet to record tests results.
All cables in the system shall be tested in accordance with 4.3.2.10 and Test Sheet T-PX-09 shall be completed.
Batteries shall be tested in accordance with 4.3.2.17 and Test Sheet T-PX-17 shall be completed.
4.3.2.25 Earthing systems - Test Sheet T-PX-26 4.3.2.25.1 Continuity of protective conductors
A continuity test shall be made in order to check the continuity of the protective conductors, including the equipotential bonding.
4.3.2.25.2 For main protective conductor, test results shall be obtained from cable test sheet T-PX-09 (see section 4.3.2.10.Equipment earth return path impedance test
4.3.2.25.3 Definitions
To comply with IEC 60364-4-41, “touch” voltages shall not exceed 50 volts AC rms. The earth impedance loop shall be lower than the RA calculated:
RA x Id < UL
RA = The earthing resistance of all exposed conductive parts connected by a protective
conductor to an earth electrode
Id = Fault current for the first dead fault between a phase conductor
UL = Conventional touch voltage.
Example:
Distribution system Id (mA) UL (V) RA (ohms)
LV 300 50 167
HV 30000 50 1.67
4.3.2.25.4 Method
All power supplies to the systems under test shall be isolated before commencing the tests. All testing shall be carried out in accordance with the attached detail drawings using an AC current injection test set.
The injected current shall be equal to 1.5 times the design current of the circuit under test except that the current shall not exceed 25 A.
The loop impedance value measured is equal to: E = current generator set test voltage generator set test This measurement is applicable for:
• Verification of trip condition upon 2nd fault phase to earth in IT system.
• Verification of trip condition upon earth fault in TN system (circuits without ELCB). It shall be performed for each switchboard/MCC on the longest cable run on onshore plants
4.3.2.25.5 Motor fed from LV motor control centre (see Example 1)
• Connect injection test set between MCC Phase Busbar “R” and switchboard earth, manually close contactor “B” and determine loop impedance E1 by shorting motor terminal “R” phase to motor earth conductor.
• Short across high impedance earthing resistor “F” and close circuit breaker “E” to determine loop impedance E2.
• Total earth return path impedance = E1 + E2. (This is a conservative value since the phase conductor resistances are also included).
4.3.2.25.6 Lighting circuit fed from distribution board (See Example 2)
• Connect injection set between Phase “T” Busbar and Distribution Board Earth. Manually close Breaker “A” and determine loop impedance E3 by shorting the end light fitting Terminal “T” to the Earth Conductor.
• Short across high impedance earthing Resistor “F” and manually close circuit breaker “E” to determine Loop Impedance E4.
• Total Earth Return Path Impedance = E3 + E4. (This is a conservative value since the phase conductor resistances are also included).
Note: Earth return path impedance tests on small power circuits shall be at the direction and the
discretion of the COMPANY Engineer.
With the level of protection provided, it is only considered necessary to test one circuit per distribution board providing results are satisfactory.
4.3.2.25.7 HV Motor fed from HV switchboard (See Example 3)
• Connect injection test set between switchboard Phase Busbar “R” and switchboard earth, close breaker/contactor A and determine loop impedance E6 by shorting motor terminal “R” phase to motor earth conductor.
• Connect injection test set between switchboard Phase Busbar “R” and switchboard earth, close earthing transformer contactor B and determine loop impedance E5 by shorting earthing transformer terminal “R” phase to transformer earth conductor.
Example 1: Typical return path impedance loop 440 V 3 phase motor circuit
Example 2: Typical return impedance loop small power circuit
Example 3: Earth return impedance path loop 6.6 kV motor circuit
4.3.3 Test Sheets master forms
5. Instrument precommissioning
5.1 Introduction
The precommissioning of instrument equipment shall be carried out in accordance with the rules given in chapter 3 of this specification.
The present chapter provides additional information and support documents, specific to the Instrument Discipline:
• Instruments Check Lists particularities • Check Lists Master Forms
• Precommissioning Tests Procedures • Test Sheets Master Forms.
5.2 Precommissioning checks
5.2.1 Check Lists index
The instrument precommissioning checks are mainly covered by 21 types of Check Lists, as follows, assuming some additional Lists can be issued for some specific equipment:
Type of equipment Check List reference
Temperature element (T/C or RTD) C-JX-00
Rotameter C-JX-00
Pitot element C-JX-00
Annubar C-JX-00 Thermowell C-JX-03
Local Temperature Indicator C-JX-05
Level Indicator C-JX-05
Level gauge (sight glass) C-JX-05
Local Pressure Indicator C-JX-05
Pressure differential - Pressure switch C-JX-08 Pressure differential - Pressure transmitter C-JX-08 Temperature/Differential temperature switch C-JX-08 Temperature/Differential Temperature
Transmitter
C-JX-08
Flow Switch C-JX-08
Level Switch C-JX-08
Level transmitter - Controller C-JX-08
Type of equipment Check List reference Limit Switch C-JX-08 Density transmitter C-JX-08 Signal selector C-JX-08 Hand Switch C-JX-08 Analyser C-JX-08 I/P Converter C-JX-08 Probe/Proximitor/Monitor (Displacement - Vibration Key Phasor)
C-JX-08 Orifice Plate C-JX-11 Turbine meter C-JX-13 Vortex meter C-JX-14 Bursting disc C-JX-20 Relief Valve C-JX-21
Actuated valve (ESDV-BDV-XV) C-JX-23 or 24
Modulating Control valve C-JX-27 or 28
Instrument panel / Annonciator C-JX-30
Actuated Valve Control Station C-JX-31
Gas detectors C-JX-42
Fire detectors C-JX-43
Fusible loop C-JX-45
Frangible bulbs / Pneumatic detection & Deluge System
C-JX-46
Indoor cabinet / Panel C-JX-48
Cabinet / Panel earthing C-JX-49
Note: All instrumentation cables checks are covered by the electrical Check List C-PX-10 and junction boxes/marshalling boxes by the electrical Check List C-PX-31 (refer to chapter 4, paragraph 4.2.2).
5.2.2 Procedures 5.2.2.1 General case
CONTRACTOR will carry out equipment checks, and fill-in relevant Check Lists as per the rules given in chapter 3, paragraph 3.3.3, except in the following cases, where specific rules apply.
5.2.2.2 Exceptions
a) In order to limit the amount of precommissioning support documentation, the following Check List: C-JX-42- 43 – 45 : (Gas – Fire detectors) shall be processed as follows:
• The Check List will be used as a front sheet and as a procedure, the equipment subject to checks being listed by tag numbers on the specific Continuation Sheet also referenced C-JX-42.- 43 - 45
• The tags listing will be done on a sub-system basis.
• Signatures and other required information will be reported, for each piece of equipment, on the Continuation Sheet(s).
b) Case of packages with simplified precommissioning scope of work: refer to chapter 3, paragraph 3.3.6.2.
5.2.2.3 Case of C-JX-00 and 08
The Check List referenced C-JX-00 and 08 will be used for many types of equipment (see § 5.2.1).
The type of equipment subject to checks shall be indicated on the Check List during the preparation phase.
Checks related to various types of equipment shall not be reported on the same Check List.
5.2.2.4 Case of C-JX-11 and C-JX-20
Precommissioning checks will be carried out once the tests have been completed, and after final installation of the concerned item.
However, orifice plates, covered by Check List C-JX-11, and bursting discs, covered by Check List C-JX-20, will be inspected for conformity and damage prior to their installation.
The Check List will be completed after their final installation.
5.2.2.5 Cabinet Earthing – C-JX-49
As per GS EP ELE 031, instrument earthing is identified as three different systems but they shall be interconnected inside each cabinet. Moreover earthing interconnection shall also be achieved at junction boxes and instruments (screen and armour). Exception is made with intrinsically safe earth (I.S.), where screen shall be earthed at only one side (at the cabinet location)
These tests will be carried out by cabinet/panel individually when all field instrument cables are connected to cabinets (through junction boxes).
When disconnected from the main earth network, have to be established:
- IPE and IE continuity since interconnections are ensured through junction boxes and instruments
- Segregation of the IS earth when applicable
5.2.3 Check Lists master forms
5.3 Precommissioning tests
5.3.1 Test Sheets index
Type of equipment Test Sheet reference
General purpose T-JX-00
Control Valve (Modulating) T-JX-01
Actuated Valve (ESD, Blowdown and Shut-Off) T-JX-02
Relief Valve T-JX-03
Instrument (Analog Output) T-JX-04
Instrument (Switched Output) T-JX-05
Instrument Tube/Pipe (Hydraulic, Pneumatic, Impulse) T-JX-06
Flow element (orifice plate) T-JX-07
5.3.2 Test Procedures
Note: Tests of instrument cables are covered by Electrical Test Sheets T-PX-10 (refer to
chapter 4, paragraph 4.3.2.11).
5.3.2.1 General Test Sheet form - T-JX-00
The general Test Sheet form (no reference) shall be used by the CONTRACTOR to report any required test on instrumentation equipment not covered by the previous Test Sheets.
5.3.2.2 Control valve (modulating) - T-JX-01
The VENDOR Calibration Manual Number, Calibration/Test Procedure Number and Data Sheet Number are all to be completed by the CONTRACTOR and are self explanatory. Project Specification for Local Instrument Calibration and Testing, indicates the basic requirements of this Test Sheet. The Air Failure, Signal Failure, and Valve Signal Range shall be obtained from the Data Sheet and checked against the valve data plate.
As a general rule, control Valves shall NOT be stroke checked by the CONTRACTOR throughout the range prior to installation, except in specific cases where transportation or storage conditions might have corrupted the equipment. The decision to carry out this
test will be made by the COMPANY.
The testing of valves shall be made in accordance with the Technical Specification for valves. However, as the method of test will vary for valve type, size and service, the Contractor will submit the test procedure to the COMPANY for approval.
The CONTRACTOR shall complete the results on the Test Sheet and note any adjustments
made in the remarks section. The CONTRACTOR shall advise the COMPANY of any remedial work required prior to it being started. Prior to operation the valve seat shall be checked for cleanliness.
All auxiliary equipment mounted with the valve shall be calibrated/function checked and all test results recorded on Test Sheets.
After stroke checking, opening and closing times of the valve are to be confirmed and noted on the Test Sheet.
A commissioning representative must be informed of the testing of the valves.
For VENDOR package valves, stroke checks shall be carried out in situ by the CONTRACTOR and the results noted as above. The COMPANY shall be advised of faults on VENDOR package valves prior to any remedial work being started.
In all cases seat leakage tests shall have completed and witnessed at the VENDORS premises. If not they shall be carried out by the CONTRACTOR upon a specific request by the company. Instruments serial number and model number shall be recorded on each Test Sheet and the relevant data sheet be copied and attached to each Test Sheet.
5.3.2.3 Actuated valve (ESD, Blowdown, Shut-off) - T-JX-02
As a general rule, actuated Valves shall NOT be stroke checked by the CONTRACTOR prior to installation, except in specific cases where transportation or storage conditions might have corrupted the equipment. The decision to carry out this test will be made by the
COMPANY.
In such cases, it is accepted valve operation from the valve control station is not part of the Precommissioning scope of work. However special attention shall be paid to overpressure protection, especially when the protection device is mounted on external equipment (e.g. accumulator).
The testing of valves shall be made in accordance with the Technical Specification for valves. However, as the method of test will vary for valve type, size and service, the Contractor will submit the test procedure to the COMPANY for approval.
The requirements of this Test Sheet are as paragraph 5.3.2.2, T-JX-01, but the Project Specification for Actuated Valve Control Stations, shall be referred to for the various types of valve. In addition whenever limit switches are installed on actuated valves they shall be adjusted as per the VENDOR recommendations.
5.3.2.4 Relief valve - T-JX-03
The initial requirements of this Test Sheet are generally as T-JX-01.
Relief valves shall be tested by the CONTRACTOR on an approved test rig.
VENDOR package valves shall be removed by the CONTRACTOR and tested in the same manner. All relief valves shall be re-installed by the CONTRACTOR prior to Commissioning. Valves with back pressure bellows fitted shall have their operational back pressure applied for 10 minutes with a zero leakage rate.
All pressure gauges shall be check calibrated by the CONTRACTOR and witnessed by the certifying authority prior to valve testing. A test record shall be kept by the CONTRACTOR. Delay between relief valve testing and start up of the installation shall be decided by the COMPANY.
All valves shall be tested on air or nitrogen and adjusted to commence to open at the cold test pressure. This cold test pressure shall include the corrections for service conditions or back pressure or temperature, or both.
The seat leakage test shall be carried out in accordance with ANSI B 147.1 and API 527 with an applied pressure under the disc of 90% of the cold test pressure. The acceptance criteria shall be as follows:
• Resilient seat seals - zero leakage
• Metal Seats - less than 5 bubbles per minute.
Should any valve not conform to the test requirements listed on the data sheet, it shall be brought to the attention of the COMPANY prior to remedial work being carried out on the valve. For safety valves installed on hydraulic packages/systems, valves shall be removed for testing only when requested by the certifying authority to avoid contamination of hydraulic circuits. The COMPANY shall make available to the certifying authority, original factory test certificates for all valves falling into this category.
5.3.2.5 Instruments (transmitters and switches : T-JX-04 and T-JX 05 )
As a general rule, instruments calibration is not required prior to the installation, as long as Vendor’s calibration datasheet is provided and transportation or storage conditions have not corrupted the instrument. The decision to carry out this test will be made by the
COMPANY.
Calibration and testing shall be carried out by the CONTRACTOR as Project Specification for Local Instrument Calibration and Testing and the relevant sections of the General Instrument Specification.
In addition, the CONTRACTOR shall conform to the requirements of the VENDOR calibration manual to enable him to complete the Test Sheet.
VENDOR package equipment shall be tested in situ. Faults found on VENDOR package equipment shall be brought to the attention of the COMPANY prior to attempted remedial work being carried out.
5.3.2.6 Instrument tube/pipe - T-JX-06 5.3.2.6.1 Hydraulic
Flushing and pressure testing shall be carried out by the CONTRACTOR as outlined in Project Specification for Cleaning, Testing and Flushing of Hydraulic pipework. All requirements and procedures are highlighted in this Specification.
The Instrument scope of work for pressure testing includes all tubes and pipes that do not carry a line number as dictated by the piping line list. This is specified as the tube and pipe after the piping isolation valve and is shown on the relevant hydraulic hook-up.
After testing and acceptance it is critical that all open pipe and tube ends are capped or taped to prevent contamination by dust or moisture.
5.3.2.6.2 Pneumatic
Pressure testing shall be carried out by the CONTRACTOR in accordance with Project Specification for Local Calibration and Testing, Pressure and Continuity Testing.
The Instrument scope of work for pressure testing includes all tubes and pipes that do not carry a line number as dictated by the piping line list. This is specified as the tube and pipe after the piping isolation valve and is shown on the relevant hydraulic hook-up.
Completion of the Test Sheet shall follow the same format as that for hydraulic pipe and tube. As with hydraulic tube it is essential that all open pipe and tube ends are capped or taped after completion of test.
5.3.2.6.3 Impulse
Pressure testing shall be carried out by the CONTRACTOR in accordance with Project Specification for Local Instrument Calibration and Testing, in particular the section relating to Impulse lines.
5.3.2.7 Flow element (orifice plate) - T-JX-07
Orifice measurements according to Test Sheet shall be performed prior to orifice plate installation by the CONTRACTOR. A test label shall be attached after the measurements have been performed.
5.4 Test Sheets master forms
Refer to Appendix 5.Note: Instrument last issued data sheet to be copied and submitted with Test Sheet.
6. Telecommunications precommissioning
6.1 Introduction
The precommissioning of telecommunications equipment shall be carried out in accordance with the rules given in chapter 3 of this specification.
The present chapter provides additional information and support documents, specific to the Telecommunication Discipline:
• Telecommunication Check Lists procedures • Check Lists Master Forms
• Precommissioning Tests Procedures.
6.2 Precommissioning checks
6.2.1 Check Lists index
Type of equipment Check List reference Nb of sheet
PA/GA Loudspeaker + JB C-IX-01 1+
PA /GA Flashing beacons + JB C-IX-02 1+
PA access unit C-IX-03 1
PA /GA Central system & Marshalling Cabinet C-IX-05 1
Telephone Hoods Eex w /Telephone beacon & Sounder
C-IX-07 1
System cabinet C-IX-12 1
Indoor radio equipment cabinet C-IX-13 1
Meteorological sensors & Cables C-IX-14 1
Monitors C-IX-18 1
CCTV Control Units C-IX-19 1
Radio base station-central units C-IX-20 1
Motorized antenna,feeder & lighting sensors C-IX-22 1
Entertainment distribution network C-IX-26 1
Type of equipment Check List reference Nb of sheet
Antenna, feeder & lighting arrestor CIX34 1
Radio remote control units CIX36 1
Radio Handheld, pagers & battery chargers CIX39 1
Fibre optic / patch panel CIX42 1
CCTV camera and housing CIX45 1
Cabling RJ45 CIX46 1
Connection box-PA/GA tank coverage CIX48 1
Mobile set-PA/GA tank coverage CIX49 1
GMDSS circuit breaker CIX50 1
PC workstation CIX51 1
Server CIX52 1
Data network equipment CIX53 1
PC screen / Keyboard switch CIX54 1
Outdoor radio cabinet CIX55 1
Radio-Indoor distribution CIX56 1
Radio-outdoor network CIX57 1
ATU CIX58 1
Remote station / Portable unit CIX59 1
GMDSS Console CIX60 1
Entertainment DVD player CIX61 1
Oceano sensors CIX62 1
Gyrocompass:Central/Interface & power supply CIX63 1
MDF / IDF Cabinet CIX64 1
Clock Unit CIX65 1
+ = Continuation Sheet As Applicable
Note: All telecommunication cables checks are covered by the Electrical Check List C-PX-10
and junction boxes by Electrical Check List C-PX-31 (refer to chapter 4, paragraph 4.2.3).
6.2.2 Procedures 6.2.2.1 General case
CONTRACTOR will carry out equipment checks, and fill-in relevant Check Lists as per the rules given in chapter 3, paragraph 3.3.3, except in the following case, where a specific rules applies.
