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MS For LV SWGR & MCC
MS For LV SWGR & MCC
MS For LV SWGR & MCC
Signature:
A Issued for Information Ibrahim Kamal Zhang Mingjun Zhang Jishou 31-OCT-2017
PROJECT:
20314 TITLE:
LOCATION: Method Statement
West Coast
For
PACKAGE:
“P” Power Plant Electric Test ForL LV SWGR & MCC
SCALE: DOCUMENT No.: REV:
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SUBCONTRACTOR Sheet 1 of 22
PACKAGE “P” POWER PLANT
YANBU POWER AND DESALINATION PLANT – PHASE-III
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TABLE OF CONTENTS
1.0 PURPOSE 4
2.0 SCOPE 4
3.0 REFERENCE STANDARDS 4
4.0 DEFENITIONS & ABBREVIATIONS 5
5.0 RESPONSIBILITIES 5
6.0 PROCEDURES & WORK SEQUENCE 8
7.0 QUALITY CONTROL 24
8.0 HSE CONTROL 25
9.0 ATTACHMENTS OF SAFETY RISK ASSESSMENT 25
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REVISION INDEX
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1- PURPOSE
The main purpose of this document is to define the Low Voltage Switchgear (LV
SWGR) & MCC Site Acceptance Test (SAT) general sequence of Test Procedures for the
Saline Water Conversion Company.
2- SCOPE
This procedure shall apply to all type of Electrical LV SWGR [400 V] electrical test
procedure specified on the approved specification and relevant standards. This method
statement does not supersede the Vendor testing procedure, specification and safety pro-
cedure
3- REFERENCE STANDARDS
3-1- Project Engineering Specification
3-2- ANSI – American National Standards Institute
3-3- IEC – International Electro-technical Commission.
3-4- NEC – National Electrical Code
3-5- NEMA – National Electrical Manufacturing Association
3-6- NFPA – National Fire Protection Authority
3-7- Approved AFC and IFC Drawings
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5- RESPONSIBILITIES
Site manager has the final responsibility for the Electrical Components Testing and
safety control of Electrical Equipment Commissioning and entirely responsible for control of
progress and subcontractors.
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carried out as per the project Specifications and Standards, Controls of materials and work-
ers at site, Notifies to Electrical Manager the completion of the preparation of site for inspec-
tion, Preparation of site for inspection, Initiates RFI for material receiving inspection, Checks
that construction work is ready for inspection and prepares RFI, Assist for inspection and
testing when required at site, Check for PPE in accordance with site condition, Check for the
equipment and material which are required for work.
of the official inspection request when their presence is required to carry out inspection, En-
suring that inspections are performed in a timely manner and recorded as per specifications
and standard detailed drawings, as per ITP and/or inspection records requirements, Sub-
duties for material receiving, all electrical & instrument works and ensure efficient recording
and reporting of results as required, Review all relevant documents and certificates, Raise
NCR for any discrepancies and shall receive all internal requests for inspection from Electri-
cal & Instrument Department, Facilitate invitation to company representatives that require
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their presence, Control quality of whole work process, arranging the field inspection and re-
viewing required inspection documents, Control the work in accordance with SWCC stand-
ards and specifications.
contractor testing and commissioning team according to site condition, representing the test-
ing team in all meetings, preparing of daily activities report and the overall progress of test-
ing, reviewing of work procedure and site test format, submission of test reports and
drawings at the end of project, submission of NCR for any defective material to Contractor.
Subcontractor T&C Engineer shall be responsible for testing for the whole devices & equip-
ment that is included in SEPCO III contract, delivering daily activities and progress report to
Sub-Contractor project manager, delivering test format after being signed to Sub-Contractor
project manager, writing NCR for any defect materials and deliver it to Sub-Contractor pro-
ject manager.
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Sub-Contractor and fix the technical difficulties, supporting the Sub-Contractor with the re-
quired Technical data and specification for the device under test, Confirmation for the Sys-
tem is ready for Energization.
a- Test objective:
- This test is considered as one of the main test, it’ s aimed to test:
b- Required Equipment:
CT analyzer has 4 leads, two should be connected to primary side which contains primary side
of CT and other two should be connected to secondary side of CT which you want to check its ra-
tio.
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After connecting CT analyzer through laptop and using CT analyzer software, test can be started
and result can be printed out for CT ratio, CT polarity, CT burden, CT knee point & CT winding
resistance.
This result should be compared with current transformer factory test and be sure that result within
acceptable tolerance.
To measure the burden: Inject 1 ampere on secondary side of CT, and using multi-meter you can
measure voltage calculate burden by multiply voltage and current and compare it with CT burden.
To test insulation: Using Insulation Tester by 1 kV injection for 1 minute, this test should be done
between primary to secondary and secondary to secondary But for Primary to Ground 5 kV injec-
tion for 1 minute.
See figure.1 which shows CT analyzer connection for CT TEST.
a- Test objective:
- This test also is considered as one of the main test and its purpose is to test:
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b- Required equipment:
Connect two leads from CPC device to primary side of voltage transformer and other two lead of
CPC with secondary side of VT, then press start from VT page of CPC.
Using CPC with same connection but from different page, you can measure winding resistance.
To check the loop burden: inject the rated secondary voltage and measure the current. Burden
will be the injected voltage * measured current and then compare it with VT burden.
Insulation test: Using Insulation Tester to test insulation by 1 kV injection for 1 minute, this test
should be done between primary to secondary and secondary to ground, But for primary to
ground 5 kilo volt injection for 1 minute.(Primary and Secondary Grounding will be removed in
that test)
See figure.2 which shows connection of VT Test.
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a- Test objective:
This test is aimed to measure the resistance of bus bar and for circuit breaker after being installed
in the site to avoid high resistive spots which may be results from welding or installing in the site.
b- Required equipment:
Contact resistance device has 4 leads, two for current and others for voltage, it depend on cur-
rent injection on bus bar or circuit breaker then sense the voltage and calculate resistance by di-
vide voltage on current (ohm’ s law)
Check the BB torqueing of all bolts and confirms the torque value as per factory inspection.
Connect current leads between the device which you want to measure its resistance, connect
voltage leads on the same terminals (but Inside not outside) of current then adjust 100A injection
then hold your hand on contact resistance pushbutton, after few second the result will be dis-
played.
See figure.3 which shows connection of Contact Resistance Test.
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6-4- Miniature Circuit Breaker Test (MCB) and Fuse Link Rating.
a- Test objective:
This test aimed to test the trip time characteristic of MCB if it is within limits or no and check MCB
auxiliary contact if it is available.
b- Required equipment:
Connect the Current Source (Sverker) direct to MCB, check MCB type and its rated current value.
Inject from Sverker twice of its rated current and measure the trip time in which MCB will be
tripped, compare the measured trip time with its acceptable limit from MCB manual depending on
its type.
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Auxiliary contact should be checked in both condition of MCB (open/close) and check that auxilia-
ry contact change its status from being open to close and vice versa, depending on its nature
Normally open or Normally close.
If Fuse is used make sure that its connectivity is OK and confirm its Blowing Current Value is as
per drawing or no
a- Test objective:
This test aimed to test relay’ s output contact, pick-up and drop off voltage, operating and reset-
ting time.
b- Required equipment :
d- Test connection:
Our Auxiliary relay/Lockout Relay/Timer has several points, 2 used for Coil, before injecting any
voltage on Auxiliary relay's Coil, check contacts at its normal condition which mean Normally
Open (NO) contact is being opened and Normally Closed (NC) contact is being closed, Inject the
desired control voltage of Aux. coil (which is normally 220 volt DC), at which Aux. relay will pick
up that’ s mean its contact will change its position i.e NO contact will be closed and NC contact
will be opened.
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Pick up voltage can be measured using voltmeter when the coil voltage is increased gradually
from Zero, the Aux. relay will operate (i.e Contacts change its normal status No will be closed and
vice versa) at a certain voltage. This voltage is called pick-up voltage, Record the reading of
voltmeter and Ammeter which is pick-up voltage and current.
Drop-off voltage can be measured using voltmeter when the coil voltage on an operate relay is
decreased gradually, the relay will release (i.e its contact will return to its normal status) at a cer-
tain voltage. This voltage is called drop-off voltage, Record the reading of Ammeter which is drop-
off current.
Adjust voltage source at the coil operation voltage of Aux. relay (in our case 220 V DC), To get
operating time, adjust sverker at (on+time location) and switched MCB ON, To get resetting time,
readjust voltage source at 220 volt DC and switch MCB OFF, For Timers the contacts operation
will happen after the Pick up by the desired Time Setting if it’ s on ON-Delay Mode and will
dropp off after losing the voltage by desired Time Setting if it’ s on OFF-Delay Mode.
Adjust voltage source (sverker) at 220 volt DC, select on position and make MCB ON.
Record reading of Ammeter.
Calculate burden by multiplying coil operated voltage and reading of Ammeter
a- Test objective:
This test is aimed to calibrate and adjust the reading of Meters (Voltage, Current , Power, .. etc)
b- Required equipment:
FREJA 300.
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a- Test objective:
This test aimed to check all current transformer loop, starting from first panel and distributed in
the whole switchgear depending on scheme, check shorting facility in terminal block [if exist].
b- Required equipment:
d- Test connection
Connect three phase current from FREJA to secondary side of current transformer, inject three
phase current by different values and use mini-clamp to measure current in each phase and fol-
low the loop until the last point.
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Check the whole loop burden by Injecting the rated secondary current (Usually 1 amp) at every
phase and measure the voltage for confirmation of the loop burden VA is small Value.
a- Test objective:
This test is aimed to check the whole loop of VT starting from first panel and distributed in the
whole substation depending on scheme (i.e. metering or protection purpose)
b- Required equipment:
FREJA.
Multi-meter.
d- Test connection:
Connect FREJA which considered as voltage source to secondary side of VT, inject three phase
voltage with different values on each phase and then use multi-meter to measure the voltage on
the whole loop starting from first panel to different location depending on the function of each VT.
Test objective:
This test aimed to check that the selected ratio of current transformer is correct and current trans-
former relay setting is OK and considered as back-up test of CT loop.
Required equipment:
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Power-clamp meter.
Check that all current transformer terminal block is tightened and normalized.
Test connection:
Connect Primary Injection Tester to inject current on bus bar including current transformer.
Start injection of current then using of mini-clamp, we can measure the current at each point of
the loop and read the primary current value on each relay as we did in the CT secondary Loop
Before
a- Test objective:
This test is considered as a major test or combined test for the whole work in switchgear panels
and a final phase for switchgear panels to confirm that everything on the Switchgear component
is working ok as per the expected function and to confirm that the wiring ferrules/tagging is as per
the Drawing.
b- Required equipment:
Multimeter.
Inspect for the whole panel if any missing or damage device which can be resulted from installa-
tion.
d- Test procedure:
Segregation of DC loop inside panel, by switching on only one MCB and follow its loop and so on
for other DC MCB.
DC Mix by Switching on all MCBs and Switching off one every time and confirm no DC is mixed
on its loop after switching off the MCB.
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a- Test objective:
This test aimed to test function of main relay according to approved final setting for each one, but
here we generally discussed main function which should be exist in most of approved final set-
ting.
b- Required Equipment:
FREJA 300.
Multi-meter.
Wires.
d- Burden test
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To test binary input: Apply rated binary input DC voltage on each input and verify the status of the
input through relay’ s software or from relay’ s LCD [if exist].
To test binary output: Using relay’ s software you can force binary output to close for certain time
and using multi-meter you can measure binary output contact resistance it should be around zero
which indicates binary output being closed.
ii. Measurements
Set CT ratio and VT ratio which used to the relay by studying the scheme.
By using FREJA we inject secondary rated voltage and secondary rated current
Record the primary value reading at relay’ s screen.
Refer to the manual of every relay type that will be under test.
As per the approved final setting check every setting from the protection function
By using FREJA we inject the required value of Current or/and Voltage required to cause the trip
and we confirm the pickup value as per the expected or not.
For Timing Check we inject a value that is for sure in the tripping zone of the trip function and we
confirm the relay tripping is as per the expected/pre-calculated time of operation for the tripping
contacts.
The Disturbance recorder of the relay to be checked for every Function tested to confirm the
recording capability of the device for fault analysis later if happened.
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Test objective:
This test aimed to check that the Transducers used to report the Current/Voltage/Power Reading
to the DCS (Control System) is Ok and Transferring the expected value by 4~20 mA
f- Required equipment:
Freja 300 For Injecting Voltage/Current/Power values as per the Transducer Type
Multimeter with mA measurement.
h- Test connection:
Connect the FREJA 300 Kit Voltage or/and Current terminals to the Transducers IN Terminals
using leads.
Convert the Transducers Full Scale to Equivalent mA Current Value from 4 mA for Zero Injected
value up to 20mA for Sull Scale Injected Value.
Take the reading of the Transducers OUT Terminals through Multimeter on mA mode and con-
firm the results are OK
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All the power cables shall be disconnected from the switchgear during high-pot or insulation re-
sistance test.
The test location shall be barricaded. also, when performing the test, safety Tags required and
watch man shall be available at the remote end of the equipment.
CT terminals shall be return back to the correct one before starting the bus bar or transformer
differential stability test.
Check all available field signals coming from the motors or transformers or other equipment in the
field.
7- QUALITY CONTROL
7-1- The complete Electrical Equipment Installation systems shall be checked and
tested as follows:
7-2- An advance written request / notice to inspect must be given by initiating and ob-
taining Request for Inspection (RFI) form in accordance with Inspection Test Plan
7-3- Confirm correct material sizes / type and other associated materials available that
would meet the requirement of the project specifications, codes and standards
7-4- All material shall be physically checked and inspected upon receipt at the site
prior to installation.
7-5- 7.4All inspections being conducted shall be recorded on approved forms, signed,
dated and approved by authorized Contractor and Owner representatives
7-6- Check if all materials are available to complete the testing process.
7-7- Ensure that qualified inspector with approved tools and equipment shall carry out
the testing processes.
7-8- Where physical damage or non-compliance with the specification had been found,
a Non Conformance Report (NCR) shall be issued.
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8- HSE CONTROL
8-1- All staff, supervisors and workers must abide to all safety and security regulations
on and off site.
8-2- Safety Officer on site will be implementing the strict adherence of the employees
with regards to the safety regulation as being mentioned in the drawn safety pro-
gram of the company.
8-3- Safety procedures will be monitored as per the specification of the Main Contrac-
tor and ensure the implementation as well.
8-4- Safety Officer on site will be directly dealing with the contractors HSE Officer for
the compliance of the procedure as provided and for any applicable revisions in-
volving HSE matters.
8-5- The company shall adhere with all the given standards agreed upon relating to
safety and security issues as the project commences and up to the completion.
See Attachment