EI-011 - e Reva Electrical Field Inspection and Testing

PETROX S.A.
REFINERÍA DE PETRÓLEO
Talcahuano, Chile
ENGINEERING STANDARD
EI - 011
ELECTRICAL
FIELD INSPECTION AND TESTING
Please discard any previous issue of this specification.
Register of Issues Number

Rev. Date By Pages Approval Remarks
A 30.11.98 P&A PREPARED FOR MTBE PROJECT
ENG. STD. No. : EI - 011
PETROX S.A. REFINERIA DE PETROLEO PAGE No. : 1
Talcahuano, Chile ISSUE No. : A
DATE : 30.11.98
ELECTRICAL
FIELD INSPECTION AND TESTING
TABLE OF CONTENTS
I SCOPE
II GENERAL INSTRUMENTS AND PROCEDURES
III GENERATORS AND MOTORS
IV TRANSFORMERS
V SWITCHGEAR, MOTOR CONTROL EQUIPMENT AND BUS DUCT
VI RELAY AND PROTECTIVE DEVICES
VII BATTERY AND BATTERY CHARGER
VIII EMERGENCY POWER
IX UNINTERRUPTIBLE POWER SYSTEMS
X WIRE AND CABLE
XI GROUNDING
XII LIGHTING
XIII WELDING RECEPTACLES
XIV ALARM SYSTEMS
XV INSTRUMENTATION
XVI HEAT TRACE SYSTEM
XVII MISCELLANEOUS ELECTRICAL EQUIPMENT
XVIII FIELD TEST REPORTS AND INSPECTOR’S CHECK – OFF LISTS
APPENDIX 1. FIELD EVALUATION, TESTING AND CALIBRATION OF INSTRUMENTS

APPENDIX 2. PRESSURE TESTING AT JOBSITE
DATE : 30.11.98
ELECTRICAL FIELD INSPECTION AND TESTING
I. SCOPE
A. This specification specifies Contractor’s general responsibilities and procedures for the testing
of electrical installations at the jobsite, prior to completely energizing an integrated electrical
system. Electrical testing at the jobsite will consist of two associated phases; the investigation
(test analysis) and the inspection (perceptual analysis). Test which are necessary to retain the
Manufacturer’s guarantee will be conducted in accordance with instructions from the electrical
equipment (material) manufacturer. In the absence of specific manufacturer’s instruction,
electrical field test will be limited to those hereinafter specified of the various materials and
equipment. The inspection will consist of the combined physical examinations for unusual
conditions of overheating, vibration, etc., mechanical and material defects prior to, during and
after the energizing of an electrical installation.
B. All electrical systems shall be checked and tested for proper operation prior to signing off as
being mechanically complete and ready to turn over to the client. Record deficiencies on Form
011-100. Check with the Vendor and/or the Client to determine what the Manufacturer’s
requirements are to maintain the equipment guarantee.
C. Contractor’s personnel should energizer electrical equipment only when required by project
specifications and with the Client’s permission.
D. Safety practices shall include, but not limited to, the following requirements:
1. Occupational Safety and Health Administration (OSHA).
2. Accident prevention Manual for Industrial Operations, national Safety Council, Chapter 4.
3. Applicable State and Local safety operating procedures.
4. NETA Safety / Accident Prevention Program.
5. Owner’s safety practices.
6. National Fire Protection Association - NFPA 70E
7. ANSI ZX244.1 American National Standard for personnel protection.
8. Clients safety rules.
E. Inspections and test shall include (where applicable), but not limited to, the following
equipment:
1. Switchgear - General
2. Transformers - Liquid Filled
DATE : 30.11.98
3. Transformers - Dry Type

4. Cables - Medium Voltage
5. Cables - Low Voltage
6. Metal Enclosed Bus Duct
7. Air Switches - High & Medium Voltage
8. Circuit Breakers - Medium Voltage - Air
9. Circuit Breakers - Medium Voltage - Oil
10. Circuit Breakers - Medium Voltage - Vacuum.
11. Circuit Breakers - Medium & High Voltage - SF6
12. Circuit Breakers - Low Voltage - Air
13. Circuit Breaker - Low Voltage - Molded Case
14. Engine Generator Sets
15. Lighting System - Normal & Emergency
16. Uninterruptible Power Systems
17. Heat Trace System
18. Protective Relays
19. Instrument Transformers
20. Metering and Instrumentation
21. Ground Fault Systems
22. Grounding Systems
23. Motor Control Centers
24. Rotating machinery
25. Automatic Transfer Switches
26. battery & Chargers Systems
27. Surge Arrestors
28. Outdoor Bus Structures
29. System Function Test
30. Welding and Power receptacles
31. Alarm Systems
32. Switchracks
33. Motor Starters
34. Contactors
35. Controllers
DATE : 30.11.98
II. GENERAL INSTRUMENTS AND PROCEDURES
A. In addition to normal testing equipment (voltmeters, ammeters, etc.) the following instruments
and procedures are required for the test hereinafter specified:
1. Short-time insulation resistance measurements shall be made with megohmmeter testers,

(Megger). Resistance measurements shall be recorded after 60 seconds of applied
voltage, preferably during dry tempered weather. Test voltages shall conform to the
following requirements:
a. Equipment rated for under 100 volts shall be tested using a 100 - volt. “Megger” with a
range to 20 megohms.
b. Equipment rated from 100 to 300 volts shall be tested using a 250 - volt “Megger” with a
range to 50 megohms.
c. Equipment rated from 301 to 100 volts shall be tested using a 1000 - volt “Megger” with
a range to 200 megohms.
d. Equipment rated from 1001 to 5000 volts shall be tested using a 2500 - volt “Megger”
with a range to 400 megohms and/or a Hi-Pot machine.
e. Equipment rated over 5001 volts shall be tested using a 5000 - volt “Megger” with a
range to 50,000 megohms and/or a Hi-Pot machine.
f. Hi-Pot machine shall be a Hipotronics, Inc. Model # H860PL with a range of 0-60 kV and
0-5 Milliamp (or approved equal).
g. A motor driven or AC Mains “Megger” is preferred for the minute or longer tests.
Note: “Megger” is a registered Trade mark of the Biddle Instrument Co.
B. Grounding connection resistance will be measured with portable low resistance “Megger”
ground testing equipment. Associated research Inc. Vibraground Tester, Biddle Instrument
Co. Earth resistance tester, or approved equal.
C. Temperature measurements shall be taken by a mercury thermometer or by a thermal-

sensitive resistor circuit.
D. When available, service personnel under contract of Contractor from local agencies shall
perform the following test:
1. Dielectric strength testing of insulating liquids.

2. Current leakage test on cable for services above 2001 volts or per specifications.
DATE : 30.11.98
3. Where local agencies are not available, the necessary test shall be performed by
Contractor personnel in accordance with this standard.
E. Prior to using testing and instrument devices, personnel shall be completely familiar with
applicable Manufacturer’s instructions.
F. Setting and calibrating of protective relays shall be performed by service personnel under
Contract to Contractor from a local agency capable of performing this function.
G. Major equipment items of a complex nature shall be checked, tested and commissioned
under supervision of the Vendor’s representative or as directed by the Client.
DATE : 30.11.98
III. GENERATORS AND MOTORS
A. Insulation Resistance
1. Alternating current synchronous and induction type machinery rated 10,000 HP and below,
shall be subjected to an insulation test prior to connecting the machine terminals to the
motor feeder. “Megger” reading not less than the following minimum values at a machine
temperature of 40°C shall be observed before energizing (one minute megger reading for
2300 V and above machines).
MINIMUM MEGOHM VALUES FOR MACHINES

10,000 HORSEPOWER & BELOW - CLASS A & B INSULATION
Volts: 110 440 550 2300 3000 4000

Megohms: 1.11 1.5 1.6 3.3 4.0 5.0
For all other voltages ratings, the minimum insulation resistance value shall be determined
from the following formula:
Rm = kV + 1
Where Rm =Recommended minimum insulation resistance in megohms at 40°C of the

entire machine winding,
kV = rated machine potential in kilovolts.
2. If the winding is not at a temperature of 40°C, the observed one minute resistance must be
reduced by multiplying the observed value by the temperature coefficient of insulation
resistance (Kt@40°C) found in the following table:
Winding Temp °C 0 5 10 15 20 25 30 35 40
Kt@40°C 0.065 0.9 0.13 0.19 0.25 0.36 0.50 0.70 1.0
3. The value of insulation resistance for low - voltage motors (up to 600 volts) may be
determined by a single measurement.
DATE : 30.11.98
4. The representative value of insulation resistance for medium - voltage motors (2300 to 4000
volts) shall be determined by the dielectric absorption ratio calculated from two megohmmeter
reading taken during the same test in accordance with the following requirements:
a. For motors rated 750 kW (1000 HP) or less, the representative value of insulation
resistance shall be the ratio of the 60 second reading to the 30 second.
b. For motors rated over 750 kW (1000 HP) the representative value of insulation resistance
shall be the 10 minute reading to the 1 minute reading (Polarization Index).
5 The minimum acceptable values area 1.25 for the 60 to 30 second ratio and 2.0 for the 10
to 1 minute ratio, provided the 30 second or 1 minute reading of the respective ratios equals
or exceeds the requirement of paragraph III.A.1 & 2 above.
6 Three-phase machines with only 3 leads brought out shall have insulation resistance
measured on T1 to ground with T2 and T3 in the clear.
a. Machines with more than one set of windings such as two-phase, dual voltage, two-
speed, Y - Delta Star and DC or there phase machines with all 6 leads brought out shall
have the insulation resistance of each windings measured separately. Check the
resistance of each winding to ground and to all other windings, correct value for
temperature and compare with the recommended minimum value of insulation
resistance. See Paragraph III. A.1 and above. See Form 011-101.
7. Motors in Storage
a. Motors and generators shall have a “Megger” readings taken as soon as practical after
they have been received on the jobsite.
b. Reading shall be recorded on Form 011-102. Larger medium voltage machines having
built-in space heaters shall have their heaters connected to a temporary source of power
while in storage or on their base the permanent source is completed.
c. A “Megger” reading shall be taken each month and recorded on Form 011-102 until
ready to commission, at which time a final reading shall be taken and record on Form
011-101.
d. Be sure a reliable source of power is provided for the heaters as periodic interruptions of
power to the heaters will do more harm than good.
e. If the corrected insulation resistance is below minimum value, the machine must be
dried out, as specified below.
f. It should be noted for machines in good condition, insulation resistance readings of 10
to 100 times the recommended minimum values are not uncommon.
DATE : 30.11.98
B. Drying Out Process
1. Machine windings shall be dried out by supplying heat from electric strip heater from
electric strip heaters, from heat lamps or by passing current through machine windings
until a sufficiently high, rising insulation resistance is obtained. When current is applied
through the windings, it shall not exceed the nameplate rating. The temperature
maintained during out process should not exceed the following.
a. Class A insulation
By a thermometer 80°C
By a resistance bridge or a thermal
sensitive resistor circuit (RDT) 90°C
b. Class B Insulation
By a thermometer 90°C
By a resistance bridge or a thermal
sensitive resistor circuit (RDT) 110°C
2. Drying out rotating machines by passing current through the winding method:
a. For machines with dual windings, connect leads for the higher voltage.
b. Take a temperature reading of the machine: Should be the same as ambient
temperature if machine has been de-energized for over two hours.
c. Take a “Megger” reading of T1 to ground with T2 and T3 in the clear and adjust
reading for temperature.
d. For motors up to 60 HP, use a single phase variable voltage transformer or rheostat.
For larger machines use a welding machine.
e. Set transformer to zero voltage.
f. Connect one lead to T1 and the other lead to both T2 and T3.
g. Energizer primary of transformer.
h. Check motor leader amperage with a clip on ammeter.
i. Raise voltage until current equals half the motor nameplate amperage.
DATE : 30.11.98
j. Disconnect and check “Megger” reading every hour until a good reading is obtained.
k. If “Megger” reading will not come up within 24 hours, there is probably a mechanical
problem with the winding.
l. If the machine is located where it is very cold and/or windy, build a tarpaulin tent over
machine to hold the heat.
3. To dry out machine with strip heaters or lamps

a. Build a tarpaulin tent over machine to hold the heat.
b. Install strip heaters or lamps inside tent, but be sure they don’t touch the tent.
c. Attach thermometer to machine.
d. Take a “Megger” reading of T1 to ground with T2 and T3 in the clear and adjust
reading for temperature.
e. Bring temperature in tent up to approximately 140°F.
f. Take “Megger” reading every hour until a good readings is obtained on all windings.
4. To dry machines with a drying oven:

a. Place machine inside oven.
b. bring temperature in oven up to approximately 140ºF.
c. Take a “Megger” reading every hour until a good reading is obtained on all winding.
5. The insulation resistance shall be periodically record during the drying out process. In
large high voltage machines the initial cold coil resistance value will be high (20
Megohms at 20°C). * As the drying process continues and water vapor is boiled out from
the internals of the machines, the insulation resistance will rapidly fall to a minimum (6
Megohms at 60°C). * As the drying process nears completion the insulation resistance
will reverse is downward trend and settle at a steady higher value (2 Megohms at 90°C).
* As the coils cool, after the drying process has been completed, the insulation
resistance will rapidly rise (150 Megohms at 20°C)*
∗ Values for comparative purposes only
6. A period of 24 hours will usually be found sufficient for drying machines rated 600 to 200
horsepower. Less time will be required for drying smaller machines. Windings which
have been exposed to moisture will take longer to dry out than machines which have
been properly stored.
DATE : 30.11.98
7. Usually the space heaters in medium voltages machines will dry out the winding in a few
weeks. If time permits, allow at least 30 days before other methods are used. If the
machines is stored in a very cold or windy location, it is advisable to cover with a
tarpaulin to conserve heat.
C. INSPECTION
1. Prior to energizing the machine, all foreign objects between the rotor and the stator field
coils should be removed. Brushes must move freely in their holders making a firm and
even contact with collector rings. Voltages and frequency. Belts for directly connected
exciters (auxiliaries) shall be in proper running condition. Bearings must be properly
filled with oil or grease. Machine shafts (rotors) shall be checked for alignment, shaft
end play and rotation before being coupled to other machinery. A final “Megger” test
shall be made from the starter on one phase to ground (record on From 011-101).
Note: Turn shaft by hand before bumping motor.
2. Drain plugs furnished on totally enclosed motors shall be removed and replaced with
approved electrical drain fittings.
3. Motor shall have a one hour (or as per Job Specification) uncoupled run-in test.
Generators shall have a one hour (or as per Job Specification) no load run-in test.
During the machine test run, inspect for smoke, unusual noises, vibration and
overheating. Operating conditions must be investigated and corrective action taken
when total temperature (ambient plus rise) exceeds the following values.
a. For Class a Insulation - 90°C.

b. For Class B insulation - 110°C.
c. For Class H Insulation - 150°C.
4. Maximum allowable vibration amplitude shall not exceed the following on rotating
machines:
DATE : 30.11.98
3600 RPM = 001” Peak - To - Peak

1200 RPM = 0025” Peak - To - Peak
DATE : 30.11.98
IV. TRANSFORMERS
A. Liquid dielectric test, filtering, repairs and drying of transformers shall be performed by a
qualified subcontractor such as G.E., Westinghouse, N.E.T.A. or approved equal. No
untanking or the major service or repairs shall be attempted by field personnel. Check
with transformer Manufacturer for recommendations.
B. All transformer windings (liquid filled & dry type) shall have theirs insulation resistance
tested:
1. Primary-to-Ground
2. Secondary-to-Ground.
3. Primary-to-Secondary.
4. See Form 011-103.
C. Sealed tank type transformers shipped assembled and filled with oil shall an oil sample
tested. For transformers shipped without oil, samples of oil shall be tested before filling
the transformer.
D. Test samples of liquid insulating immersed transformer winding rated for 150 kVA service
and above must undergo a dielectric strength test. The test sample must withstand the
following minimum voltage stress without an insulation breakdown when tested with a
standard testing device:
ASTM D 877 Method ASTM D 1816 Method

Oil 30 kV 22 kV
Silicon 30 kV 22 kV
R Temp Fluid 30 kV 26 kV
If the voltage causing a breakdown is less than the minimum value, the liquid must be
(dried) passed through a suitable filter press until the minimum voltage can be sustained.
E. ASTM D 877 method is generally suitable for testing service-aged liquid dielectric.
Dielectric strength is tested with a standard testing device consisting of a test cup,
instrument, control and high voltage power supply. The test cup internal shall support two
butted electrodes, separated by a 0.1” gap. Each electrode shall have a polished 1“
diameter circular disc parallel to the other electrode at the gap interface. Sixteen ounces of
liquid will be required for the test. After the electrode spacing has been checked with a
DATE : 30.11.98
standard round gage, having a diameter of 0.100”, the electrodes will be locked in position.
After a suitable rinsing procedure, the test cup will be immediately filled with the liquid
sample to be tested. The liquid should be at a temperature of 40°C. During the test the
uniform rate of voltages increase should be about 2,000 volts per second. One
breakdown should be made on each of 5 fillings the test cup. Any individual test
which deviates from average by more than 25% will be test recorded and replaced by an
additional test. An average of the first 5 test within the allowable deviation will be taken as
the dielectric strength of the liquid.
F. ASTM D 1816 method is similar to the method described above with the exception that it
prescribe the use of spherically capped electrodes, separated by a 0.40” (0.012 mm) gap.
It is primarily suitable for testing new oils.
G. Completed assembled, factory - sealed tank transformers shipped with an insulating liquid
successfully passing the preliminary dielectric strength test without filtering, may be put into
service after inspection if the cold coil insulation resistance between windings and between
windings and ground test is above 6 Megohms. In the event that the insulation resistance
value falls below 6 Megohms, the transformed oil must be dried.
H. Coil for factory sealed-tank-transformers shipped with an insulating liquid failing the
dielectric strength test (before filtering) and coil for tank type transformers shipped
separately without insulating liquid must undergo a short-time “Megger” test for insulation
resistance to ground and to other windings at a temperature in the 60 - 70°C range. The
insulation resistance must measure above one Megohms per thousand volts of rated line
voltage. Coils with insulation resistance values failing this requirement must be fried.
Note: Do not make “Megger” test while transformer is under vacuum (except freon filled
transformers) or without liquid over the windings and core.
I. Drying
1. In the event that drying is necessary, the transformed oil shall heated to approx. 60°C and
passed through a filter press until an acceptable oil breakdown level has been achieved.
2. If oil is to be added to the transformer in the field, it shall first be given a dielectric strength
test and after passing the test shall be passed through a filter press and heated to a
approx. 20°C (if required) before entering the transformer. See paragraph “L” below.
DATE : 30.11.98
J. The transformer tank and all fitting shall be inspected and tested for adequate sealing to
prevent leakage on insulation liquid, entrance of moisture an loss of inert gas protection
before the transformed is energized. During a leakage test the transformed tank shall not be
subjected to a pressure grater than the amount specified on the nameplate. If there is no
nameplate pressure specified, a test pressure of 5 psi (34474 N/m2) will be used. The liquid
dielectric will be slowly pumped into the sealed transformed or inert gas added until the
pressure reads 5 psi (34474 N/m2); Joint, connections and gaskets will be checked with
chalk dust to detect leaks. Any appreciable leakage will cause a pressure drop within a few
hours.
K. 1.Freon cooled transformers shall be inspected for damage in shipment. Compare the
Vendor’s temperature/pressure chart with the pressure-vacuum gage and the liquid level
gage for fluid/gas leaks. If the fluid level is low or if the negative pressure of the unloaded
transformer is higher than chart computes it should be, a leak is indicated. Fluid/gas leaks
will not be evidence by liquid stain because the fluid will immediately evaporate. See
vendor’s instruction sheet for details on leak detection. If fluid is low consult the vendor.
See paragraph “A” above.
2. No dielectric strength test are required if no gas leaks are indicated.
3. Check safety and alarm system the same as other liquid filled transformers.
L. The following precautions should be taken before placing the transformer in service:
1. Check liquid, level bushing and other externally connected or gasketed devices, such as
oil temperature and level gauges.
2. Check no-load tap changer to be sure it is in operating condition and at proper tap
setting.
3. If provided, check operation of temperature alarm and level alarm.
4. If provided, check operation of cooling fan and circuit, and fault pressure relay.
5. Check grounding of transformer.
6. Transformer shall be under a positive pressure except Freon filled transformers, see
vendor’s temperature/ pressure chart).
7. Bushing type CT’s (is furnished). Check all the CT’s secondary leads and terminal boxes
and remove all factory installed shorting jumpers on all connected CT’s. Perform current
DATE : 30.11.98
injection an excitation voltage check on all CT’s used for transformer differential
protection to verify this and CT’s ratios.
8. See Form 011-103 for test report and Form 011-114 and 011-115 for Inspector’s
Checkoff List.
DATE : 30.11.98
V. SWITCHGEAR, MOTOR CONTROL EQUIPMENT AND BUS DUCT
A. Before connecting cable leads to switchgear bus and motor control equipment terminals,
internal bus bars and connections shall undergo a short-time “Megger” test. “Megger”
test should be made preferably during dry, temperate weather.
1 The switchgear, bus duct, and motor control equipment must be dried before going into
service if the insulation resistance to ground falls bellow the following minimum values.
2 Test will consist of megohmmeter measurements between each phase and ground and
between phases.
600 volts 601 volts to Above

and below 15,000 volts 15,000 volts
3 megohms 50 megohms 200 megohms

(breakers in) (breakers out) (breakers out)
3. Hi-Pot test (if required) shall be on a go-no-go basis for one minute.
Equipment rated 5 kV : test at 20.2 kV DC

Equipment rated 15 kV : test at 37.5 kV DC
Equipment over 15 kV : Consult Manufacturer
Note: Do not Hi-Pot Test until megohm readings are within above minimum values noted in
Paragraph V.A.2.
4. Precautions required to obtain reliable insulation measurements will include disconnecting

lightning arrestor, capacitors, potential transformers and secondary ground connections on
currant transformers.
5. On completion of the wire and cable termination, a final insulation measurement using a
megohmmeter shall be obtained for the entire system. Preferably, the measurement should
be obtained just prior to the equipment being energized or, where applicable, prior to being
turned over to the Client as being mechanically complete.
Note: Do not include any solid - state relays in “Megger” tests.

DATE : 30.11.98
B. Oil - immersed contractors or circuit breakers must undergo a dielectric strength test (see
Section IV C, D & E).
C. Vacuum contractors or circuit breakers; test strictly in accordance with Manufacturer’s

instructions.
D. SF, circuit breakers; test strictly in accordance with Manufacturer’s instructions.
E. Prior to energizing the switchgear bus, the following items shall be inspected and tested for
proper operation. (Note: Contractor personnel should energize electrical equipment only when
required by project Specification and with the Client’s permission)
1. Control, protective and metering circuits.

2. Contact alignment on contractors and circuit breakers.
3. Setting and calibrating overcurrent relays as hereinafter described where his is a part of
Contractor responsibility.
4. Shorting bars must be removed from connected CT’s and at all terminal connections
throughout the system.
5. Inspect overland heaters and fuses for proper size.
6. Key interlock system must be operable.
7. Tanks for oil circuit breakers must be filled before test being. Place the circuit breakers in
its “Test Position”, (Use a plug jumper where necessary) and make the following test:
a. Close and trip the breakers with its control switch.

b. Manually trip the breakers by operating protective devices.
c. Close and trip the breakers from all remote control positions.
8. Check operation of space heaters.

9. Where the swithchgear is arranged a secondary selective system with automatic transfer
scheme, the transfer circuit shall be tested by simulated fault and undervoltage conditions.
10. Cable shield drain leads must pass through ground fault CT’s ground.
11. Operate other auxiliary devices.
12. Equipment must be properly grounded.
13. Bolted bus joint, terminals and other connections for each separate equipment installation
shall be checked for tightness in accordance with Manufacturer’s recommended torque
values.
DATE : 30.11.98
14. See From 011-104 for test report and Forms 011-116, 117, 119 and 120 for Inspector’s
Checkoff Lists.
DATE : 30.11.98
VI. RELAY AND PROTECTIVE DEVICES
A. Relay settings and coordination curves shall be furnished to field personnel by

Contractor Engineering Office.
1. Relays will be set in accordance with the relay tabulations furnished.

2. Relays with time characteristics shall be tested at 2 point on the time coordination
curves to verify conformance with the Manufacturer’s data.
3. Protective relay settings and adjustment shall be made in accordance with
Manufacturer’s applicable instruction booklets.
4. Circuit protective device that have adjustable setting, such as molded case circuit
breakers, shall be set in accordance with the system coordination requirements.
5. Heaters elements of thermal overload relays used for motor protection shall be
individually checked to ensure the proper element has been selected, installed and
set for the motor nameplate full-load current. Where fuses are used, their ampere
rating and NEMA class shall be checked for conformance with design requirements.
6. Other devices having variable timing characteristics, such as time-delay relays used
in the automatic restart of motor drivers, shall be set and tested in accordance with
the intended control function.
Note: Do not include solid-state relays in any insulation resistance tests.
B. Relays and protective devices shall be calibrated by a qualified subcontractor such as

G.E., Westinghouse or be approved, if it is within Contractor’s scope of responsibility, by
the Client. See Form 011-105 for field test report and From 011-116, Inspector’s
Checkoff List.
DATE : 30.11.98
VII. BATTERY AND BATTERY CHARGER
A. The following precautions should be taken before placing the battery in service
(CAUTION, Type of battery should be checked in advance: Lead-Acid or NI-CAD).
1. Check the battery cells for cracked jars, proper level of electrolyte, and for specific
gravity of electrolyte by using a hydrometer. (Do not use hydrometer if is a NI-CARD
Battery).
2. Check the cell connections and wiring for continuity and polarity.
3. Check protective devices for proper rating.
4. Check the battery output voltage.
5. Protect batteries during construction from mechanical damage.
B. Before energizing the battery charger, the battery should be connected across the
output terminal in such a manner that the positive battery terminal is connected to the
positive terminal of the chargers,. If the polarity of the battery terminals has been lost a
cable run, a polarity check can be made by opening the AC supply switch to the charger
and connecting the battery leads to the output terminals of the charger. Observe the
deflection of the voltmeter on the battery charger. If it reads on scale, the battery is
connected correctly to the output terminals. If the voltmeter reads off scale, reverse the
battery leads at the charger output terminals.
C. See Form 011-106 for field test report and Form 011-121 for Inspector’s Checkoff List.
DATE : 30.11.98
VIII. EMERGENCY POWER
A. Emergency generation facilities shall be checked for automatic starting, generations and
power transfer during a simulated loss of voltage. A field erection engineer from the
Manufacturer shall supervise all tests and startup, and provide Contractor with a full
report.
1. As a minimum, the unit shall be tested to determine that:
a. It is free from defects.

b. It will start automatically on voltage failure of any phase.
c. It will automatically transfers load after rated line voltage has been reached.
d. Safety shut down devices such as low oil pressure, high water temperature, over
speed & over crank are functional.
e. Unit will carry 100% of rated load (or as per Job Specifications) at rated voltages
and frequency and without stalling.
f. Alarm devices are functional.
g. Automatic transfer switch features such as the exerciser, cool down cycle timer,
transfer delay, retransfer delay etc. are functional.
2. A completed set of instruction and maintenance booklets are to be furnished to the

client.
3. An inspection shall be made to determine that unit complies with Job specifications
and Material Requisitions in all details.
DATE : 30.11.98
IX. UNINTERRUPTIBLE POWER SYSTEMS
A. The uninterruptible power supply systems shall be checked and tested for proper
operation and compliance with Job Specification and Purchase Requisition. The
following test and commissioning of equipment shall be supervised by an authorized
Manufacturer’s representative and a full report shall be submitted to Contractor.
1. Short Circuit Test - Under no load conditions, impose a bolted fault at the
distribution panel branch fuse. Record response of UPS on unfaulted circuit. Re-Do
test under partial load conditions.
2. Loss of a-c Power - Trip input breaker to battery charger and record inverted output
waveform.
3. Manual Transfer - Record waveform when manual switching from inverted to by-
pass and back.
4. Inverted Fault Clearing - Re-Do test “1” but open by-pass circuit and record
waveform as inverted attempts to clear fault. It is expected that 15 amp. fuses shall
clear without necessitating collapse.
5. Full load Test - Charge batteries to full extent. Remove a-c source to charger, and
remove a-c normal by-pass source. Using a dummy load capable of drawing 125
percent of the rated capacity in the material requisition. Record inverted output
voltage at start of the test and at completion. Verify that results are within
specifications.
DATE : 30.11.98
X. WIRE AND CABLE
A. Before being connected to equipment, installed wire and cable having all spices,
potheads, stress cones, and metallic insulation shielding completed, shall be checked in
accordance with the following requirements:
1. Test for continuity conductors and, where applicable, continuity of metallic insulation
shielding to group.
2. Test insulation resistance of low voltage and unshielded medium voltage wire and
cable using a megohmmeter according to the table in Paragraph X.C.
Measurements shall be made between phases and between each phase conductor
and group.
3. Test insulation resistance of metal-clad, metal-sheathed and shielded medium
voltage wire and cable using a megohmmeter according to the in Paragraph X.C.
Tests on metal-clad and metal-sheathed cable having no metallic insulation
shielding shall be made between each phase and metallic covering and between
phases. Test on wire and cable metallic insulation shielding for that conductor.
4. Check cable bending radius against manufacturer’s minimum.
5. Cable shall visually inspected on the reels when received at the jobsite. Where
damage to metal-clad or shielded cable is suspected, preliminary insulation tests
shall be performed to determine if cable is satisfactory before cable is installed.
B In addition, cables rated 5000 V & above shall be tested for current leakage using a
suitable DC high potential testing set. This test should be performed by a qualified
subcontractor, if available. If performed by Contractor field personnel, the operator must be
completed familiar with the operation of the equipment be used, test procedures and all
safety requirement involved with this test, and the Client’s safety rules. He shall have
available sufficient protective barriers and warning signs to conduct the specified test
safely.
Note: Hi pot test shall not be made unless cables pass a “megger” test as per paragraph
C below.
1. Test results shall be recommended on the “DC High Potential report”, From N° 011-
107. The cable shall gradually stressed to minimize harmful surge currents. Medium
voltages cables must be capable of withstanding the following stresses:
DC MAXIMUM TEST VOLTAGE *

DATE : 30.11.98
Rated Ac RMS Conductor 100% Insulation Level 133% Insulation Level

Voltage Of Cable Size. AWG/kcmil (Grounded Neutral) (Ungrounded Neutral)
5,000 V 8-1000 25 kV 25 kV
8,000 V 6-1000 35 kV 35 kV
15,000 V 2-1000 55 kV 65 kV
25,000 V 1-1000 80 kV 95 kV
28,000 V 1-1000 85 kV 100 kV
35,000 V 1/0-1000 100 kV 125 kV
∗ These values are approximately 80% of factory test values and are to be used
for initial installations only.
The above shall apply to the following insulation: Rubber type (EPR), Thermoplastic
(XLPE); all with insulation shield.
2. The following procedures apply for this testing:

a. Ensure that the maximum test voltage does not exceed the limits for terminators
specifies in IEEE standard 48 or manufacture’s specifications.
b. Apply DC test voltages slowly at fixed increments go voltage between zero and
maximum field test value. Generally a minimum of five and a maximum of ten
voltages increments are acceptable depending upon the voltage class of the
cable.
The voltage et each test increment shall be sustained for a minimum of one
minute or until the leakage current stabilizes, before reading the leakage current
and recording the value on the “DC High Potential Report” (Form No. 011-107).
After the test voltage has been reached, the current readings should show a
decreasing amount of current with time until a fairly steady current flows toward
the end of the test time. If the current begins to increase during this time, the
cable will be considered inadequate and must be corrected or replaced.
c. It is very important that the input voltage to the Hi-Pot Machine be steady or
fluctuations in current reading will be observed. Protect ends of cable under test
from wind, which will cause erratic readings. Protects cable under test from
corona with a corona shield for more accurate readings.
DATE : 30.11.98
d. The shape of the observed leakage current curve is most important. Current
values will vary widely from cable to cable due to size, type, number of splices
and terminations and length of cable as well as weather and conditions. There
is no industry standard for acceptable values. Different leakage current values
at different time intervals on the same cable my be observed due to
temperature changes and other influences.
e. If the test must be interrupted for any reason before the required test interval is
complete, the cable shall be grounded for an interval at least equal to that time
voltage was applied to the cable, before a new test can be started.
f. After completing the test, the cable shall be grounded for a time intervals at
least equal to the amount of time voltage was applied was before the cable can
be considered safe.
g. Observe all safety procedures to assure the protection of the operator and
other personnel in the vicinity of the test. As a minimum, the operator, shall
wear 15 kV rubber gloves when handling grounding probes and cables after
test. Both the test area and the area at the other end of the cable shall be
barricaded off in a suitable manner. A guard shall be posted if the other end is
out of sight if the operator. All conductors in the cable shall be grounded except
the one of the test. No more than one test shall be performed at a time on
cables that terminate in the same room without extraordinary precautions being
taken. First aid equipment. Remove rings, watches, etc. Never leave energized
equipment unattended, even momentarily.
C. Insulation resistance test for cables rated above 300 volts shall the following minimum
acceptable values when performed with the megger instruments specified in II.A.1
above.
Cable rated Test Ins. Resistance

Voltage Duration Megohms.
600 1 min. 2.0
5000 1 min. 6.0
15000 1 min. 16.00
Unless called for by Job Specification temperature correction of the IR values

observed will not de required, but the temperature at which the test were conducted
should be recorded for future information.
DATE : 30.11.98
D. See Forms 011-108 and 011-109 for fields test report.

DATE : 30.11.98
XI. GROUNDING
A. The ground system shall be checked with a suitable ground “megger” (See Paragraph
II.B. above) after the grounding network is complete. Check resistance from each
ground rod, ground bus, vessel, etc., and equipment ground point to a know value
reference point such as the fire water piping system (two point method). Note: The
instrument leaders are in the test, so their resistance may be subtracted from the
reading.
1. In process areas, resistance point shall not exceed 5 Ohms (or per Job
Specifications).
2. The grounding network resistance around a powerhouse or substation shall not
exceed 1 ohm (or as per Job Specifications).
3. The grounding network for a computer shall not exceed 1 ohm (or as per Job
Specifications).
4. Grounding electrodes for lighting protection shall not exceed 5 ohm (or as per Job
Specifications).
B. For off-site remote equipment with ground rods not connected to grounding network,
the resistance to ground shall not exceed 25 ohm by the three earth test method. See
“Megger” operators manual.
Note: If any of the above readings exceed a ground electrode under test electrodes, if
electrode under test is connected to energized equipment with a fault. Use 15 kV
rubber gloves when testing electrodes in service.
C. Safety
1 A lethal potential can exist between a ground electrode under test and test
electrodes, if electrode under test is connected to energized equipment with a fault.
Use 15 kV rubber gloves when testing electrodes in service.
2. Care should be used not to test a ground point if a welding machine is using the
ground grid for a return, as it might destroy the test instrument.
D. Record test result on From 011-111.

XII. LIGHTING
DATE : 30.11.98
A. Panels, fixtures, receptacles, switches, etc., shall comply with are classification.
Illumination levels shall be as per Job Specifications. Drains, breathers, seals, etc.
shall be installed as required.
B. See Form 011-122 for Inspector’s Checkoff List. Record any deviations on Form 011-
100 (Electrical Punchlist).
XIII. WELDING RECEPTACLES
A. Welding receptacles shall be the size and type required in Job Specifications and
installed as shown on the plan drawings, and comply with the area classifications.
B. See Form 011-123 for Inspector’s Checkoff List. Record any deviations on Form 011-
100 (Electrical Punch List).
XIV. ALARM SYSTEM
System and circuits shall be individually checked by manually operating the initiating
device for each alarm conditions and the results recorded on Form 011-112.
XV. INSTRUMENTATION
A. Loops shall be tested as shown in Engineering Standard IE-011 Appendix 1 and 2 for
Grounds, Grounding, Continuity, Polarity and proper terminations.
B. Checking and testing shall be performed by the above ground electrical contractor if
within his scope of work, otherwise by the instrumentation contractor.
C. Record all “Megger” readings on Form 011-110.
XVI. HEAT TRACE SYSTEM
A. Each cable shall be inspected and tested when received on the jobsite, carefully stored
and retested after installation along with all thermostats, relays or the auxiliary devices.
Record results on Form. 011-113.
XVII. MISCELLANEOUS ELECTRICAL EQUIPMENT.

DATE : 30.11.98
A. Electrical equipment not specifically mentioned above shall be inspected and tested for
compliance with Job Specifications & Area classification.
B. Check for correct operation and system functions as well as proper grounding and other
safety requirements.
C. Record any deficiencies on Form 011-100, Electrical Punch List records.
DATE : 30.11.98
XVIII. FIELD TEST REPORTS AND INSPECTOR’S CHECK-OFF LIST.
Form No. Description

011-100 Field Test Report - Electrical Punch List Record
011-101 Field Test Report - Generators and Motors
011-102 Field Test Report - Generators and Motors in Storage
011-103 Field Test Report - Transformers.
011-104 Field Test Report - Switchgear and MCC
011-105 Field Test Report - Instrument & Relays Calibration
011-106 Field Test Report - Battery and Charger
011-107 Field Test Report - DC High Potential report
011-108 Field Test Report - Megger Reading - Power Cable
011-109 Field Test Report - Megger Reading - Control Wire And Cable.
011-110 Field Test Report - Megger Reading - Instrument Wire and Cable
011-111 Field Test Report - Ground Bus and Ground Rods.
011-112 Field Test Report - Alarm Annunciator
011-113 Field Test Report - Electric Heat Tracing
011-114 Inspection’s Check - off List - Dry Type Transformer

011-115 Inspection’s Check - off List - Oil - Immersed Transformed (2 pages).
Form No. Description

011-116 Inspector’s Check - off List - Switchgear
011-117 Inspector’s Check - off List - 480 Volt Switchgear
011-118 Inspector’s Check - off List - Motor Control Center.
011-119 Inspector’s Check - off List - Draw - Out Air Circuit Breakers, Oil Draw -
Out Circuit Breakers, and Vacuum - Breakers.
011-120 Inspector’s Check - off List - Bus Duct - Metal Enclosed
011-121 Inspector’s Check - off List - Battery and battery Charger
011-122 Inspector’s Check - off List - Lighting & Receptacle Panel
011-123 Inspector’s Check - off List - Welding Receptacle.
011-124 U-S- Standard - Bolt Torques for Bus Connections.

FORM No. : 011-100
PETROX S.A. REFINERIA DE PETROLEO ISSUE No. : A
Talcahuano, Chile DATE : 30.11.98
FIELD TEST REPORT - ELECTRICAL PUNCH LIST RECORD
Partial Final
Items Identification And Remarks Date Supervisors.

Number Location Corrected Approval
DISTRIBUTION: By:____________
FORM No. : 011-101
FIELD TEST REPORT - GENERATORS AND MOTORS
DATE: _________________
TEST BY: _______________
WITNESSED BY: __________ EQUIPMENT No.: _____________
OPERATING VOLTAGE: HP/kW: Hz: RPN: PHASE:

FRAME No.: F.L:AMP: Ins. Class: MFG:
(AFTER DRY-OUT REQUIRED) FINAL INSULATION RESISTANCE IN MEGOHMS WINDINGS
CONNECTED
WINDING A-G 1-2 1-3 1-4 2-3 2-4 3-4 TI-G
NUMBER
1 - - -
2 - - - -
3 - - - - -
4 - - - - - -
EQUIPMENT RUN - IN (SEE NOTES) RESULTS
Rotation Check - bump Motor uncoupled to Verify
No Load current - At Beginning of Test/At end of test - In Amps.
Bearing Temperature - At 0.5 Hr./At 4 Hrs.
Vibration - record unusual Vibrations under Comments.
Noise - Investigate and Correct - record Under Comments
* Brushes - Setting Correctly - Free Movement
Bearings - Properly Lubricated
* Drain Plugs Installed
Equipment Temperature - Check for Excessive rise
Motor Control - Check Operations Before Bumping
Grounding - Check for Proper Grounding Before Bumping.
Comments: * If Applicable DISTRIBUTION
Notes: (1) See I.C & I.D For Restrictions

(2) See II.A For Megger Voltage And III For Instructions.
FORM No. : 011-102
FIELD TEST REPORT - GENERATORS AND MOTORS IN STORAGE
DATE: _________________
TEST BY: _______________
WITNESSED BY: __________
EQUIPMENT No. HEATER HEATER AMPS MEGOHMS COMMENTS

VOLTAGE T1 TO GND
Note: See II.A For Megger Voltage And III.7 For Instructions.
DISTRIBUTION: BY: __________
FORM No. : 011-103
FIELD TEST REPORT - TRANSFORMERS
DATE: _________________
TEST BY: _______________
WITNESSED BY: __________ TRANSFORMER No. _____________
RESULTS
PRIMARY VOLTAGE/ Hz.
SECONDARY VOLTAGE/ IMPEDANCE
KVA / NUMBER OF PHASES
TYPE OF LIQUID COOLANT (OR DRY TYPE)
* INSULATION BREAKDOWN VOLTAGE OF LIQUID
MEGOHMS FROM PRIMARY WINDINGS TO GROUND
MEGOHMS FROM SECONDARY WINDINGS TO GROUND
MEGOHMS FROM PRIMARY WINDINGS TO SECONDARY WINDINGS
* LIQUID LEVEL CHECK
* TAP CHANGER CHECK
GROUNDING CHECK
* SAFETY EQUIPMENT OPERATIONS CHECK
MAKE OF TRANSFORMER AND MODEL NUMBER
COMMENTS: * IF APPLICABLE DISTRIBUTION
Notes: (1) See Forms 011-114 & 011-115 For Inspectors Check - off List.
(2) See II.A For Megger Voltage And IV For Instructions.
FORM No. : 011-104
FIELD TEST REPORT - SWITCHGEAR AND MCC
DATE: _________________
TEST BY: _______________
WITNESSED BY: __________ EQUIPMENT No. _____________
RESULTS
RATED VOLTAGE
CONTROL, PROTECTIVE AND METERING CIRCUITS CHECKED
CONTACT ALIGNMENT ON ALL CONTACTORS AND CIRCUIT BREAKERS
CHECKED
SETTING AND CALIBRATIONS OF RELAYS CHECK
CIRCUIT BREAKERS OPERATION AND RATING CHECK
AUTOMATIC TRANSFERS OPERATION CHECK (*)
AUXILIARY DEVICE OPERATION CHECK
BUS JOINT BOLT AND INSULATION CHECK
C.T. RATIO AND SHORTING BAR CHECK
P.T. RATIO AND OPERATION CHECK
GROUND BUS CHECK - MUST BE PROPERLY GROUNDED TO NETWORK
PHASE ROTATION CHECK
BRAND AND MODEL OF EQUIPMENT
BUS BAR MEGGER OR HI POT (IF REQUIRED) TEST
A-G B-G C-G A-B A-C B-C
COMMENTS: (*) IF APPLICABLE DISTRIBUTION
NOTES: (1) SEE FORMS 011-116, 117, 118, 119 & 120 FOR INSPECTORS CHECK - OFF LIST.
(2) SEE II.A FOR MEGGER VOLTAGE AND V FOR INSTRUCTIONS.
FORM No. : 011-105
FIELD TEST REPORT - INSTRUMENT & RELAY CALIBRATION
DEVICE No.: ____________
DEVICE SYMBOL:
SERVICE:
MANUFACTURER:
MODEL OR STYLE N°:
CHARACTERISTIC:
TAP RANGE:
INSTRUMENT RANGE:
MANUFACTURER’S INSTRUMENTATION BOOK Nº:
C.T. OR P.T. RATIO:
OVERCURRENT RELAY SETTING (*): TAP: TIME DIAL: INST.:
RELAY RANGE FOR OTHER THAN O/C RELAYS:
RELAY SETTINGS FOR OTHER THAN O/C RELAYS:
COORDINATION CURVE:
REFERENCE ONE - LINE DIAGRAM:
SUBSTATION NAME / NUMBER:
SWITCHGEAR N° & MANUFACTURER:
SWITCHGEAR OPERATING VOLTAGE:
PLAN NAME:
COMMENT: (*) AS LEFT SETTINGS
NOTES:
1. ALL TIMES IN SECONDS
2. RELAY SETTING TO BE SUPPLIED BY FW.
ELECTRICAL ENGINEERING DEPARTMENT.
BY: ______________
DATE: ____________
DISTRIBUTION:
FORM No. : 011-106
FIELD TEST REPORT - BATTERY AND CHARGER
DATE: _________________
TEST BY: _______________
BATTERY No.: ___________ CHARGER No.: ______________ RESULTS

A.C. INPUT VOLTAGE OF CHARGER
D.C. OUTPUT VOLTAGE OF BATTERY
ELECTROLYTE LEVEL CHECK (*)
AVERAGE SPECIFIC GRAVITY OF ELECTROLYTE (*)
POLARITY CHECK - CHARGER
WIRING CHECK
PROTECTIVE DEVICES CHECK - CHARGER
NUMBER OF CELLS IN BATTERY
AMPER - HOURS OF BATTERY
KILOWATTS OF CHARGER
MAKE OF BATTERY AND TYPE
MAKE OF CHARGER AN MODEL NUMBER
NOTE: (1) SEE VII FOR INSTRUCTIONS AND FORM 011-121 FOR CHECK - OFF LIST
FORM No. : 011-107
FIELD TEST REPORT - DC HIGH POTENTIAL REPORT
DATE: _________________
TEST BY: _______________
CURRENT AT TEST
VOLTAGE IN MICROAMPS
TIME ∅A ∅B ∅C
CUSTOMER: ____________________ REACHED TEST
LOCATION: _____________________ VOLTAGE
PLANT: ________________________
CABLE 15 SEC
30 SEC
CABLE Nº: ______________________ 45 SEC
FROM: _________________________ 1 MIN
TO: ____________________________ 1.5 MIN
LENGTH: _______________ FT. ____ 2 MIN
CABLE DESCRIPTION: ____________ 3 MIN
MANUFACTURER: ________________ 4 MIN
INSULATION TYPE: _______________ 5 MIN
SHIELDED: ______________________ 6 MIN
CONDUCTOR SIZE: _______________ 7 MIN
1-3/C: _________ 3-1/C: ___________ 8 MIN
NUMBER OF SPLICES: ____________ 9 MIN
RATED VOLTAGE: _______________ KV 10 MIN
OPERATING VOLTAGE: __________ KV 11 MIN
RATED TEMPERATURE: __________ °C 12 MIN
TEST 13 MIN
TEST EQUIP. USED: _______________ 14 MIN
TEST DC. VOLTAGE: ______________ KV 15 MIN
TEMP. AT TEST: __________________ °C
HUMIDITY: _______________________ %
COMMENTS: ____________________________
FORM No. : 011-108
FIELD TEST REPORT - MEGGER READINGS POWER CABLE
DATE: _________________
TEST BY: _______________
CIRCUIT N° A-G B-G C-G A-B A-C B-C CABLE RATED WITNESSED
SIZE VOLTAGE BY
NOTE: SEE II.A FORM MEGGER VOLTAGE

DISTRIBUTION: By: ____________
FORM No. : 011-109
FIELD TEST REPORT - MEGGER READINGS CONTROL WIRE AND CABLE
DATE: _________________
TEST BY: _______________
WIRE OR CABLE
CIRCUIT N° WIRE VOLTAGE NUMBER SIZE FROM TO MEGOHMS WITNESSED
TAGGING BY
NOTE: SEE X.D FOR INSTRUCTIONS AND II.A FOR MEGGER VOLTAGE
DISTRIBUTION: BY: ____________
FORM No. : 011-110
FIELD TEST REPORT - MEGGER READINGS INSTRUMENT WIRE AND CABLE
DATE: _________________
TEST BY: _______________
WITNESSED BY: _________
DESCRIPTION: _________________________________
NOTES: (1) RECORD ONLY THE LOWEST VALUE AND INDICATE THE PAIR NUMBER
(2) MP - MULTI - PAIR CABLE. SP - SINGLE PAIR CABLE
(3) MEGGER WITH INSTRUMENTS DISCONNECTED.
(4) USE 100 V DC MEGGER.
CABLE INDICATE MP CONDUCTOR CONDUCTOR CONDUCTOR TO SHIELD TO OVERALL SHIELD TO
NUMBER OR OR SP TYPE TO CONDUIT TO SHIELD SHIELD MΩ SHIELD TO CONDUIT
INSTRUMENT (SINGLE PAIR CONDUCTOR MΩ (MULTIPLIER LEAD AND MΩ
NUMBER NON-SHIELDED MΩ CABLES ONLY) ARMOR (Single pair
CABLES) MΩ cables
MΩ NOTE 1 (MULTIPLIER only)
NOTE 2 NOTE 1 NOTE 1 CABLES ONLY)
DISTRIBUTION: BY: ________________

FORM No. : 011-111
FIELD TEST REPORT - GROUND BUS AND GROUND RODS
DATE: _________________
TEST BY: _______________
POINT Nº OR OHMS WEATHER COMMENTS WITNESSED BY

EQUIPMENT Nº
NOTE: SEE X FOR INSTRUCTIONS

DISTRIBUTION: BY ___________
FORM No. : 011-112
FIELD TEST REPORT - ALARM ANNUNCIATOR
DATE: _________________
TEST BY: _______________
DESCRIPTION: ___________________ TAG Nº: ___________________

ALARM ALARM CONTACT NAMEPLATE ALARM OUTPUT CONTACT INSTALLATION
ANNUNCIATOR IDENTIFICATION INSCRIPTION FUNCTION TO POWER APPROVAL
SYSTEM NUMBER CHECKED PER SPEC. CORRECT CONTROL HOUSE (INITIAL AND
CHECKED DATE)
DISTRIBUTION: BY: _____________

FORM No. : 011-113
FIELD TEST REPORT - ELECTRIC HEAT TRACING
DATE: _________________
TEST BY: _______________
Heater Cable No.: _______________
TYPE LENGTH RESISTANCE DESING DESING DESING DATE MAKE OF

VOLTAGE AMPERES WATTS RECEIVED CABLE
DATE RESULTS
INSULATION RESISTANCE IN MEGOHMS AS RECEIVED
CONTINUITY OF CABLE - RESISTANCE IN OHMS - DATE RECEIVED
INSULATION RESISTANCE IN MEGOHMS ON INSTALLATION
COMPLETION (PRIOR TO THERMAL INSULATION)
CONTINUITY CHECK ON INSTALLATION COMPLETION
INSULATION RESISTANCE IN MEGOHMS AT FINAL CHECK (AFTER
INSTALLATION OF THERMAL INSULATION, BUT BEFORE
ENERGIZING THE HEATING CIRCUIT).
APPLIED VOLTAGE
AMPERAGE
THERMOSTAT - TEMPERATURE ACTUATION CHECK (*)
TRANSFORMER CHECK (*)
CHECK CABLE FOR COMPLIANCE WITH SYSTEM DESIGN, REPORT
ANY DEVIATIONS UNDER COMMENTS
NOTED: CHECK INSULATION WITH A 500 V.D.C. MEGGER

FORM No. : 011-114
FIELD TEST REPORT - DRY TYPE TRANSFORMER
1. INSPECT ASSEMBLY FOR DAMAGE AND MISSING PARTS.

2. NAMEPLATE CHECKED AGAINST PURCHASE SPECIFICATIONS AND LATEST SINGLE LINE
DIAGRAM.
3. ENCLOSURE APPROVED FOR AREA CLASSIFICATION.
4. CORRECT CONDUIT CONNECTIONS. CHECK LUG AND BUS CONNECTIONS FOR TIGHTNESS.
5. CHECK CONDUCTOR SIZE AND TYPE.
6. CHECK CONDUCTOR PHASING AND IDENTIFICATION.
7. PRIMARY AND SECONDARY LEADS CONNECTED FOR REQUIRED VOLTAGE LEVEL.
8. GROUNDING CHECKED.
9. NEUTRAL WIRE CHECKED FOR PROPER GROUNDING (IF REQUIRED).
10. SPARE CONDUCTORS (PIGTAILS) PROPERLY INSULATED (*).
11. CHECK VIBRATION PADS (*).
12.MEGGER TRANSFORMER AND RECORD ON FIELD TEST REPORT - FOR 011-103
13.CHECK PHASE ROTATION X1, X2, & X3, SHOULD BE A, B, AND C.
14. CHECK PRIMARY AND SECONDARY OVERLOAD PROTECTION.
(*) IF APPLICABLE
NOTES:
1. SEE II.A FOR MEGGER VOLTAGE BY: ______________

2. RECORD FINDINGS AND COMMENTS ON FIELD TEST REPORT FORM 011-103
DATE: _____________
FORM No. : 011-115
INSPECTOR'S CHECK-OFF LIST. OIL-IMMERSED TRANSFORMER (Page 1)
1. CHECK COMPLETE ASSEMBLY FOR DAMAGE AND MISSING PARTS. TEMPORARY SHIPPING
BLOCK AND PROTECTIVE CRATING REMOVED.
2. VISUALLY INSPECT FOR CLEANLINESS, NO CHIPS, CRACKS OR OTHER APPARENT DAMAGE
TO BUSHINGS.
3. CHECK LUBRICATIONS AND FREEDOM OF ROTATION OF COOLING FANS AND PUMPS (*).
4. CHECK LUBRICATIONS AND FREEDOM OF MOTION OF TAP CHANGERS AND OTHER
OPERATING ACCESSORIES.
5. RECORD TRANSFORMER TAP SETTING (SET AT MID - TAP UNLESS OTHERWISE INDICATED
IN ENGINEERING DOCUMENTS).
6. CHECK OIL LEVEL GAUGE AND INSPECT FOR OIL LEAKAGE.
7. DETERMINE DIELECTRIC STRENGTH OF INSULATING OIL AND RECORD ON FIELD TEST
REPORT - FORM 011-103.
8. CHECK SUDDEN PRESSURE RELAY AND RELIEF DEVICE.
9. ALARM AND CONTROL CIRCUITS CONNECTED AND COMPLETE (*).
10. CHECK INERT GAS PRESSURE GAUGE (SHOULD BE 2 LBS +, EXCEPT FREON COOLED).
11. CHECK TEMPERATURE GAUGE INDICATES TEMPERATURE PROPERLY.
12. PRIMARY / SECONDARY CABLES PROPERLY SUPPORTED, CONNECTED AND INSULATED.
13. CHECK TRANSFORMER NAMEPLATE AGAINST PURCHASE SPECIFICATIONS AND LATEST
SINGLE LINE DIAGRAM.
14.INSPECT FUSES AND CUTOUTS (*).
15. CHECK CONDUIT CONNECTIONS.
16. CHECK CONDUCTOR SIZE, INSULATION CLASS AND TYPE.
17. CHECK CONDUCTORS PHASING AND IDENTIFICATION.
18. MEASURE INSULATION RESISTANCE OF THE WINDINGS AND RECORD READINGS ON FIELD
TEST REPORT - FORM 011-103.
19. CASE GROUNDING (AND GROUNDING RESISTOR IF APPLICABLE) CORRECTLY INSTALLED
AND CONNECTED PER DRAWINGS.
20. LOCATION COORDINATES AND ORIENTATION PER DRAWINGS.
21. CHECK KVA RATING AGAINST ONE LINE DIAGRAM.
22. CHECK CORRECT OPERATION OF CONTROL SYSTEM FOR FANS AND PUMPS (*).
23. CHECK CORRECT ROTATION OF COOLING FANS (*).
FORM No. : 011-115
INSPECTOR'S CHECK-OFF LIST. OIL-IMMERSED TRANSFORMER (Page 2)
24. CHECK ALL CONNECTIONS ARE TIGHT AND SECURE.

25. NEUTRAL CHECKED FOR PROPER GROUNDING AS PER ONE LINE DIAGRAM, INSULATION
AND COLOR PER DRAWINGS.
26. SPARE CONTROL /ALARM CONDUCTORS TAPED OR CAPPED (*).
27. SPARE HUBS OR KNOCKOUTS PLUGGED.
28. PAINT SCRATCHES REFINISHED.
29. HANDHOLE COVERS TIGHTLY SECURED
30. ALARM CONTACT AND ALL ACCESSORY CONTACTS OPERATING. HI - TEMPERATURE ALARM
SET AT 90° C (*).
31. CHECK IF THERE IS CONTINUITY IN ALL WINDINGS.
32. MECHANICAL RELIEF DEVICES IS RESET (*).
33. BUS DUCT FLANGE CHECKED (*).
34. BUS DUCT SHUNT INSTALLATION CHECKED (*).
35. VIBRATION PAD CHECKED (*).
36. CHECK INSTALLATION OF NEUTRAL C.T. (*).
37. CHECK PHASE C.T.’S FOR PROPER CONNECTIONS (*).
38. CHECK PHASE ROTATION. X1, X2, AND X3, SHOULD BE A, B, AND C.
(*) IF APPLICABLE
NOTES:
1. SEE II.A FOR MEGGER VOLTAGE. BY: ___________

2. SEE FINDINGS AND COMMENTS ON FIELD TEST REPORT - FORM 011-103.
DATE: __________
FORM No. : 011-116
INSPECTOR'S CHECK OFF LIST. SWITCHGEAR
1. VERIFY CORRECT EQUIPMENT TAGS, S.O. NUMBERS.

2. INSPECT ASSEMBLY INCLUDING AUXILIARY EQUIPMENT FOR DAMAGE OR MISSING PARTS.
3. CHECK BUS PHASING
4. CHECK AND INSPECT FOR COMPLETENESS OF ALL COMPONENTS. TORQUE BOLTED JOINTS PER
MANUFACTURER’S RECOMMENDATIONS OR PER FORM 011-124.
5. CHECK CONTROL WIRING (AND FIELD CONNECTIONS AT SHIPPING SPLITS).
6. MEGGER BUSES AND RECORD ON TEST REPORT - FORM 011-104.
7. MEGGER CONTROL AND POTENTIAL TRANSFORMER PRIMARY AND RECORD ON FIELD TEST REPORT -
FORM 011-104.
8. CHECK CONTROL AND POTENTIAL TRANSFORMER FUSES, TYPE AND SIZE.
9. CHECK FOR PROPER GROUNDING, BOTH ENDS OF ASSEMBLY.
10. VERIFY THAT INSTRUMENTS ARE ZEROED.
11. REMOVE SHORTING BARS CURRENT TRANSFORMERS.
12. VERIFY THAT HEATERS ARE CONNECTED AND OPERABLE.
13. VERIFY THAT ADJUSTABLE MAGNETIC TRIPPING DEVICES ON CIRCUIT BREAKERS HAVE PROPER
RANGES.
14. INTERCHANGE BREAKERS OF SAME RATING IN VARIOUS UNITS TO INSURE INTERCHANGEABILITY.
15. CHECK CONTINUITY OF ALL FUSES, CHECK SIZE AND TYPE.
16. CHECK GROUND BUS BAR CONTINUITY TO INSURE CONNECTION HAS BEEN MADE AT SHIPPING SPLIT
POINTS.
17. INSURE THAT TERMINALS AND CONNECTIONS TIGHT AND SURE. TORQUE BOLTED CONNECTIONS.
18. COMPARE EQUIPMENT NAMEPLATE INFORMATION WITH LATEST SINGLE LINE DIAGRAM AND REPORT
DISCREPANCIES.
19. CONNECT AND DISCONNECT DRAW - OUT POTENTIAL TRANSFORMER FOR PROPER OPERATION.
20. CHECK PROPER ALIGNMENT AND ANCHORAGE.
21. ELECTRIC OPERATION OF KEY INTERLOCK SYSTEM.
22. CHECK DOORS, PANELS AND SECTIONS FOR OPERATIONS AND FIT.
NOTES:
1. RECORD FINDINGS AND COMMENTS ON FIELD TEST REPORT - FORM 011-104. BY: __________
2. SEE II.A FOR MEGGER VOLTAGE V FOR INSTRUCTIONS. DATE: __________
FORM No. : 011-117
INSPECTOR'S CHECK-OFF LIST. 480 VOLT SWITCHRACK
1. INSPECT ASSEMBLY FOR DAMAGE AND MISSING PARTS.

2. CHECK THAT OVERLOAD RELAY HEATERS SIZED AS PER DRAWING.
3. CHECK THAT CONTACTOR COIL IS RATED FOR OPERATIONAL VOLTAGE.
4. VERIFY THAT RESET BUTTON IS FREE AND FUNCTIONAL.
5. VERIFY THAT CONTACTOR SIZE IS CORRECT
6. CHECK NAMEPLATE VOLTAGE AND CURRENT OF BREAKERS, CONTACTOR AND FUSES
7. VERIFY THAT NAMEPLATES ARE PER DRAWING SCHEDULE.
8. CHECK THAT ENCLOSURE HAS BREATHER AND DRAIN (*).
9. CHECK THAT COVER ARE TIGHT, ALL SCREW BOLTS IN PLACE.
10. SEALS PACKED AND POURED (AFTER CHECKOUT OF CIRCUIT).
11. CHECK GROUNDING
12. VERIFY THAT ENCLOSURE IS APPROVED FOR AREA CLASSIFICATION.
13. VERIFY CONTROL TRANSFORMER FOR SIZE AND RATING (*).
14.FEEDER BREAKERS SIZED CORRECTLY
15. RECORD MEGGER READINGS ON FIELD TEST REPORT - FORM 011-104.
16. CHECK INSTANTANEOUS TRIP BREAKERS FOR SPECIFIED SETTINGS (*).
17. COVER THREADS AND SURFACES ARE UNDAMAGED, CLEANED AND LUBRICATED (*).
18. SPACE HEATERS ARE CONNECTED AND OPERABLE (*).
(*) IF APPLICABLE
NOTES:
1. RECORD FINDINGS AND COMMENTS ON FIELD TEST REPORT - FORM 011-104 BY: ________
2. SEE II.A FOR MEGGER VOLTAGE AND V. FOR INSTRUCTIONS. DATE: ________
FORM No. : 011-118
INSPECTOR'S CHECK-OFF LIST. MOTOR CONTROL CENTER
1. INSPECT ENTIRE ASSEMBLY FOR DAMAGE AND MISSING PARTS.

2. REMOVE ALL FOREIGN AND PACKING MATERIAL FROM MOTOR CONTROL CENTER
3. INSPECT MAIN BUS AND TAPS TO SWITCHES AND POTENTIAL TRANSFORMERS. TORQUE
BOLTED JOINTS PER MANUFACTURER’S RECOMMENDATIONS OR SEE FORM 011-124.
4. INSPECT EACH UNIT OR CUBICLE FOR PROPER APPROVED NAMEPLATE PER DRAWINGS.
5. DETERMINE THAT ALL TERMINAL BLOCK CONNECTIONS ARE SECURE AND PROPERLY
IDENTIFIED INCLUDING FIELD CONNECTIONS AT SHIPPING SPLITS.
6. MANUALLY OPERATE SWITCHES AND CONTRACTORS.
7. CHECK FOR CORRECT SIZING OF OVERLOAD RELAY HEATERS IN ACCORDANCE WITH
APPROVED DRAWINGS.
8. RECORD MEGGER READINGS ON FIELD TEST REPORT - FORM 011-104.
9. INSPECT ALL PROTECTIVE RELAYS AND DEVICES FOR CORRECT SETTINGS, SET
OVERLOAD RELAYS FOR 100% MOTOR FULL LOAD CURRENT OR AS NOTED ON SETTING
SHEETS.
10. IF PROVIDED, CHECK TO SEE THAT SPACE HEATERS ARE CONNECTED AND OPERABLE.
11. CHECK OUT OVERLOAD RESET BUTTON, FREE AND FUNCTIONAL.
12. CHECK, IF PROVIDED, OPERATION OF KEY INTERLOCKS SYSTEM.
13. VERIFY THAT MCP’S OR BREAKERS INSTANTANEOUS TRIPS ARE CON CORRECT SETTING.
NOTES:
2. SEE II.A FOR MEGGER VOLTAGE AND V FOR INSTRUCTIONS. DATE: ________
FORM No. : 011-119
INSPECTOR’S CHECK-OFF LIST. BUS DUCT-METAL ENCLOSED
MAKE SURE AC AND/OR DC CONTROL VOLTAGE IS AVAILABLE.

INSERT BREAKER INTO ITS CUBICLE AND CHECK THE FOLLOWING:
1. ROLL BREAKERS INTO “TEST” POSITION. (THE SPRING CHARGING MECHANISM SHOULD
OPERATE AND CHARGE SPRING).
2. WITHDRAW BREAKERS TO “DISCONNECTED” POSITION. (THE CHARGED SPRING SHOULD
DISCHARGE).
3. ROLL BREAKERS INTO “TEST” POSITION. CLOSE BREAKERS USING DOOR SWITCH AND
CHECK INDICATOR LIGHT FOR OPERATION. CLOSE BREAKER FROM REMOTE CONTROL
STATION WHERE APPLICABLE.
4. TRIP BREAKER AND CHECK INDICATOR LIGHT. TRIP FROM DOORS SWITCH AND REMOTE
CONTROL STATION.
5. TRIP EACH BREAKER FROM PROTECTIVE DEVICE AND CHECK RELAY TARGETS FOR
OPERATION. TEST PROPER OPERATION OF LOCKOUT DEVICE IN CLOSING CIRCUIT.
* 6 PERFORM AUTOMATIC TRANSFER OPERATIONS PER TEST PROCEDURES, CHECK TRIP-
FREE AND ANTI-PUMP FEATURE OF EACH BREAKER. TURN CONTROL SWITCH TO “CLOSE”
AND HOLD. TRIP BREAKER USING ONE OF THE OVECURRENT RELAYS. (BREAKER SHOULD
NOT RECLOSE IMMEDIATELY).
7. MEASURE INSULATION RESISTANCE BETWEEN PHASES AND BETWEEN PHASE TO
GROUND WITH BREAKERS WITH BREAKER WITHDRAWN AND CLOSED. RECORD ON FORM
011-104. TEST OIL (DIELECTRIC STRENGTH) IF RECOMMENDED BY MANUFACTURER.
RECORD RESULTS UNDER “COMMENTS” ON FORM 011-104.
8. ROLL BREAKER INTO “CONNECTED” POSITION AND TEST OPERATION OF LATCH CHECK
SWITCH, IF PROVIDED.
9. NAMEPLATE DATA IN ACCORDANCE WITH VENDOR DRAWINGS (CONTINUOUS AMPERES,
INTERRUPTING AMPS, ETC.)
*
10. CHECK OPERATION OF KEY INTERLOCK SYSTEM.
* IF APPLICABLE
NOTES:
2. SEE II.A FOR MEGGER VOLTAGE AND V. FOR INSTRUCTIONS. DATE: _________
3. SEE I.A..C & D FOR OPERATION RESTRICTIONS.
FORM No. : 011-120
INSPECTOR’S CHECK-OFF LIST. BUS DUCT-METAL ENCLOSED
1. INSPECT ENTIRE ASSEMBLY INCLUDING AUXILIARY EQUIPMENT FOR ANY APPARENT

DAMAGE OR MISSING PARTS.
2. CHECK VOLTAGE AND AMPERE RATING FOR COMPLIANCE WITH JOB SPECIFICATION.
3. CHECK SPACE HEATERS AND THEIR CONTROLS.
4. MEGGER BUSES AND RECORD ON FIELD TEST REPORT - FORM 011-104
5. CHECK FOR DRYNESS AND DUST FREE.
6. CHECK FLANGE AND BUS DIMENSIONS FOR FIT.
7. TORQUE BOLTED JOINTS AS PER MANUFACTURER’S RECOMMENDATIONS OR SEE FORM
011-124.
8. CHECK PAINT FOR COLOR AND QUALITY OF WORKMANSHIP.
9. CHECK BUS DUCT SUPPORT SYSTEM.
10. INSPECT FOR PROPER BUS BRACING AND SUPPORT.
11. HI-POT, BUS REQUIRED BY JOB SPEC’S. FOR 5 KV BUS - TEST AT 20.2 KV DC AND 15 KV TEST
AT 37.5 KV DC FOR ONE MINUTE. RECORD RESULTS ON FROM 011-104.
1. Notes:
2. Record findings and comments on field test report - Form 011-104 By: ________
3. See II.A for Megger voltage and V For Instructions. Date: ________
FORM No. : 011-121
INSPECTOR’S CHECK-OFF LIST. BATTERY AND BATTERY CHARGER
1. BATTERIES AND RACKS INSTALLED AND CHECKED FOR PROPER MECHANICAL

INSTALLATIONS, INCLUDING CONNECTIONS AND NUMBER OF CELLS.
2. BATTERIES FILLED WITH ELECTROLYTE WITH PROPER LEVEL AND CHARGED IN
ACCORDANCE WITH MANUFACTURER’S RECOMMENDATIONS.
3. LEAD ACID BATTERIES CHECKED WITH HYDROMETER FOR CORRECT SPECIFIC GRAVITY.
4. BATTERY CHARGER CHECKED FOR PROPER INSTALLATION, WIRING COMPLETED AND
PROPERLY CONNECTED.
5. CHARGER OPERATES IN ACCORDANCE WITH MANUFACTURER’S RECOMMENDATIONS
CURRENT OUTPUT, VOLTAGE AND OPERATIONS OF CONTROL COMPONENTS CHECKED.
6. CHECK CHARGER NAMEPLATE AGAINST APPROVED VENDOR DRAWINGS.
7. ACCESSORY EQUIPMENT SUCH AS: HYDROMETER, THERMOMETER, SPECIAL WRENCHES
AND SPARE ELECTROLYTE ACCOUNTED FOR.
8. BATTERIES, BATTERY RACKS AND CHARGER CLEANED. TERMINALS AND
INTERCONNECTORS COVERED WITH PROTECTIVE BASE.
9. VERIFY CHARGER CAN DELIVER MAXIMUM RATED OUTPUT AND OPERATES PROPERLY.
10. BOOSTER CHARGER PER MANUFACTURER’S INSTRUCTIONS.
11. SET CHARGER FOR FLOAT OPERATION WITH ADJUSTMENT OF PROPER FLOAT VOLTAGE
SO THAT MAXIMUM VOLTAGE UNDER BOOSTER CHARGE DOES NOT EXCEED
MANUFACTURER’S INSTRUCTIONS.
12. VERIFY PROPER OPERATION OF LOW DC VOLTAGE RELAY AND ALARM CONTACTS
INDICATE SETTINGS.
13. VERIFY PROPER OPERATION OF AC FAILURE RELAY AND ALARM CONTACTS.
14. VERIFY GROUND DETECTION RELAY OR LIGHTS OPERATE PROPERLY. VERIFY ALARM
OUTPUT RELAYS OPERATE.
15. VOLTMETER CHECKED, ZEROED.
16. AMMETER CHECKED, ZEROED.
17. FUSES/CIRCUIT BREAKERS PER VENDOR DRAWINGS.
18. VERIFY OPERATION OF CHARGER OUTPUT FAILURE AND ALARM CONTACTS.
19. CHECK FOR PROPER EQUIPMENT GROUND.
NOTES:
1. SEE VII FOR INSTRUCTIONS. BY: ________

2. RECORD FINDINGS AND COMMENTS ON FIELD TEST REPORT - FORM 011-106 DATE: ________
FORM No. : 011-122
INSPECTOR’S CHECK-OFF LIST. LIGHTING & RECEPTACLE PANEL
1. MEGGER ALL RECEPTACLE CIRCUIT, MINIMUM OF, 75 MEGOHMS FROM PHASE TO GROUND
IS ACCEPTABLE WITH BREAKERS OPEN.
2. CHECK TO BE SURE THAT PHASE WIRE, NEUTRAL AND EQUIPMENT GROUND WIRES ARE
ON THE PROPER TERMINALS AND THEY HAVE CONTINUITY.
3. CHECK EACH RECEPTACLE TO BE SURE IT IS CONNECTED TO THE CIRCUIT BREAKER
SHOWN ON THE LIGHTING PLAN DRAWING.
4. ENERGIZE EACH CIRCUIT ONE AT A TIME AND CHECK THAT ALL LIGHTING FIXTURE COME
ON AND THAT THEY ARE CONNECTED TO THE CORRECT BREAKERS.
5. CHECK AMPERAGE ON EACH CIRCUIT, MUST NOT EXCEED 16 AMPS ON A 20 AMP. BREAKER.
6. CHECK ANY LOCAL SWITCHES THAT MAY BE INVOLVED FOR PROPER OPERATION.
7. CHECK EACH APPLIANCE SUCH AS SPACE HEATER, CHART DRIVE, HEAT TRACE,
INSTRUMENT AND OTHERS SHOWN ON THE DRAWING TO SEE THEY AREA ON THE
BREAKERS SHOWN.
8. CHECK PANEL SCHEDULE, IN PLACE AND AS PER PLAN DRAWING.
9. CHECK ALL DRAINS, SEALS AND GROUNDING.
10. CHECK VOLTAGE AT PANEL AND AT LAST FIXTURE ON RUN, MUST NOT EXCEED 3%
VOLTAGE DROP.
11. CHECK COLOR CODE AND PHASE SEQUENCE FOR COMPLIANCE WITH JOB SPEC.
12. CHECK PANEL WIRING SYSTEM FOR COMPLIANCE WITH JOB SPEC.
13. WITH ALL FIXTURES ON, CHECK LOAD BALANCE ON PANEL WITH PANEL SCHEDULE LOAD
CALCULATIONS.
14. CHECK PANEL, FIXTURES AND RECEPTACLES FOR COMPLIANCE WITH AREA
CLASSIFICATIONS.
15. AT NIGHT, CHECK THAT ALL AREAS ARE ILLUMINATED AT A LEVEL NOT LESS THAN CALLED
FOR IN JOB SPEC.
16. AIM FLOOD LIGHTS FOR BEST ADVANTAGE.
17. CHECK OPERATION OF ANY GFI BREAKERS & RECEPTACLES.
18. CHECK OPERATIONS ON ANY AUTOMATIC PHOTO RELAYS AND OTHER CONTROLS.
NOTES N
1. REPORT ANY DEVIATIONS FROM JOB SPECIFICATIONS ON FORM 011-100 BY: ________
2. SEE II.A FOR MEGGER VOLTAGE AND XII FOR INSTRUCTIONS. DATE: ________
FORM No. : 011-123
INSPECTOR’S CHECK-OFF LIST. WELDING RECEPTACLE
1. CHECK CONFIGURATION FOR COMPLIANCE WITH JOB SPEC’S

2. CHECK RATING OF BREAKER AND RECEPTACLE FOR COMPLIANCE WITH JOB SPEC’S.
3. CHECK ENCLOSURE FOR COMPLIANCE WITH AREA CLASSIFICATION.
4. CHECK ALL SEALS, DRAIN AND BREATHERS.
5. INSERT A PLUG CHECK OPERATION OF BREAKERS.
6. CHECK PHASE ROTATION TO DETERMINE THAT ALL RECEPTACLE ARE THE SAME AND
CORRESPOND WITH ANY OTHER EXISTING RECEPTACLE SO THAT ALL ARE COMPATIBLE
WITH ALL WELDING MACHINES IN THE PLANT. IF THERE ARE NO EXISTING RECEPTACLES
TO MATCH, THE PHASE ROTATION SHALL BE A, B, C AS VIEWED LOOKING INTO THE
RECEPTACLE.
Notes:
1. 1. Report any deviations from Job Specifications on Form 011-100 By: ________
FORM No. : 011-124
U.S. STANDARD BOLT TORQUES FOR BUS CONNECTIONS

HEAT TREATED STEEL
GRADE SAE SAE SAE SAE

1&2 5 6 8
MINIMUM
TENSILE
(P.S.I) 64 K 105 K 133 K 150 K
Bolt TORQUE (FOOT POUNDS)
Diameter
1/4 5 7 10 10.5
5 /16 9 14 19 22
3/8 15 25 34 37
7 /16 24 40 55 60
1/2 37 60 85 92
9 /16 53 88 120 132
5/8 74 120 167 180
3/4 120 200 280 296
7/8 190 302 440 473
1 282 466 660 714
Notes:
1. Reduce Torques By 20% When cadmium plated Bolts Are used. By: ________
DATE : 30.11.98

APPENDIX 2
PRESSURE TESTING AT JOBSITE
FIELD EVALUATION, TESTING, AND CALIBRATION OF INSTRUMENTS
I. SCOPE
This Appendix specifies general responsibilities and procedures for the job site inspection,
testing, and calibration of instruments prior to initial start-up of a unit.
Requirements for pressure testing instrument process piping, lead lines and manifolds are
given in Engineering Standard IE-011 Appendix 2 and are not within the scope of this Job
Specification.
II. REFERENCES
The latest editions and revisions of the following documents are referred to herein:
A. Petrox's Job Specifications
1. Engineering Standard IE-011 Appendix 2, Pressure Testing.
B. ISA Documents
1. ISA RP 7.1, Pneumatic Control Circuit Pressure Test.
Ill. GENERAL
A. All items shall be inspected for possible damage in transit. They shall be compared with
Material Requisitions and Purchase Orders to insure conformity with materials of
construction, connection size, rating and orientation, range, dimensions, proper
identification, etc.
B. Transmission and control tubing shall be cleaned by blowing out with clean. dry air. Leak
testing shall be carried out in accordance with ISA Recommended Practice RP 7.1.
Electrical transmission and control wiring shall be tested for continuity, proper
DATE : 30.11.98

APPENDIX 2
termination, and grounding.
C. Instrument air regulators shall be set at manufacturer's recommended supply pressure.

Electronic instruments shall be connected to the proper level of power supply as soon as
possible and shall remain powered at all times.
D. Controllers shall be checked for proper action (i.e., direct or reverse).
E. Seal fluid, where required, shall be provided and installed.
IV. TEMPERATURE INSTRUMENTS
A. Wells - Visual inspection.
B. Dial Thermometers - Visual inspection.
C. Thermocouples shall be checked for proper joining of wires, bottoming of elements in

wells, proper polarity throughout the thermocouple circuit to the instrument. A
thermocouple loop shall be checked from the thermocouple head to its receiving
instrument by means of a wire continuity test.
D. Thermocouple type transmitters shall be calibrated with their associated receiving

instruments against a known millivolt source for correct reading and/or output of 0, 50,
and 100% of range.
E. Bulb type controllers shall be shop calibrated against a known heat source for correct
reading and/or output at 0, 50, and 100% of range.
V. FLOW INSTRUMENTS
A. Differential type instruments shall be checked against a portable manometer for correct
reading and/or output at 0, 25, 50, 75, and 100% differential.
B. Rotameters - Visual inspection.

C. Displacement Meters - Visual inspection.
DATE : 30.11.98

APPENDIX 2
D. Turbine Meters - Visual inspection.
E. Magnetic Meters - Visual inspection.
F. Orifice Plate - Bore shall be measured and compared with orifice data sheet and shall
be properly installed according to the specified direction of flow.
VI. LEVEL INSTRUMENTS
A. Float and displacer type instruments shall be checked at minimum, midpoint, and
maximum levels while the vessel they are associated with is liquid filled. If vessels are
not field hydrostatically tested or if it is not feasible to check the instruments with the
vessels, external cages shall be filled with fluid and internal instruments shall be
mechanically actuated to check output.
B. Gauge glasses shall be checked when vessels are filled with hydrostatic test liquid.
C. Differential type shall be checked either when vessels are liquid filled, or against a
portable manometer for correct reading and/or output at 0, 25, 50, 75 and 100% of
differential.
D. Float type traps designated "Level Controllers" - Visual inspection.
E. Gauge boards shall be inspected visually when vessel contains liquid.
F. Tank Gauging - Position float either using vessel fluid or mechanically and check
reading and/or output signal at minimum, midpoint, and maximum levels.
VII. PRESSURE INSTRUMENTS

DATE : 30.11.98

APPENDIX 2
A. Recorders, Controllers, and Transmitters shall be checked against a known pressure

source such as a dead weight tester or portable manometer for correct reading and/or
output at 0, 50, and 100% of range.
B. Pressure - Visual inspection.
VIII. PANEL MOUNTED INSTRUMENTS
A. Those instruments furnished as part of a shop fabricated panel shall receive visual
inspection. Receiver type instruments, controls, and switches shall be checked when
their transmitters are calibrated. Initial controller settings shall be fixed.
B. Panel mounted controllers having a "manual position", shall be used to stroke final
element.
C. Panel mounted instruments installed at the job site shall be calibrated, preferably when
their associated transmitters are calibrated. Switches shall be set, controller actions
checked, and initial controller settings fixed.
D. For split-architecture type instrumentation, cable terminations between front-of-panel

instruments and associated rack-mounted equipment shall be visually inspected for
correctness.
E. Annunciators shall be checked for proper operation of horn, flasher, silence and
acknowledge pushbuttons, and by shorting the proper terminals for the field devices.
IX. ANALYZERS
A. When available, test, span, zero, etc. gases shall be run through the analyzer to check
proper operation. Remote receivers shall be checked when analyzers are calibrated.
X. CONTROL VALVES
A. Each remote-operated valve shall be stroked from its remote station.

DATE : 30.11.98

APPENDIX 2
B. By applying the proper signal to the valve operators, the valve stroke shall be checked
for each end and midpoint of its travel. Travel indicators, positioners, and transducers
shall be checked for proper stroke position of valve at both ends of travel.
C. Hand operated valves shall be stroked and travel indicators checked.
D. A visual inspection shall certify that valves are installed in accordance with the specified
or recommended direction of flow.
XI. SAFETY AND RELIEF VALVES
A. Visual inspection.
B. Valves shall be turned over to the Client prior to start-up. The Client performs his own
tests and marks the valves accordingly. Once turned over to the Client, the valves are
his responsibility.
XII. PREFABRICATED AND ASSEMBLED PANEL BOARDS
A. Visual inspection only. Panels (including piping and wiring) are normally inspected prior
to shipment to the job site. Final alarm, switch, relay, etc. settings shall be made.
XIII. PANEL BOARD (FIELD ASSEMBLED)
A. Visual inspection shall be performed in addition to wiring continuity test and tubing leak
test per ISA RP 7.1.
XIV. CONSOLE DESK
A. If prefabricated and shop assembled, visual inspection is required per Paragraph XII.A.
B. If field assembled, requirements shall be per Paragraph XIII.A.

DATE : 30.11.98

APPENDIX 2
I. SCOPE
This Appendix outlines the minimum requirements for field pressure testing of piping and
items of equipment, and describes tests a client may expect to have been performed prior to
the completion of field construction.
II. REFERENCES
The following documents are referred to herein. The latest editions of these documents shall
be used, unless an exception is taken.
A. ASME Boiler and Pressure Vessel Code.
Section I, Power Boilers.

Section VIII, Div. 1, Pressure Vessels.
B. ANSI/ASME Code for Pressure Piping.
ANSI/ASME 31.1, Power Piping.

ANSI/ASME 31.3, Chemical Plant and Petroleum Refinery Piping.
III. PREPARATION FOR PRESSURE TEST OF PIPING AND EQUIPMENT
A. Restrictions to flow, such as orifice plates and mixing nozzles, shall not be installed or
shall be removed. Where necessary, items removed shall be replaced with temporary
spool pieces.
B. Valves within the system to be tested shall be in an open position but not backseated,
so as to test the valve stem packing. It is particularly important that control valves be
checked to assure that they are in an open position, or that they have a by-pass valve
which is fully open.
C. Instrument Lead Lines
1. Petrox's practice is that instrument lead lines are not pressure tested except when a
fluid service designated as Category M is involved. Therefore, this standard is based
DATE : 30.11.98

APPENDIX 2
on not testing lead lines. Since this procedure is practical but does not conform to
the piping code. The first shut-off valve from the header will normally be used as a
boundary of the pressure test, but lead lines in Category M Fluid Service shall be
tested.
2. Piping ends intended for attachment of instruments shall be capped, plugged or

blanked uring the test. This may require that the instrument be both disconnected
and moved on its support, temporarily removed, or scheduled for installation after
conduct of the pressure test.
D. Test Section Boundaries
1. Equipment which is not to be hydrostatically tested in the field. such as a refractory-

lined vessel, shall be effectively isolated from field tested equipment and piping.
2. Relief and safety valves shall be blanked off by bolting a blind flange to the mate of
the inlet flange. Screwed relief and safety valves shall be removed and replaced with
caps. Test gags shall not be used.
3. In-line instruments whose maximum rated pressure is less than the hydrostatic test p
e.g., sight flow indicators. shall be removed. Insert-type instruments such as special
flowmeters and analyzer elements shall also be removed.
4. Contractor project engineering shall both designate and determine the testing
requirements for special piping systems. These systems include refractory lined pipe
and equipment and piping operating at high temperatures and/or pressures. The
project engineer shall define the extent, test pressure level and means of isolation in
a special job specification, so that any material required is available for Construction.
5. The field contractor engineer will calculate test pressures and designate the extent
of test sections for all other systems. A section isolated for testing shall be tested at
the highest pressure required at any point in that section, if the stress will not exceed
the minimum yield stress at any point. This will be the criterion for designating the
boundaries of test sections.
DATE : 30.11.98

APPENDIX 2
E. Flanged and threaded joints and all welds which have not been p re tested shall be left
bare of insulation, paint, and foreign matter which could mask a leak.
F. Underground pressure piping joints, except those encased in concrete anchors, shall be
left exposed. The function of the anchors is to prevent pull-out of 0-ring, bell. or
mechanical joints. Where such joints fail to hold test pressure, more or larger anchors
shall be provided as necessary.
G. Welded attachments. such as pipe supports and hangers, shall be made before
pressure testing.
H. Lines containing check valves shall have the source of pressure on the upstream side of
the valve. If this is impossible, swing checks shall be blocked open or their flapper
removed, whereas ball and piston checks shall have their internal parts removed. All
parts removed shall be put in a sack and wired to the valve. If none of these is practical.
the check valve shall be blocked off or completely removed.
I. Expansion joints shall be provided with temporary restraints, if necessary, to enable

them to withstand the test pressure or they shall be excluded from the test.
J. Hand-operated valves within a test section shall be temporarily tagged with large red
"Caution" tags or a similar identification to avoid accidental operation during filling or
testing. These will also help in identifying the test section.
IV. FIELD PRESSURE TEST OF VESSELS AND EQUIPMENT
A. Field fabricated vessels shall receive a hydrostatic test where supports, foundations and
subsoil permit, or where the static head of test fluid does not impose unreasonable
thickness requirements. Contractor's drawings shall specify the exact testing
requirements.
DATE : 30.11.98

APPENDIX 2
B. The pressure test shall be in accordance with the provisions of the ASME Boiler and
Pressure Vessel Code. When a straight hydrostatic test cannot be performed, a
combined pneumatic-hydrostatic test shall be performed as specified by Petrox.
C. Where valves are to be installed on vessel nozzles, it is preferable that the pressure test
be made with these valves in place, rather than with blinds on the nozzles. In some
instances. however, the test pressure may be above that of the closed valve seat,
making use of a blind mandatory.
D. Process tubing in a fired heater shall be pressure tested as specified in the requisition.
E. Pumps, turbines, blowers and compressors shall not be subjected to a pressure test in
the field. They shall be isolated from piping or other equipment being tested. Flanged
joints not tested shall be visually examined to insure that gaskets are installed, bolts
tightened, etc.
V. PRESSURE TEST OF PIPING
A. Piping shall be pressure tested in accordance with the same Code edition, plus
addenda, as that to which it was designed and fabricated. Piping Material Requisitions
shall specify the Code edition and addenda.
1. Chemical plant and refinery piping shall receive hydrostatic or pneumatic test in
accordance with Para 345 of ANSI/ASME B31.3, Chemical Plant and Petroleum
Piping Code. However, piping whose Piping Material Specification indicates it is to
be designed for Category M Fluid Service shall be tested in accordance with Para
M345, high pressure piping in accordance with Para K345, of the same Code.
2. Where a closed valve is intended to be a system limit. the test pressure shall not
exceed that used in its valve closure test, normally 110% of the ambient
temperature rating (ANSI B16.34 Para 7.2). If the system test pressure is to be
higher, the valve shall either be excluded or removed to allow blanking of the
adjacent flange which is part of the system being tested.
B. Sewers and non-pressure drains shall be filled with water to grade, but no pressure
other than static head need be applied.
DATE : 30.11.98

APPENDIX 2
C. A piping system whose Piping Material Specification indicates it will be used only for
Category D fluid service (as defined in Para 300.2 of B31.3) or which is excluded from
design per B31.3 by its Para 300.1.3 (a), may be tested in accordance with Para 345.7
of B31.3.
D. The line list will identify any piping in fluid services other than Category D which cannot
be given either hydrostatic or pneumatic test, therefore must be tested in accordance
with Para 345.9 of B31.3.
E. Testing shall be performed on all interconnected lines able to contain the same test
pressure, in preference to testing individual lines or single components of a system.
Breaking joints to insert blanks for hydrostatic testing shall be avoided wherever
possible.
F. Where hydrostatic testing is impractical, pneumatic testing may be used. Pneumatic

testing involves hazard, due to possible release of the energy stored in a compressed
gas. Therefore, permission of the Manager of Design Technology & Quality Assurance
shall be obtained for the conduct of a pneumatic or hydro-pneumatic test at any
pressure higher than 3.5 kg/cm2 g and particular care shall be taken to minimize the
chance of brittle failure. The test temperature is important in this regard and shall be
considered when the choice of material is made in the original design.
2
G. Any pneumatic test shall include a preliminary check at not more than 1.8 kg/cm g
pneumatic pressure. The pressure shall be increased in small steps, providing sufficient
time to allow the piping to equalize strains during test and to permit a check for leaks.
Piping shall be isolated from equipment during the test. The following are examples
where it may be necessary to use pneumatic testing:
1. Piping or equipment in vapor service whose supports are not capable of

supporting the weight of water required.
2. Piping or equipment .which is refractory lined.
3. Piping or equipment where moisture cannot be tolerated due to process

considerations, even when blown dry.
DATE : 30.11.98

APPENDIX 2
H. The hydrostatic pressure test procedure shall be as follows:
1. Piping and equipment shall be thoroughly vented of air during introduction of the
hydrostatic test fluid.
2. The fluid used for hydrostatic testing shall be at 15 ºC minimum when entering the
piping system. The test pressure shall be applied when the metal and its contents
are at about the same temperature. Where thickness is greater than 12 mm and
the material is one whose Nil Ductility Temperature (NDT) is inconsistent, such as
ASTM A285, consideration shall be given to setting a still higher minimum
temperature. These minima shall also apply to tightening of bolts to seal flange
leaks which the test has disclosed.
3. Precautions shall be taken, by opening vents or by other means, to prevent

building up excessive p re in portions of the piping section under test. For
example, this can occur where the test fluid will be subject to thermal expansion.
4. If it is proposed that the hydrostatic test fluid be other than water, or that a
chemical be added to the water for any reason, Petrox shall be consulted and
approval granted in writing before proceeding with the testing operation, except as
specified in the next item.
5. Water with a high chloride content shall not be used for testing austenitic stainless
steel piping and equipment. Water of moderate chloride content (50 to 100 ppm)
may be used, provided 2 % to 4 % sodium nitrate is added.
6. Exchangers or vessels already pressure tested may with the permission of the FW
exchanger or vessel engineer, be included in the test of their connecting piping.
During such a retest, the test pressure shall neither exceed the lowest test
pressure of any exchanger or vessel included nor create excessive support stress
or foundation loading.
7. Where an exchanger or vessel has been blanked off at a flanged joint during
pressure test of the piping, it shall not be necessary to pressure test the joint after
the blank is removed.
DATE : 30.11.98

APPENDIX 2
8. Where piping has been tested to a capped weld because the equipment may not
be hydrotested, the root pass of the final weld shall be subjected to magnetic
particle or liquid penetrant exam and the complete weld to 100% radiographic
exam in lieu of a pressure test.
9. Test pressure readings may be taken at a low point in a system provided that the
readings include the addition of the static head pressure to the minimum hydrotest
required at the top of the system.
10. In freezing weather, the lines and equipment shall be drained of water and blown
dry with hot air or gas to prevent freeze-up after the hydrotest is completed.
11. During pneumatic tests, welds and connections shall be swabbed with soap
solution to facilitate the detection of leaks. Masking tape shall be applied across
flanged joints with a pin hole for detecting leakage.
12. When testing instrument air lines and other small systems, a "bubbler" apparatus
at the fill point shall be used as a check on air leakage.
VI. TEST GAUGE CALIBRATION
A. Instruments and gauges used for testing shall be checked against a dead-weight tester
or calibrated master gauge on a periodic basis not greater than one week. They shad
also be calibrated within three months of test date. Calibration shall be against a
standard having a valid relationship to National Standard and done by a certified testing
lab.
B. Instruments and gauges used for testing shall have a range of about double, but not
less than 1 1/2 times, the test pressure.
VII. TEST RECORDS
Records shall be made of each system tested. These records shall include:
DATE : 30.11.98

APPENDIX 2
A. Date of test.
B. Identification of components tested.
C. Test fluid.
D. Test pressure.
E. Certification by examiner.
Provide the Owner with a copy of test records. These records need not be retained by
Contractor after completion of the piping installation if a certification by the Authorized
Inspector that the piping has been pressure tested as required by the Piping Code is retained.

EI-011 - e Reva Electrical Field Inspection and Testing

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EI-011 - e Reva Electrical Field Inspection and Testing

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PETROX S.A.

Please discard any previous issue of this specification.

Register of Issues Number

APPENDIX 1. FIELD EVALUATION, TESTING AND CALIBRATION OF INSTRUMENTS

ELECTRICAL FIELD INSPECTION AND TESTING

ELECTRICAL FIELD INSPECTION AND TESTING

3. Transformers - Dry Type

ELECTRICAL FIELD INSPECTION AND TESTING

II. GENERAL INSTRUMENTS AND PROCEDURES

1. Short-time insulation resistance measurements shall be made with megohmmeter testers,

Note: “Megger” is a registered Trade mark of the Biddle Instrument Co.

C. Temperature measurements shall be taken by a mercury thermometer or by a thermal-

1. Dielectric strength testing of insulating liquids.

ELECTRICAL FIELD INSPECTION AND TESTING

ELECTRICAL FIELD INSPECTION AND TESTING

III. GENERATORS AND MOTORS

MINIMUM MEGOHM VALUES FOR MACHINES

Volts: 110 440 550 2300 3000 4000

Where Rm =Recommended minimum insulation resistance in megohms at 40°C of the

ELECTRICAL FIELD INSPECTION AND TESTING

ELECTRICAL FIELD INSPECTION AND TESTING

B. Drying Out Process

ELECTRICAL FIELD INSPECTION AND TESTING

3. To dry out machine with strip heaters or lamps

4. To dry machines with a drying oven:

∗ Values for comparative purposes only

ELECTRICAL FIELD INSPECTION AND TESTING

Note: Turn shaft by hand before bumping motor.

a. For Class a Insulation - 90°C.

ELECTRICAL FIELD INSPECTION AND TESTING

3600 RPM = 001” Peak - To - Peak

ELECTRICAL FIELD INSPECTION AND TESTING

ASTM D 877 Method ASTM D 1816 Method

ELECTRICAL FIELD INSPECTION AND TESTING

ELECTRICAL FIELD INSPECTION AND TESTING

2. No dielectric strength test are required if no gas leaks are indicated.

ELECTRICAL FIELD INSPECTION AND TESTING

ELECTRICAL FIELD INSPECTION AND TESTING

V. SWITCHGEAR, MOTOR CONTROL EQUIPMENT AND BUS DUCT

600 volts 601 volts to Above

3 megohms 50 megohms 200 megohms

Equipment rated 5 kV : test at 20.2 kV DC

4. Precautions required to obtain reliable insulation measurements will include disconnecting

Note: Do not include any solid - state relays in “Megger” tests.

ELECTRICAL FIELD INSPECTION AND TESTING

C. Vacuum contractors or circuit breakers; test strictly in accordance with Manufacturer’s

D. SF, circuit breakers; test strictly in accordance with Manufacturer’s instructions.

1. Control, protective and metering circuits.

a. Close and trip the breakers with its control switch.

8. Check operation of space heaters.

ELECTRICAL FIELD INSPECTION AND TESTING

ELECTRICAL FIELD INSPECTION AND TESTING

VI. RELAY AND PROTECTIVE DEVICES

A. Relay settings and coordination curves shall be furnished to field personnel by

1. Relays will be set in accordance with the relay tabulations furnished.

B. Relays and protective devices shall be calibrated by a qualified subcontractor such as

ELECTRICAL FIELD INSPECTION AND TESTING

VII. BATTERY AND BATTERY CHARGER

ELECTRICAL FIELD INSPECTION AND TESTING

VIII. EMERGENCY POWER

1. As a minimum, the unit shall be tested to determine that:

a. It is free from defects.

BATTERY No.: _ CHARGER No.: ____ RESULTS

DESCRIPTION: _ TAG Nº: _