KIMANIS POWER SDN BHD (842208-H)

(A joint venture company between PETRONAS Gas Berhad and NRG Consortium (Sabah) Sdn Bhd)

KIMANIS POWER PROJECT

ENGINEERING, PROCUREMENT, CONSTRUCTION AND COMMISSIONING (EPCC)
FOR
300MW COMBINED CYCLE POWER PLANT
PROJECT
MANAGEMENT
CONSULTANT:
CONTRACTOR: CTCI Corporation, CTCI Overseas Corporation Limited,
CTCI Malaysia Sdn Bhd, Synerlitz (Malaysia) Sdn Bhd,
SCHB Engineering Services Sdn Bhd CONSORTIUM
CONTRACT NO.: PGB/HO/18/2008/0139
DOCUMENT NO.: XA96-00000-203 REV. B
TITLE:

IPB SITE TEST PROCEDURE

STATUS: FOR APPROVAL

Contractor Doc. No.: XA96-00000-203

Proj. No.: 10_0523

PROJECT CERTIFIED

B For Approval Li Chen Li 11/01/2012 Mgr. Date

A For Approval Li Chen Li 01/13/2012 Client Date

Rev. Description By Chk. App. Date Page No. 1 of 5

THIS DOCUMENT CONTAINS CTCI CORPORATION CONFIDENTIAL INFORMATION OF A PROPRIETARY NATURE. THIS INFORMATION MUST NOT BE COPIED OR DISCLOSED IN
WHOLE OR IN PART TO OUTSIDE PARTIES NOR USED FOR OTHER THAN THE PURPOSE FOR WHICH PROVIDED WITHOUT PERMISSION OF MANAGEMENT.
From: To:
Kimanis Power Project CTCI Corporation, CTCI Overseas Corporation Limited, CTCI
Engineering, Procurement, Construction and Commissioning for Malaysia Sdn Bhd, Synerlitz (Malaysia) Sdn Bhd,
300MW Combined Cycle Power Plant SCHB Engineering Services Sdn Bhd CONSORTIUM
COMMENT SHEET

Drawing/Document Number Drawing/Document Title Commenting Date

Owner Contractor Owner Contractor

IPB SITE TEST PROCEDURE
Kimanis KPP-000-XA96-203 31/July/2012 18/Aug/2012
No. Owner’s Comment Contractor’s Reply
1 Test Item No. 3: To re-confirm the IR test voltage for the IPB. 2500V The IR test voltage for the IPB is 2500V in accordance with the IEEE Std
seems low for a 20kV system. Should be test at 5kV. C37.20.2 clause 6.2.1.3.

2 Test Item No. 8: To re-confirm the IR test voltage for control circuits
and acceptance criteria. 2500V seems a bit high, normally control The IR test voltage for control circuits is 500V , acceptable value of IR is
circuits are only tested up to 500V. Normally, more than 5M ohm is 5M ohm.
considered acceptable during commissioning stage for LV wiring.

1
 SHOP TEST PROCEDURES

IPB Document No. Version Total Page 4

Field Test Procedure KPP-000-XK91C-004-007 A Page 1
1、Field test basis：
1）Standard of IEEE Standard C37.23;
2）Kimanis Power Plant Contract and Technical specification .
2、Field test items：
Equipment and
Test Acceptance & Standard as per Contract
No.
Items Methods
1、Whether the label code is right or not；
2、whether the dimensions meet with the drawing or not；
Eyeballing
Appearanc 3、Color and luster of the coat and plating is uniform or
1
e test Tape etc
not；
4、No defect of nick or deformation.

Measured data should not less than the data below：

Vernier caliper
Rated Clear span of phase to phase ， phase to
Safety Tape
2
clear span voltage ground and conductor to ground in inches
Eyeballing
（kV） （mm）

20 240
2500V The IR test value between phase to enclosure of IPB is not
Insulation
3
resistance Mega-ohmmeter less than 100MΩ. according to Acceptance Standard.

Power frequency No breakdown or discharge

Dry power withstand Rated voltage Rated power frequency withstand
frequency
4
withstand voltage platform （kV） voltage,1 minute（kV）
voltage
20 45 (Test Value=75% of 60kV)

THIS DOCUMENT CONTAINS CTCI CORPORATION CONFIDENTIAL INFORMATION OF A PROPRIETARY NATURE. THIS INFORMATION MUST NOT BE COPIED OR
DISCLOSED IN WHOLE OR IN PART TO OUTSIDE PARTIES NOR USED FOR OTHER THAN THE PURPOSE FOR WHICH PROVIDED WITHOUT PERMISSION OF
MANAGEMENT.
本文件所述及資料及文件皆為中鼎工程股份有限公司(中鼎)版權所有，未徵得中鼎同意不得將其中全部或部份翻印或轉授與第三者。
 IPB Document No. Version Total Page 4
Field Test Procedure KPP-000-XK91C-004-007 A Page 1
Hydraulic
pressure 0.1MPa
(Hose Dia.
Water
5 sprinkling 25mm, Head 11 No water mark inside the enclosure .
test metres, 45 sec. to
5 min., 3 m away
from equipment.)
Gas
sealing Soap water No evident air bubble
test
6
Air
150mm of water After the air supply is shut off the pressure drop shall not be
Tightness
column more than 75 mm of water column in 15 seconds.
Test
Functional
Test of Function running well during commissioning, no deviation
7 Eyeballing
Contral compared. Acceptance and standard as per contract.
Circuits
Insulation
Resistance
2500V
8 Check of Not less than 100MΩ
Mega-ohmmeter
Control
Circuits
3、Field test should be taken after IPB is installed and before the connection to the generator and the
transformer. Keep separating from other instruments when testing.

THIS DOCUMENT CONTAINS CTCI CORPORATION CONFIDENTIAL INFORMATION OF A PROPRIETARY NATURE. THIS INFORMATION MUST NOT BE COPIED OR
DISCLOSED IN WHOLE OR IN PART TO OUTSIDE PARTIES NOR USED FOR OTHER THAN THE PURPOSE FOR WHICH PROVIDED WITHOUT PERMISSION OF
MANAGEMENT.
本文件所述及資料及文件皆為中鼎工程股份有限公司(中鼎)版權所有，未徵得中鼎同意不得將其中全部或部份翻印或轉授與第三者。
 IPB Document No. Version Total Page 4
Field Test Procedure KPP-000-XK91C-004-007 A Page 1
4、Operating rules of IPB insulation resistance test
1) The test equipment is a 2500V Mega-ohmmeter.
2) Keep the enclosure is grounded reliably. Make sure that the inside of the enclosure and the
surface of the conductor are clean.
3) Turn Mega-ohmmeter at zero position. The positive pole is connected to the conductor and the
cathode is connected to the enclosure.
4) Turn the handle of Mega-ohmmeter equably and quickly. Write down the maximum value which
is the insulation resistance. equably
5) According to IEEE Standard C37.23（GB8349-2000）, the insulation resistance of IPB should
be no less than 100MΩ.
6) Record the reading and verify that tested value meets the acceptance criteria .
5、Operating rules of IPB dry power frequency withstand voltage test

THIS DOCUMENT CONTAINS CTCI CORPORATION CONFIDENTIAL INFORMATION OF A PROPRIETARY NATURE. THIS INFORMATION MUST NOT BE COPIED OR
DISCLOSED IN WHOLE OR IN PART TO OUTSIDE PARTIES NOR USED FOR OTHER THAN THE PURPOSE FOR WHICH PROVIDED WITHOUT PERMISSION OF
MANAGEMENT.
本文件所述及資料及文件皆為中鼎工程股份有限公司(中鼎)版權所有，未徵得中鼎同意不得將其中全部或部份翻印或轉授與第三者。
 IPB Document No. Version Total Page 4
Field Test Procedure KPP-000-XK91C-004-007 A Page 1
1) The enclosure is grounded reliably. The surface of the conductor and the inside of the enclosure
are clean.
2) The time is 60 Sec .
3) Check the equipment whether it is in available state or not. The positive pole is grounded direct.
If the red indicator light is on, it is normal. Otherwise, something is wrong with the equipment
when the indicator light is green.
4) The positive pole of the equipment is connected with the conductor and the cathode is connected
with the enclosure. Meantime, the enclosure is grounded reliably. Keep the other conductor at
least 300mm away from the bus.
5) Safety measurement. Close-off distance must be 3 meters. There should be special person
assigned for safety except the operator.
6) Press the button of “high voltage on”, and turn the handle to ensure that the voltage is 45KV
(75% of 60kV). In the meanwhile, press the “1min”button.
7) After 1min, reduce the voltage, then press the button of “high voltage off”. Assure that IPB
discharges completely. Remove the wires.
8) If the voltage is not high enough, check the insulator. And if the insulator is destroyed, continue
the test after exchanging a new one.
9) If large sound or flashover appears, check whether there is clearance between the top clamp of the
supporting insulator and the conductor. If there is clearance, install again and continue the test.
10) The test lasts for 1min, then it meets the Acceptance Criteria.
11) Record the test reading.
6、Operating rules of IPB water sprinkling test
Manual water sprinkling test is taken on the surface of IPB test segment (including welding line,
jointing of enclosure, insulator installing hole, checking hole etc). The 0.1MPa water is sprinkled to
the enclosure from a 25mm tube in a 3m distance from the enclosure, at a 45degree angle with the
horizontal. Keep sprinkling to the both sides of IPB for 5min.There should be no evident water mark.
7、Operating rules of IPB gas sealing test
1) Gas sealing test is taken at the site of installing.
2) Fill 1500Pa (equal to 150mm Water Column) compressed air in the enclosure. Check the welding
line and other joining surface with soap water. It is eligible while there is not evident air bubble (gas
leaking point).

THIS DOCUMENT CONTAINS CTCI CORPORATION CONFIDENTIAL INFORMATION OF A PROPRIETARY NATURE. THIS INFORMATION MUST NOT BE COPIED OR
DISCLOSED IN WHOLE OR IN PART TO OUTSIDE PARTIES NOR USED FOR OTHER THAN THE PURPOSE FOR WHICH PROVIDED WITHOUT PERMISSION OF
MANAGEMENT.
本文件所述及資料及文件皆為中鼎工程股份有限公司(中鼎)版權所有，未徵得中鼎同意不得將其中全部或部份翻印或轉授與第三者。