Abu Dhabi Plaza – Astana, Kazakhstan Document No.

Work Package 4 – Main Works ADP-261300-020

Method Statement for Testing & Commissioning of MV Switchgear Page 2 of 50 Rev. 003

REVISION DESCRIPTION SHEET

Rev. Para. Revision Description

000 Issued for Review / Comments
001 Issued for Review / Comments
002 Issued for Review / Comments
003 Issued for Review / Comments

Hold
Para. Description of Hold
No.

The Inspection Forms are controlled within this MS and are

included during the Review and Approval cycle.

The latest revision of an Inspection Form shall be used during

work execution.

Revisions after Rev.2 are denoted by a triangle in the left

hand margin against the revised text, with the revision
number displayed next to revision line. As shown by the
example below:-

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Method Statement for Testing & Commissioning of MV Switchgear Page 3 of 50 Rev. 003

Item
Comments On Rev.002 Contractor’s Response
No.

1. Comply.

2. Comply.

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Method Statement for Testing & Commissioning of MV Switchgear Page 4 of 50 Rev. 003

Table of Contents

1.0 Purpose

2.0 Scope of Work

3.0 References

4.0 Definitions

5.0 Resources, Roles & Responsibilities

5.1 Competency
5.2 Role & Responsibilities of Commissioning Engineer
5.3 Role & Responsibilities of QC Engineer
5.4 Role & Responsibilities of Foreman

6.0 Tools Requirement

7.0 Method and Sequence of work

7.1 General
7.2 Safety Precautions
7.3 Pre-Commissioning
7.4 Commissioning

8.0 Quality Control

9.0 Health, Safety & Environmental

9.1 Induction
9.2 PPE
9.3 Hazard Identification, Risk Assessment & Control
9.4 Toolbox Talks
9.5 Permit to Work
9.6 Training of Personnel

10.0 Attachments

10.1 MV Switchgear Schedule

10.2 General Arrangement Drawing (sample)
10.3 Form No: FM-MS-ADP-261300-020-001
10.4 Form No: FM-MS-ADP-261300-020-002
10.5 Form No: FM-MS-ADP-261300-020-003
10.6 Form No: FM-MS-ADP-261300-020-004
10.7 Form No: FM-MS-ADP-261300-020-005
10.8 Form No: FM-MS-ADP-261300-020-006
10.9 Form No: FM-MS-ADP-261300-020-007
10.10 Form No: FM-MS-ADP-261300-020-008
10.11 Form No: FM-MS-ADP-261300-020-009
10.12 JSTI
10.13 Risk Assessment

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Method Statement for Testing & Commissioning of MV Switchgear Page 5 of 50 Rev. 003

1.0 PURPOSE
The main purpose of this method statement is to demonstrate the procedure for Testing and
Commissioning of MV Switchgears.

2.0 SCOPE OF WORK

This method statement is applicable for Testing and Commissioning of MV Switchgear and Ring Main
Units as per project specification, Approved shop drawings and CML Testing & Commissioning Plan.
The method statement covers the onsite physical inspection and verification, testing & commissioning of
MV Switchgear and RMU performance to ensure that VCB Breakers, protective relays and Mechanical
& Electrical interlocking is working properly which is suitable for their purpose for energization in Abu
Dhabi Plaza.

3.0 REFERENCES

 Project Health & Safety Plan ADP-013529-002

 Approved Shop Drawings
 Approved Equipment Schedule
 General Arrangement Drawing
 Specifications: 261300_AJ_Medium Voltage Switchgears
 Specifications: 260126-Operation, Maintenance & Testing of Electrical Systems
 Testing & Commissioning Plan By CML, Ref. ADP-CML-CO-RPT-W-00016
 General Method Statement for Winter Working, Ref. No: ADP-015000-036
 Materials Approval Request. Ref. ADP-261300-001 MV Switchgear (ABB Unigear ZSI)
 Control Schematics and Wiring Diagrams – Block H: ADP-261300-002
 Project Quality Plan Ref. No: ADP-014000-020
 Risk Assessment Plan Ref. No: ADP-013529-028.001
 Approved Inspection & Test Plan, ADP-261300-018
 LOTO procedure, Ref. ADP-013529-026 (Lock-out-Tag-out)

4.0 DEFINITIONS

MML: Mott Macdonald LTD

CSC: Construction Supervision Consultant (AECOM KZ)
ACEL JV: ACEL Joint Venture
RBG: Robert Bird Group (JV Design/Structural Consultants)
P & T: P & T Architects (JV Architect/Lead Design)
RED: Red Group Services FZ-LLC, Dubai, UAE (MEP design Consultant).
CxA: CML International (Commissioning Authority)

5.0 RESOURCES, ROLES & RESPONSIBILITIES

The Commissioning Manager has the overall responsibility for the implementation of this Method of
Statement, also will individually assess the manpower required for T&C of MV Switchgear to meet the
schedule. Typically these will include:

 Commissioning Engineer
 Foreman
 QC Engineer
 Certified Specialist

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Method Statement for Testing & Commissioning of MV Switchgear Page 6 of 50 Rev. 003

5.1 Competency
The competency of all construction personnel shall be controlled in accordance with the
Competent Persons Designation Procedure Ref: ADP-013529-066.

5.2 Roles & Responsibilities of Commissioning Engineer

 Commissioning Engineer will be in charge of all operations during Testing & Commissioning
following Project HSE requirements and Project Quality Plans.
 Maintains work permits with coordination of the HSE Supervisor.
 Coordinates with QC Engineer for inspections and raise RFIC with complete attachments such
as approved (ITP, shop drawing, check list etc.).
 Ensures that only trained and competent personnel are involved for Final Testing of the MV
Switchgear.
 Ensures that tools & equipment are certified, maintained and used correctly.
 Ensure that all testing tools are calibrated and calibration is up to date.
 Ensures that all required documents and related drawings to execute the works are up to date.
 Shall prepare open front for his crew and liaise with planning department for progress reporting
and schedule monitoring.

5.3 Roles & Responsibilities of QC Engineer

 Ensure that all inspection and test reports pertaining to everyday work activities are submitted to
the QC inspection.
 Prevent the use of equipment that could cause improper test relative to project Specifications.
 Stop test activity that is not being done in accordance with the specified requirements and
approvals.
 Ensure that test have been done in accordance with approved method statement and Project
specification to offer for CSC’ & CxA’s inspection.

5.4 Roles & Responsibilities of Foreman

 The foreman will carry out his duties by maintaining continuous coordination with the
Commissioning Engineer on daily basis, and ensure proper distribution of the workforce in the
required and planned locations.
 To ensure that his assistant foreman/charge hand are aware of the job requirements and they
have enough information to carry out their duties properly.
 To ensure in consultation with the site engineer that the manpower involved in the works are
moving as agreed and planned for the work.
 To ensure that the daily work is progressing as planned and advice the Commissioning Engineer
of any requirement for additional resources.
 To ensure full coordination with the safety officer to maintain safe working and proper
housekeeping of the site, following the approved safety measures and further ensure that all his
working team are aware of the same to prevent accident and losses.
 To inform the Commissioning Engineer and of the areas ready for inspection.

5.5 Roles & Responsibilities of Equipment Specialist

 ABB’s Representative shall supervise the testing & commissioning of the MV Switchgear Panel.
 ABB’s Representative shall sign off the pre-commissioning check list and commissioning test
sheets when the requirements stated in this Method Statement are satisfied.

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Method Statement for Testing & Commissioning of MV Switchgear Page 7 of 50 Rev. 003

6.0 TOOLS REQUIREMENT

The following tools & equipment will be used during the Testing and Commissioning of MV Switchgears.

 Standard Electrician Tool Kit

 Insulation Resistance Tester – 5 kV
 Secondary Current Injection Test Kit
 CT Analyzer
 Earth Leakage Clamp Meter
 Contact Resistance Tester – 600 A
 Primary Injection Test Kit – 600 A
 Digital Multimeter
 Clampmeter
 Torque Wrench
 Discharge tools
 HV Gloves
 Rubber Mat
 PPE (Hand Gloves, Safety Goggles)

Note: All tools and equipment’s will be inspected and colour coded before use at site.

7.0 METHOD AND SEQUENCE OF WORK

7.1 General

 All necessary work permits shall be approved before commencement of the work.
 Prior to commencement of work, a tool box meeting shall be held for proper distribution of testing
personnel and relocation of other workers working during the testing.
 Prior to start the work, conduct pre-work start tool box talk and related method statement shall
be read and signed off by concerned engineers.
 All personnel involved carrying out the testing activity shall be briefed via HSE Tool box talk, on
site condition, work area, task in hand, risk, hazards, and mitigation of potential of risk.
 Secure valid calibration certificate for all testing equipment, which will be used for test.
 Ensure approval of drawing by Local Electrical Authority are in place.
 There will be a Pre-qualified contractor, authorized by the local authority, to conduct the tests on
the MV Switchgear.

7.2 Safety Precautions

 All safety precaution shall be followed as per established project safety plan.
 Only experienced and skilled technician shall be engaged for carrying out the start-up and
commissioning of MV Switchgears.
 Appropriate warning signs and tapes shall be placed during start-up and commissioning as
required.
 All PPE shall be worn as appropriate according to the nature of job.
 Work area shall be maintained neat and clean.
 Lock-Out & Tag-Out procedure (Ref. ADP-013529-026) shall be followed during entire activity
related to Testing and Commissioning as applicable.

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Method Statement for Testing & Commissioning of MV Switchgear Page 8 of 50 Rev. 003

 Check the insulation rating of the HV gloves if it is capable of withstanding the supplied voltage.
 One of the physical properties of vacuum insulation is the possibility of X-ray emission when the
interrupter contacts are open. Local emission at a distance of 10cm from the interrupter or pole
surface, should not exceed 1 mSv/h.

7.3 Pre-Commissioning

 Ensure that MV Panel installation is complete with RFIT signed off.

 Ensure that MV Cables Test is completed with RFIC signed off.
 Ensure Earthing System is with RFIC signed off.
 Check the general condition of the switchgear for any damage or defects.
 Check the lubrication of tulip contact of CB and tightness marking of screws fastening the contact
pins.
 Visually inspect the switching devices, withdrawable parts, isolating contact, insulating parts, etc.
 Remove all residues of materials, foreign objects, shipping restraints, and tools from the unit.
 Verify that the switchgear and its components have identification and labels according to the
drawings.
 Check basic dimensions according to the General Arrangement Drawing.
 Check connection of the main earthing bar to the station earthing conductor.
 Check the correct wires marking according to the drawings.
 Check the correct accommodation of the LV apparatus according to the drawings.
 Check that the protection degree comply with the requirements.
 Check that the type and ratio of each current and voltage transformer are according to design
and specification.
 Check that the type and rating of each circuit breaker is according to design and specification.
 General Arrangement Drawing shall be in place.
 Schematic Diagram shall be in place.
 Ensure that metering/measuring system is ready for integration thru BMS/IBMS for parameters
monitoring.
 Ensure that exchanged boxes for Keys Interlock was installed properly and Keys interlock
scheme is available in the panel.
 Approved Discrimination Study/Coordination Study shall be in place for Relay Testing &
Verification of Relay Final Settings.
 Back-up Supply for Auxiliary Voltages for internal lighting and heating including the DC System
of control circuits, protective device and Circuit Breaker Charger motor of MV Switchgears to be
installed and tested including Battery Discharge & Battery Charging Test prior to the
Commissioning of MV Switchgear.
 Check that Surge Arresters are mounted in the switchgear enclosure and connected to the
incoming service lead.
3  Check that cubicle heaters are installed in every circuit breaker compartment and thermostatically
controlled. Thermostat shall be set and marked with manufacturer’s recommended setting.

7.4 Commissioning

The objective is to confirm the physical condition and electrical characteristics of the MV
Switchgear installed and to ensure that it is connected to the system at a correct condition as
mandated by design specifications and equipment schedule.

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Method Statement for Testing & Commissioning of MV Switchgear Page 9 of 50 Rev. 003

7.4.1 Vacuum Circuit Breaker Tests

7.4.1.1 Visual and Mechanical Test

 Check details on nameplate are correct.

 Check general physical condition.
 Check that all terminations are tight and secure.
 Check racking mechanism for alignment and smoothness.
 Check operation of all mechanical interlocks including key interlocks.
 Check correct breaker position indication.
 Check correct spring status indication.
 Check manual operation of VCB.
7.4.1.2 Insulation Resistance Test

Perform insulation resistance test on the VCB. Apply a minimum of 2.5 kV DC

for 1 minute on each pole, phase-to-phase and phase-to-ground, with the CB
closed. Acceptance criteria should be at least 50 MΩ.
7.4.1.3 Contact Resistance Test

Perform contact resistance measurements through the bolted connections with

a low resistance ohmmeter. Inject 600 A DC with the CB in closed position.
7.4.1.4 Timing Test

Measure the closing time and tripping time with the timing test kit that will
measure the time.
7.4.2 Main Busbar Tests

7.4.2.1 Torque Test on MV Busbar

Tightness of the bolts will be tested with torque wrench to ensure correct tightness. See
below the Standard Torque Chart.
Bolt Size Class 8.8
M6 M8 M10 M12
Torque (Nm) 13 28 50 75
 The test is carried out using the calibrated torque wrench.
 The fasteners size is checked for making proper tightening.
 The desired torque value is adjusted in the torque wrench.
 Keep the torque wrench in one side and the other side with spanner for clasp.
 Rotate the torque wrench in clock wise direction until hearing the sound like
“Click”.
 Make a red mark on the bolts after tightening.
 The results are tabulated in the given formats for sign-off, see sample below.

7.4.2.2 Insulation Resistance Test on MV Busbar

IR test shall be conducted in the MV Busbar before and after the Hi-Pot Test at using an
insulation resistance tester. Before disconnecting the test leads, test object shall be
discharged through ground.
 Isolate all the control circuits by removing the control fuses/breakers.

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Method Statement for Testing & Commissioning of MV Switchgear Page 10 of 50 Rev. 003

 Isolate all the electronic devices and all neutral & earth power cables.
 Energize the insulation measurement test kit.
 Set the D.C voltage into 5 kV for 1 min. Test connection shall be as follows:
o L1 phase to L2 + L3 + E
o L2 phase to L1 + L3 + E
o L3 phase to L1 + L2 + E
7.4.2.3 High Voltage Withstand Test on MV Busbar at 80%

Hi-Pot test shall conducted in the MV Busbar using a hi-pot tester. Before disconnecting
the test leads, test object shall be discharged through ground. Voltage to be reduced to
80% of previous applied value.
 The panel under test will be isolated from the supply. Also isolate Control Circuit
and Low Voltage Circuit.
 Switch ON all breakers of power circuits and switch OFF all the breakers with
electronic trip units and switch OFF all control gear.
 Using Hi-Pot Tester, apply 22.4 kV, 50 Hz, for 1 min. Connection shall be as
follows:
o L1 phase (L2 + L3 to E)
o L2 phase (L1 + L3 to E)
o L3 phase (L1 + L2 to E)
7.4.2.4 Contact Resistance Test on MV Busbar

 The test shall be done by injecting 600 A DC between panels with CB’s inserted
in service position and closed.
 The test is considered as positive if the resistance does not exceed the value of
350 µΩ if measured without current transformers. If measured with current
transformers, the internal resistance of the CT should be taken into
consideration.
 Connect the terminals of the test equipment between the panel incoming
terminals and the furthest point reachable along the length of the main bar.

7.4.3 MV Switchgear Auxiliary and Control Circuit Tests

7.4.3.1 Insulation Resistance Test on MV Switchgear Auxiliary Circuits

IR test shall be conducted before & after Hi-Pot Test in the MV Auxiliary and Control
Circuits between DC circuits and frame and AC circuits and frame. Test object shall be
discharged through ground.
 Set the DC voltage into 500 V DC for 1 min. Connection shall be as follows:
o L1 phase to L2 + L3 + N + E
o L2 phase to L1 + L3 + N + E
o L3 phase to L1 + L2 + N + E
o N phase to L1 + L2 + L3 + E
7.4.3.2 Voltage Withstand Test on MV Switchgear Auxiliary Circuits at 80%
Hi-Pot test shall conducted in the auxiliary and control circuits using a hi-pot tester.
 Using Hi-Pot Tester, apply 1 kV AC for 1 min. Connection shall be as follows:
o L1 phase (L2 + L3 + N to E)
o L2 phase ( L1 + L3 + N to E)

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Method Statement for Testing & Commissioning of MV Switchgear Page 11 of 50 Rev. 003

o L3 phase (L1 + L2 + N to E)
o N phase (L1 + L2 + L3 to E)

7.4.4 Current Transformer Tests

According to current transformers’ ratio, inject to primary side of transformers a suitable

one or three phases current and verify correct current reading. Test is considered
positive if voltage is measured on secondary side of transformers is of the same polarity
as on primary side. Isolate CT prior to testing.
7.4.4.1 Visual & Mechanical Test
 Check details on nameplate are correct.
 General physical condition.
 Check that all terminations are tight and secure.
7.4.4.2 Insulation Resistance Test

IR Test shall be carried by applying 2.5 kV DC from primary to ground, 2.5 kV

DC from primary to the secondary, and 250 V DC from secondary to ground for
1 minute.
7.4.4.3 Polarity Test

Test report to be generated by CT Analyzer and attached.

7.4.4.4 CT Turns Ratio Test

The primary current of minimum of 25% rated primary current is to be injected

on primary side of CT with secondaries shorted and the secondary current can
be measured & recorded for all cores. Test report to be generated by CT
Analyzer and attached.
7.4.4.5 Primary Injection Test

Single point grounding shall be verified for CT circuits before starting this test.
Inject 25% of rated primary current between one phase and earth with all
connected burden. Measure secondary current at all points of CT circuits. It shall
be done for other phases.
7.4.4.6 Loop/Winding Resistance Test

Test report to be generated by CT Analyzer and attached.

7.4.4.7 Magnetization Curve Test

This test shall be conducted before ratio test and after secondary resistance and
polarity test, since residual magnetism left in the core due to DC test (polarity,
resistance), which leads additional error in ratio test. The meters used for this
test shall be having true RMS measurement. The primary should be open during
test.
Demagnetisation: Before starting the test, demagnetise the core by injecting
voltage current on secondary terminals and increase up to where considerable
increment in current with small voltage increments. Now start decreasing the
voltage to zero, the rate at which increased.

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Method Statement for Testing & Commissioning of MV Switchgear Page 12 of 50 Rev. 003

Magnetisation Test: Now increase the voltage and monitor the excitation
current up to the CT reaching near to saturation point. Record the reading of
voltage and current at several points. Plot the curve and evaluate the Vk and
Img from the graph. Test report to be generated by CT Analyzer and attached.
7.4.4.8 Burden Test
Inject the rated secondary current of the CT, from CT terminals towards load
side by isolating the CT secondary with all connected load and observe the
voltage drop across the injection points. The burden VA can be calculated as,
Burden VA = Voltage drop x rated CT sec. current. Test report to be generated
by CT Analyzer and attached.

7.4.5 Voltage Transformer Tests

According to voltage transformers’ ratio, apply on secondary side of transformers a

suitable voltage and verify correct voltmeter reading. Isolate VT prior to testing.
7.4.5.1 Visual & Mechanical Test
 Check details on nameplate are correct.
 General physical condition.
 Check that all terminations are tight and secure.
7.4.5.2 Insulation Resistance Test

IR Test shall be carried by applying 5 kV DC from primary winding to ground, 2.5

kV DC from primary winding to the secondary winding, and 250 V DC from
secondary winding to ground for 1 minute.
7.4.5.3 VT Turns Ratio Test

Inject primary voltage Vp in the primary winding and measure the corresponding
secondary voltage. The measured ratio Vp/Vs to be compared to the VT
nameplate ratio.

7.4.6 Protective Relays Tests

7.4.6.1 Visual & Mechanical Test

 Check details on nameplate are correct.
 General physical condition.
 Check that all terminations are tight and secure.
 Check that feeding supply within allowed margin.
7.4.6.2 Protection/Control Functional Test.
This will be carried out with using a secondary injection test with the relay alone.
This will verify all connections, inputs to and outputs from the relay. Inputs shall
be initiated from the source and Outputs monitored in the relay.
7.4.6.2.1 Instantaneous Overcurrent Relay (50)
 Pick-Up/Drop-Out/Trip Test
 Relay Timing Test
7.4.6.2.2 AC Inverse Time Overcurrent Relay (51)
 Pick-Up/Drop-Out/Trip Test
 Relay Timing Test
7.4.6.2.3 Instantaneous Earth Overcurrent Relay (50N)

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 Pick-Up/Drop-Out/Trip Test
 Relay Timing Test
7.4.6.2.4 AC Inverse Time Earth Overcurrent Relay (51N)
 Pick-Up/Drop-Out/Trip Test
 Relay Timing Test

7.4.7 Energy Meter/Measuring Instrument Tests

7.4.7.1 Visual & Mechanical Test

 Inspect for physical damage/defects.

 Check details on nameplate are correct.
 Verify that indication range of meter is as specified.
 Verify that meter/instrument connections are according to approved drawings.
 Check that all mounting bolts and wiring terminations are tight and secured.
7.4.7.2 Accuracy Test

The secondary injection accuracy test shall be done by injecting the input quantities
(Voltage or current or both) from test block. Injection kit shall be a calibrated, stable
source (Ex. Computerized test kit like omicron CMC). Otherwise another
standard/calibrated measuring Instrument shall be used as reference. The following
steps shall be followed. Before starting the test, zero adjustment to be done for pointer
in case of analogue meter. Injection shall be made to fix several points on the meter
scale 25%, 50%, 75%, 100% of rated primary Reading and full scale. Each measuring
point shall be fixed at meter scale and injected secondary input recorded. Meter accuracy
shall be calculated based on full-scale deflection for analogue meters. The following
quantities shall be measured & tabulated for different values.
 Current
 Voltage
 Power (KW, KVAR, KVA)
 Energy (KWH, KVRH, KVH)
 Power Factor (Phase angle)
 Frequency
Limits:
The observed accuracy of meter at various points shall be compared with meter accuracy
class. Current & Voltage Accuracy 0.5%, Active Energy 1.0%, Reactive Energy 2.0%.

7.4.8 Mechanical Operation Test of MV Panel

 Check that the cable compartment door cannot be opened if the earthing switch is open.
 Check that the earthing switch cannot be open if the cable compartment door is open.
 Check the impossibility of either inserting or isolating the circuit breaker when closed.
 Check that the mechanical interlock prevent the circuit breaker contacts closing if the
truck is positioned between service and test position.
 Check that the key interlock is working properly together with the associated Exchange
Boxes as specified in the MV Keys Interlock Drawing.
 Check that the circuit breaker cannot be inserted into service position when the earthing
switch is closed.

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 Check that the earthing switch cannot be closed when the circuit breaker is in active
positon.
 Check that the shutters are automatically and fully closed when the circuit breaker is
withdrawn out from the switchgear panel.
 Check that Mechanical Interlock for earthing, Disconnect Switches & Circuit Breaker is
working properly to avoid/prevent human error during switching operation.

7.4.9 Functional Test of MV Panel

 Check the functionality of the circuit breaker limit switches (test/service).

 Check the functionality of the circuit breaker auxiliary contacts (open/closed).
 Check the functionality of the earthing switch auxiliary contacts (open/closed).
 Check the correct function of closing/opening at reduced voltage (AC/DC – 15%).
 Check the correct tripping function of Limiters – manual activation.
 Check the motorized closing spring of the Circuit Breaker.
 Check the operation of Circuit Breaker once the thermo-controller of associated
Transformer reaches the tripping stage.
 Check Tripping of switching devices (VCB) from Protective Relays.
 Check Status of switching devices to local and remote.
 Check Alarms/indications availability to local and remote.
 Following the switchgear functional schemes and the REF logic drawings, verify the
panels and switchgear functionality. Checking: electrical interlocks between Incomer-1,
Incomer-2 & Bus Coupler, electrical sequences, functional and control indicators.

7.4.10 Verification of Final Relay Settings

 Approved Discrimination Study shall be in place for final verification of relay settings.
 ABB’s Representative shall be involved for the final verification of relay settings.

8.0 QUALITY CONTROL

 MEP RFIC should be issued by T&C Engineer for verification before submission to CSC & CxA.
 Refer to ITP No. ADP-261300-018 and strictly follow inspections steps.
 Refer to QMP-ADP-014000-625 for RFIC submission process.
 Work should be approved by consultant (submitting RFIC).

9.0 HEALTH, SAFETY & ENVIRONMENTAL

9.1 Induction

Prior to commencing work all personnel shall have attended the HSE induction course conducted by the
JV HSE department. No work shall be undertaken by personnel who have not attended the Project HSE
induction. In all aspects, work is to be carried out in a safe manner and in accordance JV approved Health
and Safety Plan and in accordance with HSE requirements

9.2 Personal Protective Equipment (PPE)

All personnel involved in the Testing and Commissioning will comply with the Project requirements for
PPE:
 Work Boots with toe protectors
 Safety Helmet

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 Eye Protection with side shields

 HV Gloves
 Dust masks (as required)
 Rubber Mat

Additional PPE identified by the task risk assessment shall also be provided. Personnel shall sign and be
responsible for their own items of PPE issued to them and the Engineer shall ensure that his team is
complying with the minimum required PPE and that damaged or defective PPE is replaced or repaired
immediately.

9.3 Hazard Identification, Risk Assessment & Control

Hazard identification, risk assessment and control are detailed in the appropriate risk assessment and
Job Safety Task Instruction (JSTI) attached herewith. Hazards may vary as the works progress and shall
be re-evaluated. All personnel undertaking testing and commissioning activities shall be aware of
particular location hazards. The Project Risk Assessment Procedure ADP-013529-028 is to be referred
to during the planning stages. Should changes occur during the course of commissioning which alters
the associated risks then the risk register shall be updated to reflect any additional risk and mitigation
measure.

The attached JSTI is provided to cover the initial work tasks relating to Testing and Commissioning of
MV Switchgears - JSTI (attached). This JSTI is prepared based on theoretical information interpreted
from the project documents. A further assessment will be required at the actual work site to verify the
control measures and address any additional hazards. Reference is to be made to the relative Health,
Safety, Environmental & Security procedures to control the risks associated with activities where they
occur.

9.4 Toolbox Talks

Prior to the commencement of site activities the Engineer, with support from the HSE Officer, shall
conduct a pre-start toolbox talk with all the crew present. The MEP Supervisor shall explain the testing
and commissioning of MV Switchgear activities, focusing on the hazards and risks involved in the activity
and the mitigation measures that shall be taken as detailed in the Risk Assessment. Regular Toolbox
talks shall be conducted in order to prevent complacency within the crew. The Engineer shall conduct a
Pre-start toolbox talk for the new person/s prior to starting work.

9.5 Permit to Work

A Permit shall be obtained when and where applicable in accordance with the requirements of Permit to
Work Procedure (ADP-013529-034) prior to performing the Installation, Testing and commissioning of
MV Switchgear. The supervisor will ensure that all relevant risk assessments, method statements and
permit to work control measures are in place and that all relevant procedures contained within
these documents are fully understood by the operative personnel.

9.6 Training of Personnel

9.6.1 Safety Training

All personnel involved in Testing and Commissioning MV Switchgears works shall be trained in
accordance with the requirements of the Project HSE Program. No personnel shall be assigned
tasks that they have not received appropriate training in or have been assessed for competency.
Further training shall be given as required and when additional training is identified during the
risk assessment process.

Page 15 of 50
 Abu Dhabi Plaza – Astana, Kazakhstan Document No.
Work Package 4 – Main Works ADP-261300-020

Method Statement for Testing & Commissioning of MV Switchgear Page 16 of 50 Rev. 003

9.6.2 Trades & Qualifications

All personnel involved in Testing and Commissioning of MV Switchgears activities shall be

assessed for qualifications, competency and if they have the required trade skills and
experience, or trained in accordance with the requirements of the project standards.

10.0 Attachments

Page 16 of 50
  

         

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 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Pre-Commissioning Checklist for MV Switchgear

FM-MS-ADP-261300-020-001 Revision: 003 Date: 20-Apr-17 Page 1 of 1

RFIC No. Date: System: Medium Voltage Sub System: Medium Voltage Switchgear

Block / Bldg. Level: Location: Switchgear Tag:

ACCEPTANCE STATUS
REQUESTED DOCUMENTATION SUBMITTED
Yes/No REMARKS
1. T&C MS
2. Signed off MV Panel Installation RFIT
3. Signed off Earthing System & MV Cables RFIC
4. General Arrangement Drawing, Schematic Drawing
5. Discrimination/Coordination Study
ACCEPTANCE STATUS
ACTIVITIES / ITEMS TO BE INSPECTED
Yes/No REMARKS
1. General condition of the switchgear is free of any damage or defects.
2. Lubrication contact of CB is OK. Screws on the contact pins are tight.
3. Switching devices, withdrawable parts, isolating contacts, and insulating parts look OK.
4. Switchgear is free from shipping restraints, foreign objects, and tools not related,
5. Switchgear and its components are identified and labelled properly.
6. Basic dimensions are correct according to the General arrangement drawings.
7. Connection of the main earthing bar to the installation earthing conductor.
8. Wires are marked correctly according to the drawings.
9. LV apparatus is correctly accommodated according to the drawings
10. Protection devices comply with the requirements.
11. Voltage/Current transformer type and ratio of each are according to design and
specification.
12. Type and rating of each circuit breaker is according to design and specification.
13. Metering/measuring system is ready for integration thru BMS/IBMS for parameters
monitoring.
14. Exchanged boxes for Keys Interlock was installed properly and Keys interlock scheme is
available in the panel.
15. Check that Surge Arresters are mounted in the switchgear enclosure and connected to the
incoming service lead.
16. Check that cubicle heaters are installed in every circuit breaker compartment and
thermostatically controlled. Thermostat shall be set and marked with manufacturer’s
recommended setting.
15. Back-up Supply for Auxiliary Voltages for internal lighting and heating including the DC
System of control circuits, protective device and Circuit Breaker Charger motor of MV
Switchgear is installed and tested incl. Battery Discharge & Battery Charging.

POSITION NAME SIGNATURE DATE

ABB’s Representative

JV Commissioning Engineer

(CSC) AECOM KZ

(CxA) CML

FM-MS-ADP-261300-020-001
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Vacuum Circuit Breaker Tests on MV Switchgear

FM-MS-ADP-261300-020-002 Revision: 003 Date: 20-Apr-17 Page 1 of 2

RFIC No. Date: System: Medium Voltage Sub System : Medium Voltage Switchgear

Block / Bldg: Level: Location: Switchgear Tag:

Vacuum Circuit Breaker Data

Make: VCB Type: Panel No.: Panel Name:

VCB Serial No.: VCB Rating:

ACCEPTANCE STATUS
Visual & Mechanical Test
Yes/No Remarks
1. Check details on nameplate are correct.
2. Check general physical condition.
3. Check that all terminations are tight and secure.
4. Check racking mechanism for alignment and smoothness.
5. Check operation of all mechanical interlocks including key interlocks.
6. Check correct breaker position indication.
7. Check correct spring status indication.
8. Check manual operation of VCB

VCB Insulation Resistance Test Ambient Temp. Voltage Applied

Test Connection Withstand Time (1min) Insulation Resistance Value Remarks
L1 - L2

L2 - L3
L3 - L1
L1L2L3 - E

VCB Contact Resistance Test

Current Injected L1 – Resistance Value L2 – Resistance Value L3 – Resistance Value

Timing Test
Actual Trip Time
Injected Current (1ϕ) Applied Voltage (2 ϕ) TMS (s) OK / NOT OK
(ms)
L1 L2L3

L2 L1L3

L3 L1L2

FM-MS-ADP-261300-020-002
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Vacuum Circuit Breaker Tests on MV Switchgear

FM-MS-ADP-261300-020-002 Revision: 003 Date: 20-Apr-17 Page 2 of 2

INSTRUMENT USED
Equipment Name Model No. Serial No. Calibration due date
1.

2.

3.

4.

POSITION NAME SIGNATURE DATE

ABB’s Representative

JV Commissioning Engineer

(CSC) AECOM KZ

(CxA) CML

FM-MS-ADP-261300-020-002
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Commissioning Record Sheet for MV Switchgears

Busbar Test
FM-MS-ADP-261300-020-003 Revision: 003 Date: 20-Apr-17 Page 1 of 2

RFIC No. Date: System: Medium Voltage Sub System : Medium Voltage Switchgear

Block/Bldg: Level Location Switchgear Tag:

Torque Test
Joint Busbar Bolt Torque Applied (N/m) Remarks

MV Busbar Insulation Resistance Test (Before Hi-Pot) Ambient Temp. Voltage Applied
Test Connection Withstand Time (1min) Insulation Resistance Value Remarks
L1 to L2+L3+E

L2 to L1+L3+E
L3 to L2+L1+E

MV Busbar Dielectric Test for 1 minute in mA Voltage Applied

Test Connection Withstand Time (1min) Leakage Current Value Remarks
L1 (L2+L3 to E)

L2 (L1+L3 to E)
L3 (L2+L1+to E)

MV Busbar Insulation Resistance Test (After Hi-Pot) Ambient Temp. Voltage Applied
Test Connection Withstand Time (1min) Insulation Resistance Value Remarks
L1 to L2+L3+E

L2 to L1+L3+E
L3 to L2+L1+E

FM-MS-ADP-261300-020-003
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Commissioning Record Sheet for MV Switchgears

Busbar Test
FM-MS-ADP-261300-020-003 Revision: 003 Date: 20-Apr-17 Page 2 of 2

MV Busbar Contact Resistance Test in µΩ Current Injected

Phase Under Test Resistance Value Remarks
L1

L2

L3

INSTRUMENT USED
Equipment Name Model No. Serial No. Calibration due date
1.

2.

3.

POSITION NAME SIGNATURE DATE

ABB’s Representative

JV Commissioning Engineer

(CSC) AECOM KZ

(CxA) CML

FM-MS-ADP-261300-020-003
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Commissioning Record Sheet for MV Switchgears

Auxiliary Circuits
FM-MS-ADP-261300-020-004 Revision: 003 Date: 20-Apr-17 Page 1 of 1

RFIC No. Date: System: Medium Voltage Sub System : Medium Voltage Switchgear

Block / Bldg Level Location Switchgear Tag:

MV Auxiliary Circuits IR Test (Before Hi-Pot) Ambient Temp. Voltage Applied

Test Connection Withstand Time (1min) Insulation Resistance Value Remarks
L1 to L2+L3+N+E

L2 to L1+L3+N+E
L3 to L2+L1+N+E
N to L1+L2+L3+E
MV Auxiliary Dielectric Test for 1 minute in mA Voltage Applied
Test Connection Withstand Time (1min) Leakage Current Value Remarks
L1 (L2+L3+N to E)

L2 (L1+L3+N to E)
L3 (L2+L1+N to E)
N (L1+L2+L3 to E)
MV Auxiliary Circuits IR Test (After Hi-Pot) Ambient Temp. Voltage Applied
Test Connection Withstand Time (1min) Insulation Resistance Value Remarks
L1 to L2+L3+N+E

L2 to L1+L3+N+E
L3 to L2+L1+N+E
N to L1+L2+L3+E

INSTRUMENT USED
Equipment Name Model No. Serial No. Calibration due date
1.

2.

3.

POSITION NAME SIGNATURE DATE

ABB’s Representative

JV Commissioning Engineer

(CSC) AECOM KZ

(CxA) CML

FM-MS-ADP-261300-020-004
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Currents Transformer Tests on MV Switchgear

FM-MS-ADP-261300-020-005 Revision: 003 Date: 20-Apr-17 Page 1 of 2

RFIC No. Date: System: Medium Voltage Sub System : Medium Voltage Switchgear

Block / Bldg: Level: Location: Switchgear Tag:

Current Transformer Data

Make: CT Type: Panel No.: Panel Name:

CT Ratio: CT Class: Capacity: CT Serial No.

CT Function/Purpose Protection Metering Spare

ACCEPTANCE STATUS
Visual & Mechanical Test
Yes/No Remarks
1. Check details on nameplate are correct.

2. Check general physical condition.

3. Check that all terminations are tight and secure.

Insulation Resistance Test

Test Points Applied Voltage Test Duration L1 – IR Value L2 – IR Value L3 – IR Value
Prim. – E

Sec. – E

Prim. - Sec

Primary Injection Test

Measured Primary Current (A) Measured Secondary Current (A)
Primary Injection in Injected Current Ok/Not Ok
L1 L2 L3 L1 L2 L3
L1

L2

L3

Magnetization Curve Test

AC mA
AC Volt Ok / Not Ok
L1 L2 L3

Vk

Ie

FM-MS-ADP-261300-020-005
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Currents Transformer Tests on MV Switchgear

FM-MS-ADP-261300-020-005 Revision: 003 Date: 20-Apr-17 Page 2 of 2

INSTRUMENT USED
Equipment Name Model No. Serial No. Calibration due date
1.

2.

3.

4.

POSITION NAME SIGNATURE DATE

ABB’s Representative

JV Commissioning Engineer

(CSC) AECOM KZ

(CxA) CML

FM-MS-ADP-261300-020-005
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Voltage Transformer Tests on MV Switchgear

FM-MS-ADP-261300-020-006 Revision: 003 Date: 20-Apr-17 Page 1 of 2

RFIC No. Date: System: Medium Voltage Sub System : Medium Voltage Switchgear

Block / Bldg: Level: Location: Switchgear Tag:

Voltage Transformer Data

Make: VT Type: Panel No.: Panel Name:

Secondary Winding 1: Volts = VA = Class =

Secondary Winding 2: Volts = VA = Class =

VT Serial No. VT Ratio:

ACCEPTANCE STATUS
Visual & Mechanical Test
Yes/No Remarks
1. Check details on nameplate are correct.

2. Check general physical condition.

3. Check that all terminations are tight and secure.

Insulation Resistance Test

Connection Applied Voltage Test Duration Insulation Resistance Value Ok / Not Ok

HV to Secondary and Earth

Secondary 1 to Secondary 2
plus HV and Earth
Secondary 2 to Secondary 1
plus HV and Earth

Voltage Ratio Test

Measured Voltage
Applied Voltage in Primary Measured Ratio Actual Ratio Ok / Not Ok
in Secondary
L1

L2

L3

INSTRUMENT USED
Equipment Name Model No. Serial No. Calibration due date
1.

2.

3.

4.

FM-MS-ADP-261300-020-006
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Voltage Transformer Tests on MV Switchgear

FM-MS-ADP-261300-020-006 Revision: 003 Date: 20-Apr-17 Page 2 of 2

POSITION NAME SIGNATURE DATE

ABB’s Representative

JV Commissioning Engineer

(CSC) AECOM KZ

(CxA) CML

FM-MS-ADP-261300-020-006
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Protective Relay Tests on MV Switchgear

FM-MS-ADP-261300-020-007 Revision: 003 Date: 20-Apr-17 Page 1 of 3

RFIC No. Date: System: Medium Voltage Sub System : Medium Voltage Switchgear

Block / Bldg: Level: Location: Switchgear Tag:

Protective Relay Data

Make: ABB Panel No.: Panel Name:

Relay Type: Relay Serial No.

ACCEPTANCE STATUS
Visual & Mechanical Test
Yes/No Remarks
1. Check details on nameplate are correct.

2. Check general physical condition.

3. Check that all terminations are tight and secure.

4. Check that feeding supply within allowed margin.

Protective Relay Functional Test

Device Function/Number: Instantaneous Overcurrent Relay (50) Trip Element: Phase

Connected CT Ratio: Instantaneous O/C Setting:

Relay Setting: Time Characteristic Curve: Time Multiplier Setting:

Pick-up and Drop-out Test

Injected Current (1ϕ) Applied Voltage (2 ϕ) Pick-up OK / NOT OK

L1 L2L3

L2 L1L3

L3 L1L2

Timing Test
Actual Trip Time
Injected Current (1ϕ) Applied Voltage (2 ϕ) TMS (s) OK / NOT OK
(ms)
L1 L2L3

L2 L1L3

L3 L1L2

FM-MS-ADP-261300-020-007
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Protective Relay Tests on MV Switchgear

FM-MS-ADP-261300-020-007 Revision: 003 Date: 20-Apr-17 Page 2 of 3

Protective Relay Functional Test

Device Function/Number: AC Inverse Overcurrent Relay (51) Trip Element: Phase

Connected CT Ratio: Instantaneous O/C Setting:

Relay Setting: Time Characteristic Curve: Time Multiplier Setting:

Pick-up and Drop-out Test

Injected Current (1ϕ) Applied Voltage (2 ϕ) Pick-up OK / NOT OK

L1 L2L3

L2 L1L3

L3 L1L2

Timing Test
Actual Trip Time
Injected Current (1ϕ) Applied Voltage (2 ϕ) TMS (s) OK / NOT OK
(ms)
L1 L2L3

L2 L1L3

L3 L1L2

Protective Relay Functional Test

Device Function/Number: Instantaneous Earth Overcurrent Relay (50N) Trip Element: Ground

Connected CT Ratio: Instantaneous E/F Setting:

Relay Setting: Time Characteristic Curve: Time Multiplier Setting:

Pick-up and Drop-out Test

Injected Current (1ϕ) Applied Voltage (2 ϕ) Pick-up OK / NOT OK

L1-N a-n

Timing Test
Actual Trip Time
Injected Current (1ϕ) Applied Voltage (2 ϕ) TMS (s) OK / NOT OK
(ms)
L1-N a-n

FM-MS-ADP-261300-020-007
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Protective Relay Tests on MV Switchgear

FM-MS-ADP-261300-020-007 Revision: 003 Date: 20-Apr-17 Page 3 of 3

Protective Relay Functional Test

Device Function/Number: AC Inverse Time Earth Overcurrent Relay (51N) Trip Element: Ground

Connected CT Ratio: Instantaneous E/F Setting:

Relay Setting: Time Characteristic Curve: Time Multiplier Setting:

Pick-up and Drop-out Test

Injected Current (1ϕ) Applied Voltage (2 ϕ) Pick-up OK / NOT OK

L1-N a-n

Timing Test
Actual Trip Time
Injected Current (1ϕ) Applied Voltage (2 ϕ) TMS (s) OK / NOT OK
(ms)
L1-N a-n

INSTRUMENT USED
Equipment Name Model No. Serial No. Calibration due date
1.

2.

POSITION NAME SIGNATURE DATE

ABB’s Representative

JV Commissioning Engineer

(CSC) AECOM KZ

(CxA) CML

FM-MS-ADP-261300-020-007
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Energy Metering/Measuring Instrument Tests on MV

Switchgear
FM-MS-ADP-261300-020-008 Revision: 003 Date: 20-Apr-17 Page 1 of 3

RFIC No. Date: System: Medium Voltage Sub System : Medium Voltage Switchgear

Block / Bldg: Level: Location: Switchgear Tag:

ACCEPTANCE STATUS
Visual & Mechanical Test
Yes/No Remarks
1. Inspect for physical damages/defects.

2. Check details on nameplate.

3. Verify that indication range of meter is as specified.

4. Verify that the meter/instrument connections are according to approved drawings.

5. Check that all mounting bolts and wiring terminations are tight and secured.

Ammeter Function

Panel No.: Panel Name:

CT Ratio: CT Accuracy Class:

Displayed Meter Reading (A) Reference Std. Meter Reading (A) OK /
Injected Current (A)
L1 L2 L3 L1 L2 L3 NOT OK

25%

50%

75%

100%

Voltmeter Function

Panel No.: Panel Name:

VT Ratio: VT Accuracy Class:

Displayed Meter Reading (V) Reference Std. Meter Reading (A) OK /
Applied Voltage (V)
L1 L2 L3 L1 L2 L3 NOT OK

25%

50%

75%

100%

FM-MS-ADP-261300-020-008
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Energy Metering/Measuring Instrument Tests on MV

Switchgear
FM-MS-ADP-261300-020-008 Revision: 003 Date: 20-Apr-17 Page 2 of 3

Frequency Function

Panel No.: Panel Name:

Applied Frequency (Hz) Measured Frequency (Hz) OK/NOT OK

100%

Power Function and Power Factor

Panel No.: Panel Name:

CT Ratio: CT Accuracy Class:

VT Ratio: VT Accuracy Class:

Applied Voltage Injected Current Phase Angle Calculated Measured
Cos ϕ OK / NOT OK
(V) (A) (deg) (KW) (KW)

Applied Voltage Injected Current Phase Angle Calculated Measured

Cos ϕ OK / NOT OK
(V) (A) (deg) (KVA) (KVA)

Applied Voltage Injected Current Phase Angle Calculated Measured

Sin ϕ OK / NOT OK
(V) (A) (deg) (KVAr) (KVAr)

Energy Function and Power Factor

Panel No.: Panel Name:

CT Ratio: CT Accuracy Class:

VT Ratio: VT Accuracy Class:

Applied Injected Phase Angle Calculated Measured
Cos ϕ Time (hr) OK / NOT OK
Voltage (V) Current (A) (deg) (KWH) (KWH)

Applied Injected Phase Angle Calculated Measured

Cos ϕ Time (hr) OK / NOT OK
Voltage (V) Current (A) (deg) (KVAH) (KVAH)

Applied Injected Phase Angle Calculated Measured

Sin ϕ Time (hr) OK / NOT OK
Voltage (V) Current (A) (deg) (KVArH) (KVArH)

FM-MS-ADP-261300-020-008
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Energy Metering/Measuring Instrument Tests on MV

Switchgear
FM-MS-ADP-261300-020-008 Revision: 003 Date: 20-Apr-17 Page 3 of 3

INSTRUMENT USED
Equipment Name Model No. Serial No. Calibration due date
1.

2.

3.

4.

POSITION NAME SIGNATURE DATE

ABB’s Representative

JV Commissioning Engineer

(CSC) AECOM KZ

(CxA) CML

FM-MS-ADP-261300-020-008
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Mechanical Operational and Functional Test on MV

Switchgear
FM-MS-ADP-261300-020-009 Revision: 003 Date: 20-Apr-17 Page 1 of 1

RFIC No. Date: System: Medium Voltage Sub System : Medium Voltage Switchgear

Block / Bldg Level Location Switchgear Tag:

ACCEPTANCE STATUS
Mechanical Operation Test
Yes/No Remarks
1. Cable compartment door cannot be opened if the earthing switch is open.

2. Earthing switch cannot be open if the cable compartment door is open/

3. Impossibility of either inserting or isolating the circuit breaker when closed

4. Mechanical interlock prevent the circuit breaker contacts closing if the truck is positioned
between service and test position.
5. Circuit breaker cannot be inserted into service position when the earthing switch is closed

6. Earthing switch cannot be closed when the circuit breaker is in active positon.
7. Shutters are automatically and fully closed when the circuit breaker is withdrawn out from
the switchgear panel.
8. Mechanical Interlock for Earthing Disconnect Switches & Circuit Breaker is working
properly.
9. Check that the key interlock is working properly together with the associated Exchange
Boxes as specified in the MV Keys Interlock Drawing.
ACCEPTANCE STATUS
Functional Test
Yes/No Remarks
1. Functionality of the circuit breaker limit switches (test/service)

2. Functionality of the circuit breaker auxiliary contacts (open/closed)

3. Functionality of the earthing switch auxiliary contacts (open/closed)

4. Functionality of closing/opening at reduced voltage (AC/DC-15%)

5. Functionality of Limiters – manual activation

6. Motorized closing spring of Circuit Breaker

7. Circuit Breaker once the thermos-controller of associated Transformer reaches tripping
stage.
8. Tripping of switching devices (VCB) from Protective Relays

9. Status of switching devices and alarms/indications to local and remote.

10. Verify the panels and switchgear functionality, electrical interlocks between incomer-1,
Incomer-2 & Bus Coupler, electrical sequences, functional and control indicators.

POSITION NAME SIGNATURE DATE

ABB’s Representative

JV Commissioning Engineer

(CSC) AECOM KZ

(CxA) CML

FM-MS-ADP-261300-020-009
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
Step 1: Task Planning (task identification and details)/ Шаг 1: Планирование задания (выявление задачи и деталей)

Supervisor name: Work area: Date:

ФИО Супервайзера: Рабочая зона: Дата:
Activity: Testing & Commissioning of MV Switchgear Work specific location:
Деятельность: Определенное место работы:
Number of crew members: JSTI Number:
Число работников: Номер Оценка Риска:
Start time/ Finish time/
Work Duration: Permit To Work number:
Начало работы Завершение работы
Продолжительность работы: Номер Наряда-Допуска:
_______________ ______________
Step 2: Job Planning (competent persons, tools and equipment necessary to do the job) Шаг 2: Планирование работы (компетентные работники, инструменты и
необходимые оборудования)

Competent Persons Required Tools Required Equipment Required

(Example: Lifting, Equipment Operator, Scaffolder, Vendors) (Example: radios, special testing meters, electric tools, special tools, (Example: excavator, man lift, compressor, crane,
Компетентные Работники SCBA.) forklift, truck)
(Пример: Операторы подъемника, лесамонтажники, производители) Необходимые инструменты (Пример: рация, метровка, Требуемая техника: (Пример: эксковатор,
электрические инструменты) подъемник, компрессор, кран, погрузчик,
грузовик)
 Commissioning Engineer  Standard Electrician Tool Kit
 Foreman  Insulation Resistance Tester – 5 kV
 QC Engineer  Hi-Pot Tester – 25 kV
 HSE Supervisor  Contact Resistance Tester – 600 A
 Primary Injection Test Kit
 Polarity Tester
 Digital Multimeter
 Clamp meter
 Torque Wrench
 Discharge tools ; Rubber Mat

Step 3: Risk Management (list any nearby activities that may impact the work) Шаг 3: Управление Рисками (перечень деятельности которые могут повлиять на работу)
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности

Step 4: Job Safety/Hazard Analysis/ Шаг 4: Анализ/Оценки Рисков

Activity
(What must be done? i.e. tools, Hazards Risks
equipment, and material used) (How could an injury occur?) What Can Happen Recommendations
Item
(Can hazards be eliminated or modified?)
Планирование работы. Опасность Риски Меры контроля
Номер (Что надо для работы. Например: (Как может произойти (Что может произойти) (Как опасность может быть устранена)
инструменты, оборудование и травма)
материалы)

 Pay attention during meeting

 Not paying attention
during tool box talk
meeting – clueless
1
Pre-start when work starts
 Poor housekeeping
 Cold weather
 Work flow will be discussed
 Wear all required PPE’s.
 Slips/Trips/fall due to poor
 Safety shoes (steel toe)
housekeeping
 Hard hat
 Injury to personnel due to  Visibility Vest
lack of knowledge to the  Dust mask (as required)
task.  Safety glass
 Hypothermia  HV Gloves
 Safety belt/ Full body harness
 Ensure to obtain permit before work.

 Defective tools, striking
against each other
Hauling of materials at the working  Pinch points
2
area  Icy surface
 Cold weather
 Injury to personnel
because they are not
wearing sufficient PPE’s
 Property damage due to
failure of machines.
 Hypothermia

 All personnel must wear sufficient PPE’s.
 Proper supervision from the concerned
supervisors.
 All tools must be inspected by the competent
person prior to use.
 Use correct way or method of lifting ( knee
down, back straight and lift)
 Monitor the temperature, and wind chill index.
 Work rest period implemented.
 Wear Winter PPE.
 Provide hot beverage for employees
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
3 Material handling
 Injury to personnel
 Improper manual because they are not
handling posture wearing sufficient PPE’s
 Slips, Trips & Fall  Property damage due to
 Pinch points failure of machines.
 Cold weather  Back injury
 Hypothermia
 All personnel must wear sufficient PPE’s.
 Proper supervision from the concerned
supervisors.
 Tools must be inspected by the competent
person prior to use.
 Evaluate the condition of floor along path from
origin to destination.
 Monitor the temperature, and wind chill index.
 Work rest period implemented.
 Wear Winter PPE.
 Provide hot beverage for employees
 When lifting bend at the knees and hold load
close to your body. Use legs as the source of
power to lift object.
 The allowable load each person can carry is
only 20 kg./person.
 Ask for help if object too heavy.
 Ensure personnel involve in task have manual
handling training.

 Keep unauthorized personnel away from the Pre

- Commissioning area.
 Barricade the workplace and provide signage for
 Improper manual
handling posture people awareness
 Slips, Trips & Fall  Ensure that all testing tools are calibrated and
 Back injuries
 Trailing cables calibration is up to date
 Foot injury
 Exposed live wires  Replace damaged cables
4 Pre - Commissioning  Personnel injury or death
 LOTO not applied  Secure all exposed wires
due to electrocutions
 Exposed live wires
 Hypothermia  Proper supervision from the concerned
 Cold weather
supervisors.
 Tools must be inspected by the competent
person prior to use.
 Implement LOTO procedure
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
Commissioning  Keep unauthorized personnel away from the
- Mechanical Operation Test Commissioning area.
 Improper manual  Barricade the workplace and provide signage for
- Insulation Resistance Test on Main and handling posture
Auxiliary Circuits people awareness
 Slips, Trips & Fall  Back injuries  Valid calibration certificate for all testing
- Voltage Withstand Test on Main and  Trailing cables  Foot injury Equipment’s.
Auxiliary Circuits at 80%  Exposed live wires  Personnel injury or death
5  Secure all exposed wires
 LOTO not applied due to electrocutions
- Contact Resistance Test on Main Circuits
 Exposed live wires  Hypothermia  Proper supervision from the concerned
- Current and Voltage Transformer Tests  Cold weather supervisors.
- Torque Test  Tools must be inspected by the competent
-Functional Test of MCC Panel person prior to use.
 Implement LOTO procedure

 Wear all required PPE’s.

 Slips, trips and fall due to  work boots/ rubber boots with toe
 Slips scattered materials or protector
rubbish.  hard hat
 Trips
 Foot injuries  visibility vest / jacket
 Fall  safety glass
6 Housekeeping  Cold weather  Hand injuries
 Dust Mask ( as required )
 Personnel injury due
 Gloves
slippery surface
 Anti -slip tract
 Hypothermia
 Supervisor must ensure that used materials
must be stored in designated, to prevent
scattered at work area
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности

Step 5: Unplanned Events (if any of the following occurs, stop work and talk to your supervisor)/ Шаг 5: Незапланированные мероприятия: если следующие случаи имеют
место, то остановите работу и известите супервайзера
Nearby work hazards Chemical spills or release
Excessive noise Fires and explosions Unusual odours Heat stress
Опасности на рабочем Утечки химических
Черезмерный шум Пожар и взрывы Странный запах Тепловой удар
месте веществ
Extreme weather/high
winds
Significant near miss Change in the following work conditions:
Evacuation alarm Экстримальные
Существенное, возможное Изменение в процессе работы:
Эвакуация/тревога погодные условия и
происшествия
сильный ветер

Step 6: Unplanned Events (if any of the following occurs, stop work and talk to your supervisor) Шаг 6: Незапланированные мероприятия: если следующие случаи имеют
место, то остановите работу и известите супервайзера
Emergency telephone number: Alarm Code (for commission period)
Телефон экстренной связи: +77015301064 Код сигнализации (при пусконаладке)
Nearest Muster Point/Safety Shelter location: Nearest First Aid Station location:
Ближайший пункт Место Сбора: Ближайший пункт Первой Помощи:
Evacuation Route (Supervisor to explain to workers): Safety shower / eye washer location:
Пути эвакуации(Супервайзер должен объяснить работникам): Пункт промывки глаз:
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
Step 7: Working Crew Details Шаг 7 Список работников (рабочей бригады)
I acknowledge receiving & understanding these instructions, I will fully comply with the assigned job requirements.
Я, подтверждаю что полученную информацию понимаю в полной мере , и я буду полностью соответствовать должностным требованиям.
Sr. Badge No. Signature Sr. Badge No. Signature
Name Ф.И.О Name Ф.И.О
№ № Бейджа Подпись № № Бейджа Подпись
1 26
2 27
3 28
4 29
5 30
6 31
7 32
8 33
9 34
10 35
11 36
12 37
13 38
14 39
15 40
16 41
17 42
18 43
19 44
20 45
21 46
22 47
23 48
24 49
25 50
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности

Supervisor Name:
Ф.И.О Супервайзера: ________________________________________ Signature/ Подпись: __________________ Date/Дата: ____________________________ /______/________

Foreman/charge hand Name:

Ф.И.О Мастера/Бригадира: ___________________________________ Signature/ Подпись: __________________Date/Дата: ____________________________ /______/________

HSE Officer Name:

Ф.И.О Инспектора по ТБ: ____________________________________ Signature/ Подпись: ___________________Date/Дата: ____________________________ /______/________

This JSTI is prepared based on theoretical information interpreted from the project documents. A further assessment will be required at the actual
work site to verify the control measures and address any additional hazards. Reference is to be made to the relative Health, Safety, Environmental
& Security procedures to control the risks associated with activities where they occur.