DEP SPECIFICATION
FIELD COMMISSIONING COMMISSIONING OF ELECTRICAL INSTALLATIONS AND EQUIPMENT FOR GLOBAL APPLICATION e l a s e r r o f t o N . l l e h S m o r f e s n e c i l t u o h t i w d e t t i m r e p g n i k r o w t e n r o n o i t c u d o r p e r o N . s e i n a p m o C f o p u o r G l l e h S t h g i r y p o C
DEP 63.10.08.11-Gen. February 2015
DESIGN AND ENGINEERING PRACTICE
© 2015 Shell Group of companies All rights reserved. No part of this document may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior written permission of the copyright owner or Shell Global Solutions International BV.
DEP 63.10.08.11-Gen. February 2015 Page 2
PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions International B.V. (Shell GSI) and, in some cases, of other Shell Companies. These views are based on the experience acquired during involvement with the design, construction, operation and maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international, regional, national and industry standards. The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to Shell companies for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the quality of their work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will typically expect them to follow those design and engineering practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, shall, without detracting from his own respons bility, consult the Principal. The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three categories of users of DEPs can be distinguished: 1)
Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2)
Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of a Service Agreement or otherwise).
3)
Contractors/subcontractors Contractors/subcontra ctors and Manufacturers/Suppliers Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these companies, that may issue DEPs or advise or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to t he user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative administrative queries should be be directed to the DEP Administrator Administrator in Shell Shell GSI.
DEP 63.10.08.11-Gen. February 2015 Page 3 TABLE OF CONTENTS 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
INTRODUCTION ................................................... ........................................................................................................ ..................................................... 5 SCOPE........................................................................................................................ ........................................................................................................................ 5 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 5 DEFINITIONS ....................................................... ............................................................................................................. ...................................................... 6 CROSS-REFERENCES ............................................................. ............................................................................................. ................................ 8 SUMMARY OF MAIN CHANGES .......................................................... ............................................................................... ..................... 8 COMMENTS ON THIS DEP ........................................................................... ....................................................................................... ............ 8 DUAL UNITS .................................................................................................. ............................................................................................................... ............. 8 NON NORMATIVE TEXT (COMMENTARY) .................................................... .............................................................. .......... 8
2. 2.1 2.2
PROCEDURES, RESPONSIB ILITIES AND DOCUMENTATION DOCUMENT ATION ............................. 9 PROCEDURES AND RESPONSIBILITIES ...................................................... ................................................................ .......... 9 DOCUMENTATION ......................................................... .................................................................................................. ......................................... 10
3. 3.1 3.2 3.3 3.4 3.5 3.6
TESTING AND COMMISSIONING METHODS M ETHODS ....................................................... 11 INSULATION TESTING ............................................................................................ ............................................................................................ 11 CONDUCTIVITY AND EARTH (GROUND) RESISTANCE TESTS ......................... 12 WIRING AND TERMINAL CHECKS....................................................... ......................................................................... .................. 12 FUNCTIONAL TESTS ...................................................... .............................................................................................. ........................................ 13 PHASING TESTS ............................................................ ..................................................................................................... ......................................... 13 POST COMMISSIONING TESTS T ESTS ............................................................................ 13
4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11
4.22
TESTING AND COMMISSIONING PROCEDURES ................................................ ................................................ 13 GENERAL ............................................................. ................................................................................................................. ....................................................13 HAZARDOUS (CLASSIFIED) AREA EQUIPMENT........................................... EQUIPMENT.................................................. ....... 13 MOTORS .................................................... ................................................................................................................. ............................................................... 14 GENERATORS ...................................................... ......................................................................................................... ...................................................15 TRANSFORMERS....................................................................................................19 BUS DUCT ............................................................................................................... ................................................................................................................. 20 SWITCHGEAR............................................................................................... .......................................................................................................... ........... 20 MCCs AND SWITCHBOARDS ................................................................................. ................................................................................. 21 PROTECTION................................................................................................ PROTECTION................................... ........................................................................ ........... 22 CABLES ..................................................... .................................................................................................................. ............................................................... ..23 VARIABLE SPEED DRIVE SYSTEMS (VSDS)/ ADJUSTABLE SPEED DRIVE SYSTEMS (ADSD) .......................................................... ................................................................................................... ......................................... 24 UNINTERRUPTIBLE POWER SUPPLY (UPS)........................................................ 25 EARTHING (GROUNDING) ( GROUNDING) AND BONDING ........................................................... ........................................................... 26 BUILDINGS.................................................................................................... ............................................................................................................... ........... 27 LIGHTING ................................................... ................................................................................................................ ............................................................... 28 ELECTRIC HEAT TRACING .................................................................................... 28 ELECTRICAL PROCESS HEATERS ....................................................................... ....................................................................... 29 CABLE SUPPORT SYSTEMS........................................... SYSTEMS.................................................................................. ....................................... 29 OVERHEAD POWER LINES AND OUTDOOR SWITCHYARDS............................ 30 MISCELLANEOUS LOW VOLTAGE EQUIPMENT.................................................. 31 ELECTRICAL NETWORK MONITORING AND CONTROL (ENMC) SYSTEM COMMISSIONING ........................................................... .................................................................................................... .........................................31 INTEGRATED MOTOR CONTROL SYSTEM (IMCS) COMMISSIONING .............. .............. 32
5.
REFERENCES ..................................................... ......................................................................................................... .................................................... 33
4.12. 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21
DEP 63.10.08.11-Gen. February 2015 Page 4 APPENDICES APPENDICE S APPENDIX A
INSPECTION AND TEST FORMS INDEX ...................................................... 36
APPENDIX B
NOMOGRAM FOR TEMPERATURE TEM PERATURE CORRECTION ....................................39
APPENDIX C
TYPICAL CURVES FOR VA RIATION OF INSULATION RESISTANCES ....40
APPENDIX D
GENERATOR SYNCHRONIZING SYSTEM SY STEM TESTING .................................. 41
APPENDIX E
RECOMMENDED TEST VOLTAGES FOR TESTING AND COMMISSIONING FOR NA APPL ICATIONS ................................................ ................................................ 42
APPENDIX F
RECOMMENDED TEST VOLTAGES FOR COMMISSIONING FOR NON-NA APPL ICATIONS............................................................................... 45
APPENDIX G
RECOMMENDED RECOMMENDED INSULATION VAL UES FOR EQUIPMENT EQUIPMENT OF NA APPL ICATIONS .......................................................................... .............................................................................................. .................... 48
APPENDIX H
RECOMMENDED INSULATION VALUES FOR EQUIPMENT OF NONNA APPL ICATIONS ........................................................................................ ........................................................................................ 49
APPENDIX I
TEST METHOD FOR EARTHING/GROUN EARTHING/GROUNDING DING SYSTEM - ref er t o (4.13)................................................................................................................ (4.13)....................................................................... ......................................... 51
APPENDIX I a
EARTH EART H (GROUND) EL ECTRODE RESIST ANCE ......................................... 52
APPENDIX Ib
EARTH EART H ELECTRODE RESISTANCE RES ISTANCE USING CL AMP METERS M ETERS .................. .................. 54
APPENDIX J
EXAMPLES OF DELTA/STAR TRANSFORMER CONNECTION...... CONNECTION............ ........... .....55
APPENDIX K
TRANSFORMER TRANSFORM ER OIL ...................................................................................... ...................................................................................... 56
APPENDIX L
VT A ND CT FL ICK TESTS ............................................................................. ............................................................................. 58
APPENDIX M
TORQUE VALUE OF B OLTS FOR NORTH AMERICAN A PPLICATION ....59
DEP 63.10.08.11-Gen. February 2015 Page 5 1.
INTRODUCTION
1.1
SCOPE This DEP specifies requirements and gives recommendations for field commissioning of electrical installations and equipment for global application. It covers the pre-commissioning and commissioning of new electrical installations and equipment, or the re-commissioning of equipment following a major overhaul. This DEP is for global use and is harmonised with the Project Guide 14b (Commissioning and Start-up). Project Guide 14b has two major milestones applicable to electrical systems and equipment: •
Mechanical Completion (Handover 1), where systems and equipment are handed over having been tested in a de-energised state (for the electrical systems and equipment this means having tests done such as continuity and insulation resistance but without being initially energised).
•
Pre-Commissioning (Handover 2), where systems are handed over ready to be started up without the introduction of process hydrocarbons (for the electrical systems and equipment this means having tests done after initial energisation such as light run of motors, check of switchgear operation when energised). This then allows the commissioning and start-up team to operate systems by running pumps etc., run utility systems.
The corresponding inspection and test forms are in DEP 63.10.08.91-Gen. ( Appendix Appendix A) provides an overview of the forms. Where activities are likely to be done outside the normal time frame (e.g., tests that have to be completed with equipment under load, which can only be done after commissioning of systems or even start-up of the plant), these are identified separately. The contents of DEP 63.10.08.14-Gen. (Field Commissioning and Testing T esting of Electrical Systems and Equipment for North American Application) have been combined in this DEP. This is a revision of the DEP of the same number dated September 2011; see (1.5) regarding the changes. 1.2
DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorized by Shell GSI, the distribution of this DEP is confined to Shell companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated by them. Any authorized access to DEPs does not for that reason constitute an authorization to any documents, data or information to which the DEPs may refer. This DEP is intended for use in facilities related to oil and gas production, gas handling, oil refining, chemical processing, gasification, distribution and supply/marketing. Application in other facilities may also apply. When DEPs are applied, a Management of Change (MOC) process shall be implemented; this is of particular importance when existing facilities are to be modified. If national and/or local regulations exist in which some of the requirements could be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable with regards to the safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned, the objective being to obtain agreement to follow this DEP as closely as possible. In general, references to IEC standards do not apply to North American (NA) applications.
DEP 63.10.08.11-Gen. February 2015 Page 6 1.3
DEFINITIONS
1.3.1 1.3.1
General defin iti ons
The Contractor is the party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party that initiates the project and ultimately pays for it. The Principal may also include an agent or consultant authorized to act for, and on behalf of, the Principal. The word shall indicates a requirement. The word should indicates a recommendation. 1.3. 1.3.2 2
Specific definitio ns Term
Definition
Au th or ized Electrical Person Person
A Competent Electrical Person authorised by the Business Unit, to supervise or to carry out specified operations on high and low voltage electrical power systems and work on electrical equipment. The authorisation may include the authority to receive a sanction for test, issue and cancel limitations of access and perform the necessary safety procedures associated with such work or testing.
Certificate
Document issued by a recognised authority certifying that it has examined a certain type of apparatus and, if necessary, has tested it and concluded that the apparatus complies with the relevant standard for such apparatus.
Certifi Certifi cate of Conformity
Certificate stating that the electrical apparatus complies with the relevant standards for apparatus for potentially explosive atmospheres.
Declaration Declaration of compliance
Document issued by the Manufacturer declaring that the electrical apparatus complies with the requirements of IEC 60079-15.
Electrical Commissioning
Putting into service a piece of equipment or system AND demonstrating that the equipment or system is fit for the purpose for which it was intended. It is the last verification point prior to the official acceptance of that portion of the installation. Commissioning therefore consists of on-line functional, load and performance tests.
Electrical Precommissioning
Those activities which are carried out after equipment erection and prior to energizing and performance checks. Pre-commissioning is therefore concerned with the verification of the state of the equipment, quality of installation work and compliance with requirements and codes.
Electrical Technical Au th or it y
The discipline engineer appointed by the Principal responsible for all technical decisions associated with the work. The Electrical Technical Authority is responsible for technical integrity.
Electrical Networ Networ k Monitoring and Control (ENMC) System
Computerized system which is dedicated to monitoring and controlling defined aspects of an electrical network.
GoCCMS
Construction and commissioning certification management system that enables the monitoring of the inspected, tested and commissioned status of individual tagged items of equipment, sub-systems or full plant systems.
DEP 63.10.08.11-Gen. February 2015 Page 7
Term
Definition
Inspection
Physical examination to determine the condition of a piece of equipment. This may involve sight, sound, smell and touch and may involve the opening of covers.
Integrated Integrated Motor Control System (IMCS)
A system comprising control modules, central unit(s), a serial bus connecting the control modules to the central unit and a communication facility enabling connection of the central unit to a distributed control system (DCS) and/or a Supervisory Control and Data Acquisition System (SCADA).
Handover
Transfer of responsibility and/or ownership from one party to another. Also known as take-over or or turnover . See Project Guide 14b.
1.3.3
Inverter
A converter for conversion from DC to AC.
Nomogram
Any graphic representation of numerical relationships.
Rectifier
A converter for conversion from AC to DC.
Test and Measurement
Verifying by means of instruments and tools the condition and the functioning of an item of equipment and to measure its parameters. (This may include re-calibration).
Abbreviations Term
Definition
AC
Alternating Current
ASD
Adjustable Speed Drive
ATEX
French ATmospheres EXplosives
AVR
Automatic Voltage Regulator
CT
Current Transformer
DC
Direct Current
DGA
Dissolved Gas Analysis
ETA
Electrical Technical Authority
FAT
Factory Acceptance Test
HOA
Hand/ Off/ Auto Switch
HV
High Voltage – IEC above 1000 V (NA above 38,000 V)
IEC
International Electrotechnical Commission
IR
Insulation Resistance
LV
Low Voltage (Voltage levels up to 1000 V)
MCC
Motor Control Center
MV
Medium Voltage (NA definition above 1000 V and less than or equal to 38,000 V)
NA
North America
PI
Polarization Index
RCU
Remote Control Unit
TTR
Transformer Turns Ratio
UPS
Uninterruptable Power Supply
DEP 63.10.08.11-Gen. February 2015 Page 8
1.4
Term
Definition
VLF
Very Low Frequency
VT
Voltage Transformer
VSDS
Variable Speed Drive System (same as ASD system)
CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section or clause number is shown in brackets ( ). Other documents referenced by this DEP are listed in (5).
1.5
SUMMARY OF MAIN CHANGES This DEP is a full revision of the DEP of the same number dated September 2011. The following are the main, non-editorial changes.
1.6
Section/Clause
Change
General
Incorporation of text from DEP 63.10.08.14-Gen.
Appendix A
Removal of inspection and test forms.
COMMENTS ON THIS DEP Comments on this DEP may be submitted to the Administrator using one of the following options: Shell DEPs Online
(Users with access to Shell DEPs Online)
Enter the Shell DEPs Online system at https://www.shelldeps.com Select a DEP and then go to the details screen for that DEP. Click on the “Give feedback” link, fill in the online form and submit.
DEP Feedback Feedback System
(Users with access to Shell Wide Web)
Enter comments directly in the DEP Feedback System which is accessible from the Technical Standards Portal http://sww.shell.com/standards http://sww.shell.com/standards.. Select “Submit DEP Feedback”, fill in the online form and submit.
DEP Standard Form
(Other users)
Use DEP Standard Form 00.00.05.80-Gen. to record feedback and email the form to the Administrator at
[email protected]..
[email protected]
Feedback that has been registered in the DEP Feedback System by using one of the above options will be reviewed by the DEP Custodian for potential improvements to the DEP. 1.7
DUAL UNITS This DEP contains both the International System (SI) units, as well as the corresponding US Customary (USC) units, which are given following the SI units in brackets. When agreed by the Principal, the indicated USC values/units may be used.
1.8
NON NORMATIVE TEXT (COMMENTARY) Text shown in italic style in this DEP indicates text that is non-normative and is provided as explanation or background information only. Non-normative text is normally indented slightly to the right of the relevant DEP clause.
DEP 63.10.08.11-Gen. February 2015 Page 9 2.
PROCEDURES, RESPONSIBIL ITIES AND DOCUMENTATION DOCUMENTAT ION
2.1
PROCEDURES AND RESPONSIBILITIES
2.1.1
General
2.1.2 2.1.2
1.
Testing and commissioning requirements shall be initially initially addressed at an early point in the design to ensure all testing requirements are identified, and the stage at which each test is best carried out is determined (i.e., FAT, pre-commissioning or commissioning). This ensures all tests are covered in the most cost effective manner and without unnecessary duplication. These requirements should form part of the Electrical Safety and Operability Review (SAFOP) review. Refer to section 2.1.2 of DEP 33.64.10.10-Gen., (section 2.3 of DEP 33.64.20.10-Gen. for NA applications).
2.
Electrical installations and equipment in in plants engineered and/or erected by Contractors and, in general, any equipment which has been completed and is ready for operation, shall be subject to certain handover/turnover procedures agreed between the Contractor and the Principal before pre-commissioning.
3.
The handover procedures shall state clearly the relevant responsibilities of Contractor and Principal to provide an orderly transition during early pre-commissioning/early energisation and commissioning transitional period.
4.
The organization and execution execution of pre-commissioning and commissioning activities shall be the responsibility of the Contractor. Unless otherwise agreed by the Principal, complex electrical systems (e.g., switchgear, generators, AVRs, ASDs, UPSs) shall be rd commissioned with the assistance of the Manufacturer/Supplier or 3 party Contractor as appropriate. The extent and level of such assistance will be dependent on the experience and expertise of the site-commissioning teams.
5.
Hold/witness points shall be agreed between the Contractor and the Principal.
6.
Where site conditions prevent full performance tests (e.g., power output, temperature rise), agreement should be reached between the Principal and Contractor on the need for such tests at a later date.
7.
If applicable, the Principal Principal should have internal procedures for equipment acceptance by Operations/Maintenance departments from Engineering/Construction departments.
Operation al Safety
1.
The necessity of safety precautions during work on electrical equipment cannot be over-emphasized. Attention is drawn to DEP 80.64.10.10-Gen. on which local safety rules and practices shall be based.
2.
Electrical work shall be inspected for compliance with applicable codes by the Authority having jurisdiction or its delegate, in accordance with the laws of the jurisdiction. For example: a.
For projects in Alberta Alberta and British British Columbia Canada, the electrical work shall be inspected for compliance using applicable safety codes as required by the Shell Quality Management Plan (Electrical Regulatory Management Plan (ERMP)) as approved by the Alberta Safety Codes Council and the British Columbia Safety Authority.
3.
Since it is likely that the whole electrical system cannot be energized at one time, the electrical system should be tested and commissioned in sub-systems of manageable size with physical controls of the boundaries e.g., application of padlocks. For safety reasons it is important to energize only a part of the electrical network that can be controlled so that neighbouring systems can be worked on safely.
4.
Work shall not continue nor equipment be energized until the appropriate documentation has been signed off by the Contractor and the Electrical Technical Authority or delegate.
DEP 63.10.08.11-Gen. February 2015 Page 10 5.
2.1. 2.1.3 3
The steps required to connect an electrical electrical system, prior to its initial energizing, to an existing electrical network, shall be jointly agreed by the authorized electrical persons (Contractor and Electrical Technical Authority) responsible.
Protection against Explosion and and Fire Hazards Hazards
1.
Before starting starting field inspection, the Contractor shall provide documentation of the qualifications and competence of the personnel carrying out inspection of electrical equipment in hazardous (classified) areas, such as the CompEx or IECEx schemes.
2.
The requirements for competence competence of the personnel should be embedded embedded in a Quality Quality System compliant with DEP 82.00.10.10-Gen. and national legislation.
2.1. 2.1.4 4 Flawless project delivery Analysis of past start-ups indicates a very strong correlation between successful, timely start-ups and the extent of start-up planning. Based on the lessons learnt from numerous projects and the common failure modes that occur during the commissioning, start-up and initial operating phases a Flawless Start-Up program has been developed and successfully applied in many projects. The recommendations for commissioning activities contained in this DEP are consistent with, and support a flawless start-up programme. 2.1.5 2.1.5
Maintenanc e management syst em data
1.
2.2
The Contractor Contractor shall provide to the Principal, in an electronic database, all relevant data and information associated with the electrical equipment installed. The format and content of the data shall be agreed in advance with the Principal. The data is intended to be used to populate the computerized maintenance management system with electrical equipment data.
DOCUMENTATION 1.
The Contractor shall complete the inspection contained in DEP Requisition/Datasheet 63.10.08.91-Gen. and listed in (Appendix A).
2.
The forms shall be pre-loaded with the the data as recorded in the electrical equipment electronic database. As part of the commissioning procedures, this data shall be verified to be correct.
3.
Use may be made of the forms forms listed in (Appendix (Appendix A), or forms generated directly from the database. In the latter case such forms shall contain, as a minimum, the same information as those contained in DEP Requisition/Datasheet 63.10.08.91-Gen.
4.
In order order to align with the Shell Certification and Completion Management System (GoCCMS), the forms in requisition DEP 63.10.08.91-Gen. h ave been split to differentiate tests conducted during the Mechanical Completion (A tests) and during the pre-commissioning (B tests). If the test is to be performed during start-up, they are classified as C tests.
5.
In cases where differences are found to exist with the as-installed equipment, the commissioning forms shall be updated with correct information. The Contractor shall then upload any changes reported into the electronic database, having first checked that the changes do not invalidate any part of the design.
4.
For pre-commissioning pre-commissioning and commissioning, 'Form 1 and Form 3' are applicable to all equipment; subsequent forms shall be used as required. It is recommended that vendor tests documentation be available on-site during the inspection and testing of equipment.
5.
The Contractor Contractor may develop additional additional inspection inspection forms for equipment equipment not not covered, or not fully covered in this DEP, only with agreement of the Principal.
6.
All deviations from requirements shall be documented on an "exception "exception list" list" presented to those responsible for the installation work for their agreement and action. Any errors in the installation shall be corrected before installation is finally handed over.
DEP 63.10.08.11-Gen. February 2015 Page 11 7.
The above documentation, including including the updated electronic database, shall form part of the official handover of plant and equipment.
3.
TESTING AND COMMISSIONING METHODS
3.1
INSULATION TESTING
3.1.1
General
1.
Insulation tests shall be performed at the the pre-commissioning stage and prior to the energizing of equipment and cables.
2.
The two methods to be used are:
NOTE 1
3.
3.1.2
3.1.3 3.1.3
3.1.4 3.1.4
3.1. 3.1.5 5
a.
Insulation Resistance (IR) testing for motors, generators, generators, transformers, LV switchgear and all equipment other than those items susceptible to damage by over-voltage (e.g., electronic components);
b.
High potential AC (0.1 Hz [VLF] up to power system frequency) or DC testing 1 for MV (NA) and HV switchgear a nd MV (NA) and HV cables .
:
High potential DC tests should not be done on XLPE cables
Refer to (Appendix E) and (Appendix G) for recommended test voltages voltages and insulation resistance values for NA applications. For other locations, use voltage and insulation resistance values from (Appendix F) and (Appendix H).
IR test s
1.
Perform IR testing by applying a DC voltage voltage from an insulation insulation tester at voltage levels given in (Appendix E) for NA applications and (Appendix F) for other locations.
2.
For correct comparative interpretation interpretation of test data, carry out subsequent IR tests at the the same voltage level as the initial test.
3.
The measured resistance value is is also dependent on the temperature of the insulation insulation and shall be corrected with the use of the nomogram in (Appendix B).
4.
As a guide, the IR of windings reduces by approximately 50 % for each 10°C (20°F) rise in temperature.
Polarizatio n Index (PI)
1.
PI testing shall be performed on all motors rated above 1000V. The PI is the ratio between the insulation resistance measured after one minute and after 10 minutes of continuous testing at the appropriate voltage (PI = R 10 min / R 1 min).
2.
(Appendix C) shows typical curves for variations of insulation resistance and the values for the Polarisation Index.
Interpr etation of resul ts – IR and PI
1.
Where obtained obtained IR or PI values fall below the minimum values given in (Appendix H), equipment should not be energized or subjected to high potential testing.
2.
Appropriate action should be taken to normalize the figures.
3.
Where 'flash-over' occurs during high potential testing, then the test shall be deemed to have failed and appropriate measures taken (e.g., cleaning, drying, repair) to eliminate the cause, following which a re-testing shall take place. The ETA or delegate should be made aware of test failures and approve re-testing.
High potential tests
1.
Before high potential tests are executed, executed, insulation resistance tests shall be carried out. Refer to (3.1.2).
DEP 63.10.08.11-Gen. February 2015 Page 12
3.1. 3.1.6 6
2.
High potential testing of electrical equipment, except LV cables, shall have been carried out at the Manufacturer's works with AC at voltage levels in accordance with the relevant DEP or International Standards.
3.
Repeated high high potential pressure tests may introduce introduce weak points in the insulation of windings, and therefore such tests shall no t be applied at site to generators, motors or transformers. If, however, for special reasons these tests are considered to be necessary, they shall be carried out only after consultation with the Manufacturer.
4.
Should 'flash-over' occur during high potential testing, then the test shall be deemed to have failed and appropriate measures taken (e.g., cleaning, drying, repair) to eliminate the cause, following which a re-testing shall take place.
5.
The ETA ETA should be made aware of test test failures and and approve re-testing.
Bearing insulatio n tests
1.
The method of insulating bearings as a means of controlling shaft current depends upon the type of construction and methods employed to support the bearings.
2.
If the pedestal bearings or sleeve bearing housings are completely insulated from the body of the machine, the insulation may be checked with the machine coupled and running at normal speed to establish an oil film in the bearing which will prevent electrical contact between shaft and bearing. An ohmmeter applied across the insulation sh ould indicate ind icate a resistance of > 10 kΩ or the Manufacturer’s/Supplier’s recommendations. Values below 10 kΩ shall be investigated.
3.
If the bearings have internally insulated 'shells' or insulated insulated shafts, carry out measurements with the machine uncoupled (and stopped). If, however, only one bearing is insulated (contrary to DEP requirements for motors and generators), verification is limited to the inspection of Manufacturer's/Supplier’s QC documentation.
4.
Where double insulation is applied to pedestal bearings, i.e., they are insulated around around the bearing 'shell' and at the pedestal base, IR measurement of the 'mid-section' with respect to ground will indicate if either insulation is bridged.
3.2
CONDUCTIVITY AND EARTH (GROUND) RESISTANCE TESTS
3.2. 3.2.1 1
Conductiv ity tests
1.
Conductivity tests shall be carried out on all field-made switchgear switchgear busbar connections connections and switchgear earth (ground) system joints and a sample of factory-tested joints with a high-current micro-ohmmeter test set in order to establish their tightness and condition.
2.
For identical connections, the measured values should not differ by more than 20 % from each other.
3.2. 3.2.2 2
Earth Earth (ground) resistance tests
3.2.2.1
General 1.
3.2.2.2
For values and method of earth resistance tests, tests, see (4.13) and (Appendix Ia) and (Appendix Ib).
Earth (ground) electrodes 1.
All earth earth (ground) electrodes shall be tested by measuring the electrode resistance against the mass of earth, using a purpose-made test set as outlined in (Appendix Ia).
NOTE:
3.3
Verification of the connection of the the earthing electrode to foundation foundation earthing should be done as part of the civil scope of works.
WIRING AND TERMINAL CHECKS 1.
Electrical wiring shall be be checked against the schematic diagrams. Factory-tested assemblies such as switchgear should require only sample checks; wiring done on site shall be checked.
DEP 63.10.08.11-Gen. February 2015 Page 13 2.
3.4
The tightness tightness of all field-made terminations shall be verified against against Manufacturer torque specifications. For North American applications, refer to (Appendix M).
FUNCTIONAL TESTS 1.
Functional tests shall be performed to demonstrate the correct operation operation of complete systems.
2.
Refer to (2.1) about the need for testing to be considered at the design stages. These considerations shall include functional testing, especially of systems such as Load Shedding. It will be necessary to consider how satisfactory functional tests may be carried out without adversely affecting a running plant or disrupting the commissioning of another plant.
3.5
3.6
3.
The functional testing of safety-related systems, such as an auto start of diesel generation on supply failure, shall be mandatory.
4.
Attention should be paid to equipment interfaces, where there is a greater likelihood of functional impairment.
5.
In cases where where complicated control and/or interlock systems are are used, the Contractor shall demonstrate compliance with the design requirements by using special case-bycase functional check lists and system logic diagrams.
PHASING TESTS 1.
Confirmation of phase rotation for switchgear and generator operation shall be done using voltage indication units. ‘Phasing sticks’ shall not be used.
2.
For LV systems, phasing should not be done across main busbars but using a visible wiring check and test downstream/after the short-circuit protection (fuse/MCB) of the voltmeters.
POST COMMISSIONING TESTS If procedures require that the equipment be tested against operating conditions, for example motor load tests, then the tests may need to be performed during the start-up or even operational phase.
1.
These tests should be identified early in in the preparation of the project project commissioning planning and agreed by the Principal.
4.
TESTING AND COMMISSIONING PROCEDURES
4.1
GENERAL
4.2
1.
All items of electrical equipment (except bulk ordered equipment) shall be inspected inspected and tested in accordance with the relevant DEP, this DEP and the Inspection and Testing Forms in DEP 63.10.08.91-Gen.
2.
All electrical equipment tags shall be verified for compliance with the the relevant drawings and specifications, i.e., equipment nameplates, etc.
HAZARDOUS (CLASSIFIED) AREA EQUIPMENT Refer to DEP 63.10.08.91-Gen., Form 4 and applicable equipment forms.
4.2.1
Installation
1.
All items items of electrical equipment installed in a hazardous (classified) area shall be subject to an initial detailed inspection in accordance with IEC 60079-14 / IEC 60079-17 and information recorded on the above forms.
DEP 63.10.08.11-Gen. February 2015 Page 14
4.2.2
2.
For North American application, all items of electrical equipment installed in in a hazardous (classified) area shall be subject to inspection in accordance with NFPA 70, CSA C22.1, IEEE 45, API RP 14F (or API RP 14FZ) where applicable, and information recorded on the above forms.
3.
Bulk ordered material such as light light fittings, junction boxes and RCUs/HOAs should be divided into circuits or sub-packages (as dictated by the installation programme) such that they may be inspected as they are completed and before access from temporary scaffolding or similar constraints are removed.
4.
Once a circuit or sub-package is inspected, itit should have readily identifiable labels or or tags attached to clearly mark what has or has not been inspected. Any subsequent installation work on that circuit or package requires that the additional works should be inspected and the tie-in points should be re-inspected.
5.
During final inspection, one Form 1 per plant area area is sufficient for each 'bulk material' type. A sample inspection of the installation may be undertaken to prove that no deterioration or interference has taken place since the sub-package inspections.
6.
The testing testing Contractor shall ensure that cable connections and terminations have been made according to specifications and by qualified personnel.
7.
Purged and pressurized enclosures shall be inspected to verify proper operation of purge and pressurization systems and alarms.
Certification
1. 4.2.3 4.2.3
Certificates shall be examined to ensure that the equipment and installation installation is in compliance with the certification requirements.
Ex / Hazardou Hazardou s Area Classif icati ons Register
1.
The Ex register / Hazardous Area Classifications register (see deliverables in DEP 33.64.10.10-Gen., Appendix 7 and DEP 33.64.20.10-Gen., Appendix 1) shall be completed in order to provide the verification dossier for compliance of the installation with the relevant standards.
4.3
MOTORS
4.3.1
General Refer to DEP 63.10.08.91-Gen., Forms 1, 3, 23, 24, 25, 26. The scope of motor testing depends upon the motor type and size indicated on the inspection forms.
4.3. 4.3.2 2
Insulation tests
1.
Typically, final motor insulation resistance testing is completed with with the the feeder cable attached. Where acceptable insulation resistance test values cannot be achieved or where capacitors and surge arresters are connected in the motor terminal box, the motor and feeder should be disconnected and testing completed on the individual components. Appropriate test vol tages and pass criteria are shown in (Appen dix E) and a nd (Appendix G) for NA applications with values for other locations in (Appendix F) and (Appendix H).
2.
Unless otherwise otherwise specified, polarization index testing test duration shall be ten minutes.
3.
If specified, specified, HV and MV (NA) motors shall be subjected to high-potential tests (DC).
4.
Insulation resistance tests shall be performed on the exciter and field winding of synchronous motors, including the exciter solid state components.
DEP 63.10.08.11-Gen. February 2015 Page 15 4.3. 4.3.3 3
Vibration tests
1.
4.3. 4.3.4 4
Motor vibration shall be measured in a tri-axial direction, i.e.: a.
point x axis - side of bearing housing at shaft height
b.
point y axis - top of bearing housing
c.
point z axis - axial of bearing housing at shaft height
2.
The measurements shall shall be performed with an instrument conforming to ISO 2954 (10-1000 Hz frequency range). With the motor at normal operating temperature, the vibration velocity shall not exceed 2.8 mm/s (0.11 in/s) RMS, or 4 mm/s (0.16 in/s) PEAK, in any direction.
3.
For bearings fitted with with proximity probes, the unfiltered peak-to-peak value of vibration (including shaft 'run-out') at any load between no load and full load, shall not exceed the following values: a.
50 µm (0.002 in) for two-pole motors
b.
60 µm (0.0024 in) for four-pole motors
c.
75 µm (0.003 in) for six-pole or higher motors
4.
For North American application, application, the vibration limits in API 541, Figure 1 and Figure 2, shall be used for MV induction motors and the API 546 for MV synchronous machines. For LV motors, the vibration limits shall be in accordance to IEEE 841.
5.
For motors with active magnetic bearings (AMB), testing and commissioning shall conform to Manufacturer’s requirements.
Bearing temperature rise tests
1.
Motors shall be operated at no load for at least 1 hour after the bearing temperatures have stabilized. The no load run shall demonstrate that bearing operation is without excessive noise. Stable temperature is defined as a change of not more than 1°C (2°F) in 30 minutes.
2.
4.3. 4.3.5 5
Synchron ous moto rs
1.
4.4
Bearing temperature rise limits shall shall be as given in in DEP 33.66.05.31-Gen. for IEC induction motors, DEP 33.65.11.31-Gen. for IC synchronous motors, DEP 33.65.11.34-Gen. for NA synchronous motors, DEP 33.66.05.36-Gen. for NA API 541 motors, and DEP 33.66.05.37-Gen. for NA API 547 motors.
Insulation resistance tests should be be performed on the exciter and motor field. This includes the exciter solid state components.
GENERATORS Refer to DEP 63.10.08.91-Gen., Forms 1, 3, 29, 30 and 31.
4.4. 4.4.1 1
4.4.1.1
Base load generators / Main Main power generators generators
1.
A detailed commissioning plan plan shall be developed before generator tests commence. Details of the test plan shall be agreed between the Principal, Contractor and Manufacturer/Supplier.
2.
The following following tests should be performed performed in order to prove the satisfactory satisfactory performance of the generator, governor, automatic voltage regulator (AVR) and synchronizing/protection systems.
Pre-commissioning checks (prior to running) 1.
All electrical pre-commissioning work work shall shall have been satisfactorily completed, i.e., i.e., all possible tests shall have been carried out, prior to the equipment being run and energised.
DEP 63.10.08.11-Gen. February 2015 Page 16 2. 4.4.1.2
Pre-synchronising checks (generator running, no-load)
4.4.1.2.1
Open circuit tests 1.
4.4.1.2.2
Verify the excitation excitation system and generator characteristics by gradually increasing excitation and plotting generator-output voltage against excitation current. Generator / busbar phase rotation
1.
4.4.1.2.3
Verify phase rotation of generator / busbar by means of an LV phase rotation meter connected as shown in (Appendix D), to generator VTs, the VTs being fed either from the busbars (test 1) or the generator (test 2). Synchronising circuit checks
1.
During the above test 1, verify in-phase indication on all of above devices and verify synchronising relay operating parameters and close command.
2.
During the above test 2, verify that operation of the synchroscope, voltmeter, auto and check synchronising relays follows the 'beat frequency', i.e., the difference between generator and network frequency and voltage.
3.
As a last check, verify, using the capacitive voltage indication on generator breaker, that the synchronising relay 'close' command coincides with the in-phase condition when comparing the generator output with a capacitive voltage indicator, measuring the busbar voltage. This will require a phasing out instrument from the same Vendor who supplied the capacitive voltage indication unit.
4.4.1.2.4
4.4.1.3
Protection relays should be tested in accordance with (4.9); however some tests may only be possible with the generator running. See (4.4.1.2.4).
Protection tests 1.
In the absence of suitable 3-phase primary injection test sets, differential relay in-zone operation and out-of-zone stability may be verified by using the generator as a current source.
2.
Differential relay stability check includes the following steps: a.
A 3-phase short circuit shall be applied at a suitable point outside of the differential protection zone.
b.
The generator shall subsequently be run up to speed and excited.
c.
The generator excitation shall be adjusted from zero to a low figure so that no more than full load current may flow. Refer to Manufacturer's test data.
3.
For a Differential Relay Sensitivity Check, Check, a 3-phase short circuit is applied at a suitable point inside the differential protection zone. Proceed further as for the stability check.
4.
Other items of protection protection and indication equipment may also be verified verified at this time if not already done by primary current injection, e.g., overcurrent, neutral displacement, negative sequence relays.
5.
For the overspeed check, operation of mechanical and electronic overspeed trip devices shall be verified.
Synchronizing and operational checks (generator running, loaded)
4.4.1.3.1
Synchronize to grid 1.
4.4.1.3.2
The network network to which the generator will be initially synchronized should be configured so that the risk of a disturbance to normal plant operations is minimized. Function tests
1.
The following function tests shall be confirmed: a.
auto and manual synchronizing;
DEP 63.10.08.11-Gen. February 2015 Page 17
4.4.1.3.3
b.
control of power factor over full range of power generation;
c.
control of load;
d.
'bumpless' change-over from Auto AVR to Manual and vice versa;
e.
change-over of AVR from power factor to voltage control (when changing from coupled to 'island operation')
Dynamic tests Refer to DEP 63.10.08.91-Gen., Form 30.
1.
Dynamic tests shall comprise: a.
active load rejection,
b.
reactive load acceptance,
c.
active load sharing,
d.
reactive load sharing,
e.
’Island' proving tests, if applicable.
2.
Test of load rejection/acceptance rejection/acceptance should be at 100 % of generator rating if suitable active load blocks are available.
3.
The following parameters shall be measured on a suitable recorder:
4.
5.
a.
generator voltage/time,
b.
current/time,
c.
speed (or frequency)/time.
The test acceptance criteria shall be: a.
no tripping of any protection device;
b.
no parameter shall exceed 80 % of the difference between nominal value and trip set points;
c.
transient response shall be within the Manufacturer/Supplier Manufacturer/Supplier design parameters.
Governor tests a.
Measure load acceptance and rejection: transient response by the switching IN and OUT of active load blocks.
b.
Measure droop settings in "island condition": speed change between zero and full load.
c.
Active load sharing: verify that the load is shared equally (or for different ratings, pro rata) between the generator being commissioned and all other combinations of generators. Verify that the load continues to be shared during changes in total load.
d.
Verify that electrical load variations are within agreed limits during the changeover of fuels.
6. AVR tests a.
Transient response. Measure the recovery of generator voltage during the reactive load acceptance and the load rejection tests to verify that it is within the limits of time and terminal voltage.
b.
Voltage droop*. Verify that voltage droop is proportional to reactive load or is according to design.
DEP 63.10.08.11-Gen. February 2015 Page 18
4.4.1.3.4
4.4.1.4
4.4.1.5
d.
Current boost*: (for AVRs whose supply is derived from their own terminal voltage), it shall be verified from design data, that generator terminal voltage is sufficiently maintained to allow operation of protective devices in the event of a short circuit.
e.
For items marked *, factory test results are acceptable.
f.
'Block load' values shall be such as to demonstrate the equipment's compliance with its design.
g.
AVR Under and Over excitation (UEL and OEL) limiters shall be checked.
1.
The operation of the Reverse Power Power relay shall be verified by decreasing the governor setting at minimum load.
2.
The operation of the Field Failure Failure relay shall be verified by decreasing the excitation at minimum load.
Load tests 1.
Load tests shall be performed as agreed between Contractor and Principal and will normally follow satisfactory completion of all the above tests and the completion of construction and testing of the various systems and sub-systems peripheral to the generator and prime mover.
2.
The final tests should be a series of load tests culminating in a protracted run, under design conditions, at maximum power output to demonstrate that the generator, prime mover and all auxiliary equipment meet the designed performance levels while running continuously at full rated load.
Utility/Grid compliance tests Tests shall shall be performed as agreed with with the public utility/local utility/local grid company. These may include operation at extremes of real and reactive power, tests at reduced voltage of auxiliary supplies, momentary interruption of supply to auxiliaries, etc. See also (4.4.3).
Black start generators 1.
4.4. 4.4.2 2
Reactive load sharing. Verify the ability of the generator being commissioned to run at the same power factor as parallel connected generators. Also verify that the power factor remains equal during changes in reactive load.
Protection tests
1.
4.4.1.6
c.
Where black black start capability is required, a suitable commissioning procedure that function tests the system shall be developed and executed.
Emergency and standby generators generators
1.
Where relevant, relevant, the tests described in (4.4.1.1) through (4.4.1.5) shall be carried out (DEP 63.10.08.91-Gen. Form F orm 31). The testing methods and procedures shall be subject to agreement between the Principal and the Contractor.
2.
Generators of the 'automatic start on mains failure' type shall be tested to start and supply the load on loss of voltage and should include the associated switchgear as a complete unit.
3.
Additional tests shall be carried out to prove that the unit functions as intended, including the number of successive starting attempts.
4.
Where an emergency generator system is designed to withstand withstand severe accident conditions of fire, explosion and strong vibration, this capability shall be verifiable from tests and inspection. These performance requirements are application specific and the standards to be followed shall be defined in the equipment specification.
DEP 63.10.08.11-Gen. February 2015 Page 19 4.4. 4.4.3 3
Addit ional tests
1.
If confirmed by the Principal, additional tests shall be performed.
2.
These may include include operation outside (DEP) standard operating limits of voltage and frequency, additional testing of excitation and governor systems, prolonged interruption of supply to auxiliaries and cascade control of voltage and power in systems with power generation at multiple voltage levels. The tests are intended to demonstrate the capabilities of systems rather than of the single major components.
4.5
3.
During testing, the configurations of the network should be kept as similar as possible to the operational configuration.
4.
The requirement requirement for the additional tests shall be confirmed by the Principal. Principal.
TRANSFORMERS Refer to DEP 63.10.08.91-Gen., Forms 1, 3 and 9.
4.5. 4.5.1 1
Oil-filled power transform ers
4.5.1.1
General 1.
Windings of transformers shall not normally be subjected to high potential testing. Refer to (Appendix E) and (Appendix G) for NA test voltages and acceptable insulation resistance values. For other locations, use (Appendix F) and (Appendix H). rd
Power transformers are typically tested by a 3 party Contractor.
2.
Test results shall be reviewed and accepted by the ETA. Tests that are typically done rd by a 3 party Contractor include: a.
Power factor using a Doble (or equivalent) test set
b.
Transformer Turns Ratio (TTR) test
3.
SFRA (Sweep Frequency Response Analysis) Analysis) should be performed on large (> 25 MVA) power transformers and compared to the factory SFRA signature which also serves as the baseline signature for future reference/analysis.
4.
After initial initial energisation of a power transformer, it should be put on no-load ‘soak’ for a few hours (e.g., overnight) before being put on load.
5.
Before parallel operation of the transformer is attempted, 'phasing-out' operations shall be carried out to verify that the two supplies are “in-phase”. Refer to (Appendix D). Refer to (Appendix J) for examples of Delta/Star Transformer connections.
4.5.1.2
Transformer oil 1.
Liquid levels levels shall be verified that they are correct. For transformers with nitrogen or other dry gas blanket, verify that a positive pressure (in accordance with the Manufacturer/Supplier data) is maintained.
2.
If this cannot be verified, transformer oil in in grid intake, generator step-up, VSDS, captive motor duty and/or large (> 25 MVA) power transformers, shall be conditioned prior to use to confirm that the transformer windings and oil are free from moisture.
3.
An oil sample should be taken from conservator type transformers and and sealed transformers with a rating over 3000 kVA and laboratory-tested in accordance with ASTM D923. Refer to (Appendix K). Tests should include: a.
Visual Examination
b.
Dissolved Gas Analysis (DGA)
c.
Liquid Power Factor
d.
Dielectric Strength
DEP 63.10.08.11-Gen. February 2015 Page 20
4.5. 4.5.2 2
4.6
e.
Acid Neutralization Number
f.
Interfacial Tension
g.
Colour
h.
PPM Water
4.
The minimum withstand withstand voltage voltage shall be 30 kV (27 kV for NA applications).
5.
For transformers with auto on-load tap changers, an oil sample should also be taken from the tap-changer compartment and laboratory-tested.
Dry type transfor mers
1.
Testing of dry type transformers other than air-cooled, dry type LV transformers for lighting and small power shall be in accordance with Manufacturer/Supplier recommendations.
2.
Air-cooled, dry type LV LV transformers for lighting and small power transformers should should have insulation-resistance tests performed winding-to-winding and each winding-toground for 1-minute duration, prior to energisation.
BUS DUCT Refer to DEP 63.10.08.91-Gen., Form 11.
1.
Bus duct shall be inspected, tested and commissioned in accordance with the test form.
2.
Functionally test the bus duct heaters to ensure they are working properly. Verify Verify that the amp meter shows current flow through the heater circuits to ensure that it is continuous and operating.
3.
Check that that the bus duct duct enclosure has adequate drainage to prevent the accumulation of moisture.
4.
Check that wall/floor penetrations are properly installed.
5.
Testing of bus duct will primarily consist of insulation resistance tests. (Appendix E) and (Appendix G) show proper test voltages and insulation resistance values for NA applications. For other locations, see (Appendix F) and (Appendix H).
4.7
SWITCHGEAR
4.7. 4.7.1 1
Air insul ated switc hgear Refer to DEP 63.10.08.91-Gen., Forms 5, 6, 7 and 19.
4.7.1.1
4.7.1.2
Conductivity tests 1.
After assembly and alignment, switchgear busbar joints shall be tightened to the Manufacturer's recommended torque settings. After correct installation, busbar joints shall be insulated in accordance with the Manufacturer's instructions.
2.
All torqued connections shall be marked to: a.
Indicate that they have been properly torqued;
b.
Show if torque torque bolts/nuts have been disturbed after the fact.
3.
Switchboard 'droppers' shall be considered as part of the busbar system.
4.
Conductivity tests shall be performed between adjacent, cubicle spouts (See 3.2.1).
5.
The measured values shall be interpreted on a comparative basis and according according to the Manufacturer’s statements regarding expected variation in conductance.
Insulation tests 1.
MV (NA) and HV switchgear components components (busbars, contactors and circuit breakers) shall be subjected to high-potential tests at the pre-commissioning stage.
DEP 63.10.08.11-Gen. February 2015 Page 21
4.7.1.3
4.7.2 4.7.2
2.
In general high potential tests are carried out with DC. Refer to (Appendix E) E) for test voltages and durations for NA applications. For applications outside NA, the test voltage shall be limited to 70 % of the peak value of the relevant AC voltage levels given in IEC 62271.
3.
For HV cast, resin-insulated switchgear, the Manufacturer shall recommend appropriate testing methods.
4.
LV switchgear components (busbars, contactors and switches) shall be subjected to IR tests at the pre-commissioning stage.
Functional tests 1.
All draw out switching devices shall be checked for for free movement and correct alignment.
2.
In addition to all checks as given in the appropriate test forms, a full check shall be performed to demonstrate that all features of the switchboard function as intended.
3.
For complex installations, the Contractor shall develop specific, functional check–lists, based upon control schematic diagrams, to demonstrate compliance with the design requirements.
4.
Function checks shall be witnessed witnessed by an ETA (or designate).
Gas ins ulated swi tch gear (GIS) (GIS)
1.
4.7.3 4.7.3
Requirements for Gas Insulated Insulated Switchgear (GIS) shall be obtained from the Manufacturer/Supplier. Commissioning of this type of switchgear shall normally be carried out by or under the supervision of the Manufacturer/Supplier.
Swit ches (AIS) Refer to DEP 63.10.08.91-Gen., Forms 19, 20 and 21.
1.
Switches shall be inspected, tested and commissioned fully in accordance with the specific test forms.
2.
The tests tests are are designed designed to confirm the performance of the switch, including: a.
Operation of the mechanical operator, space heaters and control devices;
b.
Blade alignment, wipe wipe and lubricated lubricated according according to the Manufacturer’s/Supplier’s requirements;
c.
Contact resistance across switch blade and fuse holder (if applicable); applicable);
d.
Insulation resistance tests phase to phase and phase to ground shall be measured and recorded.
3.
For fused switches, fuse resistance should be included.
4.
In addition to all checks as given given on the appropriate test forms, a full function test should be carried out to demonstrate that all features of the switch function as intended/designed.
4.8
MCCs AND SWITCHBOARDS
4.8.1
General Refer to DEP 63.10.08.91-Gen., Forms 13, 14, 15 and 16.
1.
MCCs and switchboards shall be inspected, tested and commissioned fully in accordance with the specific test forms.
2.
Closing of busbar compartments should should be witnessed by the ETA.
DEP 63.10.08.11-Gen. February 2015 Page 22 4.8. 4.8.2 2
Conductiv ity tests
1.
4.8. 4.8.3 3
4.8. 4.8.4 4
a.
Indicate that they have been properly torqued;
b.
Show if torque bolts/nuts have been disturbed after the fact.
2.
Random checks checks shall shall be carried out to verify compliance with with factory torque figures.
3.
An MCC vertical bus shall be considered part of the bus bar bar system. system.
4.
The measured values shall be interpreted on a comparative basis.
Insulation tests
1.
Components (bus bars, bars, starters and circuit breakers) shall be subjected to insulation resistance tests.
2.
Refer to (Appendix E) E) for NA test test voltages and durations. (Appendix F) should be references for locations other than NA.
Function al tests
1.
4.9
All bolts and nuts in the power current carrying circuits shall have been tightened with a torque wrench to the factory recommended figures before conductivity tests are performed. All torqued connections shall be marked to
In addition to all checks as given in the appropriate test forms, a full check shall be performed to demonstrate that all features of the motor control centre/switchboard function as intended/designed.
PROTECTION Refer to DEP 63.10.08.91-Gen., Forms 33, 34, 35, 36 and 37.
4.9. 4.9.1 1
Protection testing general
1.
Relays shall be tested and commissioned in in accordance with the Manufacturer's instructions. Use should be made of the standard test forms in this DEP; but where these prove to be inadequate, e.g., for multi-function microprocessor-based relays, specific forms may be developed.
2.
The use of digitally digitally controlled test sets which can be configured to self-document the test results and avoid the need to generate project-specific forms is recommended. Such information may also then be extracted in a digital form and may be more easily uploaded into record systems.
3.
All relay operations; indications and logic schemes shall be be checked and results recorded on test forms.
4.
CT and VT polarity polarity may be proven by flick flick tests – refer to (Appendix L).
5.
All CT ratios shall be verified by primary current injection. CT CT connections once proven by primary injection should not be removed without being retested. Break-in to CT circuits should subsequently only be made at test links provided for the purpose.
6.
All protection relays shall be tested by means of primary current injection at (wherever possible) the normal settings to verify their operating parameters. Where it is impractical to use a primary injection test set, relays may be tested by secondary injection, subject to the approval of the Electrical Technical Authority.
7.
Relay testing shall include verification of the operation of the switching device's tripping mechanism and all alarms and intertrips.
8.
Overload relays of Ex'e' motors shall be tested to verify that the tripping time of a 'warm' relay is less than the tE time shown on the motor rating plate when a current equivalent to the motor starting current is injected.
9.
Motor restart relays and systems shall be tested to verify that their settings are as recommended by a "motor restart/re-acceleration" study.
DEP 63.10.08.11-Gen. February 2015 Page 23 10. For generators and generator/transformer combinations, use may be made of the the generator as a current source. 11. After each test, itit shall be verified that the actual relay setting setting is in accordance with the setting as laid down in the overall protection scheme of the power system. 12. The last test date shall be indicated on the relay, and and a download of the settings file for numeric relays shall be performed. This shall be identified as the “as-built” record of the relay settings and shall form part of the documentation at hand over of the installation. 13. An approved software change procedure should be in place prior to testing to control Management of Change for software changes. 4.9. 4.9.2 2
4.9.3 4.9.3
4.9.4
Protection test equipment
1.
Equipment used to test relays shall have sufficient capability to drive the relay loads.
2.
Electro-mechanical relays generally have non-linear impedance characteristics and may impose high burden on the test set.
3.
Use of test sets with with inadequate drive capacity capacity can lead to significant timing errors and invalidate the test results. For these reasons current source secondary test sets with sufficient burden handling capability shall be used.
4.
If the test set is to be used with all relays at a facility, then it shall be rated to meet the higher load demands of existing protection relays as well.
5.
Test equipment equipment shall be calibrated by an authorized test laboratory and be capable of providing accurate test current and voltages applicable for the devices under test.
6.
A current calibration certificate shall be in force.
Electro nic relays
1.
Care shall be taken that electronic relay components are touched only under controlled conditions, i.e., in a workshop equipped with anti-static facilities.
2.
Electronic relays relays shall be removed or short circuited during IR tests on connected circuits.
Communications
1.
Testing of communication are proven at a Factory Integration Test and before equipment is delivered to site; site tests shall prove all communications in links disturbed since the factory test (e.g., by disconnection).
2.
This testing shall be performed either: a.
between intelligent devices and, board mounted interface units, units, or; or;
b.
between DCS or ENMC and the protection relays / switchboard interface units (where fitted)
4.10
CABLES
4.10.1
General Refer to DEP 63.10.08.91-Gen., Forms 48, 49, 51, 53, 54, 55 and 56.
1.
Cables shall be inspected for a complete installation before electrical electrical testing.
2.
Cables that are not terminated and have exposed ends shall be sealed against moisture ingress. Heat tracing cable ends shall be kept sealed under all circumstances to prevent moisture ingress which may destroy the temperature regulating characteristic of the cable.
3.
A shield-continuity shield-continuity test shall be performed on each power cable using a micro-ohm meter. For MV shielded cable, proper routing of shield drain conductors through CTs shall be verified.
DEP 63.10.08.11-Gen. February 2015 Page 24
4.10 4.10.2 .2
4.11
4.
Underground cables should be tested prior to cable trench back-filling. MV (NA) and HV cables may be tested only after terminations are completed, which generally is after trenches are backfilled. In this case, sheath integrity testing can be carried out after first fill (normally sand) of trench has been completed, provided all cable through joints are completed.
5.
Testing of all power cables shall be performed while isolated from both supply supply and load circuits. This shall include phase allocation verified by continuity checks on cable cores.
6.
For power power cables connected to an ASD/VSDS, ASD/VSDS, insulation resistance shall be tested before final termination, but after all lugs, termination kits and other preparations are complete.
7.
If completed tests indicate that a conductor or cable has been damaged, the Contractor shall notify the ETA immediately and the conductors shall not be terminated.
8.
For NA applications refer to (Appendix E) and (Appendix G) for values of test voltage, method and acceptable insulation resistance values. For other locations refer to (Appendix F) and (Appendix H).
Cable Cable joint s and termination s
1.
QA hold and witness points shall be provided for supervisor inspection via an agreed Inspection and Test plan.
2.
Jointers / terminators shall provide provide valid certificates of competence for the specific joint / termination.
3.
The first work of a jointer / terminator at site shall be checked (destructive inspection) by a Vendor supervisor; subsequently the first 10 field joints / terminations shall be inspected.
4.
The jointer / terminator shall sign their name on the completed joint / termination worksheet for traceability and ownership of the completed work, for recording by the Contractor.
VARIABLE SPEED DRIVE SYSTEMS (VSDS)/ ADJUSTABLE SPEED DRIVE SYSTEMS (ADSD) Refer to DEP 63.10.08.91-Gen., Forms 17.
4.11.1
4.11.2
General
1.
VSDS/ASDS and, if appropriate excitation controls, shall be commissioned fully in accordance with the Manufacturer's instructions. For complex equipment, the Manufacturer’s representatives will normally be used to supervise or undertake the commissioning activities.
2.
All protection devices which perform a trip, alarm or control function shall be be functionally tested up to and including the operation of the final 'device'.
3.
On completion of commissioning, a list of all equipment set points and parameters shall be recorded and attached to the relevant equipment records in the electrical equipment database.
Testing
1.
The testing of large large variable speed drives should form part of the purchase requisition due to difficulty, cost and complexity of testing. The tests to be performed on-site should be included in this protocol. Reference should be made to DEP 33.66.05.33-Gen. for more guidance on testing of VSD/ASD systems. (DEP 33.66.05.32-Gen. for NA applications).
DEP 63.10.08.11-Gen. February 2015 Page 25 2.
Testing of smaller VSD/ASD systems (typically those not covered DEP 33.66.05.33-Gen. or DEP 33.66.05.32-Gen. for NA) should follow Manufacturer’s recommendations.
3.
Testing of smaller VSD/ASD systems shall include as a minimum: a.
setting of site-specific parameters
b.
full load trials, including auto-restart and voltage voltage dip ride through
c.
full load noise tests throughout the speed range
d.
full load vibration vibration tests throughout the speed range
4.12.
UNINTERRUPTIBLE POWER SUPPLY (UPS)
4.12.1
General
4.12.2
by the
1.
UPS shall be commissioned fully in in accordance with with the Manufacturer's instructions. For complex equipment, the Manufacturer’s representatives will normally be used to supervise or undertake the commissioning activities.
2.
All protection devices which perform a trip, alarm or control control function shall be functionally tested up to and including the operation of the final 'device'.
3.
On completion of commissioning, a list of all equipment set points and parameters shall be recorded and attached to the relevant equipment records in the electrical equipment database.
AC UPS Refer to DEP 63.10.08.91-Gen., Form 39.
4.12.3
1.
The inspection, testing and commissioning procedure shall follow the Manufacturer's instructions.
2.
The procedure shall include tests designed to confirm the static and dynamic performance of the equipment, including: a.
rectifier float charge voltage level
b.
rectifier boost charge voltage level
c.
operation of Inverter and By-pass in synchronism
d.
transfer of load from Inverter to By-pass By-pass and and return
e.
when the rectifier is switched off, the battery accepts load and the UPS output remains within limits
f.
oscilloscope checks on the equipment's output waveform
DC UPS Refer to DEP 63.10.08.91-Gen., Form 40.
1.
4.12.4
The inspection, inspection, testing testing and commissioning procedure shall follow the the specific test form. These tests are designed to confirm the performance of the equipment, including: a.
rectifier float charge voltage level;
b.
rectifier boost/equalize charge voltage levels;
c.
when the rectifier is switched off, the battery accepts load and the UPS output remains within limits.
Batteries Refer to DEP 63.10.08.91-Gen., Form 41.
1.
The tests are designed to confirm confirm the performance of the battery, including:
DEP 63.10.08.11-Gen. February 2015 Page 26 a.
battery cell voltage and specific gravity measurements
b.
internal resistance and inter-cell resistance;
c.
battery discharge capacity test
2.
For flooded cell batteries, add cell temperature.
3.
Outside NA, an acceptance test of the battery capacity shall be performed in accordance with IEEE 450, IEEE 1106, IEEE 1188 or IEC 62040-3 to determine that the battery and installation meets design specifications.
4.13
EARTHING (GROUNDING) AND BONDING
4.13.1
General Refer to DEP 63.10.08.91-Gen., Forms 58, 59, 60, 61. The test numbers mentioned below are illustrated in (Appendix I). The drawing shows typical plant installation details and the appropriate test methods to be used for each installation.
1. 4.13 4.13.2 .2
4.13 4.13.3 .3
Measurements should be taken during normal ground moisture.
Electrical system earthin earthin g (groundi ng)
1.
For bonding connections to the plant earth (ground) grid or connections between plant earth (ground) grids, a clamp-on meter should be used to determine earth (ground) loop resistance (refer to Appendix Ib)
2.
Test 1: For earth (ground) electrodes the earth (ground) loop resistance should be measured against the overall impedance of the plant earth (ground) grid with one of the earth (ground) cables disconnected (n-1). (n-1). The resistance shall not exceed 4 Ω.
3.
If there is a suspect reading, a more accurate resistance test should be done using the potential fall test shown in (Appendix Ia).
4.
Test 2, Test 3: All earth (ground) connections between the electrode, the supply neutral and the plant earth loop shall be tested for continuity.
5.
Test 4: All earth (ground) connections between switchboards, switchboards, transformers and the substation earth (ground) bar shall be tested for continuity.
6.
The earth (ground) loop impedance of all power and convenience outlets shall be measured using an appropriate 'earth (ground) loop tester'.
7.
Where protection is by fuses, the impedances measured should allow a maximum 0.4 second disconnection time for portable equipment and a maximum of 5 seconds for fixed installations.
8.
Tests on lighting and small power circuits shall be performed on on each circuit at a point furthest from supply point. Where the circuit has short spurs only with limited numbers of fittings from the main circuit route, it is not necessary to test individual spurs. Where there are significant numbers of junction boxes in spur circuits, then this test shall be repeated from ends of spur circuits as well as at the end of the main circuit.
9.
Where protection protection is by earth leakage leakage circuit circuit breakers/ground fault circuit interrupters, the test currents and operating times shall be as determined by the circuit breaker characteristics.
Instrument earth (ground) (if prov ided) There may be a separate telecom and/or instrument earth (ground) system with their own earth (ground) bars within FARs/CCRs, with a connection (inside the FAR/CCR) to the electrical earth (ground) bar, with NO connection to a separate external earth (ground) electrode.
1.
Test 5, Test 6: All earth (ground) connections, between the instrument earth (ground) bar and the electrical earth (ground) bar, shall be tested for continuity.
DEP 63.10.08.11-Gen. February 2015 Page 27 4.13 4.13.4 .4
Equipment external earth earth (ground )
4.13.4.1 Process plant non-electrical equipment 1.
For bonding connections to the plant earth (ground) grid or connections between plant earth (ground) grids, a clamp-on meter should be used to determine earth (ground) loop resistance, refer to (Appendix Ib).
2.
Test 7: Sample measurements shall be taken (5 % of the total) to verify the continuity of the equipment's external earthing (grounding) cable (with the cable disconnected from the equipment) and any adjacent earthing (grounding) cable (also disconnected from its equipment).
4.13.4.2 Process plant electrical equipment, (motors, heaters, etc.)
4.13 4.13.5 .5
4.14
1.
Test 8: Measurements shall be made on the earth (ground) return path of all electrical equipment having an external earth (ground) connection.
2.
Measurements shall be made with the the equipment in operational condition and all cables connected. The earth (ground) return impedance shall be measured between the body of the equipment and the substation earth (ground) bar, using a conductivity meter and a calibrated cable.
3.
Results shall be evaluated on a comparative basis basis to identify identify any abnormal readings.
4.
Earth (ground) loop impedance shall be such as to allow the protective device to operate before damage to the cable occurs.
5.
For motor circuits with earth (ground) leakage protection, this calculation calculation shall be based upon operation of the fuse or mcb protection.
Earth Earth (ground) for light ning and static disch arge
1.
Test 9: For earth (ground) electrodes the earth (ground) loop resistance should be measured against the overall impedance of the plant earth (ground) grid with one of the earth (ground) cables disconnected (n-1). The resistance shall not exceed exceed 10 Ω.
2.
Test 10: All earth (ground) connections between the electrode and the plant earth (ground) grid shall be verified for continuity.
BUILDINGS See DEP 63.10.08.91-Gen., Forms 1, 3, 63 and various other forms as needed.
1.
Plant buildings buildings and non-plant buildings (i.e., offices, warehouses, gatehouses, workshops, etc.) shall be treated in the same manner as plant equipment and be subject to pre-commissioning and commissioning procedures.
2.
The Contractor Contractor shall have knowledge knowledge of the relevant local regulations applying to the the country of the installation and conform to these requirements. Where there are no specific local regulations, then the Contractor shall propose and obtain agreement of the Principal of the testing programme to be followed.
3.
The scope of the pre-commissioning and commissioning activities covers all electrical equipment and systems, including the following: a.
Purge systems;
b.
Lighting shall include normal, emergency and escape lighting lighting systems. Refer to (4.15) and DEP 63.10.08.91-Gen., Form 44;
c.
Switchboards and associated transformers (DEP 63.10.08.91-Gen., Form 43);
d.
Earthing (grounding) systems, refer to (4.13);
e.
Convenience outlets, refer toDEP 63.10.08.91-Gen., Form 44);
f.
HVAC electrical equipment;
DEP 63.10.08.11-Gen. February 2015 Page 28 g.
Power cables, lighting circuits and receptacle circuit conductors, Refer to (4.11) and DEP 63.10.08.91-Gen., Form 48.
h.
Miscellaneous electrical equipment:
4.15
LIGHTING
4.15.1
General
i.
Uninterruptible power supplies (DEP 63.10.08.91-Gen., Forms 39 and 40);
ii.
Automatic transfer/bypass switches (DEP 63.10.08.91-Gen., Form 21);
iii.
Battery systems (DEP (DEP 63.10.08.91-Gen., Forms 40 and 41).
Refer to DEP 63.10.08.91-Gen., Forms 43 and 44.
4.15 4.15.2 .2
1.
For hazardous area lighting, 100 % checks shall be made as described in (4.1.1).
2.
One Inspection (DEP 63.10.08.91-Gen., Form 1, 3 or 4) per equipment type and per area shall be completed.
3.
For lighting in unclassified areas, spot checks on 5 % (minimum) of the total shall be made. If any faults are found, the inspection shall be suspended and the Installation Contractor asked to check the entire installation and correct any faults found. Inspection may then be restarted with a fresh 5 % sample, and if necessary, the cycle repeated.
4.
The activities activities shall include a record of measured illumination illumination levels. Luxmeter readings readings shall be taken at the working plane or 1 m above the floor level in a horizontal plane and entered on a suitable plot or building plan.
5.
The illumination levels shall be as specified in Appendix 4 of DEP 33.64.10.10-Gen., Section 4.15.1 of DEP 33.64.20.10-Gen. or as specified by the Principal.
Emergency and escape light ing
1. 4.15 4.15.3 .3
Navigation Navigation and obstru ction light ing
1.
4.16
The operation and autonomy time of all all Emergency Emergency and Escape lighting systems systems shall be verified by testing.
Correct operation of navigation and obstruction lighting lighting and and audible warning warning systems shall be tested as per regulatory requirements.
ELECTRIC HEAT TRACING Refer to DEP 63.10.08.91-Gen., Form 65.
1.
Testing of all electric heat tracing cables shall be carried out while isolated from the power supply circuits. Heat tracing cable ends shall be kept sealed under all circumstances to prevent moisture ingress.
2.
Insulation resistance test for heat tracing cables shall be conducted (phase to braid) for the following situations: a.
When the cables are received at the job site before installation.
b.
After the cables are installed, but before insulation is applied.
c.
After insulation is applied.
3.
Insulation resistance test voltages for heat tracing cable shall be in accordance accordance with (Appendix E) for NA and (Appendix G) for other locations.
4.
Control panels shall be inspected to verify that they are complete with all components installed. Controllers shall be programmed with design parameters.
DEP 63.10.08.11-Gen. February 2015 Page 29
4.17
5.
Skin effect heat tracing systems systems shall be tested in accordance with the Manufacturer’s/Supplier’s instructions. Heat tube and connecting conductor test results shall be recorded.
6.
In addition to all checks as given in the appropriate inspection inspection and test form, a full check shall be performed to demonstrate that all features of the control system function as intended.
7.
Transformers, panel boards and associated power systems should be tested in accordance with (4.20).
8.
Insulation systems systems are a critical part of the heat tracing system. Proper insulation methods should be verified.
9.
The monitoring system of heat tracing systems on safety critical elements shall be tested and when possible, demonstrated to achieve the correct operating temperature.
ELECTRICAL PROCESS HEATERS Refer to DEP 63.10.08.91-Gen., Form 66.
1.
The Contractor / Manufacturer shall submit a test plan detailing all such tests and showing required interfaces with third parties, for approval by the Principal. Refer to DEP 33.68.30.33-Gen.
2.
The following electrical tests shall be carried out: a.
Insulation test of heaters to earth with a 500 V DC insulation resistance tester;
b.
Continuity to be tested on each phase of the heater.
3.
In addition to all checks as given in the appropriate inspection and test form, a full check shall be performed to confirm operation of the control and protection system.
4.
The power control assembly should be tested in accordance with (4.20).
5.
A full load test of the heater in its service condition shall be carried out to confirm the design output. In addition, interfaces to other connected systems shall be tested with particular emphasis on control, protection and alarm systems.
4.18
CABLE SUPPORT SYSTEMS
4.18.1
Cable tr ay Refer to DEP 63.10.08.91-Gen., Form 55.
1.
Cable tray systems inspections for proper materials and installation shall include: a.
Cable tray size and material
b.
Cable tray supports
c.
Hold downs and anchoring
d.
Cable tray grounding
e.
Expansion joints
f.
Bonding jumpers
g.
Cable tray covers where applicable
h.
Cable tray separation shall be provided for the following situations: i.
Between instrument trays and power trays
ii.
From hot services
iii.
Vertical spacing between cable trays
iv.
Stainless steel cable trays and and galvanised steel.
DEP 63.10.08.11-Gen. February 2015 Page 30 i. 4.18 4.18.2 .2
Proper tagging
Abovegro und condu it Refer to DEP 63.10.08.91-Gen., Form 53.
1.
2.
4.18 4.18.3 .3
Conduit systems inspection for proper materials and installation shall include: a.
Conduit supports
b.
Proper bend radius
c.
Conduit grounding
d.
Expansion fittings
e.
Bonding jumpers
f.
Seals and drains
g.
Proper tagging
Conduit separation shall be provided for the following situations: a.
Between instrument conduits
b.
From hot services
Underground condu it (duct banks) Refer to DEP 63.10.08.91-Gen., Form 54.
1.
Underground conduit systems shall be inspected inspected before and after concrete pour or backfill.
2.
Prior to concrete pour or backfill the following shall be verified/inspected:
3. 4.18.4 4.18.4
a.
Location, elevation and forming
b.
Conduit size and type
c.
Conduit spacing
d.
Conduit stub ups
e.
Proper bend radius
After concrete is poured or backfilled, backfilled, coverage and stub ups shall be verified.
Electri cal manho les Refer to DEP 63.10.08.91-Gen., Form 56.
1.
4.19
Electrical manholes shall be inspected before and after concrete pour or backfill. Prior Prior to concrete pour or backfill, the following shall be inspected: a.
Proper opening sizes
b.
Conduit window locations
c.
Grounding
d.
Conduit sizes and type
e.
Sump or drain
OVERHEAD POWER LINES AND OUTDOOR SWITCHYARDS Refer to DEP 63.10.08.91-Gen., Form 67.
1.
Inspection criteria criteria and responsibility shall be clearly defined at the time of contract award. Measurements and inspections include: a.
conductor tension (during and after pulling)
b.
conductor sag (temperature corrected);
DEP 63.10.08.11-Gen. February 2015 Page 31 c.
conductor to ground clearance (temperature corrected) at critical points (e.g., road crossings)
d.
resistance across line line compression joints and termination fittings
e.
structural alignment (poles in line and upright)
f.
resistance to earth earth (ground) of static earth wires, guys, structures, lightning arrestors, etc.
g.
Installation of large orange signs at grade (where overhead power lines cross roadways) in both directions warning of Overhead Overhead Power Lin es.
It is common practice for the Contractor responsible for erection of the overhead power lines to also carry out the inspection required during erection.
4.20
2.
The Contractor shall be required to submit to the Principal for approval a procedure for stringing/tensioning the line.
3.
Prior to energisation, the entire line line and associated equipment shall be checked visually and the insulation resistance of the line recorded. It is often not possible to arrange for high potential testing of the line and in this case, insulation resistance measurements may be made using a 5 kV insulation tester.
MISCELLANEOUS LOW VOLTAGE EQUIPMENT Refer to DEP 63.10.08.91-Gen., Forms 43, 44 and 45. LV equipment includes transformers, panel boards, receptacles and control panels, etc.
1.
4.21
LV equipment should be inspected for proper installation which includes: a.
Proper mounting and support.
b.
Proper grounding to cases and to the earth (ground) grid.
c.
Properly installed conduit and/or cable terminations terminations to the enclosure.
d.
Proper wire terminations.
2.
Low voltage equipment should be checked for proper proper connection per the one-line diagrams, schematic diagrams and wiring diagrams. This can also include Manufacturer/Supplier drawings. Cable types and sizes should be verified. The equipment should also be verified for proper voltage levels and short circuit capabilities, as applicable.
3.
Wire terminations to equipment should be checked for tightness. a.
Connections of power cables should be checked with a calibrated torque wrench, refer to (Appendix M).
b.
A simple pull test of the wire wire will determine that the wire is properly terminated on a terminal block in a control panel.
4.
Verify that panel boards have complete and accurate schedules at at the panel board. board.
5.
Testing of low voltage voltage equipment will primarily consist consist of insulation resistance tests. (Appendix E) and (Appendix G) show proper test voltages and insulation resistance values for NA applications. For other locations, use (Appendix F) and (Appendix H).
6.
Function checks of the equipment should be carried out as is applicable for the type of equipment.
ELECTRICAL NETWORK MONITORING AND CONTROL (ENMC) SYSTEM COMMISSIONING 1.
DEP 33.64.10.32-Gen. shall serve as guidance on commissioning of EMNC systems.
2.
In principle, the the inter-operation of the components forming the systems shall be proven during Factory Acceptance Testing before erection at site. The site-specific tests shall
DEP 63.10.08.11-Gen. February 2015 Page 32 demonstrate the site installed communication wiring or fibre optic components are operating correctly, and then confirm that the systems are communicating correctly. 3.
4.22
Thereafter, the system DEP 33.64.10.32-Gen.
testing
shall
follow
recommendations
given
in
INTEGRATED MOTOR CONTROL SYSTEM (IMCS) COMMISSIONING 1.
DEP 33.67.01.31-Gen. shall serve as guidance on commissioning of IMCS systems.
2.
The switchgear assembly including the IMCS shall be subjected to a full routine test before erection at site. The site-specific tests shall demonstrate the site installed communication wiring or fibre optic components are operating correctly, and then confirm that the systems are communicating correctly.
3.
Thereafter, the system DEP 33.67.01.31-Gen.
testing
shall
follow
recommendations
given
in
DEP 63.10.08.11-Gen. February 2015 Page 33 5.
REFERENCES
In this DEP, reference is made to the following publications: NOTES:
1. Unless specifically specifically designated by date, the latest edition of of each publication shall be used, together with any amendments/supplements/revisions amendments/supplements/revisions thereto. 2. The DEPs and most referenced external external standards are available to Shell staff on the the SWW (Shell Wide Web) at http://sww.shell.com/standards/ http://sww.shell.com/standards/..
SHELL STANDARDS
Global technical standards index
DEP 00.00.05.05-Gen.
DEP feedback form
DEP 00.00.05.80-Gen.
Electrical engineering design
DEP 33.64.10.10-Gen.
Electrical network monitoring and control system for industrial networks
DEP 33.64.10.32-Gen.
Electrical engineering design for North American application
DEP 33.64.20.10-Gen.
Synchronous AC machines (amendments/supplements to IEC 60034-1)
DEP 33.65.11.31-Gen.
Synchronous AC machines for North American application (amendments/supplements to API 546)
DEP 33.65.11.34-Gen.
Electrical machines - Cage-induction types (amendments/supplements to IEC 60034-1 and IEC 60034-14)
DEP 33.66.05.31-Gen.
AC electrical adjustable speed drive systems - Rated 375 KW and larger for North American application (amendments to IEEE STD 1566:2005)
DEP 33.66.05.32-Gen.
AC electrical variable speed drive systems
DEP 33.66.05.33-Gen.
MV induction motors for North American application (amendments/supplements to API 541)
DEP 33.66.05.36-Gen.
General-Purpose Form-Wound Squirrel Cage Induction Motors – 250 Horsepower and Larger for North American Application (Amendments/Supplements to API 547)
DEP 33.66.05.37-Gen.
Low voltage switchgear and controlgear assemblies (amendments/supplements to IEC 61439)
DEP 33.67.01.31-Gen.
Electrical process heaters
DEP 33.68.30.33-Gen.
Field Commissioning and Testing of Electrical Systems and Equipment for North American Application Application withdrawn
DEP 63.10.08.14-Gen.
Field commissioning and testing of electrical systems and equipment (Inspection and Test Forms)
DEP 63.10.08.91-Gen.
Electrical safety rules
DEP 80.64.10.10-Gen.
Static electricity
DEP 80.64.10.11-Gen.
Project Guide 14b: Commissioning and Start up
PG 14b
https://eu015sp.shell.com/sites/IPMS/List sp.shell.com/ sites/IPMS/Lists/IPMS%20Imag s/IPMS%20Images/Standards%2 es/Standards%20and%20Guides 0and%20Guides.htm .htm
GoCCMS - Certification and Completions Management System
GoCCMS
http://sww.go-ccms.shell. http://sww.goccms.shell.com/Userlo com/Userlogin.aspx gin.aspx
AMERICAN AMERIC AN STA NDARDS
Design, Installation, and Maintenance of Electrical Systems for Fixed and Floating Offshore Petroleum Facilities for Unclassified and Class 1, Division 1 and Division 2 Locations
API RP 14F
DEP 63.10.08.11-Gen. February 2015 Page 34
Recommended Practice for Design and Installation of Electrical Systems for Fixed and Floating Offshore Petroleum Facilities for Unclassified and Class I, Zone 0, Zone 1 and Zone 2 Locations Electrical installations in petroleum processing plants Form-Wound Squirrel-Cage Induction Motors—500 Horsepower and Larger Brushless Synchronous Machines - 500 kVA and Larger
API RP 14FZ
API RP 540 API STD 541 API STD 546
General-purpose Form-wound Squirrel Cage Induction Motors 250 Horsepower and Larger
API STD 547
Standard test method for dielectric breakdown voltage of insulating liquids using disk electrodes
ASTM D877
Standard practice for sampling electrical insulating liquids - reinstated
ASTM D923
Standard test method for water in insulating liquids by Coulometric Karl Fischer titration
ASTM D1533
Standard test method for dielectric breakdown voltage of insulating oils of petroleum origin using VDE electrodes
ASTM D1816
Standard test method for analysis of gases dissolved in electrical insulating oil by gas chromatography
ASTM D3612
Recommended Practice for Electrical Installations on Shipboard
IEEE 45
Guide for Field Testing of Shielded Power Cable Systems Using Very Low Frequency (VLF) (less than 1 Hz)
IEEE 400.2
Recommended practice for maintenance, testing, and replacements of vented lead-acid batteries for stationary applications
IEEE 450
Petroleum and Chemical Industry—Premium- Efficiency, Severe-Duty, Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors— Up to and Including 370 kW (500 hp)
IEEE 841
Recommended practice for electrical impedance, induction, and skin effect heating of pipelines and vessels
IEEE 844
Recommended Practice for Installation, Maintenance, Testing, and Replacement of Vented Nickel-Cadmium Batteries for Stationary Applications
IEEE 1106
Recommended Practice for Maintenance, Testing, and Replacement of Valve-Regulated Lead-Acid (VRLA) Batteries for Stationary Applications
IEEE 1188
National Electrical Code
NFPA 70
Standard for Purged and Pressurized Enclosure for Electrical Equipment
NFPA 496
CANADIAN STANDARDS
Canadian Electrical Code
CSA C22.1
INTERNATIONAL STANDARDS
Rotating Electrical Machines - Part 1:Rating and performance
IEC 60034-1
Rotating Electrical Machines - Part 5: Degrees of protection provided by the integral design of rotating electrical machines (IP code)
IEC 60034-5
Rotating Electrical Machines - Part 16: Excitation Systems for Synchronous Machines - Section 3: Dynamic Performance - Edition 1
IEC 60034-16-3
DEP 63.10.08.11-Gen. February 2015 Page 35
International Electrotechnical Vocabulary
IEC 60050
Explosive atmospheres – Part 14: Electrical i nstallations design, selection and erection
IEC 60079-14
Explosive atmospheres - Part 17: Electrical installations inspection and maintenance
IEC 60079-17
Insulating Liquids - Determination of the Breakdown Voltage at Power Frequency - Test Method – Edition 2
IEC 60156
Mineral Insulating Oils in Electrical Equipment – Supervision and Maintenance Guidance
IEC 60422
Power cables with extruded insulation and their accessories for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) – Part 1: Cables for rated voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um = 3,6 kV)
IEC 60502-1
Classification of Degrees of Protection Provided by Enclosures
IEC 60529
Power cables with extruded insulation and their accessories for rated voltages above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) – Test methods and requirements
IEC 60840
Uninterruptible power systems (UPS) – Part 3: Method of specifying the performance and test requirements
IEC 62040-3
High-voltage switchgear and controlgear – Part 1: Common specifications
IEC 62271-1
Mechanical vibration of rotating and reciprocating machinery Requirements for instruments for measuring vibration severity
ISO 2954
DEP 63.10.08.11-Gen. February 2015 Page 36 APPENDIX A
INSPECTION AND T EST FORMS INDEX
This list refers to DEP 63.10.08.91-Gen. which is a requisition for inspection and test forms. The form numbers listed in column 1 correspond to form numbers accessed within DEP 63.10.08.91-Gen. In column 2: MC means that the form has a Mechanical Completion test part. PC means that the form has a Pre-Commissioning test part. CM means that the form has a Commissioning test part. Form
Form Form Form Form
Test Part Part
1 2 3 4
- MC - MC - MC
Title of form General Electrical Equipment Receiving Checklist Inspection and Testing - Insulation Resistance Inspection of Electrical Equipment Inspection of Certified and Hazardous Area Equipment Switchgear
Form 5
- MC- PC
Form 6
- MC- PC
Form 7 Form 8
- MC- PC
Inspection and Testing of Switchgear Inspection and Testing of Medium Voltage Power Circuit Breaker and Cubicles Inspection and Testing of Low Voltage Power Circuit Breaker and Cubicles Future Transformers
Form 9 Form 10
Form 11 Form 12
- MC- PC
Inspection and Testing of Liquid-Immersed Power Transformers Future
- MC
Bus Duct Inspection and Testing of Bus Ducts Future
Form 13 Form 14
- MC- PC - MC- PC
Form 15
- MC- PC
Form 16
- MC- PC
Form 17 Form 18
- MC- PC
Motor Control Inspection and Testing of Medium-Voltage MCC Line-Ups Inspection and Testing of Medium-Voltage Motor Starters
Inspection and Testing of Low-Voltage MCC Line-Ups and Switchracks Inspection and Testing of Low-Voltage Motor Starters, Circuit Breakers and Switches Inspection and Testing of Low Voltage Adjustable Speed Drives Future Switches
Form 19
- MC
Form 20
- MC
Inspection and Testing of Medium-Voltage Metal Enclosed Air Switches Inspection and Testing of Low-Voltage Disconnect Switches
DEP 63.10.08.11-Gen. February 2015 Page 37
Form
Form 21 Form 22
Test Part Part
Title of form
- MC
Inspection and Testing of Automatic Transfer Switches (ATS) Future Motors
Form 23
- MC- PC
Form Form Form Form Form
- MC- PC - MC- PC
24 25 26 27 28
Inspection and Testing of Medium Voltage Induction Motors Inspection and Testing of Medium Voltage Synchronous Motors Inspection and Testing of Low Voltage Induction Motors Inspection and Testing - Dielectric Absorption Future Future Generators
Form 29
- MC- PC
Form 30
- CM
Form 31 Form 32
- CM
Inspection and Testing of Synchronous Generators and Control Panels Synchronous and Dynamic Testing of Synchronous Generators Inspection and Testing of Black Start/Emergency Generators Future Relays, Relays, Current Transform ers and Potential Transformers
Form 33
- MC
Form 34
- MC
Form 35
- MC
Form 36
- MC
Form 37
- MC
Inspection and Testing of Current Transformers (Single Ratio) Inspection and Testing of Current Transformers (Multi Ratio) Inspection and Testing of Voltage (Potential) Transformers Inspection and Testing of relay with Overcurrent and Undervoltage Function Future - New Inspection and Testing of relay with Differential Function AC UPS, DC UPS and Bat ter ies
Form Form Form Form
39 40 41 42
- MC- PC - MC- PC - MC- PC
Inspection and Testing of Uninterruptible Power Supply (AC UPS) Inspection and Testing of Battery Chargers (DC UPS) Inspection and Testing of Batteries and Battery Racks Future Misc. Low Voltage Equip Equip ment
Form 43 Form 44
- MC- PC - MC- PC
Form 45 Form 46 Form 47
- MC- PC
Inspection and Testing of Low Voltage Panelboards and Associated Transformers Inspection and Testing of Lighting and Receptacles Inspection and Testing of Control Panels and Control Wiring Future Future
DEP 63.10.08.11-Gen. February 2015 Page 38
Form
Test Part Part
Title of form
Form 48
- MC- PC
Wire and Cable Inspection and Testing of Low-Voltage Cable and Wire
Form Form Form Form
- MC- PC
Form Form Form Form Form
49 50 51 52
53 54 55 56 57
- MC
- MC - MC - MC - MC
Form 58 Form 59
- MC - MC
Form 60
- MC
Form 61 Form 62
- MC
Inspection and Testing of Medium-Voltage Cable and Wire Inspection and Testing - DC High Potential Inspection and Testing of Direct Buried Cable Future Conduit and Cable Tray Tray Inspection of Aboveground Conduit Systems Inspection of Underground Conduit Systems (Ductbanks) Inspection of Cable Tray Systems Inspection of Electrical Manholes Future Earthing/Grounding Inspection and Testing of Earthing/Grounding Systems Inspection and Testing of Earthing/Grounding Electrodes Inspection and Testing of High Resistance Grounding Equipment
Inspection and Testing of Low Resistance Grounding Equipment Future Substation Substation Build ings
Form 63 Form 64
- MC
Form 65
- MC- PC
Form 66
- MC- PC
Form 67 Form 68
- MC- PC
Inspection of Power Distribution/Substation Buildings (Including Transformer Yard) Future Heat Heat Tracing Systems Inspection and Testing of Electric Heat Tracing Systems Inspection and Testing of Electric Heater (including control unit) Overhead Overhead Lines Inspection and Testing of Overhead Power Lines Future
DEP 63.10.08.11-Gen. February 2015 Page 39 APPENDIX B
NOMOGRAM FOR TEMPERATURE TEM PERATURE CORRECTION
Example:
Measured resistance: 100 MΩ
Temperature at measurement: 20 °C (1000-6600 V) Corrected resistance: 70 MΩ
DEP 63.10.08.11-Gen. February 2015 Page 40
APPENDIX C
TYPICAL TYPICA L CURVES FOR V ARIA TION OF INSUL ATION RESIST ANCES
Change in one-minute and ten-minute insulation resistance during the drying process of a class B insulated alternating current armature winding. Initial winding temperature 25 °C (77 F). Final winding temperature 75 °C (167 F). °
°
DEP 63.10.08.11-Gen. February 2015 Page 41
APPENDIX D
NOTES:
GENERATOR SYNCHRONIZING SY NCHRONIZING SYSTEM TESTING
1.
Test 1, verify in-phase indication of synchroscope, check sync and voltmeter.
2.
Using a phase phase rotating meter (A), verify identical phase rotation for tests 1 and 2.
3.
Test 2 with generator energised, energised, verify that synchroscope, synchroscope, voltmeter, auto auto and check sync relays follow follow the 'beat frequency'.
DEP 63.10.08.11-Gen. February 2015 Page 42 APPENDIX E
E.1
CABLES 1.
E.1. E.1.1 1
E.1. E.1.2 2
RECOMMENDED TEST VOL TAGES FOR TESTING T ESTING AND COMMISSIONING COMM ISSIONING FOR NA APPLICATIONS
Carry out insulation insulation resistance tests and high potential tests between between each phase and and ground with the remaining phases connected to ground and loads disconnected.
Insulation resistance tests System Voltag e
Test Voltage (DC) (DC)
LV up to 1kV
1000
MV up to 5 kV
2500
MV 5 kV and above
5000
High potential tests
1.
DC test test voltages are applied to discover gross problems such as incorrectly incorrectly installed accessories or mechanical damage. a.
New cables – DC Testing Maximum DC Field Test Voltages, kV
Rated Voltage kV
100 % Insulation Level
133 % Insulation Level
5
28
36
8
36
44
15
56
64
25
80
96
35
100
124
NOTE:
When older older cables cables or other other types/classes types/classes of cables or accessories accessories are connected connected to the the system, system, voltages lower than those shown m ay be necessary.
b.
New cables – AC Testing AC Tes t Vo lt age, k V
Rated Voltage kV
Conductor Size AWG AWG or kcmil
100 % Insulation Level
133 % Insulation Level
5
8 - 1000
18
23
5
1001 - 3000
28
28
8
6 - 1000
23
28
8
1001 - 3000
35
35
15
2 - 1000
35
44
15
1001 - 3000
44
44
25
1 - 3000
52
64
35
1/0 - 3000
69
84
DEP 63.10.08.11-Gen. February 2015 Page 43 E.1.3 E.1.3
Partial dis charg e test Partial Partial Discharge Requirements f or Semicon Semicon ducti ng Coating and Tape Designs Designs Only Rated Rated Circui t Volt age Phase – to – Phase Volts
E.1.4 E.1.4
Minimum Partial Discharge Extinction Level, KV 100 % Insulation Level
133 % Insulation Level
2001 – 5000
4
5
5001 – 8000
6
8
8001 - 15000
11
15
VLF test VLF Testing Testing Levels 0.1 Hz Hz Test Volt age (rms)
E.1. E.1.5 5
System Voltage Phase – to – Phase
Proof Phase – to – Ground
(kV) (rms)
(kV) (rms)
5
10
15
22
25
33
35
47
Heat Heat tracing insul ation resistance tests Cable Type
DC Test Voltage, V
Self regulation
2500
MI
1000
Flexible pad heaters
500
E.2
MOTORS, GENERATORS, TRANSFORMERS (COIL WOUND EQUIPMENT)
E.2. E.2.1 1
Insulation resistance tests
1. E.3
Use values given in (E.1.1).
SWITCHGEAR 1.
High potential tests and insulation insulation tests on bus bar systems shall shall be performed between each phase and ground with the remaining phases connected to ground (voltage transformers and load disconnected).
2.
High potential tests and insulation resistance tests on circuit breakers and contactors may be carried out together with or separately from the bus bar and shall be carried out with the breaker/contactor closed, with loads disconnected.
DEP 63.10.08.11-Gen. February 2015 Page 44 E.3. E.3.1 1
High potential test volt ages Type of Switchgear
Rated Rated Maximum Voltage (kV) (rms)
Low-Voltage Power Circuit Breaker Switchgear
AC
DC
.254/.508/.635
1.6
2.3
4.76
14
20
8.25
27
37
15
27
37
27
45
Note 1
38
60
Note 1
Metal-Clad Switchgear
NOTE 1:
E.3. E.3.2 2
Use values given in (E.1.1).
NON-SEGREGATED BUS DUCT 1.
E.5.1 E.5.1
High potential tests on capacitor units shall exclude the cable and be performed between each phase to ground with the remaining phases connected to earth.
Insulation resistance tests
1. E.5
Use values given in (E.1.1).
CAPACITORS 1.
E.4. E.4.1 1
The Manufacturer/Supplier Manufacturer/Supplier should be contacted for recommendations recommendations before applying applying DC withstand withstand tests.
Insulation resistance test voltages
1. E.4
Insulation resistance resistance tests and high potential tests shall be performed between each each phase and ground with the remaining phases connected to ground and loads disconnected.
High potential test volt ages ages Type of Bus
Rated Rated Voltage (kV)
Nonsegregated Phase
E.5. E.5.2 2
Maximum Test Voltage kV
Insulation resistance tests
1.
Use values given in (E.1.1).
Maximum Test Voltage kV AC
DC
.254/.508/.635
1.6
2.3
4.76
14.2
20
15
27
37
25.8
45
63
38
60
-
DEP 63.10.08.11-Gen. February 2015 Page 45
APPENDIX F
F.1
CABLES 1.
F.1. F.1.1 1
F.1. F.1.2 2
RECOMMENDED TEST VOL TAGES FOR COMM ISSIONING FOR NON-NA APPL ICATIONS
Insulation resistance resistance tests and high potential tests shall be be carried out between each phase and earth with the remaining phases connected to earth and loads disconnected.
Insulation resistance tests System Voltage
Test Voltage
LV 50 V - 1 kV
500 V (DC)
HV up to 4.6 kV
2500 V (DC)
HV above 4.6 kV
5000 V (DC)
High potential tests
1.
New Paper Insulated Cables
Duration: 3 minutes
2.
Cable Cable Volt age Designatio Designatio n kV (AC) UO/U (Um )
Test Voltage kV (DC)
< 1.0
IR test only
1.8/3 (3.6)
10
3.6/6 (7.2)
15
6/10 (12)
25
8.7/15 (17.5)
35
12/20 (24)
50
18/30 (36)
70
New polymeric (e.g., cross linked polyethylene (XLPE) insulated cables
Duration: 15 minutes
Cable Cable Volt age Designatio Designatio n kV (AC) UO/U (Um)
Test Voltage kV (AC)
< 1.0
IR test only
1.8/3 (3.6)
7kV DC
3.6/6 (7.2)
7.2
6/10 (12)
12
8.7/15 (17.5)
17.5
12/20 (24)
24
18/30 (36)
36
NOTE 1: 1:
If VLF is used, used, the the test test voltage is 3 x UO
DEP 63.10.08.11-Gen. February 2015 Page 46 3.
Cables specifically manufactured for unearthed systems, i.e. Uo = U, shall be tested at the value given above for Uo. e.g., cable type 3/3 (3.6) should be tested at 11 kV. Uo is the rated power-frequency voltage between conductor and earth or metallic screen, for which the cable is designed. U is the rated power frequency voltage between conductors, for which the cable is designed. Um is the maximum value of the 'highest system voltage' for which the equipment may be used.
4. F.1. F.1.3 3
For AC test, the frequency is chosen between 0.1 Hz (VLF) up to power system frequency. (Refer to IEEE 400.2, IEC 60502-1, IEC 60502-2, IEC 60840).
DC sheath integrit y test
1.
After installation, installation, all the sheaths shall be tested for one minute at a voltage level according to the thickness of the sheath of the cable as follows: a.
Extruded PVC or polyethylene: 4 kV DC per mm of thickness thickness with with a maximum of 10 kV DC
b.
The minimum average thickness shall be used to calculate the voltage test.
F.2
MOTORS, GENERATORS, TRANSFORMERS (COIL WOUND EQUIPMENT)
F.2. F.2.1 1
Insulation resistance tests
F.3
F.3.1 F.3.1
System Voltage
Test Voltage
LV below 1 kV
500 V (DC)
HV up to 4.6 kV
2500 V (DC)
HV above 4.6 kV
5000 V (DC)
SWITCHGEAR 1.
High potential tests and insulation tests on busbar systems shall be performed between each phase and earth with the remaining phases connected to earth (voltage transformers and load disconnected).
2.
High potential tests and insulation resistance tests on circuit breakers and contactors may be carried out together with or separately from the busbar and shall be carried out with the breaker/contactor closed, with loads disconnected.
High potential test voltages Duration: 1 minute
Max System Voltage kV
3.6
7.2
12
17.5
24
36
Test Volt age kV (DC) (DC)
10
20
28
38
50
70
DEP 63.10.08.11-Gen. February 2015 Page 47 F.3. F.3.2 2
F.4
Insulation resistance test voltages Test Voltage
LV systems
500 V (DC)
HV systems up to 4.6 kV
2500 V (DC)
HV systems above 4.6 kV
5000 V (DC)
CAPACITORS 1.
F.4. F.4.1 1
System Voltage
High potential tests on capacitor units shall exclude the cable and be carried out between each phase to earth with the remaining phases connected to earth.
High potential tests (commiss ionin g only) Duration 10 s, after stabilisation of charge current. Highest System Voltage kV (AC)
1.0
3.6
7.2
12
17.5
Test Volt age kV (DC)
1.0*
10
20
28
38
1*: LV capacitor banks and cables cables shall not be HV tested, but insulation resistance tests shall be carried out. F.4. F.4.2 2
Insulation resistance tests
1.
Use values given in (F.3.2).
DEP 63.10.08.11-Gen. February 2015 Page 48 APPENDIX G
RECOMMENDED INSULATION INSUL ATION VAL V AL UES FOR EQUIPMENT OF NA APPL ICATIONS
Equipment type G.1 Switc hgear, Cable, Bu s Duct Duct , Switches, MCCs
Minimum f or acceptance at commissioning
Insulation Resistance (MΩ)
Nominal Rating of Cable in Volts -
600V
100
-
5000V
1000
-
8000V
2000
-
15000V
5000
-
25000V
20000
-
35000V
100000
G.2 G.2 Motors and Genera Generators tors
-
Insulation Resistance above 1 kV
100 MΩ
-
Insulation Resistance below 1 kV
5 MΩ
-
PI
G.3 Transformers
2 Liquid Filled (MΩ)
Dry (MΩ)
Transformer Coil Rating Type in Volts
NOTES:
-
0 – 600V
100
500
-
601 – 5000
1000
5000
-
Greater than 5000
5000
25000
1. These values values are considered considered the lowest lowest acceptable to allow energization of new equipment. Corrective action shall be taken where lower values are found. 2. The above figures are to be used, unless local local regulations are more stringent, in which which case the latter shall prevail. 3. IR to be measured measured with load disconnected. disconnected. 4. Test results are dependent dependent on the temperature of the insulating material and the humidity humidity of the surrounding environment at the time of the test. 5. Insulation-resistance Insulation-resistance test data may be used to establish establish a trending pattern. Deviations from from the baseline information permit evaluation of the insulation. 6. Minimum insulation resistance resistance values are given for 25 °C (77 °F) equipment temperature; apply corrections for differing temperatures. See (Appendix C).
DEP 63.10.08.11-Gen. February 2015 Page 49 APPENDIX H
RECOMMENDED INSULATION INSUL ATION VAL V AL UES FOR EQUIPMENT OF NON-NA APPL ICATIONS Minimum fo r acceptance at commissioning
H.1
Switchgear Insulation resistance: HV bus LV bus LV wiring (NOTE 2)
H.2
200 MΩ 20 MΩ 5 MΩ
Cables Insulation resistance: HV and LV
•
minimum length 100 m (NOTE 3)
H.3 H.3.1
Motor s and generators Polarization Index: LV and HV machines Class B and F
2.0 (6)
(NOTES 6 and 8)
H.3.2
Insulation resistance (at 25 °C) LV and HV machines:
10(kV+1) MΩ
(NOTES 4, 5, and 7)
H.4 H.4 H.4.1 H.4.2
Power transformers (max. 36 kV) OIL IMMERSED Insulation resistance:
75 MΩ
DRY TYPE Insulation resistance: HV side:
100 MΩ
LV side: H.5 H.5 H.5.1 H.5.2 H.5.2.1
10 MΩ
Equipment and compon ents FIXED INSTALLATIONS Insulation resistance: MOVABLE EQUIPMENT Hand Tools Insulation resistance Class I: Class II: Class III:
H.5.2.2
Distribution equipment (cables, distribution boards, transformers) Insulation resistance: NOTES:
5 kΩ/volt
2 MΩ 7 MΩ 2 MΩ
5 MΩ
1. These values values are considered the lowest lowest acceptable to allow allow energisation of existing existing equipment. Corrective action shall be taken where lower values are found. 2. The above figures are to be used unless local regulations are more stringent in which case the latter shall prevail. 3. IR to be measured measured with load disconnected. disconnected. Example: Required value for maintenance (M Ω) is kV rating of cable/length in km. 4. Minimum insulation resistance resistance values are given given for 25 °C (77 °F) equipment temperature; apply apply corrections for differing temperatures.
DEP 63.10.08.11-Gen. February 2015 Page 50 5. For machines < 10 MVA MVA energisation is possible possible if IR or PI PI is above the minimum minimum given. 6. PI values below below those given given may be be accepted ifif IR is > 100(kV+1) MΩ. 7. For test method and and voltage see (Appendix (Appendix F) 8. PI measurements on insulation insulation class 'F' machines with IR in the GΩ range may be difficult to obtain due to meter scale compression.
DEP 63.10.08.11-Gen. February 2015 Page 51
APPENDIX I
TEST METHOD FOR EARTHING/GROUNDING EARTHING/GROUNDING SYSTEM - refer t o (4.13)
DEP 63.10.08.11-Gen. February 2015 Page 52 APPENDIX Ia
EARTH EART H (GROUND) ELECTRODE RESIST ANCE
1
An alternating current of a steady value is is passed passed between the earth electrode T and an auxiliary earth electrode T1 placed at such a distance from T that the resistance areas of the two electrodes do not overlap.
2
A second auxiliary earth electrode T2, which may be a metal spike driven into the ground, is then inserted half-way between T and T1 and the voltage drop between T and T2 is measured.
3
The resistance of the the earth electrodes is then the voltage voltage between T and T2, divided by the current flowing between T and T1, provided that there is no overlap of the resistance areas.
4
To check that the resistance of the earth electrodes is a true value, two further readings are taken with the second auxiliary electrode T2 moved 6 m (20 ft) further from and 6 m (20 ft) nearer to T, respectively.
5
If the three results are substantially in agreement, the mean of the three readings is taken as the resistance of the earth electrode T. If there is no such agreement the tests are repeated with the distance between T and T1 increased.
6
The test is made either either with with current at power frequency, in which case the resistance resistance of the voltmeter used must be high (of the order of 200 Ω per volt), or with alternating current from an earth tester comprising a hand-driven generator, a rectifier (where necessary), and a direct-reading ohmmeter.
7
If the tests are made at power frequency the source of the current used for the test is is isolated from the mains supply (e.g., by a double-wound transformer), and in any event the earth electrode T under test is disconnected from all sources of supply other than that used for testing.
DEP 63.10.08.11-Gen. February 2015 Page 52 APPENDIX Ia
EARTH EART H (GROUND) ELECTRODE RESIST ANCE
1
An alternating current of a steady value is is passed passed between the earth electrode T and an auxiliary earth electrode T1 placed at such a distance from T that the resistance areas of the two electrodes do not overlap.
2
A second auxiliary earth electrode T2, which may be a metal spike driven into the ground, is then inserted half-way between T and T1 and the voltage drop between T and T2 is measured.
3
The resistance of the the earth electrodes is then the voltage voltage between T and T2, divided by the current flowing between T and T1, provided that there is no overlap of the resistance areas.
4
To check that the resistance of the earth electrodes is a true value, two further readings are taken with the second auxiliary electrode T2 moved 6 m (20 ft) further from and 6 m (20 ft) nearer to T, respectively.
5
If the three results are substantially in agreement, the mean of the three readings is taken as the resistance of the earth electrode T. If there is no such agreement the tests are repeated with the distance between T and T1 increased.
6
The test is made either either with with current at power frequency, in which case the resistance resistance of the voltmeter used must be high (of the order of 200 Ω per volt), or with alternating current from an earth tester comprising a hand-driven generator, a rectifier (where necessary), and a direct-reading ohmmeter.
7
If the tests are made at power frequency the source of the current used for the test is is isolated from the mains supply (e.g., by a double-wound transformer), and in any event the earth electrode T under test is disconnected from all sources of supply other than that used for testing.
Measurement of earth electrode resistance T
-
earth electrode under test, disconnected from all other sources of supply.
DEP 63.10.08.11-Gen. February 2015 Page 53 T1
-
auxiliary earth electrode.
T2
-
second auxiliary earth electrode.
X
-
alternative position of T2 for check measurement.
Y
-
further alternative position of T2 for check measurement.
DEP 63.10.08.11-Gen. February 2015 Page 54 APPENDIX Ib
EARTH ELECTRODE RESISTANCE USING CLAMP METERS
Earth/Ground clamp meters should have:
measurement of bonding of skid to plant earth/ground grid
Self-calibration Overload protection
measurement of earth/ground electrode against the impedance of the plant earth/ground grid
AC current measurement > 10 A
ski d
plant earth/ground grid
loop impedance Z b via bonding connections and plant earth/ground grid
Earthing/grounding impedance Zr of earth/ground rod against plant earth/ground grid impedance
Earthing / grounding electrode with inspection pit
DEP 63.10.08.11-Gen. February 2015 Page 55 APPENDIX J
EXAMPLES OF DELTA /STAR TRANSFORMER CONNECTION
DEP 63.10.08.11-Gen. February 2015 Page 55 APPENDIX J
EXAMPLES OF DELTA /STAR TRANSFORMER CONNECTION
DEP 63.10.08.11-Gen. February 2015 Page 56 APPENDIX K
K.1
TRANSFORMER TRANSFORM ER OIL
OIL CONDITIONING AND SAMPLING 1.
The dielectric strength of the oil shall be tested before itit is used to fill or top up the transformer.
2.
For the filling of the transformer, an oil filter/heater pump unit shall be used. The transformer shall be filled from the bottom drain valve and air released at the top.
3.
Heated oil shall be circulated/filtered for at least 48 h, after which which the oil oil shall be tested. If the test result is unsatisfactory, the oil shall be circulated/filtered until a satisfactory test result is obtained. WARNING: Transformers rated < 66 kV are unlikely to be rated to withstand full vacuum; therefore care shall be taken before connection of any oil treatment equipment. Management of change shall be used to confirm that safe operation can take place.
K.2
5.
It is important that the sample valve be be first thoroughly cleaned externally and then wiped with a clean material reasonably free from fibre, followed by a similar material soaked in oil.
6.
Finally, the valve should be flushed by draining off a sufficient quantity of oil to ensure that the sample obtained is representative of the oil at the bottom of the tank.
7.
Stoppered glass sampling bottles are recommended. They shall be absolutely absolutely clean and dry and should be rinsed with the first sample drawn.
8.
Tests should should be carried out as soon as possible after drawing a sample.
ELECTRIC STRENGTH/DIELECTRIC BREAKDOWN VOLTAGE TESTING
DEP 63.10.08.11-Gen. February 2015 Page 56 APPENDIX K
K.1
TRANSFORMER TRANSFORM ER OIL
OIL CONDITIONING AND SAMPLING 1.
The dielectric strength of the oil shall be tested before itit is used to fill or top up the transformer.
2.
For the filling of the transformer, an oil filter/heater pump unit shall be used. The transformer shall be filled from the bottom drain valve and air released at the top.
3.
Heated oil shall be circulated/filtered for at least 48 h, after which which the oil oil shall be tested. If the test result is unsatisfactory, the oil shall be circulated/filtered until a satisfactory test result is obtained. WARNING: Transformers rated < 66 kV are unlikely to be rated to withstand full vacuum; therefore care shall be taken before connection of any oil treatment equipment. Management of change shall be used to confirm that safe operation can take place.
K.2
K.3
K.4
5.
It is important that the sample valve be be first thoroughly cleaned externally and then wiped with a clean material reasonably free from fibre, followed by a similar material soaked in oil.
6.
Finally, the valve should be flushed by draining off a sufficient quantity of oil to ensure that the sample obtained is representative of the oil at the bottom of the tank.
7.
Stoppered glass sampling bottles are recommended. They shall be absolutely absolutely clean and dry and should be rinsed with the first sample drawn.
8.
Tests should should be carried out as soon as possible after drawing a sample.
ELECTRIC STRENGTH/DIELECTRIC BREAKDOWN VOLTAGE TESTING 1.
Tests shall be carried out using equipment with with a gap of 2.5 mm (0.01 in) between electrodes.
2.
Each sample shall be tested 6 times to breakdown breakdown voltage level using using equipment and methods in accordance with IEC 60156 and IEC 60422 (ASTM D877 or ASTM D1816 for NA applications).
3.
The electric strength of the oil shall be the arithmetic mean of the 6 tests and shall not be lower than 30 kV (27kV for NA applications).
TEST FOR MOISTURE 1.
If the oil sample fails the electric strength test, it may be due to moisture content, which may be simply tested by means of the 'crackle test' (whereby a metal rod is heated to a dull redness and lowered into the oil sample and stirred. Audible crackling will occur during the stirring if moisture is present in unacceptable quantities), or by means of the Coulometric Karl Fischer Titration test method per ASTM D1533.
2.
A typical specification value for new oil, as received received from the Manufacturer/Supplier, is a maximum of 35 ppm.
DISSOLVED GAS ANALYSIS (DGA) 1.
For new installations it is recommended to carry out DGA testing using a specialist specialist Contractor to provide baseline data for future reference.
2.
During evaluation of existing units units if the inspection of the samples indicates deterioration of the oil or if the oil sample fails the dielectric breakdown voltage test, DGA should be applied to investigate the root cause of the deterioration.
3.
For NA NA applications, the DGA should be performed performed in accordance with with ASTM D3612.
DEP 63.10.08.11-Gen. February 2015 Page 57 K.5
K.6
ACIDITY NEUTRALIZATION NUMBER 1.
Suggested acidity limits are as follows:
1.
< 0.5 mg KOH/g (< 500 ppm KOH)
-
No action necessary necessary ifif oil oil is satisfactory satisfactory in other respects.
2.
≥ 0.5 < 1.0 mg KOH/g (≥ 500 < 1000 ppm KOH)
-
Increase testing frequency and filter oil.
3.
≥ 1.0 mg KOH/g (≥ 1000 ppm KOH)
-
Change oil; if condition is serious and is combined with heavy sludging then further treatment of the windings and core may necessary.
INSPECTION OF SAMPLES 1.
K.7
The colour of transformer oil is indicative of the condition of the oil. In new transformers, the acceptable colour range, (typically light amber) shall be compared against Manufacturer data sheets.
SLUDGING 1.
If severe sludging is present, then hot oil cleaning of the windings and core may be required.
DEP 63.10.08.11-Gen. February 2015 Page 58 APPENDIX L
VT AND CT FLICK TESTS
VT Flick test
V 6V
CT Flick test P2
S2
A
6V
P1
S1
1.
Applying lead with arrow causes kick of voltmeter in forward direction.
2.
Removal of lead causes kick in backward (negative direction).
3.
DC current should only be momentarily applied.
DEP 63.10.08.11-Gen. February 2015 Page 59
APPENDIX M
TORQUE VAL UE OF BOL TS FOR NORTH AMERICA N APPLIC AP PLICATION ATION
NOTE:
This appendix is presented in USC units only
This Appendix contains stress area, proof load, clamp load and assembly torques (dry and lubricated) for threaded fasteners ranging in thread size from #4 to 4-½ in. nominal Unified thread size. Data is provided for grade 2, grade 5, grade 8 and grade 9 fasteners.
Grade Images
The following images have been provided for reference:
Grade 2
Grade 5
Grade 8
1.
The following table provides torque and stress information for threads.
2.
Values are determined using the following equations: •
Clamp load = 75 % * Proof * stress area.
•
Torque is R * D * T where: o
R = .200 (dry) or .150 (lubricated),
o
D = Nominal diameter (in), and
o
T = Desired clamp load (lbs).
“Lubricated” includes lubricants, lubrizing plating, and hardened washers. Ass emb ly Tor qu e Nominal Size or Basic Major Diameter of Thread
Stress Area Ar ea
Proof Load
Clamp Load
Dry
Lubricated
Dry
Lubricated
ksi
lbs
in*lb
in*lb
ft*lb
ft*lb
# 4-40
0.1120
.0060
2
55
248
5
4
# 4-40
0.1120
.0060
5
85
384
8
6
# 4-40
0.1120
.0060
8
120
542
12
9
# 4-48
0.1120
.0066
2
55
272
6
5
# 4-48
0.1120
.0066
5
85
421
9
7
# 4-48
0.1120
.0066
8
120
594
13
10
# 6-32
0.1380
.0091
2
55
374
10
7
# 6-32
0.1380
.0091
5
85
579
15
11
# 6-32
0.1380
.0091
8
120
817
22
18
# 6-40
0.1380
.0101
2
55
418
11
8
# 6-40
0.1380
.0101
5
85
646
17
13
# 6-40
0.1380
.0101
8
120
912
25
18
# 8-32
0.1640
.0140
2
55
577
18
14
in
Grade
2
DEP 63.10.08.11-Gen. February 2015 Page 60
Ass emb ly Tor qu e Nominal Size or Basic Major Diameter of Thread
Stress Area Ar ea
Proof Load
Clamp Load
Dry
Lubricated
Dry
Lubricated
ksi
lbs
in*lb
in*lb
ft*lb
ft*lb
# 8-32
0.1640
.0140
5
85
893
29
21
# 8-32
0.1640
.0140
8
120
1260
41
31
# 8-36
0.1640
.0147
2
55
607
19
14
# 8-36
0.1640
.0147
5
85
938
30
23
# 8-36
0.1640
.0147
8
120
1325
43
32
#10-24
0.1900
.0175
2
55
723
27
20
#10-24
0.1900
.0175
5
85
1117
42
31
#10-24
0.1900
.0175
8
120
1577
59
44
#10-32
0.1900
.0200
2
55
824
31
23
#10-32
0.1900
.0200
5
85
1274
48
36
#10-32
0.1900
.0200
8
120
1799
68
51
¼-20
0.2500
.0318
2
55
723
65
49
¼-20
0.2500
.0318
5
85
1117
101
76
¼-20
0.2500
.0318
8
120
1577
143 143
107
¼-20
0.2500
.0318
9
145
3460
173 173
129
¼-28
0.2500
.0364
2
55
824
75
56
¼-28
0.2500
.0364
5
85
1274
115
86
¼-28
0.2500
.0364
8
120
1799
163 163
122
¼-28
0.2500
.0364
9
145
3955
197 197
148
5/16-18
0.3125
.0524
2
55
2162
11
8
5/16-18
0.3125
.0524
5
85
3342
17
13
5/16-18
0.3125
.0524
8
120
4718
24
18
5/16-18
0.3125
.0524
9
145
5701
29
22
5/16-24
0.3125
.0581
2
55
2395
11
8
5/16-24
0.3125
.0581
5
85
3701
19
14
5/16-24
0.3125
.0581
8
120
5225
27
20
5/16-24
0.3125
.0581
9
145
6314
32
24
⅜-16
0.3750
.0775
2
55
3196
19
14
⅜-16
0.3750
.0775
5
85
4939
30
23
⅜-16
0.3750
.0775
8
120
6974
43
32
⅜-16
0.3750
.0775
9
145
8427
52
39
⅜-24
0.3750
.0878
2
55
3622
22
16
⅜-24
0.3750
.0878
5
85
5599
34
26
⅜-24
0.3750
.0878
8
120
7904
49
37
⅜-24
0.3750
.0878
9
145
9551
59
44
7/16-14
0.4375
.1063
2
55
4385
31
23
in
Grade
2
DEP 63.10.08.11-Gen. February 2015 Page 61
Ass emb ly Tor qu e Nominal Size or Basic Major Diameter of Thread
Stress Area Ar ea
Proof Load
Clamp Load
Dry
Lubricated
Dry
Lubricated
ksi
lbs
in*lb
in*lb
ft*lb
ft*lb
7/16-14
0.4375
.1063
5
85
6777
49
37
7/16-14
0.4375
.1063
8
120
9567
69
52
7/16-14
0.4375
.1063
9
145
11561
84
63
7/16-20
0.4375
.1187
2
55
4897
35
26
7/16-20
0.4375
.1187
5
85
7568
55
41
7/16-20
0.4375
.1187
8
120
10684
77
58
7/16-20
0.4375
.1187
9
145
12910
94
70
½-13
0.5000
.1419
2
55
5853
48
36
½-13
0.5000
.1419
5
85
9046
75
56
½-13
0.5000
.1419
8
120
12770
106
79
½-13
0.5000
.1419
9
145
15431
128
96
½-20
0.5000
.1600
2
55
6598
54
41
½-20
0.5000
.1600
5
85
10197
84
63
½-20
0.5000
.1600
8
120
14395
120
90
½-20
0.5000
.1600
9
145
17394
144
108
9/16-12
0.5625
.1819
2
55
7505
70
52
9/16-12
0.5625
.1819
5
85
11598
108
81
9/16-12
0.5625
.1819
8
120
16375
150
110
9/16-12
0.5625
.1819
9
145
19786
185
139
9/16-18
0.5625
.2030
2
55
8372
78
58
9/16-18
0.5625
.2030
5
85
12940
121
90
9/16-18
0.5625
.2030
8
120
18268
171
128
9/16-18
0.5625
.2030
9
145
22074
206
155
⅝-11
0.6250
.2260
2
55
9322
97
72
⅝-11
0.6250
.2260
5
85
14407
150
112
⅝-11
0.6250
.2260
8
120
20340
211
158
⅝-11
0.6250
.2260
9
145
24577
256
192
⅝-18
0.6250
.2560
2
55
10558
109
82
⅝-18
0.6250
.2560
5
85
16317
169
127
⅝-18
0.6250
.2560
8
120
23036
239
179
⅝-18
0.6250
.2560
9
145
27835
289
217
¾-10
0.7500
.3345
2
55
13796
175
130
¾-10
0.7500
.3345
5
85
21321
266
199
¾-10
0.7500
.3345
8
120
30101
376
282
¾-10
0.7500
.3345
9
145
36372
454
340
¾-16
0.7500
.3730
2
55
15384
192
144
in
Grade
2
DEP 63.10.08.11-Gen. February 2015 Page 62
Ass emb ly Tor qu e Nominal Size or Basic Major Diameter of Thread
Stress Area Ar ea
Proof Load
Clamp Load
Dry
Lubricated
Dry
Lubricated
ksi
lbs
in*lb
in*lb
ft*lb
ft*lb
¾-16
0.7500
.3730
5
85
23776
297
222
¾-16
0.7500
.3730
8
120
33566
419
314
¾-16
0.7500
.3730
9
145
40559
506
380
⅞-9
0.8750
.4617
2
33
13796
170
125
⅞-9
0.8750
.4617
5
85
21321
266
199
⅞-9
0.8750
.4617
8
120
30101
376
282
⅞-9
0.8750
.4617
9
145
36372
454
340
⅞-14
0.8750
.5095
2
33
15384
192
144
⅞-14
0.8750
.5095
5
85
23776
297
222
⅞-14
0.8750
.5095
8
120
33566
419
314
⅞-14
0.8750
.5095
9
145
40559
506
380
1-8
1.0000
.6057
2
33
14992
249
187
1-8
1.0000
.6057
5
85
38616
643
482
1-8
1.0000
.6057
8
120
54517
908
681
1-8
1.0000
.6057
9
145
65874
1097
823
1-12
1.0000
.6630
2
33
16410
273
205
1-12
1.0000
.6630
5
85
42268
704
528
1-12
1.0000
.6630
8
120
59673
994
745
1-12
1.0000
.6630
9
145
72105
1201
901
1 ⅛-7 ⅛-7
1.1250
.7633
2
33
18891
354
265
1 ⅛-7 ⅛-7
1.1250
.7633
5
74
42361
794
595
1 ⅛-7 ⅛-7
1.1250
.7633
8
120
68694
1288
966
1 ⅛-7 ⅛-7
1.1250
.7633
9
145
83066
1556
1167
1 ⅛-12 ⅛-12
1.1250
.8557
2
33
21179
397
297
1 ⅛-12 ⅛-12
1.1250
.8557
5
74
47492
890
667
1 ⅛-12 ⅛-12
1.1250
.8557
8
120
77014
1444
1083
1 ⅛-12 ⅛-12
1.1250
.8557
9
145
93059
1477
1308
1 ¼-7
1.2500
.9691
2
33
23985
499
374
1 ¼-7
1.2500
.9691
5
74
53785
1120
840
1 ¼-7
1.2500
.9691
8
120
87220
1817
1362
1 1/4-7
1.2500
.9691
9
145
105391
2195
1646
1 ¼-12
1.2500
1.0729
2
33
26555
553
414
1 ¼-12
1.2500
1.0729
5
74
59548
1240
930
1 ¼-12
1.2500
1.0729
8
120
96565
2011
1508
1 ¼-12
1.2500
1.0729
9
145
116682
2430
1823
1 ⅜-6 ⅜-6
1.3750
1.1549
2
33
28583
655
491
in
Grade
2
DEP 63.10.08.11-Gen. February 2015 Page 63
Ass emb ly Tor qu e Nominal Size or Basic Major Diameter of Thread
Stress Area Ar ea
Proof Load
Clamp Load
Dry
Lubricated
Dry
Lubricated
ksi
lbs
in*lb
in*lb
ft*lb
ft*lb
1 ⅜-6 ⅜-6
1.3750
1.1549
5
74
64096
1468
1101
1 ⅜-6 ⅜-6
1.3750
1.1549
8
120
103939
2381
1786
1 ⅜-6 ⅜-6
1.3750
1.1549
9
145
125593
2878
2158
1 ⅜-12 ⅜-12
1.3750
1.3147
2
33
32539
745
559
1 ⅜-12 ⅜-12
1.3750
1.3147
5
74
72966
1672
1254
1 ⅜-12 ⅜-12
1.3750
1.3147
8
120
118324
2711
2033
1 ⅜-12 ⅜-12
1.3750
1.3147
9
145
142974
3276
2457
1 ½-6
1.5000
1.4053
2
33
34780
869
652
1 ½-6
1.5000
1.4053
5
74
77891
1949
1462
1 ½-6
1.5000
1.4053
8
120
126472
3161
2371
1 ½-6
1.5000
1.4053
9
145
152821
3820
2865
1 ½-12
1.5000
1.5810
2
33
39130
978
733
1 ½-12
1.5000
1.5810
5
74
87746
2193
1645
1 ½-12
1.5000
1.5810
8
120
142292
3557
2667
1 ½-12
1.5000
1.5810
9
145
171936
4298
3223
1 ¾-5
1.7500
1.8995
2
33
47011
1371
1028
1 ¾-5
1.7500
1.8995
5
74
105420
3074
2306
1 ¾-5
1.7500
1.8995
8
120
170951
4986
3739
2-4.5
2.0000
2.4982
2
33
61831
2061
1545
2-4.5
2.0000
2.4982
5
74
138651
4621
3466
2-4.5
2.0000
2.4982
8
120
224840
7497
5621
2 ¼-4.5
2.2500
3.2477
2
33
80380
3014
2260
2 ¼-4.5
2.2500
3.2477
5
74
180246
6759
5069
2 ¼-4.5
2.2500
3.2477
8
120
292292
10960
8220
2 ½-4
2.5000
3.9988
2
33
98971
4213
3092
2 ½-4
2.5000
3.9988
5
74
221935
9247
6935
2 ½-4
2.5000
3.9988
8
120
359894
14995
11246
2 ¾-4
2.7500
4.9340
2
33
122166
5597
4197
2 ¾-4
2.7500
4.9340
5
74
273837
12550
9413
2 ¾-4
2.7500
4.9340
8
120
444061
20352
15264
3-4
3.0000
5.9674
2
33
147692
7384
5538
3-4
3.0000
5.9674
5
74
331189
16559
12419
3-4
3.0000
5.9674
8
120
537063
26853
20139
3 ¼-4
3.2500
7.0989
2
33
175698
9516
7137
3 ¼-4
3.2500
7.0989
5
74
393989
21341
16005
3 ¼-4
3.2500
7.0989
8
120
638901
34607
25955
in
Grade
2
DEP 63.10.08.11-Gen. February 2015 Page 64
Ass emb ly Tor qu e Nominal Size or Basic Major Diameter of Thread
Stress Area Ar ea
Proof Load
Clamp Load
Dry
Lubricated
Dry
Lubricated
ksi
lbs
in*lb
in*lb
ft*lb
ft*lb
3 ½-4
3.5000
8.3286
2
33
206133
12024
9018
3 ½-4
3.5000
8.3286
5
74
462238
26963
20222
3 ½-4
3.5000
8.3286
8
120
749575
43725
32793
3 ¾-4
3.7500
9.6565
2
33
238998
14937
11203
3 ¾-4
3.7500
9.6565
5
74
535935
33495
25121
3 ¾-4
3.7500
9.6565
8
120
869085
54317
40738
4-4
4.0000
11.0826
2
33
274293
18286
13714
4-4
4.0000
11.0826
5
74
615082
41005
30754
4-4
4.0000
11.0826
8
120
997430
66495
49871
4 ¼-4
4.2500
12.6068
2
33
312018
22101
16575
4 ¼-4
4.2500
12.6068
5
74
699677
49560
37170
4 ¼-4
4.2500
12.6068
8
120
1134611
80368
60276
4 ½-4
4.5000
14.2292
2
33
352172
26212
19809
4 ½-4
4.5000
14.2292
5
74
789720
59229
44421
4 ½-4
4.5000
14.2292
8
120
1280628
96047
72035
in
Grade
2
