1.0 PURPOSE The purpose of this document is to ensure safe, high quality and consistent installation of the electrical system at the Escravos Produced Water Disposal facility.
2.0 SCOPE This Electrical work procedure covers all onshore electrical construction activities, Installation, inspection and testing of electrical system on Main deck, Cellar deck, Jacket and Bridge of the Escravos Produced Water Disposal facility. The overviews of work are as follows: Unboxing and Sorting of Lighting Accessories Cable drum testing Fabrication and Installation of Cable Tray Supports Fabrication and Installation of Cable Tray Earth Bonding Junction Box Installation Bridge Conduit Installation and Wiring Fabrication and Installation of Stanchion / Pendant Light support Installation of Plant Lighting Systems Transformers Installation and Termination Electric Motors Installation and Termination MV, LV Power and Control Cable Pulling Cable Glanding and Termination Cable Tagging and Core Identification Testing (Meggering and Continuity) Mechanical Completion Checks
3.0 REFERENCE All construction work, installation and testing shall be carried out in accordance with good engineering practice and shall satisfy all statutory requirements of the National and/or local authorities in which the installations will be located.
The following Standards and requirements shall form an integral part of the electrical construction work, Installation, inspection and testing in the Escravos Produced Water Disposal facility:
API RP 14F Recommended Practice for Design and Installation of Electrical System for Offshore Production Platforms ASTM A123 Specification for Zinc (Hot- Galvanized) Coating on Product Fabricated from Rolled, Pressed, and Forged Steel Shaped Plates, Bars, and Strip ASTM A386 Specification for Zinc-Coating (Hot-Dip) on Assembled Steel Products IEEE 45 Recommended Practice for Electric Installation on Shipboard NPFA National Electrical Code 70 NPFA Lightning Protection Code 78
4.0 DEFINITION NONE
5.0 RESPONSIBILITIES Electrical Team Lead Shall ensure proper implementation of this procedure. He shall coordinate the activities of the Electrical Engineer who leads the Electrical team.
Electrical Engineer The Electrical Engineer Shall be responsible for the following; Verifying all activities relevant to installation and testing of field mounted Equipment and Lighting accessories. Verifying the availability of the materials required for installation. Preparation and submission of as-built drawings and resolving all technical problems that may arise during installation activities. He is also responsible for coordinating with the QA / QC Engineer for resolving technical queries.
Electrical Supervisor Shall lead the Electrical activities at construction stage; carry out all inspection required; issue the relevant report or checklist and coordinate with the QA / QC Inspector and the Electrical Engineer.
Quality Control Inspector Shall monitor the proper implementation of the project procedures and specifications. Shall also be responsible for conducting of tests on cables and instruments during delivery and before installation; responsible for all final inspection activities; rectify all punch list items and sign off all finished works.
Electrical Technician is responsible for: Installing all Electrical equipment and lighting. Coordinating with the Electrical Supervisor and QA/QC Engineer and Electrical Engineer in electrical installation and in resolving technical
6.0 PROCEDURE 6.1 Receiving and Inspection of Electrical Equipment / Material Upon receipt of electrical materials the QC Inspector and warehouse personnel shall inspect visually the materials and equipment for possible defects, physical damages or missing part.
The conformance of the electrical equipment to specifications, hazardous area classification and mechanical certification shall be verified.
The provision in the following documents shall form the basis for all the inspection required. Quality Assurance/Quality Control Inspection and Test Plan Manufacturers data and technical manuals
Electrical equipment shall be visually inspected for possible damage and defects during handling and shipment. However, for MV / LV Switchgear panels in the MCC, high voltage test on the panel should have been carried out as part of the manufacturers scope in accordance with the relevant CNLs or international Standards; all relevant documents duly signed.
6.2 Pre-Installation Test and Inspection Tests shall be carried out on cables and wires at delivery and before installation and the QC inspector shall perform these test.
6.2.1 Test on Cables The order of test shall be Insulation Resistance Test for Low Voltage Power Cable (LV) Low Voltage Control Cable (LV) Medium Voltage Cable (MV) Continuity Test for Low Voltage Power Cable (LV) Low Voltage Control Cable (LV) Medium Voltage Test for Medium Voltage Cable (HV) Test equipment to be used are as follows Megger Tester 1000V or 5000V Fluke Multi-tester Hi-Pot Tester 6.3 Electrical Equipment Storage and Preservation Material storage shall comply with the material Control Procedure provided for this project. 6.3.1 The Electrical equipment shall be stored where appropriate in accordance with vendor advice. On receiving the motors, it shall be stored in a dry and clean shelter position, which is free from vibration and rapid change in temperature. The motor shall be covered completely with tarpaulins to prevent ingress of dust or moisture until such a time installation is complete. Where the motor is fitted with anti-condensation heater. With the client approval, a suitable power supply shall be made available; the heater shall be switched on throughout the storage period, particularly where the storage period is likely to be prolonged. Warning notice shall be attached to this effect.
6.4 Calibration All test equipment shall be calibrated in accordance with Calibration Control Procedure and shall be traceable to the applicable standards.
7.0 ELECTRICAL EQUIPMENT INSTALLATION
7.1 Cable tray Supports Fabrication and Installation Structural welders shall carry out fabrication of cable tray support. These Cable tray supports shall be installed on horizontal base plate unless otherwise field adjustments are required. The cable tray supports shall be fastened with bolts and nuts and angular iron for bracing wherever possible for reinforcement. Cable tray support shall provide strength and safe working capacity (SWL) sufficient to meet the load requirement of the cables to be laid on top cable trays. The cable tray support material shall agree with the EPWD project specification. Special consideration will be given to center-supported systems considering eccentric loading.
7.2 Paint Touch-up for Cable Tray Support
Paint touch-up for cable tray support shall be done with zinc-rich galvanizing materials that meet the required specification. Cable trays that have a Hot-dip galvanized coating shall be re- touched after fabrication i.e. after cutting and drilling since the coating gets damaged over time. Other protective coatings that are cut or damaged must be touched up with compatible coatings.
7.3 Cable Trays Installation
Cable tray shall be installed in conformance with NEC A318 and standards set forth in NEMA VE-1 and VE-2 as well that provided by the project (PWD-D017-ELE-DTL- NET-000-90005 Electrical Installation Details (Power & Control) Offshore Consideration shall be given to loads associated with future cable additions or any other loads to the cable tray system or cable tray support system. Cable tray cut section shall be treated to remove sharp edges, which could cause damage to cables and cause injury to personnel. Insulation separators and insulated fitting materials shall be used to prevent contact corrosion due to the use of SS-316 in combination with steel supports. Cable tray hardware (nuts, bolts and washers..) to be used during the installation shall be of 316 stainless steel materials. Where cable trays are linked together, splice plate connectors/hinges shall be used to bolt them and cable tray shall be grounded according to EPWD Grounding specification. The linking points shall be bonded together using a dedicated bond wires, and bonding wires shall have a good surface contacts. Competent and qualified persons familiar with standards electrical construction practices, electrical equipment shall perform the work.
7.4 Cable Pulling. Prior to cable installation, cable path shall be examined to ensure that all areas are free of hazards that may cause damage during cable installation. All cables shall be pulled from the top of the drum and in the direction indicated on the drum according to vendors recommendation. Sufficient cables rollers and side roller (when required) shall be used when pulling cable in position. This will reduce the effort required and ensure the cable outer sheath is not damaged. The minimum bending radius of the cable shall be maintained to prevent damage to the cable After pulling of cables, temporary identification tags shall be attached. Permanent tags shall be attached at the end of termination activities. Correct power and control cable size and type shall be pulled. After pulling, the cable end shall be sealed to prevent moisture ingress
7.5 Cable Glanding Proper sizes of cable gland suitable for the cable shall be used to match the appropriate cable. Any unused cable entry hole shall be plugged. While glanding power cables, it shall be ensured that the loads of the cables are not coming on the glands. Close attention shall be paid to the cable glanding and sealing arrangements on all electrical equipment.
7.6 Cable Termination Termination (wiring connection) shall be done as per specification, wiring drawings and/or manufacturers instruction. Core shall be terminated with pin crimps or cable lugs. These shall be installed with crimping / compression tools and shall be tightened to manufacturers recommended torques. Each lug shall correctly match the cross-sectional area of the conductor and shall be crimped on with the correct compression tools and dies. Power cables and control cables shall be anchored to the cable tray by using cable ties (tie wraps). Sufficient length of cable for connection shall be coiled near the equipment side. Certified HV/MV jointer shall perform all MV cable termination and joints where required.
7.7 Cable Tagging and Core Identification Each cable shall be correctly tagged as per project specification and standards for suitable identification. Identification numbers for power and control cables shall read from terminals outwards Identification shall be in the form of captive o ring ferrule of appropriate diameter engraved or indelibly printed with the cable number, the core number and the terminal number. Wire maker shall be provided for cable wires/cores for power cables and control cables. 7.8 Grounding System All metallic enclosures of equipment, cable trays, cable tray structural supports, vessels, skids, structural steel supports etc. as found in bridge, main deck, cellar deck and jacket shall be grounded by connection to the common Earth Grid. The Earthing System / Pattern shall be in accordance with the approved drawings. All Earthing cables shall be PVC covered.
7.9 Electric Motor Electric motors shall be erected or installed in full accordance with the manufacturer instructions and project specification with regards to foundation, alignment, shimming etc. Before electrical hook-up of the electric motor, the Electrical Equipment Field Inspection report form shall be filled, signed and duly approved by all relevant parties. The terminations shall be in correct Phase-Sequence arrangement and marked L1, L2 & L3 at each end. The metal casing of the electric motors shall be earthed using the specified wire size according to project spec.
Electrical Unique ID BASIC INSPECTION Project Name: Sub-SystemDescription Drawing Reference Establish aand record the following: 4. Degree of enclosure protection 5. Electrical protection setting/rating CHECKLIST (ELECTRICAL EQUIPMENT) Compare nameplate information with equipment record REMARKS Date Printed Item/Tag No. Sub-System No 6. Actual maximumload/ammeter reading 1. Equipment/Circuit identification 2. Area classification 3. Type of Ex protection/gas group/temperature class 9. Adequate protection of equipment and cables against corrosion, the weather, vibration and other adverse factors Check the following items and report any deviation/defects under remarks: 1. Labeling correct 2. No unauthorized modifications 3. Enclosure and glasses satisfactory 4. Seals and gaskets satisfactory 5. Bolts and glands complete and tight 6. No undue accumulation of dust and dirt 7. No leakage of oil/compound 8. No damage to above-ground part of connected cables 10. Motor fans and couplings not rubbing on cowls/guards 11. Earthing in good condition 12. Oil levels in sight glasses correct 13. Silica gel in breathers satisfactory 14. Pressurization system correct & tested Suitable for area classified YES NO Equipment accepted YES NO Signature Date Completed By Rofcom Construction Rofcom QC CNL Construction !
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Item Result 1 2 3 4 5 6 7 8 9 Signature Date Completed By Rofcom Construction Rofcom QC CNL Construction Comments/Action (where applicable) Power, control cable 220 Volts and above, Insulation test acceptable for phase to earth (L1-E, L2-E, L3-E) core to core (L1-L2, L1-L3,L2-L3) NOTE: Ensure any electronic components are disconnected from circuit before performing Insulation test. Interface cables marked and sealed off in the splice end and coiled correctly and in accordance with coiling After termination make sure that all cuttings and debris are cleared away. Correct type of glands fitted correctly and tightened, and correct IP washer fitted. (where Check boxes for each line numbeer to be marked with OK or NA Cable according to data on cable schedule (size and type) Labeling, numbering and core ferruling correct. Bending radius, cleating and support according to specification. Termination correct and tight and no core damage. Spare cores earthed and tight. Continuity in all cores, screen, earth and armour. Acceptable value 0.2 ohm. Sub-SystemDescription Date Printed Drawing Reference Unique ID Item/Tag No. Project Name: Sub-System No Electrical CHECK PROCEDURE ELECTRICAL CABLE INSTALLATION !
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____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________ Date INSPECTION OF CABLE TRAY/LADDER Check the following and report any deviations/defects under remarks: Thick Yes/No Cable Tray/Ladder installation and fastening are in accordance with project specification Cable Trays system is provided with proper grounding Completed By Rofcom Construction Rofcom QC CNL Construction Signature Remarks: Ladder is properly fixed and that supports are properly spaced Cable trays are laid on solid and well-leveled Cable Tray supports Joints between Cable Tray/Ladder sections are firmly bolted using the correct fasteners Cable Tray/Ladder installation is in accordance with the construction plan and section detail drawing Cable bends are executed correctly and do not exceed minimum requirements Cable Tray/Ladder and accessories are of stainless steel or Galvanized Cable Tray securing bolt are well tighted Cable Tray is clean and no foreign debris or sharp objects are within Check Insulation between dissimilar metals Sub-SystemDescription Date Printed Drawing Reference Unique ID Item/Tag No. Project Name: Sub-System No Electrical !
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Item Result 1 2 3 4 5 6 7 8 9 10 Signature Date Completed By Rofcom Construction Rofcom QC CNL Construction Comments/Action (where applicable) Check boxes for each line numbeer to be marked with OK or NA Correct junction box installed according to enclosure classification and are classification, and in accordance with location drawing Labeling, numbering and ferrule correct. Junction box mechanically sound, solidly and correctly mounted. Terminal blocks are of correct type correctly mounted, mechanically sound and clearly maarked. Barriers fitted where required and all connections tight. Earthing bonding and coloring correct. Instrument screens segregated from electrical earth. No top entry cables unless authorized. Spare entries plugged. Gland plate correctly installed and drain plug installed where applicable Sufficient access for incoming cables Equipment located correctly to allow access for maintenance. Ex & IP rating as per data sheet, correctly maintained by use of plugs, glands, seals. Check that preservation and mechanical protection is in accordance with project specification and any disturbed preservation replaced. Drawing Reference Project Name: Sub-System No Sub-SystemDescription Date Printed Electrical Unique ID Item/Tag No. CHECKSHEET-ELECTRICAL INSTALLATIONS Electrical Junction Box !
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Date Date Residual Current device Date Remarks: Circuit Number (Fittings disconnected) TEST INSULATION RESISTANCE LIGHTING CIRCUIT Value Circuit Value Date M Completed By Rofcom Construction Rofcom QC CNL Construction Signature Number M CONVENIENCE OUTLETS Circuit Number IR M Sub-SystemDescription Date Printed Drawing Reference Earth loop impedance Polarity Unique ID Item/Tag No. Project Name: Sub-System No Electrical !
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Item Result 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Ensure all fixtures as per GA drawing and as built where applicable. Highlighte to show all checked equipment Attach a copy of Lighting Circuit Single line diagram Highlighted to show all Inspected cables Lights Boxes and Switches Signature Date Comments/Action (where applicable) Completed By Rofcom Construction Rofcom QC CNL Construction Spare holes plugged with correct rated plug and IP washer. (where applicable) All nuts, bolts and washers fitted and according to spec Internal earthing correct. Sufficient access for incoming cables Lighting installation installed with sufficient access for maintenance Check core continuity and circuit polarity of each circuit and supply. Max acceptable value: 0.2 Ohm Check insulation resistance from dist. Board for complete circuit at 500Vdc, live conductor to earth neutral to earth, minimum acceptable value 2 Mohms Terminations correct and tight Junction box gasket fitted to lid cover Check boxes for each line numbeer to be marked with OK or NA All equipment installed according to drawing, specification and area classification, Including all junction boxes. All tag numbers correct, securely attached and readable. All equipment undamaged and correctly mounted. Light fixtures sealed and clean Correct type of glands fitted and tightened, IP washer fitted.(where applicable) Sub-SystemDescription Date Printed Drawing Reference Unique ID Item/Tag No. Project Name: Sub-System No Electrical CHECK PROCEDURE ELECTRICAL LIGHTING INSTALLATION !