PP10 startup manual (Unofficial as Requested)

5,439 views
4,673 views

Published on

Published in: Business
3 Comments
2 Likes
Statistics
Notes
No Downloads
Views
Total views
5,439
On SlideShare
0
From Embeds
0
Number of Embeds
23
Actions
Shares
0
Downloads
252
Comments
3
Likes
2
Embeds 0
No embeds

No notes for slide

PP10 startup manual (Unofficial as Requested)

  1. 1. STARTUP MANUAL VOLUME-2 Riyadh Power Plant # 10 Page 1
  2. 2. STARTUP MANUAL VOLUME-2 Riyadh Power Plant # 10
  3. 3. Client Consultant Contractor : SEC-COA : : BEMCO Doc. No.: PP10-BS-SU-001 Riyadh Power plant # 10 “10621166/00” STARTUP MANUAL Date:13 Feb,09 Revision: 0 Annex B 1. Electrical Test Procedures 1.1. Over all Testing List (Excel Sheet)………………………………………......6 1.2. TP-HP01 High Voltage AC/DC Testing……………………………………….23 1.3. TP-CM01 MV Cable Testing.......................................................................32 1.4. TP-CM02 LV Cable Testing........................................................................44 1.5. TP-AT01 Auxiliary Transformers.................................................................51 1.6. TP-BD01 MV Bus Duct................................................................................70 1.7. TP-BD02 LV Bus Duct.................................................................................83 1.8. TP-CL01 Current limiting Reactor................................................................95 1.9. TP-CT01 Current Transformer....................................................................104 1.10. TP-PT01 Generator Transformer................................................................121 1.11. TP-AM01 Ammeter ....................................................................................160 1.12. TP-EM01 Energy Meter .............................................................................166 1.13. TP-FM01 Frequency Meter.........................................................................181 1.14. TP-PFM01 Power Factor Meter..................................................................187 1.15. TP-PM01 Power Meter...............................................................................193 1.16. TP-VM01 Voltmeter....................................................................................197 1.17. TP-BB01 MV Bus Bar.................................................................................203 1.18. TP-BB02 LV Bus Bar..................................................................................218 1.19. TP-MB01 MV Switchgear Breaker Feeder.................................................234 1.20. TP-DS01 MV Disconnect Switch................................................................282 1.21. TP-LB 01 LV Switch Gear Breaker Feeder................................................282 1.22. TP-AR01 Over current Relay.....................................................................304 1.23. TP-CR01 Trip Circuit Supervision Relay....................................................378 1.24. TP-DR01 Differential Relay........................................................................386 1.25. TP-HR01 Timing Relay..............................................................................496 1.26. TP-LR01 Tripping Relay.............................................................................503 1.27. TP-SR01 Synchronous Check Relay.........................................................510 1.28. TP-VR01 Voltage Relay.............................................................................523 1.29. TP-AX01 Current Transducer....................................................................538 1.30. TP-VX01 Voltage Transducer....................................................................545 1.31. TP-PX01 Power Transducer......................................................................552 1.32. TP-VT01 Voltage Transformer...................................................................559 1.33. TP-BT01 Battery testing and discharge test..............................................575 1.34. TP-BT02 Charger Testing (Later)..............................................................592 1.35. TP-BT03 UPS Testing (Later)....................................................................593 1.36. TP-MT01 Motors........................................................................................594 1.37. TP-GT01 Generators.................................................................................607 1.38. TP-MM01 Low Voltage Motor Control Center……………………………....618 1.39. TP-DB01 DC Switch Board …………………………………………………..635 1.40. TP-BE01 Procedure for Back Energization (Later) 1.41. TP-OS01 Procedure for Electrical Over Speed (Later) 1.42. TP-SY01 Procedure for Synchronization (Later) 1.43. TP-LG01 Procedure for Load Rejection (Later) 1.44. TP-IL01 Procedure for System Interlock Checks (later) Author: Asif Haneef
  4. 4. Client Consultant Contractor : SEC-COA : : BEMCO Doc. No.: PP10-BS-SU-001 Riyadh Power plant # 10 “10621166/00” STARTUP MANUAL Date:13 Feb,09 Revision: 0 1.45. TP-IT01 Procedure for System Inter trip Checks (later) 1.46. TP-IN01 Initial Energization of the Plant (Later) 1.47. TP-SS01 Procedure for System Stability (Later) 2. Attachment for Section–12 Testing and commissioning-Instrumentation (Later) .................................................................................................................651 2.1. CI-01 Calibration of Pressure Switches 2.2. CI-02 Calibration of Temperature gauges 2.3. CI-03 Calibration of Pressure gauges 2.4. CI-04 Exhaust over temperature alarm & trip 2.5. CI-05 Exhaust duct over pressure protection 2.6. CI-06 Compressor bleed Valves 2.7. CI 07 Emergency oil pump test & low lube oil pressure trip 2.8. CI-08 Exhaust frame blower (lead / lag test) 2.9. CI-09 Firing checks 2.10. CI-10 Flame detection test and loss of flame trip 2.11. CI-11 Cooling water lead lag test & cooling water fans vibration alarm trip 2.12. CI-12 Hydraulic oil System 2.13. CI-13 Compartment cooling Fans 2.14. CI-14 Hydraulic ratchet System 2.15. CI-15 Trip oil system checks 2.16. CI-16 Vibration protection system 2.17. CI-17 Vanadium inhibitor pip trip, lead lag and change over distillate 2.18. CI-18 Manual emergency shutdown 2.19. CI-19 High lube oil header temperature alarm & trip 2.20. CI-20 Low and high lube oil alarm 2.21. CI-21 IGV position calibration 2.22. CI-22 Mark VI processor hard 2.23. CI-23 Inlet air-filter 2.24. Instrumentation Test Sheets(Attached) 2.24.1. Orifice Plate Verification Report ......................................................653 2.24.2. Thermo well Verification. .................................................................654 2.24.3. Instrument Calibration Report For Temperature Element Transmitters……………………………………………………………...655 2.24.4. Instrument Calibration Report(Transmitters)....................................656 2.24.5. Switch Calibration Report (PS/TS/LS-DPS) ...................................657 2.24.6. Local Instrument Calibration Report (PG/TG/LG)............................658 2.24.7. Instrument Loop Test Sheet-Pressure/Level/Flow/Temperature Transmitter/Other Transmitters........................................................659 2.24.8. Instrument Loop Test Sheet-RTD....................................................660 2.24.9. Instrument Loop Test Sheet-DCS Digital Input Signal(Switches) ...661 2.24.10. Instrument Loop Test Sheet- Motor Operated Valve. ………………662 2.24.11. Instrument Loop Test Sheet- Pneumatic Valves..............................663 2.24.12. Instrument Loop Test -Solenoid valve .............................................664 2.24.13. Switch Calibration report (PS/TS/LS-DPS)…………………………...665 2.24.14. Instrument Control Cable -Megger/Continuity………………………..666 Author: Asif Haneef
  5. 5. Client Consultant Contractor : SEC-COA : : BEMCO Doc. No.: PP10-BS-SU-001 Riyadh Power plant # 10 “10621166/00” STARTUP MANUAL Date:13 Feb,09 Revision: 0 3. Attachment for Section –13 Testing and commissioning-Mechanical (Later)....................................................................................................................667 3.1. CM-01 Commissioning of Fuel Oil System 3.2. CM-02 Commissioning of Fuel Treatment Plant (Vendor) 3.3. CM-01 Commissioning of Fuel Oil System 3.4. CM-04 Commissioning of Oily Water Drainage System 3.5. CM-05 Commissioning of GT Wash Water Supply System 3.6. CM-06 Commissioning of GT Wash Water Drain System 3.7. CM-07 Commissioning of Raw Water Transfer Pumps 3.8. CM-08 Commissioning of Water Treatment Plant (Vendor) 3.9. CM-09 Commissioning of Dimin Water Plant (Vendor) 3.10. CM-10 Commissioning of Dimin Water Supply Pumps 3.11. 3.12. 3.13. 3.14. 3.15. 3.16. 3.17. 3.18. 3.19. 3.20. 3.21. 3.22. 3.23. CM-11 Commissioning of Service Water Distribution Pumps CM-12 Commissioning of Drinking Water Distribution Pumps CM-13 Commissioning of Instrument Air Compressors and Air Dryers CM-14 Commissioning of Service Air Compressors CM-15 Commissioning of Fire Water System Pumps CM-16 Commissioning of Foam System Equipments CM-17 Commissioning of Fire Water and Fire Foam Deluge System CM-18 Commissioning of HVAC Equipments CM-19 Commissioning of Sewage Treatment Plant (Vendor) CM-20 Commissioning of Irrigation System Pumps and Equipments CM-21 Commissioning and Load Testing of Overhead Cranes and Hoists CM-22 Commissioning of Black Start Diesel Generator (Vendor) Gas Turbine and Associated Auxiliaries (By GE) 4. Attachment for Section –14 Velocity Flushing...............................................668 4.1. Lube Oil Flushing Author: Asif Haneef
  6. 6. ent Clie Con nsultant Con ntractor : SEC-C COA : O : BEMCO Doc No.: PP1 c. 10-BS-SU-001 Riyadh Po R ower plant # 10 t “1062 21166/00” STARTU MANUA UP AL Date:13 D Feb,09 F Revision n: 0   LIST OF TEST F TING O OVER ALL (E EXCEL SHE L EET)       Page 6
  7. 7. Testing and commissioning (Electrical) Testing List SL No. 1 2 3 System Name 380KV SYSTEM MV/LV SYSTEM Equipment Project : Testing Activities COMMISSIONING OF GENERATOR STEP UP TRANSFORMER 1.General inspection and Name plate details 2.Winding Ratio Test 3.Winding Resistance Test 4.Magnetism Current Measurement 5.Vector Group Test 6.Magnetic Balance Test 7.Insulation and Polarization test 8.Core Insulation test 9.Tan delta Measurement 10.Frequency Response Analysis (if vendor recommended) 11.Winding Temperature Indicator Calibration 12.Oil Temperature Indicator Calibration GSU 13.Single Phase Impedance Measurement Transformer 14.Zero Sequence Impedance Measurement 15.Testing of protection devices and auxiliary circuits 16.Testing and commissioning of cooler control system 17.Testing and commissioning of OLTC 18.Testing and commissioning of remote OLTC panel 19.Current transformer test Ratio test Polarity Test Winding Resistance Test Winding Insulation test Mag Curve test COMMISSIONING OF AUXILIARY TRANSFORMER 1.General inspection and Name plate details 2.Winding Ratio Test 3.Winding Resistance Test 4.Magnetism Current Measurment 5.Vector Group Test 6.Insulation and Polarization test 7.Winding Temperature Indicator Caliberation Auxiliary 8.Oil Temperature Indicator Caliberation Transformer 9.Testing of protection devices and auxilari circuits 10.Current transformer test Ratio test Polarity Test Winding Resistance Test Winding Insulation test Mag Curve test COMMISSIONING OF MV XLPE CABLE 1.General inspection and Name plate details 2.Conductor continuity and phasing test MV XLPE MV SYSTEM 3.Cable Insulation Test befror hipot Cable 4.High Voltage Test 5. Insulation resistance test after hipot Test Proc. No Riyadh Power plant # 10 Test sheet No Commissioning Activities Proc. No Test sheet No CE-01 TP-PT01 TS-PT01 TP-PT02 TS-PT03 TS-PT04 TS-PT04 TS-PT06 TS-PT06 TS-SS01 TS-IL01 TS-1T01 TS-PT07 TS-PT08 TS-PT09 TS-PT02 TP-CT01 Commissioning Test. 1.Internal wiring and control power measurement 2.Trips fromTranformer Protection Device to protection panel 3. Alarms and trips indication to Remote checks 4.CT Loops , Burden , and Single point Grounding test 5.Secondary Injection to Verify Close circuit of the Cuts 6.Stability and sensitivity test for the Transformer and system 7. interlock test for the system 8. inter trip test for the system 9.Pre Energisation Tests Meggering Post Enegisation test Measurement of In rush current Measurement of noise level (if Vendor Recommends) 10. Load Service Checks TS-CT01 CE-02 TP-AT01 TS-AT01 TP-CT01 TS-CT01 TP-HC01 TS-HC01 Commissioning Test. 1. Internal wiring and control power measurement 2.Trips fromTranformer Protection Device to protection panel 3. Alrams and trips indication to Remote checks 4. CT Loops , Burden , and Single point Grounding test 5. Secondary Injection to Verify Close circuit of the CTs 6. Stability and sensitivity test for the Transformer 7. Pre Energisation Tests Meggering Post Enegisation test TS-AT02 TS-AT02 TS-AT02 TS-AT02 TS-AT02 TS-AT02 TS-AT03
  8. 8. Testing and commissioning (Electrical) Testing List SL No. 4 5 6 7 System Name Equipment Project : Testing Activities COMMISSIONING OF GROUNDING ZIG ZAG TRANSFORMER Neutral 1.General inspection and Name plate details Grounding 2. Impedance and resistance test ZIG ZAG Transformer 3.Insulation Resistance test COMMISSIONING OF CURRENT LIMITING REACTOR 1.General inspection and Name plate details Current 2.Impedance test Limiting 3.Insulation Resistance test before hipot 4.High Volatge test Reactor 5.Insulation resistance test after hipot COMMISSIONING OF NEUTRAL GROUNDING RESISTOR 1.General inspection and Name plate details Neutral 2.Winding Resitance Test Grounding 3.Insulation test before hipot 4.High Voltage Test Resistor 5.Insulation test after hipot COMMISSIONING OF MV BUS DUCT 1. General inspection and Name plate details 2. Bus continuity and phasing test 3. Torque test 4. Contact Resitance test MV bus duct 5. Main Circuit Contact Resitance test 6. Insulation resistance test before hipot 7. High Voltage test MV SYSTEM 8. Insulation resistance test after hipot 9. Protective earthing check COMMISSIONING OF MV SWITCHGEAR 1. Test on Disconnect switch a. Contact Resitance test. b. Insulation resistance test before hipot. c. High Voltage test. d. Insulation resistance test after hipot e. Switch operating time /motor current measurment f. Minimum voltage operation (open/close) at 90V dc. 8 MV Dis connect Switch 2. Discoonect switch operation a. Disconect Switch operation at rated Voltage. b. Functional test of local controls, alarm and indication. c. Functional test of Remote controls, alarm and indication. d. Correct settings of motor limit switches. e. Check correct operation of auxiliary switches. f. Automatic disconnection of supply to the motor on insertion of handle 3. Operation of Earth Switch. 4. Correct Functioning of Interlocks 5. Electrical control and protection/Measuring Devices Riyadh Power plant # 10 Test Proc. No Test sheet No TP-NT01 TS-NT01 TP-RT01 TS-RT01 TP-NT02 TS-NT02 Commissioning Activities Proc. No Test sheet No CE-03 TP-BD01 TS-BD01 Commssioning Test. 1. Heater Circuit Commissioning 2. Dry Air Supply commissioning 3. Pre Energisation Tests Meggering TS-BD03 CE-04 Commssioning Test. 1. Internal wiring and control power measurment 2. functional checks of feeders and ATS 3. Protection checks 3.1 CT Loops , Burden , and Single point Grounding test 3.2 Tripping of relays by secondary injection at final setting 3.3 Primary Injection test 3.4 Stability and sensitivity test for bus bar 3.5 VT Functional Check 3.5 Arc Protection Checks 3.6 Tripping and itertripping checks 4. Interlock checks 6. Alarms and indication checks 7. Remote opertion and Alarm Checks (DCS) 8. Pre Energisation Tests Meggering of the bus bar Post Enegisation test
  9. 9. Testing and commissioning (Electrical) Testing List SL No. System Name Project : Equipment Testing Activities a. MV Dis connect Switch 9 MV SYSTEM MV Switch Gear Test Proc. No Riyadh Power plant # 10 Test sheet No Insulation resistance measurment for control circuit Measurment of Voltages Phase sequence check Phasing between the line and bus b. Control power and current measurment. 6. Commissioning of Heater Circuit a. Visual Checks b. Measurment of insulation resistance of heater and lamp circuit c. Functional checks of thermostat , Heaters, d. Measurment of Current and voltage 7. Protective earthing check. Testing of bus bar 1. General inspection and Name plate details 2. Bus continuity and phasing test 3. Torque test 4. Contact Resitance test 5. Main Circuit Contact Resitance test 6. Insulation resistance test before hipot 7. High Voltage test 8. Insulation resistance test after hipot 9. Protective earthing check Testing of Feeder Breaker 1. Operation and alignment Checks of breaker liftingTrolley 2. Tests on the CB a. Breaker Manual closing/opening, and manual spring charging b. Contact gap Measurment for main contact of the VCB c. Contact Resitance test d. Insulation resistance test before hipot e. Vacuum Integrity test on VCB f. High Voltage test. g. Insulation resistance test after hipot. h. Minimum operating voltage for close and trip coil. i. j. k. l.h 3. Commissioning Activities Breaker operating time. Spring charging motor current and time t Stored energy and spring charge mechanism k Functional check of C.B Operation counter Breaker operation a. CB Racking IN and OUT Checks b. CB operation in service position mechanical and electrical c. CB operation in test position electrical Anti pumping functional check d. e. Functional test of local controls, alarm and Indication TP-BB01 TS-BB01 TP-MB01 TS-MB01 Proc. No Test sheet No
  10. 10. Testing and commissioning (Electrical) Testing List SL No. 9 System Name MV SYSTEM Project : Equipment Testing Activities MV Switch Gear f. Functional Test of Remote control, alarm, and indication 4. Checks for operation of Auxiliary switches ,limit switches for test, service and 5. Operation of Earth Switch 6. Functional check of interlock and limit switches. 7. Check for interchangeable of CB of same rating for Interference interlock 8. Commissioning of Heater Circuit a. Visual Checks b. Measurment of insulation resistance of heater and lam c. Functional checks of thermostat , Heaters, d. Measurment of Current and voltage Testing of MV Contactor General Visual Inspection Contactor operational checks Contact Resistance test insulation Resistance test Timing Test Minimum pickup/drop out voltage for the coil Vacuum Integrity test for vacuum contactors Testing of current transformer 1. General inspection and Name plate details 2. CT Winding insulation Resistance test 3. CT Ratio test by primary injection 4. CT Winding Resitance Measurment 5. CT Loop Resistance Measurment 6. CT Polarity Test 7. CT Burden test 8. CT Magnetizing Current Test (Knee Voltage test) 9. Demagnetizing CT cores after above all test 10. Inter Core Coupling Test for bus differential test 11. High voltage test 12. Verifying secondary circuits, terminals, shorting/isolating l 13. single point earthing check 14. phase identification Testing of Voltage Transformers 1. General inspection and Name plate details 2. Winding insulation Resistance test 3. Voltage Ratio test by primary injection 4. Phase Angle Error 5. Winding Resitance Measurment 6. Polarity Test 7. Loop Resistance Measurment 8. Burden test 9. Phase Sequence test 10. Fuse Failure checks 11. Protective earthing 12. Back Energization Test at rated Voltage for 15 minutes Riyadh Power plant # 10 Test Proc. No Test sheet No TP-MB01 TS-MB01 TP-MC01 TS-MC01 TP-CT01 TS-CT01 TP-VT01 TS-VT01 Commissioning Activities Proc. No Test sheet No
  11. 11. Testing and commissioning (Electrical) Testing List SL No. System Name Equipment Project : Testing Activities Test Proc. No Riyadh Power plant # 10 Test sheet No Testing of Components Phase Over current Relay 1. General inspection and Name plate details 1. Electrical Function test 1. Functional check of Test Plug 2. Shorting of links on relay case when relay is withdrawn 2. Secondary Injection 1. Relay Power measurment 2. Configuration of the relay 3. Testing of LEDs 4. Testing of out put relays 5. Testing of input Devices 6. Metering function 7. Over current Pickup/Dropout test 8. Time current characteristics i. IEC-Normal inverse TP-AR01 ii. IEC-Very inverse iii. IEC- Extremely Inverse 9 MV SYSTEM MV Switch Gear iv. Long time Inverse v. Definite Time 9. Testing of Instantaneous element 10. Reduced voltage (at 90 Volts ) trip test for all output relays 11. Testing at final setting 3.Checking the protective Earthing GE Relay ------MFII ABB Relay-----SPAJ SEL Relay------551 Ground Over Current Relay 1. General inspection and Name plate details 1. Electrical Function test 1. Functional check of Test Plug 2. Shorting of links on relay case when relay is withdrawn 2. Secondary Injection 1. Relay Power measurment 2. Configuration of the relay 3. Testing of LEDs 4. Testing of out put relays TS-AR01(MFII) TS-AR01(SPAJ) TS-AR01(SEL551) TP-AR01 Commissioning Activities Proc. No Test sheet No
  12. 12. Testing and commissioning (Electrical) Testing List SL No. System Name Project : Equipment Testing Activities 5. 6. 7. 8. Test Proc. No Riyadh Power plant # 10 Test sheet No Testing of input Devices Metering function Over current Pickup/Dropout test Time current characteristics i. IEC-Normal inverse ii. IEC-Very inverse iii. IEC- Extremely Inverse iv. Long time Inverse TP-AR01 v. Definite Time 9 MV SYSTEM MV Switch Gear 9. Testing of Instantaneous element 10. Reduced voltage (at 90 Volts ) trip test for all output relays 11. Testing at final setting 3.Checking the protective Earthing GE Relay ------MFII ABB Relay-----SPAJ Voltage Relay 1. General inspection and Name plate details 2. Electrical Function test 1. Functional check of Test Plug 2. Secondary Injection 1. Relay Power measurment 2. Testing of LEDs 3. Testing of out put relays 4. Testing of input Devices 5. Metering function 6. Under Voltage Function i. Pickup/dropout test ii. Timing test 7. Over voltage test i. Pickup/dropout ii. Timing test GE Relay--MVII ABB Relay-----610 Differential Relay 1. General inspection and Name plate details 2. Electrical Function test i. Functional check of Test Plug ii. Shorting of links on relay case when relay is with 3. Secondary Injection i. Relay Power measurment ii. Testing of LEDs iii. Testing of out put relays TS-AR01(MFI) TS-AR01(SPAJ) TP-VR01 TS-VR01(MVII) TS-VR01(MVII) TP-DR01 Commissioning Activities Proc. No Test sheet No
  13. 13. Testing and commissioning (Electrical) Testing List SL No. System Name Project : Equipment Testing Activities Testing of input Devices Metering function Differential Function 1. Differential current Function 2. Differential restraint characteristic 3. Harmonic Function 4. Instantaneous Differential current function 5. Timing Test vii. Backup over current 1. current Pickup/Dropout test 2. Time current characteristics a. IEC-Very inverse b. IEC- Extremely Inverse c. Long time Inverse d. Definite Time 3.Testing of Instantaneous elem GE Relay ------G60 GE Relay-------T6O GE Relay -------DTP AREVA-------MCAG Motor Management Relay 1. General inspection and Name plate details Test Proc. No Riyadh Power plant # 10 Test sheet No iv. v. vi. 9 MV SYSTEM MV Switch Gear 1. Electrical Function test 1. Functional check of Test Plug 2. Shorting of links on relay case when relay 2. Secondary Injection 1. Relay Power measurment 2. Configuration of the relay 3. Testing of LEDs 4. Testing of out put relays 5. Testing of input Devices 6. Metering function 7. Group elements checks 1.Thermal over load checks 2. Ground current checks 3. unbalance current checks 4. short circuit current checks 5 RTD 'S Function checks 10. Reduced voltage (at 90 Volts ) trip test for all 11. Testing at final setting 3.Checking the protective Earthing GE Relay-------369 Synchronous Relay 1.General Inspection 2. Electrical Function test 1. Functional check of Test Plug 2. Secondary Injection 1. Relay Power measurment 2. Testing of LEDs TP-DR01 TS-DR01(G60) TS-DR02(T60) TS-DR02(DTP) TS-DR03(MCAG TP-MR01 TS-AR02(369) TP-SR01 Commissioning Activities Proc. No Test sheet No
  14. 14. Testing and commissioning (Electrical) Testing List SL No. System Name Project : Equipment Testing Activities Test sheet No 3. 4. 5. 6. 9 MV SYSTEM MV Switch Gear Testing of out put relays Testing of input Devices Metering function Live line- Live bus (synchronous ) test i. Difference in voltage test ii. Difference in frequency iii. Difference in phase angle iv. Under voltage blocking test 7. Dead line –Dead bus test 8. Dead Bus-Live line test 9. Dead Line – Dead Bus ARGUS 8----VATECH SPUA --ABB CT Supervision Relay 1.General Inspection 2. Electrical Function test 1. Functional check of Test Plug 2. Secondary Injection 1. Voltage Pick-Up Verification 2. Voltage Drop-Out Verification 3. Function Check i. The CB Is In Open Position ii. The CB In Close Position Timing Relay 1. Secondary Injection 1. Minimum Voltage Pick-Up Verification 2. Operating time Measurment Ammeter 1. Electrical Function test 2. Secondary Injection Voltmeter 1. Electrical Function test 2. Secondary Injection power Meter 1. Electrical Function test 2. Secondary Injection Power Factor Meter 1. Electrical Function test 2. Secondary Injection VAR meter 1. Electrical Function test 2. Secondary Injection Energy Meter 1. Electrical Function test 2. Secondary Injection Multi function meter 1. Electrical Function test 2. Secondary Injection Current Transducer Test Proc. No Riyadh Power plant # 10 TP-CR01 TS-SR01(ARGUS TS-SR01(SPUA TS-CR01 TP-CR03 TS-CR03 TP-AM01 TS-AM01 TP-VM01 TS-VM01 TP-PM01 TS-PM01 TP-PM01 TS-PM01 TP-PM01 TS-PM01 TP-EM01 TS-EM01 TP-PM01 TS-PM01 TP-AX01 TS-AX01 Commissioning Activities Proc. No Test sheet No
  15. 15. Testing and commissioning (Electrical) Testing List SL No. System Name Project : Equipment Testing Activities Test sheet No Commissioning Activities Proc. No Test sheet No 1. 2. 9 10 11 12 13 14 Electrical Function test Secondary Injection Voltage Transducer MV Switch 1. Electrical Function test MV SYSTEM 2. Secondary Injection Gear Power Transducer 1. Electrical Function test 2. Secondary Injection COMMISSIONING OF MV /LV MOTORS 1.General inspection and Name plate details 2. winding Resistance MV/LV 3. Winding Insulation SYSTEM MV /LV Motors 4. Di-electric absorption Ratio for Motor Less then 200HP 5. Polarization index for motor above 200HP Test Proc. No Riyadh Power plant # 10 COMMISSIONING OF DRY TYPE TRANSFORMER 1.General inspection and Name plate details 2.Winding Ratio Test Dry Type 3.Winding Resistance Test Transformer 4.Insulation Resistance Test 5.Magnetising current Measurment 6.Phase Relation Checks COMMISSIONING OF LV XLPE CABLE 1.General inspection and Name plate details 2.Conductor continuity and phasing test LV Cable 3.Cable Insulation Test COMMISSIONING OF LV BUS DUCT 1. General inspection and Name plate details 2. Bus continuity and phasing test 3. Torque test 4. Contact Resitance test LV SYSTEM LV bus duct 5. Main Circuit Contact Resitance test 6. Insulation resistance test before hipot 7. High Voltage test @ 1.6KV AC 8. Insulation resistance test after hipot 9. Protective earthing check COMMISSIONING OF LV SWITCHGEAR Testing of bus bar 1. General inspection and Name plate details LV Switch Gear 2. 3. 4. 5. 6. 7. 8. 9. Bus continuity and phasing test Torque test Contact Resitance test Main Circuit Contact Resitance test Insulation resistance test before hipot High Voltage test Insulation resistance test after hipot Protective earthing check TP-VX01 TS-VX01 TP-PX01 TS-PX01 TP-MM01 TS-MM01 TP-AT01 TS-AT01 TP-HC02 Commssioning Test. 1.No load current measurment 2.Vibration measurment 3. Bearing temperature measurment 4. Full load current and voltage drop measurment 6. Vibration measurment after coupled 7. Bearing temperature measurment after couple CE-05 CP-MM01 TS-MM02 Commssioning Test. 1. Pre Energisation Tests Meggering Post Enegisation test-Measrument of voltages TS-DT02 TS-HC01 CE-06 TP-BD02 TS-BD02 Commssioning Test. 1. Pre Energisation Tests Meggering TP-BB01 TS-BB01 Commssioning Test. 1. Internal wiring and control power measurment CE-07 TP-MB01 TS-MB01 2. functional checks of feeders and ATS 3. Protection checks 3.1 CT Loops , Burden , and Single point Grounding test 3.2 Tripping of relays by secondary injection at final setting 3.3 Primary Injection test 3.4 Stability and sensitivity test for bus bar 3.5 VT Functional Check 3.5 Arc Protection Checks CP-MS01 CP-MS02 CP-MS03
  16. 16. Testing and commissioning (Electrical) Testing List SL No. System Name Project : Equipment Testing Activities Test Proc. No Riyadh Power plant # 10 Test sheet No Testing of Feeder Breaker 1 2. Tests on the CB a. Breaker Manual closing/opening, and manual spring charging c. Contact Resitance test d. Insulation resistance test before hipot f. g. h. 14 LV SYSTEM LV Switch Gear 3.6 Tripping and itertripping checks 4. Interlock checks 6. Alarms and indication checks 7. Remote opertion and Alarm Checks (DCS) 8. Pre Energisation Tests Meggering of the bus bar Post Enegisation test Measurment of Voltages High Voltage test. Insulation resistance test after hipot. Minimum operating voltage for close and trip coil. Phase sequence check Phasing between the line and bus i. Breaker operating time. j. Spring charging motor current and time measurment. k. Stored energy and spring charge mechanism checks l. Functional check of C.B Operation counter 3. Breaker operation a. CB Racking IN and OUT Checks b. CB operation in service position mechanical and electrical c. CB operation in test position electrical Anti pumping functional check d. e. Functional test of local controls, alarm and Indication f. Functional Test of Remote control, alarm, and indication 4. Checks for operation of Auxiliary switches ,limit switches for test, service and 6. Functional check of interlock and limit switches. 8. Commissioning of Heater Circuit a. Visual Checks b. Measurment of insulation resistance of heater and lamp circuit c. Functional checks of thermostat , Heaters, d. Measurment of Current and voltage Testing of current transformer TP-CT01 1. General inspection and Name plate details 2. CT Winding insulation Resistance test 3. CT Ratio test by primary injection 4. CT Winding Resitance Measurment 5. CT Loop Resistance Measurment 6. CT Polarity Test 7. CT Burden test TP-CT01 8. CT Magnetizing Current Test (Knee Voltage test) 9. Demagnetizing CT cores after above all test 11. Verifying secondary circuits, terminals, shorting/isolating links by primary injection Commissioning Activities Phasing between the line and bus TS-CT01 TS-CT01 Proc. No Test sheet No
  17. 17. Testing and commissioning (Electrical) Testing List SL No. System Name Equipment Project : Testing Activities 12. single point earthing check 13. phase identification Testing of Voltage Transformers 1. General inspection and Name plate details 2. Winding insulation Resistance test 3. Voltage Ratio test by primary injection 4. Phase Angle Error 5. Winding Resitance Measurment 6. Polarity Test 7. Loop Resistance Measurment 8. Burden test 9. Phase Sequence test 10. Fuse Failure checks 11. Protective earthing 12. Back Energization Test at rated Voltage for 15 minutes Testing of Components Phase Over current Relay 1. General inspection and Name plate details 14 LV SYSTEM LV Switch Gear 1. Electrical Function test 1. Functional check of Test Plug 2. Shorting of links on relay case when relay is withdrawn 2. Secondary Injection 1. Relay Power measurment 2. Configuration of the relay 3. Testing of LEDs 4. Testing of out put relays 5. Testing of input Devices 6. Metering function 7. Over current Pickup/Dropout test 8. Time current characteristics i. IEC-Normal inverse ii. IEC-Very inverse iii. IEC- Extremely Inverse iv. Long time Inverse v. Definite Time 9. Testing of Instantaneous element 10. Reduced voltage (at 90 Volts ) trip test for all output relays 11. Testing at final setting 3.Checking the protective Earthing Test Proc. No TP-VT01 TP-AR01 Riyadh Power plant # 10 Test sheet No TS-VT01 Commissioning Activities Proc. No Test sheet No
  18. 18. Testing and commissioning (Electrical) Testing List SL No. System Name Equipment Project : Testing Activities GE Relay ------MFII ABB Relay-----SPAJ Ground Over Current Relay 1. General inspection and Name plate details Test Proc. No Riyadh Power plant # 10 Test sheet No TS-AR01(MFI) TS-AR01(SPAJ) TP-AR01 1. Electrical Function test 1. Functional check of Test Plug 2. Shorting of links on relay case when relay is withdrawn 2. Secondary Injection 1. Relay Power measurment 2. Configuration of the relay 3. Testing of LEDs 4. Testing of out put relays 5. Testing of input Devices 6. Metering function 7. Over current Pickup/Dropout test 8. Time current characteristics i. IEC-Normal inverse ii. IEC-Very inverse iii. IEC- Extremely Inverse 14 LV SYSTEM LV Switch Gear iv. Long time Inverse v. Definite Time 9. Testing of Instantaneous element 10. Reduced voltage (at 90 Volts ) trip test for all output relays 11. Testing at final setting 3.Checking the protective Earthing GE Relay ------MFII ABB Relay-----SPAJ Voltage Relay 1. General inspection and Name plate details 2. Electrical Function test 1. Functional check of Test Plug 2. Secondary Injection 1. Relay Power measurment 2. Testing of LEDs 3. Testing of out put relays 4. Testing of input Devices 5. Metering function 6. Under Voltage Function i. Pickup/dropout test ii. Timing test TS-AR02(MFI) TS-AR02(SPAJ) TP-VR01 Commissioning Activities Proc. No Test sheet No
  19. 19. Testing and commissioning (Electrical) Testing List SL No. System Name Project : Equipment Testing Activities 7. 14 LV SYSTEM LV Switch Gear Test Proc. No Riyadh Power plant # 10 Test sheet No Over voltage test i. Pickup/dropout ii. Timing test GE Relay--MVII ABB Relay-----610 Synchronous Relay 1.General Inspection 2. Electrical Function test 1. Functional check of Test Plug 2. Secondary Injection 1. Relay Power measurment 2. Testing of LEDs 3. Testing of out put relays 4. Testing of input Devices 5. Metering function 6. Live line- Live bus (synchronous ) test i. Difference in voltage test ii. Difference in frequency iii. Difference in phase angle iv. Under voltage blocking test 7. Dead line –Dead bus test 8. Dead Bus-Live line test 9. Dead Line – Dead Bus 3.Checking the protective Earthing ARGUS 8----VATECH SPUA --ABB Timing Relay 1. Secondary Injection 1. Minimum Voltage Pick-Up Verification 2. Operating time Measurment Ammeter 1. Electrical Function test 2. Secondary Injection Voltmeter 1. Electrical Function test 2. Secondary Injection power Meter 1. Electrical Function test 2. Secondary Injection Power Factor Meter 1. Electrical Function test 2. Secondary Injection VAR meter 1. Electrical Function test 2. Secondary Injection Energy Meter 1. Electrical Function test 2. Secondary Injection Multi function meter TS-VR01(MVII) TS-VR01(MVII) TP-CR03 TS-SR01(ARGUS TS-SR01(SPUA TS-CR03 TP-AM01 TS-AM01 TP-VM01 TS-VM01 TP-PM01 TS-PM01 TP-PM01 TS-PM01 TP-PM01 TS-PM01 TP-EM01 TS-EM01 TP-PM01 TS-PM01 Commissioning Activities Proc. No Test sheet No
  20. 20. Testing and commissioning (Electrical) Testing List SL No. System Name Project : Equipment Testing Activities Test sheet No Commissioning Activities Proc. No Test sheet No 1. 2. 14 Electrical Function test Secondary Injection Current Transducer 1. Electrical Function test 2. Secondary Injection LV Switch LV SYSTEM Voltage Transducer Gear 1. Electrical Function test 2. Secondary Injection Power Transducer 1. Electrical Function test 2. Secondary Injection COMMISSIONING OF BATTERY CHARGERS General Inspection Battery Componenet test (Metering Facitlities ) Test Proc. No Riyadh Power plant # 10 TP-AX01 TS-AX01 TP-VX01 TS-VX01 TP-PX01 TS-PX01 CE-08 TP-BC01 pre energization checks post energization checks Operational Check Alarms Ckecks Load Test 15 16 COMMISSIONING OF BATTERIES Torque test Refersher Charging Batteries Battery discharge test COMMISSIONING OF DC SWITCHBOARD Testing of bus bar General Visual inspection Torque test Contact Resistance test for the joints DC SYSTEM Total conductor resistance test Insulation Resistance test Testing of Circuit Breaker General Visual Inspection Breaker operational checks Contact Resistance test 17 DC Switch board insulation Resistance test Testing of Components Voltage Relay General Inspection Power Consumption Digital input/out put checks Metering function checks Pickup /dropout checks Time -Voltage characteristics checks Lockout or Trip Relay General Inspection Pickup/drop out checks TP-BA01 TP-DB01 TS-DB01 TP-VR02 TS-VR02 TP-CR02 TP-CR02 Commssioning Test. 1. Internal wiring and control power measurment 2. functional checks of feeders and ATS 3. Protection checks 3.1 Tripping of relays by secondary injection at final setting 3.2 Primary Injection test 4. Interlock checks 5. Alarms and indication checks 6. Remote opertion and Alarm Checks (DCS) 7. Pre Energisation Tests Meggering of the bus bar Post Enegisation test Measurment of Voltages Phase sequence check CE-09 CP-FC03 CP-EN03
  21. 21. Testing and commissioning (Electrical) Testing List SL No. 18 19 System Name Equipment Project : Testing Activities Timing test Timing Relay General Inspection Pickup/drop out checks Timing test Ammeter General Inspection Caliberation of the Meter DC Switch Voltmeter board General Inspection Caliberation of the Meter Current Transducer DC SYSTEM General Inspection Caliberation of the Meter Voltage Transducer General Inspection Caliberation of the Meter COMMISSIONING OF UPS General Inspection Componenet test (Metering Facitlities ) 22 Test sheet No TP-CR03 TP-AM02 TS-AX02 TP-VX02 Test sheet No TS-VM02 TP-AX02 Proc. No TS-AM02 TP-VM02 Commissioning Activities TS-CR03 TS-VX02 CE-10 TP-UC01 pre energization checks post energization checks Operational Check Alarms Ckecks Load Test UPS COMMISSIONING OF GENERATOR PROTECTION PANEL Generator differential Relay G60- GE Breaker Failure Relay Gerator GENERATOR C60-GE 20 PROTECTION Protection Transformer Differetial Relay T60- GE Panel Lockout Relays Multifunction Meter DMM 21 Test Proc. No Riyadh Power plant # 10 TS-DR01) TS-DR01(G60) TS-AR01(C60) TS-AR01(C60) TS-DR01 TS-DR01(T60) COMMISSIONING OF GENERATOR 1.General inspection and Name plate details TP-MM01 2. Polarization index of stator @ 5kv dc 3. Polarization index of Rotor @ MV SYSTEM 4.Insulation Resistance Test of exciter stator Gerator 5. Commissioning of Heaters 1. Insulation resistance measurement test for heaters and cable 2. Measurement of Current 3. measurement of voltages COMMISSIONING OF MCC and Distrubution Board Bus Bar MCC & LV SYSTEM 1.General inspection and Name plate details DISTRIBUTION TP-MM01 2. Torque check BAORD 3. conatct resistance test for joint TS-MM01 CE-11 TS-MM01 1. Internal wiring and control power measurment 2. functional checks of feeders and ATS 3. Primary Injection test 4. Interlock checks
  22. 22. Testing and commissioning (Electrical) Testing List SL No. 22 System Name Equipment Project : Testing Activities 4. Total circuit contact resistance test 5. Insulation resistance test For Breakers MCC & 1. Primary injection test for MCCB above 100 Amps LV SYSTEM DISTRIBUTION 2. Trip test for over load above 100 amps 3. Functional Check of Starter BAORD 4. Ratio and insulation resistance test for CTs above 100 Amp Test Proc. No TP-MM01 Riyadh Power plant # 10 Test sheet No TP-MM01 Commissioning Activities 5. Alarms and indication checks 6. Remote opertion and Alarm Checks (DCS) 7. Pre Energisation Tests Meggering of the bus bar Post Enegisation test Measurment of Voltages Phase sequence check Proc. No Test sheet No
  23. 23. ent Clie Con nsultant Con ntractor : SEC-C COA : O : BEMCO Doc No.: PP1 c. 10-BS-SU-001 Riyadh Po R ower plant # 10 t “1062 21166/00” STARTU MANUA UP AL Date:13 D Feb,09 F Revision n: 0   GENERA INST AL TRUCTION FO AC OR C/DC VOLTA V AGE T TESTIN NG       Page 23
  24. 24. Client Consultant Contractor : : : SEC-COA Subject : High Voltage AC/DC Testing Doc. No: TP-HP01, MV Cable and Switch Gear 8 of 1Page Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 TABLE OF CONTENTS Page 1 1. PURPOSE 2. SCOPE 1 3. REFERENCES 1 4. NOTES .AND PRECAUTIONS 1 5. PROCEDURE 2 6. ACCEPTANCE CRITERIA 4 APPENDICES A TEST TABLES B HIGH POTENTIAL DATA RECORD 1 The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by : AH Page 24
  25. 25. Client Consultant Contractor : : : SEC-COA Subject : High Voltage AC/DC Testing Doc. No: TP-HP01, MV Cable and Switch Gear 8 of 2Page Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 1. PURPOSE The purpose of this procedure is to test and document the integrity of cables, metal enclosed bus duct, and switchgear assemblies of both 4.16kV and 13.8 kV levels using an ac/dc source. 2. SCOPE This procedure applies to both ac and dc high-potential testing. DC high-potential testing is preferred for testing on a periodic basis since it is more than a "go" or "no-go" test, as is the ac test. The dc test can indicate that the tested object is all right at the present time but may fail in the future. The ac high-potential test is more accepted standard in practice. 3. REFERENCES 3.1. IEEE Standard 62-1958, IEEE Recommended Guide for Making Dielectric Measurements in the field. 3.2. The ac high-potentla1 test levels recommended by the national standards ANSI for switchgear assemblies and rigid bus. 3.3. The ac/dc high-potentla1 test levels recommended by IEC 60502 standards for 1kv to 15 kv cables 4. NOTES AND PRECAUTIONS 4.1. Due to high voltage being used, adequate safety precautions should be taken to avoid injury to personnel and damage to property. 4.2. Always use approved and tested safety rubber gloves when connecting and disconnecting test leads to and from the apparatus, and while operating the test equipment. 4.3. Test equipment operation shall be in accordance with the manufacturer's instructions. 4.4. In the case of unshielded cable, the non-uniform electric field between conductor and the metal enclosure (ground) may introduce excessive stresses in the insulation. In the case of unshielded cable it is therefore recommended that a dc test only be carried out. 4.5. Shielded power cables require electrical stress control when they are terminated. Cables shall be made up with either stress cones or with heat-shrinkable stress control material. 4.6. The cable route or the equipment should be walked down to establish safety boundaries as necessary for personnel and equipment protection. 4.7. Ensure that all voltage transformers are disconnected for the duration of the test and that all current transformers are short-circuited. 4.8. Continuity and phasing of all cables and switchgear bus-work should be checked, where 2 The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by : AH Page 25
  26. 26. Client Consultant Contractor : : : SEC-COA Subject : High Voltage AC/DC Testing Doc. No: TP-HP01, MV Cable and Switch Gear 8 of 3Page Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 practical. 4.9. Provision should be made to ground equipment through a resistance by means of a hot stick after megger or high-potential testing. 4.10. Ensure that all cable shields and switchgear grounds have been made per the installation instructions. 4.11. Conductors of each like phase may be tested together, provided the source has adequate capacity to maintain the specified test voltage for the required period of time. Conductors not being tested shall be tied together, using a soft wire and grounded at the test end. 4.12. Phases should be properly identified and labeled 4.13. This test should be performed only by personnel who are properly trained on the test equipment. Safety rules, testing procedures and interpretation of the results. 5. PROCEDURE 5.1 Determine the test voltage, kVA and times and voltage steps to be used (refer to Appendix A). 5.2 De-energize, discharge and safety) tag the cable/equipment to be tested, as necessary. Record the scheme/cable/equipment number on the High-Potential Data Record form. 5.3 Disconnect the cable/equipment from the equipment/cables at each end and position it with maximum possible clearance from objects. The minimum clearance recommended to preclude flashover is 10 cm. Ensure that open cable ends are insulated. 5.4 Ground all equipment, cables and conductors not under test that are in contact with the cable under test or that can become energized by a flashover. NOTE Where high-potential testing of shielded cables with grounded shields is to be performed, the existing cables/equipment need not be grounded. 5.5 As a precautionary measure a 2,500 V megger reading shall be made between the test terminals to ensure that the equipment/cable is free from gross defects as a result of damage during installation and that no inadvertent grounds have been left. The megger readings should be recorded on the High-Potential Data Record form. NOTE Megger resistance values will vary over a wide range depending on the type of equipment being tested and the test environment. As a result it is difficult to state precisely what constitutes an acceptable megger resistance value. However, as a general rule, tests should be terminated if the insulation resistance is less than 5 Mohms for 5 kV class equipment and 15 Mohms for 15 kV class equipment. Abnormally low values of insulation resistance should be 3 The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by : AH Page 26
  27. 27. Client Consultant Contractor : : : SEC-COA Subject : High Voltage AC/DC Testing Doc. No: TP-HP01, MV Cable and Switch Gear 8 of 4Page Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 investigated before proceeding further with any test 5.6 Position the test instrument inside the test area keeping the high voltage lead between the test instrument and the cable/equipment being tested. 5.7 Connect the test set in accordance with the manufacturer's instructions. 5.8 Set the ammeter to its highest range. 5.9 Set the voltage to its lowest range. CAUTION Avoid overshooting the voltage. The initially applied direct-current voltage shall not be greater than three times the rated alternating-current voltage of the cable for high-potential dc testing. 5.10 Gradually increase the test voltage until the desired test level is reached. During the voltage buildup, the rate of increase of the applied voltage shall be approximately uniform so that the required time shall be no less than 10 seconds and no more than 60 seconds for dc highpotential testing and shall not exceed 10 seconds for ac high-potential testing. NOTE If cable/equipment insulation failure should occur as indicated by the high ammeter reading, secure the test voltage immediately. 5.11 Measure leakage current at the end of each step, record data on the High-Potential Data Record form. 5.12 Repeat steps 5.10 and 5.1 1 correcting any abnormalities, until the maximum test voltage is reached. 5.13 Maintain maximum test voltage as indicated in Table 3 of Appendix A. Measure leakage current every minute and record data on the High-Potential Data Record form. 5.14 Reduce test voltage continuously, but not abruptly 5.15 Turn off the test instrument and allow the voltage to decay for the minimum time in accordance with the test instrument instruction. CAUTION A dangerous charge may be stored by the apparatus unless it is grounded after the test. 5.16 Ground the cable/equipment (use a discharge rod) and allow the ground to remain in place for a period of at least 3 to 5 minutes. 5.17 Remove the test connections. 4 The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by : AH Page 27
  28. 28. Client Consultant Contractor : : : SEC-COA Subject : High Voltage AC/DC Testing Doc. No: TP-HP01, MV Cable and Switch Gear 8 of 5Page Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” 5.18 Restore the cable to its as-found condition. 5.19 Remove all grounds installed in Step 5.4. 6. Revision: 0 ACCEPTANCE CRITERIA The equipment tested shall withstand the imposed potentials for the prescribed periods of time without distress or failure. NOTE If the leakage current versus voltage are plotted as a curve, as long as this plotted curve is linear for each step. The insulation system is in good condition. At some value of step voltage if the leakage current begins to increase noticeably an increase in the slope of the curve will be noticed. as shown in the figure below. If the test is continued beyond this test voltage, the leakage current will increase even more rapidly and immediate breakdown may occur in the cable insulation. When the final test voltage of leakage current versus voltage test is reached, it can be left on for the required time and the leakage current versus time can be plotted for fixed intervals of time as the leakage current during this step reduces from an initial high value to a steadystate value. A curve for good cables will generally indicate a continuous decrease in leakage current with respect to time or steady-state value without any increase of current during the test. This is shown in the figure below. 5 The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by : AH Page 28
  29. 29. Client Consultant Contractor : : : SEC-COA Subject : High Voltage AC/DC Testing Doc. No: TP-HP01, MV Cable and Switch Gear 8 of 6Page Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” 6 The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Revision: 0 Originator: BEMCO Services Prepared by : AH Page 29
  30. 30. Client Consultant Contractor : : : SEC-COA Subject : High Voltage AC/DC Testing Doc. No: TP-HP01, MV Cable and Switch Gear 8 of 7Page Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 APPENDIX A TEST TABLES Table I Test Set kVA Required for High-Potential Testing of 5 kV Class Shielded Cable (100 m length at 10kV) Cable Size, MCM 250 EPR Cable, kVA 2.5 XLPE Cable. kVA 2.0 350 2.9 2.3 500 3.4 2.6 750 4.3 3.3 1,000 5.0 4.0 Table 2 Test Set kVA Required for High-Potential Testing of 15 kV Class Shielded Cable (100 m length at 20 kV) Cable Size, MCM 250 EPR Cable, kVA 5.7 XLPE Cable. kVA 4.5 350 6.6 5.2 500 7.5 5.9 750 9.5 7.4 1,000 10.8 8.4 NOTES: 1. The tables show' the values for both cross-linked polyethylene (XLPE) and ethylenepropylene rubber (EPR) type cables. 2. The values have been calculated based on standard cable dimensions and using a dielectric 7 Originator: BEMCO Services The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Prepared by : AH Page 30
  31. 31. Client Consultant Contractor : : : SEC-COA Subject : High Voltage AC/DC Testing Doc. No: TP-HP01, MV Cable and Switch Gear 8 of 8Page Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 constant of 3.7 for EPR and 2.5 for XLPE. as supplied by cable manufacturers. APPENDIX A (Continued) Table 3 Recommended Field Test Levels AC Testing Equipment Power Cable: Unshielded Shielded (including Cable Bus) High-potential VLF @0.1HZ Rated Partial Discharge Test Test(PF) Voltage, Test Pulse Test kV Time, Extinction Time, Time, Level, Magnitude, level, Min Level, kV Min Min kV pC kV 3XUo 4.16 N/A N/A N/A N/A N/A 60 4.16 9(13) 5 4.5(4.5) 3(3) 2 7.2 60 13.85 60 8 13(18) 5 7.5(7.5) 3(3) 2 13.8 Switchgear 19(27) 5 13(13) 3(3) 2 25 45(60) 1 19 100 2 13.8 27(36) 1 10.5(10.5) 100(100) 14(19) 27(36) 1 1 3.5(3.5) 10.5(10.5) 100(100) 100(100) 2 2 Test Time, level, Min kV 4XU0 9.6 5 9.6 15 23.9 60 N/A N/A N/A 19 15 32 15 64 1 37(50) 2 4.16 13.8 Bus Duct : Isolated phase Bus (IPB) MetalEnclosed Rigid Bus DC Testing 1 N/A N/A N/A N/A N/A N/A N/A N/A N/A NOTES: 1. 2. 3. 4. 5. Factory tests are shown in brackets. The values recommended for field ac high-potential tests are at 75 percent of the factory levels, for switchgear assemblies 70 percent of factory levels. The values recommended for field dc high-potential testing of cable as per IEC-60502 is 4times U0 Where as Uo is U/1.732. The value recommended for field AC VLF testing is 3Uo for 60 minutes above values to be used in case Vendor recommended values are not available 8 The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by : AH Page 31
  32. 32. ent Clie Con nsultant Con ntractor : SEC-C COA : O : BEMCO Doc No.: PP1 c. 10-BS-SU-001 Riyadh Po R ower plant # 10 t “1062 21166/00” STARTU MANUA UP AL Date:13 D Feb,09 F Revision n: 0   TES STING PROC CEDUR FO ME RE OR EDIUM VOLT TAGE CABLE       Page 32
  33. 33. : Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Form No: TP-CM01, MV Cable Up to 33kv Page 1 of 7 Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 TABLE OF CONTENT 1. Task a. Work Status-----------------------------------------------------------------------------------------------------------------2 b. Documentation-------------------------------------------------------------------------------------------------------------2 c. Personnel--------------------------------------------------------------------------------------------------------------------2 d. Measuring Instrumentation----------------------------------------------------------------------------------------------2 2. 3. 4. 5. Preconditions--------------------------------------------------------------------------------------------------------------2 Precautions-----------------------------------------------------------------------------------------------------------------2 Scope-------------------------------------------------------------------------------------------------------------------------3 Execution--------------------------------------------------------------------------------------------------------------------3 a. Visual Inspection--------------------------------------------------------------------------------------------------------3 b. Testing of Motor 1. Cable Sheath Testing--------------------------------------------------------------------------------------------3 2. Conductor continuity and phasing test.----------------------------------------------------------------------3 3. Insulation Resistance test Before Hipot.--------------------------------------------------------------------4 4. High voltage AC test for XLPE cable.------------------------------------------------------------------------5 5. Insulation Resistance test After Hipot-----------------------------------------------------------------------7 6. 7. 8. Documents-----------------------------------------------------------------------------------------------------------------7 Reference-------------------------------------------------------------------------------------------------------------------7 Attachment-----------------------------------------------------------------------------------------------------------------7 The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 33
  34. 34. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Form No: TP-CM01, MV Cable Up to 33kv Page 2 of 7 Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 1.0 Task All newly installed power cable (1-33kV) in the electrical system requires field testing. 2.0 Preconditions 2.1 Work Status • Erection has been completed. • Labelling of the equipment is complete 2.2 Documentation • Test Sheet TS-CM01 2.3 Personnel • 1 Testing engineer: Engineer or technician with experience in high voltage testing of electrical equipment. • 1 Helper: skilled worker with adequate on-the-job training. 2.4 Measuring Instruments and Tools • Fluke • High Voltage Tester Up to 100KV AC/DC or VLF • Insulation Tester 5KV 3.0 Precautions • The work will only proceed when a Permit to Work (PTW) in work permit area has been obtained. The PTW will be kept on site for consultation during the testing works. • Closing of the work permit after completion of the work (if the test area is to be considered in work permit area) is necessary. • The test site shall have sufficient protective barriers and warning signs to conduct the tests. • All cable section ends under test shall be grounded from accidental contact. Also the minimum separation from all ends or elements not being subject to test shall be 25.4mm/10kV of test voltage. • Before cable test operation started, conductor under test and all cable accessories shall be checked as being de-energized using reliable voltage indicator. The voltage indicator should be tested for proper operation with an independent voltage source prior to operation. • While the voltage indicator is still in contact with each component and is showing de-energized, a hot line grounded device for the purpose shall be continuously attached to all conductors under examination except while test equipment is ready for energization. • All adjacent conductors in cable circuit not on test should be de-energized and left grounded while testing the other conductor. The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 34
  35. 35. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Form No: TP-CM01, MV Cable Up to 33kv Page 3 of 7 Date:13 Feb,09 Equipment : Riyadh Power plant # 10 “10621166/00” BEMCO Revision: 0 4.0 Scope • Checking termination, • Checking shield • Checking of correct earthing, 5.0 Execution 5.1 Visual Checks • • • • Checking of the cables for any damage Inspection for termination. Inspection for correct tightness for connection Checking labels 5.2 Testing of Cable Enter the rating plate data in check list TS-CM01. The following test shall be carried out 1. 2. 3. 4. 5. 5.2.1 Cable Sheath Testing Conductor continuity and phasing test. Insulation Resistance test Before Hipot. High voltage AC test for XLPE cable. Insulation Resistance test After Hipot Cable Sheath Testing Cable sheath testing is carried out in order to detect damage to cable sheath. To do this DC test is carried out. Test voltage 3kv is applied between PVC sheath and ground provided shield is grounded and insulation resistance or leakage current is measured. 5.2.2 Conductor Continuity and Phasing Test To ensure the continuity and phasing of the cable conductor from terminal to terminal, the cable conductor shall be tested by using a minimum 500VDC megger as per figure below; tests results shall be noted down in the test sheet. M Conductor continuity test The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 35
  36. 36. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Form No: TP-CM01, MV Cable Up to 33kv Page 4 of 7 Date:13 Feb,09 Equipment : Riyadh Power plant # 10 “10621166/00” BEMCO Revision: 0 M Phase verification FIGURE-5-1 5.2.3 Insulation Resistance test Before High Voltage Test Prior to performing the high voltage test on the cable, insulation resistance test by mega ohmmeter at 5000VDC shall be performed for one minute on each cable, between the conductor and the metallic shield with the adjacent cable conductors and shield grounded as per figure below. M Grounding sheet Insulation Resistance Test FIGURE: 5-2 Minimum insulation resistance of conductor for new cables shall be determined by the following. The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 36
  37. 37. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Form No: TP-CM01, MV Cable Up to 33kv Page 5 of 7 Date:13 Feb,09 Equipment : Riyadh Power plant # 10 “10621166/00” BEMCO 5.2.4 Revision: 0 High Voltage Test High Voltage test for medium voltage cable can be accomplished either of the following method in agreement with the SEC/Consultant 5.2.4.1 AC High Voltage Testing The AC power frequency voltage shall be applied through the test set as per figure 5-3. While test, all cable conductors and shield not on test shall be grounded. The test voltage shall be pure sinusoidal wave shape. As per IEC 60840 the test voltages are as follows The maximum phase to phase voltage of the system shall be maintained for line to ground for five minutes, OR 2 X U0 for 60 Minutes OR A. C. test volts = .75(2 X equipment maximum voltage + 1kV) for one minute (as per ARMCO) In all cases voltage at the rate of 1 kV per second shall be increased until the maximum recommended test voltage is reached and maintained for required time duration. The AC high potential test results are evaluated on a go, no-go basis by slowly raising the test voltage to the required value of final test voltage and maintaining for required durat HV tester Grounding sheet AC High voltage Test FIGURE: 5-3 AC test set shall have adequate volt-ampere capacity to supply the required cable charging current. The KVA capacity of the test set shall be determined by the following KVA= 2πfCE2X10-3 C= Cable capacitance in μf/km f= Supply frequency E=Test voltage The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 37
  38. 38. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Form No: TP-CM01, MV Cable Up to 33kv Page 6 of 7 Date:13 Feb,09 Equipment : BEMCO 5.2.4.2 Riyadh Power plant # 10 “10621166/00” Revision: 0 DC High Voltage Testing The high voltage DC shall be applied to each individual cable of a 3-phase circuit. All cable conductors and shield not on test shall be grounded. High voltage DC test shall be as per IEC 60502 that is 4XU0 for 15 minutes. OR 1.7[.75(2 X equipment maximum voltage + 1kV)] for 15 Minutes (ARMCO) The test connections are as shown in figure 5-3. A DC high potential test (controlled over voltage test) is one in which the increase of applied direct voltage is controlled. The measured current is continuously observed for abnormalities with the intention of stopping the test before breakdown occurs The initially applied voltage shall not exceed 1.8 times the rated AC phase to phase voltage of the cable. After that the rate of increase of the test voltage shall be approximately uniform and shall not more than the maximum test voltage in 10 seconds or less than the maximum test voltage in 60 seconds. The maximum test voltage shall be maintained for 15 minutes, leakage current shall be recorded in TS-CMO2. No breakdown of the insulation shall occur. Maximum allowable leakage current for new cables shall be determined by the following IL=E/RX10-3 Amps Where IL= Leakage current in Amps E= DC test voltage in Kv R= Insulation resistance in MΩ OR 5.2.4.3 VLF High Voltage Testing VLF is used for the cable testing where power requirement for the test is high; VLF uses very low frequency (0.01 to 0.1 HZ) that’s why power requirement for the cable under test is less. Test voltage equal to 3U0 is applied through the test set as shown in figure 5.3. While test, all cable conductors and shield not on test shall be grounded. Test voltage is applied at the rate 1KV/second till the maximum test voltage is reached and maintain for 60 Minutes. Leakage current is recorded. The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 38
  39. 39. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Form No: TP-CM01, MV Cable Up to 33kv Page 7 of 7 Date:13 Feb,09 Equipment : Riyadh Power plant # 10 “10621166/00” BEMCO 5.2.5 Revision: 0 Insulation Resistance Test After High Voltage Test Insulation resistance test by mega ohmmeter at 5000VDC shall be performed for one minute on each cable, between the conductor and the metallic shield with the adjacent cable conductors and shield grounded after the high voltage test. Recommended Field Test Levels AC Testing Equipment Power Cable: Unshielded Shielded (including Cable Bus) DC Testing High-potential VLF @0.1HZ Rated Partial Discharge Test Test(PF) Voltage, Test Pulse Test Test kV Time, Extinction Time, Time, Time, Level, Magnitude, level, level, Min Level, kV Min Min Min kV pC kV kV 3XUo 4XU0 4.16 4.16 8 13.8 N/A 9(13) 13(18) 19(27) N/A 5 5 5 N/A 4.5(4.5) 7.5(7.5) 13(13) N/A 3(3) 3(3) 3(3) N/A 2 2 2 7.2 13.85 23.9 60 60 60 60 9.6 9.6 19 32 5 15 15 15 NOTES: 1. 2. 3. 4. 5. Factory tests are shown in brackets. The values recommended for field ac high-potential tests are at 75 percent of the factory levels, for switchgear assemblies 70 percent of factory levels. The values recommended for field dc high-potential testing of cable as per IEC-60502 is 4times U0 Where as Uo is U/1.732. The value recommended for field AC VLF testing is 3Uo for 60 minutes above values shall be used in case Vendor recommended values are not available otherwise 5.2.6 Checking the protective Earthing Check the earthing for the armour and shield is properly connected 6.0 Documents Test sheet TS-CM01 shall be completed. 7.0 References: 8.0 Attachment: 8.1 Test Sheet of Cable TS-CM01 *** End of the procedure *** The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 39
  40. 40. ent Clie Con nsultant Con ntractor : SEC-C COA : O : BEMCO Doc No.: PP1 c. 10-BS-SU-001 Riyadh Po R ower plant # 10 t “1062 21166/00” STARTU MANUA UP AL Date:13 D Feb,09 F Revision n: 0   TES SHEETS ST       Page 40
  41. 41. Customer Consultant Contractor : : : SEC-EOA Riyadh Power plant # 10 “10621166/00” BEMCO Form No: TS-CM01 Testing of Medium Voltage Cable Cable Tag No : Length : Type of cable: From Equipment: Page 1 of 3 Date:13/02/09,Revision: 0 Location : To equipment: ACTIVITIES/CHECKS (All activities are part of field commissioning) No 1. Confirms Remarks Technical data Manufacturer:............................................................................................... Size:......................................................................................... Rated voltage:.............................................................................................. 2. Visual check i. Check for Physical damage/Defects and also check for any irregular form of outer jackets caused by non-uniform shield wire distribution ii. Check for proper cable support, clamping and blocking etc iii. Verify Shields are grounded as specified iv. Check that phases are identified and colour coded 4. 4.1 Electrical test on Cable Cable Continuity and phasing test Phases Continuity Phasing Phase A Phase B Phase C 4.2 Cable Sheath Test. Phase R-G G-ohms Test Voltage--------------- KV DC Y-G B-G Test Voltage 4.3 Insulation Resistance Measurment. Before Hipot Test. Phase R-G+Y+B B-G+Y+R Insulation Resistance in MΩ Y-G+B+R Test Voltage Subcontract/Tested by Arabian BEMCO SEC-COA Name: Signature: Date: Page 41
  42. 42. Customer Consultant Contractor : : : SEC-EOA Riyadh Power plant # 10 “10621166/00” BEMCO Form No: TS-CM01 Testing of Medium Voltage Cable Cable Tag No : Length : No 4.4 4.5 Type of cable: From Equipment: ACTIVITIES/CHECKS (All activities are part of field commissioning) Page 2 of 3 Date:13/02/09,Revision: 0 Location : To equipment: Confirms Remarks AC High Pot test Hipot Test at ------------ KV AC for 60minute. VLF @ 0.1 HZ Phase R-Y+B+G Y-R+B+G B-R+Y+G Leakage current Test Voltage OR DC Hipot testing Hipot Test at ------------ KVDC for 15minute. Test voltage Leakage current /Time R-Y+B+G Y-R+B+G B-R+Y+G ----KV -----KV -----KV -----KV -----KV 15 Sec 30 sec 45 sec 1 minutes 2 minutes 3 minutes 4 minutes 5 minutes 6 minutes 7 minutes 8 minutes 9 minutes 10 minutes 11 minutes 12 minutes 13 minutes 14 minutes 15 minutes Subcontract/Tested by Arabian BEMCO SEC-COA Name: Signature: Date: Page 42
  43. 43. Customer Consultant Contractor : : : SEC-EOA Riyadh Power plant # 10 “10621166/00” BEMCO Form No: TS-CM01 Testing of Medium Voltage Cable Cable Tag No : Length : No 4.6 Type of cable: From Equipment: Page 3 of 3 Date:13/02/09,Revision: 0 Location : To equipment: ACTIVITIES/CHECKS (All activities are part of field commissioning) Insulation Resistance Measurment. After Hipot Test. Phase R-G+Y+B Insulation Resistance in MΩ B-G+Y+R Confirms Remarks Y-G+B+R Test Voltage 5 Remarks Test Equipment Model Cal due date Subcontract/Tested by Test Equipment Arabian BEMCO Model Cal due date SEC-COA Name: Signature: Date: Page 43
  44. 44. ent Clie Con nsultant Con ntractor : SEC-C COA : O : BEMCO Doc No.: PP1 c. 10-BS-SU-001 Riyadh Po R ower plant # 10 t “1062 21166/00” STARTU MANUA UP AL Date:13 D Feb,09 F Revision n: 0   TE ESTIN PRO DURE F NG OCED FOR L LOW VOLT TAGE CABL LE       Page 44
  45. 45. : Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Form No: TP-CM02, LV Cable Up to 1kv Page 1 of 4 Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 TABLE OF CONTENT 1. Task a. Work Status-----------------------------------------------------------------------------------------------------------------2 b. Documentation-------------------------------------------------------------------------------------------------------------2 c. Personnel--------------------------------------------------------------------------------------------------------------------2 d. Measuring Instrumentation----------------------------------------------------------------------------------------------2 2. 3. 4. 5. Preconditions--------------------------------------------------------------------------------------------------------------2 Precautions-----------------------------------------------------------------------------------------------------------------2 Scope-------------------------------------------------------------------------------------------------------------------------3 Execution--------------------------------------------------------------------------------------------------------------------3 a. Visual Inspection--------------------------------------------------------------------------------------------------------3 b. Testing of Motor 1. Cable Sheath Testing--------------------------------------------------------------------------------------------3 2. Conductor continuity and phasing test.----------------------------------------------------------------------3 3. Insulation Resistance test Before Hipot.--------------------------------------------------------------------4 4. High voltage AC test for XLPE cable.------------------------------------------------------------------------5 5. Insulation Resistance test After Hipot-----------------------------------------------------------------------7 6. 7. 8. Documents-----------------------------------------------------------------------------------------------------------------7 Reference-------------------------------------------------------------------------------------------------------------------7 Attachment-----------------------------------------------------------------------------------------------------------------7 The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 45
  46. 46. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Form No: TP-CM02, LV Cable Up to 1kv Page 2 of 4 Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 1.0 Task All newly installed power and control cable (1KV) in the electrical system requires field testing. 2.0 Preconditions 2.1 Work Status • Erection has been completed. • Labelling of the equipment is complete 2.2 Documentation • Test Sheet TS-CM01 2.3 Personnel • 1 Testing engineer: Engineer or technician with experience in high voltage testing of electrical equipment. • 1 Helper: skilled worker with adequate on-the-job training. 2.4 Measuring Instruments and Tools • Fluke • Insulation Tester 5KV 3.0 Precautions • The work will only proceed when a Permit to Work (PTW) in work permit area has been obtained. The PTW will be kept on site for consultation during the testing works. • Closing of the work permit after completion of the work (if the test area is to be considered in work permit area) is necessary. • The test site shall have sufficient protective barriers and warning signs to conduct the tests. • All cable section ends under test shall be grounded from accidental contact. Also the minimum separation from all ends or elements not being subject to test shall be 25.4mm/10kV of test voltage. • Before cable test operation started, conductor under test and all cable accessories shall be checked as being de-energized using reliable voltage indicator. The voltage indicator should be tested for proper operation with an independent voltage source prior to operation. • While the voltage indicator is still in contact with each component and is showing de-energized, a hot line grounded device for the purpose shall be continuously attached to all conductors under examination except while test equipment is ready for energization. • All adjacent conductors in cable circuit not on test should be de-energized and left grounded while testing the other conductor. The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 46
  47. 47. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Form No: TP-CM02, LV Cable Up to 1kv Page 3 of 4 Date:13 Feb,09 Equipment : Riyadh Power plant # 10 “10621166/00” BEMCO Revision: 0 4.0 Scope • Checking termination, • Checking shield • Checking of correct earthing, 5.0 Execution 5.1 Visual Checks • • • • Checking of the cables for any damage Inspection for termination. Inspection for correct tightness for connection Checking labels 5.2 Testing of Cable Enter the rating plate data in check list TS-CM01. The following test shall be carried out 1. 2. 5.2.1 Conductor continuity and phasing test. Insulation Resistance test Before Hipot. Conductor Continuity and Phasing Test To ensure the continuity and phasing of the cable conductor from terminal to terminal, the cable conductor shall be tested by using a 500VDC meeger or a fluke as per figure below; tests results shall be noted down. M Conductor continuity test M Phase verification FIGURE-5-1 The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 47
  48. 48. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Form No: TP-CM02, LV Cable Up to 1kv Page 4 of 4 Date:13 Feb,09 Equipment : Riyadh Power plant # 10 “10621166/00” BEMCO 5.2.2 Revision: 0 Insulation Resistance test Insulation resistance test by mega ohmmeter at 500VDC shall be performed for one minute on each cable, between the conductor and the metallic shield with the adjacent cable conductors and shield grounded as per figure below. M Grounding sheet Insulation Resistance Test FIGURE: 5-2 Minimum insulation resistance of conductor for new cables shall be determined by the following. 5.2.3 Checking the protective Earthing Check the earthing for the armour and shield is properly connected 6.0 Documents Test sheet TS-CM02 shall be completed. 7.0 References: 8.0 Attachment: 8.1 Test Sheet of Cable TS-CM02 *** End of the procedure *** The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 48
  49. 49. ent Clie Con nsultant Con ntractor : SEC-C COA : O : BEMCO Doc No.: PP1 c. 10-BS-SU-001 Riyadh Po R ower plant # 10 t “1062 21166/00” STARTU MANUA UP AL Date:13 D Feb,09 F Revision n: 0   TES SHEETS ST       Page 49
  50. 50. Customer Consultant Contractor : : : SEC-EOA Riyadh Power plant # 10 “10621166/00” BEMCO Form No: TS-CM02 Testing of Low Voltage Cable Cable Tag No : Length : Type of cable: From Equipment: Page 1 of 1 Date:13/02/09,Revision: 0 Location : To equipment: ACTIVITIES/CHECKS (All activities are part of field commissioning) No 1. Confirms Remarks Technical data Manufacturer:............................................................................................... Size:......................................................................................... Rated voltage:.............................................................................................. 2. Visual check i. Check for Physical damage/Defects and also check for any irregular form of outer jackets caused by non-uniform shield wire distribution ii. Check for proper cable support, clamping and blocking etc iii. Verify Shields are grounded as specified iv. Check that phases are identified and colour coded 4. 4.1 Electrical test on Cable Cable Continuity and phasing test Phases Continuity Phasing Phase A Phase B Phase C 4.2 Insulation Resistance Measurment. Phase Insulation Resistance in MΩ R-G+Y+B B-G+Y+R Y-G+B+R Test Voltage Test Equipment Model Cal due date Subcontract/Tested by Test Equipment Arabian BEMCO Model Cal due date SEC-COA Name: Signature: Date: Page 50
  51. 51. ent Clie Con nsultant Con ntractor : SEC-C COA : O : BEMCO Doc No.: PP1 c. 10-BS-SU-001 Riyadh Po R ower plant # 10 t “1062 21166/00” STARTU MANUA UP AL Date:13 D Feb,09 F Revision n: 0   TEST TING PROCE RE FOR AUX P EDUR R XILIARY Y TRA ANSFO ORMER R       Page 51
  52. 52. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Doc. No: TP-AT01, Auxiliary Transformer(<10MVA) Page 1 of 8 Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 TABLE OF CONTENT 1. Task a. Work Status----------------------------------------------------------------------------------------------------------2 b. Documentation------------------------------------------------------------------------------------------------------2 c. Personnel-------------------------------------------------------------------------------------------------------------2 d. Measuring Instrumentation---------------------------------------------------------------------------------------2 2. 3. 4. 5. Preconditions-----------------------------------------------------------------------------------------------------------2 Precautions--------------------------------------------------------------------------------------------------------------2 Scope----------------------------------------------------------------------------------------------------------------------3 Execution-----------------------------------------------------------------------------------------------------------------3 a. Visual Checks------------------------------------------------------------------------------------------------------3 b. Testing of Transformer 1. insulation resistance / Polarization index test----------------------------------------------------------3 2. Voltage Ratio Measurement--------------------------------------------------------------------------------4 3. Vector Group/Phase Displacement-----------------------------------------------------------------------4 4. Winding Resistance Test------------------------------------------------------------------------------------5 5. Excitation current Measurement---------------------------------------------------------------------------6 6. Temperature indicator and sensor Calibration--------------------------------------------------------7 7. Bushing Current Transformer------------------------------------------------------------------------------7 8. Testing and commissioning of cooler control cabinet------------------------------------------------7 9. Transformer protection devices functional check-----------------------------------------------------7 10. Protective Earthing Checks---------------------------------------------------------------------------------7 6. 7. 8. Documents---------------------------------------------------------------------------------------------------------------8 Reference-----------------------------------------------------------------------------------------------------------------8 Attachment---------------------------------------------------------------------------------------------------------------8 The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 52
  53. 53. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Doc. No: TP-AT01, Auxiliary Transformer(<10MVA) Page 2 of 8 Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 1. Task This instruction comprises a complete description of the testing of oil and dry type distribution or auxiliary transformers. 2. Preconditions 2.1. Work status • Erection has been completed. • Labelling of the equipment and designation of live enclosed plant sections has been carried out. 2.2. Documentation • The circuit diagram of Electrical equipment ,cabinets, etc are available • Test Sheet TS-AT01 is available • Product manual of the transformer is Available • Factory Test Results of the transformer is available 2.3. personnel • Commissioning engineer: - (1) engineer with experience in commissioning of transformer and switch gear. • Technician or helper:- (2) skilled worker with adequate on -the-job training • Witness from the client‘s concern department 2.4. Measuring instrument • Ratio meter (calibrated)---1 • Multi Meter (calibrated)—2 • Insulation resistance meter –megger(calibrated)—1 • CT tester-CPC100( calibrated)-1 • DC shunt 100 amps( calibrated)--1 • Mini clamp(calibrated)—2 • Tan delta measurement test equipment—1 • Current injection set(calibrated)—1 • 3 phase relay tester(calibrated)—1 3. Precautions The work will only proceed when a Permit to Work (PTW) in work permit area has been obtained. The PTW will be kept on site for consultation during the testing works. • Observe the rules for handling electronic components sensitive to electrostatic discharge (ESD measures). • Special safety arrangements shall be made for all areas which are not explicitly designated as” electrical operating areas” when performing tests at voltages in excess of 50V. • Closing of the work permit after completion of the work (if the test area is to be considered in work permit area) is necessary. • Before test voltages are applied a check shall be carried out to ensure that no unauthorized persons are working at the corresponding load-where ever necessary barriers should be provided. The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 53
  54. 54. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Doc. No: TP-AT01, Auxiliary Transformer(<10MVA) Page 3 of 8 Date:13 Feb,09 Equipment : 4. BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 Scope • Testing of Transformer • Checking Auxiliaries and cooling system • Checking that the mounting position is correct, • Testing of bushing CT • Checking of correct Earthing, 5. Execution 5.1. Visual Inspection. Prior to carrying out electrical tests, a visual check of the transformer should be carried out paying particular attention to the following points • Correct labeling of devices and cables • Equipment and cables are undamaged • Correct execution of the cable gland/sealing end • Name plate data, match with drawing and ambient condition • Firm cable termination/terminal connection and ferruling 5.2. Testing of Transformer Following tests to be carried out 1. insulation resistance / Polarization index test 2. Voltage Ratio Measurement 3. Vector Group/Phase Displacement 4. Winding Resistance Test 5. Excitation current Mesurment 6. Temperature indicator and sensor Caliberation a. Winding Temperature b. Oil Temperature 7. Bushing Current Transformer 8. Testing and commissioning of cooler control cabinet 9. Transformer protection devices functional check 10. Protective Earthing Checks 5.2.1. Insulation resistance/polarization index test Checking of the insulation resistance and polarization index should be carried out as under Apply the test voltage on following Connection and note down the readings Two Winding Transformers HV – LV + Earth LV – HV + Earth The insulation resistance Measurement is done from 15 seconds to 1 minute with 15 seconds interval and then for every minute up to ten minutes. Value obtained at 10 minute divided by value at 1 minute gives polarization index Please refer below for connection and test arrangement The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 54
  55. 55. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Doc. No: TP-AT01, Auxiliary Transformer(<10MVA) Page 4 of 8 Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 5.2.2. Voltage Ratio Measurement The voltage ratio measurement for two or three winding power transformer can be done either by conventional method by using Voltmeters or by using Turns ratio Meter The test shall be done for each and every phase at all tap position as follows. For Two winding Transformer • Apply 3 phase Voltage more then 220V on HV Winding and measured the corresponding voltages at the LV winding • Note down both HV and LV winding side voltages on all the three phases and all tap positions. 5.2.3. Vector group check The vector group or phase relationship can be checked by injecting three phase supply and measuring the voltages as per the figure below. One of the phase say 1U and 2U between HV and LV should be shorted together and three phase low voltage is applied on HV terminals. Then the voltage between various pairs of line terminal should be measured and compared The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 55
  56. 56. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Doc. No: TP-AT01, Auxiliary Transformer(<10MVA) Page 5 of 8 Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 Example: condition for Dyn11 is, the voltage between 1W-2V> 1W-2W=1V-2W=1V-2V 5.2.4. Winding Resistance Measurement The Winding resistance measurement can be done by either conventional method using 2V DC battery with voltmeter and Ammeter or by Transformer resistance meter. The winding resistance will be measured by a drop of potential method on all windings by injecting direct current through the phase winding as shown below. The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 56
  57. 57. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Doc. No: TP-AT01, Auxiliary Transformer(<10MVA) Page 6 of 8 Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 For the Y connected transformer the measurement should be made between each line bushing and single phase value is half of the measured value. For the delta connection, the measurement should be made between each pair of bushing and then single phase value is three half of the measured value. The measured values should be compared with factory value, for that, a conversion for the temperature correction should be done by following formula. R75 = Ra x 234.5+75 234.5+Ra Where as R75 = Corrected Resitance in ohms Ra = Measured Resistance at ambient temperature in ohms Ta = Ambient temperature in 0 C 5.2.5. Magnetization Current Measurement. The test connection is done as shown in the following drawing. Apply 200 V to the transformer HV terminals and measure the current and corresponding voltage for all the tap position. The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 57
  58. 58. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Doc. No: TP-AT01, Auxiliary Transformer(<10MVA) Page 7 of 8 Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 5.2.6. Oil Testing Oil sample should be taken from bottom, top of the main tank, OLTC chamber and also from the conservator tank, De-electric test for the oil should be performed as per IEC 156 using deelectric test machine 5.2.7. Temperature indicator and sensor. 5.2.7.1. Oil Temperature The oil and winding temperature indicators shall be calibrated by heat sink with thermometer. 5.2.7.2. Winding Temperature The winding temperature indicator shall be checked by current injection at the heater element. 5.2.8. Bushing current transformer Following tests should be done on all the bushing transformers • Ratio test • Magnetization curve • Polarity test • Insulation test • Winding resistance test • Loop resistance test All the test results shall be entered in the test form No.TS-CT01of the transformer. Refer TP-CT01 for the test procedure 5.2.9. Testing and commissioning of cooler control cabinet Prior to power up cooler control cabinet with auxiliary 3 phase/single phase/dc voltage, following check up shall be carried out. Winding insulation resistance and winding resistance for the fan motors should be carried out. Insulation resistance test for the control circuit should be carried out. After obtaining all the results and found satisfactory auxiliary power can be switched on and voltage/phase sequence measurement should be carried out. Manual/auto operation of the fans should be checked Heater and lighting circuit should be checked and made functional. 5.2.10. Transformer protection devices functional check Trip and alarm should be simulated from buchholz relay. tripping of protection relay and breakers should be observed, alarms on local and remote annunciation shall be observed Trip and alarm should be simulated from pressure relay. tripping of protection relay and breakers should be observed, alarms on local and remote annunciation shall be observed The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 58
  59. 59. Client Consultant Contractor : : : SEC-COA Subject : Testing procedure Doc. No: TP-AT01, Auxiliary Transformer(<10MVA) Page 8 of 8 Date:13 Feb,09 Equipment : BEMCO Riyadh Power plant # 10 “10621166/00” Revision: 0 Trip and alarm should be simulated from pressure relief relay. tripping of protection relay and breakers should be observed, alarms on local and remote annunciation shall be observed Trip and alarm should be simulated from oil and winding temperature indicator. tripping of protection relay and breakers should be observed, alarms on local and remote annunciation shall be observed Results for above tests shall be entered in the test form No.TS-AT01 of the power transformer. 5.2.11. Protective Earthing Check Transformer protective earthing bond must be earthed in order to afford protection to human beings. 6. Documents Test sheet TS-AT01 shall be completed. 7. References 8. Attachment 8.1. Test Sheet for oil filled transformer 13.8/4.16KV: TS-AT01A 8.2. Test Sheet for oil filled transformer 13.8/0.480KV: TS-AT01B 8.3. Test Sheet for oil filled transformer 4.16/48KV: TS-AT01C 8.4. Test for Dry Type transformer: TS-AT01/D ***End of the procedure*** The above contents may not be reproduced, transmitted, or distributed to any form or by any means with out prior permission of the originator Originator: BEMCO Services Prepared by :M AH Page 59
  60. 60. ent Clie Con nsultant Con ntractor : SEC-C COA : O : BEMCO Doc No.: PP1 c. 10-BS-SU-001 Riyadh Po R ower plant # 10 t “1062 21166/00” STARTU MANUA UP AL Date:13 D Feb,09 F Revision n: 0   TES SHEETS ST       Page 60
  61. 61. Riyadh Power Plant # 10 10721026/00' Client : SEC-COA Contradtor: BEMCO " Auxilairy TransformerTest 13.8/4.16kv Form No: TS-AT01A EQUIPMENT LOCATION TRNASFORMER NAME TAG No. FED FROM (BREAKER N FEEDING TO (BREAKER NO.) UNIT NO (BELONGS TO) VENDOR DRAWING NO. SYSTEM NO. SINGLE LINE DIAGRAM NO. EQUIPMENT NAMEPLATE DATA MANUFACTURER: TYPE: MODEL: STYLE: SERIAL NO.: INS. CLASS: FREQUENCY: AMB. TEMP.: 60 HZ 55 RATINGS KVA: NO. OF TAPS HV BIL LV BIL 5 50KV VECTOR GROUP: Dyn11 28 KV TYPE OF TAP CHANGER: TYPE OF COOLING: % IMPEDENCE SHORT CKT CURRENT TEMP RISE OF OIL TEMP. RISE OF WINDINGOIL TYPE: 45 NYNAS NYTRO 10GBN 50 HIGH VOLTAGE SIDE VOLTAGE: TAP #1:14490 TAP #2 :14145 LOW VOLT SIDE VOLTAG TAP #3 :13800 TAP #4 :13455 TAP #5: 13110 LOW VOLT SIDE CURRE HIGH VOLTAGE SIDE CURRENT: TAP #1: TAP #2 : TAP #3 : TAP #4: TAP #5: STARTUP DATA A. TRANSFORMER RATIO TEST (TTR) PHASE A WINDING TAP VOLTS 14490.00 14145.00 13800.00 13455.00 13110.00 TAP #1 TAP #2 TAP #3 TAP #4 TAP #5 ACT.RATIO MR PHASE B %ERROR MR PHASE C %ERROR 6.03 MR %ERROR 5.89 5.75 5.60 5.46 B. VECTOR GROUP TEST(CHECK OF VOLTAGE RELATIONSHIP) VOLTAGE APPLIED PHASE H1 X1 VOLTAGE MEASUR PHASE VOLTAGE H1-H2 VOLTAGE X2 H3-X3 H2-H3 H3-X2 H3-H1 X3 H2-X3 H3 H2 H2-X2 CONDITION FOR DYN11 H3-X2>H3-X3=H2-X3=H2-X2 C. MEASURMENT OF WINDING RESISTANCE : PRIMARY WINDING @ TAP 3 PHASE VOLTAGE CURRENT RESISTANCE IN OHMS CURRENT RESISTANCE IN OHMS H1-H2 H2-H3 H3-H1 SECONDARY WINDING : PHASE VOLTAGE X1-X0 X2-X0 X3-X0 TS-AT01A13.8-4.16 Page 61
  62. 62. Client : SEC-COA Riyadh Power Plant # 10 10721026/00' Contradtor: BEMCO Auxilairy TransformerTest " Form No: TS-AT01A D. MAGNETISING CUURENT MEASURMENT : VOLTAGE TAP POSITION MAGNETISATION CURRENT IN MILLI AMPS FREQ PHASE A PHASE B PHASE C TAP-1 TAP-2 TAP-3 TAP-4 TAP-5 D. INSULATION RESISTANCE TEST LV -- GND+HV HV ---GND+ LV HV -- LV TEST VOLT OHMS G TEST VOLT OHMS G TEST VOLT OHMS G 2500V 5000V 5000V E.OIL DIELECTRIC TEST. BREAK DOWN VOLTAGE TEST NO. 1 2 3 4 5 6 AVERAGE F. TRANSFORMER PROTECTIVE DEVICES FUNCTIONAL TEST 1) WINDING TEMPERATURE INDICATOR ALARM TRIP FAN OPERATION TRIP FAN OPERATION SET VALUE OPERATED VALUE 2) OIL TEMPERATURE INDICATOR ALARM SET VALUE OPERATED VALUE 2) BUCCHOLZ RELAY TRIP CONTACTS 3) OK ALARM COTACTS OK RAPID RISE RELAY TRIP CONTACTS OK ALARM CONTACTS OK TEST EQUIPMENT USED MODEL CAL.DUE TEST EQUIPMENT USED MODEL CAL.DUE DTR MULTI METER FLUK MEGGER SIGNATURE NAME COMPANY DATE TEST PERFORMED BY: WITNESSED BY: WITNESSED BY: TS-AT01A13.8-4.16 Page 62
  63. 63. Client : SEC-COA Contradtor: BEMCO Riyadh Power Plant # 10 10721026/00' " Auxilairy TransformerTest Form No: TS-AT01A G.CALIBERATION OF WINDING AND OIL TEMPERATURE GAUGE OIL TEMPERATUE GAUGE THERMO METER WINDING TEMPERATURE GAUGE GAUGE THERMO METER GAUGE 400C 500C 600C 700C 800C 900C 1000C 1100C H.CALIBERATION OF WINDING GAUGE BY CURRENT INJECTION WINDIN TEMPERATURE CT RATIO INJECTION CURRENT = TIME IN MINUTES OIL TEMP GAUGE WIND TEMP GAUGE DIFF IN TEMP 0 5 10 15 20 25 30 35 40 45 TEST EQUIPMENT USED MODEL CAL.DUE TEST EQUIPMENT USED MODEL CAL.DUE DTR MULTI METER FLUK MEGGER SIGNATURE NAME COMPANY DATE TEST PERFORMED BY: WITNESSED BY: WITNESSED BY: TS-AT01A13.8-4.16 Page 63
  64. 64. Riyadh Power Plant # 10 10721026/00' Client : SEC-COA Contradtor: BEMCO " Auxilairy TransformerTest 13.8/.48kv Form No: TS-AT01B EQUIPMENT LOCATION TRNASFORMER NAME TAG No. FED FROM (BREAKER N FEEDING TO (BREAKER NO.) UNIT NO (BELONGS TO) VENDOR DRAWING NO. SYSTEM NO. SINGLE LINE DIAGRAM NO. EQUIPMENT NAMEPLATE DATA MANUFACTURER: TYPE: MODEL: STYLE: SERIAL NO.: INS. CLASS: FREQUENCY: AMB. TEMP.: 60 HZ 55 RATINGS KVA: NO. OF TAPS HV BIL LV BIL 5 50KV 28 KV TYPE OF TAP CHANGER: TYPE OF COOLING: OFF LOAD VECTOR GROUP: Dyn11 % IMPEDENCE SHORT CKT CURRENT 9.36 TEMP RISE OF OIL TEMP. RISE OF WINDINGOIL TYPE: ONAN 45 NYNAS NYTRO 10GBN 50 HIGH VOLTAGE SIDE VOLTAGE: TAP #1:14490 TAP #2 :14145 LOW VOLT SIDE VOLTAG TAP #3 :13800 TAP #4 :13455 TAP #5: 13110 LOW VOLT SIDE CURRE HIGH VOLTAGE SIDE CURRENT: TAP #1: TAP #2 : TAP #3 : TAP #4: TAP #5: STARTUP DATA A. TRANSFORMER RATIO TEST (TTR) PHASE A WINDING TAP VOLTS 14490.00 14145.00 13800.00 13455.00 13110.00 TAP #1 TAP #2 TAP #3 TAP #4 TAP #5 ACT.RATIO MR PHASE B %ERROR MR PHASE C %ERROR 52.28 MR %ERROR 51.04 49.80 48.55 47.31 B. VECTOR GROUP TEST(CHECK OF VOLTAGE RELATIONSHIP) VOLTAGE APPLIED PHASE H1 X1 VOLTAGE MEASUR PHASE VOLTAGE H1-H2 VOLTAGE X2 H3-X3 H2-H3 H3-X2 H3-H1 X3 H2-X3 H3 H2 H2-X2 CONDITION FOR DYN11 H3-X2>H3-X3=H2-X3=H2-X2 C. MEASURMENT OF WINDING RESISTANCE : PRIMARY WINDING @ TAP 3 PHASE VOLTAGE CURRENT RESISTANCE IN OHMS CURRENT RESISTANCE IN OHMS H1-H2 H2-H3 H3-H1 SECONDARY WINDING : PHASE VOLTAGE X1-X0 X2-X0 X3-X0 TS-AT01B13.8-480 Page 64

×