electrical

1

JOB PROCEDURE FOR INSTALLATION OF ELECTRICAL CABLE TRAYS AND SUPPORTS, CONDUITS

(PROCEDURE NO: 6724-700-50-50-JP-001 )

PROJECT : PROCUREMENT AND INSTALLATION OF ADDITIONAL BOIL OFF GAS (BOG) BOOSTER

COMPRESSOR, RATNAGIRI

CLIENT : M/s RATNAGIRI GAS AND POWER PRIVATE LIMITED

. (Promoters: M/S NTPC Limited & GAIL (INDIA) Limited)

CONSULTANT : M/s ENGINEERS INDIA LIMITED

CONTRACTOR : M/s SAVAIR ENERGY LIMITED

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

ORGANIZATION SEL SEL SEL EIL

SIGNATURE

NAME Ganesh K. Rakesh P. Milind D.

DATE

2

(PROCEDURE NUMBER: 6724-700-50-50-JP-001)

JOB PROCEDURE FOR INSTALLATION OF ELECTRICAL CABLE TRAYS AND SUPPORTS, CONDUITS

CONTENTS

1. Purpose-------------------------------------------------------------------------------------------3

2. Scope---------------------------------------------------------------------------------------------3

3. References---------------------------------------------------------------------------------------3

4. Definitions----------------------------------------------------------------------------------------3

5. Responsibilities----------------------------------------------------------------------------------3

6. Procedure----------------------------------------------------------------------------------------4

7. Health safety environment Points ------------------------------------------------------6

3

1. Purpose

The purpose of this procedure is to monitor and control of All the activities related to trays and support installation and conduit fixing for control cable laying

2. Scope

This procedure covers the responsibilities, Quality procedure & documentation to be adopted during installation of Electrical cable trays, support for cable trays and conduits laying for control cables as per approved drawings at Ratnagiri Additional Boil Off Gas Compressor related Electrical works.

3. Reference

EIL Project No- 6724

EIL Standards for Earthing No 6-51-0084 Rev.3

Electrical Cable tray routing drawing

Electrical Cable schedule

4. Definitions /Abbreviations

HSE : Health and safety environment

PPE : personal protection equipment

QA/QC : Quality Assurance/ Quality control

5. Responsibilities

5.1 Project manager shall be responsible for coordinating with Site manager and organizing the necessary meeting the project quality requirement

5.2 Site manger shall be responsible for the site management and conditions associated with modification of HV switch gear works

5.3 QC Engineer/Inspector shall be responsible for following

5.3.1 Ensuring that request for inspections are send to EIL in advance and inspections are held as approved .ITP ( Doc. No. 6724-700-50-50-JP-001)

5.3.2 Co-ordination between other discipline and project engineers and site engineers as necessary

5.3.3 Ensure that inspections are performed in co-ordination with EIL and recorded as per ITP

5.3.4 Ensure that all works is ready for inspection prior to requesting to EIL to carry out inspection at site

5.3.5 Perform/ensure that all inspections are performed in a timely manner and recorded and signed by involved parties as per specification, ITP and QCP requirement.

5.4 Project/Site Engineer E&I shall be responsible for following

Ensure that all work is carried out to the job specification and detail layout drawing and minimum disruption and interference to the existing facilities shall be responsible for all works are executed in order to meet the project specification and HSE requirement

4

Also responsible for co-ordination with vendor and allotment of required manpower and monitor the .progress and reported to site manger daily basis

5.5 HSE OFFICER shall be responsible for safety and health activities on the sites, application PPE fire and explosion protection activities work place inspection induction training toolbox talk and permit verification etc

6. Procedure

6.1 Material Control

The QC Engineer shall be carry out an inspection of the material when the material arrives in the ware house the Engineer shall ensure the material confirms to the project specifications, standards and purchase order

6.2 Quality control Activities

Upon receipt at the storage and handling area the material will be inspected for mechanical damage in presence concerned vendor any damage will immediately reported concerned parties

6.2.1

Procedure

Installation of cable tray supports

Prior to start any activity at site a valid permit shall obtained and followed all GAIL safety requirements for working in a live plants and Sub stations

Prior to shifting the fabricated structural support to the site Savair QC shall be ensure that all structural related material certificate and all fabrication , welding and painting inspection was completed and all the required documents to be signed

Ensure the required material for cable tray supports and accessories are fabricated as per approved drawing and EIL specification

Once Fabricated supports reach the site make sure that proper unloading and material shall be kept in a safe area ensure that no painting damage or bending should not happened

Supporting structures are sufficient to ensure deflection of the system does not exceed recommended values it

should be meet the load requirements of the cable trays and cables

Expansion joins are specified and are in place

Repairs to damage through cutting and fabrications have been made good in the approved manner there are no sharp edges throughout the run which could cause damage to the cables

Cable tray and cable tray accessories are including bulk mechanical fasteners and splice plate and end plates drop out plates barrier plates expansion joints clips clamps fitting and brackets as per approved drawings and typical installation drawings

Cable tray runs and bends are inspected to ensure that they are installed according to design and AFC drawings

The cable tray have minimum clearance from source of heat shall be as per EIL standard

Grounding of supports to be provided as per approved drawing

5

Sufficient space is provided around cable trays to permit adequate access for installation and maintenance of cables and spacing between control cable trays and HV cable trays shall be as per EIL standard installation practice

Support are secured and fixed at intervals such that bending or sagging does not occur

Prior to cable laying Cable tray inspection shall be completed records to be signed

Conduit installation shall be in accordance with AFC / layout drawing and As per EIL standard

Threaded joints and fittings are properly fixed and tightened and exposed threads shall be painted

Pull wires to be provided in side conduit

Conduit shall be properly earthed

Prior to pulling the cable Conduit installation shall be inspected as per approved ITP and records to be signed

7 Health Safety Environment Points

7.1 Hazards

Fall injuries due to working at height/trench

Personal injuries due to use of hand tools and machines

7.2 Control Measures

Strictly ensure that the entire activities of Modification works are carried out under consolidated permit to work system

Tool box talk shall be carried out to keep the team mates aware of job activity before starting any work identification all hazards including hidden one and control measures it

Emergency evacuation contingency plan shall be known to work performing crew members

Safety equipments, warning devices and sign boards shall be position at work site

All work performing personals shall be provided with PPE and ensure proper use of it and site shall be clean

7.3 Safety precautions

GAIL safety rules/regulations shall be followed

Prior start any work on live panel makes sure that proper earthing was done

Barricades and Warning Boards are provided during the testing times

INSPECTION & TEST PLAN FOR CABLE TRAY INSTALLATION

DOC. NO. : 6724-700-50-50-ITP-001

PROJECT : PROCUREMENT AND INSTALLATION OF ADDITIONAL BOIL OFF GAS (BOG) BOOSTER COMPRESSOR , RATNAGIRI

SR NO ACTIVITY SEL EIL

RECORDS TO BE SUBMITTED/ FORMAT NO

Remarks

1 Issue and control of AFC drawings and ensure that all the drawings and documents at site are AFC

W H Yes

2 Material receiving and storage W RW Yes

3 Ensure that conformity of cable route W RW Yes

4 Inspection of support system Inspection of joints, alignments, fixing bolts, cut sections touch up paint.

W RW Yes

5 Ensure that minimum distance between trays W RW Yes

6 Ensure that proper type bonding and jumpers W RW Yes

7 Ensure that all fixing bolts properly tightened W RW Yes

8 Earth continuity W S Yes

9 Bending radius of cable tray W RW Yes

INSPECTION & TEST DOCUMENTS

Completeness of inspection and test records WC RW Yes

Prepared by Checked by Reviewed By Approved by

SEL SEL SEL EIL

INSPECTION REPORT FOR CABLE TRAY INSTALLATION

FORMAT NO. : 6724-700-50-50-IR-001 REPORT NO. :


DRAWING REFERENCE : DATE OF INSPECTION :

CABLE TRAY DESCRIPTION : CABLE TARY LENGTH :

CABLE TRAY : FROM_________________________________________TO______________________________

SR.NO. DESCRIPTION OK NOT OK

1 BEFORE CABLE LAYING

1.1 Cable tray/ ladder installed according to approved layout drawing, as per EIL standard and spec

1.2 Cable tray/ladder is clean and free from damages, debris, rough edges or burrs

1.3 Cable bracket positions correct and secure as per drawings and standards

1.4 Tray routing is complete

1.5 Free space over tray .rack allows workable access

1.6 Field bends do not violate cable bending radius

1.7 All joints bonded with earth links if required

1.8 Earthing connected As per spec

2 AFTER CABLE LAYING

2.1 Check the cable tray loading

2.2 Check the cable bending radius and spacing

2.3 Check the proper type bonding and jumpers

2.4 Check minimum distance between trays

Remark:

SAVAIR CONSTRUCTION SAVAIR QC EIL

NAME

SIGN

DATE

1

JOB PROCEDURE FOR CABLE LAYING, JOINTING, GLANDING AND TERMINATION & TESTING OF MV/HV CABLES UP TO 11KV

(PROCEDURE NO: 6724-700-50-50-JP-002 )









SIGNATURE

NAME Ganesh K. Rakesh P. Milind D.

DATE

2


JOB PROCEDURE FOR CABLE LAYING, JOINTING, GLANDING AND TERMINATION & TESTING OF MV/HV CABLES UP TO 11KV

CONTENTS

1. Purpose-------------------------------------------------------------------------------------------3

2. Scope---------------------------------------------------------------------------------------------3

3. References---------------------------------------------------------------------------------------3

4. Definitions----------------------------------------------------------------------------------------3

5. Responsibilities----------------------------------------------------------------------------------3

6. Procedure----------------------------------------------------------------------------------------4

7. Health safety environment Points ------------------------------------------------------6

3

1. Purpose

The purpose of this procedure is to monitor and control of all the activities related to Cable laying, Glanding, termination and Cable jointing, Testing of cables

2. Scope

This procedure covers the responsibilities, Quality procedure & documentation to be adopted during laying of power and control cables. Glanding termination and Jointing testing of cables as per approved drawings at Ratnagiri Additional Boil Off Gas compressor related Electrical works

3. Reference

Electrical Cable tray routing drawing No

Electrical Cable Schedule No


GAIL : GAS AUTHORITY INDIA LIMITED

CONTRACTOR : Savair Energy LTD




5. Responsibilities

5.1 Project manager shall be responsible for co-coordinating with Site manager and organizing the necessary meeting the project quality requirement

5.2 Site manager shall be responsible for the site management and conditions associated with modification of HV switch gear works

5.3. QC Engineer/Inspector shall be responsible for following

Ensuring that request for inspections are send to EIL in advance and inspections are held as approved ITP (Doc. No.6724-700-50-50-ITP-002)

Co-ordination between other discipline and project engineers and site engineers as necessary

Ensure that inspections are performed in co-ordination with EIL and recorded as per ITP

Ensure that all works is ready for inspection prior to requesting to EIL to carry out inspection at site

Perform/ensure that all inspections are performed in a timely manner and recorded and signed by involved Parties as per specs, ITP, and QCP requirement


Ensure that all work is carried out to the job specification and detail layout drawing and minimum disruption and interference to the existing facilities shall be responsible for all works are executed in order to meet the project specification and HSE requirement Also responsible for co-ordination with vendor and allotment of required manpower and monitor the progress and Reported to site manger daily basis

4

5.5 HSE OFFICER shall be responsible for safety and health activities on the sites; application PPE fire and explosion protection activities work place inspection induction training toolbox talk and permit verification etc

6. Procedure

6.1. Material Control


Ensure that all required test certificate are send by manufacturer


1 Up on receipt at the storage and handling area the material will be inspected for mechanical damage if any damage will immediately reported concerned parties

2 A preliminary Insulation value test shall be done at Storage area and Ensure that there is no damage occurred during shipment

6.2.1 Laying of cables

Procedure

Work shall be started only after getting a valid permit and all personal should be wear minimum PPE

Concrete Trench and Pipe sleeves are placed and shall be inspected by EIL and a Clearance shall be obtained from concerned parties prior start cable laying.

The entire cable route, Trench, Cable trays, shall be inspected by EIL and clearance shall be obtained prior to start cable laying

Prior to pulling Drum schedule and cutting schedule prepared and verified

As per drum schedule Cable drum shall be shifted and cable drum shall be loaded on cable jack and ensure that drum shall be freely rotate and safe pulling

Inspect the position of rollers and bends are correctly placed ensure that no sharp edges are in tray an trenches

After the preparation cable pulled manually laid neatly and cable numbers marked as per approved cable schedule

Ensure that after cutting the cable ends are properly sealed and enough loop has been provided for jointing area and termination point

Allowable cable pulling tension shall be as per Manufacturer recommendations if using cable pulling wrench

After cable laying proper cable no marking shall be provides as per EIL specification

All single core cable shall be dressed trefoil formation and clamped As per EIL specification

Cable route markers shall be provided all underground areas

After completion of dressing cable an inspection shall be carried out with EIL and obtain clearance from EIL prior starting cable termination

5

6.2.2 Cable termination

Prior to commencing the termination of cables QC inspector shall ensure that all installation inspection are completed

Insulation resistance and continuity to be verified and ensure that cable numbers are correctly placed and terminations points as per approved schedule and termination schedule

Ensure that all cable glands are suitable for area of classification and make sure that cable OD shall be match with Gland size

Ensure that cable splicing shall be in line with gland manufactures recommendations

Only specified and correct type of compression/ crimping type cable lugs shall be used

Colour coding / core identification shall be provided

Ensure that Cable tag be provided below the cable Gland

Ensure that proper Gland earthing done

Ensure Suitable shroud/ whether proof arrangement shall be done As per EIL standard

Ensure that cable has been properly supported and clamped near glanding area

6.2.3 CABLE JOINTING

This item cover the installation of sealed jointing kits or splices installed below ground or above ground

Prior to installation the unit will be inspected to ensure that the body and port size are as specified and suitable for the cables to be joined

Space for joint area shall be verified and ensure proper bending radius spaces for cables

Ensure that Joint area shall be free from dust and moisture and proper whether protection shall be provided during jointing and setting time

Joint process shall be done by only Approved jointers and 100% QC witness shall be provided

Before closing the joint the assembly will be checked for the following

The cable cores are correctly phased, Connections are secure and insulated

The steel armour is clamped and earthed, Semi conductor material are properly fixed

Outer sheathing of cable within the joint, the whole assembly will be checked to ensure is tight and secure

Joints are to be filled the compound will be mixed and poured as per manufactures instructions

Heat shrink terminations

Prior applying sleeves the cable end will be inspected for the following

Cable tails are correct length, bound and taped, steel wire armour is cut back and bound with the earth connection fitted

Before shrinking the sleeve it will be checked to ensure cable cores are correctly aligned and sleeves extends over the outer sheath

Inspection report shall be recorded on form.

Testing of cables before and termination

6

All test equipment used for the testing of the cables shall be valued calibration certificate

All control cable shall be used 250V Megger before and after termination

All medium voltage cable shall be used 500 V Megger for 1minute test and values are recorded

All high voltage cable are used 5000V Megger for 1minute test before and after termination

All high voltage cable shall be subjected to a DC high voltage test shall be applied after completion jointing/ end terminations as per EIL / IS Specification.

Test steps

Prior to starting HV test area shall be Barricade and prevent un authorized entries

Test voltage shall be as per EIL specification

Test shall be applied each conductors to earth and remain conductor shall be connected earth

Ensure cable one end shall be earthed, and test equipment and controller shall be earthed

The initial voltage applied and allowed voltage to stabilize and corresponding leakage current will be recorded on test form

The applied voltage will be increase gradually in 10% steps and the voltage leakage current recorded each steps

The final test voltage will be applied for 15 minutes and the leakage current values are recorded and intervals also mentioned When each test completed cable potential shall be discharged using hot insulated sticks and gloves rated for the test voltage After discharging the cable shall be checked again for residual voltage potential and left grounded for several hours to assure complete discharge


7.1 Hazards













INSPECTION & TEST PLAN FOR CABLE LAYING AND TESTING

DOC.NO. : 6724-700-50-50-ITP-002




Remarks


W H Yes

2 Material receiving and storage W RW Yes

3 Ensure that conformity of cable route W RW Yes

4 Ensure that size of cable and type of cable as per project requirement W RW Yes

5 Ensure that single core cables are dressed in form of trefoil W RW Yes

6 Ensure that proper type and size of cable gland used W RW Yes

7 Ensure that Terminations are tight and proper lugs are used and proper tagging is done

W RW Yes

8 Insulation resistance & continuity test W RW Yes 9 HI Pot test W RW Yes


Completeness of inspection and test records WC RW Yes

Prepared by Reviewed by Checked By Approved by

SEL SEL SEL EIL

INSPECTION REPORT FOR CABLE LAYING

Format No. : 6724-700-50-50-IR-002 Report No. :


DRAWING REFERENCE / CABLE SCHEDULE : DATE OF INSPECTION :

CABLE SIZE : CABLE LENGTH :

CABLE : FROM_________________________________________TO______________________________

SR.NO. DESCRIPTION OK NOT OK

1 EnsurethatconformityofCabletroughs

2 Cablelayingaccordingtoapprovedlayoutdrawing,asperEILstandardandspecification.

3 Cableiscleanandfreefromdamages.

4 Freespaceovertray&rack,allowsworkableaccess

5 Fieldbendsdonotviolatecablebendingradius

6 Alljointsbondedwithearthlinksifrequired

7 EarthingconnectedAsperinstallationstandardspec

8 Checkthecablebendingradiusandspacing

9 Ensurethatsizeofcable&typeofcableasperprojectrequirement

10 EnsurethatSinglecorecablesaredressedinformoftrefoil

Remark:


NAME

SIGN

DATE

1

JOB PROCEDURE FOR EARTHING AND LIGHTNING PROTECTION WORKS

(PROCEDURE NO: 6724-700-50-50-JP-003 )









SIGNATURE

NAME GANESH K. RAKESH P. MILIND D.

DATE

2


JOB PROCEDURE FOR EARTHING AND LIGHTNING PROTECTION WORKS

CONTENTS

1. Purpose---------------------------------------------------------------------------------------------------3

2. Scope-----------------------------------------------------------------------------------------------------3

3. References-----------------------------------------------------------------------------------------------3

4. Definitions-----------------------------------------------------------------------------------------------3

5. Responsibilities-----------------------------------------------------------------------------------------3

6. Procedure-----------------------------------------------------------------------------------------------4

7. Installation Procedure---------------------------------------------------------------------------------4

8. Health safety environment Points -------------------------------------------------------------5

3

1. Purpose

The purpose of this procedure is to monitor and control of all activities related to Earthing and lightning works of Additional Boil Off Gas (BOG) Booster Compressor house and associated works

2. Scope

This Job procedure covers the responsibilities, Quality procedure & documentation to be adopted during installation and testing of Earthing and Lightning works as per approved documents

3. Reference

3.1.1 Earthing pit Installation Drawing

3.2.2 Equipment Earthing and lightning layout Drawing

3.2.3 EIL Project No : 6724

3.2.4.EIL Standards for Earthing : 6-51-0084 Rev.3

3.2.5 Earthing & Lighting Drawing





5. Responsibilities


5.2 Site manger shall be responsible for the site management and conditions associated with modification of Earthing and Lightening Protection works


5.3.1 Ensuring that request for inspections are send to EIL in advance and inspections are held as approved ITP ( Doc. No. 6724-700-50-50-ITP-003)

5.3.2 Co-ordination between other discipline and project engineers and site engineers as necessary Ensure that inspections are performed in co-ordination with EIL and recorded as per ITP

5.3.3. Ensure that all works is ready for inspection prior to requesting to EIL to carry out inspection at site

5.3.4 Perform/ensure that all inspections are performed in a timely manner and recorded and signed by involved Parties as per Specs, ITP, and QCP requirement


Ensure that all work is carried out to the job specification and detail layout drawing and minimum disruption and interference to the existing facilities

Shall be responsible for all works are executed in order to meet the project specification and HSE requirement

4

Also responsible for co-ordination with vendor and allotment of required manpower and monitor the progress and Reported to site manger daily basis


6. Procedure


The QC Engineer of SEL shall be carry out an inspection of the material and also co-ordinate with third party inspectors to carry out inspection of materials when the material arrives at manufactures factory or the ware house the Engineer shall ensure the material confirms to the project specifications, standards and purchase order


6.2.1 Up on receipt at the storage and handling area the material will be inspected for any mechanical damage in presence concerned vendor any damage will immediately reported concerned parties

7. Installation Procedures

Prior to start any installation work site supervisor and site engineer shall be ensure all related activities are carried out as per GAIL permit to work system and Electrical safety rules and operational procedures

Installation of Earthing and Lightening system shall be as per EIL Standard

Layout and excavation shall be checked as per AFC drawing and Confirm location and dimensions of Earth pit

Earth main conductor size and Earth plate size shall be confirmed as per AFC drawings

Ensure that required quantity charcoal and salt to be put in to the pit prior to installing Earth main conductor plate

Ensure that the Main Earth conductor securely connected to the earth plate through bolting arrangement and type of bolt and size to be confirmed

Make sure that Earth conductor supporting pipe shall be supported to main conductor and ensure that gap of between earth plate and pipe

Ensure that salt and charcoal properly filled stage by stage during back filling of pit

Ensure that the connection arrangement individual pit shall be in a such a way that disconnection of one pit does not disconnect other pits from Earthing net work

The connection between the main conductor from earth pit and Branch connection shall be in a such way that each individual pit conductor shall be tested and measured resistance value without disconnecting other connections each other

Proper Identification & Cover use in Earthing Chamber.

7.1

Earthing of Electrical Equipment and plant equipments

All equipment mounted on a skid electrically isolated from a structure e g on a rubber/or anti vibration mountings, shall be bonded to earthing network by means of an earthing conductor connection as per relevant standards.

5

In switch boards, MCCs, Control panels etc, all sections of metal enclosures including cable boxes gland plates etc shall be bonder to earth bar

Equipment earth bar shall be connected to the main earth bar

The location of Earth bus bar /Marshalling points will be checked against the lay out drawings and located as per detailed drawings

The armour of single cables be earthed at one end only to avoid induced circulating currents

The multi core power cable armour shall be earthed at both points of cables

All metallic glands on each enclosure shall be connected to the earthing system

7.2 Lightening protection

The installation will be checked against the lay out drawing and installation details

Air terminals will be checked to ensure they are as specified assembled as per the detailed drawing correctly located and securely fixed

Earth tapes and down conductors are shall be checked against EIL specification installed as per EIL standard installation practice and securely clipped. Cross jointing, Disconnecting Plates, clamping and bonding will be inspected for tightness and electrically continuity.

Test clamps will be inspected to ensure that they are securely fixed as per installation standards and disconnect facilities are operational

Ensure that all Lightning protection down conductors are connected assigned lightning protection Earth pits only

Bonding of associated metal structures will be checked against Approved drawings

Grid on Compressor shade shall be as per drawings.

7.3 Testing

The earth electrode resistance will be checked by fall of potential method or as per EIL Standard practice / IS 3043.

The Value each individual Earth pit Electrode will recorded separately and compared with EIL standard value

The total grid value be measured and recorded compare with EIL standard

For instrument earth pit Individual pit value and combined grid value will recorded separately and compare with EIL Standard Value

The All the Test will be conducted and Recorded in presence of Approved Electrical Supervisor and EIL representative only


8.1 Hazards

Electric Shock due to Electrical power may cause to injures to personal


Personal injuries due to use of hand tools and machine


6

Strictly ensure that the entire activities of earthing are carried out under consolidated permit to work system









INSPECTION & TEST PLAN FOR INSTALLATION AND TESTING OF EARTHING & LIGHTINING PROTECTION

DOC. NO. : 6724-700-50-50-ITP-003




Remarks


WC H Yes

2 Material receiving and storage WC RW Yes

3 Ensure Lay out excavation depth and dimensions are as per AFC drawing WC RW Yes

4 Ensure that Installation and size of conductor and connection of conductors per AFC DWG

WC RW Yes

5 Ensure that Grid conductors are connected WC RW Yes

6 Ensure that charcoal and salt are sufficient quantity used filled properly WC S Yes

7 Ensure that Terminations are tight and proper lugs / Bolt are used and proper tagging is done.

WC RW Yes

8 Earth resistance & continuity test WC S Yes

9 Ring loop resistance WC S Yes

10 Lighting protection system check WC RW Yes

INSPECTION & TEST DOCUMENTS Completeness of inspection and test records WC RW Yes

Prepared by Checked by Reviewed By Approved by

SEL SEL SEL EIL

INSPECTION REPORT FOR EARTH RESISTANCE MEASUREMENT OF EARTH PIT

FORMAT NO. : 6724-700-50-50-IR-003 REPORT NO.


DRAWING REFERENCE :

DATE OF INSPECTION :

SR.NO DESCRIPTION OK NOT OK

1 GENERAL

2 Location against layout drawing

3 Earth pit and connection facilities are installed

4 Earth network disconnected for testing purpose

5 Continuity between the connection point and adjacent pit and grid

6 Network completed after completing the resistance measurement

7 Earth plates properly connected to Earth conductor

8 Charcoal and salt powders are properly installed As per standard

EARTH RESISTANCE MEASUREMENT

Sr. No. Earth Pit Reference No. Individual (ohm) Grid(ohm)

1 EPLT 1

2 EPLT 2

-- -----

-- ------

-- -----

Equipment Used :


NAME

SIGN

DATE

1

JOB PROCEDURE FOR MODIFICATION WORKS OF HV SWITCH GEAR

(PROCEDURE NO: 6724-700-50-50-JP-004 )









SIGNATURE


DATE

2

(PROCEDURE NUMBER :6724-700-50-50-JP-004)

JOB PROCEDURE FOR MODIFICATION WORKS OF HV SWITCH GEAR

CONTENTS

1. Purpose---------------------------------------------------------------------------------------------------3

2. Scope-----------------------------------------------------------------------------------------------------3

3. References-----------------------------------------------------------------------------------------------3

4. Definitions-----------------------------------------------------------------------------------------------3


6. Procedure-----------------------------------------------------------------------------------------------4


3

1. Purpose

The purpose of this procedure is to monitor and control of all activities related to Modification works HV switch gear.

2. Scope

This procedure covers the responsibilities, Quality procedure & documentation to be adopted during Modification works HV switch gear works as per approved documents.

3. Reference

EIL Project No - 6724

HV Switch Gear Schematic drawing

HV switch gear panel single line diagram





5. Responsibilities




5.3.1 Ensuring that request for inspections are send to EIL in advance and inspections are held as approved ITP (Doc. No.6724-700-50-50-ITP-004)




5.3.5 Perform/ensure that all inspections are performed in a timely manner and recorded and signed by involved parties as per specs, ITP, and QCP requirement



4


Also responsible for co-ordination with vendor and allotment of required manpower and monitor the progress and reported to site manger daily basis

5.5 HSE OFFICER shall be responsible for safety and health activities on the sites; application PPE fire and explosion protection activities work place inspection induction training toolbox talk and permit verification etc

6. Procedure




Up on receipt at the storage and handling area the material will be inspected for mechanical damage in presence concerned vendor any damage will immediately reported concerned parties

6.3 HV switch gear modification

Prior to start any activity at site a valid permit shall obtained and followed all GAIL safety requirements for working in HV panel

Ensure that panel tag no confirmed and lock out and tagging procedure to be applied in presence GAIL Maintenance personal

Ensure that panel Auxiliary supply and DC supply of particular compartment shall be switched off

Prior to start any Modification works Panel earthing to be done and Earth continuity to be verified and verified compartment cleanness and connection

Remove the existing Busbar connections and fix new Bus connections as per approved vendor drawings in presence of Panel Vendor

CT installations will be done by vendor representative under supervisor form SEL as per GA drawing.

Inner panel wiring and CT wiring shall be done as per approved Schematic Drawing

The complete assembly will inspected to ensure that all connections are made as per drawing and confirms the tightness of bolt and connection

Doors and panels will be checked and ensure the proper opening and closing

Fuse ratings, protection devices. Indicators and Ammeters will be checked against panel schedule and current transformer ratings ratios are confirmed

Bus bar joints are inspected and torqued and physical verification of colour code and phasing

The clearness between phase to phase and phase to be verified & contact resistance to be taken.

Earth bonding between panels and Earth bar verified and confirmed

After completion of Modification works all mechanical checks of breaker shall be done in presence of GAIL/EIL person and Vendor

Current transformer details are verified and tested

5

All measuring instruments and protective relays are tested as per panel schedule Relay setting value to be added in presence of vendor and EIL/GAIL personal.

Insulation resistance of panel and bus bars and control wring to be checked

Up on completion of tests and settings of the relays a final physical and Megger checks to be carried out prior to switch gear cleared for energization


7.1 Hazards

Electric Shock due to Electrical power may cause to injures to personal













INSPECTION & TEST PLAN FOR HV SWITCH GEAR MODIFICATION

DOC.NO. 6724-700-50-50-ITP-004




Remarks


W HP Yes

2

Material receiving and storage Ensure that materials are received confirms spec and AFC drawings Ensure that materials are stored as per manufacturers instructions

W RW Yes

3 Check the dimensions and size of components is matching with existing system

W RW Yes

4 Ensure that switch gear compartment doors are opening, identification and warnings labels as per approved DWG

W RW Yes

5 Check the compartment interconnection bolting ,auxiliary and control circuit wiring connection

W RW Yes

6

Check the bus bar modification are done as per approved DWG and Spec and verify clearance between Phase to phase and Earth and Ensure that minimum distance clearance

W RW Yes

7 Ensure that all busbar connection bolting tightened and torque and torque value to be verified

W RW Yes

8 Bus bar Insulation resistance & continuity test, AC Hipot test As required W S Yes

Page 1 of 2



Remarks

9 Check the earth connection and measure the earth resistance at earth bus connection are potentially bonded to main earth net work

W S YES

10 Check the feeder cubicles for detail of fuses switches breaker auxiliary relays contactor CTs, their operation

W RW YES

11 Check current transformer details installations test ratio ,polarity burden and accuracy class

W RW YES

12 Check all measuring instruments such as Ammeter. Voltmeter etc for correct details and test for correct functioning

W RW YES

13 Perform secondary injection test and set up each relay check relay response at least 5 current values of relay characteristics

W S YES

14 Check for relays details type feature code and feature code required CTs auxiliary supplies etc

W RW YES

15 Perform insulation & continuity test power and control circuits W S YES

16 Perform primary injection test and as applicable and check relays and metering instruments

W S YES

17 Cable insulation resistance test W S YES

18 Incoming & Outgoing side Cable Spare Plugging W RW YES


Completeness of inspection and test records WC RW Yes Page 2 of 2


SEL SEL SEL EIL

1

JOB PROCEDURE FOR INSTALLATION AND TESTING OF MV/HV MOTORS

(PROCEDURE NO: 6724-700-50-50-JP-005 )









SIGNATURE


DATE

2


JOB PROCEDURE FOR INSTALLATION AND TESTING OF MV/HV MOTORS

CONTENTS

1. Purpose---------------------------------------------------------------------------------------------------3

2. Scope-----------------------------------------------------------------------------------------------------3

3. References-----------------------------------------------------------------------------------------------3

4. Definitions-----------------------------------------------------------------------------------------------3


6. Procedure-----------------------------------------------------------------------------------------------4

7. Health safety environment Points-------------------------------------------------------------------5

3

1. Purpose

The purpose of this procedure is to monitor and control of all the activities related to installation and testing of HV /MV motors

2. Scope

This procedure covers the responsibilities, Quality procedure & documentation to be adopted during installation and testing of Electrical motors as per approved drawings.

3. Reference

EIL Project No 6724

EIL Specification for LV/ HV Motors No: 6-51-0032 Rev.04

EIL Standards for Earthing 6-51-0084 Rev.3

Electrical Cable schedule

Project single line Diagram





5. Responsibilities




5.3.1 Ensuring that request for inspections are send to EIL in advance and inspections are held as approved ITP





4




Also responsible for co-ordination with vendor and allotment of required manpower and monitor the progress and reported to site manger daily basis


6. Procedure


The QC Engineer of SEL shall be carry out an inspection of the material when the material arrives in the ware house the Engineer shall ensure the material confirms to the project specifications, standards and purchase order


Equipment receipt inspection


Motor shall be checked proper receipt against data sheet, specially intended to area classification

Where motors are received uncoupled the shaft shall be rotated to ensure damage not appended during transportation

Insulation resistance of winding shall be tested as follows LV motor 500V for HV motor 1000V

Where only connections are brought out of the motor terminal block these shall be connected together and the insulation resistance checked between these points to earth.

Where six connections are brought out to the motor terminal block these shall be connected together at the terminal block and insulation resistance measured this point to earth.

Where fitted bearing insulators shall be Megger tested with low voltage Megger

The insulation resistance of space heater shall be verified

If insulation resistance lowers than those specified may indicate ingress of moisture shall be established as follows

The motor terminal shall be opens up and the terminal dried out by applying a fan or heater or pacing an electric lamp or heater in the terminal box

Insulation test shall be repeated and any improvement in the test result is noted where improvement is noted the source contamination shall be investigated and corrected

If no improvement noted motor shall be put in dried out process as per vendor recommendations

5

Particular attentions should be paid for Electronic and protection devices to prevent ingress of moisture and dust,

6.2.1 Procedure for Installation and testing

The motor installation will be carried out by the mechanical erection group in accordance with their approved Quality procedure and Erection procedure

After installation prior to connecting cable insulation resistance to be measured and recorded

Motor shaft shall be rotated to ensure that there is no restriction and the lubrication of bearings to checked

Earthing will be checked ensure that it is as per detail drawing and install as per AFC drawing

After the cable termination an inspection to carried out and for glanding and termination and ensure that cable cores connected free from tension and connections are torque

Control cable terminations shall be verified against approve d schematic drawing and ensure all connection correct

In HV motors CT testing shall be done and polarity to be verified

All temperature sensors and RTD connections to be verified

Local control push buttons and control connections also verified

Prior to energization barricading to be done

Motors will be kick started and check the direction of rotation

Motors will run coupled for 4 hours during this period phase current winding and bearing temperature will be noted 30 min intervals and recorded

During test run vibration levels to be checked and recorded


7.1 Hazards

Fall injuries due to working at height/trench Personal injuries due to use of hand tools and machines











INSPECTION & TEST PLAN FOR MOTOR INSTALLATION AND TESTING

DOC. NO. : 6724-700-50-50-005




Remarks


W HP YES

2

Material receiving and storage Ensure that materials are received confirms spec and AFC drawings Ensure that materials are stored as per manufacturers instructions

W RW YES

3 Check the motors are Installed as per AFC DWG W RW YES

4 Check the motor name plate Equipment classification and IP rating, Temperature classification

W RW YES

5 Check the motor fixing and mounting secure W S YES

6 Check the fan movement is obstruction free to rotate and motor shaft rotated free by hand

W RW YES

7 Check the terminal box gaskets and seals are present and not damaged W RW YES

8 Glanding of cables completed and all spare entries are plugged termination bolts are correct and tight

W RW YES

9 Check all control connections including CT, RTD, Space heater W RW YES

10 Check the earth connection and measure the earth resistance at earth bus connection are potentially bonded to main earth net work

W RW YES

11 Check the local control stations switches installation and equipment classification IP rating

W RW YES

Page 1 of 2

INSPECTION & TEST PLAN FOR MOTOR INSTALLATION AND TESTING




Remarks

12 Check current transformer details installations test ratio ,Polarity burden and accuracy class

W S YES

13 Check all field measuring instruments such as ammeter. Voltmeter etc for correct details and test for correct functioning

W RW YES

14 Perform insulation resistance measurement of Motor winding and winding resistance measurement

W S YES

15 Check the power and control circuit insulation resistance and continuity W S YES

16 Perform Motor no load run and measurement W S YES

Page 2 of 2


SEL SEL SEL EIL

INSPECTION REPORT FOR MOTOR NO LOAD RUN TEST

FORMAT NO. 6724-700-50-50-IR-005 REPORT NO. :



MOTOR NAME PLATE DETAILS:

Start Time

Feeder Side Field Side

Voltmeter (V) Ammeter (A) Temperature C Current (A)

DE NDE Body Ammeter (LCP)

Remark : 1.DE Temperature rise is __________

2. NDE Temperature rise is__________

3. Body Temperature rise is__________

4. The above readings are found to be satisfactory.


NAME

SIGN

DATE

1

JOB PROCEDURE FOR LIGHTING POWER PANEL, JB'S & SOCKETS

(PROCEDURE NO: 6724-700-50-50-JP-004 )









SIGNATURE


DATE

2


JOB PROCEDURE FOR LIGHTING POWER PANEL, JB'S & SOCKETS

CONTENTS

1. Purpose--------------------------------------------------------------------------------------------------3

2. Scope----------------------------------------------------------------------------------------------------3

3. References----------------------------------------------------------------------------------------------3

4. Definitions-----------------------------------------------------------------------------------------------3


6. Procedure-----------------------------------------------------------------------------------------------4


3

1. Purpose

The purpose of this procedure is to monitor and control of all activities related to lighting / Small Power Panel, Junction Boxs & Sockets.

2. Scope

This procedure covers the responsibilities, Quality procedure & documentation to be adopted during installation of lighting small power panel, Junction box & Sockets works as per approved documents

3. Reference

EIL Project No - 6724

Lighting Schematic drawing

Cable schedule No

EIL Specification for lighting installation No 6-51-0083 Rev.3





5. Responsibilities


5.2 Site Manger shall be responsible for the site management and conditions associated with lighting works.


5.3.1. Ensuring that request for inspections are send to EIL in advance and inspections are held as approved ITP ( Doc.No. 6724-700-50-50-ITP-006)

5.3.2. Co-ordination between other discipline and project engineers and site engineers as necessary

5.3.3. Ensure that inspections are performed in co-ordination with EIL and recorded as per ITP

5.3.4. Ensure that all works is ready for inspection prior to requesting to EIL to carry out inspection at site


4




Also responsible for co-ordination with vendor and allotment of required manpower and monitor the progress and

Reported to site manger daily basis


6. Procedure



6.2. Quality control Activities


6.3 Procedure

Prior to start any activity at site a valid permit shall obtain and followed all GAIL safety requirements for working in site.

Work shall be carried out only in presence authorized Electrical Supervision only.

Installations will be done by vendor representative under supervisor form SEL as per GA drawing.

Installation of Lighting / Small Power Panel


Prior to start any installation works Panel earthing to be done and Earth continuity to be verified and verified compartment cleanness and connection


Fuse ratings, Indicators, Pushbutton will be checked against panel schedule

Bus bar joints are inspected and torqued and physical verification of colour code and phasing

Earth bonding between panels and Earth bar verified and confirmed

Insulation resistance and continuity to be verified and ensure that cable numbers are correctly placed and terminations points as per approved schedule and termination schedule.


5

Ensure that cable splicing shall be in line with gland manufactures recommendations.



Ensure that Cable tag be provided below the cable Gland.

Ensure that proper Gland earthing done.


Ensure that cable has been properly supported and clamped near Glanding area


Up on completion of tests final physical and Megger checks to be carried out prior to clear for Energization.

Installation of Junction Box

Ensure that Auxiliary supply shall be switched off.

Prior to start any installation works JB earthing to be done and Earth continuity to be verified and verified compartment cleanness and connection

Junction Box installations will be done by vendor representative under supervisor form SEL as per GA drawing.


The clearness between phase to phase and phase earth to be verified & contact resistance to be taken.











Up on completion of tests final physical and Megger checks to be carried out prior to cleared for Energization

Installation of Sockets

Ensure that Auxiliary supply shall be switched off

Prior to start any installation works earthing to be done and Earth continuity to be verified

Socket installations will be done by vendor representative under supervisor form SEL as per GA drawing.

6


The clearness between phase to phase and phase to earth is verified & contact resistance to be taken.











Up on completion of tests final physical and Megger checks to be carried out prior to cleared for Energization


7.1 Hazards













INSPECTION REPORT FOR INSTALLATION OF LIGHTING PANEL

FORMAT NO. : 6724-700-50-50-IR-006A REPORT NO.



CABLE - FROM TO

TYPE OF CABLE AND VOLTAGE TEST VOLTAGE :

TEST EQUIPMENT DETAILS

Cable No Cable Size Continuity Insulation Resistance

R Y B N R-Y Y-B R-B R-N Y- N B-N B-E Y-E R-E N-E


NAME

SIGN

DATE

INSPECTION REPORT FOR INSTALLATION OF JUNCTION BOX AND SOCKETS

FORMAT NO. : 6724-700-50-50-IR-006B REPORT NO. :



EQUIPMENT TAG NO MANUFACTURER

LOCATION SERIAL NO

PANEL DATA - ,AMPS RATING

VOLTS - ,PHASE HZ ,PF

AREA CLASS IFICATION IP RATING

AMBIENT TEMPRATURE CERTFYING AUTHORITY


1 EnsurethatJB/Socketsasperapproveddrawing,datasheetand,tagnumberiscorrect

2 JB/Socketsundamagedandallinsidecomponentsarelikefuses,MCB,MCCB,ELCBandwiringterminationsarecompletedasperapprovedschematic

3 InspectJB/Socketbaseframeforfixing,levelandalignment

4 Inspectterminalconnectionsaresecureandtight

5 InspectJBbusbars,wiringterminalsandothercomponentshavingidentificationmarks

6 Checkthecableearthwireorarmourisconnectedtoearthpanelisalsoearthed

7 Verifypanelcoveropeningandclosingensurethatenoughspaceformaintenancesaccess

8 Ensurethatpanelsupportingframeareproperlyfixedandsecurethetightnessofbolt

9 CheckELCBandMCB/MCCBoperationaresatisfactory

10 Checklevelandorientationoffittings

11 Checkallspareholesaresealedasperareaclassificationrequirement

12 Checkallsafetyguardsareprovided

13 CheckallIncomingandoutgoingcableGlanding,terminationasperschedule

14 Checkphasesequenceofincomingsupply

15 Ensurethatallcircuithasbeeninsulationtestwasdone

16 EnsurethatASBuiltdrawingaremarked

18 EnsurePhaseorientationofRYBNEpinsarecorrectlyconnected

19 CheckIncoming&OutgoingsideCableSparePlugging


NAME

SIGN

DATE

INSPECTION REPORT FOR INSTALLATION OF LIGHT FITTING

FORMAT NO. : 6724-700-50-50-IR-006C REPORT NO. :




LOCATION SERIAL NO






1 Ensure that all light fittings as per approved drawing and data sheet and ,tag number is correct

2 Ensure that light fittings are undamaged and all inside components are like fuses, chokes and wiring terminations are completed as per approved schematic

3 Inspect light fitting base frame for fixing ,level and alignment and painting

4 Inspect terminal connections are secure and tight

5 Inspect light fittings JB wiring terminals and other components having identification marks

6 Check the cable earth wire or armour is connected to earth panel is also earthed

7 Verify light cover opening and closing ensure that enough space for maintenances access

8 Ensure that light supporting frame are properly fixed and secure the tightness of bolt

9 Check emergency circuit operation are satisfactory

10 Check level and orientation of fittings

11 Check all spare holes are sealed as per area classification requirement

12 Check all safety guards are provided

13 Check all Incoming and outgoing cable Glanding, termination as per schedule

14 Check phase sequence of incoming supply

15 Ensure that all circuit has been insulation test was done

16 Ensure that AS Built drawing are marked

17 Ensure that required lux level obtained


NAME

SIGN

DATE

INSPECTION REPORT FOR INSTALLATION OF LIGHTING PANEL

FORMAT NO. : 6724-700-50-50-IR-006D REPORT NO. :




LOCATION SERIAL NO






1 Ensure that panel as per approved drawing and data sheet and tag number is correct

2 Panel is undamaged and all inside components are like fuses, MCB, MCCB, ELCB and wiring terminations are completed as per approved schematic

3 Inspect panel on base for fixing ,level and alignment

4 Inspect terminal connections are secure and tight

5 Inspect panel bus bars wiring terminals and other components having identification marks

6 Check the cable earth wire or armour is connected to earth panel is also earthed

7 Verify panel cover opening and closing ensure that enough space for maintenances access

8 Ensure that panel supporting frame are properly fixed and secure the tightness of bolt

9 Check ELCB and MCB/MCCB operation are satisfactory

10 Check photocell and timer operation

11 Check all spare holes are sealed as per area classification requirement

12 Check all safety guards are provided

13 Check all Incoming and outgoing cable Glanding, termination as per schedule

14 Check phase sequence of incoming supply

15 Ensure that all circuit has been insulation test was done

16 Ensure that AS Built drawing are marked

17 Check Incoming & Outgoing side Cable Spare Plugging


NAME

SIGN

DATE

1

JOB PROCEDURE FOR MODIFICATION WORKS OF MV SWITCHGEAR COMPARTMENT/ TROLLEYS

(PROCEDURE NO: 6724-700-50-50-JP-007 )








ORGANIZATION SEL SEL EIL EIL

SIGNATURE


DATE

2


JOB PROCEDURE FOR MODIFICATION WORKS OF MV SWITCHGEAR COMPARTMENT/ TROLLEYS

CONTENTS

1. Purpose---------------------------------------------------------------------------------------------------3

2. Scope-----------------------------------------------------------------------------------------------------3

3. References-----------------------------------------------------------------------------------------------3

4. Definitions-----------------------------------------------------------------------------------------------3


6. Procedure-----------------------------------------------------------------------------------------------4


3

1. Purpose

The purpose of this procedure is to monitor and control of all activities related to Modification works of MV switch gear feeder

2. Scope

This covers the responsibilities, Quality procedure & documentation to be adopted during Modification works MV switch gear works as per approved documents.

3. Reference

EIL Project No 6724

EIL Specification for MV Switch Gear No 6-51-0012 REV.3

EIL Standards for Earthing 6-51-0084 REV.3

MV Switchgear Schematic Drawing No

MV Switchgear Panel Single line diagram Drawing No



PPE : Personal protection equipment


5. Responsibilities


5.2 Site manger shall be responsible for the site management and conditions associated with modification of MV Switchgear works


5.3.1 Ensuring that request for inspections are send to EIL in advance and inspections are held as approved ITP ( DOC. NO. 6724-700-50-50-ITP-007)

5.3.2 Co-ordination between other discipline and project engineers and site engineers as necessary.



5.3.5 Perform/ensure that all inspections are performed in a timely manner and recorded and signed by involved parties as per Specification ITP and QCP requirement.


Ensure that all work is carried out to the job specification and detail layout drawing and minimum disruption

4

and interference to the existing facilities


Also responsible for co-ordination with vendor and allotment of required manpower and monitor the progress and

Reported to site manger daily basis


6. Procedure


The QC Engineer of SEL shall be carry out an inspection of the material and also co-ordinate with third party inspectors to carry out inspection of materials when the material arrives at manufactures factory or the ware house the Engineer shall ensure the material confirms to the project specifications, standards and purchase order


6.2.1 Up on receipt at the storage and handling area the material will be inspected for any mechanical damage in presence concerned vendor any damage will immediately reported concerned parties

6.2.2 MV Switchgear Modification

This modification works has been divided in two parts

Part-1 Identifying and removing of existing MCC panel trolleys and Sending the materials to panel manufactures factory for Modifying the feeders as per EIL standard and project requirement as per approved Schematic Drawing .

Prior to start any activity at site a valid permit shall obtained and followed all GAIL safety requirements for working in a live MV panel

Ensure that panel tag no confirmed and lock out and tagging procedure to be applied in presence GAIL Maintenance personal

Work shall be carried out only in presence authorized Electrical supervisor only


Prior to start any Modification works Panel earthing to be done and Earth continuity to be verified and verified compartment cleanness and connection

Remove the existing connections if any and remove the panel trolleys and covers

The complete assembly will inspected to ensure that no damages in the parts and panel

Doors and panels will be checked and ensure the proper opening and closing

After inspection of doors and panel doors to be removed and proper markings on doors compartment no Tag no

After removal inventory to be prepared and obtain the gate pass from GAIL and Material shall be properly packed

5

And sent to Manufacturer

All the removed panel compartment shall be properly closed with fire resistant martial

PART- 2 Modification works at manufactures factory

Removing the all Electrical and Mechanical complements from existing trolleys

Check the trolleys alignment mechanical damage during Transportation

Painting the trolleys as per EIL standard

Installing the new mechanical and Electrical components as per EIL and GAIL Specification and as per approved schematic drawing

A periodical Inspection shall be carried out as per project requirement

New trolleys to be fabricated and inspected as per approved drawing and EIL specification

After completion of mechanical and Electrical works Inspection shall be carried out by Savair QC and Third party

Testing of all modified MV switch gears at factory in presence of Vendor, QC Engineer and third party

After success full completion of testing and release from third party inspectors material will be shifted to site

After arriving material at site SAVAIR QC / Construction people and Vender representative shall inspect the material and ensure that no damages happened during transportation

Prior to start site Installation works a Valid work permit will obtained and GAIL. Lock out and tagging procedure to be applied

Vendor representative will inspect the panel compartment and Megger check will carried out ensure that no direct earth connection from bus bars and required modification will carried at the panel

All live panel activities carried out in presence authorized Electrical supervisor only.

The panel control wiring shall be done as per approved schematic wiring diagram.

The complete As

electrical

Documents

conduits procedure

job procedure

electrical works

procedure number

control cable laying

site engineers

project engineers

reference eil project