1 PURPOSE.
2 REFERENCE DOCUMENTS.
3 DEFINITIONS AND ABBREVIATIONS.
4 REFERENCE STANDARDS.
5 RESPONSIBILITY.
6 METHODS AND GENERAL GUIDELINES FOR CABLE CONTINUITY INSULATION RESISTANCE TEST.
7 TOOLS AND EQUIPMENT.
8 INSPECTION.
8.1 QC Inspection.
8.2 As-Built Drawing.
Test Procedure for Cable Insulation Resistance Test
1 PURPOSE
This Method Statement covers the work method and procedure for conducting Continuity and Insulation Resistance Test of cables to be carried out in Waad Al Shamal Integrated Solar Combined Cycle Power Plant Project. This method was prepared as guideline for effective enforcement of work thus; construction personnel have to determine the applicability and feasibility of this MS in accordance to approved construction drawing, cable specifications and site condition.
2 REFERENCE DOCUMENTS
• Contract Agreement
• Project Technical Specifications
• Applicable/ Approved International Standards
• Issued For Construction Drawings
• Manufacturer’s Instructions
3 DEFINITIONS AND ABBREVIATIONS
IEC International Electro-Technical Commission.
NEMA National Electrical Manufacturers Association.
RSI Request for Site Inspection.
MRR Material Receiving Report.
NCR Non-Conformity Report.
4 REFERENCE STANDARDS
IEC International Electro-technical Commission
NFPA 70/NEC National Fire Protection Association / National Electric Code
ASTM American Society for Testing and Materials
B 3 Specification for Soft or Annealed Copper Wire.
IEEE Institute of Electrical and Electronic Engineers
383 type test of class IE electric cables.
5 RESPONSIBILITY
Site Manager -Determine all requirements needed in order to comply with contractual requirements and safety standards.
Construction Manager – Lead all construction activities and enforce strict adherence to all project requirements.
Electrical Superintendent Ensure that work once started is carried out as planned and that the applicable standards are complied with. Check working methods and precautions to be taken by the supervisors/foreman before commencing work.
Field Engineer – Ensure that all related works are carried out in accordance with approved Issued for Construction drawings, specifications, schedule, quality and safety. Report to Construction Manager.
Supervisor/ Foreman -Supervise assigned field installations and test activity. Reports to Electrical Superintendent
QC Inspector — Shall be responsible for conduction surveillance and inspection duties for work and ensuring quality compliance and efficient recording and reporting of results if required. He shall review all relevant documents, material conformance certificates and non conformance reports. Prepares Request for Site Inspection.
Safety Officer — Ensure that HSE plan is being implemented and monitored. Ensure that preventive measure are applied during continuity and insulation resistance test.
6 METHODS AND GENERAL GUIDELINES FOR CABLE CONTINUITY INSULATION RESISTANCE TEST
6.1 METHODS AND GENERAL GUIDELINES FOR CABLE CONTINUITY
INSULA TJON RESISTANCE TEST
a) Insulation Resistance Tester and multi-meter must be verified for good operating condition and validity of calibration certificate.
b) Testing shall be performed by qualified technician
c) Ensure that work permit has been acquired and safety measures have been installed.
d) Prepare cable list, schedule and interconnection drawing for reference of cable to be tested. Verify and check tag and identification. Testing shall be conducted in de-energized condition.
e) Perform visual inspection of equipment and cable for any physical damage.
f) Exposed cables must be check for cleanliness. Other end must be secured from adjacent conductive material or equipment.
g) Perform continuity check between cores/phases, ground, armour or shield. Insulation resistance must be performed after passing the continuity check.
h) Where no requirements specified in the Project specifications. Potential of I OO0VDC should be applied for power cable. All unshielded
control/measuring/signalling cables rated up to SOOY should be tested at 500Vdc.
Meanwhile, SkVdc will be applied for insulation resistance test of medium voltage cable.
i) Perform insulation resistance test. Measure and record the insulation value at each core-core, core-ground or core to armour as applicable. Test duration shall be 1 minute measured value in mega ohms.
j) Where no standard specified, insulation resistance value should be greater than 1 Mega ohm.
k) After test of each core or phase, discharge the induced voltage prior to test of other cores.
I) Cable ends shall be insulated after test to prevent ingress of moisture or water. Disconnected cables made for insulation tests must be returned to its proper terminals as per cable schedule and interconnection drawing. Tighten or properly torque the terminals and clean the area after completing the test.
7 TOOLS AND EQUIPMENT
a) Electrician’s Standard Toolbox
b) Communication device ( i.e. bravo phone )
c) VOM (Volt-Ohm meter)
d) Insulation Resistant Tester (Megger)
e) Warning Tape/barricading Tape for Safety purposes
f) Warning Sign
8 INSPECTION
8.1 QC Inspection
a) All inspections shall be coordinated by CGA QA/QC Inspector, who will implement the inspection program and notify all parties involved in advance of the scheduled dates of inspection to enable them to participate. Insulation resistance test and high potential test will be applied according to vendor’s recommended lest voltages and testing procedures.
b) Cable shall be inspected and tested (pre-installation and pre-commissioning requirement) using approved forms.
c) Internal and preliminary inspection shall be done before submitting to Contractor for Final Inspection. Verify and check that cable installation complies with project specification, cable schedule and approved construction drawing.
d) RSI will be raised for inspection once work and internal inspection was completed.
e) Relevant records shall be signed by all the required parties and originals kepi by the QA/QC Department.
f) Acceptance criteria for inspection will be within Project specification and standards. Required actions will be taken place as per site work condition for remarks and punch lists noted during inspection and testing.
8.2 As-Built Drawing
a. Document controller will be responsible for maintaining a complete set of Construction drawings, Material Take-off (MTO) and Data sheets dedicated for up-to-date marked-up of any actual field changes lo the drawing issued or any revisions.
b. Once the scheduled area/portion is completed, foreman will inform the supervisor for any changes in the approved drawings.
c. The Supervisor makes “As-built” drawings in Master Copy immediately after completion of works (“As-built” – any changes in the approved drawings, P&ID and specifications marked in red according to actual constructed condition) and submits to field engineer who will review and forward the As-built Drawings to QA/QC department
d. After QA/QC department reviewed and verified it, the gathered “As-built” red marked drawings submitted by Construction will be processed for submittal to client and a Master copy will be kept by document controller.
Step by Step Guide for Insulation Resistance
Explain in detail the steps that must be taken to ensure that the task is carried out safely (include drawing and sketches where required, include pre commencement of work activities and the work itself in a chronological manner)
A. Verify IFC drawings availability
B. Verify Documents for QC material receiving inspection
C. Material and Test equipment preparation
D. Continuity Checking
E. Insulation Resistance Test.
A. Preparation of materials and tools (Ensure permit to work must be obtain, prior to start the activity. Conduct toolbox talk prior to the task to be done. And wearing of PPE to all personnel. All tools and equipment is in good condition. Test equipment calibration certificate).
B. Preparation of Cable & Continuity Checking (Competent person to perform the task. Ensure wear of PPE. Proper handling of cable during preparation of cable ends. Tools and equipment in good condition. Test equipment certified calibration).
C. Insulation Resistance Test (Task Supervisor must organized the preparation and set-up the area to ensure Unauthorized personnel will keep away from the test area test will be performed to check the integrity of the cable. Wearing appropriate PPE shall follow the agreed instruction and safety procedure initiated with their supervisor. Area must be cleared with proper barricade with signage. Standby man must be strictly monitor the area ).
D. Discharging (Ensure personnel are wearing appropriate PPE nonconductive gloves must be use and area must be clear and discharge on the apparatus or by bonding into by the grounding bond or rod to drain the stored energy.)
E. Daily housekeeping (Full supervision on the area remind personnel for safe working and good housekeeping on the area should be done before and after the work).