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
ORGANIZATION

CHECKED BY

REVIEWED BY

SEL

SEL

SEL

Ganesh K.

Rakesh P.

Milind D.

APPROVED BY
EIL

SIGNATURE
NAME
DATE

(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

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.

5.

Definitions /Abbreviations
HSE

: Health and safety environment

PPE

: personal protection equipment

QA/QC

: Quality Assurance/ Quality control

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

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

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
RECORDS TO BE

SR
NO

ACTIVITY

Issue and control of AFC drawings and

ensure that all the drawings and documents
at site are AFC

Yes

Material receiving and storage

RW

Yes

Ensure that conformity of cable route

RW

Yes

RW

Yes

SEL

EIL

SUBMITTED/

Remarks

FORMAT NO

Inspection of support system

4

Inspection of joints, alignments, fixing bolts,

cut sections touch up paint.

Ensure that minimum distance between

trays

RW

Yes

Ensure that proper type bonding and

jumpers

RW

Yes

Ensure that all fixing bolts properly

tightened

RW

Yes

Earth continuity

Yes

Bending radius of cable tray

RW

Yes

WC

RW

Yes

INSPECTION & TEST DOCUMENTS

Completeness of inspection and test records

Prepared by
SEL

Checked by

Reviewed By

Approved by

SEL

SEL

EIL

INSPECTION REPORT FOR CABLE TRAY INSTALLATION

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

REPORT NO. :

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

DATE OF INSPECTION :

CABLE TRAY DESCRIPTION :

CABLE TARY LENGTH :

CABLE TRAY : FROM_________________________________________TO______________________________

SR.NO.
1

DESCRIPTION

OK

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

NOT OK

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
NAME
SIGN
DATE

SAVAIR QC

EIL

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 )

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
ORGANIZATION

CHECKED BY

REVIEWED BY

SEL

SEL

SEL

Ganesh K.

Rakesh P.

Milind D.

APPROVED BY
EIL

SIGNATURE
NAME
DATE

(PROCEDURE NUMBER: 6724-700-50-50-JP-002)

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

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
4. Definitions /Abbreviations
GAIL
CONTRACTOR

: GAS AUTHORITY INDIA LIMITED

: Savair Energy LTD

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 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
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 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
Ensure that all required test certificate are send by manufacturer
6.2 Quality control Activities
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

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

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 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 LAYING AND TESTING

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

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

SR
NO

ACTIVITY

Issue and control of AFC drawings and

ensure that all the drawings and documents
at site are AFC

Yes

Material receiving and storage

RW

Yes

Ensure that conformity of cable route

RW

Yes

Ensure that size of cable and type of cable

as per project requirement

RW

Yes

Ensure that single core cables are dressed in

form of trefoil

RW

Yes

Ensure that proper type and size of cable

gland used

RW

Yes

Ensure that Terminations are tight and

proper lugs are used and proper tagging is
done

RW

Yes

7
8

Insulation resistance & continuity test

RW

Yes

HI Pot test

RW

Yes

WC

RW

Yes

SEL

EIL

SUBMITTED/

Remarks

FORMAT NO

INSPECTION & TEST DOCUMENTS

Completeness of inspection and test records

Prepared by
SEL

Reviewed by

Checked By

Approved by

SEL

SEL

EIL

INSPECTION REPORT FOR CABLE LAYING

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

Report No. :

PROJECT : PROCUREMENT AND INSTALLATION OF ADDITIONAL BOIL OFF GAS (BOG) BOOSTER COMPRESSOR ,
RATNAGIRI
DRAWING REFERENCE / CABLE SCHEDULE :

DATE OF INSPECTION :

CABLE SIZE :

CABLE LENGTH :

CABLE : FROM_________________________________________TO______________________________
SR.NO.

DESCRIPTION

OK

EnsurethatconformityofCabletroughs

Cablelayingaccordingtoapprovedlayoutdrawing,asperEILstandardand
specification.

Cableiscleanandfreefromdamages.

Freespaceovertray&rack,allowsworkableaccess

Fieldbendsdonotviolatecablebendingradius

Alljointsbondedwithearthlinksifrequired

EarthingconnectedAsperinstallationstandardspec

Checkthecablebendingradiusandspacing

Ensurethatsizeofcable&typeofcableasperprojectrequirement

10

EnsurethatSinglecorecablesaredressedinformoftrefoil

NOT OK

Remark:

SAVAIR CONSTRUCTION
NAME
SIGN
DATE

SAVAIR QC

EIL

JOB PROCEDURE FOR EARTHING AND LIGHTNING PROTECTION WORKS

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

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
ORGANIZATION

CHECKED BY

REVIEWED BY

SEL

SEL

SEL

GANESH K.

RAKESH P.

MILIND D.

APPROVED BY
EIL

SIGNATURE
NAME
DATE

(PROCEDURE NUMBER: 6724-700-50-50-JP-003)

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

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
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
Earthing and Lightening Protection 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-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
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

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 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 Quality control Activities
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.

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 Health Safety Environment Points
8.1 Hazards
Electric Shock due to Electrical power may cause to injures to personal
Fall injuries due to working at height/trench
Personal injuries due to use of hand tools and machine
8.2 Control Measures

Strictly ensure that the entire activities of earthing 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
8.3 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 INSTALLATION AND TESTING OF EARTHING & LIGHTINING PROTECTION
DOC. NO. : 6724-700-50-50-ITP-003
PROJECT : PROCUREMENT AND INSTALLATION OF ADDITIONAL BOIL OFF GAS (BOG) BOOSTER COMPRESSOR ,
RATNAGIRI
RECORDS TO BE

SR
NO

ACTIVITY

Issue and control of AFC drawings and

ensure that all the drawings and
documents at site are AFC

WC

Yes

Material receiving and storage

WC

RW

Yes

Ensure Lay out excavation depth and

dimensions are as per AFC drawing

WC

RW

Yes

Ensure that Installation and size of

conductor and connection of conductors
per AFC DWG

WC

RW

Yes

Ensure that Grid conductors are

connected

WC

RW

Yes

Ensure that charcoal and salt are

sufficient quantity used filled properly

WC

Yes

Ensure that Terminations are tight and

proper lugs / Bolt are used and proper
tagging is done.

WC

RW

Yes

Earth resistance & continuity test

WC

Yes

Ring loop resistance

WC

Yes

10

Lighting protection system check

WC

RW

Yes

WC

RW

Yes

SEL

EIL

SUBMITTED/

Remarks

FORMAT NO

INSPECTION & TEST DOCUMENTS

Completeness of inspection and test records

Prepared by
SEL

Checked by
SEL

Reviewed By
SEL

Approved by
EIL

INSPECTION REPORT FOR EARTH RESISTANCE MEASUREMENT OF EARTH PIT

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

REPORT NO.

PROJECT : PROCUREMENT AND INSTALLATION OF ADDITIONAL BOIL OFF GAS (BOG) BOOSTER COMPRESSOR ,
RATNAGIRI
DRAWING REFERENCE :
DATE OF INSPECTION :
SR.NO

DESCRIPTION

OK

GENERAL

Location against layout drawing

Earth pit and connection facilities are installed

Earth network disconnected for testing purpose

Continuity between the connection point and adjacent pit and grid

Network completed after completing the resistance measurement

Earth plates properly connected to Earth conductor

Charcoal and salt powders are properly installed As per standard

NOT OK

EARTH RESISTANCE MEASUREMENT

Sr. No.

Earth Pit Reference No.

EPLT 1

EPLT 2

--

-----

--

------

--

-----

Individual (ohm)

Grid(ohm)

Equipment Used :

SAVAIR CONSTRUCTION
NAME
SIGN
DATE

SAVAIR QC

EIL

JOB PROCEDURE FOR MODIFICATION WORKS OF HV SWITCH GEAR

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

PROJECT

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

COMPRESSOR, RATNAGIRI

CLIENT

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

CONSULTANT
CONTRACTOR

M/s RATNAGIRI GAS AND POWER PRIVATE LIMITED

:
:

M/s ENGINEERS INDIA LIMITED

M/s SAVAIR ENERGY LIMITED

PREPARED BY
ORGANIZATION

CHECKED BY

REVIEWED BY

SEL

SEL

SEL

GANESH K.

RAKESH P.

MILIND D.

APPROVED BY
EIL

SIGNATURE
NAME
DATE

(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
5. Responsibilities-----------------------------------------------------------------------------------------3
6. Procedure-----------------------------------------------------------------------------------------------4
7. Health safety environment Points

-------------------------------------------------------------5

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
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-ITP-004)
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 specs, 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
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
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

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 Health Safety Environment Points
7.1 Hazards
Electric Shock due to Electrical power may cause to injures to personal
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 HV SWITCH GEAR MODIFICATION

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

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

SR
NO

ACTIVITY

Issue and control of AFC drawings and

ensure that all the drawings and documents
at site are AFC

SEL

EIL

SUBMITTED/

Remarks

FORMAT NO

Material receiving and storage

Ensure that materials are received confirms
spec and AFC drawings

HP

Yes

RW

Yes

Ensure that materials are stored as per

manufacturers instructions
3

Check the dimensions and size of

components is matching with existing
system

RW

Yes

Ensure that switch gear compartment doors

are opening, identification and warnings
labels as per approved DWG

RW

Yes

Check the compartment interconnection

bolting ,auxiliary and control circuit wiring
connection

RW

Yes

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

RW

Yes

Ensure that all busbar connection bolting

tightened and torque and torque value to
be verified

RW

Yes

Bus bar Insulation resistance & continuity

test, AC Hipot test As required

Yes

Page 1 of 2

RECORDS TO BE

SR
NO

ACTIVITY

SEL

EIL

SUBMITTED/

Remarks

FORMAT NO

Check the earth connection and measure the

earth resistance at earth bus connection are
potentially bonded to main earth net work

YES

10

Check the feeder cubicles for detail of fuses

switches breaker auxiliary relays contactor
CTs, their operation

RW

YES

11

Check current transformer details

installations test ratio ,polarity burden and
accuracy class

RW

YES

12

Check all measuring instruments such as

Ammeter. Voltmeter etc for correct details
and test for correct functioning

RW

YES

13

Perform secondary injection test and set up

each relay check relay response at least 5
current values of relay characteristics

YES

14

Check for relays details type feature code

and feature code required CTs auxiliary
supplies etc

RW

YES

15

Perform insulation & continuity test power

and control circuits

YES

16

Perform primary injection test and as

applicable and check relays and metering
instruments

YES

17

Cable insulation resistance test

YES

18

Incoming & Outgoing side Cable Spare

Plugging

RW

YES

WC

RW

Yes

INSPECTION & TEST DOCUMENTS

Completeness of inspection and test records

Page 2 of 2

Prepared by
SEL

Reviewed by

Checked By

Approved by

SEL

SEL

EIL

JOB PROCEDURE FOR INSTALLATION AND TESTING OF MV/HV MOTORS

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

PROJECT

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

COMPRESSOR, RATNAGIRI

CLIENT

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

CONSULTANT
CONTRACTOR

M/s RATNAGIRI GAS AND POWER PRIVATE LIMITED

:
:

M/s ENGINEERS INDIA LIMITED

M/s SAVAIR ENERGY LIMITED

PREPARED BY
ORGANIZATION

CHECKED BY

REVIEWED BY

SEL

SEL

SEL

GANESH K.

RAKESH P.

MILIND D.

APPROVED BY
EIL

SIGNATURE
NAME
DATE

(PROCEDURE NUMBER :6724-700-50-50-JP-005)

JOB PROCEDURE FOR INSTALLATION AND TESTING OF MV/HV MOTORS
CONTENTS
1. Purpose---------------------------------------------------------------------------------------------------3
2. Scope-----------------------------------------------------------------------------------------------------3
3. References-----------------------------------------------------------------------------------------------3
4. Definitions-----------------------------------------------------------------------------------------------3
5. Responsibilities-----------------------------------------------------------------------------------------3
6. Procedure-----------------------------------------------------------------------------------------------4
7. Health safety environment Points-------------------------------------------------------------------5

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
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
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 specs, 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
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 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
6.2 Quality control Activities
Equipment receipt inspection
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
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

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 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 MOTOR INSTALLATION AND TESTING

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

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

SR
NO

ACTIVITY

Issue and control of AFC drawings and

ensure that all the drawings and documents
at site are AFC

SEL

EIL

SUBMITTED/

Remarks

FORMAT NO
W

HP

YES

RW

YES

Material receiving and storage

2

Ensure that materials are received confirms

spec and AFC drawings
Ensure that materials are stored as per
manufacturers instructions

Check the motors are Installed as per AFC

DWG

RW

YES

Check the motor name plate Equipment

classification and IP rating, Temperature
classification

RW

YES

Check the motor fixing and mounting secure

YES

Check the fan movement is obstruction free

to rotate and motor shaft rotated free by
hand

RW

YES

Check the terminal box gaskets and seals

are present and not damaged

RW

YES

Glanding of cables completed and all spare

entries are plugged termination bolts are
correct and tight

RW

YES

Check all control connections including CT,

RTD, Space heater

RW

YES

10

Check the earth connection and measure the

earth resistance at earth bus connection are
potentially bonded to main earth net work

RW

YES

11

Check the local control stations switches

installation and equipment classification IP
rating

RW

YES
Page 1 of 2

INSPECTION & TEST PLAN FOR MOTOR INSTALLATION AND TESTING

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

SR
NO

ACTIVITY

SEL

EIL

SUBMITTED/

Remarks

FORMAT NO

12

Check current transformer details

installations test ratio ,Polarity burden and
accuracy class

YES

13

Check all field measuring instruments such

as ammeter. Voltmeter etc for correct details
and test for correct functioning

RW

YES

14

Perform insulation resistance measurement

of Motor winding and winding resistance
measurement

YES

15

Check the power and control circuit

insulation resistance and continuity

YES

16

Perform Motor no load run and

measurement

YES
Page 2 of 2

Prepared by
SEL

Reviewed by

Checked By

Approved by

SEL

SEL

EIL

INSPECTION REPORT FOR MOTOR NO LOAD RUN TEST

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

REPORT NO. :

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

DATE OF INSPECTION :

MOTOR NAME PLATE DETAILS:

Feeder Side
Start Time

Voltmeter (V)

Field Side
Ammeter (A)

Temperature C
DE

NDE

Current (A)
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.
SAVAIR CONSTRUCTION
NAME
SIGN
DATE

SAVAIR QC

EIL

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

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

PROJECT

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

COMPRESSOR, RATNAGIRI

CLIENT

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

CONSULTANT
CONTRACTOR

M/s RATNAGIRI GAS AND POWER PRIVATE LIMITED

:
:

M/s ENGINEERS INDIA LIMITED

M/s SAVAIR ENERGY LIMITED

PREPARED BY
ORGANIZATION

CHECKED BY

REVIEWED BY

SEL

SEL

SEL

GANESH K.

RAKESH P.

MILIND D.

APPROVED BY
EIL

SIGNATURE
NAME
DATE

(PROCEDURE NUMBER :6724-700-50-50-JP-006)

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

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
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 lighting 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-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
5.5.5 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

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
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
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 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
Ensure that panel Auxiliary supply and DC supply of particular compartment shall be switched off
Prior to start any installation works Panel earthing to be done and Earth continuity to be verified and verified
compartment cleanness and connection
The complete assembly will inspected to ensure that all connections are made as per drawing and confirms
the tightness of bolt 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.
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
Space for joint area shall be verified and ensure proper bending radius spaces for cables
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 complete assembly will inspected to ensure that all connections are made as per drawing and confirms
the tightness of bolt and connection
The clearness between phase to phase and phase earth to be verified & contact resistance to be taken.
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
Space for joint area shall be verified and ensure proper bending radius spaces for cables
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.

The complete assembly will inspected to ensure that all connections are made as per drawing and confirms
the tightness of bolt and connection
The clearness between phase to phase and phase to earth is verified & contact resistance to be taken.
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
Space for joint area shall be verified and ensure proper bending radius spaces for cables
Up on completion of tests final physical and Megger checks to be carried out prior to cleared for Energization
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 REPORT FOR INSTALLATION OF LIGHTING PANEL

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

REPORT NO.

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

DATE OF INSPECTION :

CABLE - FROM

TO

TYPE OF CABLE AND VOLTAGE

TEST VOLTAGE :

TEST EQUIPMENT DETAILS

Cable No

Cable Size

Continuity
R

SAVAIR CONSTRUCTION
NAME
SIGN
DATE

Insulation Resistance
N

R-Y

Y-B

R-B

R-N

SAVAIR QC

Y- N

B-N

B-E

Y-E

EIL

R-E

N-E

INSPECTION REPORT FOR INSTALLATION OF JUNCTION BOX AND SOCKETS

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

REPORT NO. :

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

DATE OF INSPECTION :

EQUIPMENT TAG NO

MANUFACTURER

LOCATION

SERIAL NO

PANEL DATA VOLTS AREA CLASS IFICATION

AMBIENT TEMPRATURE
SR.NO

,AMPS

RATING

,PHASE

HZ

,PF

IP RATING
CERTFYING AUTHORITY

DESCRIPTION

OK

NOT OK

EnsurethatJB/Socketsasperapproveddrawing,datasheetand,tag
numberiscorrect

JB/Socketsundamagedandallinsidecomponentsarelikefuses,
MCB,MCCB,ELCBandwiringterminationsarecompletedasper
approvedschematic

InspectJB/Socketbaseframeforfixing,levelandalignment

Inspectterminalconnectionsaresecureandtight

InspectJBbusbars,wiringterminalsandothercomponentshaving
identificationmarks

Checkthecableearthwireorarmourisconnectedtoearthpanelis
alsoearthed

Verifypanelcoveropeningandclosingensurethatenoughspacefor
maintenancesaccess

Ensurethatpanelsupportingframeareproperlyfixedandsecurethe
tightnessofbolt

CheckELCBandMCB/MCCBoperationaresatisfactory

10

Checklevelandorientationoffittings

11

Checkallspareholesaresealedasperareaclassification
requirement

12

Checkallsafetyguardsareprovided

13

CheckallIncomingandoutgoingcableGlanding,terminationasper
schedule

14

Checkphasesequenceofincomingsupply

15

Ensurethatallcircuithasbeeninsulationtestwasdone

16

EnsurethatASBuiltdrawingaremarked

18

EnsurePhaseorientationofRYBNEpinsarecorrectlyconnected

19

CheckIncoming&OutgoingsideCableSparePlugging

SAVAIR CONSTRUCTION
NAME
SIGN
DATE

SAVAIR QC

EIL

INSPECTION REPORT FOR INSTALLATION OF LIGHT FITTING

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

REPORT NO. :

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

DATE OF INSPECTION :

EQUIPMENT TAG NO

MANUFACTURER

LOCATION

SERIAL NO

PANEL DATA VOLTS -

,AMPS

RATING

,PHASE

HZ

AREA CLASS IFICATION

AMBIENT TEMPRATURE
SR.NO

,PF

IP RATING
CERTFYING AUTHORITY

DESCRIPTION

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

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

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

Inspect terminal connections are secure and tight

Inspect light fittings JB wiring terminals and other components having

identification marks

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

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

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

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

OK

NOT OK

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

SAVAIR CONSTRUCTION
NAME
SIGN
DATE

SAVAIR QC

EIL

INSPECTION REPORT FOR INSTALLATION OF LIGHTING PANEL

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

REPORT NO. :

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

DATE OF INSPECTION :

EQUIPMENT TAG NO

MANUFACTURER

LOCATION

SERIAL NO

PANEL DATA VOLTS -

,AMPS

RATING

,PHASE

HZ

AREA CLASS IFICATION

AMBIENT TEMPRATURE
SR.NO

,PF

IP RATING
CERTFYING AUTHORITY

DESCRIPTION

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

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

Inspect panel on base for fixing ,level and alignment

Inspect terminal connections are secure and tight

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

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

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

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

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

OK

NOT OK

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

SAVAIR CONSTRUCTION
NAME
SIGN
DATE

SAVAIR QC

EIL

JOB PROCEDURE FOR MODIFICATION WORKS OF MV SWITCHGEAR

COMPARTMENT/ TROLLEYS
(PROCEDURE NO: 6724-700-50-50-JP-007 )

PROJECT

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

COMPRESSOR, RATNAGIRI

CLIENT

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

CONSULTANT
CONTRACTOR

M/s RATNAGIRI GAS AND POWER PRIVATE LIMITED

:
:

M/s ENGINEERS INDIA LIMITED

M/s SAVAIR ENERGY LIMITED

PREPARED BY
ORGANIZATION

CHECKED BY

REVIEWED BY

SEL

SEL

EIL

GANESH K.

RAKESH P.

MILIND D.

APPROVED BY
EIL

SIGNATURE
NAME
DATE

(PROCEDURE NUMBER :6724-700-50-50-JP-007)

JOB PROCEDURE FOR MODIFICATION WORKS OF MV SWITCHGEAR COMPARTMENT/ TROLLEYS
CONTENTS
1. Purpose---------------------------------------------------------------------------------------------------3
2. Scope-----------------------------------------------------------------------------------------------------3
3. References-----------------------------------------------------------------------------------------------3
4. Definitions-----------------------------------------------------------------------------------------------3
5. Responsibilities-----------------------------------------------------------------------------------------3
6. Procedure-----------------------------------------------------------------------------------------------4
7. Health safety environment Points

-------------------------------------------------------------5

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
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 MV
Switchgear 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-ITP-007)
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
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 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 Quality control Activities
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
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 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

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 Assembly will be checked and ensure that alignment and bolt was correctly torqued and
proper opening and closure of doors and withdrawal unit movement will checked and ensure the free
movement
Fuse ratings protection devices indicators and ammeters will be checked against the panel schedule
and current transformers ratios to be verified.
After completion vendor installation works all the modified compartment shall be tested as per site
acceptance procedure and approved ITP
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 MV SWITCH GEAR MODIFICATION

DOC NO. : 6724-700-50-50-ITP-007

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

SR
NO

ACTIVITY

Issue and control of AFC drawings and

ensure that all the drawings and documents
at site are AFC

SEL

EIL

SUBMITTED/

Remarks

FORMAT NO
W

HP

YES

YES

Material receiving and storage

2

Ensure that materials are received confirms

spec and AFC drawings
Ensure that materials are stored as per
manufacturers instructions

Check the dimensions and size of

components is matching with existing
system

RW

YES

Ensure that switch gear compartment doors

are opening, identification and warnings
labels as per approved DWG

RW

YES

Check the compartment interconnection

bolting ,auxiliary and control circuit wiring
connection

RW

YES

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

YES

Ensure that all busbar connection bolting

tightened and torque and torque value to
be verified

RW

YES

Bus bar Insulation resistance & continuity

test, AC Hipot test As required

YES

Page 1 of 2

INSPECTION & TEST PLAN FOR MV SWITCH GEAR MODIFICATION

DOC NO. : 6724-700-50-50-ITP-007

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

SR
NO

ACTIVITY

Check the earth connection and measure the

earth resistance at earth bus connection are
potentially bonded to main earth net work

RW

YES

10

Check the feeder cubicles for detail of fuses

switches breaker auxiliary relays contactor
CTs, their operation

YES

11

Check current transformer details

installations test ratio ,polarity burden and
accuracy Class

RW

YES

12

Check all measuring instruments such as

Ammeter, Voltmeter etc for correct details
and test for correct functioning

YES

13

Perform insulation & continuity test power

and control circuits

RW

YES

14

Incoming & Outgoing side Cable Spare

Plugging

RW

YES

15

Check the Tagging of feeder, Hardware,

Alignment, Switch Operation

RW

YES

SEL

EIL

SUBMITTED/

Remarks

FORMAT NO

Page 2 of 2

Prepared by
SEL

Checked by

Review By

Approved by

SEL

SEL

EIL