ABSTRACT

The site inspection and tests cover the mechanical

completion and precommissioning checks and tests
which shall be carried out on the electrical equipment
before it is put into service.

Hatem Hussein
Electrical Engineering in Oil and Gas Industry

ELECTRICAL
INSPECTION AND
TESTING MANUAL
Hatem Hussein

Electrical Engineering in Oil and Gas Industry Hatem Hussein

 ELECTRICAL TESTING AND INSPECTION MANUAL

1.0 TESTING
1.1 General
1.1.1 The site inspection and tests cover the mechanical completion and
precommissioning checks and tests which shall be carried out on the electrical
equipment before it is put into service.
Mechanical completion checks are to establish that the installation work has
been done correctly and the pre-commissioning checks are to establish that
the equipment is in a ready to energise condition.
1.1.2 Subcontractor shall provide at his expense all appliances, instruments, labour
and other facilities required for pre-commissioning tests and shall perform the
work as directed by Contractor and as specified in the Contract Documents.
1.1.3 The installations’ inspection and testing shall comprise part of the pre-
commissioning of electrical equipment. It shall be understood that the features
specified within the following sections do not preclude the necessity for further
inspection and testing to suit individual features or Sellers instructions.
1.1.4 Equipment and materials shall be physically inspected before testing to ensure
they are functioning correctly, are undamaged and have not deteriorated in
storage or since being installed.
Inspection of the equipment and materials shall include for:
• Compliance of the installation with the contract documents
• Cleanliness of the equipment
• Correctness of identification labels, Sellers nameplates, operation and
warning notices and hazardous area equipment certification details
(including cable glands & entry plugs).
• Correctness of equipment component parts to Approved For Construction
and to Seller’s drawings
• Correct equipment degree of protection, particularly with regard to cable
gland entries
• Configuration, alignment and tightness of fixing and holding down bolts
• Earth bonding of equipment
• Mechanical and electrical interlocks, door and isolating handle interlocks,
Castell key interlocks, etc.
• Padlocking facilities
• Correctly fitted guards and protective covers
• Correctness of circuit details with interconnection diagrams
1.1.5 Equipment shall be physically inspected after test and any damage recorded
for remedial action.
1.1.6 All commissioning spares are to be made available for the mechanical
completion tests.
1.2 Safety Requirements and Precautions
1.2.1 Safety notices shall be provided and displayed in substations and other
locations when it is considered to be advisable. The following notices shall be
included:
a) Isolation of the electrical power supply before working on equipment
b) Prohibition of unauthorised persons from tampering with electrical
apparatus
c) Procedure in case of fire
d) Treatment for electrical shock.
The safety notices shall be of a graphic nature and all written instructions shall
be in the English language.
1.2.2 During the insulation resistance tests, care shall be taken to ensure that high
voltage and insulation resistance tests are not applied to circuit items, such as
electronic components, which can be damaged.
1.2.3 Before commencing any high voltage tests, the area shall be roped off and
warning notices posted. It is obligatory that these tests are only carried out in
Contractor’s presence. All cable ends shall be suitably supported and insulated
against the test voltage to prevent danger to personnel and equipment. The
area at each end of the cable shall be kept clear of all personnel excepting
those involved in the test.
1.2.4 Subcontractor shall not energise any equipment until written approval is
obtained from the Contractor representative.
1.2.5 Before working on any equipment which can be energised, the appropriate
safety procedures in operation shall be adopted.
1.2.6 All checks detailed in the relevant mechanical completion test sheets shall be
completed before the high voltage and insulation resistance test are
commenced.
1.2.7 No high voltage tests are to be made if the insulation resistance value is below
the minimum acceptable value as detailed in this specification (see 6.17.5). In
these circumstances the drying out procedure detailed below shall be followed:
i) Energise anti-condensation heaters where fitted and regularly re-check
insulation resistance reading until a consistent, acceptable value is
obtained
ii) Where anti-condensation heaters are not fitted, temporary ‘space’
heaters are to be used until a consistent acceptable insulation resistance
value is obtained. Cables with a value below the minimum specified
 shall be examined for mechanical damage or presence of moisture and,
if present, rectified: if neither moisture nor damage is present the
decision on whether to apply the voltage test shall be made in
consultation with Contractor
1.2.8 After each high voltage or insulation resistance test has been performed the
winding or cable under test shall be connected to earth and discharged.
1.2.9 The Mechanical Completion Inspection shall be accepted by Contractor before
tests are carried out.
1.2.10 All temporary wiring and test equipment shall be removed after the testing is
completed.
1.2.11 All connections and covers removed during the tests shall be replaced and the
equipment/cables left ready for service.

1.3 Test Equipment

1.3.1 When required by the material requisition, Sellers of special (e.g. UPS)
equipment shall provide all required test equipment and qualified staff to
provide a full and complete on site testing and commissioning service.
1.3.2 Subcontractor shall provide all other test equipment. Test equipment shall
include, but not be limited to, the following items which shall be at least
equivalent to the model stated and have a current calibration certificate.
Quantity Description
1 Megger insulation tester MB 200, 500 - 1000 V dc.
1 Megger insulation tester MJ10, 100 - 1000 V dc.
2 Megger insulation tester WM5/500, 500 V dc.
1 Megger earth tester ET3/2, 0.01 - 9990 ohms
1 Megger insulation tester LL1, 500-2500 V dc.
1 Megger insulation tester SH1, 1000 - 5000 V dc.
1 Primary injection test set. 3000 A
1 Secondary injection test set.
1 Cable test set (40 kV dc).
1 Variac variable auto-transformer, 0-270 volts, 10 amps, 1
phase
50/60Hz.
2 AVO multimeter 8Mk7.
2 AVO multimeter 1000
2 Phase rotation meter, 100 - 500 V, 3 phase, 50/60 Hz.
 1 Stop watch
1 Tachometer, 0 - 5000 RPM
1 Megger low resistance ohmmeter D007, 0 - 10 ohms.
2 Megger loop tester LT5, 0 -199.9 ohms.
1 Megger RCD tester CBT2,3 - 500 mA
1 Clip-on ammeter, 0 - 1000 A.
1 Amprobe clip-on ammeter, 0 - 300 A
2 Live conductor tester/phasing equipment (for 3 kV).
2 Surface Temperature Gauge.
1 Wattmeter, Accuracy Class 0.5, Ranges 0-10A & 0-300V
1 Light Meter with separate cell, 0-250/500/1000 Lux Ranges
1 Stroboscopic Revolution Counter, 0-600/6000/12000rpm
1 Insulating Oil Test Set

1.4 Cables
1.4.1 All instrument cables and all power and control cables 600/1000 V grade and
above shall be tested in accordance with this Section.
1.4.2 Carry out the following insulation resistance tests on every length of cable after
laying and sand cover but before final backfill and before jointing and
terminating.
1.4.2.1. Insulation resistance tests shall be carried out before, and repeated after the
high voltage tests and the values recorded. Before starting any cable testing
make certain that the cable ends are insulated and connected in such a way as
to avoid any danger to personnel and equipment.
1.4.2.2. The insulation resistance tests shall be carried out between each core and
earth in turn, with the remaining cores bunched and connected to the cable
metallic sheath, armour and earth.
1.4.2.3. For single core cables, the insulation resistance test shall be made between
the conductor and the metallic sheath and armour which are connected to
earth.
1.4.2.4. The insulation resistance test voltage shall be applied for one minute.
 Table I: The test voltages and minimum values of insulation resistance shall
be as below:
Voltage Designation Insulation Minimum Resistance
Uo/U Resistance Test up to 1 km *
Voltage (d.c.)
Up to 500V 500 V 1 M Ohm
600/1,000 V 1,000 V 10 M Ohm
3.6/6.0kV 2500 V 25 M Ohm
8.7/15kV 5000 V 50 M Ohm
*For cable length above 1 km *,
Minimum resistance required = Minimum Resistance up to 1 km*
Cable length in km
If the minimum resistances above are not achieved Contractor shall advise
what further action is required, such as either proceed with high voltage test,
put cable into service, or replace cable.
1.4.3 Carry out the following tests after all jointing and terminating is completed and
with conductors disconnected from switchgear and apparatus. Tests shall be
completed before paving of trenches in paved areas.
1.4.3.1. On all cables that have been straight jointed, repeat the above insulation tests.
1.4.3.2. High Voltage tests.
1.4.3.3. High voltage tests are not required on cables with a voltage rating up to and
including 600/1,000 volts.
1.4.3.4. The voltage test on a new installation shall be made with direct current at the
appropriate voltage, specified in Table II below, and the leakage current
recorded.
1.4.3.5. The voltage shall be increased gradually to the specified value and maintained
for 15 minutes, between each conductor and earth, and between conductors.
The test between each conductor and earth shall be done before the tests
between conductors.

1.4.3.6. It should take approximately 10 seconds to reach 75% of the final test voltage
and the same time to raise the test voltage from 75% to 100% of the final value.
 Table II: Test Voltages on New Installed Cables, as below:
Voltage Designation D.C. Test Voltage
Uo/U

Between Each Conductor and

Earth with the other phases
connected to earth - Note (1)
(+ Volts, To Earth)
3,600 / 6,000 V 14,400 V

8,700 / 15,000 kV 34,800 V

Note (1): For cables having metal sheathing (e.g. lead sheath) and/or
armouring, the voltage shall be applied between each
conductor and the earthed sheath/armour.
Outer Sheath Test - Buried Cable only
Outer sheath test shall be carried out only when specifically requested.
Sheath testing is normally carried out on high voltage cables (above
600/1,000 V grade).
a) This test is conducted to ensure the integrity (that is freedom from
damage) of a cable’s outer sheath. This sheath provides a barrier
against the ingress of corrosive substances which would lead to
eventual damage and deterioration of the metal armour. Integrity of
armour is of prime importance particularly when it forms an earth
continuity conductor.
b) If required, this test is to be carried out before terminating cable
armouring and sheath. The cable sheath shall be tested by applying a
test voltage of 4,000 volts d.c. for each millimetre of sheath thickness,
between the unearthed cable armour or metal sheath and earth. The
test voltage shall be maintained for one minute.
c) Repairs to damaged sheathing may be carried out using cable Seller’s
recommended procedures approved by the Contractor
1.4.4 For all cables, before connecting the terminations, conductors shall be checked
for continuity from end-to-end and ferrules, markers or coloured phase
identification tapes shall be installed.
1.4.5 Subcontractor shall inspect and verify that all cable terminations have been
completed correctly (including cable, core and terminal identification,
wire/terminal block tightness, shield and armour earthing, cable gland
tightness, earthing and assembly).
1.5 Earthing and Lightning Protection System
1.5.1 Test shall be carried out using a null balance hand powered earth resistance
tester, to check resistance to earth of interconnected systems or specific items.
1.5.2 Test earth continuity from each item of equipment to the main earth system.
1.5.3 Any proposed additions to an earthing system to achieve specified values, shall
be submitted to Contractor for approval.
1.5.4 The resistance of each of the earthing systems, on its own, to the mass of earth
is normally specified as not to exceed the following (considering 6.9.4):
a) General electrical earthing 1 ohm
b) Static earthing 10 ohms
c) Lightning protection earthing 10 ohms
d) Instrument “clean” earth 1 ohm
e) Instrument “signal” earth 1 ohm
f) Intrinsically safe earth 1 ohm

1.6 Lighting, Small Power and Power Outlets

1.6.1 Measure cable insulation resistance of each lighting circuit using a 500V
Megger, between phases and between phases and earth. Tests shall be made
before installing lamps.
Required minimum resistance: 1 M ohm.
1.6.2 Check rating of fuses or miniature circuit breakers against distribution board
schedules and that circuit is correctly labelled.
1.6.3 With power supply on, check the function of manual lighting switches.
1.6.4 With all the lighting switched on, measure the voltage at all lighting distribution
boards located away from the sub-station.
Also measure the voltage at the sub-station MCC and check the voltage
drop.
Allowed maximum voltage drop: 2½% (or 5% to the last fitting on road /
fence lighting circuits)
1.6.5 Fluorescent fittings with individual emergency battery/inverter units shall be
tested as follows:
a) Ensure that power supply to the lighting circuit has been on for at least
24 hours, so that battery is charged. (Lighting need not be switched on
during this period).
b) Switch on the lights and check all are functioning. Switch off the supply
to the lighting to simulate mains failure. Visually check the emergency
 lighting fittings over a 1 hour period. Required minimum period of
effective operation : 1 hour.
1.6.6 Wiring insulation resistance of each power circuit shall be measured, using a
500V Megger, between phases, between phases and neutral, between phases
and earth. Required minimum resistance : 1Mohm.
1.6.7 Following installation of the lighting system and under night-time conditions,
Subcontractor shall:
• Take readings of illumination levels throughout the plant or platform with
the normal lighting system energised
• Energise only the emergency lighting system to prove adequacy
• Adjust orientation of floodlight fittings for maximum efficient use
• Check load balance on three phases of lighting panels, by measuring
currents with a clip-on ammeter.
The required minimum levels are stated on Project Standard Lighting Detail
drawings.
1.6.8 With power supply on, the following tests shall be carried out at all power
outlets:
a) Using a mains powered line-earth loop tester measure the line-ground loop
impedance at convenience outlets and 3 phase power outlets.
Required maximum loop impedance:
Convenience outlet- 4.8 ohms
Power outlet - 1.2 ohms
b) At power outlets check that phasing of all outlets is the same throughout the
project areas. Test as follows:
i) At the MCC feeder end, energise Yellow phase only. Test at outlet to
confirm that Yellow phase is connected to the same “pin” at all outlets
ii) Energise all phases at MCC end and check that phase rotation is the
same at all outlets, using a phase rotation meter

1.7 Transformers
1.7.1 Power transformers and Neutral Earthing Transformers shall be tested in
accordance with Seller’s instructions and under Seller’s supervision.
1.7.2 Before commencing tests, physically check the transformer for leaks and
damage or deterioration of ancillary components (e.g. terminal bushings) since
installation. Check that the Buchholz by-pass valve and any drain-or-filter
valves are shut and plugged/locked as required and valves between tank and
ancillary devices are open. Check any breathers and dry the desiccant if
necessary. Check (using Vents) that oil filling is completed in every internal
 space and air is completely vented out. Vent out air from radiators if provided
with suitable vent. Check that safety valve is provided with rupture disc. Test
the electrical continuity of the windings, polarity of the terminals and phase
sequence.
1.7.3 Measure insulation resistance between HV and LV windings and between
windings and earth.

Required values:
Winding Voltage RMS Test Voltage Insulation Resistance
3 kV and above 2500 V Megger 100 M ohms
Up to 1000 V 1000 V Megger 50 M ohms

If resistance value is lower than that specified, inspect all external bushings,
including those in the oil-filled disconnect chambers, for defects or
contamination. If no defect is apparent thoroughly clean all bushings and
repeat the test.
If there is an apparent defect or if the re-test is unsatisfactory the Seller must
be called in.
1.7.4 Measure Insulation resistance to earth of all auxiliary wiring and devices - (all-
in test), using 500 V Megger. Required Minimum resistance: 2 M ohms.
1.7.5 Test the operation of temperature relays and any other alarm/trip devices by
simulation, in accordance with Seller’s instructions.
1.7.6 After cable connections from HV switchgear are completed, carry out
comparative conductivity tests to include HV cable connections at switchgear
and transformer, transformer tap changer and windings as follows.
Using a Ducter (or equivalent DC test equipment) inject a DC test current at the
HV switchgear through phases Yellow and Blue to include HV cables, tap
changer at Tap No.1 and transformer windings Yellow and Blue and measure
the loop resistance/conductivity.
Repeat the above test at all tap positions.
Repeat all of the above tests through phases Yellow and Blue and then through
phases Blue and Red
These are comparative tests to prove cable connections and transformer tap
changer connections and contacts.
1.7.7 Measure oil dielectric strength, taking one sample from the drain plug and from
each barrel to be used for filling/topping up. If the value results lower than the
 value specified by the manufacturer or codes, transformer oil shall be dried and
treated in accordance with Seller’s instructions.

1.7.8 After all tests are complete, check that the off-voltage tap changer is in the
proper position corresponding to the final load flow study and lock changer in
that position.

1.8 Switchgears and Motor Control Centres

1.8.1 HV and LV switchgear/MCC’s shall be tested in accordance with Seller’s
instructions and under Seller’s supervision.
1.8.2 Caution: On no account shall solid-state components be subjected to Megger
or high voltage test. Such components shall be completely disconnected from
any conductor included in a test.
1.8.3 When the switchgear/MCC is completely assembled and before any cables are
connected, measure the insulation resistance between phases and between all
phases and earth. These tests shall be carried out with all circuit breakers
racked in and closed, all MCC starters racked in but contactors open, auxiliary
wiring fuses withdrawn and all voltage-transformer primary fuses withdrawn.
Secondary wiring shall be earthed during the tests.

Required minimum values:

Rated Voltage Test Voltage Insulation Resistance
3.3 kV 2500 V Megger 200 M ohms
Up to 1 kV 1000 V Megger 10 M ohms

1.8.4 For high voltage switchgear/MCC and in the same state as above carry out two
high voltage, mains frequency, pressure tests between phases and between
all phases and earth as follows:
1) ( Yellow and Blue) to ( Red + earth)
2) ( Yellow and Red) to ( Blue + earth)
Test Voltage shall be:
Rated Voltage RMS Test Voltage RMS
High Voltage Switchgear As recommended by Seller
Up to 1000 V 2 kV for 1 minute
The test voltage shall be increased gradually (about 1 kV/sec) and held for
1 minute.
1.8.5 With all instrument terminals and VT secondaries bridged and secondary earth
links opened, measure the overall insulation resistance of the secondary wiring
to earth, using a 500 V Megger. Required minimum resistance: 2 M ohms.
1.8.6 Test all current transformers by primary injection to confirm CT ratio
approximately and to check relative polarity of grouped or matched CTs.
(These are confirmatory of comparative tests which do not require great
accuracy of readings. When protection or instrumentation is to be tested by
primary injection, this ratio test may be omitted).
1.8.7 All protective relays shall be tested by primary injection preferably, or by
secondary injection by a method to include all the secondary circuit. (These
tests are not intended to repeat factory calibration tests and may be done at
convenient settings sufficient to allow a spot check against the relay curve).
1.8.8 Current/voltage relays and instruments shall be tested according to the Seller’s
approved instructions.
1.8.9 No primary or secondary injection tests need be carried out on low voltage
motor protection current transformers, thermal overloads or on earth leakage
ring CT’s.
Check ratings of fuses and thermal overload elements against schedules.
1.8.10 Voltage operated devices shall be tested at specified minimum and maximum
AC or DC volts by means of variable voltage supplies. (Some of these tests
may be done as a complete switchgear/MCC with variable voltage applied to
the auxiliary bus).
1.8.11 Relays and other devices shall be set at the positions specified in the
schedules.
1.8.12 With auxiliary AC and DC supplies connected to their switchgear/MCC bus,
check the operation of the circuit breaker closing and tripping by manual
operation of controls and relays.
1.8.13 After auxiliary cabling is completed, test switchgear operation in conjunction
with remote controls, alarms and double-ended protection systems.
Test the operation of MCC starters by local and remote control.
1.8.14 After cable connections are completed, inspected and verified, carry out
comparative ductor tests to include HV and LV power cable connections and
all field-made busbar connections.
These tests shall be loop tests in the manner described for Transformers
above.
As an alternative to D.C., the loop tests may be carried out using high-current
AC and accurate voltmeter and ammeter.
1.8.15 All parallel incoming feeders shall be finally phased out “live”, after all cable
connections are completed.
Phasing may be done, as convenient, across incomers or bus-sections.
1.8.16 Kilowatt-hour metering and ammeters not included in the foregoing tests shall
be checked during test running of equipment.
1.8.17 The ease of withdrawal and insertion of all incomers, bus couplers, starters and
feeders shall be checked in addition to checks regarding general Panel
alignment.

1.8.18 Test all mechanical and electrical interlocks within the switchgear and to remote
equipment for correct / safe operation.

1.8.19 Test space heater circuits.

1.8.20 Test automatic transfer circuits for incomers and bus couplers, simulating fault
conditions on each bus-bar in turn.

1.9 Busbar Trunking

1.9.1 Busbar trunking shall be tested in accordance with the Seller’s instructions.
1.9.2 When the busbar trunking is fully assembled but prior to making the
connections to switchgear, transformers, etc. at either end, measure the
insulation resistance between phases and between all phases and earth.
Required minimum values:
Rated Voltage Test Voltage Insulation Resistance
3.3 kV 2500 V Megger 200 M ohms
Up to 1kV 1000 V Megger 10 M ohms

1.9.3 For high voltage busbar and in the same state as above carry out two high
voltage, mains frequency, pressure tests between phases and between all
phases and earth as follows:
• ( Yellow and Blue) to ( Red + Earth)
• ( Yellow and Red) to ( Blue + Earth)
Test Voltage shall be:
Rated Voltage RMS Test Voltage RMS
High Voltage Busbars As recommended by Seller
Up to 1000 V 2 kV for 1 minute
The test voltage shall be increased gradually (about 1 kV/sec) and
held for 1 minute.
1.9.4 Subsequent to making the connections to switchgear, transformers, etc. at
either end of the trunking, the overall continuity and phasing shall be checked.
1.10 Battery Systems and Chargers
1.10.1 Checks and tests on DC Supply Units shall be carried out in accordance with
Seller’s instructions and, for larger units, under Seller’s supervision.
1.10.2 Caution: On no account shall solid-state components be subjected to Megger
or high voltage test. Such components shall be completely disconnected from
any conductor included in the Test.
1.10.3 All equipment and including batteries, battery isolators and outgoing switchgear
shall be inspected for mechanical integrity.
1.10.4 Incoming voltage shall be checked.
1.10.5 The following inspection shall be performed on all batteries.
a) Check battery cells for correct voltage, connection tightness and cleanliness
of terminal links
b) On non sealed-for-life batteries check the specific gravity and level of
electrolyte.
c) Check that the charging rate is set in accordance with the Seller’s
instructions and ensure the battery is fully charged before leaving in
operation.
d) Carry out battery discharge tests in accordance with Seller’s instructions.
e) Ensure that the battery assembly is left in a clean state free from moisture
on external surfaces.
f) All Battery connections are to be coated with “Chemodex” or equivalent
grease to prevent any corrosion.

1.11 UPS Systems (Inverters)

1.11.1 Checks and tests on UPS Units shall be carried out in accordance with Seller’s
instructions and under Seller’s supervision.
1.11.2 Caution: on no account shall solid-state components be subjected to Megger
or high voltage test. Such components shall be completely disconnected from
any conductor included in the test.
1.11.3 All equipment and including batteries, battery isolators and outgoing switchgear
shall be inspected for mechanical integrity.
1.11.4 Incoming voltages shall be checked.
1.11.5 The following inspection shall be performed on all batteries:
• Check battery cells for correct voltage connection and cleanliness of
terminal links
• On non sealed-for-life batteries check the specific gravity and level of
electrolyte
 • Check that the charging rate is set in accordance with the Seller’s
instructions and ensure the battery is fully charged before leaving in
operation
• Carry out battery discharge tests in accordance with Seller’s instructions
• Ensure that the battery assembly is left in a clean state free from
moisture on external surfaces

1.12 Rotating Machines

1.12.1 General
1.12.1.1. Checks and tests on motors and generators shall be carried out in accordance
with Seller’s instructions.
1.12.1.2. Measure insulation resistance to earth. (After 1 minute)
Required minimum values:
Rated Voltage Test Voltage Insulation Resistance

H.V. AC. Stator 1000 V Megger 50 M ohms

L.V. AC. Stator 500 V Megger 10 M ohms
Any V. DC. Motor 500 V Megger 5 M ohms
230 V AC. Heater 500 V Megger 2 M ohms

1.12.1.3. If the insulation resistance of a HV machine stator winding is below the

minimum acceptable value the polarisation index shall also be measured. A
motorised megger, or similar equipment, is required for this test.
1.12.1.4. When direct current is applied to sound insulation, the readings should continue
to rise for many minutes, even hours. The Polarisation Index being the ratio of
the final value ( after 10 minutes )over the initial resistance ( after 1 minute )
1.12.1.5. The minimum acceptable polarisation index value is 1.5 , but the winding
resistance is only acceptable provided the final resistance value is in excess of
the minimum value listed above.
1.12.1.6. If the polarisation index is less than 1.5 then the motor Seller’s instructions must
be followed.
1.12.1.7. To test the bearing insulation of a machine the earthing link shall be removed
and the insulation resistance tested with a 500 Volt Megger. A resistance
greater than 50,000 ohms is adequate; lower resistance shall be investigated.
1.12.1.8. The earthing link must be replaced when the test is completed.
1.12.1.9. Check the bearing lubrication. On oil lubricated machines check, by sight-glass
or other means, that the bearing oil-wells are at the correct level and top-up or
drain-off if necessary.
1.12.1.10. On DC machines if applicable check brush gear for tightness, correct alignment
and proper brush movement and tension.
1.12.1.11. Check earthing connections and terminal box studs/connections for tightness.
1.12.1.12. For motors uncoupled, switch on briefly to check rotation:
a) If AC motor rotation is incorrect, interchange two stator connections.
Confirm cooling airflow is maintained for unidirectional motors.
b) In the unlikely event of a DC motor’s rotation being incorrect the
(armature + interpoles, if any) circuit polarity must to be reversed relative
to the (shunt + series, if any, field) circuit or vice-versa whichever is
easier. Since the brush gear position may be affected the Seller’s
instructions must be sought.
c) Test the correct operation of the motor from the local control station,
motor control centre and DCS (as applicable).
1.12.1.13. Run machine uncoupled for at least 1 hour.
a) For short time rated machines the test run may be reduced.
b) If, for any reason, it is impractical or impossible to run a machine
uncoupled the 1 hour check must be done coupled, in conjunction with
the driven or driver equipment test.
1.12.1.14. During the test run:
a) Check for undue noise or vibration.
b) On oil-lubricated machines check for correct operation of lube-oil system
and bearing temperatures by sight, feel and by any indicators which may
be fitted.
c) Observe ammeter for excessive or uneven current reading. Check for
phase out-of-balance on AC machines.
d) Observe temperature indicated by winding temperature detectors (if
fitted) and check for phase balance.
Insulation tests and lubrication checks shall be repeated before the machine is
finally put into operation if the time period following pre commissioning is
prolonged.

1.12.2 Standby Diesel Generator

1.12.2.1. Testing of standby diesel generators and their associated controls and
instrumentation shall be carried out under Seller’s supervision.
1.12.2.2. Before commencing tests, confirm that the generator incomer on the
appropriate Switchgear has been tested, including current injection and proving
of electrical interlocks, etc.
1.12.2.3. Live phasing out between generator and mains supply shall first be carried out
using temporary test connections at one end of the feeder before the main
cables are finally laid up and terminated at the generator or switchgear,
whichever end is convenient. After this preliminary check the main cables shall
be laid up in correct formation and terminated. Phasing shall again be carried
out across the generator incomer as part of the final tests.
CAUTION: On no account shall solid-state components be subjected to
Megger or high voltage tests.
No Megger tests shall be carried out on the rotor and excitation system.
1.12.2.4. With generator incomer at switchgear open and all voltage fuses withdrawn, all
local panel voltage fuses withdrawn and any generator CT secondaries
earthed, measure the stator winding insulation resistance to ground using a
500V Megger. Required minimum resistance: 20 M ohms.
1.12.2.5. Replace voltage fuses, remove temporary test connections, carry out pre-run
checks and set controls in accordance with Seller’s instructions.
1.12.2.6. Check engine lube-oil, cooling water and fuel day-tank, carry out pre-run
checks in accordance with Seller’s instructions.
1.12.2.7. Start engine by local manual controls. Check engine to Seller’s instructions.
Test all engine alarms and shut-down devices.
1.12.2.8. At local panel, adjust engine speed and voltage. At switchgear check
frequency and voltage indication against local indication. Test operation of
governor and voltage controls at switchgear. If necessary change over control
connections to correct direction.
1.12.2.9. Carry out the following test using temporary test connections. At the switchgear
adjust the speed and voltage to match mains supply, keep generator in step
with synchroscope at zero and phase out across all three phases using a
voltmeter. (Thus proving phasing and synchroscope).
Lay up and finally terminate the feeder cables. Repeat the test.
1.12.2.10. With main cables terminated, generator circuit breaker open in TEST position
and generator running, select “Hand” control.
a) Block the check synchronising contacts to inhibit circuit breaker closure,
bring generator into step with mains supply and try to close circuit breaker
by manual switch. It should not close.
b) Unblock the check synchronise contacts and repeat test. The circuit
breaker should now close. Open circuit breaker.
c) Maintain generator volts equal to mains volts. Vary frequency and observe
operation of the check synchroniser relay against synchroscope.
 d) Maintain generator frequency steady with synchroscope at zero. Vary
voltage and observe operation of check synchroniser relay.
(Tests (c) and (d) are not intended to repeat factory calibration tests but only to
check that check synchroniser operates in its correct approximate zone)
1.12.2.11. Stop generator and leave in “Standby” mode. Leave circuit breaker open in
TEST position. Select “Auto” control. De-energise undervoltage relay to
simulate mains failure.
1.12.2.12. Observe and time auto-start of generator, build-up of volts and frequency and
circuit breaker closure. Open circuit breaker, select “Hand” control and return
under voltage relay to normal. Rack in circuit breaker to SERVICE position.
1.12.2.13. If the system is designed for a ‘no break’ transfer and/or for on stream load
testing the following tests should be carried out when main generator power is
available and with as much “dead”(i.e. non motor) load as possible connected.
(Motor load may be left on for test (a) but drops off in test (b)):
Synchronise generator and parallel to mains by “Hand” control. Transfer all
load to generator by means of governor control. A load not less than 75%
generator full load is desirable but may not be available. Adjust power factor
(PF) to 0.85 lag. by means of voltage control.
Without moving voltage control, reduce generator load to a minimum by means
of governor control. Record kW, Volts, PF and Frequency.
Without moving voltage control, transfer all load back onto generator. (P.F.
should read 0.85 lag. without adjustment).
Allow generator to run on load for 10 minutes and record any change in load
sharing or PF.
1.12.2.14. Record kW, Volt, PF and Frequency on load. Open generator circuit breaker
on load. Do not move governor or voltage control. Mark positions of controls.
Record Volts and Frequency in transient and off-load state.
1.12.2.15. Leave generator running.
a) Open mains Circuit Breaker
Close generator Circuit Breaker. Record kW, Volts, PF and Frequency in
transient and off-load state.
b) Open generator circuit breaker. Stop generator. Do not move governor or
voltage control. Close generator circuit breaker and select “Auto” control.
1.12.2.16. Observe and time auto-start of generator, build-up of volts and frequency and
record kW, Volts, PF and Frequency in transient and on-load state.
1.12.2.17. Synchronise and parallel mains supply switchgear. Open generator circuit
breaker. Do not move governor or voltage controls.
Provided that test results are satisfactory, leave governor and voltage controls
in their marked positions. Leave generator circuit breaker open in SERVICE
position, select “Auto” control and leave generator in “Standby” mode.
1.12.2.18. Compare test results with Seller’s performance specification.
Make any necessary adjustments in accordance with Seller’s instructions. If
performance still does not conform to specification, the Seller must be called
in.

1.12.3 Main Power Generators

1.12.3.1. Testing of main power generators and its associated excitation equipment shall
be carried out in accordance to Seller’s instruction and under Seller’s
supervision.
Before commencing tests confirm that the generator incomer on the
appropriate Switchgear has been tested, including current injection and proving
of electrical interlocks, etc.
1.12.3.2. CAUTION: On no account shall solid-state components be subjected to Megger
or high voltage tests.
No Megger tests shall be carried out on the rotor and excitation system.
1.12.3.3. Prior to starting the machine, with generator incomer at switchgear open and
all voltage fuses withdrawn, all local panel voltage fuses withdrawn and any
generator CT secondaries earthed, measure the stator winding insulation
resistance to earth.
1.12.3.4. Replace voltage fuses, remove temporary test connections, carry out pre-run
checks and set controls in accordance with Seller’s instructions. Check remote
operation of the governor from the switchgear.
1.12.3.5. When machine is running, at local panel adjust speed and voltage. Check
remote frequency and voltage indication against local indication. Test
operation of governor and voltage controls at each control point. If necessary
change over control connections to correct direction.
1.12.3.6. Carry out the following test using temporary test connections. Adjust the speed
and voltage to match mains supply, keep generator in step with synchroscope
at zero and phase out at switchgear across all three phases using phasing
sticks. (Thus proving phasing and synchroscope).
Lay up and finally terminate the feeder cables. Repeat the test.
1.12.3.7. With generator circuit breaker open in TEST position and generator running,
select “Hand” control.
a) Block the check synchronising contacts to inhibit circuit breaker closure,
bring generator into step with mains supply and try to close circuit breaker
by manual switch. It should not close.
b) Unblock the check synchronise contacts and repeat test. The circuit
breaker should now close. Open circuit breaker.
c) Maintain generator volts equal to mains volts. Vary frequency and observe
operation of the check synchroniser relay against synchroscope.
 d) Maintain generator frequency steady with synchroscope at zero. Vary
voltage and observe operation of check synchroniser relay.
(Tests (c) and (d) are not intended to repeat factory calibration tests but only
to check that check synchroniser operates in its correct approximate zone)
1.12.3.8. Stop generator. Leave circuit breaker open in TEST position. Select “Auto”
control.
1.12.3.9. Operate remote start switch, observe and time auto-start of generator, build-up
of volts and frequency and circuit breaker closure.
1.12.3.10. Open circuit breaker, select “Hand” control. Rack in circuit breaker to SERVICE
position.
1.12.3.11. Synchronise generator and parallel with other generators by “Hand” control.
Transfer load to generator by means of governor control. A load not less than
75% generator full load is desirable but may not be available. Adjust power
factor (PF) to 0.85 lag. by means of voltage control.
1.12.3.12. Without moving voltage control, reduce generator load to a minimum by means
of governor control. Record kW, Volts, PF and Frequency.
1.12.3.13. Without moving voltage control, transfer all load back onto generator. (P.F.
should read 0.85 lag. without adjustment).
1.12.3.14. Allow generator to run on load for 10 minutes and record any change in load
sharing or PF.
1.12.3.15. Adjust governor control to make generator share load equally with other on site
generators.
1.12.3.16. Switch to Isochronous control. Check load sharing periodically.
1.12.3.17. Leave generator running.
1.12.3.18. Compare test results with Seller’s performance specification.
Make any necessary adjustments in accordance with Seller’s instructions. If
performance still does not conform to specification, the Seller must be called
in.

1.13 Electric Process Heaters

1.13.1 CAUTION: On no account shall solid-state components be subjected to Megger
tests. For this reason, no Megger or high voltage tests shall be carried out on
the controllers.
1.13.2 Tests on the controllers shall be carried out according to Seller’s instructions in
conjunction with Field Instrumentation Group.
1.13.3 Continuity and insulation resistance tests shall be performed on heating
elements prior to and after installation of the heater bundles.
1.13.4 Measure continuity and insulation resistance of heating elements using a 500
V Megger.
1.13.5 Required minimum insulation resistance of heating elements is:
• Mineral insulated elements: 100 M ohms
• All parallel resistance elements: 20 M ohms
1.13.6 After final installation connections have been completed, switch on power
supply and measure voltage and current for the whole system, and for
individual sections if feasible.
1.14 Trace Heating
1.14.1 Electric trace heating shall be carried out in accordance to Seller’s instructions.
1.14.2 Continuity and insulation resistance tests shall be performed on heating
elements, at the following stages:
• Prior to installation
• After installation, but before thermal insulation is fitted.
• After thermal insulation has been fitted.
1.14.3 Measure continuity and insulation resistance of heating elements using a 500V
Megger.
1.14.4 Required minimum insulation resistance of heating elements is:
• Mineral insulated elements: 100 M ohms
• All parallel resistance elements: 20 M ohms
1.14.5 After final installation connections have been completed, switch on power
supply and measure voltage and current for the whole system, and for
individual sections if feasible.
1.14.6 Set thermostats in accordance with contract drawings and instructions.
1.15 Miscellaneous
1.15.1 Substation interface panels and Miscellaneous Control Panels
Substation interface panels shall be tested under Seller’s supervision.

1.15.2 Distribution Boards

1.15.2.1. Distribution boards shall be carried out in accordance to Seller’s instructions.
1.15.2.2. Measure cable insulation resistance of each individual circuit between phases
and also between phases and earth, using a 500 V Megger.
1.15.2.3. Check ratings of protective devices against that stated in the distribution board
schedule.