Earthling System Electrical and Instruments Test Procedure

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0
NATIONAL IRANIAN OIL COMPANY

South Pars Gas Field Development
OIEC NJ.G.C
Phases 20 & 21
Pars Oil &, Gas Company
ngwl/mngII.n" ConsbucfiOf1
DOCUMENT TITLE DOCUMENT No. Rev. : 0 I Class: 1
Earthling System Electrical and
Instruments Test Procedure Test TOT -SP20210NCO999P3320015 Page 1 of 23
Procedure
EarthingSystem Electricaland InstrumentsTest
Procedure
(ONSHOREFACILITIES- PRECOMMISSIONING)
CONTRACT NO. : POGC572-88-35
PROJECT: SOUTH PARS GAS FIELD DEVELOPMENT
PHASES 20&21
COMPANY: PARS OIL & GAS COMPANY
SITE: ASSALUYEH, IRAN
o 30/Sep/2013 Issued For Approval oleo
Rev. Date Description Originator Prepared Checked
A.Razzaghi
Approved

OilIndustriesEngineeringandConstruction

Phases 20 & 21

DOCUMENT TITLE DOCUMENT No. Rev.: 0 Class: 1
Instruments Test Procedure Test
Procedure
TOT-SP2021-ON-CO-999-P332-0015 Page 2 of 23

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TABLE OF CONTENT

1. Object...............................................................................................................................................5
2. Definitions........................................................................................................................................5
3. General.............................................................................................................................................5
4. Test Methods...................................................................................................................................6
4. 1 Insulation Resistance (IR) tests...............................................................................................6
4. 2 High voltage tests.......................................................................................................................6
5. Test procedures..............................................................................................................................6
6. Earthing systems - Test Sheet T-PX-26......................................................................................7
a. Continuity of protective conductors.............................................................................................7
b. For main protective conductor,.....................................................................................................7
7. Equipment earth return path impedance test.............................................................................7
a. Definitions........................................................................................................................................7
b. Method.............................................................................................................................................8
c. Motor fed from LV motor control centre......................................................................................8
d. Lighting circuit fed from distribution board (See Example 2).................................................10
e. HV Motor fed from HV switchboard (See Example 3)............................................................12
8. Grounding System Testing..........................................................................................................14
a. Fall-of-Potential Method or 3-Point Test...................................................................................14
b. Graphing & Evaluation.................................................................................................................16
c. Invalid Tests..................................................................................................................................17
d. Induced Frequency Testing or Clamp-On Testing..................................................................18
e. Test Application............................................................................................................................19
f. Ground Resistance Monitoring...................................................................................................20
9. Appendix........................................................................................................................................20


Phases 20 & 21

Procedure

9.1. Appendix01: Electrical LV Power Cables (T-PX-09)...................................................................21
9.2. Appendix02: Electrical Earthing / Lightning System (T-PX-26).................................................22
9.3. Appendix03: Electrical Earthing (C-PX-26)..................................................................................23


Phases 20 & 21

Procedure

1. Object
Pre-commissioning is a phase associated with the construction stage such that the completion
of pre-commissioning marks the end of the construction for any specific equipment. Its object is
to prepare and statically test the equipment, which has been constructed and installed, so that
the equipment is ready to undergo dynamic testing during the commissioning phase.
This document outlines the pre-commissioning activities and tests of the EARTHING SYSTEM.
2. Definitions
PRE-COMMISSIONING: Includes all activities required to make the facilities ready for
COMMISSIONING (Conformity Checks, Static Tests, Flushing and Cleaning).
3. General
Record check results as required on the relevant check-list forms (CPX-26) (Refer to Appendix).
Test voltages and frequency:
The project procedures and Test Sheets shall take into account the project voltages and
frequency.
The power frequency dielectric test voltages shall be based on the following IEC
recommendations and shall be adjusted to take into account the fact that some equipment has
already been subjected to factory tests.
In no case the test voltage shall exceed the value indicated in the equipment VENDOR
maintenance manual.

IEC 60034 for Rotating Electrical machines
IEC 60060 High Voltage test techniques
IEC 60071 - Insulation co-ordination
IEC 60076 for Electrical Transformers
IEC 60502-2 for HV cables


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Procedure

IEC 62271 and IEC 60694 for HV and LV switchgears
4. Test Methods
4. 1 Insulation Resistance (IR) tests
IR testing shall be carried out by applying a D.C. voltage from an insulation tester at voltage
levels given in this specification.
4. 2 High voltage tests
Before high voltage tests are executed, insulation resistance tests shall be carried out.
High voltage testing shall be carried out by D.C. voltage at a level above the operating voltage.
High-voltage testing of electrical equipment, except LV cables, shall have been carried out at
the Manufacturer's works with A.C. at voltage levels in accordance with the IEC.
Repeated high voltage tests may introduce weak points in the insulation of windings, and
therefore such tests shall not be applied at site to generators, motors or transformers.
The HV tests at full voltage shall not be repeated two times. If however for special reasons
these tests are considered to be remade a second time, they shall be carried out only after
consultation with the Manufacturer and with a test voltage of 80 % of the initial full test voltage.
5. Test procedures
Prior of any test, relevant Project Specifications and MANUFACTURER's Test Procedures shall
be adhered to.
The CONTRACTOR shall carry out tests as laid down on the Test Sheet.
If the obtained IR or PI values fall below the minimum values, then the equipment should not be
energized or subjected to high voltage testing.
Appropriate action should be taken, e.g. drying, to normalize the figures.
In case of 'flash-over' during high voltage testing appropriate measures shall be taken (e.g.
cleaning, drying, repair) to eliminate the cause. Re-testing shall be performed after repair.


Phases 20 & 21

Procedure

In the event that any of the tests fails to meet the specification requirements, it will be necessary
for the CONTRACTOR to list any discrepancies and to present them to the COMPANY
Engineer.
The Test Sheet will be completed, signed and dated, and presented to the COMPANY Engineer
for approval.
Copies of the Test Sheet will be issued to the Certifying Authority if required. The original shall
be inserted in the Ready for Commissioning dossier.
6. Earthing systems - Test Sheet T-PX-26
a. Continuity of protective conductors
A continuity test shall be made in order to check the continuity of the protective conductors,
including the equipotential bonding.
b. For main protective conductor,
Test results shall be obtained from cable test sheet T-PX-09 LV POWER CABLES AND
CONTROL CABLE.
7. Equipment earth return path impedance test
a. Definitions
To comply with IEC 60364-4-41, touch voltages shall not exceed 50 volts AC rms.
The earth impedance loop shall be lower than the RA calculated:
RA x Id < UL
RA = the earthing resistance of all exposed conductive parts connected by a protective
conductor to an earth electrode
Id = Fault current for the first dead fault between a phase conductor
UL = Conventional touch voltage.
Example:


Phases 20 & 21

Procedure

Distribution system Id (mA) UL (V) RA (ohms)
LV 30 50 167
HV 30000 50 1.67

b. Method
All power supplies to the systems under test shall be isolated before commencing the tests.
All testing shall be carried out in accordance with the attached detail drawings using an AC
current injection test set.
The injected current shall be equal to 1.5 times the design current of the circuit under test
except that the current shall not exceed 25 A.
The loop impedance value measured is equal to:
E = (test set generator current) / (test set generator voltage)
This measurement is applicable for:
Verification of trip condition upon 2nd fault phase to earth in IT system.
Verification of trip condition upon earth fault in TN system (circuits without ELCB).
It shall be performed for each switchboard/MCC on the longest cable run on onshore plants.
c. Motor fed from LV motor control centre
Connect injection test set between MCC Phase Busbar R and switchboard earth,
manually close contactor (outgoing feeder) and determine loop impedance E4 by
shorting motor terminal R phase to motor earth conductor.
Short across high impedance earthing resistor F and close circuit breaker E to
determine loop impedance E4.
Total earth return path impedance = E3 + E4. (This is a conservative value since the
phase conductor resistances are also included).


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Procedure

Example 1: Typical return path impedance loop 440 V 3 phase motor circuit


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Procedure

d. Lighting circuit fed from distribution board (See Example 2)
Connect injection set between Phase T Busbar and Distribution Board Earth. Manually
close Breaker A and determine loop impedance E3 by shorting the end light fitting
Terminal T to the Earth Conductor.
Short across high impedance earthing Resistor F and manually close circuit breaker
E to determine Loop Impedance E4.
Total Earth Return Path Impedance = E3 + E4. (This is a conservative value since the
phase conductor resistances are also included).

Note: Earth return path impedance tests on small power circuits shall be at the direction and the
discretion of the COMPANY Engineer.
With the level of protection provided, it is only considered necessary to test one circuit per
distribution board providing results are satisfactory.


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Procedure

Example 2: Typical return impedance loop small power circuit


Phases 20 & 21

Procedure

e. HV Motor fed from HV switchboard (See Example 3)
Connect injection test set between switchboard Phase Busbar R and switchboard
earth, close breaker/contactor A and determine loop impedance E6 by shorting motor
terminal R phase to motor earth conductor.
Connect injection test set between switchboard Phase Busbar R and switchboard
earth, close earthing transformer contactor B and determine loop impedance E5 by
shorting earthing transformer terminal R phase to transformer earth conductor.
Total earth return path impedance = E5 + E6.


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Procedure

Example 3: Earth return impedance path loop
6.6 kV motor circuits


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Procedure

8. Grounding System Testing
The measurement of ground resistance for an earth electrode system is very important. It
should be done when the electrode is first installed, and then at periodic intervals thereafter.
This ensures that the resistance-to-ground does not increase over time. There are two (2)
methods for testing an existing earth-electrode system. The first is the 3-point or fall-of-
Potential method and the second is the Induced Frequency test or clamp-on method. The 3-
point test requires complete isolation from the power utility. Not just power isolation, but also
removal of any neutral or other such ground connections extending outside the grounding
system. This test is the most suitable test for large grounding systems and is also suitable for
small electrodes. The induced frequency test can be performed while power is on and actually
requires the utility to be connected to the grounding system under test. This test is accurate only
for small electrodes, as it uses frequencies in the kilo Hertz range, which see long conductors
as inductive chokes and therefore do not reflect the 60 Hz resistance of the entire grounding
system.
a. Fall-of-Potential Method or 3-Point Test
The 3-point or fall-of-potential method is used to measure the resistance-to-ground of existing
grounding systems. The two primary requirements to successfully complete this test are the
ability to isolate the grounding system from the utility neutral and knowledge of the diagonal
length of the grounding system (i.e. a 10 x 10 grounding ring would have a 14 diagonal
length).
In this test, a short probe, referred to as probe Z, is driven into the earth at a distance of ten
times (10X) the diagonal length of the grounding system (rod X). A second probe (Y) is placed
in-line at a distance from rod X equal to the diagonal length of the grounding system.


Phases 20 & 21

Procedure

At this point, a known current is applied across X & Z, while the resulting voltage is measured
across X & Y.
Ohms Law can then be applied (R=V/I) to calculate the measured resistance. Probe Y is then
moved out to a distance of 2X the diagonal length of the grounding system, in-line with X & Z, to
repeat the resistance measurement at the new interval.
This will continue, moving probe Y out to 3X, 4X ... 9X the diagonal length to complete the 3
point test with a total of nine (9) resistance measurements.
Record all the results in the related test sheet (TPX26) (Refer to Appendix).


Phases 20 & 21

Procedure

b. Graphing & Evaluation
The 3-point test is evaluated by plotting the results as data points with the distance from rod X
along the X-axis and the resistance measurements along the Y-axis to develop a curve.
Roughly midway between the center of the electrode under test and the probe Z, a plateau or
flat spot should be found, as shown in the graph. The resistance of this plateau (actually, the


Phases 20 & 21

Procedure

resistance measured at the location 62% from the center of the electrode under test, if the soil is
perfectly homogeneous) is the resistance-to-ground of the tested grounding system.
c. Invalid Tests
If no semblance of a plateau is found and the graph is observed to raise steadily the test is
considered invalid. This can be due to the fact that probe Z was not placed far enough away
from rod X, and can usually indicate that the diagonal length of the grounding system was not
determined correctly. If the graph is observed to have a low plateau that extends the entire
length and only rises at the last test point, then this also may be also considered invalid. This is
because the utility or telecom neutral connection remains on the grounding system.


Phases 20 & 21

Procedure

d. Induced Frequency Testing or Clamp-On Testing
The Induced Frequency testing or commonly called the Clamp-On test is one of the newest
test methods for measuring the resistance-to-ground of a grounding system or electrode. This
test uses a special transformer to induce an oscillating voltage (often 1.7 kHz) into the
grounding system. Unlike the 3-point Test which requires the grounding system to be
completely disconnected and isolated before testing, this method requires that the grounding
system under test be connected to the electric utilities (or other large grounding system such as
from the telephone company) grounding system (typically via the neutral return wire) to provide
the return path for the signal. This test is the only test that can be used on live or hot systems.
However, there are some limitations, primarily being:
1. The amount of amperage running through the tested system must be below the
equipment manufacturers limits.
2. The test signal must be injected at the proper location, so that the signal is forced
through the grounding system and into the earth.
3. This instrument actually measures the sum of the resistance of the grounding system
under test and the impedance of the utility neutral grounding, including the neutral
wiring. Due to the high frequency used, the impedance of the neutral wiring is non-
negligible and can be greater than the ground resistance of a very low resistance
grounding system, which can therefore not be measured accurately.
4. The ground resistance of a large grounding system at 60 Hz can be significantly lower
than at 1.7 kHz.
Many erroneous tests have been conducted where the technician only measured metallic loops
and not the true resistance-to-ground of the grounding system. The veracity of the Induced
Frequency Test has been questioned due to testing errors, however when properly applied to a


Phases 20 & 21

Procedure

small to medium sized, self-standing grounding system, this test is rapid and reasonably
accurate.
e. Test Application
The proper use of this test method requires the utility neutral to be connected to away-type
transformer. The oscillating voltage is induced into the grounding system at a point where it will
be forced into the soil and return through the utility neutral. Extreme caution must be taken at
this point as erroneous readings and mistakes are often made. The most common of these
occur when clamping on or inducing the oscillating voltage into the grounding system at a point
where a continuous metallic path exists back to the point of the test. This can result in a
continuity test being performed rather than a ground resistance test.


Phases 20 & 21

Procedure

Understanding the proper field application of this test is vital to obtaining accurate results. The
induced frequency test can test grounding systems that are in use and does not require the
interruption of service to take measurements.
f. Ground Resistance Monitoring
Ground resistance monitoring is the process of automated timed and/or continuous resistance-
to ground measurement. These dedicated systems use the induced frequency test method to
continuously monitor the performance of critical grounding systems. Some models may also
provide automated data reporting. These new meters can measure resistance-to-ground and
the current that flows on the grounding systems that are in use. Another benefit is that it does
not require interruption of the electrical service to take these measurements.
9. Appendix
TPX09 ElectricalLVPowerCables
TPX26 ElectricalEarthing/LightningSystem
CPX26 ElectricalEarthingSystem


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Procedure

9.1. Appendix01: Electrical LV Power Cables (T-PX-09)
Tas k Number :
Form :
Dwg / PID :
Tas k Location : Us er Group :
Estimated Time (MH) : Expended Time (MH) :
Punch Lis t Items :
Module :
Subsystem :
TPX09 - LV POWER CABLES
PRECOMMISSIONING TEST SHEET
ELECTRICAL
LV POWER CABLES
0

T ES T I N G I N S T R U M EN T S U S ED
T YP E / S E R I AL N : T YP E / S E R I AL N :
T YP E / S E R I AL N :
EL EC T R I C A L T ES T S ( C A B L E D I S C O N N EC T ED )
UPS TREA M CO NNECTIO N A CCO RDING CA B L E S CHEDUL E
DO W NS TREA M CO NNECTIO N A CCO RDING CA B L E S CHEDUL E
CRO S S S ECTIO N A CCO RDING CA B L E S CHEDUL E
P H 1
P H 2
P H 3
A RMO UR CO NTINUITY
PRO TECTIV E CO NDUCTO R CO NTINUITY
P H 1 / P H 2 - P H 3 - E
P H 2 / P H 1 - P H 3 - E
P H 3 / P H 1 - P H 2 - E
CO RE / A RMO UR Mo h m
CA B L E IS CO RRECTL Y RE- CO NNECTED.
N o t e : Th e Min imu m A c c e p t a b le V a lu e W ill b e :
* 4 4 0 V c a b le s - 5 0 Mo h m- 1 0 0 0 v Me g g e r
* 2 4 0 V c a b le s - 1 0 Mo h m- 5 0 0 v Me g g e r
( M o h m )
( M o h m )
( M o h m )
CO RES / EA RTH Mo h m
I N S U L A T I O N
CO RE CO NTINUITY
C O N T I N U I T Y

S i g n
T P A / C O M P A N Y C O M M I S S I O N I N G C O N S T R U C T I O N S U B C O N T R A C T O R
D a t e
N a m e


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Procedure

9.2. Appendix02: Electrical Earthing / Lightning System (T-PX-26)
1.
T a s k N u m b e r :
F o r m :
D w g / P I D :
T a s k L o c a t i o n : U s e r G r o u p :
E s t i m a t e d T i m e ( M H ) : E x p e n d e d T i m e ( M H ) :
P u n c h L i s t I t e m s :
M o d u l e :
S u b s y s t e m :
T P X 2 6 - E A R T H I N G S Y S T E M
P R E C O M M I S S I O N I N G T E S T S H E E T
E L E C T R I C A L
E A R T H I N G / L I G H T N I N G S Y S T E M
0

2.
T E S T I N G I N S T R U M E N T S U S E D
T Y P E / S E R I A L N : T Y P E / S E R I A L N :
T Y P E / S E R I A L N :
T E S T R E S U L T S
G L O B A L E A R T H I N G R E S I S T A N C E O h m T E S T C U R R E N T A
E A R T H I N G R O D R E S I S T A N C E O h m
E A R T H I N G / L I G H T N I N G E L E C T R O D S A R E T O B E T E S T E D I N D I V I D U A L L Y A N D A S A G R O U P
* I N D I V I D U A L L E L E C T R O D E R E S I S T A N C E :
N o . 1 : . . O h m N o . 2 : . . O h m
N o . 3 : . . O h m N o . 4 : . . O h m
* I N D I V I D U A L L G R O U P R E S I S T A N C E A S A P P L I C A B L E : . . O h m
D R A W I N G N
A S S O C I A T E D
C A B L E N
L O O P
R E S I S T A N C E E A R T H D I S P A T C H E R ( T O ) E Q U I P M E N T N ( F R O M )

3.

S i g n
C O M P A N Y C O M M I S S I O N I N G C O N S T R U C T I O N S U B C O N T R A C T O R
D a t e
N a m e


Phases 20 & 21

Procedure

9.3. Appendix03: Electrical Earthing (C-PX-26)
T a s k N u m b e r :
I T EM
P R E C O M M I S S I O N I N G C H E C K L I S T
E L E C T R I C A L
E A R T H I N G S Y S T E M
T a s k L o c a t i o n :
S u b s y s t e m :
C P X 2 6 - EA R T H I N G S Y S T EM

U s e r G r o u p :
E s t i m a t e d T i m e ( M H ) : E x p e n d e d T i m e ( M H ) :
C H EC K L I S T
F o r m :
M o d u l e :
1
2
3
4
5
6
7
8
9
1 0
1 1
1 2
1 3
1 4
1 5
1 6
1 7
1 8
1 9
2 0
2 1
N / A N o t A p p l i c a b l e P N o t a c c e p t e d ( P u n c h ) C h e c k e d & A c c e p t e d
D r a w i n g s & d o c . r e f . :
R E M AR K S :
P r o d u c e m a r k e d - u p d r a w i n g s i n a c c o r d a n c e w i t h i n s t a l l a t i o n .
C h e c k L i g h t n i n g a i r t e r m i n a l i n s t a l l e d a s p e r t h e
D r a w i n g s / S p e c i f i c a t i o n .
P r o d u c e a d e f e c t s l i s t f o r p u n c h l i s t i s s u e .
C h e c k e a r t h i n g / l i g h t n i n g W e l l ( P i t ) l o c a t i o n a s p e r d r a w i n g s .
C h e c k c o n n e c t i o n e a r t h c a b l e / e l e c t r o d e b e f o r e b a c k f i l l i n g .
C h e c k c o n t i n u i t y e l e c t r o d e - e a r t h b a r / p l a n t e a r t h r i n g .
C h e c k c o n t i n u i t y e l e c t r o d e - e a r t h p i t t o e a r t h b a r .
C h e c k c o n t i n u i t y o f e q u i p m e n t l o o p p r o t e c t i o n c o n d u c t o r s .
C h e c k e a r t h i n g n e t w o r k s s e g r e g a t i o n ( I S )
C h e c k e a r t h r o d s c o r r e c t i n s t a l l a t i o n
C h e c k a l l e a r t h b a r s i n s t a l l a t i o n a n d t a g g i n g a g a i n s t d r a w i n g s .
C h e c k e a r t h i n g c a b l e s i n s t a l l a t i o n a n d t a g g i n g a g a i n s t d r a w i n g s .
C h e c k a l l c o n n e c t i o n s a r e t i g h t , c l e a n a n d c o a t e d w i t h a n
a p p r o ve d a n t i - c o r r o s i ve g r e a s e .
C h e c k e a r t h i n g c a b l e s c r o s s s e c t i o n a g a i n s t d r a w i n g s .
C h e c k d i s p a t c h e r c o n t i n u i t y a n d d r a w i n g .
C h e c k vi s u a l i n s p e c t i o n b e f o r e b a c k f i l l i n g .
C h e c k t h e r m a l c o n n e c t i o n i n s u l a t i o n .
C h e c k t h e r m a l c o n n e c t i o n b e f o r e b a c k f i l l i n g .
C h e c k r i s e r c o n d u i t i n s t a l l a t i o n w i t h r e l a t e d d r a w i n g .
C h e c k c o m p r e s s i o n o f c o n n e c t i o n s .
C h e c k i n s u l a t i o n o f c o m p r e s s i o n c o n n e c t i o n s .

D a t e
N a m e
S i g n
T P A / C O M P A N Y C O M M I S S I O N I N G C O N S T R U C T I O N S U B C O N T R A C T O R

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