El 4
El 4
PROCEDURES FOR
JANUARY 1994
J237 (Rev 06/01)
EL4
CONTENTS
Page
FOREWORD iii
BRIEF HISTORY v
1. SCOPE 1
2. APPLICATION 1
2.1 General 1
2.2 Commissioning 1
2.3 Maintenance 1
3. REFERENCES 1
4. DEFINITIONS 1
5. GENERAL REQUIREMENTS 2
TABLES
Page
APPENDICES
A LIST OF REFERENCES 13
B RECORD SHEETS 15
FOREWORD
Comments and queries regarding the Technical content of this engineering document should be directed to:
Engineering Policy
Transco
Brick Kiln Street
Off Coventry Road
Hinckley
Leicestershire
LE10 0NA
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designation) and your cost code.
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they are in possession of the latest edition by referring to the Transco Register of Engineering Documents
available on TransNet.
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statutory or other legal obligations.
Contractors and other users external to Transco should direct their requests for further copies of Transco
engineering documents to the department or group responsible for the initial issue of their contract
documentation.
DISCLAIMER
This engineering document is provided for use by Transco and such of its contractors as are obliged by the
terms and conditions of their contracts to comply with this engineering document. Where this engineering
document is used by any other party it is the responsibility of that party to ensure that the engineering
document is correctly applied.
BRIEF HISTORY
© Transco plc.
This engineering document is copyright and must not be reproduced in whole or in part by any means
without the approval in writing of Transco plc.
PROCEDURES FOR
INSPECTION AND TESTING OF FIXED ELECTRICAL
EQUIPMENT AND SYSTEMS
1. SCOPE
1.1 These Transco Procedures* specify requirements for the inspection and testing of new and
relocated fixed electrical equipment and systems installed for the use of Transco. They also specify the
information required by Transco for completion of inspection and test records.
1.2 These procedures are limited to equipment with maximum ratings of 11 kV and 2 MVA.
Equipment having ratings in excess of these should have procedures for inspection and testing specified in
the relevant contract documents.
2. APPLICATION
2.1 General
The purpose of inspection and testing is to prove that the equipment and systems concerned comply with
the relevant contractual requirements and to demonstrate that such equipment and systems are fit for
purpose.
2.2 Commissioning
2.2.1 These procedures form the basis of the inspections and tests required to be undertaken before
fixed electrical equipment and systems can be commissioned. They may be supplemented by further
requirements specified in the relevant contract documents.
2.2.2 Where fixed electrical equipment forms a direct interface with mechanical plant and/or process
systems, the overall commissioning requirements need to be co-ordinated.
2.3 Maintenance
The records of inspections and tests should provide data for comparative analysis during maintenance
throughout the active life of each item of electrical equipment.
3. REFERENCES
These procedures make reference to the documents listed in Appendix A. Unless otherwise specified the
latest editions of the documents, including all addenda and revisions, shall apply.
4. DEFINITIONS
4.1 For the purposes of these procedures the definitions listed in 4.2 to 4.9 inclusive shall apply.
Competent Person: a person adjudged to have the education, training and practical experience to
implement procedures or to carry out tasks to the satisfaction of Transco.
Contractor: the person, firm or company with whom Transco enters into a contract to which these
Procedures apply, including the Contractor's personal representatives, successors and permitted assigns.
Engineer: the Engineer appointed from time to time by Transco and notified in writing to the Contractor to
act as Engineer for the purposes of the contract.
equipment: anything used, intended to be used or installed for use, to generate, provide, transmit,
transform, rectify, convert, conduct, distribute, control. store, measure or use electrical energy.
inspection: the detailed examination of the electrical equipment and systems, to confirm compliance with
the final contract drawings, specifications and standards, prior to the commencement of testing.
system: an electrical system in which all the electrical equipment is, or may be, electrically connected to a
common source of electrical energy, and includes such source and such equipment.
testing: the detailed testing of the electrical equipment and systems, which may include energization from
the site supplies, to confirm compliance with the final design and manufacturing drawings and
specifications, and to ensure satisfactory performance before being put into service.
5. GENERAL REQUIREMENTS
5.1 In no circumstances shall a circuit or equipment be put into service before it has been inspected
and tested.
5.2 The inspection and testing shall normally be undertaken by the person responsible for the
installation of that equipment. In all other circumstances. the person nominated for such work shall be
subject to the Engineer's approval.
5.3 There shall be close liaison between the Engineer and the person carrying out the work to ensure
that the Engineer is fully informed of the testing programme.
5.4 The person who undertakes the testing shall be responsible for all safety measures relating to that
equipment and shall ensure than no personnel are exposed to any danger.
5.5 No item of equipment shall be energized from the site supplies until prior permission, in writing,
has been obtained from the Engineer.
5.6 When an electricity supply is introduced on site, the Transco Electrical Safety Rules (EL6) shall
be observed.
5.7 Final inspection shall normally be undertaken immediately prior to testing. Where this is not done,
part or all of the inspection shall be repeated at the discretion of the Engineer.
5.8 Following testing, it is necessary to recheck that cover plates, doors, shields, shrouds, barriers,
etc., which may have been removed for the purpose of testing, have been refitted.
5.9 The Contractor, equipment manufacturer or Transco department responsible for the testing shall
provide all the necessary test equipment, and the services of Competent Persons for its use. Test
equipment used shall have current calibration certificates.
6.2 If supplementary tests are required, for which there are no standard test record sheets, the
Engineer shall determine suitable testing procedures and provide the required test sheets.
7.1.2 Equipment shall be examined for correct identification, rigidity of fixture, freedom from physical
defects, and completeness of assembly and installation. Reference shall also be made to Transco Inspection
reports to confirm that any required remedial works have been undertaken.
7.1.3 A check shall be made to verify that all identification labels and rating plates are correct.
7.1.5 Cover plates, doors, associated fixing bolts, catches, hinges and gaskets shall be checked for
satisfactory fit and freedom from distortion.
7.1.6 Protective shields, shrouds and barriers shall be firmly secured in position.
7.1.7 Damaged and missing components shall be replaced with items of the correct type and rating.
7.1.8 Unused apertures shall be sealed with the correct blanking plates, knock-outs or plugs.
7.2.2 The testing of equipment and systems may require the introduction of potentially dangerous test
voltages. Safety shall be controlled in accordance with EL6.
7.2.3 All the tests specified in these procedures and detailed on the record sheets (see Appendix B)
shall be performed unless this requirement is varied, in writing, by the Engineer.
7.2.4 Supplementary tests shall be carried out, where necessary, to ensure that any equipment or part
of the installation is capable of satisfactory operation (see 6.2).
7.2.5 Where factory tests, supported by records, are witnessed by Transco or approved in writing by
the Engineer, these tests need not be repeated on installation of the equipment unless so required by these
procedures.
7.2.6 Prior to testing, all test parameters shall be established, having regard to such existing equipment
and installations which will, as a result, be subject to retest. The Contractor, or Transco department,
performing the tests will be held responsible for any damage which may be caused to cables or equipment
by failure to obtain the Engineer's approval of the test voltages.
7.2.7 The primary injection method shall be used for current transformer polarity/ratio checks and,
preferably, for the testing and calibration of all current-operated protective, control, metering and indicating
devices. In certain circumstances, secondary injection may be acceptable provided that the prior approval
of the Engineer has been obtained.
7.3.1 Inspection
7.3.1.1 The inspection of electrical equipment and systems for use in potentially explosive atmospheres
shall be in accordance with the relevant Part(s) of BS 5345 (wherein such inspection is termed 'initial
inspection').
7.3.1.2 Copies of all equipment certificates of conformity shall be provided and each certificate shall be
checked by the installer to ensure that any special installation requirements are met.
7.3.2 Testing
7.3.2.1 The testing of electrical equipment and systems for use in potentially explosive atmospheres shall
be in accordance with the relevant Part(s) of BS 5345.
7.3.2.2 Earth fault loop impedance testing shall only be carried out at locations where the installation can
be shown to be free of a potentially explosive atmosphere. Such tests are restricted to the pre-
commissioning stage on a new or refurbished installation, prior to the introduction of a potentially
hazardous area. Where these conditions do not apply the earth fault loop impedance ( Z s ) (see Note) shall
be determined as follows:
a) the external earth fault loop impedance ( Z e ) shall be measured at the origin of the
installation (outside the potentially hazardous area) with only the earth electrodes, or other
means of earthing via the earthing conductor and earth terminal, connected. Before this test
is undertaken, other installation bonding and protective conductors shall be temporarily
disconnected and the power supply to the site isolated;
b) the resistance of the earth loop ( r1 + r2 ) associated with each individual circuit shall be
measured by an earth conductivity test using an intrinsically safe dc ohm-meter. This test
requires that the circuit to be tested be completely isolated from all sources of power and
temporary connections applied between conductors and earth.
NOTE - Z s = Z e + ( r1 + r2 )
7.4.1 Inspection
7.4.1.1 The identification of all cables shall be checked for compliance with the specified requirements.
7.4.1.2 Cables shall be checked for correct type and size against the contract documents.
7.4.1.3 The installation of all cables shall be checked for compliance with EL5 and BS 7671, as
appropriate. A close visual inspection shall also be undertaken to ensure that the cables are free from any
damage.
7.4.1.4 All connections and terminations shall be inspected to confirm compliance with BS 7671.
7.4.2 Testing
7.4.2.1 The testing of a cable to meet the requirements of these procedures shall only be undertaken
when the cable has been permanently installed in its final position, with its joints and terminations
completed and sealed, where appropriate.
7.4.2.2 Where disconnecting links are provided in low voltage (LV) terminal enclosures, they should be
removed before cable tests are made and refitted immediately after completion of the tests. The appropriate
cables shall be disconnected from their terminals where it is necessary to protect sensitive equipment.
7.4.2.3 Where disconnecting links are not provided in the terminal enclosures of high voltage (HV)
equipment, equipment suppliers shall be consulted prior to testing to ensure that the specified cable test
voltages can be applied without risk of damage to the connected equipment.
7.4.2.4 Values of insulation resistance shall not be less than the values given in Table 1.
7.4.2.5 Following completion of the insulation resistance tests, each conductor shall be checked for
correct identification and connection at each end.
7.4.2.6 High voltage XLPE insulated cables shall be voltage (i.e. pressure) tested in accordance with
BS 5467. clause B.8 or BS 6622, clause C.8.1 as appropriate to the voltage rating of the cable.
7.5.1 Inspection
7.5.1.1 All small wiring undertaken at site shall be checked to ensure that numbering is in accordance
with the specified requirements.
7.5.1.2 Switch contacts of circuit-breakers, contactors and relays shall be checked for correct
alignment, good surface condition and freedom of operation.
7.5.1.3 The alignment of the fixed and moving parts of draw-out and drop-down switchgear shall be
checked.
7.5.1.4 The interior of switchgear oil tanks shall be examined and, prior to being filled, thoroughly
cleaned and dried if necessary.
7.5.2 Testing
7.5.2.1 The ratios and polarity of all current transformers shall be checked by primary current injection.
7.5.2.3 Current-operated protective, control, metering and indicating devices shall be tested for correct
operation by primary injection. Where such devices have an operating range, they shall be checked not only
at the operational setting, but at a minimum of three points in their range, in order to prove satisfactory
operation. Adequate reset and cooling times shall be allowed between tests where such devices incorporate
thermal delay or damping features.
Other similar devices shall be adjusted in accordance with the settings required by the Engineer.
7.5.2.4 Voltage-operated protection relays shall be checked to ensure that drop-out and pick-up voltages
comply with the relevant Part of BS 5992.
7.5.2.5 All remote control devices shall be checked for correct operation.
7.5.2.6 Before oil circuit-breaker tanks are filled, the oil shall be tested for breakdown voltage and water
content in accordance with BS 148.
7.5.2.7 The insulation resistance of all current carrying components shall be tested in accordance with
the relevant Part(s) of BS 5486 and BS 6626 as applicable.
Values of insulation resistance shall not be less than the values given in Table 2.
7.5.2.8 After completion of insulation testing, switchgear provided with automatic operating and
protective devices shall, before being made 'live', be fully operated to prove that all parts function correctly.
These checks shall include the operation of all tripping relays and inter-tripping circuits.
7.5.2.9 Overload trip tests on switchgear shall be carried out to establish operating times, having regard
to the permissible current/time characteristics of the associated cable under overload and fault conditions.
Each overload element shall be tested individually, and the trip bar shall be reset before, and be operated by,
each test. Sufficient time shall be allowed between each test to permit the overload to reset fully. The time
delays which occur shall be within the permissible range for the currents concerned, as stated on the
overload manufacturer's data sheets, copies of which shall be available on site prior to the commencement
of testing.
7.5.2.10 Switchgear incorporating arrangements for the control of generators shall, additionally, be tested
as follows:
7.5.2.11 Controlgear used in conjunction with motors shall be tested and adjusted in accordance with the
manufacturer's recommendations. Overload settings shall be in accordance with the motor manufacturer's
recommendations.
7.6.1 Inspection
7.6.1.1 The oil level of power transformers shall be checked. Tanks and cooling tubes shall be examined
to ensure that there are no traces of oil leakage.
7.6.1.2 Drain valves shall be examined to ensure that they are clear when open and oil-tight when closed.
7.8.1.3 Moisture absorbing breathers shall be examined to ensure that they are charged with silica gel and
that the crystals are coloured blue. The oil bath shall be filled.
7.6.2 Testing
7.6.2.1 Alarms and trips shall be tested for correct operation in association with the related switchgear
and, if necessary, adjusted.
7.6.2.2 Manually operated off-load tap changing gear shall be checked for correct operation and voltage
output against the data on the rating plate.
7.6.2.3 Where transformers are not of the hermetically sealed type, samples of oil shall be drawn from
the main tank and conservator and tested for breakdown voltage, water content and acidity in accordance
with
BS 148.
7.6.2.4 Insulation resistance tests shall be carried out on all windings and, where possible, the core. The
values obtained shall be as given in Table 3. In all resistance measurements, care shall be taken to ensure
that the effects of self induction are minimized.
7.7.1 Inspection
7.7.1.1 All machines shall be checked for freedom of rotation and correct alignment with the driven
machine.
Care shall be taken to ensure that the surface to which the machine is bolted down is aligned in all
directions. The fact that the shaft revolves easily does not necessarily mean that there is no deflection. The
large overload capacity of ball and roller bearings may give no distress signs under conditions that would
cause trouble with plain bearings.
7.7.1.2 The location of the machine shall be such that the air intakes and exits are not obstructed (e.g. by
adjacent walls or canopies) and that no contaminants such as diesel fumes, exhaust gases, dusts or water
can be drawn into the machine.
7.7.1.3 Where applicable, the bearings of electric machines shall be examined to ensure that they are
correctly charged with grease or oil of the grade recommended by the manufacturer.
Attention is drawn to the need for avoiding excess lubrication. Excess grease may lead to the overheating
of bearings, and excess oil may escape into the windings.
The presence of a proper means for the topping up of lubricants shall be checked.
7.7.1.4 Slip rings and commutators should be thoroughly clean. It may be assumed that new machines
will have been dispatched from the manufacturer’s works with the slip rings and commutators in good
surface condition.
7.7.1.5 For machines having ratings greater than 200 kW, the following checks shall be carried out:
7.7.2 Testing
7.7.2.1 Machines having self-contained or separate auxiliary cooling systems shall be checked as follows:
a) Air temperature indicators and alarms shall be checked for correct indication and operation.
b) Air control dampers shall be checked for correct operation.
c) Filters shall be checked to ensure that they are properly fitted with the correct filtering
media.
d) Water cooling systems shall be checked for the specified quality of water, direction of flow,
flow control and freedom from water leaks.
7.7.2.2 Bearing temperature indicators and alarms, if fitted, shall be checked for correct indication and, if
necessary, adjusted.
7.7.2.3 All components associated with motor and generator controls, (exciters, current transformers,
winding temperature indicators, etc.), shall be checked for correct operation.
7.7.2.4 Internal heaters, where fitted, shall be checked for correct rating, insulation resistance, correct
operation and that the switching arrangements effect proper control.
7.7.2.5 Separately driven ventilation fans shall be checked to ensure correct direction of air flow.
7.7.2.6 Insulation resistance tests shall be carried out on all motor and generator windings and the values
obtained shall be as given in Table 3.
7.8.1 Inspection
7.8.1.1 A thorough visual inspection of the earthing system shall be carried out to verify that it complies
with the requirements of EES1, BS 7430 and BS 7671.
7.8.1.2 The presence, size and security of fixing of earthing and bonding connections shall be checked.
7.8.2 Testing
7.8.2.1 The safety precautions to be taken when testing earth electrodes shall be as detailed in EL6.
7.8.2.2 The method of testing earthing systems shall be in accordance with IEE Guidance Notes No.3,
Test method 1. Each electrode shall be tested individually, followed by a test on the complete earthing
system.
7.8.2.3 Each separate earthing point provided for the protection of tanks, structures, fences, etc., against
lightning, shall be tested to ascertain its resistance to earth. The combined resistance to earth of the
lightning protective system shall not be greater than 10 ohms (see BS 6651).
7.9.1 Inspection
7.9.1.1 Cable fixings and runs shall generally be in accordance with EL5, and shall be checked to ensure
that snagging does not occur over the full working range of the holder.
7.9.1.2 The cable support mast shall extend more than 50% of the lift height to ensure than no cable
loops enter the cup or tank water.
7.9.1.3 The length of the cable shall be checked to ensure that it is sufficiently long by inflating the
holder to its maximum height.
7.9.1.4 The inspection of modular anti-freeze units shall include the following:
7.9.1.5 In element systems, the fixing of the heating cables in the cable clips within the holder cups shall
be inspected to ensure that the cables are secure, clear of any obstructions and remain under water over
the full working range of the holder.
7.9.2 Testing
7.9.2.1 Air and water thermostats shall be checked for correct settings and operation. Water level
sensing devices, where fitted, shall be tested to ensure that the associated alarms operate. Where such
thermostats and sensing devices are incorporated in the control system, a functional test shall be carried
out.
7.9.2.2 The testing of modular anti-freeze units shall include the following:
a) Check that water flowing through the air bleed pipe is routed back to the cup.
b) Confirm that water circulates freely and check that the outlet nozzle points away from the
unit.
c) The load current shall be checked to confirm that all heaters are operating.
7.9.2.3 The testing of heating element systems shall include the following:
a) The load current for each heating element shall be measured and checked against the design
parameters.
b) Unclip a section of heating element and expose a loop to the air. Switch on power to the lift
and after 5 min measure and record the surface temperature of the element, checking that it
meets the design specification. On completion of this test, switch off the power supply and
refix the element in its clips.
7.10.1 Inspection
7.10.1.1 The cooling and ventilation arrangements shall be checked to ensure that these are adequate and
that air flow is not impeded by any obstructions.
7.10.1.2 Batteries and charging equipment shall be inspected in accordance with EBC1.
7.10.2 Testing
7.10.2.1 A functional test shall be carried out to confirm that the change-over arrangements between the
mains supply and the standby supply operate satisfactorily.
7.10.2.2 All indication and alarm circuits shall be tested for correct operation.
7.10.2.3 A full discharge test of the uninterruptible power supply (UPS) shall be carried out to verify the
design rating of the system.
7.10.2.4 The output waveform shall be verified on load to ensure that distortion is within the specified
tolerance.
TABLE 3 - Minimum insulation resistance for transformer, motor and generator windings
APPENDIX A
LIST OF REFERENCES
These procedures make reference to the documents listed below (see clause 3).
British Standards
BS 148 - Specification for unused mineral insulating oils for transformers and
switchgear
Transco specifications
EBC1 - Notes for guidance for the supply, charging, installation, setting to
work, maintenance and safety of batteries
EES1 - Code of practice for the installation and testing of earths and earthing
systems
APPENDIX B
RECORD SHEETS
B.1 The record sheets listed in Table B.1, specimen copies of which are provided in this Appendix,
may be photocopied for use as necessary to cover the inspection and testing of standard electrical
equipment.
TABLE B.1 - List of electrical site inspection and test record sheets
B.2 In cases where the standard record sheets do not cover a specific requirement, reference shall be
made to 6.2 of these procedures.
B.3 The record sheets provided in this Appendix shall be read in conjunction with the corresponding
main text in these procedures.
B.4 The record sheets are complementary, so that a particular installation may require the use of
more than one sheet. For example, a transformer installation may require the use of sheets EL4/1, EL4/3,
EL4/5 and EL4/7.
B.5 The following abbreviations are used in the record sheets listed in Table B.1:
B - blue
BS - British Standards
CT - current transformer
E - Earth
IR - insulation resistance
kV - kilovolt
N - neutral
ph - phase
Py - primary
QA - Quality Assurance
R - red
R1 }
R2 } - earth resistances measured in accordance with IEE
R3 } Guidance Notes No.3, Test method 1
Sy - secondary
VT - voltage transformer
Y - yellow