ELC-SC-4744-D

ELECTRICAL SYSTEMS CHECKOUT AND COMMISSIONING

APPLICATION: ONSHORE, TOPSIDES

Commented Copy - Not for Supplier Distribution

This document is the confidential property of Chevron U.S.A. Inc. Neither

the whole nor any part of this document may be disclosed to any third
party without the prior written consent of Chevron U.S.A. Inc. Neither the
whole nor any part of this document may be reproduced, stored in any
retrieval system or transmitted in any form or by any means (electronic,
mechanical, reprographic, recording or otherwise) without the prior
written consent of Chevron U.S.A. Inc.

Rev Date Description Author Sponsor

C 10/08 General Revision AVFQ MCFO
D 01/10 General Revision NTUY MCFO
05/10 Editorial revision to Commented version only: MCFO MCFO
reference to SWP 5159 changed to “OE
Corporate Required Standard - Electrical Safe
Work Practice.” No technical content change
made.

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Electrical Systems Checkout and Commissioning ELC-SC-4744-D

CONTENTS

1.0 Scope ..........................................................................................................................4

2.0 References ..................................................................................................................4
2.1 ......Purchaser Documents ......................................................................................4
2.2 ......Industry Codes and Standards .........................................................................4
3.0 Terminology ................................................................................................................5
3.1 ......Acronyms .........................................................................................................5
3.2 ......Definitions .........................................................................................................5
4.0 Labor, Materials, and Equipment ..............................................................................7
5.0 Documentation ...........................................................................................................7
5.1 ......General .............................................................................................................7
5.2 ......Commissioning Procedures and Report ...........................................................8
5.3 ......Forms for Inspection and Testing .....................................................................9
5.4 ......Punchlists .........................................................................................................9
5.5 ......As-Built Drawings ...........................................................................................10
6.0 Safety ........................................................................................................................10
6.1 ......General ...........................................................................................................10
6.2 ......Lockout Procedure .........................................................................................11
6.3 ......Equipment Isolation ........................................................................................11
6.4 ......Switching ........................................................................................................12
6.5 ......Remotely and Automatically Controlled Equipment .......................................12
6.6 ......High-Voltage Testing ......................................................................................12
6.7 ......Mechanically-Driven Electrical Equipment .....................................................13
6.8 ......Portable Electrical Equipment ........................................................................13
7.0 General Inspection and Test Requirements ..........................................................13
7.1 ......General ...........................................................................................................13
7.2 ......Insulation Resistance and Polarization Index Testing ....................................14
7.3 ......High Potential Testing ....................................................................................14
7.4 ......Vibration .........................................................................................................15
7.5 ......Protective Relays ...........................................................................................15
7.6 ......Electrical Equipment Insulating Oil .................................................................16
7.7 ......Noise Tests ....................................................................................................16
7.8 ......Temperature Tests .........................................................................................16
8.0 Specific Inspections and Tests ...............................................................................17
8.1 ......Conduit System ..............................................................................................17
8.2 ......Cable Tray and Cable Support System ..........................................................18
8.3 ......Wire and Cable ...............................................................................................19
8.4 ......Switchgear and Motor Control Equipment ......................................................21
8.5 ......Transformers ..................................................................................................22
8.6 ......Bus Duct .........................................................................................................23
8.7 ......Uninterruptible Power Supply .........................................................................24

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Electrical Systems Checkout and Commissioning ELC-SC-4744-D

8.8 ......Battery and Battery Charger ...........................................................................24

8.9 ......Panelboards ...................................................................................................26
8.10 ....Grounding .......................................................................................................26
8.11 ....Grounding Resistors .......................................................................................27
8.12 ....Motors ............................................................................................................28
8.13 ....Motor Control ..................................................................................................30
8.14 ....Generators .....................................................................................................31
8.15 ....Programmable Controllers .............................................................................32
8.16 ....Lighting ...........................................................................................................32
8.17 ....Receptacles ....................................................................................................33
8.18 ....Communication and Alarm Systems ..............................................................33
8.19 ....Aids to Navigation ..........................................................................................33
8.20 ....Lightning Protection ........................................................................................33
8.21 ....Heat Tracing ...................................................................................................33
8.22 ....Miscellaneous Electrical Equipment ...............................................................34
Appendix A List of Forms in ELC-DS-4744 and ELC-DS-2469 ......................................35

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Electrical Systems Checkout and Commissioning ELC-SC-4744-D

1.0 SCOPE
1. This specification covers requirements for checkout and commissioning of newly installed or
overhauled (refurbished) electrical equipment and facilities including, but not limited to,
onshore facilities, production platforms, drilling platforms, wellhead platforms, and living
quarter platforms.
2. Requirements of this specification include inspection of electrical equipment and facilities
throughout the construction phase. Requirements for construction of electrical facilities are
found in ELC-SU-1675.
3. Some content of this document is reproduced and used under PIP’s Membership Agreement.
Comment: This specification is meant to cover most electrical facility checkout and
commissioning work done on large projects. Projects shall tailor the specification to
its specific needs. Small projects may choose to use only the necessary inspection and
testing checklists in lieu of issuing the complete specification. Generally, this
specification is applicable only for electrical facilities through 15 kV.
Although this specification may be issued to a checkout and commissioning Service
Supplier separately from the construction contract, it is recommended that this be
done with extreme care. There are many gray areas between checking or testing
something and actually completing a construction task. In order to issue this
specification separately from the construction specification (ELC-SU-1675 or
equivalent), the division of responsibilities should be more clearly defined than that
found in these documents.
Procedures outlined in this specification may be used by Owner personnel when a
Service Supplier is not involved.

2.0 REFERENCES
1. The following documents are referenced herein and are considered part of this specification.
2. Use the latest edition of each document referenced below unless otherwise specified.

2.1 Purchaser Documents

ELC-SU-1675 Installation of Electrical Facilities
ELC-SU-2469 DC Insulation Testing of Electrical Equipment
ELC-DS-2469 Data Sheet for DC Insulation Testing of Electrical Equipment
ELC-DS-4744 Data Sheet for Electrical Equipment and Systems Checkout and
Commissioning
The following documents appear only in commented text. They are for Purchaser use only.
OE Corporate Required Standard - Electrical Safe Work Practice

2.2 Industry Codes and Standards

American Society for Testing and Materials (ASTM)
ASTM D 877 Standard Test Method for Dielectric Breakdown Voltage of Insulating
Liquids Using Disk Electrodes
ASTM D 1816 Standard Test Method for Dielectric Breakdown Voltage of Insulating Oils
of Petroleum Origin Using VDE Electrodes

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Electrical Systems Checkout and Commissioning ELC-SC-4744-D

National Fire Protection Association (NFPA)

NFPA 70 National Electric Code (NEC)
The following documents appear in commented text. They are for Purchaser use only.
Institute of Electrical and Electronics Engineers (IEEE)
C57.12.00 Standard General Requirements for Liquid-Immersed Distribution, Power,
and Regulating Transformers
National Electrical Manufacturers Association (NEMA)
NEMA MG 1 Motors and Generators

3.0 TERMINOLOGY

3.1 Acronyms
CT—Current Transformer
FAT—Factory Acceptance Test
GFCI—Ground Fault Circuit Interrupter
Hi-Pot—High Potential
HVAC—Heating, Ventilation, and Air Conditioning
MCC—Motor Control Center
PI—Polarization Index
PT—Potential Transformer
PVC—Polyvinyl Chloride
RTD—Resistant Temperature Detector
UPS—Uninterruptible Power Supply

3.2 Definitions
Acceptance—The point at which Owner considers equipment or a system functional and
operational. Acceptance occurs after the equipment or system has started to operate and
satisfactorily demonstrates its integrity.
Comment: See the definition of “commissioning” below for further information.
Checkout—Bringing equipment or a system to a state of readiness for startup. This includes, but
is not limited to, visual inspections for shipping damage and water intrusion, insulation resistance
and dielectric tests, functional tests of control systems, calibration, and alignments.
Commissioning—Bringing equipment or a system to an operating condition. This includes, but is
not limited to, energizing electrical equipment and subjecting it to the available load, running
motors, and checking illumination provided by lighting systems.
Comment: Some projects may only require Service Supplier to take the facility to a point of
mechanical completion and not energize equipment. The definition of commissioning
and acceptance, as related to Service Supplier’s responsibilities, should be changed as

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required. In addition, certain requirements of this specification that relate to

energizing or operating equipment should be deleted. It is recommended that projects
expand the definitions given here in order to more fully define the scope of work.
Construction Completion—Activities leading to acceptance of fabrication and/or hook-up. Ser-
vice Supplier’s primary scope of work has been completed in accordance with drawings, specifica-
tions, and requirements of the contract, and non-operational “static” checks have been completed.
Factory Acceptance Test (FAT)—Inspection, testing, and reporting by Service Supplier/
Equipment Supplier leading to acceptance of the Equipment Supplier’s equipment and/or Service
Supplier’s scope of work. Tests shall be completed in accordance with drawings, specifications,
and requirements of the purchase order/contract.
Heat Run—Operation of electrical equipment (usually generators, motors, or transformers) at
full-load for a sufficient amount of time for temperatures of bearings, windings, rotors, etc. to
stabilize and operate at their normal operating temperature. The usual operating time period at full
load is 4 hours.
Hook Up—Offshore construction activities associated with final interconnection of facilities and
completion of work carried over from onshore fabrication after offshore installation and removal
of installation aids and internal seafastenings.
Mechanical Completion—Completion of construction activities and clean-up as described in the
terms and conditions. At this point, the facilities are ready for a full handover to Owner by Service
Supplier, or operation by Service Supplier.
Operational Testing—Testing of equipment, process areas, or entire process systems to verify
operability under conditions other than design. This may involve testing with off-design fluids
and/or under off-design conditions to test for functionality and establish actual operating limits.
Performance Testing—Testing of equipment, facilities, or parts of facilities to verify acceptance
of operation at design conditions. This is usually tied to contractual obligations for payment.
Pre-Commissioning—(Part of “construction completion”) Activities that include non-operational
tests and calibrations such as adjustments, cold alignment checks, dielectric tests, etc., as described
in this specification. These are performed as part of the “construction completion” scope prior to
being ready for commissioning.
Punchlist—(Also called a discrepancy list) A list of outstanding (not completed) work items in a
system when the system has progressed to the next phase of work (e.g., construction completion to
commissioning). Typically punch list items may be classed as A-Punch list or B-Punch list.
A-Punch list items generally impact the operability of the system or equipment and must be
completed before going to the next phase of work. B-Punch list items do not affect operability and
can be carried forward to the next phase of work. Punch list items shall be cleared prior to
achieving mechanical completion.
Ready For Commissioning—This occurs when facilities or parts of facilities have been erected in
accordance with drawings and specifications, and activities have been completed to the extent
necessary to permit commissioning activities to take place in a safe manner.
Run-In Operation—Running of equipment (such as motors) for a period of time prior to first oil,
with the objective of precipitating early life problems.
Startup—Energizing electrical equipment or an electrical system.

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System—Logical subdivision of the overall electrical facility. Owner and Service Supplier shall
jointly decide how to subdivide the facility into separate systems. Owner acceptance of the overall
facility will occur only after all systems have been accepted.
Comment: For checkout and commissioning purposes, it is generally advisable to divide the
overall electrical facility into smaller parts or systems. This allows for easier
documentation and tracking of progress.

4.0 LABOR, MATERIALS, AND EQUIPMENT

1. Owner shall supply a completed copy of Form 21 in ELC-DS-4744, which lists equipment
requiring Equipment Supplier assistance during startup.
Comment: On most projects, Equipment Supplier assistance is required for the startup of
large and/or complex pieces of equipment. The project engineer should complete
Form 21 in ELC-DS-4744 in order to define the scope of Equipment Supplier
assistance to be provided to Service Supplier. It is assumed that Owner will
provide Equipment Supplier with any necessary assistance and will reimburse
Equipment Supplier for their assistance.
2. This specification shall be used in conjunction with equipment specific technical requirements
and data sheets.
3. Requirements reflect minimum standards and procedures to be followed before electrical
equipment and facilities are accepted by Owner. Service Supplier shall be responsible for
performing additional checkouts or tests necessary for safe, reliable, and functionally
complete installation.
4. Service Supplier shall provide labor, materials, utilities, tools, test equipment, and other items
required to complete the work outlined in this specification.
a. Test equipment shall have a valid calibration sticker or certification paperwork.
b. Owner has the right to reject tools or equipment that it feels are inadequate or
inappropriate for the application.
5. Unless otherwise specified, Owner shall be responsible for engaging the services of listed
Equipment Suppliers to assist Service Supplier in equipment checkout and commissioning.
6. While Equipment Supplier representatives are supervisory, Service Supplier shall be
responsible for labor necessary to complete the required inspections and tests.
Comment: Service Supplier shall be responsible for the protection and security of equipment
during all stages of commissioning. Section 4.0, item 4 may need to be modified for a
particular project. For example, Owner may want to supply utilities at the job site.

5.0 DOCUMENTATION

5.1 General
1. Prior to initiating work, Service Supplier shall review and become familiar with applicable
specifications, drawings, data sheets, codes and standards, and Equipment Supplier
documentation.
a. Service Supplier shall bring to the attention of Owner areas of drawings and/or
specifications that conflict or do not meet safe and acceptable electrical practices.

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b. Service Supplier shall not perform tests that would either void Equipment Supplier
warranties or damage the equipment.
Comment: It is recommended that the terms of equipment warranties be provided to the
Service Supplier. The list should highlight special warranty requirements,
such as Equipment Supplier assistance for startup.
2. Unless otherwise agreed to by Owner, Service Supplier shall submit checkout and
commissioning documentation to Owner at least once a week.
Comment: The schedule for and quantity of checkout and commissioning documentation
formally submitted by Service Supplier to Owner will vary from project to project.
Where Owner field representatives are involved in day to day activities, frequent
submittals may not be necessary. The once a week requirement for documentation
is included as a starting point. Owner field representative should determine the
frequency of submittals required and modify item 2 above to reflect the required
frequency.

5.2 Commissioning Procedures and Report

5.2.1 Procedures
1. Prior to the startup (energization) of equipment or systems, Service Supplier shall pre-
pare a comprehensive commissioning procedure detailing the steps to be followed in
starting up the equipment or system. As a minimum, the following shall be included:
a. Applicable inspection and testing forms (refer to Appendix A).
b. Equipment Supplier’s recommended procedures for commissioning pieces of
equipment and/or the complete system with parameters to be set, monitored, or
not exceeded per Equipment Supplier’s recommendations.
c. Relevant drawings, specifications, and data sheets.
d. Data from prior testing (e.g., factory acceptance tests (FATs), run-ins, and heat
run).
e. Recommended settings for devices in the system or equipment.
2. Comprehensive commissioning procedures shall be submitted to Owner for review at
least 30 days prior to implementation.
Comment: At the beginning of any medium to large-sized project, checkout and
commissioning manuals (field books) should be prepared for each system.
The manuals should contain necessary drawings, inspection and testing
checklists, startup procedures, operating manuals, and any other relevant
documentation. They may be used by field personnel when performing
inspections and tests. This also provides an easy way to track completed
work. It may be desirable to have Service Supplier present on-site
training for complicated systems or commissioning procedures.
3. In preparing system commissioning procedures, Service Supplier shall consider the
impact that one system has on all others and on existing plant operations.
a. Service Supplier shall prepare an overall facility startup procedure, reflecting the
order in which individual systems shall be commissioned and the extent to which
systems shall be isolated.

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b. Overall facility startup procedure shall be submitted to Owner for review at least
30 days prior to commissioning the first system.
Comment: Overall system commissioning procedure/flow diagram should be
developed in cooperation with all disciplines on the project. Remember
that electrical power facilities are often completed early in the startup of
a plant.

5.2.2 Report
1. Following the successful commissioning of equipment or a system, Service Supplier
shall prepare a commissioning report with a narrative of events and data recorded
during startup to supplement the commissioning procedure.
2. Report shall highlight construction and operational discrepancies discovered during
startup.
3. Service Supplier shall submit commissioning report to Owner no later than 1 week
following the system startup.

5.3 Forms for Inspection and Testing

1. Service Supplier shall use the forms in ELC-DS-4744 for inspecting, testing, and recording
test data. Refer to Appendix A for a complete list of forms required by this specification.
a. Additional required forms shall be developed by Service Supplier and submitted for
review by Owner.
b. Alternate or modified forms, if preferred by Service Supplier, shall be submitted for
review by Owner.
Comment: Inspection and testing forms in ELC-DS-4744 repeat most of the information
included in the specification. The information is organized for easy use by field
personnel. This data is especially useful if given to field personnel as part of an
overall system checkout and commissioning manual (see commentary in
Section 5.2.1, item 1).
Inspection and testing forms in ELC-DS-4744 have blank fields for Service
Supplier and Owner inspector signatures. These fields may be used to the extent
required by each individual project. For example, some projects may require that
Service Supplier obtain Owner-acceptance prior to pulling wire into conduit.
Other projects may not require in-progress hold points and only stipulate that
final testing be witnessed. A general understanding of the extent of Owner
involvement in the inspection and testing contract program should be reached
with Service Supplier prior to contract award.
2. Inspection and testing forms included in ELC-DS-4744 contain specific requirements that may
not be included in this specification.
3. Service Supplier shall complete inspections and tests included in these forms.

5.4 Punchlists
1. Service Supplier shall be responsible for ensuring that electrical installations are in accordance
with project documents.
2. Service Supplier shall document discrepancies in the form of a punchlist, which shall be
submitted to Owner for review.

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3. Service Supplier shall use Form 22 of ELC-DS-4744 as a punchlist form unless Owner agrees
to another format.
4. Service Supplier shall take prompt action to remedy discrepancies.
5. Punchlist items that have been resolved shall be initialed by both Service Supplier field
personnel and Owner field personnel.
Comment: On reimbursable-type contracts, Owner may want to reserve the right to review
punchlist items before Service Supplier takes action on them. This may help prevent
Service Supplier from performing unnecessary rework.

5.5 As-Built Drawings

Service Supplier shall maintain a redline set of construction and Equipment Supplier drawings
throughout the project.
1. This drawing set shall reflect changes made throughout checkout and commissioning.
2. At the conclusion of the project, these changes shall be drafted onto reproducible drawings and
submitted to Owner.
Comment: Projects should modify this requirement to suit specific needs. In some cases, Owner
may want to assume responsibility for bringing the drawings to an as-built state. In
some cases, the redline drawings may be used as the file copy.

6.0 SAFETY

6.1 General
1. Personnel safety shall be a primary concern throughout checkout and commissioning of the
electrical equipment and facilities.
a. Service Supplier shall have a comprehensive safety program in effect at all times
throughout the project.
b. Service Supplier shall review and adhere to Owner safety regulations as specified in
contract documents.
Comment: Reputable Service Suppliers have published safety procedures. These procedures
and “OE Corporate Required Standard - Electrical Safe Work Practice” should
be reviewed with Service Supplier prior to project initiation in order to ensure
their adequacy and compatibility with existing plant programs.
2. As construction and/or normal operating activities will be ongoing throughout much of the
testing program, the following requirements shall be met:
a. Special precaution shall be taken to properly inform personnel of tests being conducted.
b. Barriers and caution signs shall be used in areas where potentially dangerous conditions
may exist.
Comment: A common safety hazard occurs when personnel installing a new facility become
accustomed to the idea that equipment is de-energized. Once equipment is being
tested or powered up, personnel should assume that it is energized.
3. Only personnel who are qualified in the use of electrical test equipment shall be allowed to
perform tests.

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6.2 Lockout Procedure

1. Service Supplier shall submit electrical equipment lockout procedures to Owner for review a
minimum of 72 hours prior to the start of work.
2. Once feedback and comments have been received from Owner, Service Supplier shall ensure
that personnel involved in checkout and commissioning work receive a copy and review it
with the foreman.
Comment: As soon as equipment in the plant is energized, lockout procedures should be carefully
followed. If Owner lockout procedure is used, revise the wording of Section 6.2 as
necessary.

6.3 Equipment Isolation

6.3.1 General
1. Equipment shall be physically disconnected from its power source to prevent
accidental injury to personnel resulting from inadvertent re-energization.
2. Equipment isolation shall ensure that voltages applied to equipment under testing are
not allowed to backfeed into power transformers, generators, and associated upstream
synchronizing and control circuits.
Caution Consequences of backfeeding voltages include danger to personnel and
damage to equipment.
3. Unless otherwise required by local authorities and/or procedures, Service Supplier
shall procure and use 1/4-inch (6.35-mm) diameter long-hasp Master Lock® brand
locks, nickel-plated with plastic skirting to minimize scratching equipment.
4. Unless otherwise required by local authorities and/or procedures, locks shall be
master-keyed and at least two master keys shall be provided.
5. Quantity shall be sufficient to individually lockout isolation devices.
6. If required by Owner, Service Supplier shall procure two sets of six keyed-alike locks
for lockouts of related equipment in addition to individually-keyed locks.
7. If applicable, these locks shall be surrendered to Owner upon Owner acceptance of
facilities.

6.3.2 Equipment Controlled by Switches or Circuit Breakers

1. Before work may be performed on electrical equipment fed by a circuit breaker or
switch, the circuit breaker or switch shall be locked in the open position with a safety
padlock.
2. Padlock key shall be kept in a lockout box.
3. Lockout box shall be 14-gauge sheet steel with markable tags and metal key rings of
sufficient quantity to accommodate all locks, including keys from lockable panels/
devices.
4. Lockout box shall contain a reproducible key legend to identify the associated lock/
panel/device.
5. If the circuit breaker or switch cannot be padlocked, the outgoing cable shall be
disconnected from the switch or circuit breaker.

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6. Cable shall be coiled-back and/or taped to prevent accidental reconnection.

7. An acceptable voltage indicator that has been recently checked for proper operation
shall be used to verify that the circuit under test is de-energized.
8. A caution notice shall then be applied to identify the circuit being tested.

6.3.3 Electrical Equipment Supplied Through Fuses

1. Before work may be performed on electrical equipment supplied from a fused source,
an acceptable voltage indicator that has been recently checked for proper operation
shall be used to verify that the circuit under test is de-energized, and fuses shall be
removed.
2. A caution notice shall be applied to the distribution board to identify the circuit being
tested.

6.3.4 Electrical Equipment Supplied Through a Motor Control Center

Before work may be performed on electrical equipment supplied from a motor starter or
feeder unit of a motor control center (MCC), an acceptable voltage indicator that has been
recently checked for proper operation shall be used to verify the following:
1. The circuit under test is de-energized.
2. The starter or feeder unit disconnect switch or breaker is opened, locked open, and
tagged in accordance with Section 6.3.2 of this specification.

6.4 Switching
1. If the testing procedure involves a succession of switching operations, Service Supplier shall
prepare a switching schedule that lists operations to be performed and the order of completion.
2. Energizing or de-energizing equipment in accordance with prearranged understandings, such
as elapsed time intervals or visual signals, shall be strictly prohibited.

6.5 Remotely and Automatically Controlled Equipment

Before testing remote or automatic equipment (e.g., circuit breakers, motor starting devices, and
air compressors), remote or automatic control features shall be rendered inoperative.

6.6 High-Voltage Testing

1. While high-voltage testing is being conducted, Service Supplier shall ensure that the test area
is properly guarded to prevent unauthorized entry and that “DANGER” notices are posted
adjacent to and at access ways to the test area during the period of the test.
2. Cables shall be discharged before and after applying test voltage.
3. Associated cables not being tested shall be grounded during the test (e.g., other phase
conductors of a three-phase circuit).
4. Temporary conductors used for test purposes shall not be sized less than the rating of the
circuit under test.
5. Test connections shall not be applied in cells or cubicles if there is exposed metal at high
voltage.

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6. When acceptable voltage indicators or phase measuring devices must be attached to high
voltage conductors, the conductors shall be de-energized before attaching or detaching test
connections.

6.7 Mechanically-Driven Electrical Equipment

Work on electrical equipment driven by mechanical prime movers, such as gas turbine generators
and standby diesel generators, shall not be initiated until the following precautions are observed:
1. Prime mover shall be inoperative and valves supplying fuel to the prime mover shall be locked
in the “off” position using a safety padlock.
2. When a prime mover field circuit is energized from a separate DC supply, the field circuit shall
be isolated and locked with a safety padlock.
3. DC supply to the starter circuit shall be isolated and locked with a safety padlock. Safety
padlock keys shall be held by the supervisor at the work area or placed in an Owner-accepted
lockout box.
4. Caution notices shall be posted adjacent to and at access ways to the test area.

6.8 Portable Electrical Equipment

Unless portable electrical equipment is double-insulated or connected to ground fault interrupters,
equipment shall be grounded using flexible supply cable that incorporates a ground continuity
conductor.

7.0 GENERAL INSPECTION AND TEST REQUIREMENTS

1. Owner shall be notified in advance and have the right to witness checkout and commissioning
activities.
2. Owner and Service Supplier personnel shall agree upon the extent to which Owner wishes to
be notified of these activities and the timing of the advance notice.
3. Owner field representative shall initial the appropriate checklist entry after witnessing each
activity.

7.1 General
The following general inspection and test requirements shall apply to equipment:
1. Proper installation of equipment identification nameplates and labels shall be checked.
2. Information on equipment nameplates and labels shall agree with information on drawings,
specifications, and checklists.
3. Conduits, cables, wires, and enclosures shall be labeled in accordance with drawings and
specifications.
4. The suitability of equipment and material for the area classification in which it is installed
shall be checked.
5. Equipment shipping splits shall be properly aligned and bolted, and torque values shall be
recorded as specified.
6. Equipment shipping blocks and wrappings shall be removed.
7. Phase orientation is properly indicated on buses and cables and direction of rotation shall be
indicated on motors.

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8. Current transformer shorting bars shall be removed.

9. Proper resistance and operation of equipment space heaters shall be checked.
10. Equipment, cable shields, raceways, and tanks shall be grounded in accordance with drawings
and specifications.
11. Equipment shall be undamaged and clean. Equipment damage shall be reported to Owner
immediately.
12. Damage to equipment paint or other protective coatings shall be touched up.
13. Nameplates, nametags, and signs shall be installed.
14. Alignment of equipment shall be checked in accordance with Equipment Supplier’s
instructions.
15. Service Supplier shall record discrepancies between equipment and the latest issue of
drawings for incorporation in the as-built drawings. See Section 5.5.
16. Service Supplier shall indicate torque mark on each electrical connection bolt and record its
value on Form 5 of ELC-DS-4744.
Comment: The above inspections and tests are required on most equipment in electrical facilities.
The item requiring the most constant attention is item 4. It ensures that equipment is
suitable for the area in which it is installed. As most of the Owner’s facilities have
hazardous (classified) areas, it is imperative that installed equipment be suitable
and labeled as being suitable for those areas. The label shall be from a nationally-
recognized testing laboratory, acceptable to the authority having jurisdiction.

7.2 Insulation Resistance and Polarization Index Testing

1. When specified, insulation resistance and polarization index (PI) testing of electrical cable and
equipment shall be performed in accordance with ELC-SU-2469.
2. Results shall be recorded and/or plotted on ELC-DS-2469.
3. Service Supplier shall be responsible for disconnecting any solid-state devices, meters, and
other equipment that could be damaged by insulation resistance and PI testing. Such
equipment shall be properly reconnected after tests are complete.
Comment: The insulation resistance is a relatively quick test used to determine the general
condition of electrical insulation. This test is typically performed using a test
instrument that reads out directly in Megaohms. The PI test provides information
about the state of electrical insulation deterioration and moisture content. Unlike the
insulation resistance test, PI test results can be compared with past test results without
temperature compensation.

7.3 High Potential Testing

1. Service Supplier shall notify Owner in writing of schedule and location, prior to performing
any high potential (Hi-Pot) dielectric tests, other than on transformer oil samples.
2. Insulation resistance and PI testing shall be completed before performing hi-pot tests on
equipment.
3. Medium voltage cable and equipment shall be tested with a hi-pot DC test set in accordance
with ELC-SU-2469.
4. Results shall be recorded and plotted on ELC-DS-2469.

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5. Service Supplier shall be responsible for disconnecting solid-state devices, meters, and other
equipment that could be damaged by hi-pot testing. Such equipment shall be properly
reconnected after tests are complete.
Comment: The DC hi-pot test specified in ELC-SU-2469 is a step voltage test which allows the
tester to foresee pending insulation failure and discontinue the test. A DC hi-pot test is
specified as it is less stressful on the insulation than an AC hi-pot test. Equipment
should be AC hi-potted in Equipment Supplier’s plant as specified in the applicable
equipment specifications.
Field hi-potting of medium voltage transformer, generator, and motor windings is
normally done at 65 to 75 percent of factory test voltage. Because of the possibility of
overstressing the insulation at these high test voltages, hi-potting of windings should
be kept to a minimum. Some project engineers may choose not to hi-pot transformer,
generator, and motor windings in the field.

7.4 Vibration
1. Service Supplier shall monitor and record shaft and bearing bracket vibration on motors and
generators provided with built-in vibration detection equipment.
2. Motors and generators larger than 100 hp, not equipped with built-in vibration transducers,
shall be monitored with a portable vibration test device.
3. Vibration levels shall be documented and shall be less than 1 mil peak-to-peak displacement.
4. Extensive vibration testing on small motors and generators less than 100 hp should be
performed only if the machine appears to be running roughly.

7.5 Protective Relays

Comment: Specialized equipment is needed to perform relay tests. It may be advisable to engage
the services of a (sub) Service Supplier who specializes in relay calibration and
testing.
1. Service Supplier shall calibrate protective relays in accordance with Equipment Supplier’s
recommendations.
a. Relays shall be set in accordance with setpoints provided by Owner and tested at these
setpoints.
b. A separate test and calibration sheet, supplied by Service Supplier, shall be completed for
relays.
Comment: Protective relay setpoints may be obtained from the project’s relay coordination
study. Relays shall be tested for proper calibration and operation at the final
setpoint in order to ensure precise operation. Relays are blocked at the factory
prior to shipment and are inoperative until the block is removed.
2. Service Supplier shall perform primary injection tests. In the event primary injection tests are
not practicable, Service Supplier shall notify Owner in writing prior to performing secondary
injection testing, in lieu of primary injection testing.
Comment: In order to realistically test how protective relays will perform during actual
operation, they should be tested in conjunction with their respective current and
potential transformers. As it is sometimes difficult to employ the necessary current
and voltage sources to simulate in-service conditions, secondary current and

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potential levels may be used (e.g., 0 to 5 amps current transformer [CT]

secondary current and 0 to 120 volts potential transformer [PT] secondary
potential).
3. Service Supplier shall visually check protective relaying current transformers (CTs) and
potential transformers (PTs) for proper polarity and ratio.
Comment: Switchgear assemblies are typically tested in Equipment Supplier’s plant prior to
shipment. Therefore, extensive field testing of CTs and PTs is usually not
warranted for most industrial systems. Project engineers may require that ratio,
polarity, excitation, saturation, and burden tests be done.
4. Service Supplier shall clean protective relays to remove dust, dirt, and foreign material.

7.6 Electrical Equipment Insulating Oil

1. Service Supplier shall record data on Form 11 of ELC-DS-4744.
2. The dielectric strength of new insulating oil shall be measured by Service Supplier in
accordance with one of the following ASTM testing methods:
a. ASTM D 877
b. ASTM D 1816
3. The ASTM D 1816 method is preferred for testing mineral oils. Synthetic insulating media,
such as askarel and silicone, shall be tested using the ASTM D 877 method.
4. Should there be any question of insulating oil integrity, Owner shall require that Service
Supplier perform further tests, including color, acidity, power factor, and interfacial tension
tests.
a. Tests shall be in accordance with ASTM standards.
b. Additional testing shall be charged to Owner’s account, unless specified otherwise.
c. Results shall be recorded on Form 11 of ELC-DS-4744.
Comment: It is usually unnecessary to perform extensive tests on insulating oil unless there is
reason to believe it may have become contaminated. If oil is shipped separately
from the equipment, further analysis (in addition to dielectric strength test) should
be considered.

7.7 Noise Tests

1. Service Supplier shall perform tests on noise-emitting equipment to ensure that noise levels
are within the limits specified on equipment data sheets and in applicable technical
requirements.
2. Results of these tests shall be recorded on the appropriate inspection and test sheets.

7.8 Temperature Tests

1. Service Supplier shall perform temperature tests and record results as specified by Owner.
2. Temperatures shall be measured by one of the following standard methods:
a. Direct by thermometer
b. Computed using resistance temperature detectors
c. Computed using thermocouples

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3. In order to detect excessive temperature rise, temperatures shall be measured both before and
during equipment maximum load tests.
4. Temperature rise shall be recorded and checked against Equipment Supplier’s acceptable
values. Ambient temperatures shall also be recorded.

8.0 SPECIFIC INSPECTIONS AND TESTS

Inspections required in this section shall ensure that electrical installations conform to the
requirements of ELC-SU-1675.

8.1 Conduit System

1. Checklist items, as described in Form 2 of ELC-DS-4744, shall be followed throughout the
installation of conduits.
2. During the installation of conduits, but prior to pulling wire, Service Supplier shall verify
the following:
a. Material is of the type specified, in new condition and undamaged.
b. Conduit is installed in a good workmanlike manner.
c. Field-cut conduit has been reamed and is free of burrs.
d. Field-made bends are smooth and the conduit sidewall is not distorted.
e. Conduit is properly supported and installed with proper supports to prevent galvanic
action.
f. Threaded joints have been made up wrench-tight or bonded.
g. Conduit and conduit body threads have been lubricated with an electrically conductive
compound accepted for the purpose.
h. There are no excessive bends or offsets between pull points.
i. Fittings and pull boxes are accessible.
j. Conduit, fittings, and pull boxes are sized in accordance with Owner drawings.
k. Unions are installed where necessary to allow equipment removal.
l. Drains are installed at low points.
m. Sealing fittings are installed as shown on drawings and as required by the project
specification and area classification drawings.
n. Flexible conduit has been installed where required.
o. Conduits in banks or ducts have been properly spaced.
p. Conduits have been properly spaced for separation between different power levels.
q. Conduit termination points are as shown on Owner drawings.
r. Conduit bank and duct routing is per Owner drawings and underground conduit is encased
with red concrete where required.
s. Conduit routing does not interfere with walkways, ladders, or equipment access.
t. Conduits have been internally cleaned and unused conduits are capped. On specified
conduit runs, a properly sized mandrel has been pulled through the conduit.

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u. Bonding jumpers have been installed on flexible conduit and grounding bushings.
Comment: It is extremely important to ensure that conduit installation meets project
requirements prior to pulling in the wire and cable. This should be considered an
inspection or hold-point requiring Service Supplier and Owner sign-off.
3. Following wiring completion, but prior to the final sign-off, Service Supplier shall verify the
following:
a. Exposed threads and damaged areas of polyvinyl chloride (PVC) coated conduit have
been properly touched up.
b. Conduits have been tagged as required.
c. Fitting covers are tightly in place.
d. Sealing fittings have been poured in accordance with the project specification and
Section 8.1.
Comment: Items listed above are typically not completed until the end of a job and are
examples of punchlist items.
4. Service Supplier shall pour conduit sealing fittings only after the complete electrical system
has been commissioned and accepted by Owner. Service Supplier shall verify that each seal
has been properly poured.
Comment: Seal pouring should be one of the last tasks in any job. Small modifications to
wiring are often required during commissioning activities. Therefore, it is
important to wait until after these activities are complete before seals are poured.
5. Seals located in a classified area of an operating plant should be poured prior to system
energization.
Note There may be some good reasons not to wait until commissioning is complete to pour
certain seals.
6. After the sealing fittings are poured, Service Supplier shall mark them with red paint to
indicate that the sealing compound has been poured.

8.2 Cable Tray and Cable Support System

1. Checklist items, as described in Form 3 of ELC-DS-4744, shall be followed throughout the
installation of cable trays and cable supports.
2. Prior to installing cable in a cable tray or cable support system, Service Supplier shall verify
the following:
a. Cable trays and supports are of the type, material, and size specified.
b. Cable tray is properly supported on supports in a manner that prevents galvanic action.
c. Cable tray hardware is properly installed.
d. Radii of cable tray fittings are as specified.
e. Cable trays or cable supports do not interfere with walkways, ladders, or equipment
access.
f. Cable tray and cable support routing are as shown on Owner drawings.
g. Cable tray is properly bonded.
h. Expansion joints are properly installed.

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i. There are no obstructions to prevent pulling of cable.

j. Tray system has no sharp edges to cut cable and tray hardware is assembled with bolt
heads flush with inside of tray side rail.
k. Nonconductive coatings have been removed at splice joints ensuring continuity of
electrical ground path.
l. Spacing between cable trays of different power levels are maintained as per
ELC-SU-1675.
Comment: Sufficient space shall be provided between hot (insulated) pipe services and tray
system in accordance with project specifications. It is extremely important to
ensure that the cable tray system is installed in accordance with project
requirements prior to installing the cable. Therefore, it is recommended that this
be an inspection or hold point requiring Service Supplier and Owner sign-off.
3. After the cable installation, Service Supplier shall verify the following:
a. Cable tray deflection is less than allowable maximum.
b. Required cable tray supports and cable supports have been installed.
c. Power cables are installed in one layer only, unless specifically shown otherwise on
Owner drawings.
d. Cables are individually secured to the tray at proper intervals with materials suitable for
the location.
e. Covers, fire stops, and partitions are properly installed.
f. Fireproofing, if installed, is properly installed.

8.3 Wire and Cable

1. Checklist items, as described in Form 4 of ELC-DS-4744, shall be followed throughout the
installation of wires and cables.
2. Service Supplier shall check the following during wire and cable installation:
a. Proper type, size, color, and number of wires and cables are being installed.
b. Cable pulling plan is developed and reviewed with Owner representative for long, difficult
(e.g., multiple bends), or critical (e.g., main substation feeders) pulls, and the pull is
performed as specified on the pulling tension calculation sheet.
c. Number of cable bends during pulling process does not exceed the maximum
recommended by the cable manufacturer.
d. Ambient temperature is above the minimum allowed for cable insulation.
e. Proper pulling compound is used.
f. For long, difficult (e.g., multiple bends), or critical (e.g., main substation feeders) pulls,
allowable pulling tensions are not exceeded.
g. Cable bending radius shall not be less than the minimum recommended by cable
manufacturer.
h. Wire and cable is protected and kept clean throughout the pulling operation.
i. Cable fill does not exceed NEC requirements and cable jam ratios are verified.

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j. Proper hydraulic crimp tool and die are used.

Comment: Owner representatives should pay special attention to long, difficult (e.g., multiple
bends), or critical (e.g., main substation feeders) pulls, especially during the early
stages of the project. Ensuring proper setup and execution of difficult pulls helps
to avoid costly problems.
3. Wire and cable shall be megohmmeter-tested by the Service Supplier after it is pulled, but
prior to termination. Megohmmeter testing shall be in accordance with Section 7.2 of this
specification.
4. Medium voltage cable shall be given a hi-pot test by the Service Supplier after it is pulled and
stress relief is installed, but prior to termination. The hi-pot tests shall be in accordance with
Section 7.3 of this specification.
Comment: Prior to terminating wires and cables, it is necessary to ensure that the correct
conductors have been pulled and that the insulation was not damaged during the
pull.
It is recommended that conductors be megohmmeter-tested soon after they are
pulled. Usually they are tied together and megohmmeter-tested to ground, and
each one is megohmmeter-tested to the rest. This is a reasonably quick check of
conductor integrity. An inspection and testing checklist is not provided for this
test, as documenting the megohmmeter readings takes more effort than it is worth.
However, should a project want to document these values, a form should be
developed. It should be kept in mind that most power conductors are
megohmmeter tested at least one more time prior to being energized.
5. Following conductor termination, Service Supplier shall make a complete point to point
continuity test for each conductor.
6. Service Supplier shall highlight verified terminations on the connection diagram, which in turn
shall be attached to the applicable raceway, cable, and wire inspection and testing record sheet.
The following items shall be checked at this stage by Service Supplier:
a. Proper wire and cable tagging
b. Use of proper cable terminators
c. Proper grounding of cable shields
d. Properly taped terminations
e. Torque mark on each cable terminator
f. Form 6 in ELC-DS-4744 completed
Comment: A complete point-to-point check of wiring is desirable in order to avoid problems
during equipment startup. The simplest way to document that this test has been
performed is to highlight the connection diagram.
7. Service Supplier shall pour cable sealing fittings after the complete electrical system has been
commissioned and Owner acceptance has been received. Service Supplier shall verify that
each seal has been properly poured.
Comment: Like conduit seals, cable seal pouring should be one of the last tasks on a job
(unless pouring is required earlier due to special circumstances).
8. After cable sealing fittings are poured, Service Supplier shall mark them with red paint to
indicate that sealing compound has been poured.

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9. Service Supplier shall maintain an up-to-date copy of Form 1 in ELC-DS-4744.

Comment: ELC-DS-4744 provides a simple form to track the stages of circuit installation. It
also serves as an inspection sign-off record. Early in projects, it should be decided
which entries will require Service Supplier, Owner, or both Service Supplier and
Owner signature(s) prior to work continuation.
Project engineer may decide that it is unnecessary to record inspections at each
stage of a circuit’s installation. It may be decided to require an overall inspection
prior to energization. In this case, it might be easier to use the conduit and cable
schedule than ELC-DS-4744 as a sign-off record.

8.4 Switchgear and Motor Control Equipment

Switchgear and motor control equipment shall be checked, tested, and energized by Service
Supplier in accordance with Equipment Supplier’s recommendations and the following guidelines:
1. Service Supplier shall record data on Form 7 in ELC-DS-4744. Service Supplier shall
maintain an up-to-date copy of Form 7.
2. Low-voltage drawout air circuit breakers shall be inspected and tested in accordance with
Form 8 in ELC-DS-4744. An up-to-date copy of Form 8 for each breaker shall be maintained.
3. Medium voltage circuit breakers shall be inspected and tested in accordance with Form 9 in
ELC-DS-4744. An up-to-date copy of this form shall be maintained for each breaker.
4. Prior to feeder termination, an insulation resistance test shall be performed on buses in
accordance with Section 7.2 of this specification.
5. Prior to feeder termination, a hi-pot test on medium voltage equipment buses shall be
performed in accordance with Section 7.3 of this specification.
6. Protective relays shall be calibrated, set, and tested in accordance with Section 7.5 of this
specification. Tripping of circuit breakers from associated relays shall be tested by impressing
appropriate test currents and/or voltages.
7. Molded-case circuit breakers with adjustable trip settings shall be set in accordance with
Owner drawings.
8. Motor circuit protectors shall be set in accordance with project documentation.
a. If settings are not specified, they shall be set at approximately 1000 percent of motor
full-load current, or at the lowest setting required to start the motor.
b. In no instance shall this setting exceed 1300 percent of full-load motor current.
Comment: It is good practice to set the motor circuit protectors as low as possible without
causing spurious trips during motor starting. It is likely that the setpoint will need
to be adjusted during startup activities.
9. Thermal overload relays used for motor protection shall be individually checked to ensure that
the proper heater element is installed for the motor nameplate full load current.
a. This setting shall not exceed 125 percent of full-load current for 1.15 service factor motors
and motors with a marked temperature rise not exceeding 104°F (40°C), or 115 percent of
full-load current for other motors.
b. For electronic overloads, settings shall be uploaded to the device in accordance with the
motor full-load amps, device requirements, and code requirements.
Comment: For exceptions to these requirements, see NEC Article 430 34.

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10. Fuses, circuit breakers, contactors, and control power transformers shall be checked for proper
rating, size, and type in accordance with the one-line diagram and Equipment Supplier
drawings.
Comment: Even though equipment is usually inspected thoroughly and tested at Equipment
Supplier’s plant, it is good practice to reinspect all components to ensure the
proper rating, size, and type for the application.
11. Molded-case circuit breakers and motor circuit protectors shall be insulation resistance tested
in accordance with Section 7.2 of this specification.
12. Current transformers and potential transformers shall be checked for proper rating, size, ratio,
polarity, and type in accordance with the one-line diagram and accepted Equipment Supplier
drawings.
13. Space heaters shall be checked for proper operation.
14. A complete functional check shall be performed. It shall include, but not be limited to,
interlocks, automatic transfer schemes, and circuit breaker and contactor operation from
associated control devices.
Comment: Normally a control power source will be needed for these tests.
15. Prior to energizing switchgear or motor control equipment, a final megohmmeter test of the
switchgear or MCC buses shall be performed. Care shall be taken to disconnect lightning
arrestors, capacitors, potential transformers, and secondary ground connections on current
transformers, as necessary.

8.5 Transformers
Service Supplier shall check, test, and energize transformers in accordance with Equipment
Supplier’s instructions and the following guidelines:
1. Service Supplier shall record data on Form 10 in ELC-DS-4744. Service Supplier shall
maintain an up-to-date copy of Form 10.
2. Prior to feeder termination, Service Supplier shall perform an insulation resistance test on
transformers in accordance with Section 7.2 of this specification.
3. Service Supplier shall visually inspect liquid-immersed transformers for leakage of liquid at
fittings, bushings, and other externally connected or gasketed devices (e.g., oil temperature
and level gages).
4. Service Supplier shall verify proper operation of control and protective equipment on
transformers (e.g., shutdown and alarm devices and forced air cooling facilities).
5. On power transformers, tap changers shall be manually operated and set at the proper tap
setting prior to energizing the transformer.
a. Service Supplier shall measure the transformer turn ratio for each tap setting and compare
it to nameplate data.
b. Measured values shall not deviate from nameplate values by more than 0.5 percent.
Comment: The turn ratio test helps to identify trouble with transformer windings (such as
turn-to-turn short circuits). The 0.5 percent allowable margin around nameplate
value is established in IEEE C57.12.00. It is usually not necessary to perform this
test on smaller transformers.

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6. Where liquid-immersed transformers have been completely assembled, filled, factory-tested

and shipped by Equipment Supplier, Service Supplier shall not open tanks for internal
inspections unless specific conditions indicate otherwise.
Comment: Unless transformer has been mishandled, it is not necessary to perform an
internal inspection of transformers shipped with insulating oil from the factory. If
a sealed transformer is opened, insulating liquid will become contaminated and
have to be replaced or reconditioned. See the comment in Section 7.6, item 4 for
further information.
7. Service Supplier shall verify that liquid level, temperature, and pressure are within acceptable
limits prior to energizing a liquid-immersed transformer.
8. Service Supplier shall conduct a dielectric breakdown test on a sample of each
liquid-immersed transformer’s insulating fluid.
a. Test shall be in accordance with Section 7.6, item 2 of this specification.
b. Breakdown shall not be below Equipment Supplier’s recommended minimum, and in no
instance shall it be less than 25 kV.
9. Service Supplier shall verify correct sizing of current transformers and/or lightning arrestors,
if installed.
10. Just prior to energizing a transformer, Service Supplier shall perform an insulation resistance
test on the entire system (including primary and secondary feeders).
11. Service Supplier shall monitor transformer closely after being initially energized for proper
operation. After approximately one week of continuous operation, Service Supplier shall
perform a dielectric breakdown test on a sample of insulating fluid from liquid-filled
transformers in accordance with Section 7.6, item 2 of this specification.
Comment: If transformer is only lightly loaded, it may be beneficial to delay this liquid
dielectric breakdown test for several weeks.
12. Service Supplier shall perform a baseline dissolved gas analysis on transformer oil.

8.6 Bus Duct

Service Supplier shall perform inspection and testing on the bus duct in accordance with
Equipment Supplier’s instructions and the following guidelines:
1. Service Supplier shall record data on Form 12 in ELC-DS-4744. Service Supplier shall
maintain an up-to-date copy of Form 12.
2. Service Supplier shall verify the following:
a. Lap joints are properly cleaned and greased in accordance with Equipment Supplier’s
instructions prior to splices being made.
Comment: Equipment Suppliers sometimes recommend that a thin coating of protective
grease be left on the bus at splice points.
b. Bus duct is properly supported in accordance with Owner drawings and specifications.
c. Bus splices have been properly fastened per Equipment Supplier’s recommendations.
d. The integrity of the bus insulation by visual inspection.
3. Service Supplier shall check drains and breathers for cleanliness.

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4. Service Supplier shall ensure that removable insulation boots are properly installed after
splices are made.
5. Service Supplier shall perform the following tests:
a. An insulation resistance test in accordance with Section 7.2 of this specification.
b. A hi-pot test for medium voltage bus duct in accordance with Section 7.3 of this
specification.
6. Service Supplier shall check space heaters for proper operation.
7. Service Supplier shall ensure covers have been properly installed prior to energizing the bus
duct.

8.7 Uninterruptible Power Supply

Uninterruptible power supply (UPS) systems shall be checked, tested, and energized by Service
Supplier in accordance with Equipment Supplier’s instructions and the following guidelines:
Comment: UPS equipment is often quite complex. On UPS systems over 10 kVA, it is advisable to
have Equipment Supplier’s field service representative assist in startup. Units that
have been in storage for an extended period (e.g., over 6 months) may need to have
their output (smoothing capacitors) gradually brought up to full voltage per
Equipment Supplier’s instructions to prevent damage to capacitors.
1. Service Supplier shall test the battery charger and battery in accordance with Section 8.8 of
this specification.
2. Alarms and shutdowns shall be tested as follows:
a. Simulate inverter failure and operation of transfer switch without loss of load.
b. Retransfer full load to inverter without loss of load.
c. Simulate AC power failure to the battery charger and DC power from the charger.
d. Simulate battery failure where facilities are provided to enable successful inverter
operation under this condition.
e. Energize the single largest inductive load or combination of loads that may be energized
simultaneously without loss of other operating loads.

8.8 Battery and Battery Charger

Service Supplier shall test and energize batteries and battery chargers in accordance with
Equipment Supplier’s instructions and the following guidelines:
1. Service Supplier shall record data on Form 13 in ELC-DS-4744. Service Supplier shall
maintain an up-to-date copy of Form 13.
2. Prior to introducing electrolyte into battery cells, Service Supplier shall visually check for
cracks and other damage. Service Supplier shall verify that the electrolyte in the containers is
properly mixed (i.e., the electrolyte at the bottom of the container does not have a higher
specific gravity than the electrolyte at the top).
Comment: Pre-mixed electrolyte that has been stored for an extended period may begin to
separate. To ensure that every cell is filled with similar strength electrolyte, it is
recommended to make sure it is well mixed in its storage containers.

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3. Service Supplier shall take specific gravity and voltage readings for each cell after all cells
have been filled, but before the charger is energized.
Comment: This provides a base reading which may help to identify cells that have gone bad
during storage, or cells that were filled with bad electrolyte.
4. Battery charger shall be energized in float mode. Service Supplier shall take voltage readings
across the battery and at the charger.
a. Float voltage shall be set in accordance with Equipment Supplier’s instructions.
b. If applicable, charger shall be placed in equalize mode and the same procedure followed.
Comment: Battery chargers for lead-acid cells normally have two voltage setpoints, float and
equalize. Nickel-cadmium battery chargers usually only have a single float
voltage setting.
5. Battery shall be completely charged with charger in either float or equalize mode, as
recommended by Equipment Supplier.
a. Specific gravity and voltage readings shall be taken for each cell and recorded on Form 13
in ELC-DS-4744.
b. Values shall be within Equipment Supplier’s tolerances.
c. Cell temperature shall be checked daily during initial charging to ensure that Equipment
Supplier’s recommended maximum is not exceeded.
Comment: Lead-acid-type batteries will normally be charged on the higher equalize voltage
setting, whereas nickel-cadmium cells are kept at a single float voltage. As long as
batteries are charged within the voltage limits recommended by Equipment
Supplier, cell overheating should not occur.
6. After battery has been completely charged, it shall be given a discharge test in accordance with
Equipment Supplier’s instructions. (Nickel-cadmium batteries shall be deep-cycled twice prior
to performing this test.)
a. With total load on the system, charger shall be turned off. Battery voltage and load
amperage shall be recorded every 30 minutes.
b. When battery reaches the minimum allowable voltage, as specified by Equipment
Supplier, charger shall be turned back on and battery shall be recharged.
c. After the cells have been fully recharged, voltage and specific gravity readings shall be
taken and recorded.
Comment: For lead acid-type batteries, discharge rates should be closely observed so that
batteries are not drawn down below minimum acceptable levels (this is
approximately 1.75 volts per cell). Specific attention should be paid to minimum
voltage levels on systems that do not have automatic shutdown devices.
7. Battery charger alarms shall be verified for proper operation and setpoints.
8. After testing is complete, battery charger shall be left operating in float mode. Service Supplier
shall maintain battery systems until electrical facilities have been accepted by Owner.
Comment: A regular maintenance program should be initiated as soon as batteries are
placed in service. Verify that Service Supplier does this.

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9. The same hydrometer, thermometer, or other test equipment shall never be used for both
lead-acid and nickel-cadmium batteries. Separate equipment shall be used.
Comment: If the same test equipment is used on different types of battery systems, batteries
could be ruined due to electrolyte contamination.

8.9 Panelboards
1. Service Supplier shall record data on Form 14 in ELC-DS-4744. Service Supplier shall
maintain an up to date copy of Form 14.
2. Service Supplier shall verify the following:
a. Types, ratings, and sizes of panelboards are as shown on Owner drawings.
b. Circuit breakers and fuses are sized in accordance with Owner drawings.
c. Color coding of conductors.
d. Circuits serves the proper load.
3. Prior to energizing panelboards, Service Supplier shall perform insulation resistance tests on
panelboards, including incoming feeders.
4. Service Supplier shall test ground fault circuit interpreter (GFCI) type breakers.
5. After completing the above checks, Service Supplier shall verify that the panelboard circuit
schedule is properly filled out and in place in the panelboard.

8.10 Grounding
1. Service Supplier shall record data on Form 15 in ELC-DS-4744. Service Supplier shall
maintain an up-to-date copy of Form 15.
2. Service Supplier shall verify that grounding systems are in accordance with Owner drawings
and specifications, and NFPA 70.
a. System and equipment grounding conductors shall be verified for proper sizing and color
coding.
b. Mechanical bonding connections shall be checked for tightness.
3. The grounding system tests shown in Table 1 shall be performed by Service Supplier where a
grounding loop is installed.

Table 1: Grounding Tests Where Grounding Loop is Installed (1 of 2)

Items to Test Test Requirements
Grounding Loop • Service Supplier shall measure and record resistance of individual
ground rods prior to connection into the overall grounding system.
• If the resistance of any rod is greater than 5 ohms, another rod shall be
installed in parallel and extended and driven deeper, or another means,
acceptable to Owner, shall be utilized to decrease resistance.
• Resistance of grounding loop shall be measured to earth at several
points and readings shall be recorded.
• Where a metallic conduit system serves as the equipment ground path,
resistance from conduit to earth shall be measured and recorded.
Resistance of ground system to earth shall not be greater than 1 ohm.

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Table 1: Grounding Tests Where Grounding Loop is Installed (2 of 2)

Items to Test Test Requirements
Equipment Grounds • Service Supplier shall measure resistance between grounding loop (or
metallic conduit) and the following grounding points:
• Electrical equipment enclosures
• Nonelectrical equipment (e.g., vessels, tanks, and fences)
• Lightning protection equipment
• Wiring support systems (e.g., conduit and cable tray)
• Armors and sheaths of cables
• In no case shall total resistance to ground (i.e., equipment to ground
loop plus ground loop to earth) exceed 1 ohm.
System Grounds • Service Supplier shall measure and record resistance between
grounding loop and system neutrals at the point of grounding.
• In no case shall total resistance to ground (i.e., neutral to ground loop
plus ground loop to earth) be greater than the value of the grounding
resistor (if any) plus 1 ohm.

4. The grounding system tests shown in Table 2 shall be performed by Service Supplier where a
steel structure is used as the grounding electrode (e.g., offshore platforms).

Table 2: Grounding Tests Where Steel Structure is Grounding Electrode

Items to Test Test Requirements
Equipment Grounds • Service Supplier shall measure and record resistance between the
platform’s structural steel and the following grounding points:
• Electrical equipment
• Nonelectrical equipment (e.g., vessels, tanks, and fences)
• Lightning protection equipment
• Wiring support systems (e.g., conduit and cable tray)
• Armors and sheaths of cables
• In no case shall resistance exceed 1 ohm.
System Grounds • Service Supplier shall measure and record resistance between the
platform’s structural steel and system neutrals at the point of grounding.
• In no case shall measured resistance be greater than the value of the
grounding resistor (if any) plus 1 ohm.

8.11 Grounding Resistors

1. Service Supplier shall record data on Form 16 in ELC-DS-4744. Service Supplier shall
maintain an up-to-date copy of Form 16.
2. With resistor disconnected from neutral, Service Supplier shall measure and record cold
resistance. Service Supplier shall set variable resistors in accordance with drawings.
3. With resistor disconnected from ground, Service Supplier shall perform an insulation test with
a 500-volt insulation tester, in accordance with Section 7.2 of this specification.
4. For medium voltage grounding resistors, Service Supplier shall perform a hi-pot test in
accordance with Section 7.3 of this specification. Resistor shall be disconnected from ground
for this test.
5. Service Supplier shall verify proper operation of pulsing equipment on high-resistance
grounding systems.
6. When adding resistance grounding to the secondary of transformers, Service Supplier shall
ensure that the grounding strap between transformer frame and XO bushing is removed.

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Electrical Systems Checkout and Commissioning ELC-SC-4744-D

8.12 Motors

8.12.1 Mechanical Inspection

1. Service Supplier shall inspect motor frame, end bells, and shaft extensions for
mechanical damage.
2. On motors with grease-lubricated bearings, Service Supplier shall verify that bearings
are adequately, but not excessively, greased. This requirement shall not apply to
motors with sealed bearings.
Comment: Care should be taken not to over grease motor bearings, as this will cause
grease to leak past the seals and contaminate the windings. During initial
motor run-in, the cap should be removed from overflow port to allow
grease expansion.
3. Service Supplier shall verify that motors are suitable for the area classification.
4. On motors with oil-lubricated bearings, Service Supplier shall verify that oil rings
rotate freely and that reservoir is filled with oil recommended by Equipment Supplier.
For motors with forced oil lubrication, verify that oil piping is complete and that
lube-oil system has been cleaned and checked out.
5. Service Supplier shall properly align motor to driven equipment using the reverse dial
alignment procedure, unless specified otherwise.
a. Coupling shall not be installed until uncoupled run test has been completed.
b. On motors with sleeve bearings, verify that limited end float couplings have been
supplied.
c. Verify that motor rotor turns easily by hand and that there is no friction
or binding.
Comment: Some project engineers may not include motor alignment in electrical
Service Supplier’s scope of work. This and other references to alignment
should be modified for those applications.
The reverse dial alignment procedure is the preferred alignment method
for large machinery where access to shafts is possible.
6. Service Supplier shall verify that the motor is properly anchored and that bolts are
properly fastened per Equipment Supplier’s recommendations.
7. Service Supplier shall verify that specified air filters or screens are installed.
8. Service Supplier shall verify that enclosure seals and gaskets are intact.

8.12.2 Electrical Inspection

1. Service Supplier shall perform an insulation resistance test on motor windings in
accordance with Section 7.2 of this specification.
2. Service Supplier shall, on medium voltage motor windings, perform a hi-pot test in
accordance with Section 7.3 of this specification.
3. Service Supplier shall verify that each motor is properly terminated and grounded.
Service Supplier shall ensure that surge arrestors and surge capacitors are properly
grounded.

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4. Service Supplier shall, on insulated bearings, verify the insulation level with a volt
ohmmeter set on the highest resistance scale.
a. Use of a megohmmeter for this test shall not be permitted.
b. The minimum acceptable reading shall be 100K ohms.
c. If a reading below 100K ohms is obtained, and oil rings are not providing a
ground path, Service Supplier shall notify Owner representative.
5. Service Supplier shall verify that motor differential current transformers and ammeter
current transformers, if provided, are properly wired and short-circuited on the
secondaries.
Comment: Running the motor with open-circuited current transformer secondaries
could cause high voltages on secondaries and overheating.
6. Service Supplier shall verify that motor accessories (e.g., space heaters, vibration
switches, thermocouples, resistant temperature detectors [RTDs], and air filter
differential pressure switches) are properly wired, operational, and suitable for the
area classification.
7. Service Supplier shall check motor RTDs to ensure they are of the type specified on
Owner drawings.

8.12.3 Running Tests

1. Service Supplier shall record data on Form 17 in ELC-DS-4744. Service Supplier
shall maintain an up-to-date copy of Form 17. With minor additions, this form may
also be used for other types of machines.
2. Should a small motor need to be disassembled for inspection, Service Supplier shall
do so in accordance with procedures outlined in Form 18 in ELC-DS-4744.
a. Assistance from Equipment Supplier shall be requested for large motors.
b. In all cases, Service Supplier shall notify Owner and Equipment Supplier, in
writing, prior to disassembly of any motor.
Comment: Field disassembly of motors without prior Equipment Supplier
authorization is likely to void the warranty.
3. An explosion-proof motor should be disassembled only in a motor shop authorized to
recertify it after it is reassembled.
4. Service Supplier shall verify that motors rotate in the proper direction.
Comment: Motors should be checked to ensure the direction of rotation matches that
of the driven equipment. Before a rotation check is performed, driven
equipment shall be checked to ensure mechanical damage is not caused if
rotation is incorrect. Uncoupling may be necessary.
5. Where feasible, Service Supplier shall run motors uncoupled from their driven
equipment for a run time determined by bearing type (e.g., ball bearing or sleeve) or
until bearing temperatures have stabilized, whichever is longer.
a. Motor alarm and shutdown circuits shall be activated during running tests. Only
shutdowns related to motor protection should be activated during motor run in
testing.
b. Process-related shutdowns shall be bypassed.

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Electrical Systems Checkout and Commissioning ELC-SC-4744-D

6. Service Supplier shall record motor running currents.

7. Service Supplier shall monitor vibration in accordance with Section 7.4 of this
specification.
8. Service Supplier shall check for abnormal temperature rise in motor bearings.
a. If equipped, RTDs or thermocouple readouts shall be monitored.
b. Bearing temperatures shall not exceed Equipment Supplier’s recommended levels
or 180°F (82°C), whichever is less.
Comment: If bearing housing or motor frame directly surrounding bearings is cool
enough to touch for several seconds, bearings are not too hot.
9. If equipped with RTDs or thermocouple readouts, Service Supplier shall check for
abnormal temperature rise in motor windings and readouts shall be monitored.
10. For oil-lubricated motors, Service Supplier shall verify that oil rings are rotating
properly. Reservoir oil level shall fall slightly when motor is started and rise again
when motor is stopped.
11. For motors supplied with a forced lube-oil system, Service Supplier shall verify
proper flow, temperature, and pressure of lube-oil.
12. Following satisfactory completion of uncoupled motor run test, Service Supplier shall
couple motor to its driven equipment and run motor until temperatures have stabilized
(not less than 4 hours). Checks and tests performed during motor uncoupled run test
shall be repeated for the coupled run test.
Caution Pumps shall not be run without fluid.
Comment: Process fluids may not be available to run through some pumps while the
electrical Service Supplier is still on the job. Owner representative shall
decide which pumps will be started by others.

8.13 Motor Control

Service Supplier shall inspect and test motor control equipment in accordance with Section 8.4 of
this specification and the following guidelines:
1. Service Supplier shall verify proper operation of control stations.
2. Service Supplier shall perform a complete functional test of motor control circuits with motor
leads disconnected from starter and buses de-energized.
a. Starting, alarm, and shutdown functions shall be tested.
b. At completion of the functional test, disconnected wiring shall be reconnected.
Comment: With leads removed and control power available, motor running may be simulated
by closing the contactor from local and remote operators. Permissives and
shutdowns should also be tested.

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8.14 Generators
Service Supplier shall inspect and test power generation equipment in accordance with Equipment
Supplier’s instructions. As a minimum, Service Supplier shall perform the following inspections:
Comment: With the exception of small, standard-design, engine-driven generator packages, it is
recommended that Equipment Supplier assistance be requested for startup of
generators. For large and complex turbine-driven generator packages, a
comprehensive, written, field test procedure should be requested from Equipment
Supplier.
1. Service Supplier shall record data on Form 19 in ELC-DS-4744. Service Supplier shall
maintain an up to date copy of Form 19.
2. Service Supplier shall perform a complete visual inspection to verify that equipment and
devices are properly installed, valves and switches are in their proper position, shipping
restraints and covers have been removed, wire and cable terminations are tight, unit is clean,
and anything else necessary for equipment to run is in its proper operating mode.
3. Service Supplier shall perform an insulation test on generator windings in accordance with
Section 7.2 of this specification.
4. Medium voltage windings shall be given a dielectric test in accordance with Section 7.3 of this
specification.
5. Generator shall be properly aligned to its driver using the reverse dial alignment method,
unless otherwise specified.
6. Service Supplier shall verify insulation level of insulated bearings using a volt ohmmeter,
set on the highest resistance scale.
a. Use of a megohmmeter shall not be permitted.
b. Service Supplier shall ensure that oil rings are centered and that generator is uncoupled.
c. If reading is below 100K ohms, Service Supplier shall notify Owner representative.
7. Prior to startup, a complete functional test shall be done on generator controls.
a. Auxiliary equipment such as fans, lube-oil pumps, and coolers shall be run as part of the
functional test.
b. Alarm and shutdown circuits shall be functionally tested for proper operation.
8. Service Supplier shall perform a complete four-hour, full-load, test run on generators when at
least 40 percent of full-load is available.
a. Generators shall be unloaded when started.
b. Loads shall be added gradually.
c. Vibration shall be monitored under all load conditions in accordance with Section 7.4 of
this specification.
d. After it has been determined that generator is operating satisfactorily, it shall be step
loaded and unloaded with the largest single load it is expected to carry during normal
operation.
e. Proper voltage and frequency response shall be verified.

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9. Where generators are designed to operate in parallel with one another or in parallel with the
utility, Service Supplier shall test generators in parallel mode over as wide a load range as is
available.
a. Proper operation of governor and voltage regulator shall be verified.
b. Where a generator is connected to a utility system through a critical load bus (so that either
power supply will pick up the entire critical load in case the other fails), operation under
both modes of failure shall be checked.
Comment: Synchronizing equipment should be thoroughly checked before attempting to
synchronize or parallel generators. Synchronizing meter and lights should be
confirmed with a voltmeter at each phase across an open breaker.
10. Where standby power system includes automatic start of generator and automatic transfer of
loads to generator, Service Supplier shall verify proper operation of generator and automatic
transfer system on both failure and restoration of normal power.
11. Service Supplier shall develop and maintain a complete running log for generators.

8.15 Programmable Controllers

Comment: Checking and testing programmable controllers and associated devices is normally
covered in more depth by instrument and control specifications.
1. Service Supplier shall check programmable controllers in accordance with Equipment
Supplier’s instructions and instructions from Owner representatives.
2. As a minimum, Service Supplier shall verify proper field wiring and interface between PC and
end devices.
3. Service Supplier shall verify power source is as specified on drawings (e.g., UPS, battery
back-up, or redundant).

8.16 Lighting
1. Service Supplier shall inspect lighting fixtures to verify that the proper type and wattage
fixture is installed in accordance with Owner drawings.
2. Proper labeling for the area classification in which it is installed shall be verified.
3. Service Supplier shall verify that fixtures are installed in the location and at the height shown
on Owner drawings.
4. Service Supplier shall energize fixtures one circuit at a time and ensure that each one is served
from the proper circuit. Service Supplier shall record actual lighting circuit operating currents
on the appropriate panel schedule drawing.
5. Service Supplier shall verify proper operation of photocells, switches, motion detectors,
lighting contactors, and other control devices.
6. Service Supplier shall highlight appropriate lighting drawing(s) after fixtures or devices are
inspected and tested.
7. Service Supplier shall perform a night test of both normal and emergency lighting systems.
a. Fixtures shall be reoriented and adjusted, as needed, to properly illuminate intended areas
and equipment.

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b. Illumination levels shall be recorded on lighting plans, which shall be submitted to Owner
for review.
Comment: Addition and/or relocation of fixtures would normally be considered a design change
and result in a contract change.

8.17 Receptacles
1. Service Supplier shall energize receptacles one circuit at a time and ensure that each one is
served from the proper circuit.
a. Receptacles shall be checked for proper voltage, polarity, and grounding.
b. GFCI-type receptacles shall be tested for proper operation.
2. Service Supplier shall check three-phase receptacles (e.g., welding receptacles) for common
phasing (i.e., all receptacles phased alike) and proper voltage.
3. Service Supplier shall highlight appropriate drawing(s) after each receptacle is inspected and
tested.

8.18 Communication and Alarm Systems

1. Service Supplier shall inspect and test communication and alarm systems in accordance with
Equipment Supplier’s instructions.
2. As a minimum, systems shall be given an operational test.
3. Devices shall be individually tested and adjusted as necessary.
Comment: Speakers, amplifiers, and receivers usually need to be adjusted for proper orientation
and/or volume.

8.19 Aids to Navigation

Service Supplier shall inspect and test aids to navigation in accordance with Equipment Supplier’s
instructions. As a minimum, devices shall be given a complete operational test.
Comment: Local requirements should be checked to confirm if witness testing is required by
regulatory bodies or agencies (i.e., Federal Aviation Administration).

8.20 Lightning Protection

1. Service Supplier shall visually inspect lightning protection system to verify that it conforms to
Owner drawings.
a. Connections at air terminals and ground rods shall be checked for tightness.
b. Air gaps shall be checked for contamination.
2. Resistance measurements shall be taken and recorded in accordance with Section 8.10, item 3
and item 4 of this specification.

8.21 Heat Tracing

1. Service Supplier shall record data on Form 20 in ELC-DS-4744. Service Supplier shall
maintain an up-to-date copy of Form 20.
2. Service Supplier shall perform continuity and insulation resistance tests for electric heat trace
cable and pad heaters, prior to installation, following installation but prior to insulation, and
following insulation, in accordance with Section 7.2 of this specification.

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Electrical Systems Checkout and Commissioning ELC-SC-4744-D

Comment: It is not uncommon for heat trace material to be damaged by pipe fitters and
insulators. Therefore, it is a good idea to test it at various stages of installation.
Some heat trace cables may be damaged by megohmmeter testing. Contact heat
tracing cable Equipment Supplier if in doubt.
3. Service Supplier shall ensure that heat tracing system is suitable for the area classification.
4. A visual inspection shall be made by Service Supplier of the heat trace system prior to pipe
and equipment insulation.
a. Heaters shall be checked for type and wattage, and verified to ensure that each system
conforms to Owner drawings.
b. Thermostats shall be checked for type and range, and compared to drawings.
5. Thermostat setpoints shall be set in accordance with drawings.
a. Service Supplier shall energize heaters and record starting and running currents.
b. Thermostat operation shall be verified by adjusting the setpoint.
6. Service Supplier shall test individual monitor panels, if provided.
7. Following installation of pipe and equipment insulation, Service Supplier shall check heaters
again for proper operation. Pipe and equipment shall be inspected to ensure that proper caution
signs are installed in accordance with project specifications.

8.22 Miscellaneous Electrical Equipment

1. Service Supplier shall inspect and test equipment not specifically listed above in accordance
with Equipment Supplier’s instructions and direction from Owner representatives.
2. Miscellaneous equipment includes, but is not limited to, disconnect switches, motor-operated
valves, and heating, ventilation, and air conditioning (HVAC) equipment.
3. It shall be the intent of this specification that Service Supplier completely inspect, test, and
start-up equipment shown on electrical drawings and other miscellaneous equipment normally
associated with the electrical portion of a facility.

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Electrical Systems Checkout and Commissioning ELC-SC-4744-D

APPENDIX A
LIST OF FORMS IN ELC-DS-4744 AND ELC-DS-2469

The following forms, found in ELC-DS-4744, shall be used by Service Supplier as a guide when
performing inspections and tests and recording test results.

A.1 Inspection Records

1. Inspection and Testing Record-Raceway—Wire and Cable (Form 1)
2. Inspection Checklist—Conduit (Form 2)
3. Inspection Checklist—Cable Tray and Cable Supports (Form 3)
4. Inspection and Testing Checklist—Cable and Wire (Form 4)

A.2 Torque Value Records

1. Torque Value Record—Electrical Equipment (Form 5)
2. Torque Value Record—Cable Terminator (Form 6)

A.3 Insulation Resistance Records

1. Insulation Resistance Record—Electrical Equipment (ELC-DS-2469)
2. Insulation Resistance Record—Rotating Electric Machinery (ELC-DS-2469)
3. Insulation Resistance Record—Transformers (ELC-DS-2469)

A.4 Inspection and Testing Checklists

1. Inspection and Testing Checklist—Switchgear and Motor Control Equipment (Form 7)
2. Inspection and Testing Checklist—Low Voltage Draw Out Air Circuit Breakers (Form 8)
3. Inspection and Testing Checklist—Medium Voltage Circuit Breakers (Form 9)
4. Inspection and Testing Checklist—Transformers (Form 10)
5. Testing Record—Electrical Equipment Insulating Oil (Form 11)
6. Inspection and Testing Checklist—Bus Duct (Form 12)
7. Inspection and Testing Record—Battery and Battery Charger (Form 13)
8. Inspection and Testing Record—Panelboards (Form 14)
9. Inspection and Testing Record—Grounding (Form 15)
10. Inspection and Testing Checklist—Neutral Grounding Resistor (Form 16)
11. Inspection and Testing Checklist—Squirrel Cage Induction Motors (Form 17)
12. Inspection Checklist—Inspection of Disassembled Squirrel Cage Induction Motors (Form 18)
13. Inspection and Testing Checklist—Electrical Generator (Form 19)
14. Inspection and Testing Record—Heat Tracing (Form 20)

A.5 Other
1. Tabulation of Equipment Requiring Equipment Supplier Assistance for Start-up (Form 21)
2. Punchlist (Form 22)

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