Ke01 A1 000 NC e PR 0001 000 C01

ORIGINATING COMPANY:
NORTH CASPIAN CONSTRUCTORS
DOCUMENT NUMBER:
PROJECT: MAIN WORKS CONSTRUCTION

KASHAGAN DEVELOPMENT EXPERIMENTAL PROGRAM
KE01-A1-000-NC-E-PR-0001-000
CONTRACT DESCRIPTION:
CONTRACT FOR THE MAIN WORKS CONSTRUCTION
AGIP KCO CONTRACT NO:
2004-0504
CONTRACTORS
JOB NO:
DOCUMENT TITLE:
HOLDS
N/A
SHEET NO.
1 OF 30
CONTRACTORS DOCUMENT NUMBER:
PROCEDURE FOR ELECTRICAL INSTALLATION
ABSTRACT: This document describes procedures to be used

for electrical works within the Kashagan Main Works Project.
APPROVED FOR
CONSTRUCTION
REVISED AND RE-ISSUED FOR
APPROVAL
F.GURBUZ
Y.Z.TFEK
R.MCCORKLE
P.MATTER
F.GURBUZ
Y.Z.TFEK
R.MCCORKLE
P.MATTER
30.03.06
ISSUED FOR REVIEW
F.GURBUZ
Y.Z.TFEK
R.MCCORKLE
P.MATTER
DATE
REASON FOR ISSUE
PREPARED
CHECKED
APPROVED
COMPANY
C01
05.10.06
P02
21.09.06
P01
REV
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 2 of 30
REVISION DESCRIPTION SHEET
Rev.
Para.
Revision Description
P01
ISSUED FOR REVIEW
P02
REVISED AND RE-ISSUED FOR APPROVAL
C01
APPROVED FOR CONSTRUCTION
Hold
No.
Para.
Description of Hold
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 3 of 30
TABLE OF CONTENTS
1.0
PURPOSE....................................................................................................................... 5
2.0 SCOPE...................................................................................................................... 5
3.0 ABBREVIATIONS......................................................................................................5
4.0 REFERENCES.......................................................................................................... 6
5.0 CODES AND STANDARDS.......................................................................................7
Industrial Codes and Standards...............................................................................7
Precedence................................................................................................................. 8
6.0 DESIGN REQUIREMENTS........................................................................................9
Design Life.................................................................................................................. 9
Design Temperature...................................................................................................9
Voltage and Frequency Requirements.....................................................................9
7.0 EQUIPMENT INSTALLATION..................................................................................10
General..................................................................................................................... 10
Transformers............................................................................................................. 11
Bus-Duct Systems....................................................................................................11
Metalclad Switchgear and Large Control Panels...................................................12
DCPS and UPS......................................................................................................... 12
Cable Installation......................................................................................................13
General.................................................................................................................. 13
Cable Separation..................................................................................................14
Cable Installation above Ground.........................................................................15
Cable Installation Below Ground.........................................................................17
Cable Termination....................................................................................................19
Cable Glands and Entries....................................................................................19
Cable Termination................................................................................................20
Cable and Core Identification..............................................................................21
Earthing and Lightning Protection.........................................................................22
Earthing System Installation...............................................................................22
Bonding................................................................................................................. 23
Lightning Protection............................................................................................23
Lighting and Small Power Installation....................................................................23
Equipment Plates, Nameplates, Rating Plates and Labels...................................24
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 4 of 30
8.0 INSPECTION, TESTING, PRE-COMMISSIONING AND COMMISSIONING...........25
Insulation Testing.....................................................................................................26
Insulation Resistance Tests.................................................................................26
High Voltage Withstand Tests..............................................................................26
Polarisation Index....................................................................................................27
Interpretation of Results......................................................................................27
Insulating Oil Tests...................................................................................................27
Bearing Insulation Tests..........................................................................................27
Conductivity and Earth Resistance tests...............................................................28
Conductivity Tests................................................................................................28
Earth Resistance Tests........................................................................................28
Equipment Wiring and Terminal Checks................................................................28
Functional Tests.......................................................................................................28
9.0 PRE-COMMISSIONING...........................................................................................29
SPARE PARTS AND SPECIAL TOOLS.........................................................................30
10.0 DOCUMENTATION................................................................................................30
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 5 of 30
1.0
PURPOSE
This procedure is prepared to set the requirements for electrical installation both for temporary
and permanent works.
2.0
SCOPE
Includes but not limited to for the Main Works Constraction Project, Kashagan Field
Development, Temporary contractor facilities and any work in the scope of project works.
3.0
ABBREVIATIONS
AC
Agip KCO
Alternating Current
-
COMPANY
Kazakhstan North Caspian Operating Company
is the party that initiates the project and ultimately pays for its design
and construction. The COMPANY will generally specify the technical
requirements. The COMPANY may also include an agent or consultant
authorised to act for, and on behalf of, the COMPANY.
CONTRACTOR
is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project, or
operation or maintenance of a facility. The COMPANY may undertake all
or part of the duties of the Contractor
CB
Circuit Breaker
CT
Current Transformer
DC
Direct Current
F&G
Fire and Gas
HVAC
Heating Ventilating & Air Conditioning
IEC
International Electrotechnical Commission
HV
High Voltage
HVSG
High Voltage Switchgear
LV
Low Voltage
LVSG
Low Voltage Switchgear
MCB
Miniature Circuit Breaker
MCCB
Moulded Case Circuit Breaker
PE
Protective Earthing
RCD
Residual Current Device
RoK
Republic of Kazakhstan
SCADA
Supervisory Control and Data Acquisition
UPS
Uninterrupted Power Supply
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 6 of 30
4.0
REFERENCES
D01
PROJECT
TESTING
KE01-00-000-KD-E-ST-0001-000
D01
PROJECT SPECIFICATIONINDUCTION MOTORS
KE01-00-000-KD-E-ST-0003-000
D02
PROJECT SPECIFICATIONPOWER TRANSFORMERS
D01
PROJECT SPECIFICATIONINTEGRATED ELECTRICAL PROTECTION

AND CONTROL
D01
PROJECT
SPECIFICATIONELECTRICAL
PACKAGE UNITS
KE01-00-000-KD-E-ST-0007-000
D04
PROJECT SPECIFICATIONELECTRICAL CABLES AND GLANDS
KE01-00-000-KD-E-ST-0008-000
D01
PROJECT SPECIFICATION ELECTRICAL TRACE HEATING
KE01-00-000-KD-E-ST-0009-000
D01
PROJECT SPECIFICATION ELECTRICAL BULK MATERIALS
D01
PROJECT SPECIFICATIONAC UNINTERRUPTIBLE POWER SUPPLIES

(ac UPSs)
D01
PROJECT SPECIFICATIONDC UNINTERRUPTIBLE POWER SUPPLIES

(dc UPSs)
D01
PROJECT SPECIFICATIONSTATIONARY BATTERIES
D01
PROJECT
SPECIFICATIONLOW
VOLTAGE
ENCLOSEDSWITCHGEAR AND MOTOR CONTROL CENTRES
KE01-00-000-KD-E-ST-0017-000
D01
PROJECT SPECIFICATIONSAFE AREA DISTRIBUTION BOARDS
KE01-00-000-KD-E-ST-0018-000
D01
PROJECT SPECIFICATIONPOWER BUSBARS
KE01-00-000-KD-E-YP-0001-000
D01
ELECTRICAL DESIGN CRITERIA
KE01-00-000-KD-E-YP-0002-000
D01
LIGHTING PHILOSOPHY
KE01-00-000-KD-E-YP-0003-000
D02
CABLE SIZING PHILOSOPHY
KE01-00-000-KD-E-YP-0004-000
D01
ELECTRICAL CONTROL PHILOSOPHY
KE01-00-945-KD-E-YP-0005-000
D01
EARTHING PHILOSOPHY
KE01-00-000-KD-E-YP-0006-000
D01
HAZARDOUS AREA CLASSIFICATION PHILOSOPHY
KE01-00-000-KD-E-YP-0007-000
B01
OVERALL ELECTRICAL PHILOSOPHY
KE01-00-000-KD-E-YP-0008-000
V01
ELECTRICAL INTERFACES PHILOSOPHY
KE01-00-000-KD-E-DS-0001-001
C01
Lighting Installation Standard (LS-12)
KE01-00-000-KD-E-DS-0002-001
C01
KE01-00-000-KD-E-DS-0003-001
D01
KE01-00-000-KD-E-DS-0004-001
D01
KE01-00-000-KD-E-DS-0005-001
D01
KE01-00-000-KD-E-DS-0006-001
D01
KE01-00-000-KD-E-DS-0007-001
D01
KE01-00-000-KD-E-DS-0008-001
D01
KE01-00-000-KD-E-DS-0009-001
D01
KE01-00-000-KD-E-DS-0010-001
D01
KE01-00-000-KD-E-DS-0011-001
D01
KE01-00-000-KD-E-DS-0012-001
D01
Power Installation Standard (PS-18)
KE01-00-000-KD-E-DS-0013-001
D01
KE01-00-000-KD-E-DS-0014-001
D01
KE01-00-000-KD-E-DS-0015-001
D01
KE01-00-000-KD-E-DS-0016-001
D01
KE01-00-000-KD-E-DS-0017-001
D01
KE01-00-000-KD-E-DS-0018-001
D01
KE01-00-000-KD-E-DS-0019-001
D01
KE01-00-000-KD-E-DS-0020-001
D01
KE01-00-000-KD-E-DS-0021-001
D01
KE01-00-000-KD-E-DS-0022-001
D01
KE01-00-000-KD-E-SF-0020-000
KE01-00-000-KD-E-ST-0005-000
KE01-00-000-KD-E-ST-0006-000
KE01-00-900-KD-E-ST-0011-000
KE01-00-900-KD-E-ST-0012-000
KE01-00-000-KD-E-ST-0013-000
KE01-00-000-KD-E-ST-0015-000
SPECIFICATION
FORELECTRICAL INSTALLATION
REQUIREMENTS
AND
FOR
METAL
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 7 of 30
5.0
KE01-00-000-KD-E-DS-0023-001
D01
KE01-00-000-KD-E-DS-0024-001
D01
KE01-00-000-KD-E-DS-0025-001
D01
KE01-00-000-KD-E-DS-0026-001
D01
KE01-00-000-KD-E-DS-0027-001
D01
KE01-00-000-KD-E-DS-0028-001
D01
KE01-00-000-KD-E-DS-0029-001
D01
Earthing Installation Standard (ES-16)
KE01-00-000-KD-E-DS-0030-001
D01
KE01-00-000-KD-E-DS-0031-001
D01
KE01-00-000-KD-E-DS-0032-001
D01
KE01-00-000-KD-E-DS-0033-001
D01
KE01-00-000-KD-E-DS-0034-001
D01
KE01-00-000-KD-E-DS-0035-001
D01
KE01-00-000-KD-E-DS-0036-001
D01
KE01-00-000-KD-E-DS-0037-001
D01
KE01-00-000-KD-E-DS-0038-001
D01
KE01-00-000-KD-E-DS-0039-001
D01
KE01-00-000-KD-E-DS-0040-001
D01
KE01-00-000-KD-E-DS-0041-001
D01
KE01-A0-000-KD-E-DS-0001-001
D01
KE01-A0-000-KD-E-DS-0002-001
D01
KE01-A0-000-KD-E-DS-0003-001
D01
KE01-A0-000-KD-E-DS-0004-001
D01
KE01-A0-000-KD-E-DS-0005-001
D01
KE01-A0-000-KD-E-DS-0006-001
D01
KE01-A0-000-KD-E-DS-0007-001
D01
KE01-A0-000-KD-E-DS-0008-001
D01
KE01-A0-000-KD-E-DS-0009-001
D01
KE01-A0-000-KD-E-DS-0010-001
D01
KE01-A0-000-KD-E-DS-0011-001
D01
KE01-A0-000-KD-E-DS-0012-001
D01
KE01-A0-000-KD-E-DS-0013-001
D01
KE01-A0-000-KD-E-DS-0014-001
D01
KE01-A0-000-KD-E-DS-0015-001
D01
KE01-A0-000-KD-E-DS-0016-001
D01
KE01-A0-000-KD-E-DS-0017-001
D01
KE01-A0-000-KD-E-DS-0018-001
D01
KE01-A0-000-KD-E-DS-0019-001
D01
CODES AND STANDARDS

Industrial Codes and Standards
The equipment and the installation shall be in compliance with the latest revisions of the
standards listed in document no.
KE01.00.000.KD.Q.LS.0001.000. Contractor may advise
equivalent alternatives to satisfy the works which shall be identified and mutually agreed with
company. In case when any deviation is required from those standards, written permission shall
be requested from the company.
PUE
VSN 59-88
SN 174-75
Rules for Electrical Installation

Electrical Equipment in Residential and Public Buildings
Guidelines for Design of Power Supply for Industrial Plants
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 8 of 30
RDS RK 4.04- 191-02
SNIP 3.05.06-85
18220f 07.12.2000g
GOST 28668.1-91
Guidelines for Design of Town and Village Electrical Supply Networks

Electrotechnical Devices
Regulations on Use of Electric Power
Low Voltage Distribution and Control Packages
GOST 22789-94
RD 34.21.122-87
Low Voltage Packages General Requirements

Design of Lightning Protection for Buildings & Structures
IEC-60050
International electrotechnical vocabulary.
IEC-60079
Electrical apparatus for explosive gas atmospheres
IEC-60287
Calculation of the continuous current rating of cables (100% load factor)
IEC-60364
Electrical installations of buildings
IEC-60445
Identification of equipment terminals and of terminations of certain

designated conductors including general rules for alphanumerical systems
IEC-60446
Identification of conductors by colours or numerals.
IEC-60529
IEC 60840
Degrees of protection provided by enclosures

Tests for power cable with extruded insulation for rated voltages above 30kV
IEC 60885
Electrical test methods for electrical cables
IEC 61035
Specification for conduit fittings for electrical installations
IEC 61084
Cable trunking and ducting systems for electrical installations.
Precedence
Where any conflict and/or contradiction between this procedure, the requisition, data sheets,
drawings, specifications, codes & standards or lack of clear definition, this will be identified by
CONTRACTOR
in
writing
to
the
COMPANY
immediately
or
within
30
days
for
resolution/clarification prior to execution of works.

In general, the order of precedence shall be:
Contract
Data sheets
Project Specifications
Drawings
International/National Standards
Referenced Industry Codes & Standards e.g. IEC or other National Standards
In the event of any conflict arising between the referenced standards the more stringent shall
be applied.
Except for Republic of Kazakhstan Regulations, GOSTs and SNiPs where the original
language version takes precedence, the English version shall take precedence should there be
any conflict between English & Russian versions of the applicable documents.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 9 of 30
6.0
DESIGN REQUIREMENTS
Design Life
Project design life shall be 40 years and all equipment shall be designed accordingly for normal
operating conditions.
Design Temperature
Design temperature for the equipments shall be as follows;
External
-40 C Min
+40 C Max
Internal
-5 C Min
+40 C Max
Relative humidity
% 85 Max
Voltage and Frequency Requirements

Electrical equipment shall be suitable to operate with voltage variations of 5% and AC
electrical equipment shall be suitable to operate with frequency variations of 5% rated values.
Normal operating conditions system voltage drops is limited by 5 %, under transients it will be
10 %.
Cable voltage drops shall be limited to the following values:
Main feeders:
1% at rated load
Motors:
4% at rated load (to motor terminals)

15% on motor starting (to motor terminals)
Process heater circuits:
5% at rated load
1% to heater panels
4% from panel to heater
Lighting circuits:
5% at rated load
2% to lighting distribution panels
3% for lighting branch circuits
Socket outlet circuits:
5% at rated load
2.5% to distribution panels
2.5% for branch circuits
7.0
ROLES AND RESPONSIBILITIES

Project Manager : has ultimate responsibility of compliance of work to, relevant methodologies,
standards, specifications listed, while assuring adequate organization resources to conduct the
work.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 10 of 30
QA/QC Manager : Responsible for controlling and directing the activities complying with the
quality requirements given in the references. He reports to the Project Manager.
HSE Manager: Responsible for the implementation of the HSE Plan and management system.
Supervisor: shall be responsible for Inspection of the electrical system to ensure quality and
confirm compliance with project documents and specifications. Timely delivery of the material to
site and ensure the work is progressing according to the schedule. Provide technical directions
and monitor "checkout test" associated with pre-commissioning. Evaluate shipping damage to
electrical equipment and recommend corrective action. He reports to construction manager.
Foreman: shall be responsible for site activities for the execution o the works. He shall organize
the site and ensure the site is ready for installation of material. He shall prepare daily reports for
the progress and manpower. He shall be responsible for maintaining good workmanship and
direct the craft installing the electrical systems. He shall manage his crew in a safe manner and
enforce all safety regulations. He reports to supervisor.
8.0
EQUIPMENT INSTALLATION
General
Utmost attention shall be given to the following during installation of the equipment;
Compatibility of the equipment to the environment
Ensure work carried out is of the highest quality
No damage on the installation material
Protection of fire-proofing
Using suitable tools for installation
Ensure minimum clearances for the installations are complied with
Ensure all unused entries are properly plugged according to the installation area code
No bare cable shall be present for the distribution systems
Equipment shall be installed in accordance with applicable standards and suppliers

recommendations
All necessary precautions shall be taken to prevent damage to equipment during the
transportation the equipment from warehouse to site
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 11 of 30
Contractor is responsible to protect the equipment from site hazards, adverse weather and
loss of any parts during the construction period
Work in hazardous area shall be carried out in accordance with regulations.
Loose components like commissioning spares/keys/operating tools to be documented and

identified and hand over.
Transformers
Transformer and associated fixing material shall be taken from Company warehouses. Prior to
transportation a visual inspection shall be made for any damage. Packing list and material shall
be compared at the warehouse; any deficiencies shall immediately be reported to the Company.
Transformer label shall be checked and verified against project drawings. Due care shall be
given to the kVA rating, primary and secondary voltage rating, altitude and winding conditions.
Any loose items delivered with the transformer like gauges, switches, marshalling boxes shall
be installed under the supervision of the supplier. The work shall be completed in accordance
with supplier instructions and shall be performed under his supervision.
If the transformer oil is supplied in drums, it will be stored in a clean and dry area. All measures
shall be taken to avoid contamination of the oil by moisture or dirt particles. Drum seals shall
only be broken immediately prior to the oil being tested and used to fill the transformer.
Prior to starting installation, all civil works shall be inspected, cable-bus duct entry position and
any embedded elements properly located.
Transformer shall be positioned and if necessary shall be aligned according to supplier
installation drawings. Transformer shall be earthed immediately after the installation is
completed.
Bus-Duct Systems
All field joints shall be torqued and ductored to ensure proper surface contact is made.
Where specified, bus-duct systems shall be installed between transformers and low voltage
switchgears. All fixing materials, support, elbows, terminals and couplings shall be included in
the package. Suitable tools and materials shall be provided as required for fixing and
installation. If required over-casting of epoxy insulation material for junctions shall be applied. All
connections torque values according to the supplier instructions, phase rotation and insulation
resistance shall be checked prior to over-casting. Installed and pending parts of bus duct
system shall be properly protected to avoid ingress of moisture and dust.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 12 of 30
Metalclad Switchgear and Large Control Panels
Sections of the HV and LV Switchgear, generator control panels, large MCC and similar control
panels shall be assembled and connected at site.
Switchgear shall be stored and preserved in a suitable controlled environment as defined in
suppliers documentation. Space heaters may be temporarily energized from a reliable source
after permission is granted from the Company.
Prior to transportation of the switchgear an inspection shall be performed. Future use all
commissioning spares/operation tools/keys to be documented and stored properly. Installation
site should be clean and free of dust. Floor installation should be flat and level deviations
should be with in the manufacturer recommended tolerances.. All civil job, electrical job such as
lighting and small power system, HVAC duct and insulation job shall be completed.
Switchgear shall be positioned according to the project drawings and comply with the
clearances defined. The sections shall be positioned on the installation site in the desired order
of the assembly. Cover panels and parts shall be removed to facilitate access for switchgear
assembly. First section shall be positioned and secured to the floor. Position the second section,
secure to the floor and interconnect the two sections with the manufacturer recommended bolts.
Same manner shall be proceed for the other sections.
Earthing and phase bars of various sections shall be connected together via suitable nuts and
bolts. Assembly of the bars shall be done using torque wrenches as recommended by the
supplier. Bus-ducts shall be aligned, fixed and bolted to correct torque settings. Withdrawable
units shall be checked for alignment and correct operation.
Circuit identifications and labels shall be checked against the drawings and verified, all inter
cubicle bus wiring shall be completed. Base plates and cover panels shall be properly secured.
Equipotential connection shall be created for the doors by using yellow/green flexible cables.
All foreign objects (screws, wires, bolts, nuts, etc,) that might effect the operation of the
switchgear shall be removed and switchgear shall be vacuumed to remove any dust. An overall
insulation measurement and continuity test shall be carried out as recommended by the
supplier. A final check for the tightness of connections shall be made with a torque wrench,
earth continuity, mechanical locking of switchgears if there is any, and the electrical contacts
shall be lightly greased. All field joints shall be ductored with a micro ohmmeter to ensure
contact surface made or proper and within to trance.
DCPS and UPS

Prior to installation and/or transportation of the system, inspect the packing for any sign of
damage.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 13 of 30
An inspection shall be carried out for the site installation location to verify;
Floor installation is completed and should be flat. Deviations should be within the
manufacturer recommended tolerances, fixing arrangements and cable entries are all
suitably completed.
Enough room was provided for air intake and outlet
Environment temperature and humidity is within the specification requirements
No moisture, dust or corrosion
All finishing civil work, electrical work such as L&SP. HVAC duct and installation shall be
completed.
After all conditions stated above are met, system shall be unpacked and positioned to the
intended location. Units shall be fixed and bolted to the floor as recommended by the
manufacturer and unit shall be assembled accordingly. Batteries shall be delivered separately,
fully charged and ready for installation including interconnection link cables. The contractor shall
install links between battery cells and connect the external cables only when directed by the
company during precommissioning activity. All cable links and cables connections shall be made
secure and checked for tightness.
Cable Installation
General
All rackways / ladder supporting systems to be completed fully and signed off prior to
commencement of cables.
Cables shall be run on the cable trays or racks as the preferred method of cable installation,
however where defined in drawings or by agreement with the Company, cables may be installed
directly buried.
Cable routes and cable groups shall be strictly followed according to the contract drawings.
Where specific routes are not defined, routes shall be defined and proposed to the Company
approval by the contractor. Care should be given to select the shortest route for cable
installation.
Cables shall be pulled from cable drums and directly laid on the cable trays, racks or into the
trenches. If necessary cables shall be stored prior to laying in a heated environment at a
minimum temperature of 20 C for a period of at least 24 hours.
All armoured and un-armoured cables up to 38 mm overall diameter shall be installed by hand
Larger diameter cables may be installed using suitable tools approved by the Company. All
armoured cables shall be laid with the help of rollers.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 14 of 30
Utmost care shall be given while pulling the cables, not to exceed maximum tension levels
recommended by the manufacturer. Cables shall be laid in parallel formations as defined in the
construction drawings. Consideration shall be given at all times not to exceed the maximum
bending radius of the cables both during and after installation. Twisting, crossing and intertwinning of cables are not acceptable. Cable ends shall be protected by heat shrink end caps.
Cables shall be tagged temporary after the installation, permanent labelling shall be done every
30 meters, includes direct buried cables. at every direction change and at both sides of every
cable transit.
Cables shall be laid without splice or joint as much as possible unless otherwise is stated in the
construction drawings. Where jointing is mandatory only Company approved joint kits shall be
used and Company approval shall be granted prior to joint. All joint points shall be indicated in
the respective drawings.
Cables shall be cut according to drum and pulling schedules, however the route length shall be
measured prior to cutting the cable.
Cable Separation
Power cables and signal cables shall be separated according to below-mentioned table to avoid
occurrence of Magnetic Disturbance. As per project specifications cables shall be installed in
accessible groups wherever possible.
Power Wiring Capacity
Minimum Separation Between

Power Cables and Signal Cables
Max.
Max.
Instrument
Instrument
Instrument
Voltage less
Current less
Category 1
Category 2
Category 3
than:
125V
than
10 A
12 (300mm)
12 (300mm)
12 (300mm)
250V
50 A
12 (300mm)
12 (300mm)
18 (450mm)
690V
200 A
12 (300mm)
12 (300mm)
24 (600mm)
5kV
800 A
12 (300mm)
24 (600mm)
48 (1200mm)
10kV
1000 A
12 (300mm)
24 (600mm)
60 (1500mm)
12 (300mm)
24 (600mm)
72 (1800mm)
35kV
2000A
System 2
System 1
System definitions are;
System 1
System 2
System 3
High voltage systems (above 1000V).

Low voltage power supply and control cables for electrical systems
(1000V and below).
Instrumentation and Telecommunication systems.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 15 of 30
Additionally System 3 is further categorized;
Instrument power and control wiring (above 50V);

Category 1
Includes a.c. and d.c. power supplies and control signals (including
emergency shutdown circuits).
High level signal wiring (5V to 50V d.c.);
System 2
Includes digital signals, alarm signals, shutdown signals and high level
(e.g. 4-20mA) analogue signals.
Low level signal wiring (below 5V d.c.);
System 3
Includes temperature signals and low level analogue signals, e.g. analyser
measuring circuits.
Where power cables shall cross the instrument and telecom cables care shall be given to the
following:
Cables shall not touch each other, (300 mm separation)
Intersection shall be made with right angles,
For equipment entries and/or parallel runs of not more than 20 m, the minimum separation may
be considered as 300 mm.
Cable Installation above Ground
Cables shall be run on the cable trays or racks as the preferred method of cable installation.
Heavy duty cable trays of the type hot dipped, deep galvanized and silicon enriched shall be
installed. All racks and trays shall have ventilated covers up to a height of 2.5 m above grade.
Above 2.5 meter ventilation cover shall only be installed to protect cables from direct sun light.
Cables that shall be connected to electrical equipment shall be installed on trays, channel or
angle supports, fitted between the main rack and the equipment. In non-elevated substation
cable racks shall be suspended underneath the ceiling. In the elevated substation cable racks
shall be suspended underneath the floor. Cable racks and trays shall be bolted or clamped to
the structure, and single cables may be attached to the structure by cleats. Cables must not be
attached to access ladders or their supports. Welding shall not be permitted. Appropriate
mitigation measures shall be applied to prevent galvanic corrosion.
Single cables routed by the contractor, may be individually attached to structures with approved
cable cleats, but shall not be supported or attached to ladders.
Earthing continuity shall be provided throughout the route for the cable trays and ladders at the
splice plates and expansion joints where mechanical continuity is not satisfactory. All parts shall
be bonded together and to earth, at intervals specified in the contract drawings.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 16 of 30
Where cable passes vertically through floor platforms, walkways substantial metallic plates up
to a height 150 mm above the floor level shall be provided as protection against mechanical
damage.
Overhead cable entry points to the buildings shall be inclined with 10 below the horizontal axis
away from the entry to avoid water ingress into the building.
Following minimum clearances shall be provided as per project specification unless otherwise
stated in the approved contract drawings;
HV multicore cables up to 35kV
1 cable diameter
HV Single core cables in trefoil between trefoil

groups
250mm
LV Single core cables in trefoil between trefoil

groups
100mm
LV power cable to any other LV power or control

cable
100mm
LV power cable to any HV power cable
Separate cable rack or

tray
LV motor cables
Single layer
touching
Lighting, small power cables, control cables, etc
Bunched
with
maximum 100mm bunch
diameter
Electrical power and control to Instruments
Refer
to
Cable
Separation section
on
tray
Minimum spacing between multiple layer ladder racks shall be 600 mm in vertical between rack
surfaces.
Following clearances shall be applied as per project specification unless otherwise stated in the
approved construction drawings;
Maintenance roads, for crane access
5.500mm
Operating areas, for truck access
4.300mm
Operating areas, over walkways, minor access ways and stairwells
2.200mm
Between cables and pipes
Between cables and oil/gas pipes
500mm
1.000mm
Cable entry penetrations shall be sealed to avoid ingress of moisture, dust and fire. Seals shall
have the same fire rating of the building.
All sharp edges and burrs from the cable racks and trays shall be removed after installation.
Cold galvanizing paint shall immediately be applied for repair purposes.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 17 of 30
All sharp edges and bars are removed from cable ladder rack and tray following cutting on site.
Any damaged surfaces shall made good immediately with a proprietary cold galvanising paint.
The paint shall be subject to the approval of the company representative.
All HV and LV multi-core power cables run above ground and having an overall diameter in
excess of 30mm shall be fixed with proprietary non-corrodible cable cleats. All other cables
shall be fixed with EVA coated stainless steel cable straps. Cable cleats shall be two holes
fixing, mechanically rated for the highest prospective short circuit fault level. Single core a.c
power cables shall be installed on ladder rack in trefoil formation and secured along their
complete length by heavy duty non-corrodible trefoil cleats with intermediate straps fitted
midway between the cleats. Cleats and straps shall be Type-Tested and have a certified cable
containment capability to a level in excess of the prospective short circuit levels. Maximum
fixing intervals shall be as follows;
Overall Diameter of Cable (mm)
< 20
20
Spacing of Trefoil Cleats (mm)
Voltage
Horizontal Run
HV, LV
900
Spacing of Single Cleats or Straps (mm)

Horizontal Run
Vertical Run
900
225
2,000
600
Flat Bend / Riser
300
Vertical Run
600
Where cable runs are inclined at up to 30 O from horizontal, spacing shall be as for horizontal
runs.
Where cable runs are inclined at more than 30 O from horizontal, spacing shall be as for
vertical runs.
Where horizontal runs are installed with rack or tray in the vertical plane, the spacing shall
be as for vertical runs.
Where closer spacing are required to comply with short circuit fault ratings of cleats, the
manufacturers recommended spacing shall be used.
Cable Installation Below Ground

Cable trench depths shall have the following depths unless otherwise stated in the contract
drawings and specifications ;
Cable rating up to 35 kV
1000mm
35 kV and above
1200mm
Width of the cable trenches shall not be less than 500mm unless otherwise mentioned in the
contract drawings.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 18 of 30
Direct buried cables shall have sand bedding and cover. Where cable routes intersect, there
shall be a vertical separation of at least 500mm of backfill material or sand between them. This
separation may be reduced to 150mm provided the cables are separated along the whole
intersection, plus 1 meter either side, by pipes or plates of concrete or other materials of similar
strength. Concrete tiles shall be laid above the cables in unpaved areas; however tiles may be
omitted where red colored concrete paving is placed above cable trenches. Where cables leave
the main trenches they may be run for short lengths in PVC ducting in suitable size. Cables
shall be in concrete encased ducts at road crossings. Cables installed underground in any
areas that may be subject to hydrocarbon contamination shall either be installed in concrete
encased ducts through the area or be lead sheathed for the whole of the route. However,
routing of 35kV and 110kV cables underground through areas of potential hydrocarbon
contamination shall be avoided.
Cables shall not be laid into the cable trenches unless the whole section is excavated and sand
bedding is completed. Prior to pulling cable, continuity test shall be performed on the drum.
Prior to laying cables into the trenches a visual inspection shall be made that the trench is
levelled, compacted and minimum 75 mm sand has been laid. Cables shall be laid with a slight
snaking to avoid possible stress during ground settlement.
Unless stated otherwise on the approved contract drawings, cables installed direct buried
underground shall maintain the following minimum clearances:
Any cable to any foundation or other structure
600mm
Up to 35kV cable to gas pipelines
2000mm
Up to 35kV cable to pipelines (other than gas),

water ducts, sewerage pipes or drainage
systems
1000mm
35kV cable to any other cable
250mm
10kV or 6kV cable to any other 10kV, 6kV, LV

power or any control cable
100mm
Single core cables in trefoil to any other cable
250mm
LV power cable to any other LV power or control

cable
100mm
Lighting, small power cables, etc
Bunched
Electrical power and control to Instruments
Refer to section Cable

Separation
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 19 of 30
After each layer of cables is in place, and before covering with sand, each cable shall be
visually inspected and subjected to a continuity and insulation test. Any cable proven defective
shall be reported to Company before installing the next layer of cables. All test data shall be
recorded by the Contractor, as installation progresses, and such test data shall be submitted to
the COMPANY for acceptance prior to back-filling cable trench. A final 75mm layer of sand
shall be placed over the top layer of cables, followed by a row of correct width, suitably marked
cable tiles. The tiles shall cover the width of the cable run, with a minimum 50 mm overlap at
each side. A continuous line of proprietary plastic warning marker tape shall be installed along
the line of the cable trench, 300mm below the surface. The back fill material in cable trenches
shall be well compacted and the ground re-instated to its finished grade level. The back fill shall
be free from large stones or other injurious objects to a level at least 150 mm above the cable
protection tiles. Installed cables shall be fitted with corrosion resistant identification tags at 30m
intervals, at joints, at bends and either side of wall penetrations. All tags shall be suitable for
installation below ground. The routes of buried cables shall be identified by red concrete cable
markers set into the ground and projecting approximately 600mm above grade. The markers
shall be positioned at 50m intervals on straight runs and at points where the cable route
changes direction. The markers shall be placed directly above the underground cable
identification tags. Cable trenches shall be provided with single markers on the centreline of the
run. Similar markers suitably inscribed shall be used to indicate the position of any underground
joints.
Cable ducts shall be cleaned and inspected prior to installation, to ensure the absence of debris
and sharp objects, and temporarily sealed immediately after cable installation to prevent the
entry of such debris, or water. The ducts shall be permanently sealed as soon as all cables are
installed with easily removable material. French chalk shall be applied to the outer sheath of
cables before installation to prevent abrasion between cables and between cables and duct.
Cable Termination
Cable Glands and Entries
Compression type cable glands of the correct type and size shall be used for the cable
terminations. All cable glands used in plant areas shall be dual certified EExd IIC / EExe.
Industrial glands shall be used indoor in non-hazardous area buildings. Conductors shall be
terminated using approved pin crimp ferrules or compression lugs. Cable gland shrouds shall
not be installed and barrier type cable glands shall not be employed for power cable
termination.
The type and size of gland shall be in strict accordance with the construction drawings, data
sheets and schedules.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 20 of 30
Glands for multi-core power and control cables shall be manufactured from brass. Glands for
single core aluminum armored power cables shall be manufactured from aluminum. All glands
shall have an appropriate IP rating and utilize fiber washers between the gland body and the
gland plate to maintain the IP rating of the enclosure. Prior to installing cable glands into EExd
threaded entries, threads of the gland shall be lubricated with non toxic grease.
Hazardous area equipment shall in no case be drilled out and/or altered. Unused entries shall
be blinded with appropriate type plugs maintaining the same temperature rating of the
equipment. Where enclosures have clearance holes instead of threaded gland entries, cable
glands shall be secured by locknuts fitted with serrated star washers to ensure earth continuity.
Where the design of HV switchgear and control-gear necessitates the provision of an externally
mounted core balance current transformer for earth fault protection, the following requirements
shall be implemented:
a)
b)
c)
d)
e)
All conductors shall pass through the current transformer.

Insulated gland adaptors shall be fitted to the respective gland plates
Earth tags shall be fitted between gland bodies and the insulated adaptors
Earth tags at each termination shall be bonded together and earthed by an insulated earth
cable passing back through the core balance current transformer prior to terminating on the
switchboard earth bar.
Each gland plate shall be bonded with a protective conductor to the respective earth bar or
stud.
Generally, cable entries to equipment in external locations shall be located on the underside of
equipment. Where this is impracticable, side entry may be used provided the cables are
installed with a downward slope. All cables shall be supported to avoid strain on either the cable
gland or the equipment and at least 100mm of straight cable shall be left before a bend is
formed.
Cable Termination
HV cable terminations above 6kV shall be of a stress relieving design. Power cable connections
to Generators, transformers and motors shall, generally, be affected via proprietary moulded,
separable, elbow/bushing connectors. Cable connections to HV switchgear and control-gear
shall be carried out using stress-relieving sleeves with trifurcating gloves, or heat shrink type
terminations. The manufacturers instructions regarding cable end preparation and termination
shall be followed exactly, employing any recommended special tools. It is particularly important
that the Manufacturers recommendation for the length of individual core terminations is
followed. The Contractor shall immediately notify COMPANY representatives if this requirement
is compromised by space limitations within the equipment terminal box.
representatives will take responsibility for defining the required solution.
COMPANY
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 21 of 30
Prior to fitting termination lugs, cables shall be inspected for strain free connections. Then
proprietary compression lugs shall be fitted for terminations. LV cables with conductor crosssection up to and including 6mm2 shall be fitted with insulated pin crimp type ferrules and
terminated into SAK, or similar, type terminals, as supplied or approved by the COMPANY
representative. Cables with conductor cross-section larger than 6mm 2 shall be fitted with
compression lugs to suit the equipment terminals. The shanks of compression lugs used for the
termination of cables in LV motor terminal boxes and other field-mounted equipment shall be
insulated with heat shrink sleeving to avoid the possibility of inadvertent contact between
adjacent un-insulated lugs. Where practical, an adequate length of cable tail shall be left at all
cable terminations to enable cores to be connected to any terminal by the longest route. Cable
tails shall be neatly looped or coiled and supported. Spare cores shall be marked as spare and
terminated in spare terminals, provided within the equipment, and earthed. Where insufficient
spare terminals are available, spare cores shall be connected directly to a convenient earth
point. Spare core length shall be maximized within the constraints imposed by the equipment.
Exceptions to this requirement, whereby only one conductor end is terminated due to potential
EMC constraints, will be defined in the construction drawings.
Unless noted otherwise on
construction drawings, conductor earthing at one end only shall be at the field end.
For control cables, no more than two conductors shall be connected to any one terminal, one
incoming and one outgoing. Where multiple conductors are required to be terminated at the
same point, then the required number of terminals shall be interconnected by proprietary links.
The link shall not occupy the same terminal as the conductor.
The arrangement and connection of power cables within LV Distribution Boards shall provide
sufficient room to enable a clip-on ammeter to be used without stressing the cable.
Cable and Core Identification
Every cable shall have a unique identification number, as recorded in the construction drawings
and cable schedules. All cables shall be identified at their points of origin and destination and at
both sides of any wall or floor penetration. The DOT cable marking system shall be used.
Identification labels shall consist of user printable flame retardant heat shrink sleeves for cable
cores and smaller diameter cables, and polyamide strips for larger cables. Marker strips shall
have slotted ends to permit fixing to the cable by means of nylon ties. Each cable core shall be
uniquely identified at both ends by a core number or by phase color, as applicable, and as
shown on the construction drawings, schematic and connection diagrams. For power cables
where the core insulation color matches the corresponding phase color, no further marking is
necessary.
However, where core insulation does not match the phase color, appropriately
colored sleeves shall be fitted at the termination point. Core identification shall be by proprietary
heat shrink ferrules suitable for thermal print inscription. Cable core identification on horizontally
terminated cores shall read from left to right, and on vertically terminated cores shall read from
bottom to top.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 22 of 30
Earthing and Lightning Protection
Earthing System Installation
The plant earth system for onshore plants shall take the form of a ring of insulated copper
conductors laid around the plant with sub-rings connected, as required, to the main ring and
with branch interconnections to equipment and structures. Exothermic fusion welded type joints
shall be used for underground connections and compression type crimps for above ground
connections. All underground connections shall be insulated with suitable insulation tape or heat
shrink insulation. Stainless steel rod electrodes shall be installed at selected points around the
ring to form a multi-point earthing system. The rods shall be driven directly into the ground
without excavation or drilling. Locations and depths of electrodes are indicated on the
construction drawings. The maximum value of resistance of individual earthing electrodes to the
general mass of earth shall not exceed 1 ohm. Rod type earth electrodes shall be spaced at
intervals
required
to
comply
with
resistance
values
stated
on
drawing
number
KE01-00-945-KD-E-YS-0001-001, Earthing Methods Diagram. If earth loop impedance tests

are unsatisfactory, the Contractor will be required to install additional lengths of electrodes until
the specified value of resistance is attained. Where necessary, buried earth mats shall be
formed from stainless steel tapes. The electrodes shall be bonded by PVC insulated copper
cables to the earth mats and to the main earth bars located in Substations, within buildings and
on external steel plant structures. Disconnecting links shall be installed at earth bars to permit
periodic maintenance testing. Electrodes shall be connected by clamps. Earth electrodes shall
be installed via proprietary earth pits, as recorded on the construction drawings and earthing
layouts. Underground earthing conductors routed independently from cable rack or plant
structures, outside of a dedicated cable trench, shall be installed at a minimum depth of 600mm
below grade. Earthing systems within substations or electrical equipment rooms shall be
installed in accordance with the construction drawings. Where applicable, earth bus bars shall
be installed 600mm above floor level and adequately supported from the substation or electrical
room walls in accordance with the Standard Earthing Details.
Joints and tees between sections of copper bar shall be tinned and bolted; each joint shall have
a minimum of two bolts. Cable connections to earth bars shall be bolted via tinned lugs crimped
to earth cables; the earth bar shall be tinned at the point of connection.
The armour of all cables shall be earthed via the cable glands and gland plates. Cable armour
shall not be used as the principal earth conductor. Where necessary, power system earth
continuity shall be maintained via a separate earth core.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 23 of 30
Bonding
Every structure and item of plant equipment, including prefabricated steel buildings and piperack, shall be substantially and effectively connected to earth in the manner specified in the
construction drawings. Minimum conductor size shall be 6mm2 for earthing and bonding
connections and shall be arranged such that disconnection of an earth conductor from a piece
of equipment does not break the continuity of the earthing and bonding system. Two earth lugs
on to a single point connection is not acceptable. All non-current carrying metallic parts of
electrical equipment shall be connected directly to the main earth system.
The armour of cables in feeder circuits at LV distribution boards shall be bonded together and
directly connected to earth. Unless a conductive contact is established naturally (via bolts,
welds, etc), all exposed metalwork of electrical and non-electrical equipment shall be bonded to
the structure to ensure that the entire installation is an equipotential zone. Pipes entering or
leaving hazardous areas shall be bonded together and to a common local earth bar connected
to the main earth system. Pipe-work flanges and pipe to vessel, or equipment, connections,
where not electrically continuous, shall be provided with copper bonding straps unless cathodic
protection is installed.
All earthing studs on equipment shall be cleaned prior to connection of earth conductors. The
connection shall be secured by locking nuts then coated with an approved anti-oxidant
corrosion inhibitor.
Instrument and control panel steelwork in control rooms or in plant areas shall be bonded in
accordance with the construction drawings. Particular care shall be taken to ensure that
instrument earth and power system earth systems remain isolated up to the common point of
connection.
Lightning Protection
The maximum earthing value shall in no case exceed 10 Ohms. Where practicable, lightning
protective systems shall utilize the same earth electrodes as used for power system earthing
installations but the interconnections from structures to earth electrodes shall be by separate
tapes or insulated cables.
Lighting and Small Power Installation

The precise location of the fixtures, switches and sockets shall be determined by the Contractor
according to the construction drawings.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 24 of 30
Unless shown otherwise on the construction drawings the mounting height of luminaries and
accessories shall comply with the following, measured from the finished floor level, or working
platform, to the centre of the item:
Switches for lights
1400mm
Socket outlets
500mm
Socket outlets above work tops.
1100mm
Bulkhead luminaires
2500mm
Emergency luminaries at exits
2000 - 2500mm
Distribution boards
1500mm
Luminaries shall be positioned so that areas or fixtures such as stairways, landings, and ladders
are adequately illuminated. In order to facilitate re-lamping, light fittings over walkways and
platforms shall be mounted not less than 2000mm and not more than 2200mm above the
walkway, or platform, and shall be mounted not less than 1000mm inside the edge of any such
platform or walkway. In the case of narrow platforms or walkways, less than 2000mm wide, the
luminaries shall be mounted on the centre line of the platform. The top handrails of walkways,
stairways and platforms shall not be obstructed by supports of stanchion type lighting fixtures.
In pump compounds, and other areas at ground level, luminaries shall not be mounted more
than 3250 mm above the level of the floor, unless otherwise specified on the construction
drawing.
The number of junction boxes used on lighting circuits shall be kept to a minimum. When
junction boxes are used they shall be located in easily accessible positions, in-board of platform
edges, and not more than 2200mm above the working floor level. All junction boxes shall be
fitted with permanent labels denoting circuit reference.
Luminaries and socket outlets shall be wired strictly in accordance with the circuits shown on
the construction drawings and Standard Detail drawings. Where two or more lighting cables are
run together they shall be fixed to cable tray, or run in trunking. Single cables may be fixed
direct to steelwork. All lighting fittings shall be labelled with the fitting and circuit references
shown on the construction drawings. Labels shall be fixed near lighting fittings but not on them.
Certified lighting and small power equipment shall not be modified, altered or drilled in any way,
neither shall terminals be added or substituted in marshalling and junction boxes.
Equipment Plates, Nameplates, Rating Plates and Labels

Manufacturers Equipment Plates, Nameplates and Rating Plates will be fitted to all equipment.
Additional Danger or Warning plates shall be fitted where necessary. All information shall be
given in dual language (Russian and English). Warning notices, cable route markers, cable
markers and wiring ferrules shall be installed in accordance with the contract documentation.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 25 of 30
All electrical minor equipment, bulk materials and components, as listed below, shall be clearly
identified with labels supplied and fitted. The wording and character size of all labels shall be in
accordance with the contract documentation. Labels shall be provided for the following items:
Luminaries
Junction boxes/marshalling boxes
Control stations
Motors
Heaters
Isolating switches
Control switches
Cable ladder rack and tray
Cable Transit
Labels shall be of the engraved laminated plastic type, or approved equal and shall be dual
language, Russian/English. Identification labels shall comprise black characters on a white
background.
Warning labels shall comprise black characters on a yellow background,
complying with the requirements of the relevant IEC Standard, and shall be fitted directly to all
items of electrical equipment.
Rotating machinery subject to automatic, remote, control shall be provided with a warning label
reading:
DANGER THIS MACHINE LIABLE TO START AUTOMATICALLY
Warning of electrical hazard shall be provided on equipment and component cover plates and
on any access doors not provided with interlocked isolators. Warning labels shall be fitted with
appropriate legends including:
WARNING SUPPLIES MUST BE ISOLATED BEFORE REMOVING COVER
WARNING HEATER ENERGISED WHEN MOTOR STOPPED
ISOLATE ELSEWHERE
Labels shall be fixed to equipment or supporting steelwork with stainless steel screws and shall
not infringe hazardous area Ex certification or IP rating of the respective enclosures. Selftapping screws shall not be employed.
8.0
INSPECTION, TESTING, PRE-COMMISSIONING AND COMMISSIONING

All necessary competent, certified personnel and tools, certified/calibrated test instrumentation
and test power supplies, to carry out inspection, testing and pre-commissioning testing activities
in accordance with this specification and as per the procedures and standards shall be
provided.
In the specific case of a.c and d.c UPS systems a suitably rated load bank to
facilitate battery discharge and re-charge tests shall be provided.

Required permits / authorization for carry out test to be obtained prior to commencement of test.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 26 of 30
A complete set of As-Built documentation for the installations prior to any commissioning
activities being undertaken shall be provided.
All inspection and test results shall be recorded on the appropriate approved Inspection and
Test Record Sheets. All tests shall be performed under the supervision of Company
representative, unless otherwise stated by Company, record sheets shall be mutually signed.
The Contractor shall transfer all original Inspection & Test Record sheets in accordance with,
and as indicated in the project procedures.
The Suppliers of major electrical equipment will provide, within their IOM manuals, details for
installing, site testing and commissioning equipment within their scope of supply and will provide
representatives to assist during installation, site testing, commissioning and initial energisation
of the equipment. All items of electrical equipment will have been fully tested at the respective
Suppliers works and complete test records will be supplied with the equipment.
The Contractor shall carry out standard tests of insulation, continuity, phase orientation and
correct operation, together with all other tests that may be deemed necessary to prove that the
electrical installation is satisfactory. Installations failing to pass such tests will be rejected and all
work necessary to bring the electrical installation to a satisfactory working condition shall be
carried out and tests shall be repeated.
Insulation Testing
Insulation tests shall be carried out during construction and at the pre-commissioning stage,
prior to the energisation of equipment or cables. The following two methods shall be used:
Insulation resistance testing, applicable to all electrical equipment including, but not
limited to, generators, transformers, switchgear, motors, UPS systems, distribution
boards, trace heating installations, lighting and small power installations, field cables,
earthing and bonding systems and all other items of electrical equipment. Where
equipment contains components, such as silicon diodes or transistors, or wiring, that is
susceptible to damage by over voltage, these items shall be disconnected prior to
commencing tests.
High voltage testing, applicable to switchgear rated at 400V and above and HV cables.
Test voltages shall be in accordance with the relevant IEC Standard or manufactures
recommendation and shall be specified in the equipment commissioning procedure.
Insulation Resistance Tests
Insulation resistance tests shall be conducted prior to executing high voltage tests. Insulation
resistance shall be measured by applying a d.c test voltage from a Megger insulation meter or
equal. For correct comparison of test data, any subsequent insulation resistance tests should
be carried out at the same voltage level as the initial test.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 27 of 30
The measured resistance value is also dependent on the temperature of the insulation and shall
be corrected as necessary. As a guide, the insulation resistance of windings reduces by
approximately 50% for each 10C rise in temperature.
High Voltage Withstand Tests
Prior to and on completion of conducting high voltage tests, insulation resistance tests shall
have been carried out.
High voltage testing may be carried out by applying either an a.c. power frequency voltage, a
very low frequency voltage (VLF) or a d.c. voltage, at a level above the operating voltage, in
accordance with the relevant International Standards.
Testing at power frequency is preferred and a.c test equipment must be capable of supplying
the capacitive current requirement of the item under test. As such test equipment is bulky, and
normally impractical for field use, d.c test equipment may be used for cables whereas a.c test
equipment shall be used for switchgear. Cable tests shall record values of leakage current
versus time.
High voltage a.c testing of major electrical equipment will have been conducted at the Suppliers
works to values specified in the relevant International Standards. As repeated high voltage
testing may stress winding insulation such tests shall not be applied at site to generators,
motors or transformers. If, however, for special reasons (e.g. when equipment has been partially
assembled at site) such tests are considered to be necessary, they may be carried out after
consultation and agreement with the COMPANY and the Suppliers Site Representative but at a
reduced voltage level corresponding to 70% of the factory test voltage.
Polarisation Index
Polarisation Index tests will be carried out on all HV motors. The test results will be compared
with those values obtained during the Factory Acceptance Tests.
The Polarisation Index is the ratio of the value of insulation resistance measured after one
minute to that measured after ten minutes, during continuous testing, at the appropriate
voltage, i.e.: PI = R10 min/R1 min.
The Polarisation Index, being a ratio, is practically independent of winding temperature and test
voltage. The ten minute measurement allows the capacitive current, the leakage current over
the surface of the insulation and the dielectric absorption current to stabilise.
The Polarisation Index gives an indication of the condition of winding insulation, with regard to
its dryness and cleanliness. The value will be lower for dirty, wet or chemically contaminated
windings.
Interpretation of Results
Should values of insulation resistance or Polarisation Index fall below the minimum values
specified, the equipment should not be energized nor subjected to high voltage testing. The
equipment and windings should be heated and dried out prior to re-test.
Should a flash-over occur during high voltage testing then the test shall be deemed to have
failed. Appropriate remedial measures, such as cleaning, drying or, if necessary, repair should
be adopted after which re-testing shall take place.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 28 of 30
Insulating Oil Tests

High voltage withstand tests shall be carried out using a standard Foster oil test set, or equal,
with 25mm diameter sphere head electrodes and a sphere gap of 2.5mm.
The minimum breakdown voltage shall be 30kV. The test sample shall be tested 6 times without
breakdown using the same cell filling.
Bearing Insulation Tests

Bearing Insulation tests shall be carried out on all HV motors.
The method of insulating bearings, as a means of controlling shaft current, depends upon the
design and type of construction and the methods employed to support the bearings.
In the case of pedestal bearings, or sleeve bearings, where housings are completely insulated
from the body of the machine, the insulation may be checked with the machine coupled and
running at normal speed. This is to establish that an oil film in the bearing will prevent electrical
contact between shaft and bearing. An ohm-meter applied across the insulation should indicate
a resistance of >10k; values below this shall be investigated.
In the case of bearings having internally insulated shells or having insulated shafts,
measurements shall be carried out with the machine uncoupled and stationary. If, however, only
one bearing is insulated verification is limited to the inspection of the Suppliers QC
documentation.
Where double insulation is applied to pedestal bearings, i.e. insulated around the bearing shell
and at the pedestal base, insulation resistance measurement at the mid section with respect to
earth will indicate if either insulation is bridged.
All tests shall be carried out in accordance with Suppliers instructions.
Conductivity and Earth Resistance tests

Conductivity Tests
Conductivity tests shall be carried out on switchgear bus-bar connections, and switchgear earth
system joints, in order to establish their tightness and condition. Conductivity testing shall be
carried out with a Ducter (or equal) low-resistance test set having a 20A, d.c, output.
Test results shall be recorded across all connections and for identical connections the
measured values shall not differ by more than 20% from each other.
Earth Resistance Tests
Earth resistance tests shall be conducted in accordance with the relevant International
Standards.
All earth electrodes shall be tested by measurement of the resistance of the electrode against
the mass of earth, using a purpose made test set.
On offshore installations, random continuity checks using a Ducter or similar low resistance
ohmmeter shall be carried out to verify that equipment is effectively bonded to the structure.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 29 of 30
Equipment Wiring and Terminal Checks

Electrical wiring shall be checked against the Suppliers Schematic Diagrams and Diagrams of
Connections, or against the Contractors Interconnection Diagrams, as applicable.
The tightness of all terminals shall be verified.
Functional Tests
Functional mechanical & electrical tests shall be carried out to demonstrate the correct
operation of all electrical equipment and associated systems. This shall include primary and/or
secondary current injection tests to check the protection and metering circuits. Particular
attention shall be paid to equipment interfaces, where there is a greater likelihood of functional
discrepancies.
Where complex control or interlock systems are used, the Contractor shall demonstrate
compliance with the design requirements using specific functional check-lists and system logic
diagrams. Where such complex systems require the input of the Suppliers site representative,
for pre-commissioning activities, the Contractor may be required to provide assistance.
9.0
PRE-COMMISSIONING
The Contractor shall provide means of access to enable a complete visual inspection of the
installation and the following visual checks shall be carried out in accordance with the
Companys approved Pre-Commissioning Check Lists. All results shall be recorded.
i.
Removal and safe keeping of selected packing materials.
ii.
Cleanliness of all equipment and components.
iii.
Equipment identification plates, manufacturers nameplates and rating plate data comply with
the Drawings and the provision of cautionary or danger notices.
iv.
Certified EEx (Ex) protection certification labels are correct and comply with the design
documentation and Hazardous Area Certification Schedule.
v.
Certified EEx (Ex) equipment enclosures and bulk materials comply with the manufacturers
specification, drawings and certification details.
vi.
Configuration, alignment and tightness of fixing and holding down bolts.
Integrity and
tightness of all electrical connections, terminations and cable glands.

vii.
Operation of mechanical and key interlocks, safety shutters, access doors and locks. Provision
of padlocks and padlocking facilities.
viii.
Correct degree of protection for equipment and materials. Provision, correct fitting and location
of gaskets and cable gland O ring seals.
ix.
Application of approved corrosion resistant greases. Oil levels and grease packing of machine
bearings is satisfactory.
x.
Provision of earthing connections and effective earth bonding of equipment.
xi.
Checking of fuse, MCCB and MCB ratings.
KE01-A1-000-NC-E-PR-0001-000
Rev. C01 Date-05-10-2006
Page 30 of 30
xii.
Correct identification of equipment, cables and cable cores, cable ladder rack and cable tray.
xiii.
Correctness of circuit details with Schematic, Wiring and Interconnection Diagrams.
xiv.
Distribution board circuit schedules within the enclosures have been completed correctly.
On completion of all inspection, testing and pre-commissioning activities, the Contractor shall
assist the COMPANY in the commissioning of electrical installations as and when required. The
Contractor shall not energise any electrical equipment without prior approval of the Companys
Site Representative and, where appropriate, the local RoK inspection authority.
Energisation of electrical equipment/systems will be done so under the strict control of the
Permit to Work system that will be in operation on the plant. The Contractor will be responsible
for obtaining such Permit to Work documents from the COMPANY representative or its
appointed representative prior to any work being carried out and such Permit to Work
documents will be renewed on a daily basis.
Spare Parts and Special Tools

The Contractor shall take due notice where applicable of any special instructions detailed in the
manufacturers Manual for Erection and Testing.
All special tools supplied by equipment or material vendors for the installation, testing,
commissioning and maintenance of equipment, including any lifting equipment, shall be returned
to the COMPANY after commissioning.
Equipment Installation, Operation and Maintenance Manuals, which shall include a list of special
tools, shall also be returned to the COMPANY after commissioning.
10.0 DOCUMENTATION
The Contractor shall, as part of the scope of the electrical installation contract, supply complete
sets of Red-Marked drawings, and any other related design documentation as defined in the
Contract documents.
As-Built drawings shall comprise the Contractors construction issue drawings, or Suppliers
drawings, marked up to accurately reflect all site implemented modifications or revisions to the
design for the completed electrical installation, as installed, connected, tested and
commissioned.
The Contractor shall also supply As-Built drawings recording all work carried out under the
Contract but not covered in detail by the Companys or Suppliers documentation. Typically this
shall include cable routing drawings above and below ground including any transits and rack
numbers, supplementary lighting and small power circuit diagrams and any additional support
steel details.
All As-Built drawings and documentation shall be subject to the approval of the COMPANY
representative.
One set of drawings shall be retained on site for an interim period whilst another set is used to
revise the Master Drawings.
The Contractor will be required to complete all Inspection and Test Record sheets.

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Ke01 A1 000 NC e PR 0001 000 C01

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ORIGINATING COMPANY:

NORTH CASPIAN CONSTRUCTORS

PROJECT: MAIN WORKS CONSTRUCTION

CONTRACTORS DOCUMENT NUMBER:

PROCEDURE FOR ELECTRICAL INSTALLATION

ABSTRACT: This document describes procedures to be used

ISSUED FOR REVIEW

REASON FOR ISSUE

ISSUED FOR REVIEW

REVISED AND RE-ISSUED FOR APPROVAL

APPROVED FOR CONSTRUCTION

Kazakhstan North Caspian Operating Company

Fire and Gas

Heating Ventilating & Air Conditioning

International Electrotechnical Commission

High Voltage Switchgear

Low Voltage Switchgear

Miniature Circuit Breaker

Moulded Case Circuit Breaker

Residual Current Device

Supervisory Control and Data Acquisition

Uninterrupted Power Supply

PROJECT SPECIFICATIONINDUCTION MOTORS

PROJECT SPECIFICATIONPOWER TRANSFORMERS

PROJECT SPECIFICATIONINTEGRATED ELECTRICAL PROTECTION

PROJECT SPECIFICATIONELECTRICAL CABLES AND GLANDS

PROJECT SPECIFICATION ELECTRICAL TRACE HEATING

PROJECT SPECIFICATION ELECTRICAL BULK MATERIALS

PROJECT SPECIFICATIONAC UNINTERRUPTIBLE POWER SUPPLIES

PROJECT SPECIFICATIONDC UNINTERRUPTIBLE POWER SUPPLIES

PROJECT SPECIFICATIONSTATIONARY BATTERIES

PROJECT SPECIFICATIONSAFE AREA DISTRIBUTION BOARDS

PROJECT SPECIFICATIONPOWER BUSBARS

ELECTRICAL DESIGN CRITERIA

CABLE SIZING PHILOSOPHY

ELECTRICAL CONTROL PHILOSOPHY

HAZARDOUS AREA CLASSIFICATION PHILOSOPHY

OVERALL ELECTRICAL PHILOSOPHY

ELECTRICAL INTERFACES PHILOSOPHY

Lighting Installation Standard (LS-12)

Lighting Installation Standard (LS-13)

Lighting Installation Standard (LS-14)

Lighting Installation Standard (LS-15)

Lighting Installation Standard (LS-16)

Lighting Installation Standard (LS-17)

Lighting Installation Standard (LS-18)

Lighting Installation Standard (LS-19)

Lighting Installation Standard (LS-20)

Lighting Installation Standard (LS-21)

Lighting Installation Standard (LS-22)

Power Installation Standard (PS-18)

Power Installation Standard (PS-18)

Power Installation Standard (PS-19)

Power Installation Standard (PS-20)

Power Installation Standard (PS-21)

Power Installation Standard (PS-22)

Power Installation Standard (PS-23)

Power Installation Standard (PS-24)

Power Installation Standard (PS-25)

Power Installation Standard (PS-26)

Power Installation Standard (PS-27)

Power Installation Standard (PS-28)