Electric Rev F1 ITP Electrical

PREPARATION OF INSPECTION & TEST

PLAN ELECTRICAL INSTALLATION & TESTING WORKS

CONSTRUCTION OPERATIONS

WORK PRACTICE

9980-8710-PR-0020 PAGE 1 OF 16 REV F1

REVISION 01 F1 F2 F3 F4 F5 DATE Feb 04 May 04 ORIG. BY P Moss P Moss APP. BY T Herbert QA REVIEW -

Contract: 1-14-9980/9

Client's Name: Esso Petroleum Co. Ltd

Project Title: Fawley Sulphur Free Mogas

Project Location: Fawley, Southampton, UK

Document Category: CLASS 1

CONTENTS SECTION SUBJECT 1 PURPOSE 2 SCOPE 3 DEFINITIONS 4 REFERENCE DOCUMENTS 5 REPONSIBILITIES 6 PROCEDURE 6.1 General Overview 6.2 Responsible Parties 6.3 Responsibility Definition 6.4 Inspection Forms 6.5 Submission of Inspection Forms 6.6 Compilation of Turnover Dossiers ATTACHMENT 1 Inspection and Test Plan

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1. PURPOSE

The purpose of this procedure is to define Inspection and Test requirements for the project electrical works.

2. SCOPE

The scope of this document is limited to electrical installation and testing works associated with the Fawley Sulphur free Mogas Project.

3. DEFINITIONS

Client Esso Petroleum Company Ltd Foster Wheeler Foster Wheeler Energy Ltd (FWEL) ITP Inspection and Test Plan

4. REFERENCE DOCUMENTS

ASME V Non-destructive Examination ASME IX Welding and Brazing Qualifications 9980-8710-QA-0001 Site Quality Plan 9980-8820-IN-0001 Global Practices Index 9980-46C1 Structural Steelwork Supply, Fabrication and Erection 9980-70D20 Electrical Installation Specification 9980-83A1 Protective Paint and Coatings

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5. RESPONSIBILITIES 5.1 E&I Works Contractor

The E&I Works Contractor shall be responsible for preparing an inspection and test plan in accordance with the requirements of this procedure and for undertaking electrical installation and testing works in accordance with the contract and documents referenced in Section 4 above and Attachment 1.

5.2 Foster Wheeler

Foster Wheeler shall be responsible for monitoring the Contractor in the execution of the contract and for ensuring the inspection and test plan produced by the Contractor is produced to meet the requirements specified. Foster Wheeler shall also be responsible for monitoring the adherence by the Contractor to the agreed inspection and test plan for the work.

5.3 Client

The Client shall review and monitor Foster Wheeler and the Contractor in the execution of the agreed inspection and test plan as specified in Attachment 1.

6. PROCEDURE 6.1 General Overview

Attachment 1 provides guidelines that are generic for the work to be undertaken. The Contractor shall provide a specific Quality Plan and necessary procedures that define how the quality of the listed activities in Attachment 1 shall be controlled, specific to area(s) or element(s) of work being undertaken.

6.2 Responsible Parties

Responsible parties listed in Attachment 1 of this overall Inspection and Teat Plan are as follows:

C = Contractor F = Foster Wheeler N = Client





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6.3 Responsibility Definition

Responsibilities listed in Attachment 1 of this overall Inspection and Test plan are as follows:

X = Responsible for implementing the work and for undertaking Quality

Control inspection of the work on an ongoing basis R = Responsible for reviewing and authorising submissions I = Responsible for inspecting the work on an auditing or monitoring basis

only W = Responsible for witnessing and signing work releasing Hold Points

6.4 Inspection Forms

Inspection forms have been defined in Attachment 1 that are available for use by the Contractor in undertaking the work. Contractors inspection forms may be submitted for approval for the work, providing they meet the minimum content of those Foster Wheeler forms available for use. Where Contractor inspection forms are approved for use, the Contractor shall substitute the agreed forms for those identified in Attachment 1. Supplementary Contractor forms may also be added to the list identified.

6.5 Submission of Inspection Forms

The Contractor shall submit completed inspection forms to Foster Wheeler for acceptance in those instances where work has been inspected by Foster Wheeler personnel. Such submission shall take place within 24 hours of the actual inspection having taken place. Foster Wheeler shall be responsible for ensuring that Client acceptance is obtained for those inspections also witnessed by Client personnel.

6.6 Compilation of Turnover Dossiers

The Contractor shall compile Turnover dossiers on an ongoing basis for all work being undertaken. An area or system, as defined by Foster Wheeler, shall be subjected to punch listing once all work has been deemed to be completed by the Contractor. The Contractor shall offer the area or system to Foster Wheeler immediately upon completion of the last inspection. In undertaking punch list activities, the Client shall be invited to participate. A punch list of outstanding activities shall be agreed between the Contractor, Foster Wheeler and the Client, including a categorisation of outstanding items. Where items are identified as Category A on the punch list, the Contractor shall rectify all outstanding works prior to offering the system or area for Turnover acceptance. Such outstanding Category A items must be cleared before Turnover acceptance is granted. The Turnover Dossier, as prepared by the Contractor, shall be presented to the Client for acceptance immediately following acceptance of all inspections by Foster Wheeler





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9980-8710-PR-0020 PAGE 5 REV F1

and the Client and shall include within it a copy of the agreed punch list. Category B items contained on the punch list will require to be cleared by the Contractor within an agreed timescale. All necessary Turnover documentation shall be prepared by the Contractor and shall be included within the Turnover Dossier. Upon acceptance of the Turnover documentation by the Client, a copy of the Turnover certificate shall be provided to the Contractor. Acceptance of Turnover packages shall not preclude the Contractor in completing outstanding punch list item work. Once all punch list item work has been completed within the agreed timescale, the Contractor shall provide a copy of the completed punch list to Foster Wheeler who shall be responsible for forwarding the copy to the Client.


PREPARATION OF INSPECTION & TEST PLAN ELECTRICAL INSTALLATION &

TESTING WORKS ATTACHMENT 1 - ITP

CONSTRUCTION OPERATIONS WORK PRACTICE

9980-8710-PR-0020 PAGE 6 REV F1

RESPONSIBILITY ITEM

ACTIVITY CONTROL DOCS PROCEDURE REQUIRED

REPORT FORM/ CHECKLIST

NUMBER HOLD

C F NCOMMENTS

1. DESIGN DOCUMENTS

1.1 Review Workscope Contract Requisition and associated documents and drawings

Review workscope and accept contract

X

1.2 Prepare Inspection and Test Plan

Agreed Inspection and Test Plan

No work to be proceed without an agreed inspection and test plan

X R R

1.3 Contract kick-off meeting Contract Requisition and associated documents and drawings

Notes of meeting X X X

2. DOCUMENTS REQUIRING APPROVAL

2.1 Method Statements Field erectionprocedures

X R R

3. INSPECTION MEASUREMENT & TEST EQUIPMENT

3.1 Calibration Control All inspection, measurement and test equipment to be calibrated. Certificates to be available for review.

X R Calibration status to be identified on the equipment. Out of calibration equipment to be removed from use

4. FREE ISSUE MATERIALS/EQUIPMENT

4.1 Raise material issue request and obtain approval

MIR MIR Requests to be approved by appropriate FW Supervisor prior to being submitted to FW Material Controller

X H





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RESPONSIBILITY ITEM



NUMBER HOLD

C F NCOMMENTS

4.2 Obtain material/equipmentfrom FW stores

MIR MIR Contractor to confirm all material is in accordance with drawing BOM/MIR and undamaged

X H

4.3 Receipt ofmaterials/equipment

Quantity and Quality received to be checked. Storage and inspection of materials. Certification and marking to be checked.

X H

4.4 Preservation ofmaterials/equipment

Vendor's instructions X I I Maintenance log to be maintained by Contractor throughout duration of Contract from receipt to system Turnover

5. CONTRACTOR SUPPLIED MATERIALS

5.1 Assessment of suppliers Contract Requisition "B"

Contractor to assess suppliers to ensure technical requirements are met and to the appropriate quality level

X R Suppliers to operate a Quality Management System meeting ISO 9000 requirements. Certification not essential.

5.2 Purchase order placement Requisition "B" specification

FWEL approval prior to purchase

X H Purchase orders to be maintained

5.3 Inspection of purchased items

All purchased items to be inspected against the requirements of the purchase order. Accompanying certification to be checked and included in data book

X R Purchased items without appropriate certification to be rejected and quarantined. No material to be released for use until appropriate certification is available.

5.4 Preservation of materials Vendor's instructions FWEL4088 X I I Maintenance log to be maintained by Contractor throughout duration of Contract from receipt to system Turnover.





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RESPONSIBILITY ITEM



NUMBER HOLD

C F NCOMMENTS

6. INSPECTION, MEASUREMENT AND TEST EQUIPMENT

6.1 Calibration control All inspection, measurement and test equipment to be calibrated. Certificates to be available for review. Prior to commencement of works.

X R I Calibration status to be identified on the equipment. Out of calibration equipment to be removed from use.

7. TRENCHING & CABLE TRAY/RACK

7.1 Check drawings for cable trench routing

Layout drawings X R I

7.2 Obtain work permits for trenching activities

Project instructions FWEL Permit to Work X H FWEL Safety Advisor involvement

7.3 Prepare materials for use in excavation

X R Tags, cable markers, cable ties, sand

7.4 Trench excavation 70D20 FWEL3362 X W

7.5 Trench inspection prior to pulling

70D20 FWEL3376 FWEL approval prior to cable pulling

X H I

7.6 Placement of sand layer in trench bottom

70D20 FWEL3376 X IH

7.7 Position cable rollers at trench corners for continuous pulling

70D20 X I I

7.8 Cable pulling 70D20 X

7.9 Check cable for damage 70D20 Continual inspection during cable pulling

X W I Care of the works





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RESPONSIBILITY ITEM



NUMBER HOLD

C F NCOMMENTS

7.10 Check proper laying of cable and cable markers

70D20 FWEL3376 X IW FWEL continual inspection

7.11 Backfill and restore cable trench after cable pulling is complete

70D20 FWEL3376 X W I

7.12 Check drawings for cable tray/rack routing

Layout drawings X R I

7.13 Obtain work permits for cable tray/rack installation

Project instructions FWEL Permit to Work X H FWEL Safety Advisor involvement

7.14 Install cable tray/rack and steel supports

70D20 FWEL3384 Welder qualifications and WPS approved

X H

7.15 Tray and racking inspection 70D20 FWEL3384 X IH

7.16 Cable pulling 70D20 X IW

7.17 Check cable for damage 70D20 Continual inspection during cable pulling


7.18 Check proper laying of cable in cable racks

70D20 FWEL3384 X IW

7.19 Check cable markers 70D20 FWEL3384 X IW FWEL continual inspection

7.20 Check cable ties 70D20 FWEL3384 X IW

8. CABLING

8.1 Megger and continuity test at warehouse

70D20 FWEL3377FWEL3378 FWEL3379

X W I





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RESPONSIBILITY ITEM



NUMBER HOLD

C F NCOMMENTS

8.2 Cable visual check for damage

70D20 Continual inspection during cable pulling


8.3 Cable pulling Layout drawing X W

8.4 Inspection check following installation

Layout drawing X W I

8.5 Megger test after cable laying


X W I

8.6 Gland, terminate and megger test for last time


X W I

8.7 High Potential test for cables over 1000V

70D20 FWEL3378 100% Witness of all tests by FW

X H I After installation of termination

9. TRAY, LADDER, RACK AND STEEL SUPPORT FABRICATION

9.1 Submit weld procedures for acceptance

88A1 ASME IX

Submission of weld procedure specifications and weld procedure qualification records

X H FWEL approvals required prior to commencing work

9.2 Qualify welders ASME IX FWEL3417 X H

9.3 Assess steel, tray and ladder/rack suppliers

Layout drawing X R

9.4 Purchase steel, trays and ladders/rack

Contract Requisition "B" for specification

Material approval by FWEL prior to purchase

X H

9.5 Inspect steel, trays and ladders/rack upon receipt from supplier

Discrepancy report to record damage

X H I





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NUMBER HOLD

C F NCOMMENTS

9.6 Fabricate steel supports 46C1 FWEL3384 X R I

9.7 Inspect welding work ASME V FWEL3460 X W I

9.8 Visual inspection and NDE ASME V FWEL3460 X W I

9.9 Inspect shotblast and painting work

83A1 FWEL3461 X W I

9.10 Install trays, ladders and fabricated supports

Layout drawing FWEL3384 X I I

9.117 Inspect installed supports, trays and ladders

Layout drawing FWEL3384 X W I

9.12 Inspect mechanical damage and repair painting work on fabricated supports

83A1 Repair procedure to be approved by FWEL

X W I

9.13 Inspect installed tray and racking

FWEL3384 X W I

10. ELECTRICAL EQUIPMENT

10.1 Obtain permit to work Project Instructions FWEL Permit to Work X H FWEL Safety Advisor involvement

10.2 Check existing equipmentisolation

70D20 X IW

10.3 Check equipment mountingand cable entry arrangement

70D20 FWEL3384 X IW

10.4 Position and install electrical equipment as detailed in drawings

70D20 FWEL3384 X IW





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NUMBER HOLD

C F NCOMMENTS

10.5 Visual inspection 70D20 FWEL3384 X IW

10.6 Gland and terminate cables and final megger test


X W

10.7 Visual cleanliness check of equipment internals prior to closure

70D20 FWEL3382FWEL3383

X W I

10.8 Complete electricalequipment in safe area inspection report

FWEL3382 X R I

10.9 Complete electricalequipment in hazardous area inspection

FWEL3383 X R I

10.10 Prepare test reports for all equipment for testing and commissioning work

X R I

10.11 Miscellaneous inspection of panels and cabinets

70D20 FWEL3362 X R I

11. EARTHING

11.1 Obtain permit to work Project Instruction FWEL Permit to Work X FWEL Safety Advisor involvement

11.2 Check cable routing Layout drawing X R I

11.3 Install earthing system Layout drawings X W I

11.4 Inspect earthing system and complete earthing test


X W I

11.5 Earth loop impedance test 70D20 FWEL3381 X H I





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NUMBER HOLD

C F NCOMMENTS

12. EARTHING AND LIGHTNING PROTECTION

12.1 Obtain permit to work Project Instructions FWEL Permit to Work X H FWEL Safety Advisor involvement

12.2 Check cable route X W I

12.3 Cable route marking 70D20 X IW FWEL continual inspection

12.4 Install earthing and lightning protection system

70D20 FWEL3402 X

12.5 Inspect earthing and lightning protection system and complete earthing test


X H I

12.6 Perform earth loop impedance test

70D20 FWEL3381 X IH

13. LIGHTING AND SMALL POWER

13.1 Obtain work permit Project instruction FWEL Permit to Work X H

13.2 Install lighting supports and accessories as required

70D20 X IW

13.3 Label cabling in conduit 70D20 X IW

13.4 Label interconnecting cable in junction boxes

70D20 FWEL3626 X IW

13.5 Inspect and test lighting and power outlet circuits

70D20 FWEL3402 X IH

13.6 Inspect and test lighting illumination values

70D20 FWEL3401 X IH





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NUMBER HOLD

C F NCOMMENTS

13.7 Inspect and test electrical distribution board


X H I

13.8 Inspect and test electrical equipment in safe areas

70D20 FWEL3382 X IH

13.9 Inspect and test electrical equipment in hazardous areas

70D20 FWEL3383 X IH

13.10 Earth loop impedance test 70D20 FWEL3381 X IH

13.11 Electric Trace Heating Test

70D20 FWEL3403 X IH

14. ELECTRICAL TESTING & COMMISSIONING

14.1 Inspect general condition of equipment, grounding connection, control cubicle, auxiliary supply and control scheme

70D20 X IW

14.2 Inspect levelling andalignment

70D20 X IW

14.3 Test and tighten bus bar and connect

70D20 FWEL3386 X IH

14.4 Individual wiring test 70D20 FWEL3379 X IW

14.5 Check circuit breaker 70D20 C IW

14.6 Circuit breaker mechanical operating test

70D20 X IW





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NUMBER HOLD

C F NCOMMENTS

14.7 Circuit breaker electrical operating test

70D20 X IW

14.8 Circuit breaker interlock test 70D20 X IW

14.9 Contact resistance test 70D20 X IW

14.10 Function and interlock test 70D20 X IW

14.11 Motor control centre test 70D20 X IH

14.12 Switchboard and busbarinspection and test


X H I

14.13 Electrical distribution boardtest

70D20 FWEL3387 X IH

14.14 UPS system inspection and test

70D20 FWEL3388 X IH

14.15 Voltage relay test 70D20 FWEL3389 X IH

14.16 Battery Charge/DischargeTest

70D20 X IW

14.17 Battery charger test 70D20 FWEL3390 X IH

14.18 CT and protection relay test 70D20 FWEL3394 X IH

14.19 CT and protection relay "mag" test

70D20 FWEL3395 X IH

14.20 Earth fault relay test 70D20 FWEL3396 X IH

14.21 Overload/overcurrent Test 70D20 ManufacturerInspection Form

X W I


PREPARATION OF INSPECTION & TEST PLAN ELECTRICAL INSTALLATION & TESTING WORKS ATTACHMENT 1 - ITP


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RESPONSIBILITY ITEM



NUMBER HOLD

C F NCOMMENTS

14.22 Contractor starter test 70D20 FWEL3398 X IH

14.23 Control circuit function test 70D20 FWEL3399 X IH

14.24 Electric motor test 70D20 FWEL3400/04 X H I

14.25 Transformer test 70D20 FWEL3392FWEL3634

X H I

14.26 Insulating oil test 70D20 FWEL3391 X IR

14.27 Miscellaneous item tests 70D20 FWEL3389 X IH

14.28 GTG differential stability and sensitivity test

70D20 X IH

14.29 NER Test 70D20 X IW

15. SYSTEM COMPLETION

15.1 Request final acceptance X H R

15.2 Construction and final punchlists

FWEL3291FWEL3293

X H H

15.3 Turnover pack and handover to FW for system completion

FWEL3295 X H R

15.4 System acceptance FWEL3294 X H H

15.5 Prepare site QC dossier and submit to FW

X H R

15.6 Prepare red-line "as builts" and submit to FW for acceptance

X R

ELECTRICAL TESTING & COMMISSIONING

Documents

Electric Rev F1 ITP Electrical