Pr808-13 Electrical Systems

Nigeria LNG Limited Natural Gas Liquefaction Complex Bonny Island, Nigeria

Electrical Systems Revision B2 Page 1 of 10

T S K J

NLNG PLUS PROJECT PROJECT PROCEDURE No. PR808-13 QUALITY CONTROL DOCUMENTATION ELECTRICAL SYSTEMS

Rev B1

Rev B2

Rev B3

Rev B4

Prepared By: A Chopra

Checked By: D Gevaux

D Gevaux

JP Oppenheim

JP Oppenheim

Approved By: (Executive Project Manager)

Date: Pages Revised:

24 Jan 03 4,5,7,8,9,10+ Forms

NOTE: Type in date, and initials and sign the appropriate box for the current revision. JP 1000 NLG Procedure 808-13 /conversion/tmp/scratch/460649486.doc

Nigeria LNG Limited Natural Gas Liquefaction Complex Bonny Island, Nigeria

Electrical Systems Revision B2 Page 2 of 10

TABLE OF CONTENTS 1.0

PURPOSE

2.0

QUALITY CONTROL PROCEDURES

3.0

INSPECTION AND TEST PLANS

4.0

RESPONSIBILITIES

5.0

IMPLMENTATION

6.0

RECORDS

7.0

ELECTRICAL CIRCUIT FOLDERS

8.0

REFERENCES

9.0

ATTACHMENTS

JP 1000 NLG Procedure 808-13 /conversion/tmp/scratch/460649486.doc

Nigeria LNG Limited Natural Gas Liquefaction Complex Bonny Island, Nigeria

1.0

Electrical Systems Revision B2 Page 3 of 10

PURPOSE The purpose of this procedure is to outline the project quality requirements pertaining to Electrical Systems.

2.0

QUALITY CONTROL PROCEDURES Quality control procedures covering the subcontractor's scope of work shall be submitted to the Contractor QA/QC Manager for review within 60 days after award of subcontract. The procedures will identify the persons responsible for performing the work, conducting quality control inspections, preparing, signing and maintaining quality documentation, interfacing with Contractor QA/QC group and other functions required to assure complete implementation of a quality program that is acceptable to the Contractor and the Company. The procedures will be reviewed/commented and must be approved prior to the start of construction.

3.0

INSPECTION AND TEST PLANS The subcontractor shall prepare inspection and test plans in accordance with project procedure PR 831 to list each stage of construction/inspection with references to the applicable code, standard, drawing and specification. These inspection and test plans must be approved by the Contractor not later than 30 days before scheduled construction. The subcontractor shall submit a request for Contractor Hold and Witness inspection items no later than one working day before the inspection is to take place.

4.0

RESPONSIBILITIES The subcontractor is responsible for implementing a quality assurance/quality control program, which includes 100% inspection and documentation of the work. The Contractor area engineers and supervisors will provide assistance to the subcontractors as needed and will provide full time surveillance of the work in progress. The engineers will attend the Hold, Witness and Random inspection and the Records Review as shown on the subcontractors' inspection and test plan. The Contractor QA personnel will audit and monitor the quality control/ inspection of the work. Contractor QA/QC will determine if the inspections are being performed in a competent and satisfactory manner and that the relevant documentation is being prepared, signed and maintained in a retrievable manner.

JP 1000 NLG Procedure 808-13 /conversion/tmp/scratch/460649486.doc

Nigeria LNG Limited Natural Gas Liquefaction Complex Bonny Island, Nigeria

5.0

Electrical Systems Revision B2 Page 4 of 10

IMPLEMENTATION

1.1

For handling of materials and equipment, see the “Job Site Material Control” Procedure No. PR 803 and for preservation, see “Material Storage and Preservation”, Procedure No. PR 805.

1.2

Installation of Electrical Systems shall be in accordance with relevant Codes, Project Drawings, Specifications and relevant Vendor Specifications/Drawings.

1.3

Non-conformances shall be documented in accordance with Procedure PR 809. All deviations shall be approved by Contractor and/or Company.

1.4

Underground installations shall not be backfilled without Contractor approval and completion of Form PR 808-01-A5 (Authorisation to Backfill - Cables or Pipe Installations).

1.5

Subcontractor shall maintain and complete all Forms on a progressive basis and obtain Contractor’s signature.

6.0

RECORDS The subcontractors' quality system shall provide procedures to assure that sufficient records are maintained to verify that the requirements of the subcontract documents have been fully met. A full list of forms to be used by the Subcontractor on completion of his work is shown in paragraph 9 of this procedure. The Subcontractor will obtain the required signatures of the Contractor and will maintain all documentation required for hand-over of the work.

7.0

ELECTRICAL CIRCUIT FOLDERS Circuit Folder – Is a file folder containing all construction PR 808-13-N series QC Records for specific electrical equipment.

7.1

Circuit Folder Contents Circuit folders shall include the following:  Relevant mark up/as-built drawings pertinent to the circuit folder (Example: circuit booklets, single line diagrams, earthing system drawings, lighting layouts, trace heating circuit drawings etc.)  Copy of the relevant pages of the Cable Summary marked up to identify the necessary PR 808-N15/15U/16/16U forms for the cables included within the Circuit Folder.  Equipment specific PR 808-13-N-Series Electrical QC Records.  Form PR808-13-N1 on outside of circuit folder.  Specific PR808-13-N form numbers shall be indicated with signoff dates in relevant boxes of QC Document Index.

JP 1000 NLG Procedure 808-13 /conversion/tmp/scratch/460649486.doc

Nigeria LNG Limited Natural Gas Liquefaction Complex Bonny Island, Nigeria

Electrical Systems Revision B2 Page 5 of 10

Electric Circuit Folders shall be prepared for and located as indicated below:  Switchboards, Transformers, Neutral Earth Resistors and Generators including associated cables - Circuit Folders retained in the substation they are located in  Power and Lighting including associated cables - Circuit Folders retained in the substation in which their distribution board is located.  Each Cathodic Protection Systems including associated cables - Identified geographically and retained in a common Circuit Folder retained in a nominated substation included within the geographic area.  Electric Heat Tracing Circuits including associated cables - Retained in a common Circuit Folder in the Substation in which the controller/power cabinet is located.  Earthing Systems - Identified geographically and retained in a common Circuit Folder in a nominated substation included within the geographic area.  PMS & EMS – Circuit folders shall be prepared and during Commissioning shall be kept in Substation –21 with a copy in SS –31  Other Equipment/Circuits not identified above - As directed by TSKJN Electrical Coordinator. 7.2

Instructions for processing circuit folders to Mechanical Completion

7.2.1

Subcontractor shall prepare circuit folders for each component identified by TSKJN Construction and TSKJN Quality Assurance on a QC Document Index. Subcontractor shall also include a copy of the relevant pages of the Cable Summary marked up to identify the necessary PR 808-N15/15U/16/16U forms for the cables included within the Circuit Folder.

7.2.2

As each folder is prepared, the TSKJN Electrical Coordinator or designee shall review the contents and if acceptable shall sign in the space provided for this purpose on form PR808-13-N1 attached to the outside of the circuit folder. Circuit Folders shall be retained in a file cabinet within its applicable substation. In the case of the more remote Off Sites substations, the TSKJN Electrical Coordinator may elect to locate their files within a more centralised substation.

JP 1000 NLG Procedure 808-13 /conversion/tmp/scratch/460649486.doc

Nigeria LNG Limited Natural Gas Liquefaction Complex Bonny Island, Nigeria

Electrical Systems Revision B2 Page 6 of 10

7.2.3

Subcontractor shall remain fully responsible for all Circuit Folders until such time as they are transferred to TSKJN when the folder is considered complete.

7.2.4

In the event that it becomes absolutely necessary for TSKJN, TSKJN’s Vendors or NLNG to borrow the Circuit Folder FOR ANY REASON, they shall be logged in and out by signature of the individual borrowing the folder.

7.2.5

Subcontractor shall have Circuit folders available for signing whenever inspections or tests involving TSKJN, its Vendors and NLNG have been requested. TSKJN Superintendents, Supervisors and Field Engineers are responsible for notifying NLNG and for initialling / signing off Subcontractor QC Forms at the time inspections and tests are conducted. TSKJN and its Vendors are NOT AUTHORIZED to carry off Circuit Folders for signing at a later time or in the convenience of their offices. NLNG are asked to comply with this ruling.

7.2.6

As electrical components become mechanically complete, the Subcontractor shall inspect the installation for compliance with drawings and specifications. Any discrepancies shall be recorded on form PR 834-01, General Punch List. If there are no discrepancies, this shall be noted on form PR 834-01.

7.2.7

A copy of the punch list shall be passed to the TSKJN Senior Site Engineer and the responsible TSKJN Electrical Field Engineer / Supervisor. The Field Engineer / Supervisor shall arrange with NLNG and TSKJN Commissioning to commence punch-out. Any discrepancies shall be added to the punch list and returned to the subcontractor. A copy shall also be passed to the Senior Site Engineer. Clearing construction punch list items shall remain the responsibility of the Construction subcontractor. Copy of punch list shall be included in the circuit folder.

7.2.8

Punch List and subsequent Exception Lists at MC and RFSU shall be prepared and updated in accordance with PR 834. Punch Lists shall be prepared by circuit folder. MC Exception lists shall be prepared by System. RFSU Exception Lists shall be prepared based on the scope of the RFSU.

7.2.9

When the contents of a Circuit Folder are agreed to be Mechanically Complete, Subcontractor, TSKJN Construction, TSKJN Commissioning and NLNG shall sign form PR808-13-N1 in the spaces provided and possession of the Circuit Folder shall transfer to TSKJN. The Circuit Folder shall remain within the file cabinet inside the substation in which it has been stored.

7.2.10

When TSKJN commissioning take over a substation, possession of the Circuit Folders shall transfer to them.

7.3

Instructions for processing circuit folders to RFSU

7.3.1

After transfer, TSKJN Commissioning shall retain possession of the Circuit Folders within their file cabinets. Borrowing shall be controlled by log book.

JP 1000 NLG Procedure 808-13 /conversion/tmp/scratch/460649486.doc

Nigeria LNG Limited Natural Gas Liquefaction Complex Bonny Island, Nigeria

Electrical Systems Revision B2 Page 7 of 10

7.3.2

At RFSU, TSKJN Commissioning and NLNG shall sign form PR808-13-N1 in the spaces provided and possession of the Circuit Folder shall transfer to NLNG.

7.4

TSKJN Quality Assurance interface at Mechanical Completion.

7.4.1

Approximately 18 calendar days before Mechanical Completion of a SYSTEM, TSKJN QA shall review all Circuit Folders within the system and request any Punch Lists with incomplete items.

7.4.2

TSKJN QA shall compile all open punch list items onto the consolidated Mechanical Completion Exception List and track their completion as well as any incomplete QC records identified on the Circuit Folder QC Document Index.

7.5

TSKJN Quality Assurance interface at RFSU

7.5.1

Within one month of a portion of the plant reaching RFSU, TSKJ QA shall review all Circuit folders and compile a list of missing QC records and begin expediting the TSKJN responsible supervisors on a daily basis for their completion.

7.5.2

Within 18 calendar days of RFSU, TSKJN QA shall secure a copy of all commissioning phase electrical punch lists with incomplete items and consolidate these items onto the RFSU Exception List. This list shall be tracked to completion of all items by QA.

8.0

REFERENCES

9.0

ATTACHMENTS

PR 803 PR 805 PR 809 PR 834 PR 836

Job site Material control Material Storage & Preservation Non Conformance Reporting Construction/ Commissioning Punch List and Exception Lists. Systems Compilation Manual

The Subcontractor is required to complete and maintain the following forms (as applicable) and to submit to the Contractor and completion of his work: FORM No. Appendix - A

D

Surplus Site Cables

PR808-13-N01

:

Electrical Circuit Folder – cover sheet

PR808-13-N02

:

Basic Field Inspection - Electrical Equipment

PR808-13-N03

:

Field Inspection of Substations

PR808-13-N04

:

Field Inspection of Bus-Bar Assembly - HV /LV Switchgear

PR808-13-N05

:

Field Inspection of Switching Units - HV /LV Switchgear

PR808-13-N06

:

Field Inspection of Voltage Transformer & UV Relay

JP 1000 NLG Procedure 808-13 /conversion/tmp/scratch/460649486.doc

Nigeria LNG Limited Natural Gas Liquefaction Complex Bonny Island, Nigeria

Electrical Systems Revision B2 Page 8 of 10

FORM No.

PR808-13-N08

D :E Field Inspection of Current Transformers : Field Inspection of Induction Type 0/C & E/F Protection Relays

PR808-13-N09

:

Field Inspection of Thermal Type 0/C & E/F Relays

PR808-13-N10

:

Field Inspection of LV/ELV Distribution Boards

PR808-13-N11

:

Field Inspection of Power Transformers

PR808-13-N12

:

Field Inspection of Electrical Motors & Adjacent Control Units

PR808-13-N13

:

Field Inspection of Battery Chargers & Batteries

PR808-13-N14

:

Field Inspection of Lighting & Small Power Installations

PR808-13-N15

:

Field Inspection of HV Cables (Above Ground Installation)

PR808-13-N15U

:

Field Inspection of HV Cables (Underground Installation)

PR808-13-N16

:

Field Inspection of LV/MV Cables (Above Ground Installation)

PR808-13-N16U

:

Field Inspection of LV/MV Cables (Underground Installation)

PR808-13-N17

:

Field Inspection of Earthing Systems

PR808-13-N18

:

Field Inspection of Cathodic Protection Cable-to-Pipe Connections

PR808-13-N19

:

Field Inspection of Protection Relay Type MCAG

PR808-13-N20

:

Field Inspection of Protection Relay Type MCGG

PR808-13-N21

:

Field Inspection of Protection Relay Type MVAA

PR808-13-N22

:

Field Inspection of Protection Relay Type MWTU 01

PR808-13-N23

:

Field Inspection of Electrical Meters

PR808-13-N24

:

Field Inspection of Protection Relay Type MVAS

PR808-13-N25

:

Field Inspection of Protection Relay Type HHTA4 & SJA

PR808-13-N26

:

Field Inspection of Motor Starters (Contractor)

PR808-13-N27

:

Field Inspection of Motor-Operated Valve (M.O.V.)

PR808-13-N28

:

Field Inspection of Annunciator Panels

PR808-13-N29

:

Field Inspection of Transducers

PR808-13-N30

:

Field Inspection of Over Current/Under Current Relays

PR808-13-N31

:

Field Inspection of Protection Relay Type Solkor RF &

PR808-13-N07

JP 1000 NLG Procedure 808-13 /conversion/tmp/scratch/460649486.doc

Nigeria LNG Limited Natural Gas Liquefaction Complex Bonny Island, Nigeria

Electrical Systems Revision B2 Page 9 of 10

FORM No.

PR808-13-N32

D E Associated Relays S : Checklist for Heat Shrink Stress Control H.V.Cable Terminators

PR808-13-N33

:

Field Inspection of Protection Relay Type PBSJ 3E5 N11 P&B Golds Motor Protection Relay

PR808-13-N34

:

Field Inspection of Protection Relay Type MBCH 12

PR808-13-N35

:

Field Inspection of Protection Relay Type MCTH 01

PR808-13-N36

:

Field Inspection of Protection Relay Type MET 131

PR808-13-N37

:

Field Inspection of Protection Relay Type MFVU 21

PR808-13-N38

:

Field Inspection of Protection Relay Type MRTP 03

PR808-13-N39

:

Field Inspection of Protection Relay Type MVAJ 23

PR808-13-N40

:

Field Inspection of Protection Relay Type MVAP 22

PR808-13-N41

:

Field Inspection of Protection Relay Type MVTD 11/12

PR808-13-N42

:

Field Inspection of Protection Relay Type MVTT 14

PR808-13-N43

:

Field Inspection of Protection Relay Type MVTW 02

PR808-13-N44

:

Field Inspection of Protection Relay Type MFAC

PR808-13-N45

:

Field Inspection of Protection Relay Type MVTU 11/12

PR808-13-N46

:

Field Inspection of Protection Relay Type IDMT / INST

PR808-13-N47

:

Field Inspection of Protection Relay Type MCR1 01

PR808-13-N48

Load Test of Tank Base Heating

PR808-13-N49

:

Field Inspection of Differential Protection Relay (General Test)

PR808-13-N50

:

Field Inspection of Trace Heating Circuits

PR808 13-N51

:

Field Inspection of Synchronous Machines (including Exciter)

PR808-13-N52

:

Field Inspection of Static AC Power Supply Unit

PR808-13-N53

:

Field Inspection of Synchronous AC Generator Dynamic Test

PR808-13-N54

:

Field Inspection of Protection / metering Relay Type Motor manager II

PR808-13-N55

:

Electrical Special purpose Inspection Report

PR808-13-N56

:

Field Inspection of Electrical Heaters

PR808-13-N57

:

Field Inspection of Thyristor Control Panels

JP 1000 NLG Procedure 808-13 /conversion/tmp/scratch/460649486.doc

Nigeria LNG Limited Natural Gas Liquefaction Complex Bonny Island, Nigeria

Electrical Systems Revision B2 Page 10 of 10

FORM No. PR808-13-N58

D :E Field Inspection of VSD Cabinets ( Cooling Fan Mortors)

JP 1000 NLG Procedure 808-13 /conversion/tmp/scratch/460649486.doc