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PT Bajra Mandalasakti Graha Mobisel Building, 2nd Floor Jl. Buncit Raya No. 139 JAKARTA SELATAN 12740 INDONESIA
INSTALLATION PROCEDURE NUMBER
INP 17022-P4-E-0A1H-QA-00801
PROJECT TITLE
WARA CRUSHING PLANT PROJECT
DESCRIPTION
WARA CRUSHING PLANT PROJECT
PAGE
1 of 15
JOB No.
17022
DIR. REF
17022-1.9.1.INP
EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN OFFICE OF ORIGIN
PT BAJRA MANDALASAKTI
WRITTEN BY
DARREN HOUSE
REVIEWED BY
EDMUND ANDERSON DATE:
DATE: 25.01.2018 CLIENT PO 25.01.2018 CLIENT REP.
TITLE OF REVIEWER PROJECT SPONSOR
STATUS APPROVAL BY CLIENT RESPONSIBLE MANAGER/ENGINEER SIGNED
DATE
REV.
..........................
....................
.............
ACCEPTED EXCEPT AS NOTED ..........................
....................
.............
....................
.............
ACCEPTED (Alpha or Numeric)
(Alpha)
REVISE AND RESUBMIT
..........................
(Alpha or Numeric)
APPROVAL BY CLIENT RESPONSIBLE MANAGER (Numeric)
..................................................................................
Rev.
Date
0
01.02.2018
Description Issued for Use
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
DATE: ................................
By
Chk’d
Reviewed
Client
PT Bajra Mandalasakti Graha Mobisel Building, 2nd Floor Jl. Buncit Raya No. 139 JAKARTA SELATAN 12740 INDONESIA
INSTALLATION PROCEDURE NUMBER
INP 17022-P4-E-0A1H-QA-00801
PROJECT TITLE
WARA CRUSHING PLANT PROJECT
DESCRIPTION
WARA CRUSHING PLANT PROJECT
PAGE
2 of 15
JOB No.
17022
DIR. REF
17022-1.9.1.INP
EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN OFFICE OF ORIGIN
PT BAJRA MANDALASAKTI
WRITTEN BY
DARREN HOUSE
REVIEWED BY
EDMUND ANDERSON DATE:
DATE: 25.01.2018 CLIENT PO 25.01.2018 CLIENT REP.
TITLE OF REVIEWER PROJECT SPONSOR
STATUS APPROVAL BY CLIENT RESPONSIBLE MANAGER/ENGINEER SIGNED
DATE
REV.
..........................
....................
.............
ACCEPTED EXCEPT AS NOTED ..........................
....................
.............
....................
.............
ACCEPTED (Alpha or Numeric)
(Alpha)
REVISE AND RESUBMIT
..........................
(Alpha or Numeric)
APPROVAL BY CLIENT RESPONSIBLE MANAGER (Numeric)
..................................................................................
Rev.
Date
0
01.02.2018
Description Issued for Use
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
DATE: ................................
By
Chk’d
Reviewed
DH
DH
EA
Client
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 3 of 15
CONTENTS 1.0
INTRODUCTION................................................................................................. 4 1.1
Specification ...................................................................................................... 4
2.0
SUBSTATION EARTHING ................................................................................. 5
3.0
EQUIPMENT PLANT EARTHING ...................................................................... 6
4.0
CABLE LADDER AND STRUCTURAL BONDING ............................................ 7
5.0
LIGHTNING PROTECTION ................................................................................ 8
6.0
TESTING ............................................................................................................ 9
LIST OF APPENDICES APPENDIX - A APPENDIX - B APPENDIX - C
LIST OF INSPECTION & TEST PLAN (ITP’s) ...................................... A-1 LIST OF INSTALLATION CHECK SHEETS ......................................... B-1 LIST OF TEST SHEETS ...................................................................... C-1
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
1.0
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 4 of 15
INTRODUCTION The purpose of this document is to describe the procedure employed to ensure that all Lightning Protection, Substation and Plant Earthing is installed, tested and documented in accordance with project requirements and general electrical specifications.
1.1
Specification The Earthing and Lightning Protection installation shall be in accordance with the Project Specifications, Indonesian Standards, IEC or Australian Standards (in that order of priority);
Relevant Project Specific Customer Standards and Specifications.
Standards National Indonesia - General Requirements for Electrical Installation 2000 (PUIL 2000)
AS/NZS 3000:2007 Electrical installations (known as the Australian/New Zealand Wiring Rules)
AS/NZS 1768:2007 Lightning Protection.
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
2.0
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 5 of 15
SUBSTATION EARTHING Main earthing grids shall be installed and tested in accordance with the project drawings and specifications. In the event that project specific documentation is not available, below outlines Company minimal requirements for main earthing grid installations. An Earthing Loop shall be installed around each substation in accordance the respective Substation Earthing Layout Drawings. Substation Earthing Loops shall consist of Copper Earthing Rods and Inspection Pits interconnected with an earth loop of underground bare Copper Conductor. Sizing of Earth Rods and Bare Copper Earthing Conductor shall be as indicated on the Substation Earthing Layout Drawings. After Installation of the Substation Earthing Loop and all rods interconnected should have a resistance to ground on less than one Ohm at any point. The Substation Earth Loop shall be connected using approved underground bare copper cable connectors to a Substation Main Earth Bar using Green/Yellow PVC Earthing Conductor connected at two points using Cable Sizing as indicated on Substation Earthing Layout Drawings. All Main Electrical Equipment installed in the Substation will be connected with a separate Green/Yellow PVC Earthing Conductor back to the Substation Main Earth Bar using Cable Sizing as indicated on Substation Earthing Layout Drawings. Four Wire Systems shall be effectively earthed at the Start Point of the secondary winding of Distribution Transformers at each substation using Green/Yellow PVC Earthing Conductor connected to the Substation Main Earth Bar using Cable Sizing as indicated on Substation Earthing Layout Drawings. Where applicable, Steel Support Sections of the Substation Building will be connected back to the Bare Copper Earth Loop with approved connectors using Green/Yellow PVC Earthing Conductor with sizes as shown on Substation Earthing Layout Drawings. Transformer Compound Fencing will be connected back to the Bare Copper Earth Loop with approved connectors using Green/Yellow PVC Earthing Conductor with sizes as shown on Substation Earthing Layout Drawings. A flexible earthing connection will be made between Stationary Fencing Poles and Transformer Compound Gates ensuring that the Gate has a solid earth connection at all times.
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
3.0
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 6 of 15
EQUIPMENT PLANT EARTHING Equipment plant earthing shall be installed and tested in accordance with the project drawings and specifications. In the event that project specific documentation is not available, below outlines Company minimal requirements for equipment earthing. Generally all plant equipment will be solidly earthed with the earthing core conductor in the multicore power supply cable. All Earthing conductors for power supply cabling must be connected to the Switchboard, Motor Control Centre or Distribution Board where the source originates and be connected at the Plant Equipment. High Voltage electrical equipment will be earthed by a separate earthing conductor. The earthing conductor should be connected to the Main HV Switchboard at which the HV source originates and shall be connected at the field equipment.
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
4.0
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 7 of 15
CABLE LADDER AND STRUCTURAL BONDING Cable Ladder and Steel Structure earthing shall be installed and tested in accordance with the project drawings and specifications. In the event that project specific documentation is not available, below outlines Company minimal requirements for Cable Ladder and Steel Structure earthing installation. Cable Ladder and Steel Structure earthing shall be installed throughout the plant and connected back to the Substation Main Earth Bar using Green/Yellow PVC Earthing Conductor. A 70mm2 Green/Yellow PVC Earthing Conductor will be installed for the complete length in each complete Cable Ladder Run. The Earth Conductor will be bonded to the Cable Ladder every 10 Meters using a proprietary Clamping Device and connected back to the Substation Main Earth Bar. Where more than one Cable Ladders is installed on the same route, only one continuous earth conductor will be installed, however all cable ladders will be bonded to the earthing conductor every 10 Meters. An Earthing Loop shall be installed around each free standing steel structure in accordance the respective Earthing Layout Drawings. Steel Structure Earthing Loops shall consist of Copper Earthing Rods and Inspection Pits interconnected with an earth loop of underground bare Copper Conductor. Sizing of Earth Rods and Bare Copper Earthing Conductor shall be as indicated on the Conveyor Transfer Tower Earthing Layout Drawings. The Steel Structure will be connected using Green/Yellow PVC Earthing Conductor to the Bare Copper Earth Loop with approved connectors at points as detailed on the Steel Structure Earthing Layout Drawings.
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
5.0
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 8 of 15
LIGHTNING PROTECTION Lightning protection shall be installed and tested in accordance with the project drawings and specifications. In the event that project specific documentation is not available, below outlines Company minimal requirements for Lightning Protection installation. Lightning Protection is installed in accordance with AS1768 and based on approximately 50 thunder days per year. Lightning Protection where required, will be connected using Green/Yellow PVC Earthing Conductor to earth rods and earthing loop as detailed Layout Drawings. The earthing loop will be separate and not connected back to the substation earthing systems.
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
6.0
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 9 of 15
TESTING Earthing and Lightning protection shall be tested in accordance with the project specifications. In the event that project specific documentation is not available, below outlines Company minimal requirements for Earthing and Lightning Protection testing. Resistance of each individual Earth Rod will be tested and recorded after installation and prior to interconnection to other earth rods in an earthing loop. Once complete earthing loops are installed the complete earthing loop will be tested at two points and recorded on the appropriate test sheet. Earthing resistance at any point on the earth loop shall not exceed one ohm.
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
APPENDIX - A
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 A-1 of 15
LIST OF INSPECTION & TEST PLAN (ITP’s)
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
NO 1
DOCUMENT NUMBER INP 17022-P4-E-0A1H-IT-00801
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 A-2 of 15
TITLE Earthing & Lightning Protection Installation
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
PT Bajra Mandalasakti INSPECTION & TEST PLAN
Owner
Date
Project Name
ITP No.
INP 17022-P4-E-0A1H-IT-00801
Contract / PO No.
Revision
0 - For Use
Description of Item Manufacture / Construction Process
Acceptance
Reference or
Inspection / Test Point Description
Criteria
Specification
Test
Earthing & Lightning Protection Installation Const.
Inspection /
Frequency
Procedure
Test Method
Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation
INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801
INSPECTORATE
Verifying
Item
1
Earth Rod Size and Quantity Correct
Earthing Drawing
2
Earth Rod Inspection Pit Installed Correct
Earthing Drawing
3
Correct Earth Loop Cable Type & Size Installed
Earthing Drawing
4
Earth Loop Cable Installed Underground at the Correct Depth
Earthing Drawing
5
Earth Bar Installed Correct with Correct Connections to Earth Loop and Main Equipment
Visual Inspection
6
Substation Distribution Transformer Start Point Earthed
Visual Inspection
7
Structural Steel Bonding Installed as required
Earthing Drawing
8
Transformer Compound and Gate Earth Bonding Correct
Visual Inspection
9
Cable Ladder Bonding Cable Size Correct
Visual Inspection
10
Cable Ladder Bonding every 10 Meters
Visual Inspection
11
Earth Rod Resistance Measured and Recorded
Test Results
12
Earthing Loop, Compete Earthing Resistance Test after earth rods are interconnected
Test Results
13
Lightning Protection Air Terminals and Conductor Size and Locations Correct
Visual Inspection
14
Lightning Protection and Earthing Systems are separated.
Visual Inspection
LEGEND
X-
Inspected Performed By
R-
Random Inspection
W-
Witness Point
H
Hold Point
INP 17022-P4-E-0A1H-IT-00801_0 Earthing & Lightning Protection Installation ITP - ITP
BMS
BUMA
App.
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
W
Visual
X
R
N/A
Visual
X
R
N/A
Record INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801
NOTES 1.
The appropriate abbreviation shall be placed in the Inspectorate Column under the organization responsible for the Inspection (X) or the authority to witness (W) or the authority to release a Hold Point (H) etc.
2.
The authority to witness a Witness Point or release a Hold Point is required to sign in the App. Column in the Inspectorate Section before the next task can be executed.
Page 1 of 1
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
APPENDIX - B
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 B-1 of 15
LIST OF INSTALLATION CHECK SHEETS
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
NO 1
DOCUMENT NUMBER INP 17022-P4-E-0A1H-IC-00801
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 B-2 of 15
TITLE Earthing Installation Verification Check Sheet
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
PT Bajra Mandalasakti INSTALLATION CHECKLIST EARTHING & LIGHTNING PROT. SYSTEM INP 17022-P4-E-0A1H-IC-00801 Description:
Earthing Installation Verification Check Sheet
File:
Contract Title:
Contract
Location:
Date:
ITEM
1
ACTIVITY
By BMS
Yes / No
Pre Installation Activities 1.1 JSA's / Procedures in place for task 1.2 Check cable route for completeness
2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13
Date
Client
N/A N/A
Installation Earth Rod Size and Quantity installed as per Installation Drawings Inspection Pits installed Correctly at the Correct Locations Earth Loop Conductor Size Correct as per Installation Drawings Earth Loop Conductor Installed at the Correct Depth Earth Connection from Earth Loop to Main Earth Bar Correct All Main Equipment Correctly Connected to Main Earth Bar Substation Distribution Transformer Star Point Earthed Correctly Structural Steel Bonded installed as per Installation Drawings Transformer Compound Fencing and Gates Bonded Correctly Cable Ladder Bonding Cable Size Correct and Installed Correctly Cable Ladder Bonding every 10 Meters Air Terminal Size and Locations Correct Lightning Protection and Earth System Separate
N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Remarks
Work Complete and Verified by PT Bajra Mandalasakti Name and Signature:
Date:
PT Bukit Makmur Mandiri Utama Name and Signature:
INP 17022-P4-E-0A1H-IC-00801_0 Earthing Installation Verification Check Sheet - Installation Checklist
Date:
Page 1 of 1
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
APPENDIX - C
LIST OF TEST SHEETS
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 C-1 of 15
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
NO 1
DOCUMENT NUMBER INP 17022-P4-E-0A1H-TR-00801
Dir. Ref: Date: Page:
TITLE Earth System Test Sheet
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
17022-1.9.1.INP 25/01/18 C-2 of 15
PT Bajra Mandalasakti TEST RECORD EARHING TEST SHEET
(Main Contractor Logo)
(Project Owner Logo)
INP 17022-P0-E-0A1H-TR-00801 Description:
Earth System Test Sheet
File:
Contract Title:
Contract
Location:
Date:
INSTALLATION Main Earth Bar Size Earth Loop Cable Size
Dwg No.
Description TEST RESULTS Earth Tester Make / Model :
Serial No.
Cal Certificate No.
Valid Until:
TEST RESULTS Individual Earth Rod Resistance Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Location No. 1
Resistance
Ohms
Location No. 2
Resistance
Ohms
Complete Earth Loop Resistance (@ Two Locations)
Remarks
Tested, Verified and Accepted by: PT Bajra Mandalasakti Name and Signature:
Date:
Main Contractor Company's Name Name and Signature:
Date:
Project Owner Company's Name Name and Signature:
INP 17022-P0-E-0A1H-TR-00801_A Earthing Test Sheet - Test Record
Date:
Page 1 of 1
INSTALLATION PROCEDURE NUMBER
INP 17022-P4-E-0A1H-QA-00801
PROJECT TITLE
WARA CRUSHING PLANT PROJECT
DESCRIPTION
WARA CRUSHING PLANT PROJECT
PAGE
1 of 15
JOB No.
17022
DIR. REF
17022-1.9.1.INP
EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN OFFICE OF ORIGIN
PT BAJRA MANDALASAKTI
WRITTEN BY
DARREN HOUSE
REVIEWED BY
EDMUND ANDERSON DATE:
DATE: 25.01.2018 CLIENT PO 25.01.2018 CLIENT REP.
TITLE OF REVIEWER PROJECT SPONSOR
STATUS APPROVAL BY CLIENT RESPONSIBLE MANAGER/ENGINEER SIGNED
DATE
REV.
..........................
....................
.............
ACCEPTED EXCEPT AS NOTED ..........................
....................
.............
....................
.............
ACCEPTED (Alpha or Numeric)
(Alpha)
REVISE AND RESUBMIT
..........................
(Alpha or Numeric)
APPROVAL BY CLIENT RESPONSIBLE MANAGER (Numeric)
..................................................................................
Rev.
Date
0
01.02.2018
Description Issued for Use
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
DATE: ................................
By
Chk’d
Reviewed
Client
PT Bajra Mandalasakti Graha Mobisel Building, 2nd Floor Jl. Buncit Raya No. 139 JAKARTA SELATAN 12740 INDONESIA
INSTALLATION PROCEDURE NUMBER
INP 17022-P4-E-0A1H-QA-00801
PROJECT TITLE
WARA CRUSHING PLANT PROJECT
DESCRIPTION
WARA CRUSHING PLANT PROJECT
PAGE
2 of 15
JOB No.
17022
DIR. REF
17022-1.9.1.INP
EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN OFFICE OF ORIGIN
PT BAJRA MANDALASAKTI
WRITTEN BY
DARREN HOUSE
REVIEWED BY
EDMUND ANDERSON DATE:
DATE: 25.01.2018 CLIENT PO 25.01.2018 CLIENT REP.
TITLE OF REVIEWER PROJECT SPONSOR
STATUS APPROVAL BY CLIENT RESPONSIBLE MANAGER/ENGINEER SIGNED
DATE
REV.
..........................
....................
.............
ACCEPTED EXCEPT AS NOTED ..........................
....................
.............
....................
.............
ACCEPTED (Alpha or Numeric)
(Alpha)
REVISE AND RESUBMIT
..........................
(Alpha or Numeric)
APPROVAL BY CLIENT RESPONSIBLE MANAGER (Numeric)
..................................................................................
Rev.
Date
0
01.02.2018
Description Issued for Use
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
DATE: ................................
By
Chk’d
Reviewed
DH
DH
EA
Client
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 3 of 15
CONTENTS 1.0
INTRODUCTION................................................................................................. 4 1.1
Specification ...................................................................................................... 4
2.0
SUBSTATION EARTHING ................................................................................. 5
3.0
EQUIPMENT PLANT EARTHING ...................................................................... 6
4.0
CABLE LADDER AND STRUCTURAL BONDING ............................................ 7
5.0
LIGHTNING PROTECTION ................................................................................ 8
6.0
TESTING ............................................................................................................ 9
LIST OF APPENDICES APPENDIX - A APPENDIX - B APPENDIX - C
LIST OF INSPECTION & TEST PLAN (ITP’s) ...................................... A-1 LIST OF INSTALLATION CHECK SHEETS ......................................... B-1 LIST OF TEST SHEETS ...................................................................... C-1
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
1.0
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 4 of 15
INTRODUCTION The purpose of this document is to describe the procedure employed to ensure that all Lightning Protection, Substation and Plant Earthing is installed, tested and documented in accordance with project requirements and general electrical specifications.
1.1
Specification The Earthing and Lightning Protection installation shall be in accordance with the Project Specifications, Indonesian Standards, IEC or Australian Standards (in that order of priority);
Relevant Project Specific Customer Standards and Specifications.
Standards National Indonesia - General Requirements for Electrical Installation 2000 (PUIL 2000)
AS/NZS 3000:2007 Electrical installations (known as the Australian/New Zealand Wiring Rules)
AS/NZS 1768:2007 Lightning Protection.
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
2.0
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 5 of 15
SUBSTATION EARTHING Main earthing grids shall be installed and tested in accordance with the project drawings and specifications. In the event that project specific documentation is not available, below outlines Company minimal requirements for main earthing grid installations. An Earthing Loop shall be installed around each substation in accordance the respective Substation Earthing Layout Drawings. Substation Earthing Loops shall consist of Copper Earthing Rods and Inspection Pits interconnected with an earth loop of underground bare Copper Conductor. Sizing of Earth Rods and Bare Copper Earthing Conductor shall be as indicated on the Substation Earthing Layout Drawings. After Installation of the Substation Earthing Loop and all rods interconnected should have a resistance to ground on less than one Ohm at any point. The Substation Earth Loop shall be connected using approved underground bare copper cable connectors to a Substation Main Earth Bar using Green/Yellow PVC Earthing Conductor connected at two points using Cable Sizing as indicated on Substation Earthing Layout Drawings. All Main Electrical Equipment installed in the Substation will be connected with a separate Green/Yellow PVC Earthing Conductor back to the Substation Main Earth Bar using Cable Sizing as indicated on Substation Earthing Layout Drawings. Four Wire Systems shall be effectively earthed at the Start Point of the secondary winding of Distribution Transformers at each substation using Green/Yellow PVC Earthing Conductor connected to the Substation Main Earth Bar using Cable Sizing as indicated on Substation Earthing Layout Drawings. Where applicable, Steel Support Sections of the Substation Building will be connected back to the Bare Copper Earth Loop with approved connectors using Green/Yellow PVC Earthing Conductor with sizes as shown on Substation Earthing Layout Drawings. Transformer Compound Fencing will be connected back to the Bare Copper Earth Loop with approved connectors using Green/Yellow PVC Earthing Conductor with sizes as shown on Substation Earthing Layout Drawings. A flexible earthing connection will be made between Stationary Fencing Poles and Transformer Compound Gates ensuring that the Gate has a solid earth connection at all times.
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
3.0
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17022-1.9.1.INP 25/01/18 6 of 15
EQUIPMENT PLANT EARTHING Equipment plant earthing shall be installed and tested in accordance with the project drawings and specifications. In the event that project specific documentation is not available, below outlines Company minimal requirements for equipment earthing. Generally all plant equipment will be solidly earthed with the earthing core conductor in the multicore power supply cable. All Earthing conductors for power supply cabling must be connected to the Switchboard, Motor Control Centre or Distribution Board where the source originates and be connected at the Plant Equipment. High Voltage electrical equipment will be earthed by a separate earthing conductor. The earthing conductor should be connected to the Main HV Switchboard at which the HV source originates and shall be connected at the field equipment.
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
4.0
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 7 of 15
CABLE LADDER AND STRUCTURAL BONDING Cable Ladder and Steel Structure earthing shall be installed and tested in accordance with the project drawings and specifications. In the event that project specific documentation is not available, below outlines Company minimal requirements for Cable Ladder and Steel Structure earthing installation. Cable Ladder and Steel Structure earthing shall be installed throughout the plant and connected back to the Substation Main Earth Bar using Green/Yellow PVC Earthing Conductor. A 70mm2 Green/Yellow PVC Earthing Conductor will be installed for the complete length in each complete Cable Ladder Run. The Earth Conductor will be bonded to the Cable Ladder every 10 Meters using a proprietary Clamping Device and connected back to the Substation Main Earth Bar. Where more than one Cable Ladders is installed on the same route, only one continuous earth conductor will be installed, however all cable ladders will be bonded to the earthing conductor every 10 Meters. An Earthing Loop shall be installed around each free standing steel structure in accordance the respective Earthing Layout Drawings. Steel Structure Earthing Loops shall consist of Copper Earthing Rods and Inspection Pits interconnected with an earth loop of underground bare Copper Conductor. Sizing of Earth Rods and Bare Copper Earthing Conductor shall be as indicated on the Conveyor Transfer Tower Earthing Layout Drawings. The Steel Structure will be connected using Green/Yellow PVC Earthing Conductor to the Bare Copper Earth Loop with approved connectors at points as detailed on the Steel Structure Earthing Layout Drawings.
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
5.0
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 8 of 15
LIGHTNING PROTECTION Lightning protection shall be installed and tested in accordance with the project drawings and specifications. In the event that project specific documentation is not available, below outlines Company minimal requirements for Lightning Protection installation. Lightning Protection is installed in accordance with AS1768 and based on approximately 50 thunder days per year. Lightning Protection where required, will be connected using Green/Yellow PVC Earthing Conductor to earth rods and earthing loop as detailed Layout Drawings. The earthing loop will be separate and not connected back to the substation earthing systems.
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
6.0
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 9 of 15
TESTING Earthing and Lightning protection shall be tested in accordance with the project specifications. In the event that project specific documentation is not available, below outlines Company minimal requirements for Earthing and Lightning Protection testing. Resistance of each individual Earth Rod will be tested and recorded after installation and prior to interconnection to other earth rods in an earthing loop. Once complete earthing loops are installed the complete earthing loop will be tested at two points and recorded on the appropriate test sheet. Earthing resistance at any point on the earth loop shall not exceed one ohm.
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
APPENDIX - A
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17022-1.9.1.INP 25/01/18 A-1 of 15
LIST OF INSPECTION & TEST PLAN (ITP’s)
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
NO 1
DOCUMENT NUMBER INP 17022-P4-E-0A1H-IT-00801
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17022-1.9.1.INP 25/01/18 A-2 of 15
TITLE Earthing & Lightning Protection Installation
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
PT Bajra Mandalasakti INSPECTION & TEST PLAN
Owner
Date
Project Name
ITP No.
INP 17022-P4-E-0A1H-IT-00801
Contract / PO No.
Revision
0 - For Use
Description of Item Manufacture / Construction Process
Acceptance
Reference or
Inspection / Test Point Description
Criteria
Specification
Test
Earthing & Lightning Protection Installation Const.
Inspection /
Frequency
Procedure
Test Method
Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation Once - After Installation
INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801 INP 17022-P4-E0A1H-QA-00801
INSPECTORATE
Verifying
Item
1
Earth Rod Size and Quantity Correct
Earthing Drawing
2
Earth Rod Inspection Pit Installed Correct
Earthing Drawing
3
Correct Earth Loop Cable Type & Size Installed
Earthing Drawing
4
Earth Loop Cable Installed Underground at the Correct Depth
Earthing Drawing
5
Earth Bar Installed Correct with Correct Connections to Earth Loop and Main Equipment
Visual Inspection
6
Substation Distribution Transformer Start Point Earthed
Visual Inspection
7
Structural Steel Bonding Installed as required
Earthing Drawing
8
Transformer Compound and Gate Earth Bonding Correct
Visual Inspection
9
Cable Ladder Bonding Cable Size Correct
Visual Inspection
10
Cable Ladder Bonding every 10 Meters
Visual Inspection
11
Earth Rod Resistance Measured and Recorded
Test Results
12
Earthing Loop, Compete Earthing Resistance Test after earth rods are interconnected
Test Results
13
Lightning Protection Air Terminals and Conductor Size and Locations Correct
Visual Inspection
14
Lightning Protection and Earthing Systems are separated.
Visual Inspection
LEGEND
X-
Inspected Performed By
R-
Random Inspection
W-
Witness Point
H
Hold Point
INP 17022-P4-E-0A1H-IT-00801_0 Earthing & Lightning Protection Installation ITP - ITP
BMS
BUMA
App.
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
R
N/A
Visual
X
W
Visual
X
R
N/A
Visual
X
R
N/A
Record INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801 INP 17022-P4-E0A1H-IC-00801
NOTES 1.
The appropriate abbreviation shall be placed in the Inspectorate Column under the organization responsible for the Inspection (X) or the authority to witness (W) or the authority to release a Hold Point (H) etc.
2.
The authority to witness a Witness Point or release a Hold Point is required to sign in the App. Column in the Inspectorate Section before the next task can be executed.
Page 1 of 1
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
APPENDIX - B
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17022-1.9.1.INP 25/01/18 B-1 of 15
LIST OF INSTALLATION CHECK SHEETS
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
NO 1
DOCUMENT NUMBER INP 17022-P4-E-0A1H-IC-00801
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 B-2 of 15
TITLE Earthing Installation Verification Check Sheet
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
PT Bajra Mandalasakti INSTALLATION CHECKLIST EARTHING & LIGHTNING PROT. SYSTEM INP 17022-P4-E-0A1H-IC-00801 Description:
Earthing Installation Verification Check Sheet
File:
Contract Title:
Contract
Location:
Date:
ITEM
1
ACTIVITY
By BMS
Yes / No
Pre Installation Activities 1.1 JSA's / Procedures in place for task 1.2 Check cable route for completeness
2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13
Date
Client
N/A N/A
Installation Earth Rod Size and Quantity installed as per Installation Drawings Inspection Pits installed Correctly at the Correct Locations Earth Loop Conductor Size Correct as per Installation Drawings Earth Loop Conductor Installed at the Correct Depth Earth Connection from Earth Loop to Main Earth Bar Correct All Main Equipment Correctly Connected to Main Earth Bar Substation Distribution Transformer Star Point Earthed Correctly Structural Steel Bonded installed as per Installation Drawings Transformer Compound Fencing and Gates Bonded Correctly Cable Ladder Bonding Cable Size Correct and Installed Correctly Cable Ladder Bonding every 10 Meters Air Terminal Size and Locations Correct Lightning Protection and Earth System Separate
N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Remarks
Work Complete and Verified by PT Bajra Mandalasakti Name and Signature:
Date:
PT Bukit Makmur Mandiri Utama Name and Signature:
INP 17022-P4-E-0A1H-IC-00801_0 Earthing Installation Verification Check Sheet - Installation Checklist
Date:
Page 1 of 1
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
APPENDIX - C
LIST OF TEST SHEETS
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
Dir. Ref: Date: Page:
17022-1.9.1.INP 25/01/18 C-1 of 15
WARA CRUSHING PLANT PROJECT EARTHING & LIGHTNING PROTECTION INSTALLATION AND TESTING QUALITY PLAN
NO 1
DOCUMENT NUMBER INP 17022-P4-E-0A1H-TR-00801
Dir. Ref: Date: Page:
TITLE Earth System Test Sheet
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing
17022-1.9.1.INP 25/01/18 C-2 of 15
PT Bajra Mandalasakti TEST RECORD EARHING TEST SHEET
(Main Contractor Logo)
(Project Owner Logo)
INP 17022-P0-E-0A1H-TR-00801 Description:
Earth System Test Sheet
File:
Contract Title:
Contract
Location:
Date:
INSTALLATION Main Earth Bar Size Earth Loop Cable Size
Dwg No.
Description TEST RESULTS Earth Tester Make / Model :
Serial No.
Cal Certificate No.
Valid Until:
TEST RESULTS Individual Earth Rod Resistance Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Earth Rod Number
Locatio n
Resistance
Ohms
Location No. 1
Resistance
Ohms
Location No. 2
Resistance
Ohms
Complete Earth Loop Resistance (@ Two Locations)
Remarks
Tested, Verified and Accepted by: PT Bajra Mandalasakti Name and Signature:
Date:
Main Contractor Company's Name Name and Signature:
Date:
Project Owner Company's Name Name and Signature:
INP 17022-P0-E-0A1H-TR-00801_A Earthing Test Sheet - Test Record
Date:
Page 1 of 1
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