Form No.

P- 000 Issue Date: March 2006 Sheet 1 of 4

SAUDI ARAMCO PRE-COMMISSIONING FORM
TESTING GUIDE LINES
INTRODUCTION

GI 2.710, Mechanical Completion and Performance Acceptance of Facilities, defines mechanical

completion as being achieved when a facility defined in the approved project scope, construction
documentation, drawings and specification and material requisitions has been installed and
Precommissioned and is available for commissioning and start-up.

The following Precommissioning forms are based on industry standards (IEEE, ANSI, NEMA, UL, and
IEC) as well as the basic requirements of several major equipment manufacturers. The
Precommissioning forms describe the minimum requirements to ensure that the electrical equipment
addressed will perform reliably and in accordance with industry standards.

Electrical Tests Reference Information

Insulation Resistance Test

Measure the insulation resistance of electrical equipment phase to phase and phase to ground for one (1) minute. Test
voltage and minimum acceptable values.

Equipment Voltage Rating Recommended Test Voltage

100 - 250 500
251 - 600 1000
601 - 5000 2500
Over 5000 5000

Values of insulation resistance less than manufacturer's minimum or rated voltage + 1kV in megohms should be
investigated. Over potential or high potential tests should not proceed unless insulation resistance levels are equal to or
above the listed minimum values.

High potential Test

Direct Current
A DC high potential test (controlled over voltage test) is one in which the increase of applied direct voltage is controlled.
The measured current is continuously observed for abnormalities with the intention of stopping the test before breakdown
occurs.

 A polarization index test should be performed on large rotating equipment by applying an initial voltage step of about
one-third of the recommended maximum voltage from the above table and maintain the voltage at a constant level for
10 minutes. The polarization index is calculated by dividing the one-minute resistance value by the ten-minute
resistance value. The index value should be 2 or greater values less than this should be investigated. After the initial
ten-minute test, the D. C. test voltage should be increased in 10 uniform steps, each step being one-minute in duration,
up to the maximum recommended D. C. value.

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 Form No. P- 000 Issue Date: March 2006 Sheet 2 of 4
SAUDI ARAMCO PRE-COMMISSIONING FORM
TESTING GUIDE LINES

 In high potential testing of cable, the D. C. test voltage is applied in a minimum of four steps
(each step approximately equal to the rated rms voltage of the cable) of one (1) minute
duration each, except for the final test voltage which shall be maintained for fifteen (15)
minutes.

Alternating Current
Perform AC high potential test phase to ground and phase to phase. Potential application shall be for one (1) minute. Test
voltage shall be in accordance with the manufacturer's recommendations. When the manufacturer's recommended values
are not available the values in the values listed in the following table can be used but should be considered the maximum
voltage to be applied. Increase the voltage at the rate of 1 kV per second until the maximum recommended test voltage is
reached.
MAXIMUM HIGH-POTENTIAL TEST VOLTAGES

Equipment Rated KV Test Voltage KV

A. C. D. C.
2.5 6.0 10.0
5.0 14.0 24.0
15 27.0 46.0
35 60.0 102.0

Recommended maximum values of field test voltages are determined by the following:
A. C. test volts = 0.75 X (2 X equipment maximum voltage + 1kV).
The D. C. test voltage is 1.4 X [0.75 X (2 X equipment maximum voltage + 1kV)]

The AC high potential test results are evaluated on a go, no-go basis by slowly raising the test voltage to the required
value of final test voltage and maintaining for one (1) minute,

Low Voltage Cables

Perform DC High Potential Testing on critical cables after installation. Test each cable with respect to ground and
adjacent cables. Test value shall be reviewed with the proponent. The DC test voltage shall not exceed 1.4 X (2 X rated
voltage + 1000).

Switchgear and Metal Enclosed Bus

Perform AC high potential tests on each bus section, phase to phase and phase to ground for one (1) minute. Maximum
test voltage shall be as listed above.

Contact Resistance.

Measure and record the contact resistance of each phase line to load, of bus, breakers and contactors. For equipment 600
amps and higher, values of resistance in excess of 200 micro-ohms and deviations of more than +/- 20% must be
investigated. The contact resistance is measured with the circuit breaker/contactor in the closed position. The contactor
must be closed and latched not held closed by hand pressure.

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 Form No. P- 000 Issue Date: March 2006 Sheet 3 of 4
SAUDI ARAMCO PRE-COMMISSIONING FORM
TESTING GUIDE LINES

Thermo-vision Inspection

Electrical equipment safely accessible and visible such as outdoor bus connections, isolation switches, terminations on
circuit breakers and transformers should be checked with Thermo-vision for temperature abnormalities.

New Insulating Oil Test Requirements

The following table lists the Dielectric Fluid Specifications for new insulating Oil as Received from the supplier. Note that
the values listed are described as minimum or maximum recommended values. The oil must be tested before oil filling of
the equipment begins and, depending on the results of the test and the operating voltage of the equipment, may require
processing before it is put into the equipment. See P-051 for additional information.

Dielectric Fluid Specification (New Insulating Oil as Received Before Transformer Filling)

TEST LIMIT VALUE TEST RESULTS

Dielectric strength D-877, kV, minimum 30
Power Factor, D924,
25 deg., % maximum. 0.05
100 deg., % maximum 0.30
Interfacial Tension D 971, mN/M minimum 40
Color, D-1500 ASTM Units maximum 0.5
Visual Examination D1524 Bright and Clear
Acid Number D974, mg KOH/g, maximum 0.03
Water Content, D 1533, ppm, maximum 35

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 Form No. P- 000 Issue Date: March 2006 Sheet 4 of 4
SAUDI ARAMCO PRE-COMMISSIONING FORM
TESTING GUIDE LINES

The following torque table is for general reference. The manufacturers recommended torque values should be
used. In the absence of manufacturer's recommendations, the following values are the recommended maximum
torque values that should be applied. Note that grade 5 hardware should be used in switchgear as a minimum.

U.S. STANDARD BOLT TORQUE FOR BUS CONNECTIONS HEAT TREATED STEEL (MAXIMUM)

GRADE SAE NO. 1&2 SAE NO. 5 SAE NO. 6 SAE NO. 8

MINIMUM 64K 105K 133K 150K

TENSILE (PSI)
BOLT TORQUE
DIAMETER (FT-LBS)
1/4 5 7 10 10.5

5/16 9 14 19 22

3/8 15 25 34 37

7/16 24 40 55 60

1/2 37 60 85 92

9/16 53 88 120 132

5/8 74 120 167 180

3/4 120 200 280 296

7/8 190 302 440 473

Reduce the maximum torque values listed by 10% to 20% for plated or lubricated bolts.

SILICON BRONZE

Bolt Diameter 1/4 - 20 5/16 - 18 3/8 - 16 7/16 - 14 1/2 - 13 9/16 - 12 5/8 - 11

and Thread
Torque in Ft-lb 6 10 18 29 40 53 86

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