PREPARATION OF INSPECTION & TEST PLAN ELECTRICAL INSTALLATION & TESTING WORKS REVISION DATE ORIG. BY APP.

. BY QA REVIEW 01 Feb 04 P Moss T Herbert Contract: Client's Name: Project Title:

CONSTRUCTION OPERATIONS WORK PRACTICE F1 May 04 P Moss F2 F3 F4

9980-8710-PR-0020 PAGE 1 OF 16 REV F1 F5

1-14-9980/9 Esso Petroleum Co. Ltd Fawley Sulphur Free Mogas Fawley, Southampton, UK CLASS 1

Project Location: Document Category:

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

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

4.

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

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5. 5.1

RESPONSIBILITIES 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. 6.1

PROCEDURE 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 F N = = = Contractor Foster Wheeler 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 R I W = = = = Responsible for implementing the work and for undertaking Quality Control inspection of the work on an ongoing basis Responsible for reviewing and authorising submissions Responsible for inspecting the work on an auditing or monitoring basis only 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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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.

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

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ITEM

ACTIVITY

CONTROL DOCS

PROCEDURE REQUIRED

REPORT FORM/ CHECKLIST NUMBER

HOLD

RESPONSIBILITY C F N

COMMENTS

1. 1.1

DESIGN DOCUMENTS Review Workscope Contract Requisition and associated documents and drawings Agreed Inspection and Test Plan Contract Requisition and associated documents and drawings Notes of meeting Review workscope and accept contract X

1.2

Prepare Inspection and Test Plan Contract kick-off meeting

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

1.3

2. 2.1 3. 3.1

DOCUMENTS REQUIRING APPROVAL Method Statements Field erection procedures X R R

INSPECTION MEASUREMENT & TEST EQUIPMENT 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. 4.1

FREE ISSUE MATERIALS/EQUIPMENT 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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PREPARATION OF INSPECTION & TEST PLAN ELECTRICAL INSTALLATION & TESTING WORKS ATTACHMENT 1 - ITP

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REPORT FORM/ CHECKLIST NUMBER
MIR

9980-8710-PR-0020 PAGE 7 REV F1

RESPONSIBILITY C F
H

ITEM

ACTIVITY

CONTROL DOCS

PROCEDURE REQUIRED

HOLD

COMMENTS

4.2

Obtain material/equipment from FW stores

MIR

Contractor to confirm all material is in accordance with drawing BOM/MIR and undamaged Quantity and Quality received to be checked. Storage and inspection of materials. Certification and marking to be checked.

4.3

Receipt of materials/equipment

4.4

Preservation of materials/equipment

Vendor's instructions

Maintenance log to be maintained by Contractor throughout duration of Contract from receipt to system Turnover

5. 5.1

CONTRACTOR SUPPLIED MATERIALS Assessment of suppliers Contract Requisition "B" Contractor to assess suppliers to ensure technical requirements are met and to the appropriate quality level FWEL approval prior to purchase All purchased items to be inspected against the requirements of the purchase order. Accompanying certification to be checked and included in data book Vendor's instructions FWEL4088 X R Suppliers to operate a Quality Management System meeting ISO 9000 requirements. Certification not essential. Purchase orders to be maintained Purchased items without appropriate certification to be rejected and quarantined. No material to be released for use until appropriate certification is available. I Maintenance log to be maintained by Contractor throughout duration of Contract from receipt to system Turnover.

5.2 5.3

Purchase order placement Inspection of purchased items

Requisition "B" specification

X X

H R

5.4

Preservation of materials

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RESPONSIBILITY C F N

ITEM

ACTIVITY

CONTROL DOCS

PROCEDURE REQUIRED

HOLD

COMMENTS

6. 6.1

INSPECTION, MEASUREMENT AND TEST EQUIPMENT 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. 7.1 7.2 7.3 7.4 7.5 7.6 7.7

TRENCHING & CABLE TRAY/RACK Check drawings for cable trench routing Obtain work permits for trenching activities Prepare materials for use in excavation Trench excavation Trench inspection prior to pulling Placement of sand layer in trench bottom Position cable rollers at trench corners for continuous pulling Cable pulling Check cable for damage 70D20 70D20 70D20 70D20 FWEL3362 FWEL3376 FWEL3376 FWEL approval prior to cable pulling Layout drawings Project instructions FWEL Permit to Work X X X X X X X R H R W H H I I I I I FWEL Safety Advisor involvement Tags, cable markers, cable ties, sand

7.8 7.9

70D20 70D20 Continual inspection during cable pulling

X X W I Care of the works

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

CONSTRUCTION OPERATIONS WORK PRACTICE

REPORT FORM/ CHECKLIST NUMBER
FWEL3376 FWEL3376

9980-8710-PR-0020 PAGE 9 REV F1

RESPONSIBILITY C
X X

ITEM

ACTIVITY

CONTROL DOCS

PROCEDURE REQUIRED

HOLD

COMMENTS

F
W W I I

N
FWEL continual inspection

7.10 7.11

Check proper laying of cable and cable markers Backfill and restore cable trench after cable pulling is complete Check drawings for cable tray/rack routing Obtain work permits for cable tray/rack installation Install cable tray/rack and steel supports Tray and racking inspection Cable pulling Check cable for damage Check proper laying of cable in cable racks Check cable markers Check cable ties CABLING Megger and continuity test at warehouse

70D20 70D20

7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 8. 8.1

Layout drawings Project instructions 70D20 70D20 70D20 70D20 70D20 70D20 70D20 FWEL3384 FWEL3384 FWEL3384 Continual inspection during cable pulling FWEL3384 FWEL3384 FWEL Permit to Work Welder qualifications and WPS approved

X X X X X X X X X

R H H H W W W W W

I FWEL Safety Advisor involvement

I I I I I I FWEL continual inspection Care of the works

70D20

FWEL3377 FWEL3378 FWEL3379

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RESPONSIBILITY C F
W W W W I I I

ITEM

ACTIVITY

CONTROL DOCS

PROCEDURE REQUIRED

HOLD

COMMENTS

N
Care of the works

8.2 8.3 8.4 8.5

Cable visual check for damage Cable pulling Inspection check following installation Megger test after cable laying Gland, terminate and megger test for last time High Potential test for cables over 1000V

70D20 Layout drawing Layout drawing 70D20 FWEL3377 FWEL3378 FWEL3379 FWEL3377 FWEL3378 FWEL3379 FWEL3378

Continual inspection during cable pulling

X X X X

8.6

70D20

8.7 9. 9.1

70D20

100% Witness of all tests by FW

After installation of termination

TRAY, LADDER, RACK AND STEEL SUPPORT FABRICATION Submit weld procedures for acceptance Qualify welders Assess steel, tray and ladder/rack suppliers Purchase steel, trays and ladders/rack Inspect steel, trays and ladders/rack upon receipt from supplier 88A1 ASME IX ASME IX Layout drawing Contract Requisition "B" for specification Material approval by FWEL prior to purchase Discrepancy report to record damage Submission of weld procedure specifications and weld procedure qualification records FWEL3417 X H FWEL approvals required prior to commencing work

9.2 9.3 9.4 9.5

X X X X

H R H H I

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

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REPORT FORM/ CHECKLIST NUMBER
FWEL3384 FWEL3460 FWEL3460 FWEL3461 FWEL3384 FWEL3384 Repair procedure to be approved by FWEL FWEL3384

9980-8710-PR-0020 PAGE 11 REV F1

RESPONSIBILITY C
X X X X X X X R W W W I W W

ITEM

ACTIVITY

CONTROL DOCS

PROCEDURE REQUIRED

HOLD

COMMENTS

F
I I I I I I I

9.6 9.7 9.8 9.9 9.10 9.117 9.12

Fabricate steel supports Inspect welding work Visual inspection and NDE Inspect shotblast and painting work Install trays, ladders and fabricated supports Inspect installed supports, trays and ladders Inspect mechanical damage and repair painting work on fabricated supports Inspect installed tray and racking

46C1 ASME V ASME V 83A1 Layout drawing Layout drawing 83A1

9.13

10. 10.1 10.2 10.3 10.4

ELECTRICAL EQUIPMENT Obtain permit to work Check existing equipment isolation Check equipment mounting and cable entry arrangement Position and install electrical equipment as detailed in drawings Project Instructions 70D20 70D20 70D20 FWEL3384 FWEL3384 FWEL Permit to Work X X X X H W W W I I I FWEL Safety Advisor involvement

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

CONSTRUCTION OPERATIONS WORK PRACTICE

REPORT FORM/ CHECKLIST NUMBER
FWEL3384 FWEL3377 FWEL3378 FWEL3379 FWEL3382 FWEL3383 FWEL3382

9980-8710-PR-0020 PAGE 12 REV F1

RESPONSIBILITY C
X X

ITEM

ACTIVITY

CONTROL DOCS

PROCEDURE REQUIRED

HOLD

COMMENTS

F
W W I

10.5 10.6

Visual inspection Gland and terminate cables and final megger test Visual cleanliness check of equipment internals prior to closure Complete electrical equipment in safe area inspection report Complete electrical equipment in hazardous area inspection Prepare test reports for all equipment for testing and commissioning work Miscellaneous inspection of panels and cabinets EARTHING Obtain permit to work Check cable routing Install earthing system Inspect earthing system and complete earthing test Earth loop impedance test

70D20 70D20

10.7

70D20

10.8

10.9

FWEL3383

10.10

10.11 11. 11.1 11.2 11.3 11.4 11.5

70D20

FWEL3362

Project Instruction Layout drawing Layout drawings 70D20 70D20

FWEL Permit to Work

X X X R W W H I I I I

FWEL Safety Advisor involvement

FWEL3380 FWEL3396 FWEL3381

X X

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

CONSTRUCTION OPERATIONS WORK PRACTICE

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RESPONSIBILITY C F N

ITEM

ACTIVITY

CONTROL DOCS

PROCEDURE REQUIRED

HOLD

COMMENTS

12. 12.1 12.2 12.3 12.4 12.5

EARTHING AND LIGHTNING PROTECTION Obtain permit to work Check cable route Cable route marking Install earthing and lightning protection system Inspect earthing and lightning protection system and complete earthing test Perform earth loop impedance test 70D20 70D20 70D20 FWEL3402 FWEL3380 FWEL3402 FWEL3381 Project Instructions FWEL Permit to Work X X X X X H I H W W I I FWEL continual inspection FWEL Safety Advisor involvement

12.6 13. 13.1 13.2 13.3 13.4 13.5 13.6

70D20

LIGHTING AND SMALL POWER Obtain work permit Install lighting supports and accessories as required Label cabling in conduit Label interconnecting cable in junction boxes Inspect and test lighting and power outlet circuits Inspect and test lighting illumination values Project instruction 70D20 70D20 70D20 70D20 70D20 FWEL3626 FWEL3402 FWEL3401 FWEL Permit to Work X X X X X X H W W W H H I I I I I

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

CONSTRUCTION OPERATIONS WORK PRACTICE

REPORT FORM/ CHECKLIST NUMBER
FWEL3386 FWEL3387 FWEL3382 FWEL3383

9980-8710-PR-0020 PAGE 14 REV F1

RESPONSIBILITY C
X X X H H H

ITEM

ACTIVITY

CONTROL DOCS

PROCEDURE REQUIRED

HOLD

COMMENTS

F
I I I

13.7 13.8 13.9

Inspect and test electrical distribution board Inspect and test electrical equipment in safe areas Inspect and test electrical equipment in hazardous areas Earth loop impedance test Electric Trace Heating Test

70D20 70D20 70D20

13.10 13.11

70D20 70D20

FWEL3381 FWEL3403

X X

H H

I I

14. 14.1

ELECTRICAL TESTING & COMMISSIONING Inspect general condition of equipment, grounding connection, control cubicle, auxiliary supply and control scheme Inspect levelling and alignment Test and tighten bus bar and connect Individual wiring test Check circuit breaker Circuit breaker mechanical operating test 70D20 X W I

14.2 14.3 14.4 14.5 14.6

70D20 70D20 70D20 70D20 70D20 FWEL3386 FWEL3379

X X X C X

W H W W W

I I I I I

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

CONSTRUCTION OPERATIONS WORK PRACTICE

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RESPONSIBILITY C
X X X X X

ITEM

ACTIVITY

CONTROL DOCS

PROCEDURE REQUIRED

HOLD

COMMENTS

F
W W W W H H I I I I I I

14.7 14.8 14.9 14.10 14.11 14.12

Circuit breaker electrical operating test Circuit breaker interlock test Contact resistance test Function and interlock test Motor control centre test Switchboard and busbar inspection and test Electrical distribution board test UPS system inspection and test Voltage relay test Battery Charge/Discharge Test Battery charger test CT and protection relay test CT and protection relay "mag" test Earth fault relay test Overload/overcurrent Test

70D20 70D20 70D20 70D20 70D20 70D20 FWEL3385 FWEL3386 FWEL3393 FWEL3387 FWEL3388 FWEL3389

14.13 14.14 14.15 14.16 14.17 14.18 14.19 14.20 14.21

70D20 70D20 70D20 70D20 70D20 70D20 70D20 70D20 70D20

X X X X

H H H W H H H H W

I I I I I I I I I

FWEL3390 FWEL3394 FWEL3395 FWEL3396 Manufacturer Inspection Form

X X X X X

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

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REPORT FORM/ CHECKLIST NUMBER
FWEL3398 FWEL3399 FWEL3400/04 FWEL3392 FWEL3634 FWEL3391 FWEL3389

9980-8710-PR-0020 PAGE 16 REV F1

RESPONSIBILITY C
X X X X X X X X H H H H R H H W

ITEM

ACTIVITY

CONTROL DOCS

PROCEDURE REQUIRED

HOLD

COMMENTS

F
I I I I I I I I

14.22 14.23 14.24 14.25 14.26 14.27 14.28 14.29 15. 15.1 15.2 15.3 15.4 15.5 15.6

Contractor starter test Control circuit function test Electric motor test Transformer test Insulating oil test Miscellaneous item tests GTG differential stability and sensitivity test NER Test SYSTEM COMPLETION Request final acceptance Construction and final punchlists Turnover pack and handover to FW for system completion System acceptance Prepare site QC dossier and submit to FW Prepare red-line "as builts" and submit to FW for acceptance

70D20 70D20 70D20 70D20 70D20 70D20 70D20 70D20

X FWEL3291 FWEL3293 FWEL3295 FWEL3294 X X X X X

H H H H H R

R H R H R

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