SECTION 16030 ELECTRICAL TESTS

PART 1. - GENERAL 1.01 DESCRIPTION A. This section specifies the work necessary to test, commission and demonstrate that the electrical work satisfies the criteria of this specification and functions as required by the Contract Documents. B. The work of this Section includes furnishing the labor, equipment, and power required to support the testing of equipment specified in other sections of the specification. Electrical testing specified in Division 16 functional testing of all power and controls shall be completed before commencement of start-up. This scope of work may require the Contractor to activate circuits, shutdown circuits, and run equipment, make electrical measurements, replace blown fuses, install temporary jumpers, etc. C. Contractor is responsible for all work, equipment damage, power interruptions and schedule delays caused by the testing agency. 1.02 SUBMITTALS A. Results of all testing shall be submitted prior to final project acceptance, per Specification 01300. Three copies are required to be included as part of final Operations and Maintenance Manuals. Submittal shall describe test conditions, weather including temperature and humidity, test date, plant flows, duration of test, test equipment, tested equipment, testing technician, as found and as-left results, expected results, actual results, pass/fail status Report based on listed testing standards and NETA (latest edition) and a registered Professional Engineers stamp and signature; registered in Electrical Engineering in the State of California. A Professional Engineer, providing Pass or Fail equipment and system status, as well as recommendation to allow energizing equipment, shall author Report. B. Specific data relative to insulation resistance, voltage levels, load currents, relay settings, dial settings, etc., shall be provided for all equipment and material required to be tested. C. Test result shall be submitted in one submittal D. Test reports shall be based on NETAs latest Acceptance Testing Specifications having a sign-off, pass/fail data filed for each line item covered by NETAs Acceptance Testing Specifications latest edition.

City of Ceres Well No. 19R

16030-1

Electrical Tests July 2009

1.03

OPERATION AND MAINTENANCE MANUALS A. Include the Electrical Test Result Study and Engineers Report within the Operation and Maintenance Manuals.

1.04

TESTING ORGANIZATION QUALIFICATIONS A. Testing organization shall be corporately and financially independent of the supplier, producer and installer of the equipment, who has been regularly engaged in the testing of equipment for a period of at least 10 years. All testing shall be conducted under the direct supervision of an electrical Engineer, registered in the State of California. This registered electrical Engineer will prepare and sign test Reports with values, recommendations, and comments. B. Testing equipment required to conduct the specified tests shall be furnished by the testing organization. Testing equipment shall be in good working condition and comply with the requirements of this Specification and applicable industry standards. C. Testing shall be done in accordance with the manufacturer's instructions, these Specifications, and applicable NETA Acceptance Testing Specifications, NEMA, ANSI, NFPA, and ASTM Standards. All testing shall be done in the presence of the Engineer, and forms shall include space for Engineer sign off at time of test. Testing organization shall meet Federal OSHA criteria for accreditation of testing laboratories, Title 29, Part 1907, 1910 and 1936. Membership in the National Electrical Testing Association constitutes proof of meeting such criteria. D. The testing organization shall cooperate with any manufacturer's representative that may be retained by the Contractor. Testing organization shall be Cutler-Hammer; Electro-test; Power Systems; General Electric; or equal.

1.05

APPLICABLE CODES, STANDARDS AND REFERENCES A. All inspections and tests shall be in accordance with the following codes and latest standards as provided otherwise herein: 1. National Electrical Manufacturer's Association - NEMA 2. American Society for Testing and Materials - ASTM 3. Institute of Electrical and Electronic Engineers - IEEE 4. InterNational Electrical Testing Association - NETA Acceptance Testing Specifications 5. American National Standards Institute - ANSI C2: National Electrical Safety Code 6. State and local codes and ordinances 7. Insulated Cable Engineers Association - ICEA

City of Ceres Well No. 19R

16030-2

Electrical Tests July 2009

8. Association of Edison Illuminating Companies - AEIC 9. Occupational Safety and Health Administration - OSHA 10. National Fire Protection Association - NFPA B. Inspections and tests shall utilize the following references: 1. Project Specifications 2. Project Drawings 3. Manufacturer's instruction manuals applicable to each particular apparatus 1.06 SAFETY AND PRECAUTIONS A. Safety practices shall include, but are not limited to, the following requirements: 1. Occupational Safety and Health Act Accident Prevention Manual for Industrial Operations, National Safety Council 2. Applicable state and local safety operating procedures 3. Owner's safety practices 4. National Fire Protection Association - NFPA 70E 5. American National Standards for Personnel Protection B. All tests shall be performed with apparatus de-energized. Exceptions must be thoroughly reviewed to identify safety hazards and devise adequate safeguards. C. The testing firm shall have a designated safety representative on the project to supervise the testing operations with respect to safety.

1.07

SCHEDULING A. Perform Electrical Tests after electrical installation is 100% completed.

1.08

LIST OF ITEMS TO BE TESTED A. Switchboard/Motor Control Center B. RTU Panel C. Panelboard D. Cables E. System Ground F. Miscellaneous Testing

City of Ceres Well No. 19R

16030-3

Electrical Tests July 2009

PART 2. - MATERIALS NOT USED

PART 3. - EXECUTION 3.01 TESTING A. The following test requirements are intended to supplement test and acceptance criteria that may be stated elsewhere. B. Switchboard: Clean equipment prior to testing. Verify lubrication on moving and sliding surfaces. 1. Inspect all devices installed such as breakers, fuses, insulators, barriers, doors, panels, hardware, etc. for physical damage, sizing, and compare equipment nameplate information with latest one line diagram and report discrepancies. Inspect and verify anchorage, area clearance and correct alignment. Verify current and potential transformer ratios, and inspect installation. 2. Test insulation on each bus, phase-to-phase and phase-to-ground with a suitable megohmmeter. 3. Test insulation of all control and relay field wiring circuits to ground with a suitable megohmmeter. 4. Functional test of all devices, such as circuit breakers, space heaters, relays, switches and alarm points. Confirm correct operation and sequencing of electrical and mechanical interlock system. 5. Check for proper grounding connections at both ends of assembly. Check for external, visible ground lug connections. Check ground bus continuity. Perform ground resistance tests. 6. Perform current injection tests on entire current circuit in each section of switchboard. 7. Check for proper torquing of all bolted connections. 8. Calibrate and test all circuit breakers and relays in the switchboard. Test circuit breakers according to Miscellaneous Testing, this specification. Determine accuracy of all meters and calibrate as required. C. Motor Control Center 1. Clean equipment prior to testing. 2. Inspect for nameplate compliance, physical damage, and proper operation of alarm and control devices. Inspect and verify anchorage, area clearance, and proper connections. Verify correct mounting of circuit breakers. 3. Functional test of all devices, such as contactors, relays, switches, solid state

City of Ceres Well No. 19R

16030-4

Electrical Tests July 2009

overloads, protective relays, breakers, indicating lights and meters. adjustments for final settings in accordance with coordination study.

Perform

4. Test insulation of the bus phase-to-phase and phase-to-ground for power buses and phase-to-ground for all control circuits with a suitable megohmmeter. 5. Test operation of each switch or breaker in each starter assembly. Test door interlocking. Test Circuit Breakers according to Miscellaneous Testing, this specification. 6. Energize space heaters and check operation. 7. Check for proper torquing of all bolted connections. 8. Verify grounding of lugs, conduit hubs and MCC. 9. Contractor shall tabulate the following data for all three-phase motors. Tabulation shall be submitted to the Engineer at least two weeks prior to performing the testing specified in this section. Tabulation to include: a. Motor identification including tag number. b. Motor nameplate full load amps, horsepower, voltages and phase. c. Recommended Motor Circuit Protector (MCP) setting. 10. The work of this section requires that the Contractor record the following data to the tabulation specified in paragraph above. a. Measurable amperes when motor is drawing normal process load. b. Changes required to MCP setting. c. Date of test. d. Remarks (i.e. difficulty in motor attaining full speed, abnormal process conditions, and abnormal line voltage). D. Remote Terminal Unit (RTU) Panel 1. Clean equipment prior to testing. 2. Inspect for physical damage, grounding, proper connections, and anchorage. 3. Owner shall witness energizing. 4. Functional Loop Testing 1) General: The Contractor shall provide the services of factory-trained and experienced field personnel to perform verification and functional loop testing as described below. The purpose of functional loop testing is to (1) verify field cabling and wiring; (2) to verify circuits are performing their intended function by testing individual instrument loops; and (3) to verify radio telemetry communication. These functional loops consist of the following types; analog, discrete, and control and logic system. The Contractor shall notify the

City of Ceres Well No. 19R

16030-5

Electrical Tests July 2009

Engineer in writing a minimum of two (2) weeks prior to the proposed date for commencing functional loop testing. The Resident Engineer and City O&M personnel will witness all functional loop testing. Each functional loop must be complete before testing. Partial loops will not be tested. 2) One month prior to testing the Contractor shall submit a functional loop test plan. The plan shall include the list loops to be tested and the type of test for each loop listed. A loop may have multiple type tests. List all tests individually. 3) Analog Functional Loop Testing: Verify that each analog loop is operating by simulating the primary elements output at the instrument using a loop calibrator. Simulate signals at 0%, 25%, 50%, 75%, and 100% of span. Record the readings of the loop receiver device(s) (i.e. recorder, indicator, alarm, PLC point, etc.) on an analog loop test form. For analog output loops the PLC will be used to force output signals to verify proper function of final control elements. The test documentation for each analog loop shall consist of (1) analog test form, (2) Contractor submitted loop drawing, (3) individual instrument calibration sheets. 4) Discrete Loop Testing: Verify that each discrete instrument loop is operating by simulating discrete outputs from the primary element of each loop to mimic device operational function. Verify correct operation of loop receiver instruments or indicators. The test documentation for each discreet loop shall consist of (1) discrete loop test form, (2) Contractors submitted loop drawing, (3) individual instrument calibration sheets. 5) Control & Logic Testing: Verify that each control and logic system is operating correctly by verifying the operation of each device within that system. An example would be a pump control circuit as shown on a Contract control wiring diagram. The system being tested must be operational, e.g. a pump must be ready to run and pump water. Verification of each component in the system will be documented by circling the component on the Contractors submitted control and wiring diagram. The test documentation for each control and logic system test shall consist of (1) control and logic system test form, (2) Contractors submitted control wiring diagram, (3) Contract control wiring diagram, (4) individual instrument calibration sheets. 6) All defects and malfunctions disclosed by tests must be corrected and loop retested before final sign-off. 7) Documentation completed during testing will include: a) c) Instrument Field Calibration Sheets Discrete Loop Test Form b) Analog Loop Test Form d) Control and Logic System Test Form

City of Ceres Well No. 19R

16030-6

Electrical Tests July 2009

8) The Contractor is to bid two days of field service time to accomplish the functional loop testing as defined by this Section. E. Panelboard 1. Clean equipment prior to testing. 2. Inspect for physical damage, grounding, proper connections, and anchorage. 3. Test insulation of the bus phase to phase and phase to ground. Record data. 4. Test operation of each circuit breaker. 5. Verify nameplate data, panelboard schedule information. 6. Check for proper torquing of all bolted connections. 7. Verify proper grounding of lugs, conduit hubs, and panelboard. F. Cables 1. Refer to Section 16120 - Wires and Cables, for the testing requirements. 2. Perform a shield continuity test by ohmmeter method for instrumentation cables. Ohmic value shall be recorded. 3. Check for proper termination of cables. G. System Ground 1. Verify each ground system, is installed in compliance with Drawings and Specifications. 2. Provide ground-resistance tests with a ground-resistance megger at each facility, transformer and motor control center. Use appropriate method (fall of potential, three-terminal method) to measure ohmic value of ground system to earth (maximum 5 ohms). Verify all equipment ground terminations with respect to prime point used to establish ohmic value stated above. H. Miscellaneous Testing 1. Insulation Resistance, Continuity, Rotation: Perform routine insulation resistance, continuity and rotation tests for all distribution and utilization equipment including all motors horsepower and larger. All testing shall be performed in the presence of the Engineer. The testing laboratory shall be responsible for implementing all final settings and adjustments on protective devices and tap changes. Any system material or workmanship, which is found defective on the basis of acceptance tests, shall be reported directly to the Engineer. The testing laboratory shall maintain a written record of all tests and upon completion of the project, assemble and certify a final test report. 2. Demonstrate that light fixture outlets are switched as indicated on the Contract Drawings. Test photocell and lighting timer switch. Demonstrate that circuitry is in accordance with panel schedules. Test Ground Fault Interrupter (GFI)

City of Ceres Well No. 19R

16030-7

Electrical Tests July 2009

receptacles. 3. Perform overall system function tests upon completion of equipment tests. Verify correct operation of all interlock devices, alarms, sensing devices and indicating devices. Demonstrate the proper functioning of circuits in all modes of operation, including alarm conditions and demonstrate satisfactory interfacing with the data acquisition and alarms system. 3.02 TESTING SEQUENCE A. Setting the breakers and PFR relays is required prior to functional testing and checking of the electrical components specified in this section. B. After initial settings have been completed, each system shall be operated in the manual mode and it shall be demonstrated that operation is in compliance with the Contract. Once the manual mode of operation has been proven, automatic operation shall be demonstrated to verify such items as proper start and stop sequence of pumps, etc. 3.03 WITNESS REQUIREMENTS A. All testing shall be witnessed and signed-off by the Owner and Engineer. Each test sheet must be signed-off prior to submittal. **END OF SECTION**

City of Ceres Well No. 19R

16030-8

Electrical Tests July 2009