Rio Tinto Iron Ore

Standard Specification – Electrical

Testing and Commissioning of Electrical

Installations

SS-E115

Additional Guidance Check sheets

10 Vuk Bursac Jamie Cullen 22/08/2018
added and cable testing requirements
Updated Appendix A: Underground
9 Stuart Nell Kevin Chong Kenny Kramara 25/11/16
Service Installation Checklist
Daniel Abetz Rupesh
8 General Updates Kenny Kramara 29/03/16
Nijhawan
Updated and added Appendix A.42
7 Vuk Bursac Jamie Cullen 15/09/15
and A.43
Rev Description Originator Reviewed Approved Date
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Document Attributes
This Standard specification, complies with the requirements of Document Management Standards and
Guidelines.

Custodian Principal Engineer - Electrical

Reviewer: Specialist Engineer - Electrical

Audience: All sites

Document Type: Specification

Engineering Standard Requirements

Standards are published to the Rio Tinto Iron Ore “IOWA Standards” sharepoint page, and must be accessed
only from there.

Standards must not be copied and filed on personal computer drives.

Standards are controlled documents and as such are not to be changed or modified without being subjected
to a thorough review and approval process.

If you identify this Standard requires revision contact the Custodian.

Contact Details

For all enquiries regarding this Standard, please contact [email protected]

RTIO-AM-0031949 Page 2 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Contents
Section 1 - Scope.............................................................................................................................................. 7

Section 2 - General Requirements .................................................................................................................. 8

Section 3 - Applicable Documents ................................................................................................................. 9

3.1 Iron Ore Engineering Standards ............................................................................................................... 9

3.2 Australian Standards ................................................................................................................................ 9

3.3 Other Documents ..................................................................................................................................... 9

3.4 Rio Tinto Safety Requirements .............................................................................................................. 10

Section 4 - Acronyms and Terms ................................................................................................................. 11

4.1 Acronyms ................................................................................................................................................ 11

4.2 Terms ..................................................................................................................................................... 11

Section 5 - Testing.......................................................................................................................................... 12

Section 6 - Commissioning Stages .............................................................................................................. 13

Section 7 - Construction Verification ........................................................................................................... 14

Section 8 - Documentation ............................................................................................................................ 15

Section 9 - Energisation ................................................................................................................................ 16

9.1 Notice of Energisation (NOE) ................................................................................................................. 16

9.2 Energisation ............................................................................................................................................ 16

Section 10 - Inspections ................................................................................................................................ 17

10.1 General ................................................................................................................................................... 17

10.2 Luminaires .............................................................................................................................................. 17

10.3 Wiring Systems....................................................................................................................................... 18

10.4 Earthing .................................................................................................................................................. 18

10.5 Electrical Enclosures .............................................................................................................................. 19

10.6 Switchgear .............................................................................................................................................. 20

10.7 Motors ..................................................................................................................................................... 21

10.8 Transformers .......................................................................................................................................... 21

10.9 Overhead Lines ...................................................................................................................................... 22

Section 11 - Pre-Operational Testing ........................................................................................................... 23

11.1 Vendor Equipment .................................................................................................................................. 23

11.2 AS/NZS 3000 Requirements .................................................................................................................. 23

11.3 Fire Protection ........................................................................................................................................ 24

11.4 Earth Systems ........................................................................................................................................ 24

11.4.1 Earth Resistance .......................................................................................................................... 24

RTIO-AM-0031949 Page 3 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.4.2 Step and Touch Potential ............................................................................................................. 25

11.4.3 Earth Continuity ............................................................................................................................ 25

11.4.4 Functional Separation .................................................................................................................. 25

11.5 High Voltage Cables ............................................................................................................................... 26

11.5.1 Insulation Resistance Testing ...................................................................................................... 26

11.5.2 High Voltage Withstand Testing (VLF Testing) ............................................................................ 27

11.5.3 Phasing and Cable Continuity ...................................................................................................... 28

11.5.4 Ductor Test ................................................................................................................................... 28

11.5.5 Offline and online partial discharge tests ..................................................................................... 28

11.5.6 Tan Delta tests ............................................................................................................................. 29

11.6 Reeling and Trailing Cables ................................................................................................................... 29

11.7 Low Voltage Cables................................................................................................................................ 31

11.7.1 Phasing and Cable Continuity ...................................................................................................... 31

11.7.2 Ductor Test ................................................................................................................................... 31

11.8 Instrument and Communications Cables ............................................................................................... 32

11.9 Fibre Optic Cables .................................................................................................................................. 32

11.10 Socket and Welding Outlets ................................................................................................................... 32

11.11 High Voltage Switchgear ........................................................................................................................ 33

11.11.1 Ductor Test ................................................................................................................................ 33

11.11.2 Insulation Resistance ................................................................................................................. 33

11.11.3 AC Withstand Test ..................................................................................................................... 33

11.12 Protection Relays ................................................................................................................................... 34

11.12.1 Secondary Injection Testing ...................................................................................................... 34

11.12.2 Input and Output testing ............................................................................................................ 34

11.12.3 Switchgear Function Trip Testing .............................................................................................. 34

11.12.4 SCADA system integration ........................................................................................................ 35

11.13 Communication and SCADA Equipment ................................................................................................ 35

11.14 LV Switchgear, Switchboards and Load Centres ................................................................................... 35

11.14.1 Phasing and continuity ............................................................................................................... 35

11.14.2 Ductor Test ................................................................................................................................ 35

11.14.3 Insulation Resistance ................................................................................................................. 36

11.15 Current and Voltage Transformers ......................................................................................................... 36

11.16 Motors ..................................................................................................................................................... 36

11.17 Transformers .......................................................................................................................................... 37

11.17.1 Insulation Resistance Test ......................................................................................................... 37

RTIO-AM-0031949 Page 4 of 91 Approved: 22/08/18
Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.17.2 Winding Ratio Test..................................................................................................................... 37

11.17.3 DC Winding Resistance Test ..................................................................................................... 38

11.17.4 Transformer Guards Testing ...................................................................................................... 38

11.17.5 Cooling System Checks ............................................................................................................. 38

11.17.6 Transformer Oil Testing ............................................................................................................. 38

11.18 Overhead Lines ...................................................................................................................................... 39

11.19 Batteries ................................................................................................................................................. 39

11.20 Valves ..................................................................................................................................................... 39

11.21 Other Instrumentation ............................................................................................................................. 40

11.22 Pre-Energisation Insulation and Continuity Test .................................................................................... 40

Section 12 - Test Equipment ......................................................................................................................... 41

Appendix A - Pre-Operational Inspection and Test Forms ................................................................. 42

A.1 Test Sheet – AC Induction Motors, Sheet 1 of 2 .................................................................................... 43

A.2 Test Sheet – AC Induction Motors, Sheet 2 of 2 .................................................................................... 44

A.3 Test Sheet – Battery Charger and Batteries, Sheet 1 of 3 ..................................................................... 45

A.4 Test Sheet – Battery Charger and Batteries, Sheet 2 of 3 ..................................................................... 46

A.5 Test Sheet – Battery Charger and Batteries, Sheet 3 of 3 ..................................................................... 47

A.6 Test Sheet – Buried Cable / Conduit ...................................................................................................... 48

A.7 Test Sheet – Current Transformers, Sheet 1 of 2 .................................................................................. 49

A.8 Test Sheet – Current Transformers, Sheet 2 of 2 .................................................................................. 50

A.9 Test Sheet – Earthing Tests, Sheet 1 of 2 ............................................................................................. 51

A.10 Test Sheet – Earthing Tests, Sheet 2 of 2 ............................................................................................. 52

A.11 Test Sheets – Generator Sets ................................................................................................................ 53

A.12 Test Sheet – HV Cable, Sheet 1 of 3 ..................................................................................................... 54

A.13 Test Sheet – HV Cable, Sheet 2 of 3 ..................................................................................................... 55

A.14 Test Sheet – HV Cable, Sheet 3 of 3 ..................................................................................................... 56

A.15 Test Sheet-LV Cable, Sheet 1 of 3........................................................................................................ 57

A.16 Test Sheet- LV Cable, Sheet 2 of 3........................................................................................................ 58

A.17 Test Sheet- LV Cable, Sheet 3 of 3........................................................................................................ 59

A.18 Test Sheet –Instrumentation Cable, Sheet 1 of ..................................................................................... 60

A.19 Test Sheet –Instrumentation Cable, Sheet 2 of 3 .................................................................................. 61

A.20 Test Sheet –Instrumentation Cable, Sheet 3 of 3 .................................................................................. 62

A.21 Underground Service Installation Checklist, Sheet 1 of 1 ...................................................................... 63

A.22 Test Sheet – Insulation Oil ..................................................................................................................... 64

A.23 Test Sheet – HV Switchgear, Sheet 1 of 3 ............................................................................................. 65

RTIO-AM-0031949 Page 5 of 91 Approved: 22/08/18
Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.24 Test Sheet – HV Switchgear, Sheet 2 of 3 ............................................................................................. 66

A.25 Test Sheet – HV Switchgear, Sheet 3 of 3 ............................................................................................. 67

A.26 Test Sheet – LV Switchgear, Sheet 1 of 3 ............................................................................................. 68

A.27 Test Sheet – LV Switchgear, Sheet 2 of 3 ............................................................................................. 69

A.28 Test Sheet- LV Switchgear, Sheet 3 of 3 ............................................................................................... 70

A.29 Test Sheet – Instrumentation ................................................................................................................. 71

A.30 Test Sheet – On-Drum Cable Tests, Sheet 1 of 2 ................................................................................. 72

A.31 Test Sheet – On-Drum Cable Tests, Sheet 2 of 2 ................................................................................. 73

A.32 Test Sheet – Power Transformer, Sheet 1 of 4 ...................................................................................... 74

A.33 Test Sheet – Power Transformer, Sheet 2 of 4 ...................................................................................... 75

A.34 Test Sheet- Power Transformer, Sheet 3 of 4 ....................................................................................... 76

A.35 Test Sheet- Power Transformer, Sheet 4 of 4 ....................................................................................... 77

A.36 Test Sheet –Transformer Commissioning Requirements, Sheet 1 of 3................................................. 78

A.37 Test Sheet – Transformer Commissioning Requirements, Sheet 2 of 3................................................ 79

A.38 Test Sheet – Transformer Commissioning Requirements, Sheet 3 of 3................................................ 80

A.39 Test Sheet – Voltage Transformer, Sheet 1 of 2 .................................................................................... 81

A.40 Test Sheet - Air Break Switch ................................................................................................................ 82

A.41 Test Sheet- Relay Testing ITP Template ............................................................................................... 84

A.42 Test Sheet: Electrical Installation, Sheet 1 of 2 ...................................................................................... 85

A.43 Test Sheet: Electrical Installation, Sheet 2 of 2 ...................................................................................... 86

A.44 LV Circuit Voltage Test Sheet ................................................................................................................ 87

A.45 Pre-Energisation Insulation & Continuity Test ........................................................................................ 89

Appendix B - Document Revision Control Table ........................................................................................ 91

RTIO-AM-0031949 Page 6 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Section 1 - Scope
This specification applies to Rio Tinto Iron Ore Operations in the Iron Ore (WA), including Iron Ore (WA),
Hamersley Iron, Robe River Mining and Hamersley HMS.

This specification details the technical requirements for the testing and commissioning of electrical installations.

This specification describes the minimum on-site pre-operational inspection and testing procedures which shall
be followed to determine that the electrical facilities have been correctly installed, that any defects in the
installation, associated equipment or materials have been corrected and that the electrical facilities are ready
and can be safely energised ready for pre-commissioning.

Prior to testing and commissioning, the Contractor shall compile and submit an inspection and test plan to be
approved by the RTIO representative. The ITP shall list each individual asset that is to be tested and each test
or test sheet that is applicable for each asset.

This specification does not cover testing of equipment at the manufacturer’s works.

RTIO-AM-0031949 Page 7 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Section 2 - General Requirements

There are no general pre-requisite requirements for compliance to this standard specification.

RTIO-AM-0031949 Page 8 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Section 3 - Applicable Documents

Documents applicable to this specification are listed below.

3.1 Iron Ore Engineering Standards

Standard No. Title

SS-E109 Overhead Powerlines up to 33kV

SS-E112 Battery Banks, Chargers and UPS

SS-E123 Preferred Equipment List

SS-E169 Energisation

SS-E273 Earthing Management Standard

SS-T013 Optical Fibre Cable Testing and Commissioning

3.2 Australian Standards

Standard No. Title

Electric cables - Polymeric insulated - For working voltages 1.9/3.3 (3.6) kV
AS 1429.1. up to and including 19/33 (36) kV
AS 1767 Insulating Liquids

AS 2067 Substations and High Voltage Installations Exceeding 1 kV AC

Guide to the Installation, Maintenance, Testing and Replacement of

AS 2676.2
Secondary Batteries in Buildings – Sealed Cells

AS 3007 Electrical Installations–Surface Mines and Associated Processing Plant

AS 3017 Electrical Installations – Verification Guidelines

Reeling, Trailing and Feeder Cables used for Mining – Repair, Testing and
AS NZS 1747
Fitting of Accessories

AS NZS 2293.2 Emergency Escape Lighting and Exit Signs for Buildings

AS NZS 3000 Electrical Installations (known as The Australian/New Zealand Wiring Rules)

AS/ NZS 7000 Overhead line design - Detailed procedures

AS NZS ISO Quality Management Systems – Requirements

9001

3.3 Other Documents

Document
Title
No.

Guide for Field Testing of Shielded Power Cable Systems

IEEE 400.2
Using Very Low Frequency (VLF)

ENA EG1:2006 Substation earthing guide

- Electricity (Licensing) Regulations 1991.

- Mines Safety and Inspection Regulations 1995

- WA Electrical Requirements 2014 (WAER)

ANSI/NETA MTS – 2011 Maintenance Testing Specification for Electrical Equipment

RTIO-AM-0031949 Page 9 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

3.4 Rio Tinto Safety Requirements

Document
Title
No.

HSEC-B-14 C2 – Electrical Safety

Guidance Note C2 Electrical Safety

RTIO-AM-0031949 Page 10 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Section 4 - Acronyms and Terms

4.1 Acronyms

The following acronyms have been used in this document:

Acronym Definition

AC Alternating current

DC Direct current

E Earth

EWP Elevated work platform

FIP Fire indicator panel

HV High voltage

I/O Input / Output

ITP Inspection and test plan

LV Low voltage

PLC Programmable logic controller

NOE Notice of Energisation

PVC Polyvinyl chloride

RCD Residual current device

SWP Safe working procedure

VLF Very low frequency

4.2 Terms

The following terms have been used in this document:

Term Definition

shall Indicates a mandatory requirement.

Indicates a highly desirable, non-mandatory requirement. Deviations from

should
these requirements shall be justified to the RT Company Representative.

RTIO-AM-0031949 Page 11 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Section 5 - Testing
All equipment shall be tested in accordance with Australian Standards as appropriate, but specifically

AS/NZS 3000 and AS/NZS 3017.

All pre-operational inspection and testing as defined in the codes of practice shall be adopted as appropriate.
In particular the provisions of the following codes shall apply:

 AS/NZS 7000

 ENA EG1:2006 Substation earthing guide.

On completion of testing, the equipment shall be left in a safe condition with all circuit breakers and switches
turned off.

RTIO-AM-0031949 Page 12 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Section 6 - Commissioning Stages

There are typically five stages of commissioning within a project:

 Stage 1: Construction Verification

 Stage 2: Pre-commissioning

 Stage 3a: Process Control System Verification

 Stage 3: No-load commissioning

 Stage 4: Load Commissioning

 Stage 5: Performance Verification.

RTIO-AM-0031949 Page 13 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Section 7 - Construction Verification

Construction verification encompasses:

 visual inspection

 pre-operational testing

Construction verification is required to prove and certify that:

 all installation work has been carried out in accordance with the drawings, specifications and statutory
requirements

 the installation can be safely energised

 the installation is ready for handover to the pre-commissioning team

Construction verification shall include, but not be limited to, inspections and tests involving visual inspection,
continuity, insulation resistance, polarity and ductor testing of all electrical and communications equipment.

RTIO-AM-0031949 Page 14 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Section 8 - Documentation
All inspection and test results shall be accurately recorded and where applicable checked against the drawings
and other data. The completed test data record sheets shall be signed by the person(s) carrying out the tests
and countersigned by the person(s) witnessing the tests.

All testing undertaken shall be recorded on the standard test sheets (refer to Appendix A).

At the completion of pre-operational testing, all documentation shall be submitted in the form of a dossier,
which shall include as a minimum:

 geographical and process summary of the area(s) pre-operationally tested, including description of
relevant battery limits

 list of all electrical equipment and cables tested

 details of correctional works performed on any electrical equipment

 outstanding punch list items, as previously agreed with the company

 all test sheets

 red line mark ups of all electrical drawings

 red line mark ups of piping and instrumentation diagrams

 Notice of Completion for the Works completed in accordance with Regulation 52 of the Electricity
(Licensing) Regulations 1991.

The electrical log book shall be updated as required by the Mines Safety and Inspection Regulations 1995.

All test results, particularly of HV equipment, shall be returned to the designer such that they can validate the
installation meets the original design intentions and requirements.

RTIO-AM-0031949 Page 15 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Section 9 - Energisation
9.1 Notice of Energisation (NOE)

At the completion of construction activities (including construction verification and documentation)

a Notice of Energisation shall be prepared and approved by the appropriate authorities. The
Notice of Energisation certifies that construction works and pre-operational testing on the
equipment or system has been completed. Its main purpose is to inform all people affected by
the Energisation that the Energisation will happen.

NOEs shall be distributed to all affected parties at least 24 Hours before the planned
Energisation. The distribution of a NOE is a gate to Energisation – i.e. if a NOE has not been
issued 24 Hours prior to Energisation, then the Energisation will not proceed.

9.2 Energisation

Preparation and conduct of Energisation shall be conducted in accordance with SS-E169

Energisation. SS-E169 contains process guidance, inspection regime, templates and examples
on what is required to be completed in order to energise a piece of equipment / system.

RTIO-AM-0031949 Page 16 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Section 10 - Inspections
10.1 General

General inspections shall consist of checking that equipment is correctly mounted and that it
operates mechanically (e.g. push buttons, pull wire switches etc.). This should include (but not
be limited to) the following:

 check that cable ladders, conduit and brackets do not impede maintenance access (e.g. slide
out idler frames, doors, removable platforms, guards, hatches and pulling eye attachments)

 check that insulating washers are installed wherever dissimilar metals would otherwise be in
contact (e.g. stainless steel panels and galvanised steel brackets)

 check that all panels, instruments, and devices are accessible without use of a ladder or
scaffold

 check that pull wires are correctly routed and tensioned

 check the mechanical operation of all emergency stop systems, i.e. push buttons, pull wire
switches etc. and

 Check that drives are visible from, and wherever possible adjacent to, the corresponding
local control station

10.2 Luminaires

Luminaires should be checked for the following:

 have been correctly mounted

 are orientated away from beaches

 are fitted with back shields to reduce light spill (where applicable)

 are free from rust

 are complete with all fasteners

 are fitted with the correct type and size of lamp or tub

 are accessible without the use of a step-ladder, scaffold, or elevated work platform (EWP)

 Where fitted on a hinged light pole, that the pole lowers to a suitable position for
maintenance

RTIO-AM-0031949 Page 17 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

10.3 Wiring Systems

The following checks shall be carried out on wiring systems:

 Ensure that all wiring has been correctly installed and terminated in accordance with the
specified method

 Check that each conductor has been identified with the correct ferrule, and is firmly secured
to the terminal

 Check that all cables have been fitted with identification tags and that tags are secure and
bear the correct identification reference

 Check that all cables have sufficient bending radii

 Inspect all pipes, conduits, trays, racks, brackets and fixings to ensure that they have been
correctly fixed, located and are the appropriate size for the duty. Check that all burrs and
sharp edges have been removed

 Check that metal coatings have not been compromised and have had an appropriate repair
system applied

 Ensure that all covers, lids and plates have been fitted and that all screws are in place and
tight

 Check that cable tie off cuts have been collected and disposed of, particularly ensuring that
they have not been left in sumps

10.4 Earthing

The following checks shall be carried out on earthing systems:

 Perform a thorough visual check of all earth electrodes and the associated cabling, with
particular attention being paid to ensure that clamps, joints and points of termination have
been correctly installed and that each system is electrically and mechanically continuous

 Make certain that all earth conductors have been correctly terminated at the earth terminals
or blocks and that all earth conductors within the equipment enclosures are green/yellow
PVC insulated conductors in accordance with AS/NZS 3000

 For live metal which is uninsulated check clearances to earth and between phases for
compliance with AS/NZS 3000, AS 2067 and AS 3007

 Check that all equipotential bonding conductors are installed

 Check for proper earthing of enclosures and earth, screen and drain wires in cables.
Instrument screen wires shall be earthed at the marshalling panel in the switchroom only, as
shown on the drawings

 Ensure all outdoor earth bars are tinned copper or have adequate corrosion protection
installed

RTIO-AM-0031949 Page 18 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

10.5 Electrical Enclosures

In all distribution boards, marshalling cabinets, control panels (e.g. metal detectors, weight
meters, etc.), relay panels and junction boxes, visual checks shall be undertaken as follows:

 Check that all items of electrical equipment and their mechanical supports have been
securely mounted, are plumb and that no damage or rusting of metal parts is evident

 Check that all hinges and operators are free and have been greased

 Ensure that enclosures are equipped with drain and a breather fitting if specified and inspect
all boxes for any moisture collection

 Check that gland plates are properly fitted and sealed

 Check for proper sealing of conduit connections, cable glands, etc.

 Check that all warning and identification labels are fitted

 Check that all fuse bases, circuit breakers, contactor blocks, overloads, relays, bases
switches, terminals and other detachable items are secure within their enclosures and that
all moving parts are free to operate

 Check that all relay coils are suitable for the designed operating voltage and that the relays
are fitted with the required number of and correct size and type of contacts, the contacts are
free of oxidisation and the armature is free to operate

 Check that all switches are correctly rated for duty, are free to operate and that no oxidisation
is present on the contacts or blades

 Check that all fuse links are sound, properly fitted into their carriers and are correctly rated
for their duty

 Check all switches, push-buttons for completeness of movement, installation, adjustment,

rating and labelling

 Check that all control devices and protective equipment are free from damage, have been
properly set up and if applicable that their operators are free and have been greased

 Check all terminals connections are tight and correct

 Check for correct identification of wires, terminals, terminal boxes, instruments, control
switches and electrical relays, in accordance with the drawings

 Check that all spare conductors are identified and terminated

 Check cable polarities, cable sizes and cable types against the drawings

 Check polarity of all static devices such as diodes

 Check that all circuit reference charts, identification labels and escutcheon plates have been
correctly completed or engraved, that the descriptions are correct and are fitted as specified.
Circuit schedules shall be clean, typed, and contain no handwritten modifications

 Check shrouds are fitted and enclosure is free of dust and debris

 Attached spreadsheet checklist that can be used as an in depth guide capturing references
specific to IOWA Standard Specification Requirements for Rotor Resistor Cubicles.

Rotor Resistor
Cubicle Checklist.xlsx

RTIO-AM-0031949 Page 19 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

10.6 Switchgear

All high voltage and low voltage switchgear shall undergo the following visual checks (in addition
to those required for electrical panels):

 Check switchboards and panels are square and plumb

 Check clearance, tightness of bolts and operation of all moving parts and remove any
wedges, ties and blocks and the like installed by manufacturer

 Main panel labels shall be checked against installed cables to confirm each drive is
connected to the correct starter

 Check withdrawable equipment for correct alignment and ease of withdrawal and insertion.
Check isolating contacts of withdrawable equipment for correct mating

 Where applicable, check the line-up and ease of operation of each circuit breaker carriage
for horizontal insertion and withdrawal, and vertical raising and lowering in each of the
‘operation’, ‘test’ and ‘earthing’ positions, ensuring proper main and auxiliary contact
alignment and shutter operation. Manual closing and tripping of circuit breakers shall also be
checked

 Where applicable, the switching chamber level or pressure of a circuit breaker shall be filled
or topped up as required using the appropriate medium as recommended by the
manufacturer

 Check alignment and operation of main isolating switches and correct adjustment where
necessary

 Check labels are fixed near each relay and meter.

 Check phase indicators installed as required to allow for visual check for zero energy
verification

 All relays shall be checked for:

a) loose terminals; holding and locking screws are in place

b) damage to coil, resistors, wiring, indicator targets and holding devices

c) foreign material in magnet gaps

d) any cause for sluggish action

 See attached spreadsheet checklist that can be used as an in depth guide capturing
references specific to IOWA Standard Specification Requirements for LV MCCs and
Switchboards.

LV MCC and
Switchboard Checklist.xlsx

RTIO-AM-0031949 Page 20 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

10.7 Motors

The following checks shall be carried out on motors:

 Check name plate data against motor data sheets and drawings

 Check that all transport packing has been removed

 Check that bearings have been greased

 Where it is a requirement for motors to be fitted with an auto lube system, check that it is
correctly installed and functioning

 Check that the rotor shaft is free to rotate by hand

 On totally enclosed machines the condition of drain plugs shall be inspected. Drain plugs
shall be replaced if found leaky

 Ensure that the motor connections are firmly attached to motor terminals and star or delta
connections are correctly made

 For unidirectional motors, check the direction of rotation corresponds with that of the gearbox

 For wound rotor motors, check the slip ring housing is clean and dry

 Check for proper sealing of conduit connections, cable glands, etc.

10.8 Transformers

The following checks shall be carried out on transformers:

 Check name plate data against transformer data sheets and drawings

 Inspect bushings for chips or cracks

 Check for physical damage to tank, fins, etc.

 Inspect all gaskets and fittings for oil leakage

 Check oil level

 Check cooling fan mounting and general condition

 Check cooling fan control panel

 Check all radiator valves are in the open position

 Check tap-changer for proper operation

 Check operation of temperature and pressure indicators and alarm relays

 Check that gland plates are properly fitted and sealed

 Check for proper sealing of conduit connections, cable glands, etc.

 See attached spreadsheet checklist that can be used as an in depth guide capturing
references specific to IOWA Standard Specification Requirements for Transformers.

Transformer
Checklist.xlsx

RTIO-AM-0031949 Page 21 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

10.9 Overhead Lines

The following checks shall be carried out on overhead lines.

 Inspect all line insulators after installation for cleanliness and for evidence or existence of
damage such as chips or hairline fractures. Insulators so damaged shall be replaced

 Check electrical clearances at the towers, under still-air conditions

 Check mid-span electrical clearances, especially in landing spans and spans where phases
are rolled

 Check that all temporary earths have been removed and that permanent tower/pole earthing
is installed

 A random selection (minimum 10%) of bolts in every tower shall be checked to ensure the
correct fasteners and washers have been used and are correctly installed, spring washers
are fully compressed, and there is no physical damage to the bolt or individual components

 All bolt tensions in current carrying connections shall be torque tested

 Sag and tension of overhead line conductors shall be surveyed and recorded. To determine
the correct conductor temperature in order to obtain accurate sag and tension results, the
method according to AS7000 shall be employed

 Check alignment and operation of main isolating switches, links and drop out fuses and
correct adjustment where necessary

 Check that vibration damper quantity and placement is in accordance with the vibration
damper placement schedule

 Check that over crossing markers are fitted where required and correctly installed

 Check that fault locators are fitted where required and correctly installed and functioning

 The full length of the line must be inspected to ensure that all poles and lines are straight and
true, and within acceptable tolerances.

Additional tests are specified in SS-E109.

RTIO-AM-0031949 Page 22 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Section 11 - Pre-Operational Testing

During pre-operational testing, electrical systems power circuits should not be energised and mechanical
equipment shall not be operated by an electrical drive.

11.1 Vendor Equipment

For pre-operational testing of equipment not specifically listed in this specification a procedure
shall be agreed between the installer, the equipment manufacturer and the RT Company
Representative. Documentation in the form of test or check sheets shall be submitted to the RT
Company Representative for approval.

Where applicable, pre-operational testing of equipment shall be carried out in accordance with
the equipment manufacturer’s instructions and recommendations. For complex or major
equipment the manufacturer’s representative shall be consulted for advice and support.

11.2 AS/NZS 3000 Requirements

After completion of, or in association with, the visual inspections, tests shall be conducted in
accordance with AS/NZS 3000.

AS/NZS 3000 sets out the following mandatory tests:

 continuity of the earthing system (earth resistance of the main earthing conductor,
protective earthing conductors and bonding conductors)

 insulation resistance

 polarity

 correct circuit connections

 fault-loop impedance

 verification of operation of residual current devices.

Guidance on the test equipment and methods of carrying out electrical installation tests are given
in AS/NZS 3017.

It should be noted that fault-loop impedance testing is a live test, and may require additional
controls to be completed safely.

RTIO-AM-0031949 Page 23 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.3 Fire Protection

Work associated with testing and commissioning of fire protection system packages should be
done by a Rio Tinto nominated fire specialist.

Testing and commissioning of the fire protection systems, shall include the following equipment:

 fire extinguishers

 fire indicator panels (FIP)

 break glass alarm stations

 aspirated smoke detection system

 point type smoke detectors

 point type thermal detectors

 sirens

 flashing lights

 gaseous extinguishing agent system

 do not enter signs

 evacuate signs

 passive fire treatments.

On completion of the installation, termination, testing and commissioning of the switchroom

associated equipment and cabling, all cable penetrations shall be sealed with a fire protective
coating specified in SS-E123.

11.4 Earth Systems

Earthing systems shall be tested according to the requirements given in SS-E273 for new
installations. Where substantial modifications are being made to an existing earth grid, e.g.
extension to a grid, additional rods, etc., then it shall be tested as per the new installation
requirements of SS-E273.

11.4.1 Earth Resistance

Readings shall be taken for the overall resistance of each grid. Readings shall be taken
for scenario of the standalone earth grid when all earthing interconnections are removed
(e.g. cable screens, running earths, etc.) and also for the final scenario of all
interconnections in place. Individual electrode readings are not required. Care shall be
taken to ensure that the minimum test distances specified in SS-E273 are met,
particularly for large grids, recognising that the required distances may be several
hundred metres for many substations. All earth readings achieved for an earth grid shall
be recorded on the “earthing tests” form in Appendix A.

RTIO-AM-0031949 Page 24 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.4.2 Step and Touch Potential

Step and touch potential measurements shall be made at high voltage substations to
confirm safe levels to the High Voltage Work Notification. Step and touch voltages shall
be confirmed safe by current injection and voltage measurement.

The test instrument shall be connected between a remote earth electrode and the local
substation earth grid. Where possible, the actual source should be used, i.e. the cable
or overhead line that is supplying the substation should form part of the injection circuit.
The current range and open line voltage shall be set in accordance with the
manufacturer's recommendations, but in no circumstances shall exceed 500V. Tests
shall be conducted as per the requirements given in SS-E273.

Locations of the test shall be marked on a general arrangement drawing and attached
to the test records.

The step and touch voltages under earth fault conditions shall be calculated using the
measured voltages, and these values shall be compared with the statutory required
values.

All readings shall be recorded on the “earthing tests” form in Appendix A.

11.4.3 Earth Continuity

A low resistance ohm-meter shall be used to test each earthing system from the main
earth terminal to the enclosure of each piece of equipment as per the requirements of
SS-E273. A multimeter is not an acceptable instrument for this test.

11.4.4 Functional Separation

A 1kV insulation tester shall be used to test the insulation resistance between the main
earth bar and the insulated instrument earth bar in the marshalling cubicle in each
switchroom. With the connecting cable disconnected the insulation resistance shall not
be less than 1MΩ.

RTIO-AM-0031949 Page 25 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.5 High Voltage Cables

High voltage (HV) cables are defined as those with insulation rated in excess of 0.6/1kV.

HV cable testing results shall be recorded on the form “HV Cable” given in Appendix A.

Note: for all tests in section 11.5 (and subsections), exemptions from these tests shall only be
approved by the asset owner.

The following tests shall be performed on all HV cables:

 continuity of the earthing system (continuity check of each of the following components: the
main earthing conductor; protective earthing conductors; cable screen; and bonding
conductors)

 Insulation Resistance: Core and Sheath (as per section 11.5.1)

 Phasing and cable continuity

 Ductor Tests.

For new cables the following additional tests shall be performed:

 VLF testing (as per section 11.7.2)

 Offline partial discharge tests (33kV and above, plus 11kV cables in a power station).

For existing cables (including new cables joint to existing), the following additional tests shall be
performed:

 Offline partial discharge (11kV and above)

 power factor (tan-delta) tests (11kV and above) (Refer to IEEE 400.2 for analysis of results).

On completion of all these tests, if no insulation breakdown has occurred and the test results are
compliant with the values given by the cable manufacturer’s data sheets, then the normal
operating voltage of the system can be applied.

The cable has been successfully tested after the normal operating voltage has been applied for
24 hours as per AS/NZS 1429.1.

11.5.1 Insulation Resistance Testing

Two types of insulation resistance testing shall be performed during cable installation:
cable sheath insulation resistance testing, and core insulation resistance testing as
detailed below.

Sheath integrity testing is conducted to prove the integrity of the outer cable sheath. It
shall be performed by applying a 5kV insulation resistance tester between the outermost
metallic layer and earth as per AS 1429.1. This test is required on every cable section
before cables are joined, to ensure the cable sheath integrity of each section of cable,
and to aid finding faults prior to commissioning. The test shall be re-performed at the
completion of all joints to ensure the sheath integrity has been maintained through the
jointing process.

RTIO-AM-0031949 Page 26 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

If the sheath integrity test is failed, the fault must be located with a cable sheath fault
locator and the issue rectified.

For cables with very high insulation resistance readings, and for very long cables, the
guard terminal of the test equipment shall be used according to the test equipment
manufacturer’s instructions.

Core insulation resistance tests shall be performed by applying a 5kV insulation

resistance tester between the phase conductor and earth as per AS 1429.1. Care shall
be taken to ensure correct connections of test equipment, particularly around the use of
the guard terminal. All values shall be temperature corrected and checked against the
manufacturer’s specifications. The expected value shall be calculated from the data
sheet, and the test results shall not be less than 95% of the calculated value. As an
example, 70mm 2 single core Cu 19.1/33kV cable from Olex has a nominal insulation
resistance of 16000MegOhm.km at 20ºC. Therefore a 3km length of this cable would
have an expected IR test result of 5.33GΩ, determined by:

16000MegOhm.km = 5333MegOhm = 5.33 GΩ

3km

Below is a guideline for minimum values to be expected for 1.9/3.3Kv and 3.8/6.6kV.

Insulation Resistance Testing – ( Between each phase conductors and screen) -

duration of test to be carried out until reading is stable

New Cable – Minimum 10 GΩ reading using a 5kV insulation resistance tester

Existing Cable - Minimum 1 GΩ reading using a 5kV insulation resistance tester

Sheath Integrity Test- (Between each screen an earth) - duration of test to be carried out
until reading is stable

New Cable – Minimum 1 GΩ reading using a 5kV insulation resistance tester

Existing Cable - Minimum 100 MΩ reading using a 5kV insulation resistance tester

Readings below these values shall prompt further investigation/monitoring and/or

replacement.

Where an old cable is to be re-terminated or jointed, an insulation resistance test shall be

performed prior to disturbing the old cable.

11.5.2 High Voltage Withstand Testing (VLF Testing)

A high voltage withstand test (VLF test) shall be performed if the nominal voltage is 11kV
or above. For new cables VLF testing shall be performed at 3*Uo (three times RMS line
to ground voltage, i.e. 57.3kV RMS for a 33kV system) for 60 minutes and at no less than
0.1 Hz. For cable systems where all components (cable, terminations and joints) are rated
to 22kV but are to be operated at 11kV, they shall still be VLF tested to 22kV levels.

The Company’s VLF testing standards align more closely VDE/Cenelec standards than
IEEE standards, so care should be taken when referencing IEEE 400.2. In any case, this
document takes precedence over international standards when it comes to VLF testing.
Cosine-rectangular waveforms are acceptable, and the type of waveform used shall be
recorded on the test form along with peak and RMS voltages.

RTIO-AM-0031949 Page 27 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

For existing cables (including new cables joined to existing) VLF testing shall not be
undertaken under any circumstances (NB. this clause does not exclude the use of a VLF
source for tan delta or offline PD testing):

 In the case where a high voltage withstand test is required, a 5kV insulation
resistance tester shall be first be applied for one minute as per section 11.5.1. If no
breakdown in insulation is measured, a high voltage withstand test shall be applied
at very low frequency (VLF)

 Cables shall be disconnected from equipment either by unbolting the lugs, via an
isolator, or by racking out the contactor/circuit breaker. The isolator and its
terminations (i.e. cable box or thermoplastic heat shrink type) should be stressed
with the cable, unless otherwise specified by the switchgear/termination
manufacturer. Cables shall not be connected to transformers during VLF testing

 Where cables are terminated with plug-in type terminations, including bolted dead
break elbows, and are required to be disconnected from equipment for testing,
additional measures shall be required to ensure the integrity of the termination during
the VLF test. These measures shall be taken in consultation with the termination
manufacturer and may include options such as parking bushings or ‘Feed-Thru’
inserts with a pre-terminated cable end attached. Plug in terminations shall never
be stressed by VLF testing without these protective measures in place

 On completion of VLF testing the 5kV insulation tester shall be used to check the
insulation resistance of the cable. Insulation values both before and after the VLF
test shall be recorded, and shall meet the values prescribed in section 11.5.1.

DC ‘hi pot’ testing shall not be performed on any XLPE cables.

11.5.3 Phasing and Cable Continuity

Ensure that cable cores are isolated at both ends; surge diverters and any voltage
transformers are disconnected. Each phasing/continuity test shall be carried out with a
suitable low reading ohm meter or wheatstone bridge to measure the loop resistance from
the test point to the circuit origin and back. Continuity test instruments shall have a
resolution of 0.01 ohm. The difference between readings should be less than 10%. The
results shall be verified against manufacturer’s test reports/data sheets.

11.5.4 Ductor Test

Ductor tests shall be performed for all power cable terminations excluding elbow
terminations. The acceptable resistance will depend on the voltage and current flows at
the joint. A resistance of 50µΩ or less will usually be acceptable.

11.5.5 Offline and online partial discharge tests

This test is to determine if any local faults are present in the cable with such a severity
that electrical discharge activity is occurring. In particular, this test is useful for detecting
material and workmanship issues in terminations and joints.

RTIO-AM-0031949 Page 28 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

This test shall be performed whenever a new cable section is jointed into an old cable at
11kV or above, or as specified elsewhere in this document. An OWTS or PD free VLF
source shall be used to conduct this test. This test shall be conducted in stages, with the
voltage being raised sequentially. Ordinarily, the test sequence shall continue on until
2*U0 (RMS), however, if high levels of PD activity (>5000pC) are detected, then testing
should cease to prevent further damage to the cable and the issue rectified. On existing
cable sections, voltages higher than 1.7*U0 (RMS) shall not be applied, e.g. no more than
33kV RMS shall be applied to 33kV cables.

Offline PD tests may be conducted concurrently with Tan Delta measurements if the
equipment allows.

Online tests shall be conducted with Longshot or similar level equipment on the cable
screens. The equipment must be able to capture individual PD occurrences and phase
correlate them. This test is susceptible to industrial noise, and is not considered a
replacement for offline tests following installations. However, if requested, this test shall
be used as a baseline to assist with interpreting future online test results.

11.5.6 Tan Delta tests

The tan-delta test (also known as Power Factor or Dielectric Dissipation Factor (DDF)) is
used to determine the overall quality of a cable, and in particular to detect the presence
of water trees in XLPE. An OWTS or PD free VLF source shall be used to conduct this
test. Surge arrestors must be removed from the cable system. IEEE 400.2 shall be used
as the basis for interpreting test results.

As per the offline PD test, the test voltage should be raised in a stepped sequence to a
level of 2*U0 (RMS). Again, if breakdown or poor tip-up value is detected, then testing
should stop to prevent further damage to the cable. As a minimum, test voltages of
0.5*U0, 1.0*U0, 1.5*U0, 1.7*U0 and 2.0*U0 shall be used. If the installation contains
sections of existing cable, then testing shall cease at 1.7*U0. Note that all these figures
are given as RMS values.

Negative tan-delta values are an indication of a testing error and the test setup should be
reviewed. Semi conductive screened terminations, such as dead break elbows, need
extra care to prevent the screen from providing false tan-delta readings.

11.6 Reeling and Trailing Cables

Tests on new reeling and trailing cables shall be conducted as recommended by the
manufacturer. As a minimum, the tests shall include the HV cable/LV cable tests from this
standard and fibre optic cable tests as per SS-T013 (as appropriate).

Tests shall be conducted in accordance with AS/NZS 1747 for surface mining cables and cable
accessories (where applicable).

All mandatory testing as required by AS/NZS 1747 shall be conducted, with the following
qualifications:

 An insulation resistance test of the power conductors shall be conducted with a 5kV insulation
resistance tester applied for one minute. An insulation resistance test of the pilot conductors
shall be conducted with a 500V insulation resistance tester applied for one minute

RTIO-AM-0031949 Page 29 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

 The high voltage proof test shall be applied using the applicable AC test voltage as specified
in AS/NZS 1747

 The symmetrical load and partial break tests need only be performed if the cable has been
joined or repaired. These tests require specialist test equipment and are best performed by
a company specialising in electrical testing

 The sheath integrity test described in AS/NZS 1747 is not required

 Fibre optic cores shall be tested in accordance with RT Standard Specification SS-T013.

RTIO-AM-0031949 Page 30 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.7 Low Voltage Cables

Low voltage cables are defined as those intended for power or control having insulation rated
equal or below that of 0.6/1kV. The following four tests shall be conducted:

 Continuity of the earthing system (earth resistance of the main earthing conductor, protective
earthing conductors and bonding conductors)

 Insulation resistance

 Phasing and cable continuity

 Ductor test

 Correct circuit connections.

Control cables shall be regarded as single phase cables.

Insulation resistance testing shall be performed as follows:

 all tests shall be performed after glanding but prior to the connection

 500V insulation resistance tester shall be used for all LV cables.

 Minimum values to be expected for existing LV cables is 1 MΩ, readings below this value
shall prompt further investigation/monitoring and/or replacement.

Results from cable tests shall be recorded on the form “LV cable” (see Appendix A.15).

A useful test sheet for checking polarity, cable transpositions and voltages for new or modified
connections can be found in A.45.

11.7.1 Phasing and Cable Continuity

Ensure that cable cores are isolated at both ends, surge diverters and any voltage
transformers are disconnected. Each phasing/continuity test shall be carried out with a
suitable resistance box to measure the loop resistance from the test point to the circuit
origin and back. Continuity test instruments shall have a resolution of 0.01 ohm. The
difference between readings should be less than 10%. The results shall be verified
against manufacturer’s test reports/data sheets.

11.7.2 Ductor Test

Ductor tests shall be conducted for all busbar connections at 200A. The acceptable
resistance will depend on the voltage and current flows at the joint. A resistance of 50µΩ
or less is usually acceptable.

RTIO-AM-0031949 Page 31 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.8 Instrument and Communications Cables

Instrument and communications cables are defined as twisted pair, coaxial, or other
communications cable not intended for use as low voltage cable.

Insulation resistance tests shall not be applied to instrument or communications cables.

A continuity tester shall be used to carry out point to point checks of wiring to confirm each
conductor is terminated at the correct terminal. The maximum test voltage for continuity is 50V
DC. Cables terminating on computers, processors or other circuits containing semi-conductor
devices shall be tested only when disconnected at the semi-conductor circuit end.

Checked, marked up and signed prints of all termination and interconnection drawings are
required (as confirmation of completed testing).

Results from cable tests shall be recorded on the form “Instrumentation cable” (see Appendix A).

11.9 Fibre Optic Cables

Visual inspection, pre-operational testing and pre-commissioning of fibre optic cables shall be
performed in accordance with RT Standard Specification SS-T013.

11.10 Socket and Welding Outlets

Pre-operational polarity and correct circuit connection tests shall be performed.

Verification of operation of residual current device tests shall be performed for all circuits supplied
from RCD circuit breakers, by applying a simulated increasing earth fault at each outlet and noting
the tripping current and time.

The tripping current and time must be within the acceptable ranges specified in AS 3190.

Pushing an RCD test button on a socket outlet does not constitute a satisfactory test.

RTIO-AM-0031949 Page 32 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.11 High Voltage Switchgear

The following tests shall be performed:

 Continuity of the earthing system (earth resistance of the main earthing conductor,
protective earthing conductors and bonding conductors)

 Insulation resistance

 Correct circuit connections

 Ductor test

 AC Withstand Test ( for switchgear 11kV and above).

An electrical continuity check shall be performed on all current, potential and control circuits.
Wiring diagrams shall be compared with actual connections and non-conformances reported to
the Company.

High voltage Switchgear test results shall be recorded on “HV Switchgear” form in Appendix A.

Each circuit breaker, relay, and timer shall be set to appropriate values as approved by the RT
Company Representative to achieve correct performance and protection of load side devices.

11.11.1 Ductor Test

Conductor ductor tests shall be performed for all busbar connections and circuit
breaker/isolator/earth switch contacts at 200A. The acceptable resistance will depend on
the voltage and current flows at the joint.

11.11.2 Insulation Resistance

 Testing shall be carried out with the surge diverters and high voltage power cables
disconnected from the switchgear. Electronic and other voltage sensitive equipment
shall be isolated before tests are carried out. Voltage transformers shall be
disconnected or isolated and control fuses removed. Current transformer secondaries
shall be short circuited and earthed

 All circuit breakers shall be placed in the ‘service’ position and closed. A 5kV insulation
resistance tester shall be applied for one minute in the following configurations:

 R to [W + B + E]

 W to [B + R + E]

 B to [R + W + E]

 Immediately after the test, all current transformer shorting devices shall be removed
and voltage transformers reconnected.

11.11.3 AC Withstand Test

An AC withstand test shall be performed on all high voltage switchgear 11kV and above.
This shall be performed by applying a “Hi-Pot” testers at 80% of the rated withstand
voltage for 1 minute or as per the manufacturer’s recommendation. The measured
RTIO-AM-0031949 Page 33 of 91 Approved: 22/08/18
Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

leakage current shall be recorded. Insulation resistance measurements at 5kV shall be

recorded before and after the test.

11.12 Protection Relays

The following tests shall be performed:

 Secondary injection testing

 Input and Output testing

 Switchgear functional trip tests

 SCADA system integration.

An ITP similar to “Relay Testing ITP Template” in Appendix A shall be used to perform the tests
and shall be submitted to Asset owner for review before commencing.

Note: exemptions from any requirement shall only be approved by the asset owner.

11.12.1 Secondary Injection Testing

All protection relays shall be secondary injection tested to prove functionality of the relay
logic and timing characteristics. A minimum of three points shall be tested for each IDMT
element. Pickup and drop off test shall be performed for each definite time element.
Where secondary injection testing cannot be performed, primary injection testing shall be
undertaken to prove functionality of the relay.

During the testing, operation of trip flags shall be verified.

11.12.2 Input and Output testing

Every input, including spares, shall be proved and verified for correct function against the
drawings. Where an input is responsible for tripping, it shall be time tested.

Every output shall be tested and verified for correct function against the drawings. Where
an output is responsible for tripping or inter-tripping, it shall be time tested.

Latching of all outputs shall be verified against SS-E168, Protection Philosophy and
requirements.

11.12.3 Switchgear Function Trip Testing

The circuit breaker, or other primary fault interrupting equipment, shall be tripped via the
protection relay as a final check of the integrity of the protection circuits.

RTIO-AM-0031949 Page 34 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.12.4 SCADA system integration

During the above tests, signals shall be crosschecked with the SCADA system to ensure
all signals are correctly reported and no false signals are received. Signals refer to
analogue values, status indications and alarms.

11.13 Communication and SCADA Equipment

Please refer to SS-E157, Power System Control and Communication standard for details on
commissioning tests for SCADA equipment.

11.14 LV Switchgear, Switchboards and Load Centres

The following tests shall be performed:

 Continuity of the earthing system (earth resistance of the main earthing conductor,
protective earthing conductors and bonding conductors)

 Insulation resistance

 Phasing and continuity

 Correct circuit connections

 Ductor test.

An electrical continuity check shall be performed on all current, potential and control circuits.
Wiring diagrams shall be compared with actual connections and non-conformances reported to
the RT Company Representative.

Each circuit breaker, relay, and timer shall be set to appropriate values as approved by the RT
Company Representative to achieve correct performance and protection of load side devices.

All circuit breakers shall be tested in accordance with the manufacturer’s recommendations to
establish proper functional operation of the mechanical and electrical equipment.

All test results shall be recorded on “LV Switchgear” form in Appendix A.

11.14.1 Phasing and continuity

This test should be performed to ensure busbars are continuous inside the switchgear.
Each phasing/continuity test shall be carried out with a suitable low reading ohm meter.
The difference between readings should be less than 10%. The results shall be verified
against manufacturer’s test reports/data sheets.

11.14.2 Ductor Test

Ductor tests shall be conducted for all busbar connections at 200A. The acceptable
resistance will depend on the voltage and current flows at the joint. A resistance of 50µΩ
or less is usually acceptable.

RTIO-AM-0031949 Page 35 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.14.3 Insulation Resistance

Before connecting incoming and outgoing cables, the switchgear shall undergo a 500V
insulation test for one minute.

11.15 Current and Voltage Transformers

The following checks shall be completed:

 Check current and voltage transformer polarity

 Check current and voltage transformer ratio

 Primary and secondary winding insulation resistance

 Check magnetizing curves and knee point voltage for current transformers

 Check that current transformer secondaries are not left open circuited (after testing).

Current transformer results shall be recorded on the form “Current Transformers” (see
Appendix A).

Voltage transformer results shall be recorded on the form “Voltage Transformers” (see
Appendix A).

11.16 Motors

Insulation resistance shall be measured at ambient temperature using a 500V insulation

resistance tester for low voltage and a 5kV insulation resistance tester for high voltage machines.
The test shall be applied for one minute. The insulation resistance readings shall not be
substantially lower than values shown on manufacturer’s test certificates (or other manufacturer
supplied minimum value).

If manufacturer’s data is not available, the following shall be considered as minimum acceptable
values for motors up to 750kW:

Minimum Acceptable
Voltage
Resistance

415V 1.5MΩ

3,300V 4.3MΩ

≥ 6,600V 6.0MΩ

 On motors fitted with anti-condensation heaters and winding temperature detectors, the
insulation resistance of the heaters, and the resistance for the winding temperature detectors
shall be measured

 Results shall be recorded on the relevant test sheet

 Where fitted, autolube systems shall be set for the lubrication requirements of the particular
motor and the settings recorded.

RTIO-AM-0031949 Page 36 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.17 Transformers

The following tests shall be performed for all transformers:

 Insulation Resistance Test and Polarization Index (HV-LV, HV-LV&E, LV-HV&E)

 Winding Ratio Test

 DC Winding Resistance Test

 Magnetizing Current Measurement

 Ductor test on cable connections and earth

 Functional checks of all transformer guards e.g. PRV, Winding and oil temp etc.

 Functional checks of cooling system including fans and radiator valves

 Dissolved Gas Analysis and Oil quality tests including Furan analysis.

For Transformers 9MVA and above following additional tests shall be performed:

 Sweep Frequency Response Analysis (SFRA)

 Winding Power Factor and Capacitance test (Tan Delta).

For transformers which contain an on load tap changer (OLTC) the following additional tests shall
be performed.

 Tap changer timing test

 Tap changer functional check.

Results shall be recorded on the forms “Power Transformers” or “Three-Phase Pole Mounted
Transformer” in Appendix A.

For transmission transformers refer to SS-E142 for additional tests required.

11.17.1 Insulation Resistance Test

An insulation resistance test shall be conducted with the primary, secondary and neutral
cables disconnected. The insulation resistance (HV-LV, HV-LV&E and LV-HV&E) shall
be checked against the manufacturer’s test certificate.

Polarization Index test shall be performed during HV-LV&E insulation resistance test.
Insulation resistance readings shall be recorded at all intervals shown on the test sheet.

5kV test voltage shall be used for windings of 1kV and above; and 500V test voltage shall
be used for windings below 500V. For windings between 500V and 1kV, a test voltage of
1kV shall be used.

11.17.2 Winding Ratio Test

A winding ratio test shall be conducted on all tap positions.

RTIO-AM-0031949 Page 37 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.17.3 DC Winding Resistance Test

A DC winding resistance test shall be conducted on all tap positions. For transformers
with on load tap changer a dynamic resistance test shall be conducted to verify make
before break operation of the tap changer.

11.17.4 Transformer Guards Testing

All guards shall be functionally tested to prove operation of transformer protection device
(relay, associated CB or fuse switches).

11.17.5 Cooling System Checks

Active cooling system such as fans and oil pumps shall be functionally checked with
activation and de-activation thresholds recorded on the test sheets. Radiators valves shall
be verified open and recorded on test sheet.

11.17.6 Transformer Oil Testing

All transformers must pass an oil dielectric strength test before being put into service. If
oil has been stored for more than six (6) months then they must also pass an oil water
content test. Sampling and testing may be performed on-site in accordance with AS 1767
or sent to an external laboratory for analysis (see further explanation below). Pass criteria
shall be as defined by the manufacturer. Tests are also applicable to non-flammable
transformer liquid insulates.

As a minimum, tests shall include an assessment of oil condition including dielectric

strength, water content, acidity, inhibitor content, corrosive sulphur content, solid
insulation condition (furan analysis) and a dissolved gas analysis. This data shall serve
as a base line for future maintenance. Reports shall be submitted to the RT Company
Representative for approval and to be kept as base line records.

Note: Oil Test reports shall not be older than 1month before initial energisation.

RTIO-AM-0031949 Page 38 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

11.18 Overhead Lines

The following tests shall be conducted on overhead lines:

 Earth resistance shall be checked in accordance with section 0 at all pole footing earthing
systems and the results recorded

 Earth continuity shall be checked in accordance with section 11.4.3

 Check phasing of circuits

 Conduct ductor tests of all power cable joints and terminations and record the results for
comparison with the manufacturer’s data

 5kV insulation resistance tests shall be applied for one minute along the line as required.

Additional tests are specified in SS-E109.

11.19 Batteries

The inspection and testing of sealed type batteries shall be performed in accordance with
AS 2676.2.

The receipt, unpacking, storage, mounting and connection of batteries shall be performed in
accordance with AS 2676.2.

The batteries shall receive an initial charge in accordance with the manufacturer’s
recommendation and the procedures outlined in AS 2676.2.

Lithium Iron Phosphate Batteries should be commissioned by the vendor. The battery
management system (BMS) should be disconnected and isolated for transport and storage. The
wiring of the BMS must be correctly connected before energisation. Post commissioning cell
voltage balance test is mandatory 1 week after commissioning.

The yearly maintenance inspection as described in AS 2676.2 shall be performed. In addition, all
connections shall be checked to ensure they are tight and greased.

A battery capacity test, including performance test, shall be conducted for trip supply and UPS
batteries in accordance with AS 2676.2. The test shall be conducted at the nominal discharge
rate for the critical period for which the battery is sized.

Results shall be recorded in accordance with the requirements of AS 2676.2. A typical battery
report sheet is also given in AS 2676.2.

Refer to Test sheet A.4 and SS-E112

11.20 Valves

Checks shall be conducted as recommended by the manufacturer. In addition, the following

checks shall also be completed:

 Check that limit switches and associated cables are clear of moving parts

 Check that limit switches operate satisfactorily at the appropriate point of travel. These
checks shall account for any free play in the actuator mechanisms and how the valve
hardware will behave when in service

RTIO-AM-0031949 Page 39 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

 Check to ensure that the installation is free from air leaks

 Valves are to be stroked by manual operation (where possible) to ensure that there is free
travel over the full range of expected movement i.e. that the valve fully opens and closes.

11.21 Other Instrumentation

Checks shall be conducted as recommended by the manufacturer.

11.22 Pre-Energisation Insulation and Continuity Test

The Pre-Energisation Insulation and Continuity Test Sheet (A.45) attached in Appendix A shall
be completed before energisation of a new HV installation consisting of multiple pieces of
equipment (overhead lines, underground cable, transformers, switchgear etc.). These test sheets
shall be followed to ensure that phases are not crossed anywhere in the installation and also to
prove end to end continuity of each HV circuit.

RTIO-AM-0031949 Page 40 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Section 12 - Test Equipment

All test equipment shall be of a high quality and shall be calibrated and checked for accuracy.

Calibration and certification of all test equipment shall be provided as information to support the quality and
accuracy of equipment used.

RTIO-AM-0031949 Page 41 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Appendix A - Pre-Operational Inspection and Test

Forms

RTIO-AM-0031949 Page 42 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.1 Test Sheet – AC Induction Motors, Sheet 1 of 2

Iron Ore (WA) –Asset Management Sheet 1 of

2
Test Report No

AC Induction Motors
Date

Site Area Equipment No

Description
Single Line Diagram General Arrangement Drawing
Manufacturer Frame
Type Full load speed
Serial No. Full load voltage
Power (kW) Full load current
Insulation Class No load voltage
No. of Poles No load current
Rotation (drive end) Shaft diameter
Terminal Connections (delta or star)
U1 о о __________
U2 о о __________
U3 о о __________
Physical Checks
 x N/A  x N/A
Inspect motor for damage □ □ □ Check motor earth cable □ □ □
Check heater operation □ □ □ Check mounting is secure □ □ □
Check thermistor/RTD connected □ □ □ Check gland/shroud □ □ □
Ensure bearings are greased □ □ □ Check motor rotation □ □ □
Inspect terminations □ □ □ Brinelling check □ □ □
Insulation Resistance Tests
Test Equipment: Serial No: Calibration date:

PI Index (10 min/1

Test Points Test Voltage Result (1 min) Result (10 mins.)
min)
Stator Winding to Earth
Rotor Winding to Earth
Heater to Earth
Continuity Tests
Test Equipment: Serial No: Calibration date:

U1 - U2
V1 - V2
W1 - W2

RTIO-AM-0031949 Page 43 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.2 Test Sheet – AC Induction Motors, Sheet 2 of 2

Iron Ore (WA) –Asset Management Sheet 2 of 2

Test Report No

AC Induction Motors
Date

Digital Photographs (to be attached)

Photo description Taken by

Completion
 x N/A
Check terminations are correctly tensioned □ □ □
Check terminal box covers are replaced □ □ □
Circuit left isolated and out of service □ □ □
Drawings marked up with As Constructed changes □ □ □
Request for Energisation completed □ □ □
Notify Commissioning Manager □ □ □
Comments / Remedial Action Required
Item Date Rectified Signature
1.

2.

3.

4.

5.

Inspected and Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 44 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.3 Test Sheet – Battery Charger and Batteries, Sheet 1 of 3

Iron Ore (WA) –Asset Management Sheet 1 of 3

Test Report No

Battery Charger and Batteries

Date

Site Area Equipment No

Description

Single Line Diagram General Arrangement Drawing

Battery Charger Cells

Manufacturer Manufacturer
Model Model
Serial No. Type
Input voltage Battery capacity (Ahr)
Output voltage No. of cells
Charger rating Nominal battery volts
Phases
Float voltage

Physical Checks
 x N/A  x N/A
Inspect for damage
□ □ □ Inspect internal wiring
□ □ □
Check location
□ □ □ Check terminals
□ □ □
Check orientation
□ □ □ Check cable ferrules
□ □ □
Inspect access
□ □ □ Inspect signage
□ □ □
Check battery connections
□ □ □ Inspect labelling
□ □ □
Check cable terminations
□ □ □ Inspect door seals
□ □ □
Ensure installation is secure
□ □ □ Inspect door operation
□ □ □
Inspect Earthing
□ □ □ Inspect ducting
□ □ □
Battery Charger Tests
Connected load during charge W
Charger voltage with fully discharged cells with load connected V
Charger voltage with fully charged cells with load connected V
Cell charge rate with fully charged cells mA
Low battery voltage alarm setting V

RTIO-AM-0031949 Page 45 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.4 Test Sheet – Battery Charger and Batteries, Sheet 2 of 3

Iron Ore (WA) –Asset Management Sheet 2 of 3

Test Report No

Battery Charger and Batteries

Date

Voltage Voltage Voltage Voltage Cell rate

Cell Cell Cell
Ambient before after after after (A) after
No. Time temp rate (A) Time
temp charge charge discharge recharge recharge
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.

RTIO-AM-0031949 Page 46 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.5 Test Sheet – Battery Charger and Batteries, Sheet 3 of 3

Iron Ore (WA) –Asset Management Sheet 3 of 3

Test Report No

Battery Charger and Batteries

Date

Test Equipment: Serial No: Calibration date:

Digital Photographs (to be attached)

Photo description Taken by

Completion
 X N/A
Check covers are replaced □ □ □
Circuit left isolated and out of service □ □ □
Drawings marked up with As Constructed changes □ □ □
Request for Energisation Completed □ □ □
Notify Commissioning Manager □ □ □
Comments / Remedial Action Required
Item Date Rectified Signature
1.
2.
3.
4.
5.
Inspected and Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 47 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.6 Test Sheet – Buried Cable / Conduit

Iron Ore (WA) –Asset Management Sheet 1 of 1

Test Report No

Buried Cable / Conduit

Date

Site Area
Description

General Arrangement Drawing Cable Schedule

Physical Checks
 x N/A  x N/A
Inspect trench □ □ □ Bedding material □ □ □
Check trench depth ___________ mm Bedding depth _________mm
Check danger tape depth ___________ mm Backfill suitability □ □ □
Service separation ___________ mm Backfill compaction □ □ □
Bending radius □ □ □ Route Markers □ □ □
Digital Photographs (to be attached)
Photo description Taken by

Completion
 x N/A
Drawings marked up with As Constructed changes □ □ □
Notify Commissioning Manager □ □ □
Comments / Remedial Action Required
Item Date Rectified Signature
1.
2.
3.
4.
5.
Inspected and Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 48 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.7 Test Sheet – Current Transformers, Sheet 1 of 2

Iron Ore (WA) –Asset Management Sheet 1 of 2

Test Report No

Current Transformers one sheet per core

Date

Site Area Equipment Number

Description
Single line diagram General Arrangement Drawing
Manufacturer Ratio
Type Maximum voltage
Serial No. Rated short-time current
Accuracy Class Frequency
Insulation Class Burden
Insulation Resistance Measurement
Test Results
Test Connection Test Voltage Test Duration
Red White Blue
Primary to Earth
Primary to Secondary
Secondary to Earth
Transformer Polarity Test
Test Equipment Serial No: Calibration date:
Spill Current (mA)
Phase Primary Current Meter Injected V/A Meter Reading
Neutral
R-W
R-B
W-B
Transformer Ratio Test
Test Equipment: Serial No: Calibration date:
Phases Primary Amps Secondary Amps Ratio Tap
R-N
W-N
B-N

RTIO-AM-0031949 Page 49 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.8 Test Sheet – Current Transformers, Sheet 2 of 2

Iron Ore (WA) –Asset Management Sheet 2 of 2

Test Report No

Current Transformers one sheet per core

Date

CT Knee Point Test

Test Equipment: Serial No: Calibration date:
Phase Current (A)
Injection Voltage
R Phase W Phase B Phase Neutral

Inspected and Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 50 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.9 Test Sheet – Earthing Tests, Sheet 1 of 2

Iron Ore (WA) –Asset Management Sheet 1 of 2

Test Report No

Earthing Tests
Date

Site Area
Description

Earthing Diagram General Arrangement Drawing

Electrode length Method of installing cable

Electrode type Method of installing electrodes
Cable size Hole diameter
Cable type Backfill material

Physical Checks
 x N/A  x N/A
Inspect earth bar installation □ □ □ Inspect earth pits □ □ □
Check earth bar connections □ □ □ Inspect electrode connections □ □ □
Check earth cable sizes □ □ □ Inspect electrode installation □ □ □
Check earth cable labelling □ □ □ Check MEN connection □ □ □
Resistance Tests
Test method
Test Equipment: Serial No: Calibration date:
Standalone grid: Combined System:
Ω Ω
Soil Condition Soil Type
Step and Touch Voltage Measurements
Test method Injected Current: Touch Voltage Limit:
Test Equipment: Serial No: Calibration date:
Measurement Location Touch Voltage Step Voltage

RTIO-AM-0031949 Page 51 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.10 Test Sheet – Earthing Tests, Sheet 2 of 2

Iron Ore (WA) –Asset Management Sheet 2 of 2

Test Report No

Earthing Tests
Date

Step and Touch Voltage Measurements

Measurement Location Touch Voltage Step Voltage

Sketch showing location of Earth Stakes , Step and Touch Voltage measurement points

Completion
 x N/A
Drawings marked up with As Constructed changes □ □ □
Notify Commissioning Manager □ □ □
Electrode resistance entered in Mine Record Book □ □ □
Comments / Remedial Action Required
Item Date Rectified Signature
1.
2.
Inspected and Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 52 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.11 Test Sheets – Generator Sets

Iron Ore (WA) –Asset Management Sheet 1 of 1

Test Report No

Generator Sets
Date

Site Area Equipment No.

Description
Single Line Diagram General Arrangement Drawing
Engine Alternator
Manufacturer Manufacturer
Model Model
Serial No. Year of manufacture
No. of cylinders kVA
Cooling Volts
Physical Checks
 x N/A  x N/A
Check for damage □ □ □ Check access □ □ □
Ensure no oil leaks □ □ □ Inspect door seals □ □ □
Check labelling □ □ □ Inspect door operation □ □ □
Check signage □ □ □ Inspect radiator & fan □ □ □
Check location □ □ □ Ensure bund is adequate □ □ □
Check orientation □ □ □ Ensure installation is secure □ □ □
Location of MEN: (ensure matches the design)

Completion
 x N/A
Circuit left isolated and out of service □ □ □
Drawings marked up with As Constructed changes □ □ □
Request for Energisation Completed □ □ □
Notify Commissioning Manager □ □ □
Comments / Remedial Action Required
Item Date Rectified Signature
1.
2.
Inspected and Tested by: Company Signature Date

Accepted by Company Signature Date

RTIO-AM-0031949 Page 53 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.12 Test Sheet – HV Cable, Sheet 1 of 3

Iron Ore (WA) –Asset Management Sheet 1 of 3

Test Report No

HV Cable Date

Site Area
Description:
Location (from):
Location (to):
Single Line Diagram Cable Schedule
Cable Layout Drawing
Cable No Rated Voltage
Cable Type No. of in-line joints
Cable Size Cable Length

Visual Inspection Checks

 x N/A  x N/A
Inspect cable for damage □ □ □ Check armour earthed □ □ □
Check cable protection (kick
Check cable numbering □ □ □ guard) □ □ □
Check cable size and type □ □ □ Check cable bending radius □ □ □
Check core numbering and
colour □ □ □ Check cable spacing/fixing to tray □ □ □
Inspect all crimp lugs □ □ □ Inspect cable joint/termination kit □ □ □
Check bolt connections tight □ □ □ Check joint spiral lay □ □ □
Check no stress on Check clamping of single core
terminations □ □ □ cables □ □ □
Check clearances of
Check gland/shroud □ □ □ cores/bushings □ □ □
Check phasing □ □ □ Check buried depth □ □ □
Check continuity of Check cable joints & terminations
earth/screen □ □ □ for jointer’s SAP number □ □ □
Joint Kit Details
Type Cat. No.
Termination Details
Supply End
Type Cat. No.
Load End
Type Cat. No.

RTIO-AM-0031949 Page 54 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.13 Test Sheet – HV Cable, Sheet 2 of 3

Phasing and Continuity Test

Cable cores are isolated at both ends, surge diverters and any voltage transformers are disconnected Use low
resistance ohm meter or Wheatstone bridge (refer to Section 11.7 of SS-E115)
Test Equipment: Serial No: Calibration date:

Test Connections Phasing Check (Pass/Fail) Continuity Check (Resistance in

ohms)
R- Screen Ω

W- Screen Ω

B- Screen Ω

N- Screen (if applicable) Ω

Insulation Resistance Tests

Test Equipment: Serial No: Calibration date:

Minimum Values (as

Test Connection per Section 11.7.1 of Test Result
Conduct an insulation resistance test SS-E115)
for 1 to 10 minutes (subject to the R- WBNE Ω
length of the cable) or until the
reading is stable. W- RBNE Ω
Use a 5 kV test voltage between
each phase conductor and the B- RWNE Ω
corresponding cable screen.
N- RWBE (if applicable) Ω

Sheath Integrity Checks

Test Equipment: Serial No: Calibration date:

Minimum Values
Conduct an insulation resistance test Test Connection Test Result
(old/new cable)
for 1 to 10 minutes (subject to the
R:Screen- Earth Ω
length of the cable) or until the >100 MΩ/1 GΩ
reading is stable.
Use a 5 kV test voltage between W:Screen- Earth >100 MΩ/1 GΩ Ω
each cable screen and earth. If
B:Screen- Earth Ω
breakdown occurs, then fault must >100 MΩ/1 GΩ
be located using cable sheath fault
N:Screen- Earth (if Ω
locator. >100 MΩ/1 GΩ
applicable)
VLF Tests
Set the VLF tester to apply the required voltage. (refer to Section 11.5.2 of SS-E115)
Wave form type: Frequency:
Test Equipment: Serial No: Calibration date:

Test Voltage (Both peak &

Test Points Test Duration Result (Pass/Fail)
RMS shall be recorded)
R 60min
W 60min
B 60min
N (if applicable) 60min

RTIO-AM-0031949 Page 55 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.14 Test Sheet – HV Cable, Sheet 3 of 3

Insulation Resistance Tests (Post VLF test)

Test Equipment: Test Voltage: Serial No: Calibration date:
Final Insulation Resistance (M)
Test Time [minutes]
R to W/B/N/E B to R/W/N/E W to B/R/N/E N to R/W/B/E
Min.values (as per Sec 11.7.1)
1
10

Ductor Tests Test Current:

Conductor ductor tests shall be performed for all power cable terminations. The acceptable resistance will depend on
the voltage and current flows at the joint. A resistance of 50μΩ or less will usually be acceptable.
Test Equipment: Serial No: Calibration date:

Supply End Load End

R μΩ R μΩ
W μΩ W μΩ
B μΩ B μΩ
N (if applicable) μΩ N μΩ
Completion
 x N/A
Check terminations are correctly tensioned □ □ □
Photos of significant cables & terminations □ □ □
Check terminal box/pit covers are replaced □ □ □
Circuit left isolated and out of service □ □ □
Drawings marked up with As Constructed changes □ □ □
Notify Commissioning Manager □ □ □
Comments / Remedial Action Required
Item Date Rectified Signature
1.
2.
3.
4.
5.
6.
7.
Inspected and Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 56 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.15 Test Sheet-LV Cable, Sheet 1 of 3

Iron Ore (WA) –Asset Management Sheet 1 of 3

Test Report No

LV Cable Tests Date

Site Area
Description

Single Line Diagram Cable Schedule

Cable No Voltage rating
Cable Size Cable route
Physical Checks
 x N/A  x N/A
Inspect cable for damage □ □ □ Check screen earthed □ □ □
Check cable numbering □ □ □ Check cable bending radius □ □ □
Check cable spacing/fixing to
Check cable size and type □ □ □ tray □ □ □
Check core numbering and
colour □ □ □ Check cable ferrules □ □ □
Inspect terminations □ □ □ Check gland/shroud □ □ □
Inspect terminals □ □ □ Check continuity of cores □ □ □
Check continuity of
Check buried depth □ □ □ earth/screen □ □ □
Phasing and Continuity Test
Cable cores are isolated at both ends, surge diverters and any voltage transformers are disconnected. Use low reading
ohm meter or Wheatstone bridge. (refer to Section 11.9 of SS-E115)
Test Equipment: Serial No: Calibration date:

Test Connections Phasing Check (Pass/Fail) Continuity Check (Resistance in

ohms)
Ω

RTIO-AM-0031949 Page 57 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.16 Test Sheet- LV Cable, Sheet 2 of 3

Iron Ore (WA) –Asset Management Sheet 2 of 3

Test Report No

LV Cable Tests Date

Insulation Resistance Tests Test Voltage: Test Duration:

Test Equipment: Serial No: Calibration date:

Minimum Values (as

Conduct an insulation resistance test Test Connection per Section 11.7.1 of Test Result
for 1 to 10 minutes (subject to the SS-E115)
length of the cable) or until the R- WBNE Ω
reading is stable.
W- RBNE Ω
Use a 500V insulation resistance
tester between each phase
B- RWNE Ω
conductor and the corresponding
cable screen or earth
N- RWBE Ω

Ductor Tests Test Current:

Conductor ductor tests shall be performed for all power cable terminations. The acceptable resistance will depend on
the voltage and current flows at the joint. A resistance of 50μΩ or less will usually be acceptable.
Test Equipment: Serial No: Calibration date:

Supply End Load End

R μΩ R μΩ
W μΩ W μΩ
B μΩ B μΩ
N μΩ N μΩ
Completion
 x N/A
Check terminations are correctly tensioned □ □ □
Photos of significant cables & terminations □ □ □
Check terminal box/pit covers are replaced □ □ □
Circuit left isolated and out of service □ □ □
Drawings marked up with As Constructed changes □ □ □
Notify Commissioning Manager □ □ □

RTIO-AM-0031949 Page 58 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.17 Test Sheet- LV Cable, Sheet 3 of 3

Iron Ore (WA) –Asset Management Sheet 3 of 3

Test Report No

LV Cable Tests
Date

Comments / Remedial Action Required

Item Date Rectified Signature
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Inspected and Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 59 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.18 Test Sheet –Instrumentation Cable, Sheet 1 of

Iron Ore (WA) –Asset Management Sheet 1 of 3

Test Report No

Instrumentation Cable Tests

Date

Site Area
Description

Single Line Diagram Cable Schedule

Cable No Voltage rating
Cable Size Cable route
Physical Checks
 x N/A  x N/A
Inspect cable for damage □ □ □ Check screen earthed □ □ □
Check cable numbering □ □ □ Check cable bending radius □ □ □
Check cable spacing/fixing to
Check cable size and type □ □ □ tray □ □ □
Check core numbering and
colour □ □ □ Check cable ferrules □ □ □
Inspect terminations □ □ □ Check gland/shroud □ □ □
Inspect terminals □ □ □ Check continuity of cores □ □ □
Check continuity of
Check buried depth □ □ □ earth/screen □ □ □
Continuity Tests
Test Equipment: Serial No: Calibration date:

Insulation Resistance Tests Test Voltage: Test Duration:

Test Equipment: Serial No: Calibration date:

Cable Tests
Test Connections Continuity Test Insulation Resistance Test
1.
2.
3.
4.
5.
6.
7.
8.
9.

RTIO-AM-0031949 Page 60 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.19 Test Sheet –Instrumentation Cable, Sheet 2 of 3

Iron Ore (WA) –Asset Management Sheet 2 of 3

Test Report No

Instrumentation Cable Tests

Date

Cable Tests
Test Connections Continuity Test Insulation Resistance Test
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Completion
 x N/A
Check terminations are correctly tensioned
□ □ □
Check terminal box/pit covers are replaced
□ □ □
Circuit left isolated and out of service
□ □ □
Drawings marked up with As Constructed changes
□ □ □
Notify Commissioning Manager
□ □ □

RTIO-AM-0031949 Page 61 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.20 Test Sheet –Instrumentation Cable, Sheet 3 of 3

Iron Ore (WA) –Asset Management Sheet 3 of 3

Test Report No

Instrumentation Cable Tests

Date

Comments / Remedial Action Required

Item Date Rectified Signature
1.
2.
3.
4.
5.
Inspected and Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 62 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.21 Underground Service Installation Checklist, Sheet 1 of 1

Iron Ore (WA) –Asset Management Sheet 1 of 1

Test Report No

Underground Service Installation Checklist Date

Site Area
Description:
Location (from):
Location (to):

INSPECTION ITEM GUIDELINES Y/N/NA Date Sign Comments

DESIGN SPECIFICATION
Approved construction drawing provided (current)
SITE REFERENCES
boundaries pegged
Final surface levels can be determined
TRENCH
WIDTH - To design specification eg. shared services use
DEPTH - Compliant with plan and final surface level
OFFSET - Alignment correct
DEVIATION - No unapproved route deviations
BEDDING SAND
Correct depth when compacted (min 50mm)
Correct grade/type
Free of rocks, sharp or foreign objects
SERVICE PITS
Location – correct boundaries
Entry conduits installed
Body not distorted, lid fitted & operational
CONDUITS
Correct size and category
DEPTH - Compliant with plan and final surface level
Road crossing – Telco separation (AS per AS3000) incl. tape
Separation to other utilities (as per AS3000)
Spare/future conduits capped or sealed
Warning tape installed (300mm +/- 50mm from final ground level)
AS BUILT DETAILS
Assets details recorded prior to cover/backfill
Supporting digital photographs recorded/attached
PROVIDE NAME AND COMPANY RESPONSIBLE

RTIO-AM-0031949 Page 63 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.22 Test Sheet – Insulation Oil

Iron Ore (WA) –Asset Management Sheet 1 of 1

Test Report No

Insulation Oil
Date

Site Area Equipment Number

Description
Equipment Type
Voltage Rating
Current Rating
Instructions
The oil sample to be tested shall be taken from the bottom of the tank. Either from the sampling valve if provided or
from the lower drain valve, preferably at operating temperatures.
The quality of the sample taken is to be one (1) litre.
The valve should be cracked to allow any sludge in the tank to drain off prior to taking a one (1) litre sample in a clean
dry container.
The sample must be allowed to stand for five (5) minutes prior to the initial test and stirred between each test and
allowed to stand for a further two (2) minutes.
Acceptance breakdown voltage 2.5 mm gap
Transformers
36kV and below 25kV (min)

66kV and above 45kV (min)

Switchgear
Less than 145kV 20kV
145kV and above 30kV (min)
Acceptance Criteria
Average of six tests to greater than 30kV
Test Results
Test Equipment: Serial No: Calibration date:
kV Breakdown at 2.5mm gap
Test Number Average
Batch No. 1 2 3 4 5 6

Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 64 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.23 Test Sheet – HV Switchgear, Sheet 1 of 3

Iron Ore (WA) –Asset Management Sheet 1 of 3

Test Report No

HV Switchgear
Date

Site Area Equipment No

Description
Single Line Diagram General Arrangement Drawing
CHECKS
Physical Checks
 x N/A  x N/A
Check paintwork for damage □ □ □ Check busbar clearance □ □ □
Inspect external components □ □ □ Check warning labels □ □ □
Inspect internal components □ □ □ Check explosion vent □ □ □
Inspect busbar chamber □ □ □ Inspect internal wiring □ □ □
Check name plate rating □ □ □ Inspect cable ducting □ □ □
Check installation secure □ □ □ Check wiring looms □ □ □
Check location □ □ □ Check cable ferrules □ □ □
Check orientation □ □ □ Check cable terminations □ □ □
Check panel arrangement □ □ □ Inspect cable terminals □ □ □
Inspect CTs □ □ □ Check cable colours □ □ □
Check internal lights □ □ □ Check space heater operation □ □ □
Ductor Tests Test Current:
Test Equipment: Serial No: Calibration date:
Measured Resistance
Test
Item Location Red White Blue
Current Neutral Earth
Phase Phase Phase
1
2
3
4
5
6
7
8
9
10

RTIO-AM-0031949 Page 65 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.24 Test Sheet – HV Switchgear, Sheet 2 of 3

Iron Ore (WA) –Asset Management Sheet 2 of 3

Test Report No

HV Switchgear
Date

Testing Levels
High Potential Test level & Frequency Insulation Resistance Test Level
Volts Hertz Volts DC
Pre- Hi Pot Test Data –Insulation Resistance
Test Equipment: Serial No: Calibration Date:

Test Points Test Voltage Test Duration Results

R to W/B/N/E
B to R/W/N/E
W to B/R/N/E
N to R/W/B/E (if applicable)
High Potential Test Data
Ramp-Up Test Periods Applied Voltage Leakage Current
Steps [minutes] R to W/B//E B to R/W/E W to B/R/E R to W/B//E B to R/W/E W to B/R/E
1
2
3
4
5
Post- Hi Pot Test Data –Insulation Resistance
Final Insulation Resistance (M)
Test Time [minutes]
R to W/B//E B to R/W/E W to B/R/E
1
10
Polarisation Index PI
(R10min/ R1min)

Polarisation Index > 1 □ Pass □ Pass □ Pass

RTIO-AM-0031949 Page 66 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.25 Test Sheet – HV Switchgear, Sheet 3 of 3

Iron Ore (WA) –Asset Management Sheet 3 of 3

Test Report No

HV Switchgear
Date

Completion
 x N/A
Check terminations are correctly tensioned
□ □ □
Check covers/shrouding is replaced
□ □ □
Circuit left isolated and out of service
□ □ □
Drawings marked up with As Constructed changes
□ □ □
Request for Energisation completed
□ □ □
Notify Commissioning Manager
□ □ □
Comments / Remedial Action Required
Item Date Rectified Signature
1.
2.
3.
4.
5.
Inspected and Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 67 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.26 Test Sheet – LV Switchgear, Sheet 1 of 3

Iron Ore (WA) –Asset Management Sheet 1 of 3

Test Report No

LV Switchgear
Date

Site Area Equipment No

Description
Single Line Diagram General Arrangement Drawing
Physical Checks
 x N/A  x N/A
Check paintwork for damage □ □ □ Check busbar clearance □ □ □
Inspect external components □ □ □ Check warning labels □ □ □
Inspect internal components □ □ □ Check explosion vent □ □ □
Inspect busbar chamber □ □ □ Inspect internal wiring □ □ □
Check name plate rating □ □ □ Inspect cable ducting □ □ □
Check installation secure □ □ □ Check wiring looms □ □ □
Check location □ □ □ Check cable ferrules □ □ □
Check orientation □ □ □ Check cable terminations □ □ □
Check panel arrangement □ □ □ Inspect cable terminals □ □ □
Inspect CTs □ □ □ Check cable colours □ □ □
Check internal lights □ □ □ Check space heater operation □ □ □
Check phase indicators to
ensure zero energy verification □ □ □
Location of MEN: (ensure matches the design)

Phasing and Continuity Test

Test Equipment: Serial No: Calibration date:

Test Connections Phasing Check (Pass/Fail) Continuity Check (Resistance in

ohms)
Ω

RTIO-AM-0031949 Page 68 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.27 Test Sheet – LV Switchgear, Sheet 2 of 3

Iron Ore (WA) –Asset Management Sheet 2 of 3

Test Report No

LV Switchgear
Date

Ductor Tests Test Current:

Test Equipment: Serial No: Calibration date:
Connection
Red Phase White Phase Blue Phase Neutral Earth
Points

Insulation Resistance Tests

Test Equipment: Serial No: Calibration Date:
Test Points Test Voltage Test Duration Results
R to W/B/N/E
B to R/W/N/E
W to B/R/N/E
N to R/W/B/E
Digital Photographs (to be attached)
Photo description Taken by

RTIO-AM-0031949 Page 69 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.28 Test Sheet- LV Switchgear, Sheet 3 of 3

Iron Ore (WA) –Asset Management Sheet 3 of 3

Test Report No

LV Switchgear
Date

Completion
 x N/A
Check terminations are correctly tensioned
□ □ □
Check covers/shrouding is replaced
□ □ □
Circuit left isolated and out of service
□ □ □
Drawings marked up with As Constructed changes
□ □ □
Request for Energisation completed
□ □ □
Notify Commissioning Manager
□ □ □
Comments / Remedial Action Required
Item Date Rectified Signature
6.
7.
8.
9.
10.
Inspected and Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 70 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.29 Test Sheet – Instrumentation

Iron Ore (WA) –Asset Management Sheet 1 of 1

Test Report No

Instrumentation Test Sheet

Date

Site Area Equipment Number

Description

Drawing

Field Transmitter □ Field Actuator □ Panel Instrument □

Calibrated At Installed location □ Factory □
□ _________________V AC

□ 2 WIRE _________________ V DC

□ _________________OTHER

□ NONE

Calibration
Input simulated by
Output measured by
0% 25% 50% 75% 100% UNITS
INPUT
OUTPUT

ZERO NOTES/REMARKS

SPAN

OTHER
SPECIFY

Earthing
Earthed at Instrument Not Earthed at Instrument Not Applicable
INSTRUMENT □ □ □
INPUT CABLE SCREEN □ □ □
OUTPUT CABLE SCREEN □ □ □
Inspected and Tested by: Company Signature Date

Inspected and Tested by: Company Signature Date

RTIO-AM-0031949 Page 71 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.30 Test Sheet – On-Drum Cable Tests, Sheet 1 of 2

Iron Ore (WA) –Asset Management Sheet 1 of 2

Test Report No

On-Drum Cable Tests

Date

Site Area
Description
Drum No. Voltage rating
Cable Type Cable length
Cable Size Supplier
Physical Checks
 x N/A  x N/A
Inspect cable for damage/defect □ □ □ Check core colour □ □ □
Inspect drum for damage □ □ □ Check outer sheath □ □ □
Check cable size and type □ □ □ Check ends sealed □ □ □
Check phase continuity □ □ □ Check earth continuity □ □ □
Insulation Resistance Tests
Test Equipment: Serial No: Calibration date:

Test Points Test Voltage Test Duration Result

R to W/B/E
W to B/R/E
B to R/W/E
Fibre Optic OTDR Tests
Test Equipment: Serial No: Calibration date:

Distance from End 1 Distance from End 2 Loss from Loss from
Fibre number Fibre Colour
to discontinuity (m) to discontinuity (m) End 1 (dB) End 2 (dB)

Digital Photographs (to be attached)

Photo description Taken by

RTIO-AM-0031949 Page 72 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.31 Test Sheet – On-Drum Cable Tests, Sheet 2 of 2

Iron Ore (WA) –Asset Management Sheet 2 of 2

Test Report No

On-Drum Cable Tests

Date

Completion
 x N/A
Check cable discharged
□ □ □
Check ends sealed
□ □ □
Comments / Remedial Action Required
Item Date Rectified Signature
1.
2.
3.
4.
5.
Inspected and Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 73 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.32 Test Sheet – Power Transformer, Sheet 1 of 4

Iron Ore (WA) –Asset Management Sheet 1 of 4

Test Report No

Power Transformer Tests

Date

Site Area Equipment No.

Description

Single Line Diagram General Arrangement Drawing

Manufacturer Type of tank
Serial No. Oil level indicator
Year of manufacture Oil temp indicator
Rating Winding temp relay
Primary voltage Buchholz relay
Secondary voltage Pressure relief vent
Vector group Pressure relay
Primary current Tap changer type
Secondary current Oil drain valve
Impedance voltage Top oil valve
Insulation level Radiator type
Insulation liquid volume Cooling fans
Oil pumping Impedance %

Physical Checks
 x N/A  x N/A
Inspect for oil leaks □ □ □ Inspect cable to HV side □ □ □
Inspect for corrosion □ □ □ Inspect cable to LV side □ □ □
Inspect for damage □ □ □ Inspect control wiring □ □ □
Check oil temp alarm setting □ □ □ Check radiator valves □ □ □
Check oil temp trip setting □ □ □ Inspect oil level □ □ □
Check winding temp alarm
setting □ □ □ Check tank pressure □ □ □
Check winding temp trip
setting □ □ □ Check breather silica gel □ □ □
Check Buchholz relay
Check earthing to tank □ □ □ operation □ □ □
Check warning signs &
Check earthing to gate □ □ □ labelling □ □ □
Check earthing to concrete
pad □ □ □ Ensure installation is secure □ □ □

RTIO-AM-0031949 Page 74 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.33 Test Sheet – Power Transformer, Sheet 2 of 4

Iron Ore (WA) –Asset Management Sheet 2 of 4

Test Report No

Power Transformer Tests

Date

On-load Tap Changer Off-Load Tap Changer

 x N/A  x N/A
Check aux power supply □ □ □ Check manual operation □ □ □
Check local operation □ □ □ Check lock facility □ □ □
Set tap on number: _____________
Set voltage regulator □ □ □
Check auto operation □ □ □
Check Master/Follower □ □ □
Check Manual operation □ □ □
Check oil level □ □ □
DC Winding Resistance Test: Ensure transformer is demagnetized after this test
Test Equipment: Serial No: Calibration date:
Primary Windings
Winding Resistance(ohms)
Tap No
R-W W-B B-R R-N (if app.) W-N (if app.) B-N (if app.)

Secondary Winding

R-W W-B B-R R-N W-N B-N

RTIO-AM-0031949 Page 75 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.34 Test Sheet- Power Transformer, Sheet 3 of 4

Iron Ore (WA) –Asset Management Sheet 3 of 4

Test Report No

Power Transformer Tests

Date

Ratio Tests
Test Equipment: Serial No: Calibration date:

Tap No HV Side Ph-Ph (V) LV Side Ph-Ph (V) Calculated Ratio Name Plate Ratio
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Insulation Resistance Tests
Test Equipment: Serial No: Calibration date:

LV Winding - HV Winding Test Voltage: kV, 1 min MΩ

HV Winding - LV Winding earthed LV Winding - HV Winding earthed

Test Voltage ____________ kV Test Voltage ____________ kV

15 secs _______________ MΩ 15 secs _______________ MΩ

60 secs _______________ MΩ 60 secs _______________ MΩ

10 min _______________ MΩ 10 min _______________ MΩ

PI _______________ PI _______________
Miscellaneous Tests
Buchholz Manufacturer Serial No Type

Surge Operation Gas Operation Insulation Resistance MΩ

Temperature alarm set at °C Temperature alarm operated at °C
Temperature trip set at °C Temperature trip operated at °C
Digital Photographs (to be attached)
Photo description Taken by

RTIO-AM-0031949 Page 76 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.35 Test Sheet- Power Transformer, Sheet 4 of 4

Iron Ore (WA) –Asset Management Sheet 4 of 4

Test Report No

Power Transformer Tests

Date

Completion
 x N/A
Circuit left isolated and out of service □ □ □
Drawings marked up with As Constructed changes □ □ □
Request for Energisation Completed □ □ □
Notify Commissioning Manager □ □ □
Comments / Remedial Action Required
Item Date Rectified Signature
1.
2.
3.
4.
5.
Inspected and Tested by: Company Signature Date

Accepted by: Company Signature Date

RTIO-AM-0031949 Page 77 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.36 Test Sheet –Transformer Commissioning Requirements, Sheet 1 of 3

Iron Ore (WA) –Asset Management Sheet 1 of 3

Project

Transformer (Commissioning Requirements)

Test Date

Site Area Pole No.

Single Line Diagram General Arrangement Drawing

Purpose: This instruction covers the testing and commissioning of all replacements or new installations of three-phase pole-
mounted distribution transformers up to 315 kVA before energisation.
Note: The following tests and checks must be carried out after installation and before the transformer is put into service.
Note: Bolts and screws in all electrical connections across the network must be properly tightened.

1. PRE-INSTALLATION CHECKS

Ensure that the earth resistance test has been completed with acceptable
☐
results prior to commissioning.
Complete these checks and tests before
Ensure that the high voltage (HV) and low voltage (LV) windings of the
installing the wiring.
transformer are de-energised, the HV and LV connections are removed, and the ☐
transformer LV neutral is disconnected from the MEN link/ N-E connections.
Test
Test Connection Resistance Expected Results
Voltage
Insulation resistance test on the
Primary/HV to Tank 5 kV Ω >1 GΩ ☐
transformer winding. (Short circuit all
winding terminals of the source of the
Primary/HV to Secondary/LV 5 kV Ω >100 MΩ ☐
same voltage level together.)
Secondary/LV to Tank 1 kV Ω >100 MΩ ☐

2. INSTALLATION AND CONSTRUCTION CHECKS

Transformer matches system voltage. ☐

Transformer tap is at the position as per network planning (new installations) or

☐
as per the tap switch position of existing trasnfromer being replaced.

Inspect the following: Transformer bushings and tank in good condition (no oil leaks). ☐
• Rating plate
• Tap setting Oil level satisfactory (if visible). ☐
• Tank and bushings
• Oil level Transformer installed as per construction standards and applicable design
• Wiring installation ☐
drawings.
• Neutral connection
• MEN/N-E connections Neutral connected and earthed and MEN / N-E link connected. ☐

All labels fitted and numbered correctly. ☐

LV lead connections to the transformer LV bushings are correct as per

☐
construction standards (as per manufactures for new connection).

RTIO-AM-0031949 Page 78 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.37 Test Sheet – Transformer Commissioning Requirements, Sheet 2 of 3

Pole/Ground Mounted Transformer Sheet 2 of 3

3. ENERGISATION OF TRANSFORMER WITHOUT LOAD

Check if HV fuses are correct. Record the fuse rating: A. ☐
Energise the transformer HV as per the HV switching program (and check for abnormal
☐
• Check that the noise). Record the switching program number:
transformer LV is not
connected to the LV Conduct a voltage and phase sequence test on the LV side of the transformer,
☐
network. preferably at the LV disconnectors or fuse box, and record the results below.
• Check the HV fuse
rating before energising R to N W to N B to N Phase-to-neutral
the transformer HV. voltages
V V V (216–253 V)
• Conduct the voltage
and phase sequence R to W W to B B to R Phase-to-phase
test once the voltages
transformer is V V V (376–440 V)
energised.
Phase sequence test result:
The phase sequence test result must be 123/ABC/RWB for a new installation or as previously recorded
for existing transformer being replaced.
4. PHASE-OUT TEST

Conduct the phase-out test on points of the LV network where the potential of the energised transformer
can be matched with the potential of another energised transformer. This test ensures the interconnection
Conduct a phase-out of transformers is made or can be made for operational purposes.
test on open points of • If the LV conductors are energised from an interconnected transformer, conduct the phase-out test at
the LV network, where the new transformer’s LV disconnector or fuse box.
the LV supply comes • If the LV conductors are not energised, proceed to item 5 (ENERGISATION OF THE NETWORK WITH
from another LOAD) and conduct the phase-out test on normally open points where it can be interconnected from
transformer. another transformer.
• When erecting a new or reconstructed LV apparatus. Phase out at an existing LV point, if possible.
Phase out any newly fitted LV disconnectors and check them for sound operation.

5. ENERGISATION OF THE NETWORK WITH LOAD

If applicable, ensure all short-circuiting equipment is removed from the LV network. ☐

If applicable, check that the LV fuses are correct.

☐
Record the fuse rating: A.
Energise the LV circuit in accordance with the switching program. Record the switching
☐
program number:
Ensure that the LV network is returned to its normal operating configuration. If
• Carry out the LV applicable, ensure that the LV circuits are not interconnected with any other ☐
switching program and transformers and are supplied only from the supply transformer.
return the LV network to Conduct a voltage test on the LV disconnector or fuse box of the new transformer to
its original operating ascertain that the transformer supply is within statutory limits during load conditions and ☐
configuration. record the results below.
• Perform a voltage test
to recheck the voltage. R to N W to N B to N Phase-to-neutral
voltages
V V V (216–253 V)
R to W W to B B to R Phase-to-phase
voltages
V V V (376–440 V)
Conduct a service connection test on all installations where the service connections
☐
have been disturbed.

RTIO-AM-0031949 Page 79 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.38 Test Sheet – Transformer Commissioning Requirements, Sheet 3 of 3

Pole/Ground Mounted Transformer Sheet 3 of 3

6. HANDOVER OF RESPONSIBILITY

I hereby certify that all items have been completed with satisfactory results and transfer control to RTIO Utilities.

Commissioning Officer

Signature

Date & Time

Notes

RTIO-AM-0031949 Page 80 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.39 Test Sheet – Voltage Transformer, Sheet 1 of 2

Iron Ore (WA) –Asset Management Sheet 1 of 1

Test Report No

Voltage Transformer
Date

Site Area Equipment Number

Description

Single line diagram General Arrangement Drawing

Manufacturer Ratio
Type HV fuses
Serial No. LV fuses
Accuracy Class VA rating
Insulation Class Function
Transformer Ratio Test
Test Equipment: Serial No: Calibration date:

Phases Primary Voltage Winding 1Voltage Winding 2 Voltage Ratio

R-N
W-N
B-N

Insulation Resistance Tests

Test Equipment: Serial No: Calibration date:

Result
Test Points Test Voltage Test Duration
Red White Blue
HV to Earth
LV to Earth
HV to LV

Inspected and Tested by: Company Signature Date

Accepted by Company Signature Date

RTIO-AM-0031949 Page 81 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.40 Test Sheet - Air Break Switch

Iron Ore (WA) –Asset Management Sheet 1 of 2

Test Report No

Air Break Switch Inspection

Date

Site Area Equipment No.

Description

Single Line Diagram General Arrangement Drawing

Physical Checks
  x N/A  x N/A
Ensure poles are straight □ □ □ Check pole identification tags □ □ □
Ensure pole position is correct □ □ □ Check DOF ratings □ □ □
Inspect surface of poles □ □ □ Inspect earth mat □ □ □
Check cross arm installation □ □ □ Inspect earth electrode □ □ □
Inspect insulators □ □ □ Check cable earths □ □ □
Check all fixings □ □ □ Check earth bar □ □ □
Check signage □ □ □
Digital Photographs (to be attached)
Photo description Taken by

Ductor Tests Test Current:

Test Equipment: Serial No: Calibration date:
Measured Resistance
Test
Item Location Red White Blue
Current Neutral Earth
Phase Phase Phase
1
2
3
4
5
6
7
8
9
10

RTIO-AM-0031949 Page 82 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Iron Ore (WA) –Asset Management Sheet 2 of 2

Test Report No

Air Break Switch Inspection

Date

Completion
 x N/A
Circuit left isolated and out of service □ □ □
Drawings marked up with As Constructed changes □ □ □
Request for Energisation Completed □ □ □
Notify Commissioning Manager □ □ □
Comments / Remedial Action Required
Item Date Rectified Signature
1.
2.
3.
4.
5.
Inspected and Tested by: Company Signature Date

Accepted by Company Signature Date

RTIO-AM-0031949 Page 83 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.41 Test Sheet- Relay Testing ITP Template

Iron Ore (WA) –Asset Management Sheet 1 of 1

Test Report No
Relay Testing ITP
Relay Testing ITP template can be found at the
following link: Click here (RTIO-AM-0115597) Date

Site(s)

Equipment
Reference
Material
Involved
Personnel
Comments / Remedial Action Required
Item Date Rectified Signature
1.
2.
3.
4.
5.
Inspected and Tested by: Company Signature Date

Accepted by Company Signature Date

RTIO-AM-0031949 Page 84 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.42 Test Sheet: Electrical Installation, Sheet 1 of 2

Iron Ore (WA) –Asset Management

Electrical Installation Test Sheet
Test Report No

Date

Pre-test EFLI and Voltage

(when connected) conducted
at any socket in the
Date Time installation, results less than
values in table 8.1 AS3000 or
do not proceed

Electrical Workers
Name

Installation
EW Licence Number
Address

Electrical Contractors
Business name

(include board
Electrical Contractors
location and number
EC/IH Number
if needed)
Task being carried out (as much detail as is needed):

Prelim/Completion
Work Order/Project
Notice number (if ESC Number
applicable) Number (if applicable)

Test Equipment details:

Brand/Type/Serial/Test date

Visual Checks - ALL TO BE VERIFIED FOR ALL AFFECTED WORK COMPLETED Y N NA

all parts/equipment are insulated and/or enclosed

all designed guards/panels and/or covers are in place

Physical all penetrations have been sealed
Protection
Physical condition of electrical equipment has been confirmed safe

all unused equipment has been disconnected and/or removed (where practicable)

consumer mains have been calculated for current carrying capacity and volt drop
Consumer
mains consumer main installation methods have been considered for de-rating as per AS
3008.1.1

RTIO-AM-0031949 Page 85 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.43 Test Sheet: Electrical Installation, Sheet 2 of 2

are switchboards accessible and located where they can be worked on safely

all circuits protected by appropriately set protective devices

Switchboards Main Switches are correctly rated

and labelling all neutral, earth and active links are installed correctly

all connections and fixings have been checked

all equipment has been labelled correctly

sub circuits have had their conductor sizes calculated for current carrying capacity
and volt drop
all cable cores have been identified and labelled correctly
Wiring
installation methods have been considered for de-rating
Systems
all cabling is adequately supported

segregation is provided (where applicable)

Isolation devices are in place where required for protection against mechanical
movement and thermal effects – eg, HWS, Air Conditioners, Motors etc.
equipment installed in special situations is adequately designed – eg damp areas,
Electrical hazardous areas
Equipment adequate smoke alarms are installed as per BCA requirements and they are less
than 10yrs old?
all equipment is provided with necessary switches – eg, outlets, Cookers, water
heaters
MEN is installed and connected (where applicable)

Earth Electrode installed and connected

Earthing
Equipotential Earthing conductors connected (where applicable)

Earthing conductors are adequately sized for all circuits and identified accordingly

Faults/Defects found as per above (where applicable):

Exit EFLI Test after all works are complete - Name -

Has the MEN been reinstated (Main Earth and Main Neutral) - Signature -

RTIO-AM-0031949 Page 86 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.44 LV Circuit Voltage Test Sheet

Iron Ore (WA) –Asset Management

Circuit Voltage Test Test Report No
Sheet 1 of 2

Date
Location:

All main switches in the OFF position, all circuits OFF, main neutral removed

Voltage Test Voltage Reading

Independent Earth to Red Phase
Independent Earth to Neutral
Independent Earth to White Phase
Independent Earth to Blue Phase
Earth Bar to Red Phase
Earth Bar to Neutral
Neutral to Red Phase
Neutral to White Phase
Neutral to Blue Phase
Red Phase to White Phase
Red Phase to Blue Phase
Blue Phase to White Phase

Phase Rotation: Clockwise / Anticlockwise

Notes:

Company Name & EW# Signature Date

Inspected &
Tested

Accepted

RTIO-AM-0031949 Page 87 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Iron Ore (WA) –Asset Management

Circuit Voltage Test Test Report No
Sheet 2 of 2

Date
Location:

All main switches in the OFF position, main neutral connected

Voltage Test Voltage Reading

Independent Earth to Red Phase
Independent Earth to Neutral
Independent Earth to White Phase
Independent Earth to Blue Phase
Earth Bar to Red Phase
Earth Bar to Neutral
Neutral to Red Phase
Neutral to White Phase
Neutral to Blue Phase
Red Phase to White Phase
Red Phase to Blue Phase
Blue Phase to White Phase

Impedance Tests Impedance Reading

Line Loop Impedance Test

Turn Main Switch ON (Add load if possible)

Voltage Test Voltage Reading

Independent Earth to Red Phase
Independent Earth to Neutral
Independent Earth to White Phase
Independent Earth to Blue Phase

Impedance Tests Impedance Reading

Earth fault loop impedance test (at a GPO & only if possible)

Company Name & EW# Signature Date

Inspected &
Tested

Accepted

RTIO-AM-0031949 Page 88 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

A.45 Pre-Energisation Insulation & Continuity Test

Iron Ore (WA) Sheet 1 of 2

Test Report No

Pre-Energisation Insulation & Continuity Test

Date

Procedure
1. Record test equipment information
2. Locate and attach SLD of the test area. Identify and mark on the SLD the test area and ensure;
 Circuit state will allow for continuity through entire length of circuit under test
 All earths removed
 All VTs Disconnected
 No circuits that are part of this test are connected
 All multiple circuits where applicable are bonded Red-Red, White-White, Blue-Blue at both ends of
test area (or repeat this test for each individual circuit)
 Ensure there is adequate Earth continuity through the entire length of the circuit under test
3. Identify Red/White/Blue phases on both ends of the circuit under test (for the purpose of this test, each
end of the test area will be named point-A and point-B)
4. Connect all three phases to earth at point-A
5. Measure insulation level between Red phase and ground at point-B. Record value in the Continuity test
table below
6. Remove earth from Red phase at point-A
7. Measure insulation level between Red phase and ground at point-B. Record value in the Continuity test
table below
8. Measure insulation level between White phase and ground at point-B. Record value in the Continuity
test table below
9. Remove earth from White phase at point-A
10. Measure insulation level between White phase and ground at point-B. Record value in the Continuity
test table below
11. Measure insulation level between Blue phase and ground at point-B. Record value in the Continuity
test table below
12. Remove earth from Blue phase at point-A, no earths are now applied to point-A
13. Measure insulation level between Blue phase and ground at point-B. Record value in the Continuity
test table below
14. Measure insulation from Red phase to White phase at point-B (no earths applied)
15. Measure insulation from Red phase to Blue phase at point-B (no earths applied)
16. Measure insulation from White phase to Blue phase at point-B (no earths applied).

RTIO-AM-0031949 Page 89 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Sheet 2 of 2
Iron Ore (WA)

Pre-Energisation Insulation & Continuity Test

Test Equipment: Serial No: Calibration date:

Continuity test
Test Points Test Voltage Test Duration Result
R/W/B/E (point-A)
R to E (point-B)
W/B/E (point-A)
R to E (point-B)
W/B/E (point-A)
W to E (point-B)
B/E (point-A)
W to E (point-B)
B/E (point-A)
B to E (point-B)
All open (point-A)
B to E (point-B)

Insulation test
Test Points Test Voltage Test Duration Result
Red to White

Red to Blue

White to Blue

Inspected and Tested: Company Signature Date

Accepted: Company Signature Date

RTIO-AM-0031949 Page 90 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only
 Asset Management & Engineering Services SS-E115 – Testing and Commissioning of Electrical Installations

Appendix B - Document
Revision Control Table
DOCUMENT REVISION CONTROL
Version 8 Version 9
Appendix A Appendix A Added a new test sheet - Underground Service Installation Checklist
Version 7 Version 8 Change
3 3 Updated all Standards Lists
4.1 4.1 Corrected VLF abbreviation
10.4 10.4 Added corrosion protection bullet point to Earthing section
10.8 10.8 Added radiator valve checks
Removed tower bolt torque checks and added current carrying connection torque
10.9 10.9
tests.
11.4 11.4 Major update to Earthing Systems to reflect practices of SS-E273
Clarification of what tests are required. VLF not to be performed on existing
11.7 11.5
cables.
11.7.1 11.5.1 Clarified requirements on what to do with a failed sheath integrity test.

11.7.2 11.7.2 VLF Section extensively modified to reflect use of RMS voltages
11.7.5 N/A PI Test removed for HV cables
N/A 11.5.5 New section PD testing added

N/A 11.5.6 New section on Tan Delta testing added

11.13 11.11 PI test removed from switchgear
11.13.4 11.11.3 AC withstand test voltage set to 80% of rated withstand capability
11.14 11.12 Added function trip test to protection commissioning
N/A 11.22 New section added for combined insulation and continuity test
 Modified HV Cable Test Sheets with further info on sheath integrity testing
Appendix A Appendix A and VLF test data. Removed PI test from sheet.
 Modified A.9 Earthing Test sheet to reflect changes in body of document.
Appendix A N/A Removed Overhead Line inspection sheets
N/A Appendix A  Added sheets A.45 and A.46.

RTIO-AM-0031949 Page 91 of 91 Approved: 22/08/18

Printed copies are uncontrolled Rev: 10
© 2018, Held within Rio Tinto
For internal use only