9 INP 17022-P4-E-0A1H-QA-00801 - 0 Earthing Installation and Testing

PT Bajra Mandalasakti
Graha Mobisel Building, 2nd Floor

Jl. Buncit Raya No. 139
JAKARTA SELATAN 12740
INDONESIA
INSTALLATION PROCEDURE PAGE 1 of 15
NUMBER INP 17022-P4-E-0A1H-QA-00801
PROJECT TITLE WARA CRUSHING PLANT PROJECT JOB No. 17022
DESCRIPTION WARA CRUSHING PLANT PROJECT

EARTHING & LIGHTNING PROTECTION
INSTALLATION AND TESTING
QUALITY PLAN
OFFICE OF ORIGIN PT BAJRA MANDALASAKTI DIR. REF 17022-1.9.1.INP
WRITTEN BY DARREN HOUSE DATE: 25.01.2018 CLIENT PO

25.01.2018 CLIENT REP.
REVIEWED BY EDMUND ANDERSON DATE:
TITLE OF REVIEWER PROJECT SPONSOR
STATUS APPROVAL BY CLIENT RESPONSIBLE MANAGER/ENGINEER
SIGNED DATE REV.
ACCEPTED .......................... .................... .............

(Alpha or Numeric)
ACCEPTED EXCEPT AS NOTED .......................... .................... .............

(Alpha)
REVISE AND RESUBMIT .......................... .................... .............

(Alpha or Numeric)
APPROVAL BY CLIENT RESPONSIBLE MANAGER

(Numeric)
.................................................................................. DATE: ................................
Rev. Date Description By Chk’d Reviewed Client

0 01.02.2018 Issued for Use
INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

Graha Mobisel Building, 2nd Floor
Jl. Buncit Raya No. 139
JAKARTA SELATAN 12740
INDONESIA
INSTALLATION PROCEDURE PAGE 2 of 15
NUMBER INP 17022-P4-E-0A1H-QA-00801
PROJECT TITLE WARA CRUSHING PLANT PROJECT JOB No. 17022
DESCRIPTION WARA CRUSHING PLANT PROJECT

EARTHING & LIGHTNING PROTECTION
INSTALLATION AND TESTING
QUALITY PLAN
OFFICE OF ORIGIN PT BAJRA MANDALASAKTI DIR. REF 17022-1.9.1.INP
WRITTEN BY DARREN HOUSE DATE: 25.01.2018 CLIENT PO

25.01.2018 CLIENT REP.
REVIEWED BY EDMUND ANDERSON DATE:
TITLE OF REVIEWER PROJECT SPONSOR
STATUS APPROVAL BY CLIENT RESPONSIBLE MANAGER/ENGINEER
SIGNED DATE REV.
ACCEPTED .......................... .................... .............

(Alpha or Numeric)
ACCEPTED EXCEPT AS NOTED .......................... .................... .............

(Alpha)
REVISE AND RESUBMIT .......................... .................... .............

(Alpha or Numeric)
APPROVAL BY CLIENT RESPONSIBLE MANAGER

(Numeric)
.................................................................................. DATE: ................................
Rev. Date Description By Chk’d Reviewed Client

0 01.02.2018 Issued for Use DH DH EA

WARA CRUSHING PLANT PROJECT
EARTHING & LIGHTNING PROTECTION Dir. Ref: 17022-1.9.1.INP
INSTALLATION AND TESTING Date: 25/01/18
QUALITY PLAN Page: 3 of 15
CONTENTS
1.0 INTRODUCTION................................................................................................. 4
1.1 Specification ...................................................................................................... 4
2.0 SUBSTATION EARTHING ................................................................................. 5
3.0 EQUIPMENT PLANT EARTHING ...................................................................... 6
4.0 CABLE LADDER AND STRUCTURAL BONDING ............................................ 7
5.0 LIGHTNING PROTECTION ................................................................................ 8
6.0 TESTING ............................................................................................................ 9
LIST OF APPENDICES
APPENDIX - A LIST OF INSPECTION & TEST PLAN (ITP’s) ...................................... A-1

APPENDIX - B LIST OF INSTALLATION CHECK SHEETS ......................................... B-1
APPENDIX - C LIST OF TEST SHEETS ...................................................................... C-1

1.0 INTRODUCTION
The purpose of this document is to describe the procedure employed to ensure that all
Lightning Protection, Substation and Plant Earthing is installed, tested and documented in
accordance with project requirements and general electrical specifications.
1.1 Specification
The Earthing and Lightning Protection installation shall be in accordance with the Project
Specifications, Indonesian Standards, IEC or Australian Standards (in that order of
priority);
 Relevant Project Specific Customer Standards and Specifications.
 Standards National Indonesia - General Requirements for Electrical Installation 2000

(PUIL 2000)
 AS/NZS 3000:2007 Electrical installations (known as the Australian/New Zealand

Wiring Rules)
 AS/NZS 1768:2007 Lightning Protection.

2.0 SUBSTATION EARTHING

Main earthing grids shall be installed and tested in accordance with the project drawings
and specifications. In the event that project specific documentation is not available, below
outlines Company minimal requirements for main earthing grid installations.
An Earthing Loop shall be installed around each substation in accordance the respective
Substation Earthing Layout Drawings. Substation Earthing Loops shall consist of Copper
Earthing Rods and Inspection Pits interconnected with an earth loop of underground bare
Copper Conductor.
Sizing of Earth Rods and Bare Copper Earthing Conductor shall be as indicated on the
Substation Earthing Layout Drawings.
After Installation of the Substation Earthing Loop and all rods interconnected should have
a resistance to ground on less than one Ohm at any point.
The Substation Earth Loop shall be connected using approved underground bare copper
cable connectors to a Substation Main Earth Bar using Green/Yellow PVC Earthing
Conductor connected at two points using Cable Sizing as indicated on Substation
Earthing Layout Drawings.
All Main Electrical Equipment installed in the Substation will be connected with a separate
Green/Yellow PVC Earthing Conductor back to the Substation Main Earth Bar using Cable
Sizing as indicated on Substation Earthing Layout Drawings.
Four Wire Systems shall be effectively earthed at the Start Point of the secondary winding
of Distribution Transformers at each substation using Green/Yellow PVC Earthing
Conductor connected to the Substation Main Earth Bar using Cable Sizing as indicated on
Substation Earthing Layout Drawings.
Where applicable, Steel Support Sections of the Substation Building will be connected
back to the Bare Copper Earth Loop with approved connectors using Green/Yellow PVC
Earthing Conductor with sizes as shown on Substation Earthing Layout Drawings.
Transformer Compound Fencing will be connected back to the Bare Copper Earth Loop
with approved connectors using Green/Yellow PVC Earthing Conductor with sizes as
shown on Substation Earthing Layout Drawings. A flexible earthing connection will be
made between Stationary Fencing Poles and Transformer Compound Gates ensuring that
the Gate has a solid earth connection at all times.

3.0 EQUIPMENT PLANT EARTHING

Equipment plant earthing shall be installed and tested in accordance with the project
drawings and specifications. In the event that project specific documentation is not
available, below outlines Company minimal requirements for equipment earthing.
Generally all plant equipment will be solidly earthed with the earthing core conductor in
the multicore power supply cable. All Earthing conductors for power supply cabling must
be connected to the Switchboard, Motor Control Centre or Distribution Board where the
source originates and be connected at the Plant Equipment.
High Voltage electrical equipment will be earthed by a separate earthing conductor. The
earthing conductor should be connected to the Main HV Switchboard at which the HV
source originates and shall be connected at the field equipment.

4.0 CABLE LADDER AND STRUCTURAL BONDING

Cable Ladder and Steel Structure earthing shall be installed and tested in accordance with
the project drawings and specifications. In the event that project specific documentation is
not available, below outlines Company minimal requirements for Cable Ladder and Steel
Structure earthing installation.
Cable Ladder and Steel Structure earthing shall be installed throughout the plant and
connected back to the Substation Main Earth Bar using Green/Yellow PVC Earthing
Conductor.
A 70mm2 Green/Yellow PVC Earthing Conductor will be installed for the complete length
in each complete Cable Ladder Run. The Earth Conductor will be bonded to the Cable
Ladder every 10 Meters using a proprietary Clamping Device and connected back to the
Substation Main Earth Bar.
Where more than one Cable Ladders is installed on the same route, only one continuous
earth conductor will be installed, however all cable ladders will be bonded to the earthing
conductor every 10 Meters.
An Earthing Loop shall be installed around each free standing steel structure in
accordance the respective Earthing Layout Drawings. Steel Structure Earthing Loops shall
consist of Copper Earthing Rods and Inspection Pits interconnected with an earth loop of
underground bare Copper Conductor.
Sizing of Earth Rods and Bare Copper Earthing Conductor shall be as indicated on the
Conveyor Transfer Tower Earthing Layout Drawings.
The Steel Structure will be connected using Green/Yellow PVC Earthing Conductor to the
Bare Copper Earth Loop with approved connectors at points as detailed on the Steel
Structure Earthing Layout Drawings.

5.0 LIGHTNING PROTECTION

Lightning protection shall be installed and tested in accordance with the project drawings
and specifications. In the event that project specific documentation is not available, below
outlines Company minimal requirements for Lightning Protection installation.
Lightning Protection is installed in accordance with AS1768 and based on approximately

50 thunder days per year.
Lightning Protection where required, will be connected using Green/Yellow PVC Earthing
Conductor to earth rods and earthing loop as detailed Layout Drawings. The earthing loop
will be separate and not connected back to the substation earthing systems.

6.0 TESTING
Earthing and Lightning protection shall be tested in accordance with the project
specifications. In the event that project specific documentation is not available, below
outlines Company minimal requirements for Earthing and Lightning Protection testing.
Resistance of each individual Earth Rod will be tested and recorded after installation and
prior to interconnection to other earth rods in an earthing loop.
Once complete earthing loops are installed the complete earthing loop will be tested at
two points and recorded on the appropriate test sheet. Earthing resistance at any point on
the earth loop shall not exceed one ohm.

QUALITY PLAN Page: A-1 of 15
APPENDIX - A LIST OF INSPECTION & TEST PLAN (ITP’s)

QUALITY PLAN Page: A-2 of 15
NO DOCUMENT NUMBER TITLE
1 INP 17022-P4-E-0A1H-IT-00801 Earthing & Lightning Protection Installation

Owner Date
PT Bajra Mandalasakti Project Name ITP No. INP 17022-P4-E-0A1H-IT-00801
INSPECTION & TEST PLAN Contract / PO No. Revision 0 - For Use
Description of Item Earthing & Lightning Protection Installation
Manufacture / Construction Process Acceptance Reference or Test Const. Inspection / INSPECTORATE Verifying
Item
Inspection / Test Point Description Criteria Specification Frequency Procedure Test Method BMS BUMA App. Record
Once - After INP 17022-P4-E- INP 17022-P4-E-

1 Earth Rod Size and Quantity Correct Earthing Drawing Visual X R N/A
Installation 0A1H-QA-00801 0A1H-IC-00801
2 Earth Rod Inspection Pit Installed Correct Earthing Drawing Visual X R N/A
3 Correct Earth Loop Cable Type & Size Installed Earthing Drawing Visual X R N/A
4 Earth Loop Cable Installed Underground at the Correct Depth Earthing Drawing Visual X R N/A
Earth Bar Installed Correct with Correct Connections to Earth Loop and Once - After INP 17022-P4-E- INP 17022-P4-E-
5 Visual Inspection Visual X R N/A
Main Equipment Installation 0A1H-QA-00801 0A1H-IC-00801
6 Substation Distribution Transformer Start Point Earthed Visual Inspection Visual X R N/A
7 Structural Steel Bonding Installed as required Earthing Drawing Visual X R N/A
8 Transformer Compound and Gate Earth Bonding Correct Visual Inspection Visual X R N/A
9 Cable Ladder Bonding Cable Size Correct Visual Inspection Visual X R N/A
10 Cable Ladder Bonding every 10 Meters Visual Inspection Visual X R N/A
11 Earth Rod Resistance Measured and Recorded Test Results Visual X R N/A
Earthing Loop, Compete Earthing Resistance Test after earth rods are Once - After INP 17022-P4-E- INP 17022-P4-E-
12 Test Results Visual X W
interconnected Installation 0A1H-QA-00801 0A1H-IC-00801
Lightning Protection Air Terminals and Conductor Size and Locations Once - After INP 17022-P4-E- INP 17022-P4-E-
13 Visual Inspection Visual X R N/A
Correct Installation 0A1H-QA-00801 0A1H-IC-00801
14 Lightning Protection and Earthing Systems are separated. Visual Inspection Visual X R N/A
LEGEND NOTES
X- Inspected Performed By The appropriate abbreviation shall be placed in the Inspectorate Column under the organization responsible for the Inspection (X) or
1.
Random Inspection the authority to witness (W) or the authority to release a Hold Point (H) etc.
R-
W- Witness Point The authority to witness a Witness Point or release a Hold Point is required to sign in the App. Column in the Inspectorate Section
2.
H before the next task can be executed.
Hold Point
INP 17022-P4-E-0A1H-IT-00801_0 Earthing & Lightning Protection Installation ITP - ITP Page 1 of 1
QUALITY PLAN Page: B-1 of 15
APPENDIX - B LIST OF INSTALLATION CHECK SHEETS

QUALITY PLAN Page: B-2 of 15
1 INP 17022-P4-E-0A1H-IC-00801 Earthing Installation Verification Check Sheet

INSTALLATION CHECKLIST
EARTHING & LIGHTNING PROT. SYSTEM
INP 17022-P4-E-0A1H-IC-00801
Description: Earthing Installation Verification Check Sheet File:

Contract Title: Contract
Location: Date:
ITEM ACTIVITY By BMS Yes / No Date Client
1 Pre Installation Activities

1.1 JSA's / Procedures in place for task N/A
1.2 Check cable route for completeness N/A
2 Installation
2.1 Earth Rod Size and Quantity installed as per Installation Drawings N/A
2.2 Inspection Pits installed Correctly at the Correct Locations N/A
2.3 Earth Loop Conductor Size Correct as per Installation Drawings N/A
2.4 Earth Loop Conductor Installed at the Correct Depth N/A
2.5 Earth Connection from Earth Loop to Main Earth Bar Correct N/A
2.6 All Main Equipment Correctly Connected to Main Earth Bar N/A
2.7 Substation Distribution Transformer Star Point Earthed Correctly N/A
2.8 Structural Steel Bonded installed as per Installation Drawings N/A
2.9 Transformer Compound Fencing and Gates Bonded Correctly N/A
2.10 Cable Ladder Bonding Cable Size Correct and Installed Correctly N/A
2.11 Cable Ladder Bonding every 10 Meters N/A
2.12 Air Terminal Size and Locations Correct N/A
2.13 Lightning Protection and Earth System Separate N/A
Remarks
Work Complete and Verified by
Name and Signature: Date:
PT Bukit Makmur Mandiri Utama

INP 17022-P4-E-0A1H-IC-00801_0 Earthing Installation Verification Check Sheet - Installation Checklist Page 1 of 1
QUALITY PLAN Page: C-1 of 15
APPENDIX - C LIST OF TEST SHEETS

QUALITY PLAN Page: C-2 of 15
1 INP 17022-P4-E-0A1H-TR-00801 Earth System Test Sheet

TEST RECORD (Main Contractor Logo) (Project Owner Logo)
EARHING TEST SHEET
INP 17022-P0-E-0A1H-TR-00801
Description: Earth System Test Sheet File:

Contract Title: Contract
Location: Date:
INSTALLATION
Main Earth Bar Size Dwg No.

Earth Loop Cable Size
Description
TEST RESULTS
Earth Tester
Make / Model : Serial No.
Cal Certificate No. Valid Until:
TEST RESULTS
Individual Earth Rod Resistance

Earth Rod Number Locatio n Resistance Ohms
Complete Earth Loop Resistance (@ Two Locations)

Location No. 1 Resistance Ohms
Location No. 2 Resistance Ohms
Remarks
Tested, Verified and Accepted by:
Main Contractor Company's Name

Project Owner Company's Name

INP 17022-P0-E-0A1H-TR-00801_A Earthing Test Sheet - Test Record Page 1 of 1

9 INP 17022-P4-E-0A1H-QA-00801 - 0 Earthing Installation and Testing

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PT Bajra Mandalasakti

Graha Mobisel Building, 2nd Floor

INSTALLATION PROCEDURE PAGE 1 of 15

NUMBER INP 17022-P4-E-0A1H-QA-00801

PROJECT TITLE WARA CRUSHING PLANT PROJECT JOB No. 17022

DESCRIPTION WARA CRUSHING PLANT PROJECT

OFFICE OF ORIGIN PT BAJRA MANDALASAKTI DIR. REF 17022-1.9.1.INP

WRITTEN BY DARREN HOUSE DATE: 25.01.2018 CLIENT PO

STATUS APPROVAL BY CLIENT RESPONSIBLE MANAGER/ENGINEER

SIGNED DATE REV.

ACCEPTED .......................... .................... .............

ACCEPTED EXCEPT AS NOTED .......................... .................... .............

REVISE AND RESUBMIT .......................... .................... .............

APPROVAL BY CLIENT RESPONSIBLE MANAGER

.................................................................................. DATE: ................................

Rev. Date Description By Chk’d Reviewed Client

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

INSTALLATION PROCEDURE PAGE 2 of 15

NUMBER INP 17022-P4-E-0A1H-QA-00801

PROJECT TITLE WARA CRUSHING PLANT PROJECT JOB No. 17022

DESCRIPTION WARA CRUSHING PLANT PROJECT

OFFICE OF ORIGIN PT BAJRA MANDALASAKTI DIR. REF 17022-1.9.1.INP

WRITTEN BY DARREN HOUSE DATE: 25.01.2018 CLIENT PO

STATUS APPROVAL BY CLIENT RESPONSIBLE MANAGER/ENGINEER

SIGNED DATE REV.

ACCEPTED .......................... .................... .............

ACCEPTED EXCEPT AS NOTED .......................... .................... .............

REVISE AND RESUBMIT .......................... .................... .............

APPROVAL BY CLIENT RESPONSIBLE MANAGER

.................................................................................. DATE: ................................

Rev. Date Description By Chk’d Reviewed Client

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

APPENDIX - A LIST OF INSPECTION & TEST PLAN (ITP’s) ...................................... A-1

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

 Relevant Project Specific Customer Standards and Specifications.

 Standards National Indonesia - General Requirements for Electrical Installation 2000

 AS/NZS 3000:2007 Electrical installations (known as the Australian/New Zealand

 AS/NZS 1768:2007 Lightning Protection.

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

2.0 SUBSTATION EARTHING

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

3.0 EQUIPMENT PLANT EARTHING

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

4.0 CABLE LADDER AND STRUCTURAL BONDING

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

5.0 LIGHTNING PROTECTION

Lightning Protection is installed in accordance with AS1768 and based on approximately

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

APPENDIX - A LIST OF INSPECTION & TEST PLAN (ITP’s)

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

NO DOCUMENT NUMBER TITLE

1 INP 17022-P4-E-0A1H-IT-00801 Earthing & Lightning Protection Installation

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

Once - After INP 17022-P4-E- INP 17022-P4-E-

APPENDIX - B LIST OF INSTALLATION CHECK SHEETS

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

NO DOCUMENT NUMBER TITLE

1 INP 17022-P4-E-0A1H-IC-00801 Earthing Installation Verification Check Sheet

INP 17022-P4-E-0A1H-QA-00801_0 Earthing Installation and Testing

Description: Earthing Installation Verification Check Sheet File:

ITEM ACTIVITY By BMS Yes / No Date Client

1 Pre Installation Activities