Inspection and Test Plan (ITP) - Electrical Works
Qaremy Construction - NSW Solar Farm Project
Document Control
- Document No: QAR-ITP-ELE-001
- Revision: A
- Date: October 2025
- Discipline: Electrical Works
1. Purpose and Scope
This Inspection and Test Plan defines the inspection and testing requirements for electrical works associated with the Solar Farm project.
Scope includes:
- PV module installation
- DC cabling and terminations
- Inverters and inverter stations
- MV transformers
- LV/MV switchgear
- 33kV underground and overhead cabling
- 132kV substation equipment
- Earthing and lightning protection
- SCADA and monitoring systems
- Testing and commissioning
2. Applicable Standards
- AS/NZS 5033:2021 - Installation and safety requirements for photovoltaic arrays
- AS/NZS 3000:2018 - Electrical installations (Wiring Rules)
- AS/NZS 4777.1:2016 - Grid connection of energy systems via inverters
- AS/NZS 3017:2022 - Electrical installations - Verification guidelines
- AS 2067:2016 - Substations and high voltage installations
- AS/NZS 61439 series - Low-voltage switchgear and controlgear assemblies
- IEC 62446 - Grid connected PV systems - Minimum requirements for documentation, commissioning tests and inspection
3. Inspection Point Definitions
| Symbol | Type | Definition |
|---|---|---|
| 🛑 H | Hold Point | Work must stop until inspection completed and approval given |
| 👁️ W | Witness Point | Inspector must be given opportunity to witness |
| 📋 R | Review Point | Documentation reviewed, work may proceed during review |
4. ITP Table - PV Module Installation
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Pre-Installation | ||||||
| Module delivery inspection | Visual inspection, quantity verification | R | QC | AS/NZS 5033 | No visible damage, datasheet matches order | Delivery checklist |
| Module data verification | Datasheet and certification review | H | QA | AS/NZS 5033, IEC 61215 | Valid IEC certification, meets design specification | Product certificates |
| Module flash test report | Factory test data | R | QA | IEC 61215 | Power rating within tolerance (typically +/-3%) | Flash test reports |
| Module storage | Storage conditions check | R | QC | AS/NZS 5033 | Protected from weather, off ground, stable stacking | Inspection record |
| Installation | ||||||
| Mounting clamp installation | Torque verification | W | QC | AS/NZS 5033, OEM spec | Torque per specification (typically 8-12 Nm) | Torque log (sample 10%) |
| Module placement | Orientation and alignment | R | QC | Design drawings | Correct orientation, aligned in array | Inspection checklist |
| Module serial number recording | Serial number capture | R | QC | AS/NZS 5033 | All serial numbers recorded per string | Module register |
| Electrical Connections | ||||||
| DC connector inspection | Connector type and condition | H | QC | AS/NZS 5033 | IP68 rated, no damage, positive click connection | Connector checklist |
| String polarity check | Polarity verification | H | QC | AS/NZS 5033 | Correct polarity confirmed before paralleling | Polarity test record |
| String open-circuit voltage | Voc measurement | H | QC, TP | AS/NZS 5033 | Within 5% of calculated Voc (considering temperature) | String test sheet |
| String short-circuit current | Isc measurement | W | QC | AS/NZS 5033 | Within 10% of expected Isc | String test sheet |
| String insulation resistance | Insulation test (DC+ and DC- to earth) | H | QC, TP | AS/NZS 5033 | >1 MΩ (test at 500V DC) | Insulation test certificate |
| String continuity | Continuity check | W | QC | AS/NZS 5033 | Continuous circuit verified | Test record |
| Post-Installation | ||||||
| Final visual inspection | Physical condition check | R | QC | AS/NZS 5033 | No damage, all modules secure, clean | Inspection checklist |
| String labeling | Label verification | R | QC | AS/NZS 5033 | All strings clearly labeled per numbering system | Photo evidence |
| As-built documentation | String layout confirmation | R | QC | Project requirements | Matches as-installed configuration | As-built drawings |
Testing Frequency:
- Torque verification: 10% sample per array
- Voc/Isc: 100% of strings
- Insulation resistance: 100% of strings
5. ITP Table - DC Cabling and Combiner Boxes
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| DC Cabling | ||||||
| Cable material certification | Material certificates review | H | QA | AS/NZS 5033 | UV resistant, rated for 1500V DC, compliant with AS/NZS 5000.1 | Cable certificates |
| Cable installation | Installation method check | R | QC | AS/NZS 5033 | Correct routing, support, no sharp bends (min radius >10× cable diameter) | Inspection checklist |
| Cable sizing verification | Conductor size check | R | QC | AS/NZS 5033 | Per design calculations, voltage drop ❤️% | Cable schedule |
| Cable terminations | Visual inspection | W | QC | AS/NZS 5033 | Proper crimping, correct ferrules, no exposed conductor | Termination checklist |
| Cable gland installation | IP rating verification | R | QC | AS/NZS 5033 | IP68 rating maintained, properly sealed | Inspection record |
| Combiner Boxes / DC Switchboards | ||||||
| Equipment certification | Type approval | H | QA | AS/NZS 5033 | Compliant with AS/NZS 61439, IP rating suitable (typically IP65) | Equipment certificates |
| Installation location | Mounting and accessibility | R | QC | AS/NZS 5033 | Secure mounting, accessible, correct labeling | Inspection checklist |
| Fuse ratings verification | Fuse/breaker sizing check | H | QC | AS/NZS 5033 | Rated for string Isc × 1.25 minimum | Fuse schedule |
| Polarity check | DC polarity verification | H | QC | AS/NZS 5033 | Correct polarity throughout | Polarity test sheet |
| Insulation resistance test | Insulation test | H | QC, TP | AS/NZS 5033 | >1 MΩ at 500V DC (each circuit to earth and circuit-to-circuit) | Test certificate |
| Earth continuity test | Earth bonding verification | H | QC | AS/NZS 3000 | <0.5Ω resistance to main earth | Earth test certificate |
6. ITP Table - Inverters and Inverter Stations
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Pre-Installation | ||||||
| Inverter certification | Type test certificates | H | QA | AS/NZS 4777.2, IEC 62109 | Valid certification, meets grid connection requirements | Product certificates |
| Equipment receipt inspection | Physical inspection on delivery | R | QC | Manufacturer specs | No transit damage, complete accessories | Delivery checklist |
| Foundation/mounting verification | Civil/structural inspection | H | QC | Design drawings | Foundation level and dimensions correct | Survey certificate |
| Installation | ||||||
| Inverter mounting | Alignment and fixing | R | QC | OEM manual | Level, secure mounting per manufacturer instructions | Inspection checklist |
| DC connections | Termination inspection | H | QC | AS/NZS 5033 | Correct polarity, torque per spec, no damage | Termination record |
| AC connections | Termination inspection | H | QC | AS/NZS 3000 | Phase sequence correct, torque verified | Termination record |
| Communication cabling | Network connections | R | QC | OEM manual | Correct cable type, properly terminated | Inspection checklist |
| Testing | ||||||
| DC input insulation test | Insulation resistance | H | TP | AS/NZS 5033 | >1 MΩ at 500V DC | Test certificate |
| AC output insulation test | Insulation resistance | H | TP | AS/NZS 3000 | >1 MΩ at 500V AC | Test certificate |
| Earth continuity | Main earth connection | H | QC, TP | AS/NZS 3000 | <0.5Ω to main earth | Test certificate |
| Polarity and phase rotation | AC output verification | H | QC, TP | AS/NZS 3000 | Correct phase sequence (A-B-C / R-Y-B) | Test certificate |
| Protection settings | Settings verification | H | ENG, TP | AS/NZS 4777.2 | Per network connection agreement | Settings sheet |
| Functional testing | Operation verification | W | TP, ENG | AS/NZS 4777.2 | Start-up, normal operation, alarms tested | Functional test report |
| Commissioning | ||||||
| String-to-inverter assignment | Logical connection check | R | QC | Design drawings | Correct strings connected to correct inverters | Connection schedule |
| Initial energization | First power-up | H | TP, ENG | OEM manual | No faults, normal operation | Commissioning log |
| Performance testing | Power output verification | W | TP, ENG | IEC 62446 | Output within expected range for irradiance | Performance test report |
| Grid protection tests | Anti-islanding, over/under voltage, frequency | H | TP, ENG | AS/NZS 4777.2 | Trips within required time limits | Protection test certificate |
7. ITP Table - MV Transformers and Switchgear
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Transformer (LV/MV) | ||||||
| Factory acceptance tests | Review of factory test reports | H | QA, ENG | AS 60076, IEC 60076 | All routine tests passed | Factory test certificates |
| Delivery inspection | Physical condition check | R | QC | AS 60076 | No damage, oil level correct, accessories complete | Inspection checklist |
| Installation alignment | Mounting and leveling | R | QC | OEM manual | Level within tolerance, secure mounting | Survey report |
| Oil sampling and testing | Oil dielectric strength | H | TP | AS 1767.1 | >50 kV breakdown voltage | Oil test certificate |
| Winding resistance | DC resistance measurement | H | TP | AS 60076 | Within manufacturer tolerance (typically ±2%) | Test certificate |
| Insulation resistance | Megger test | H | TP | AS 60076 | >1000 MΩ (HV-LV, HV-E, LV-E) | Test certificate |
| Voltage ratio test | Turns ratio verification | H | TP | AS 60076 | Within ±0.5% of nameplate | Test certificate |
| Vector group verification | Winding configuration | H | TP | AS 60076 | Matches nameplate (e.g., Dyn11) | Test certificate |
| MV Switchgear | ||||||
| Equipment certification | Type test certificates | H | QA | AS 62271, IEC 62271 | Valid type test certificates | Product certificates |
| Delivery and storage | Condition on receipt | R | QC | AS 62271 | No damage, stored per manufacturer requirements | Inspection checklist |
| Installation | Alignment and fixing | R | QC | OEM manual | Level, securely fixed, clearances maintained | Inspection checklist |
| Cable terminations | Termination inspection | H | QC, TP | AS 2067 | Correct termination kit, torque verified, no voids | Termination checklist |
| Insulation resistance | Megger test | H | TP | AS 2067 | >1000 MΩ at 5000V DC | Test certificate |
| HV withstand test | High voltage AC test | H | TP | AS 62271 | No breakdown at test voltage (typically 95 kV for 33kV equipment) | Test certificate |
| Circuit breaker operation | Mechanical operation test | H | TP | AS 62271 | Correct operation (open/close times within spec) | Test certificate |
| Protection relay settings | Settings verification | H | ENG, TP | Protection study | Per approved protection coordination study | Settings sheets |
| Earthing and Bonding | ||||||
| Earth grid installation | Visual inspection | W | QC | AS 2067 | Correctly installed per design | Inspection checklist |
| Earth grid resistance | Earth resistance test | H | TP | AS 2067 | <1Ω (or per design requirement) | Test certificate |
| Earthing conductor sizing | Physical verification | R | QC | AS 2067 | Minimum 70mm² copper (or per design) | Inspection checklist |
| Bonding connections | Visual and physical check | R | QC | AS 2067 | All metalwork bonded, secure connections | Bonding checklist |
8. ITP Table - HV Cabling (33kV Underground)
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Cable Supply | ||||||
| Cable certification | Material certificates | H | QA | AS/NZS 1429.1 | Type tested, meets specification (XLPE, 19/33kV) | Cable certificates |
| Cable drum inspection | Condition on delivery | R | QC | AS 1026 | No damage, correct labeling, drum rotation check | Delivery checklist |
| Cable storage | Storage conditions | R | QC | AS 1026 | Protected from weather, drums secure | Inspection record |
| Cable Installation | ||||||
| Trench/conduit preparation | Civil works sign-off | H | QC | ITP-CIV-001 | Trenches/conduits ready per civil ITP | Civil completion cert |
| Cable pulling setup | Installation method check | W | QC | AS 1026 | Correct equipment, tension monitoring, no sharp bends | Installation checklist |
| Cable pulling | Tension and bend radius monitoring | W | QC | AS 1026 | Tension <70% max rating, bend radius >15× cable diameter | Pulling log |
| Cable identification | Cable labeling | R | QC | AS 1026 | All cables clearly labeled per numbering system | Photo evidence |
| Cable Jointing and Terminations | ||||||
| Jointer qualifications | Certification check | H | QA | AS/NZS 3017 | Valid jointing certification for voltage level | Qualification certificates |
| Work environment | Jointing area inspection | W | QC | AS 1026 | Clean, dry, temperature controlled (10-30°C typically) | Environmental log |
| Cable preparation | Cable sheath stripping | W | QC, TP | OEM instructions | Clean, no damage to insulation, correct dimensions | Preparation checklist |
| Joint/termination installation | Installation process witness | H | QC, TP | OEM instructions | Per manufacturer instructions, no contamination | Installation log |
| Joint/termination resistance | DC resistance check | W | TP | AS 1026 | <1 mΩ per joint | Test certificate |
| Testing | ||||||
| Insulation resistance | Megger test (phase-to-earth and phase-to-phase) | H | TP | AS/NZS 3017 | >1000 MΩ at 5000V DC | Test certificate |
| HV withstand test | AC voltage test | H | TP, ENG | AS/NZS 3017 | No breakdown at 95 kV (for 33kV cable) for 1 minute | Test certificate |
| Partial discharge test | PD measurement | W | TP | IEC 60270 | <5 pC at 1.5 × Uo (optional but recommended) | Test certificate |
| Tan delta test | Dissipation factor | W | TP | IEEE 400 | Within acceptable range (optional) | Test certificate |
| Sheath integrity test | Sheath voltage test | H | TP | AS 1026 | No breakdown at 4 kV DC for 1 minute | Test certificate |
| Post-Installation | ||||||
| Cable identification tags | Tagging verification | R | QC | AS 2067 | All cables tagged at accessible points | Photo evidence |
| As-built survey | Cable route recording | H | QC | AS 2067 | Accurate as-built records before backfill | As-built drawings |
| Backfilling | Backfill inspection | R | QC | ITP-CIV-001 | Per civil ITP requirements | Civil inspection record |
Critical Hold Point: All HV testing must be witnessed by qualified electrical testing technician and approved by Engineer before energization.
9. ITP Table - 132kV Substation (Primary Plant)
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Power Transformer (132/33kV) | ||||||
| Factory acceptance tests | Review FAT reports | H | ENG, QA | AS 60076 | All type and routine tests passed | FAT certificates |
| Transport and delivery | Condition on arrival | R | QC | AS 60076 | No damage, nitrogen pressure maintained | Inspection checklist |
| Installation | Foundation and alignment | W | ENG | Design drawings | Level, aligned, torque on foundations | Installation record |
| Oil processing | Oil filtering/degassing | W | TP | AS 1767.1 | Moisture <10 ppm, breakdown >60 kV | Oil test certificate |
| Winding resistance | DC resistance test | H | TP | AS 60076 | Per FAT values ±2% | Test certificate |
| Insulation resistance | Megger test (10 kV) | H | TP | AS 60076 | >10,000 MΩ | Test certificate |
| Voltage ratio | Turns ratio all taps | H | TP | AS 60076 | Per nameplate ±0.5% | Test certificate |
| Vector group | Phase displacement check | H | TP | AS 60076 | Matches nameplate | Test certificate |
| Frequency response analysis (FRA) | Winding integrity check | W | TP | IEC 60076-18 | Compared to factory baseline, <2% deviation | FRA report |
| Dissolved gas analysis | Oil quality test | H | TP | AS 1767.1 | No abnormal gases indicating faults | DGA report |
| 132kV Circuit Breakers | ||||||
| Type test certificates | Certificate review | H | QA, ENG | AS 62271 | Valid type tests for breaking capacity | Product certificates |
| SF6 gas quality | Gas moisture and purity | H | TP | IEC 60480 | Dew point <-40°C, purity >97% | Gas test certificate |
| Contact resistance | Micro-ohm test | H | TP | AS 62271 | <100 µΩ per pole | Test certificate |
| Insulation resistance | Megger test | H | TP | AS 62271 | >10,000 MΩ at 10 kV | Test certificate |
| HV withstand test | AC voltage test | H | TP | AS 62271 | 230 kV for 1 minute (for 132kV equipment) | Test certificate |
| Timing tests | Operation timing | H | TP | AS 62271 | Opening/closing times per manufacturer spec | Test certificate |
| Trip circuit verification | Protection trip test | H | TP, ENG | Protection design | Correct trip operation from all protection relays | Test certificate |
| 132kV Disconnectors | ||||||
| Mechanical operation | Operation test | H | TP | AS 62271 | Smooth operation, correct alignment | Test certificate |
| Contact resistance | Micro-ohm test | H | TP | AS 62271 | <100 µΩ per pole | Test certificate |
| Insulation resistance | Megger test | H | TP | AS 62271 | >10,000 MΩ at 10 kV | Test certificate |
| Protection and Control | ||||||
| Protection relay settings | Settings review | H | ENG | Protection study | Per approved coordination study | Settings sheets |
| Protection relay testing | Secondary injection test | H | TP | Relay manual | Correct operation for all functions | Test certificates |
| SCADA integration | Communications test | W | TP | SCADA spec | All signals verified, control functions tested | SCADA test report |
10. ITP Table - Earthing and Lightning Protection
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Earth Grid Installation | ||||||
| Material certification | Conductor and exothermic weld material | H | QA | AS 2067 | Complies with AS/NZS 4431 | Material certificates |
| Conductor sizing | Physical verification | R | QC | AS 2067 | Minimum 70mm² copper (or per design) | Inspection checklist |
| Grid layout | As-installed verification | W | QC | Design drawings | Per earthing design layout | Survey report |
| Exothermic welding | Weld quality inspection | W | QC | AS 2067 | Complete fusion, no cracks, correct mold | Weld log (100% visual) |
| Earth electrode installation | Depth and spacing | R | QC | AS 2067 | Per design (typically 3-4.5m depth) | Installation record |
| Earth Testing | ||||||
| Soil resistivity test | Four-point test | H | TP | AS 2067 | For design verification | Test certificate |
| Earth grid resistance | Fall-of-potential test | H | TP | AS 2067 | <1Ω (or per design requirement) | Test certificate |
| Touch and step potential | Potential gradient measurement | W | TP | AS 2067 | Within safe limits per AS 2067 | Test certificate |
| Lightning Protection | ||||||
| Air terminal installation | Height and location | R | QC | AS/NZS 1768 | Per protection zone calculation | Inspection checklist |
| Down conductor installation | Routing and fixing | R | QC | AS/NZS 1768 | Direct routes, secure fixing, correct spacing | Inspection checklist |
| Surge arrestor installation | Connection and rating | H | QC | AS 1768, AS 4768 | Correct voltage rating, proper installation | Installation checklist |
| Lightning conductor continuity | End-to-end resistance | H | TP | AS 1768 | <1Ω from air terminal to earth | Test certificate |
11. Pre-Energization Checklist
Before any electrical circuit can be energized, the following must be completed and approved:
- [ ] All installation ITPs completed with no open items
- [ ] All testing completed and certificates submitted
- [ ] Insulation resistance tests passed
- [ ] Earth testing completed and acceptable
- [ ] Protection settings approved
- [ ] Lockout/tagout procedures established
- [ ] Energization procedure approved
- [ ] Electrical safety risk assessment completed
- [ ] Electrical workers hold appropriate licenses (ESA/contractor license)
- [ ] Client/Engineer approval to energize obtained
Hold Point: Energization authority must be obtained from Engineer's Representative before any circuit is energized.
12. Electrical Licensing Requirements (NSW)
All electrical work must be performed by appropriately licensed personnel:
- Electrical Contractor License: Required for electrical business
- Electrical Worker License: Required for individual workers
- HV Authorization: Additional qualification required for work >1kV
Verify licenses before commencement and maintain license register.
13. Testing Frequency Summary
| Test Type | Frequency |
|---|---|
| String Voc/Isc | 100% of strings |
| String insulation resistance | 100% of strings |
| Module torque check | 10% sample per array |
| Cable insulation resistance | 100% of circuits |
| Earth continuity | 100% of circuits |
| HV cable withstand test | 100% of cables |
| Transformer routine tests | 100% of units |
| Protection relay tests | 100% of relays |
| Earth grid resistance | Once per grid, re-test after modifications |
14. Quality Records Retention
All electrical inspection and test records shall be retained for minimum 7 years or life of asset (whichever is longer) as per AS/NZS 3000 and electrical safety regulations.
15. Revision History
| Revision | Date | Description | Prepared By | Approved By |
|---|---|---|---|---|
| A | Oct 2025 | Initial Issue | Lead QC Inspector (Electrical) | QA Manager |
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