Download Chapter 1: Commissioning Management

TESTING & COMMISSIONING
DET310
CHAPTER ONE
COMMISSIONING
MANAGEMENT
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TESTING & COMMISSIONING
Introduction
The commissioning of electrical power systems
may, in the first instance, be thought of a purely
engineering activity, associated with understanding
and proving the technical integrity, it is however,
also a management process, requiring such
qualities as; setting of objectives; planning;
organising; documentation control; and, most
important, the creation of team work.
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COMMISSIONING MANAGEMENT
1.0 COMMISSIONING
OBJECTIVES
The objectives of commissioning is to prove that
the individual items of equipment, which are
interconnected to form systems, circuits and
substations, are suitable for their intended purpose
and acceptable for commercial service.
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COMMISSIONING MANAGEMENT
COMMISSIONING OBJECTIVES
This global objective can be subdivided into
a) Verifying that the equipment has not been
damaged in transit, that it has been properly
installed, and performs as specified
b) Obtaining test data as the basis for comparison
with future maintenance and fault investigations
results
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COMMISSIONING MANAGEMENT
COMMISSIONING ACTIVITIES
Commissioning activities includes
a) Off load commissioning test
Objectives: To prove the integrity of the installed
equipment, hence its suitable for connection to the power
system, by observing its performance under test conditions
which, as far as practicable, simulate in service conditions
and requirements.
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COMMISSIONING MANAGEMENT
COMMISSIONING ACTIVITIES
b) On-Load Commissioning Test
Tests which are carried out with the equipment
connected to the power system.
Objectives: This test utilized the power system itself to
demonstrate that the installation is technically
acceptable for commercial operation
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COMMISSIONING MANAGEMENT
COMMISSIONING ACTIVITIES
c) Inspection:
-Pre-energisation Inpection: Process which are carried out
before the circuit being energised
Objectives: To ensure that all equipment are properly
connected and in proper condition before energisation
- Post Commissioning Inspection: Process which are
carried out after circuit/system has been energised
Objectives: To ensure and recheck that the equipments
have been left in the service condition
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1.2 COMMISIONING PANEL
The commissioning panel is responsible for managing
the whole commissioning process. The commissioning
panel typically consists of the following representation:
a) Chairman, usually project manager
b) Technical engineer from the supply company capable of
defining the required tests and accepting the test results.
c) Contractor representatives
d) supply company power system operations department (mainly
concerned with the energisation process)
e) representatives of any companies whose
interfaces with that being commissioned.
equipment
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1.3 COMMISSIONING
PROGRAM
The commissioning program is the key activity to be
progressed by the commissioning panel. It should
ideally cover the following stages:
1. Pre-commissioning inspection
2. Off load commissioning test program
3. Pre-energised inspection
4. Energisation and on load commissioning tests
(usually covered by the switching program)
5. Post commissioning inspection
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COMMISSIONING PROGRAM
PREPARE DESIGN
SPECIFICATIONS
(ESC)
ISSUE TENDER
DOCUMENT
AND AWARD
CONTRACT
(ESC)
OFF LOAD
COMMISSIONING
TEST
(CONTRACTOR/
ESC)
PRECOMMISIONING
INSPECTION
(CONTRACTOR/
ESC)
PREENERGISATION
INSPECTION
(CONTRACTOR/
ESC)
ON-LOAD
COMMISSIONING
TEST
(CONTRACTOR/
ESC)
MANUFACTURE
EQUIPMENT
(CONTRACTOR)
ERECT
EQUIPMENT ON
SITE
(CONTRACTOR/
ESC)
POST
COMMISSIONING
INSPECTION
(CONTRACTOR/
ESC)
* ESC=electric Supply Company
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COMMISSIONING MANAGEMENT
COMMISSIONING PROGRAMME
1.31 Pre-Commissioning Inspection
This would consists of an inspection of the installation to
determined whether work is complete and satisfactory to
the point where off-load commissioning test can
commence
1.32 Off-load commissioning Test
A programme of test which include:
a) Test associated with AC circuit diagram
i) Test on current and voltage Transformer
ii) Primary Injections
b) Test associated with DC circuit diagram
i) Secondary injection on DC relays
ii) Circuit diagram logic tests
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COMMISSIONING MANAGEMENT
COMMISSIONING PROGRAMME
c) Equipment Secondary Injections
d) Power Supplies
i) 110V battery and distribution board
ii) 48 V battery and distribution board
iii) Diesel Generator
iv) low voltage AC supplies
e) High Voltage equipment test
i) Circuit Breaker
ii) Switches
iii) Disconnectors
iv) Earth Switches
v) Transfomers
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COMMISSIONING MANAGEMENT
COMMISSIONING PROGRAMME
vi) Reactors
vii) Busbars
viii) Cables
f) Common Equipment
i) Busbar Protection
ii) Interlocking
iii) Synchronizing
iv) air system
v) Substation Control Systems
g) Earthing System
i) Substation earthing mat
ii) interconnection of earthing system
iii) Tower earthing
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COMMISSIONING MANAGEMENT
COMMISSIONING PROGRAMME
h) High-voltage pressure Test
i)
Auto-switching off-load simulation tests
j)
End to end Test
i) Power Line Carier
ii) Intertripping
iii) Protection System
iv) Substation Control System
k) Insulation resistance Test associated with the above
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COMMISSIONING PROGRAMME
COMMISSIONING MANAGEMENT
1.33 Pre-Energization Inspection
Pre-energisation inspection must be carried out prior to the circuit
being energised
Example:
a) Confirmation of circuit nomenclature
b) Confirmation that equipment phase connections are in accordance
with the phasing diagram
c) Application of locks
d) Checking the correct position of all valves
e) Ensuring satisfactory indication of all pressure valves
f) Checking that all equipment is satisfactorily earthed
h) Ensuring the satisfactory conditioned of all battery supplies
i) Checking that all test connections have been removed
j) Confirmation of the tightness of all terminations
k) Confirmation that all current transformers are normal
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COMMISSIONING PROGRAMME
k) Confirmation that all current transformers links are normal
COMMISSIONING MANAGEMENT
l) All realay settings have been applied correctly
m) Confirmation that all commissioning documentation is
completed.
1.34 Switching Programme
This is a formal and precise worded procedure which specifies the
sequence of events required to energise the circuit and carry out
the on-load commissioning test. It needs to be circulated to all
parties concerned to ensure unanimityof agreement and
understanding. It should be provided and approved by the
commissioning panel.
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COMMISSIONING PROGRAMME
1.35 Post-Commissioning Inspection
COMMISSIONING MANAGEMENT
The purpose of this inspection is to double check that the
commissioned equipment has been left in the in service
position.
Example:
i) Ensuring that all temporary commissioning equipment has
been removed.
ii) Ensuring that all current transformers links are normal
iii) Checking the correct position of all IN/OUT switches and
transformers tap position
iv) Ensuring that all relay settings are normal
v) General visual inspection
vi) Ensuring that all commissioned equipment are clearly
identify
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1.4
DOCUMENTATION
An essential requirement of the commissioning process is the formal
COMMISSIONING MANAGEMENT
documentation on both the management activities and the
commissioning test. Two type of documentation are
a) Commissioning report- The commissioning report is the formal
record of the managerial process. It should consists of
i)
A contents sheet, updated as the project progress
ii) A copy of high level design specifications
iii) Formal minutes of commissioning meetings
iv) The programmed of work to be carried out, showing planned and
actual completion dates
v) A schedule of commissioning test
vi) A commissioning completion documentation, to certify that all
work is completed.
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1.4
DOCUMENTATION
b) Commissioning Log
COMMISSIONING MANAGEMENT
Is the record of the technical process, comprising the complete
commissioning test schedule, test certificates, inspection report,
switching programme and other relevant technical document
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1.5
COMMISSIONING CERTIFICATES
a) Acceptance Certificate
COMMISSIONING MANAGEMENT
This certificate declares that
i)
The equipment is ready to be connected to the power system
ii) The equipment has been energised and subject to on-load
commissioning tests
b) Contract Taking Over certificate
When the work has been completed satisfactorily and the
equipment commissionied, a contract taking-over certificte or
similar documents will require completion.
This document notifies the contractor that the supply company
has accepted and that the warranty period has commence
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