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04/09/23 Module Zero 1
SUBSTATION COMMISSIONING COURSE
MODULE ZERO
ELECTRICAL SYSTEM COMMISSIONING&
NETA ACCEPTANCE TESTING STANDARD
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INTRODUCTION
• The electrical commissioning and acceptance testing of electric power systems is essential for the energization of any electrical system for the first time
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INTRODUCTION
Module Zero:• Describe the commissioning
process• Introduce ANSI / NETA ATS-
2009 Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems
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INTRODUCTION
By the end of MODULE ZERO:• recognize the structured
requirements of the commissioning process
• use the ANSI / NETA ATS-2009 Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems
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TESTING
• WHY ARE WE TESTING ?
• WHAT ARE WE TESTING ?
• HOW ARE WE TESTING ?
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WHY ARE WE TESTING ?
FIRST PURPOSE OF TESTING
• Check the installation• Check the insulation
system• Check the functional
performance
Installation checks:• Nameplate Data• Equipment supplied as
per drawing• Visual inspection, check
for level / plumbness• Bolting, is it secure ?• Identification / labels• Warning signs• Working space /
clearance
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WHY ARE WE TESTING ?
FIRST PURPOSE OF TESTING
• Check the installation• Check the insulation
system• Check the functional
performance
Insulation tests:• Insulation resistance• DC hi-pot test• AC hi-pot test• AC VLF test• Power factor test• Gas Density / purity• Liquid Insulation
Dielectric test
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WHY ARE WE TESTING ?
FIRST PURPOSE OF TESTING
• Check the installation• Check the insulation
system• Check the functional
performance
Performance tests:• Tap changer function• Breaker trip / close• Exciter response• Governor response• Start up / shut down• Auto synchronizer• Infra-red thermography
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WHY ARE WE TESTING ?
SECOND PURPOSE TESTING
• Develop a baseline of test results for future testing comparison
Test data trending:• Partial discharge• Power factor• Insulation resistance• Vibration signature• Gas in oil analysis• Breaker / relay timing• Winding resistance• Sweep frequency
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WHAT ARE WE TESTING
• Equipment damage during transport or installation
• Equipment deterioration from storage & environment; moisture and other contaminants
• Wiring inter-connections to other systems / equipment
• Operations of equipment• Control power, polarity, voltage level,
capacity• Functional performance of equipment
and systems
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HOW ARE WE TESTING ?
• Develop a test plan• Review drawings and documents• Use manufacturer’s recommended
procedures• Know the applicable standards, rules,
regulations and by-laws• Apply proper test procedures
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COMMISSIONING
DEFINITION OF COMMISSIONING (Cx)A systematic verification, documentation andtraining process applied to all activities during thedesign, construction, static verification, start-upand functional performance testing of equipmentand systems in a new installation or facility toensure that the installation or facility operates inconformity with the owners project requirementsand the basis of design as specified in the contract documents.
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COMMISSIONING
TYPES OF COMMISSIONING1. Initial Commissioning (I-Cx)2. Retro-Commissioning (Retro-Cx)3. Re-Commissioning (Re-Cx)4. On-Going Commissioning (On-going Cx)
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Commissioning Process
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COMMISSIONING TYPES
1. INITIAL COMMISSIONING (I-Cx)• Start at the conceptual design phase• Ends at the post-acceptance phase• The CxP depends on the Owner’s Project Requirements
– Can be defined in a contract
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COMMISSIONING TYPES
2. RETRO-COMMISSIONING (Retro-Cx)• Applied for facility without documented commissioning
process (CxP)– New owner buy used facility
• Lets check what we actually have and see if it all works !
• Things aren’t running that well anymore, let’s assess everything, decide if we should we fix it, buy brand new and replace or tear it down and built new ?
• Cost benefit ratios ?
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COMMISSIONING TYPES
3. RE-COMMISSIONING (Re-Cx)• Re-Cx is implemented in the post-acceptance phase• Re-Cx due to a lack of confidence in the system
performance– Frequent down-time– Increase operational cost– Reliability is in question
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COMMISSIONNING TYPES
4. ON-GOING COMMISSIONING (On-Going Cx)• A CxP that is implemented after the equipment / system
has been accepted– Equipment / system may need optimizing– Equipment / system may have deficiencies but is
needed for production, modifications or test are ongoing until the issue is resolved
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COMMISSIONING TEST
TESTING AND INSPECTION• Visual inspection• Mechanical Inspection• Mechanical tests• Electrical test
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COMMISSIONING TEST
TESTING AND INSPECTION
• Visual inspection• Mechanical Inspection• Mechanical tests• Electrical test
Visual Inspections• Nameplates, breaker
rating, fuse size versus drawings and specifications
• Physical / mechanical conditions
• Anchorage, alignment, grounding and clearance
• Cleanliness, shipping bracing removed
• And others
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COMMISSIONING TEST
TESTING AND INSPECTION
• Visual inspection• Mechanical Inspection• Mechanical tests• Electrical test
Mech. Inspections / tests• Inspect physical and
mechanical condition• Inspect anchorage,
alignment and bolt torque• Check key interlock
scheme• Check filters and vents• Exercise doors, drawers,
slides• And others
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COMMISSIONING TEST
TESTING AND INSPECTION
• Visual inspection• Mechanical Inspection• Mechanical tests• Electrical test
Electrical tests• Resistance measurements
of bolted connections• Insulation resistance• Dielectric withstand; AC /
DC• Ratio, polarity, phasing• Meter / relay calibration• CT / VT ratio, polarity,
burden, wiring integrity• And others
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COMMISSIONING RECORD
• Becomes legal document• Establish a baseline test result for future
reference and data trending• Identifies equipment with less than
desirable test values accepted with restricted operating conditions for production reasons
• Data need to be complete, comprehensive and meaningful
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COMMISSIONING COST
• Cost varies with project size, complexity and levels of reliability expected
• Cost avoidance and reduce project’s life cost is the beneficiaries of the CxP
• 1.5 - 2% of project cost• Is project cheaper without Cx ?
Answer: Not in the long run
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GLOSSARY OF Cx TERMINOLOGIES
• As-built records• Certificate of readiness• Checklist• Commissioning (Cx)• Cx Authority• Cx Plan• Cx Process (CxP)• Cx Progress Report
• Cx Provider• Construction Documents• Design Professionals• Design Requirements
(DR)• Functional Performance
Test (FPT)• Owner’s Program (OP)• Owner’s Project
Requirements (OPR)
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GLOSSARY OF Cx TERMINOLOGIES
• Request For Qualification• Risk Evaluation• System Manuals• Testing, Adjusting and
Balancing (TAB)
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CxP & DOCUMENT FLOW
Production• Pre-design
– Program / planning• Design
– Preliminary / working design
• Elaboration– Elaboration
• Construction– Construction
/acceptance
Operation & Maintenance• occupancy and operation
– Pre-acceptance / normal operation
Summary:2 stages5 phases9 steps
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CxP & DOCUMENT FLOW
Pre-Design Phase
Program step• Owner’s Program (OP) is developed
– Conceptual design– Expected profit– Energy conservation– Environmental assessment
• RFQ_CA• Solicits CA
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CxP & DOCUMENT FLOW
Pre-Design Phase
Planning step• Owner’s Project Requirement (OPR)
– OPR developed with the aid of CA
– OPR becomes Design Requirement (DR)
• Cx plan, system manual, training
• Test plans, checklist– RFQ_Design Professional
(RFQ_Des)• selected
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CxP & DOCUMENT FLOW
Design Phase
Preliminary Design step• Preliminary Design developed by
design professionals– CA reviews design compliance to
OPR, standards, rule /regulations and by-laws
– CA make recommendation as required
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CxP & DOCUMENT FLOW
Design Phase
Working Design step• Working Design finalized• Owner approves design• Working Design distributed
– CA and contractors– Cx plan, system manual,
operating and maintenance training plans are developed
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CxP & DOCUMENT FLOW
ElaborationPhase
Elaboration step• Construction documents
generated• Bid submissions requested• CA provides information on Cx
requirements to the contractors and Cx providers
• Contractors are selected
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CxP & DOCUMENT FLOW
ConstructionPhase
Construction step• Construction documents
generated• CA provides information on Cx
requirements to the contractors and Cx providers
• Contractors are selected• Construction begins
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CxP & DOCUMENT FLOW
ConstructionPhase
Acceptance step• Cx, Testing, Adjusting and
Balancing begins• CA review Cx test results• Cx progress reporting increased• Installation completed• Certificate of Readiness issued,
accepted and FPT conducted
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CxP & DOCUMENT FLOW
Occupancy & Operation
Phase
Post Acceptance step• I-Cx System / design
deficiencies are corrected• Seasonal FPT are performed
and confirmed• Cx progress report, system
manual, operations and maintenance procedure are submitted for approval and acceptance
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CxP & DOCUMENT FLOW
Occupancy & Operation
Phase
Normal Operation step• Cx ends• Milestone marked with
acceptance of all documents
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Cx PLAN
Why do we need a commissioning plan ?• To ensure all necessary equipment / sub-
systems / systems are tested and in compliance with design requirements
• Serves as a checklist of all required tests
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Cx PLAN
WHAT IS A COMMISSIONING PLAN ?• A strategy document that identifies
– Equipment / sub-systems / systems– Required test– Required test procedures
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Cx PLAN
WHAT IS A Cx PLAN ?• A strategy document that
identifies– Equipment / sub-
systems / systems– Required test– Required test
procedures
Eqpt / Sub sys / System• Major apparatus
– Transformer– Breakers– Scada– Alarm systems– Telemetry …
• Critical equipment– Identified through
RCM based process
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Cx PLAN
WHAT IS A Cx PLAN ?• A strategy document that
identifies– Equipment / sub-
systems / systems– Required test– Required test
procedures
Required test• Acceptance test• Dielectric test• Timing test• Calibration test• Load test• Performance test …
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Cx PLAN
WHAT IS A Cx PLAN ?• A strategy document that
identifies– Equipment / sub-
systems / systems– Required test– Test procedures
Test procedures• Insulation resistance• Polarizing index• Power factor• Capacitance / dissipation• Motion analyzer
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Cx Plan
DEVELOPING A Cx Plan
• Owner provide OPR to CA to develop the CxP• Owner provides Final Design to CA and contractors• CA with contractors develops the Cx plan• Cx plan are coordinated in the construction schedule• CA assigns roles and responsibilities to the Cx team
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Cx Plan
Developing a Cx Plan• Survey of system
equipment• Listing of critical System
equipment• Commissioning Tests• Test Procedures• Forms, Report, Records• Safety precautions• Test equipment
Survey of system eqpt.• System description / OPR• Short circuit / arc flash
studies• Drawings / equipment
manuals
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Cx Plan
Developing a Cx Plan• Survey of system
equipment• Listing of critical System
equipment• Commissioning Tests• Test Procedures• Forms, Report, Records• Safety precautions• Test equipment
Listing of critical systems• System description / OPR• Short circuit / arc flash
studies• Equipment manuals• Drawings
– 1-line diagrams– Block diagram– Schematics– Logic diagrams …
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Cx PLAN – RCM PROCESS
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Cx Plan
Developing a Cx Plan• Survey of system
equipment• Listing of critical System
equipment• Commissioning Tests• Test Procedures• Forms, Report, Records• Safety precautions• Test equipment
Commissioning Tests• Best instituted during the
construction phase• Sub-standard performance
are reported, documented and corrected to achieve the required performance
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Cx Plan
Developing a Cx Plan• Survey of system
equipment• Listing of critical System
equipment• Commissioning Tests• Test Procedures• Forms, Report, Records• Safety precautions• Test equipment
Test Procedures• A step-by-step process
conducted on the eqpt• Used to verify the
functional performance of the equipment
• Test data are recorded on approved test record forms
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Cx Plan
Developing a Cx Plan• Survey of system
equipment• Listing of critical System
equipment• Commissioning Tests• Test Procedures• Forms, Report, Records• Safety precautions• Test equipment
Forms, Report, Records• Specific form for all
functions• Test documents the test
results and provides analysis of the test results
• Test report provides analysis of the test records.
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Cx Plan
Developing a Cx Plan• Survey of system
equipment• Listing of critical System
equipment• Commissioning Tests• Test Procedures• Forms, Report, Records• Safety precautions• Test equipment
Safety Precautions• Safety training is required• Testing can involve the
application of high voltages and currents
• Test value can be hazardous to life and destructive to equipment
• Safety rule must be instituted and training on test eqpt and procedures
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Cx Plan
Developing a Cx Plan• Survey of system
equipment• Listing of critical System
equipment• Commissioning Tests• Test Procedures• Forms, Report, Records• Safety precautions• Test equipment
Test Equipment• Proper equipment for
specific test• Equipment to be calibrate
within 12 months of use• Operate as per equipment
manual• Use of regulated power
supply is recommended
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ANSI/NETA ATS-2009
Standard for Acceptance Testing Specifications
for Electrical Power Equipment and
Systems
• Uniform testing specification
• Adopted by ANSI on Feb 19, 2009
• Comprehensive series of tests
• Let see what is in NETA ?