Substation Commissioning - etouches · PDF fileSubstation Commissioning •All commissioning tasks require a good plan. In order to prove proper operation, the technician must

Substation Commissioning


• What is substation commissioning?– Proving the proper operation of a newly • Installed• Replaced• Modified• Repairedpiece of equipment before it is placed into service


• New/replaced/repaired circuit breakers

• New/replaced/repaired transformers


• Green field substation


• Control Devices


• New relays or modified relay settings


• All commissioning tasks require a good plan. In order to prove proper operation, the technician mustunderstand proper operation.


• Safety– Always mitigate safety concerns

– LOTO– Clearance, Hold, Tag out– May require help from other departments

– When in doubt, stop


• Levels of commissioning– Simple– Moderate– Difficult


• Creating a game plan– Simple Checklist

• Cooling system contactor replacement– Fans/Pumps working properly?

– All stages?– SCADA alarms?

– Simple component replacement should be checked for proper operation


• Moderate to difficult commissioning– Intense familiarity with all aspects of the task at hand isn’t always necessary. Sometimes there are other groups involved in the commissioning process. General familiarity with other work groups responsibilities is highly encouraged.

– Thorough knowledge and expertise in the responsibilities of the relay technician is required.


• Most asked question from:– Project Managers– Management– Operation center

• How long will this take?


• Task boxes– Identify all tasks required to complete a job

– Consult with peers to determine how long to complete the tasks within the box

– Add up all the hours


• Comprehensive checklist needed for more complicated commissioning tasks

SUBSTATIONCOMMISSIONINGCHECKLIST

TRANSFORMERINFORMATIONMANUFACTURER:

SERIEL NUMBER:

MVA:

NUMBER OF WINDINGS:

SELF NUMBER:

WINDING H VOLTAGE:

WINDING X VOLTAGE:

WINDING Y VOLTAGE:

WINDING Z VOLTAGE:

LTC ? : Y N

LTC SENSING VOLTAGE LEVEL:

LTC SENSING VOLTAGE SOURCE:

COOLING SYSTEM:

COOLING SYSTEM VOLTAGE LEVEL:

COOLING SYSTEM VOLTAGE SOURCE:

COOLING SYSTEM CONFIGURATION: OA FA OAFA FOFA

NUMBER OF PRESURE RELIEF DEVICES:

STYLE OF SUDDEN PRESSURE DEVICE: RAPID RISE FAULT PRESSURE BUCHOLTZ NA

N2 SYSTEM: Y N

TYPE OF N2 REGULATION: SINGLE STAGE MULTISTAGED

MANUFACTURER RECOMMENDED N2 PRESSURE:


• Large component replacement– Transformers and Circuit Breakers

• Acceptance tests can be performed without prints and relay settings– CT saturation, ratio, polarity, and insulation testing– VT ratio, polarity, insulation testing– Power Factor testing– Transformer turns ratio testingAcceptance testing really only proves that the equipment was built to specifications at the factory, it survived the travel and installation, and is the baseline for future performance comparison.


• CT Ratio..Polarity..Saturation..Insulation Tests


• CT Ratio…Polarity…Saturation…Insulation Tests


• Testing that requires prints and settings is really the crux of the commissioning process.

• These tests include:– DC Circuit checks– AC Circuit checks– Relay testing– Trip Checks– Communication processor programming

– Point to Point testing


• DC Checks– DC circuit checks can be accomplished in a few different ways, but all must be documented to stay on track.

– A good place to start is comparing the schematics to the wiring diagrams. Mistakes can be identified and possibly rectified during construction, or upon arrival of equipment to the job site.

– Good time “go to lunch” with engineering to review found mistakes


• DC Checks– Note the voltage rating of the power supply and the I/O of the relay before powering up

– Note proper DCV polarity. Most devices are not polarity sensitive, but some are and will not work properly unless connected properly


• DC Checks– Circuits can be “pre‐tested” with continuity before DCV is applied

– (+) DCV can be applied without (‐) DCV and checks can be made

– DCV can be applied without “pre‐testing” and the location of the smoke can be noted


• DC Checks– Yellow lining prints is a good way to keep track of what has checked good

– Test switches, start with all open, then mark and close when checked good

– Leave checked test switches closed


• AC Voltage Checks– Goal of AC voltage circuit checks is to prove proper phasing and polarity throughout the circuit

– Existing phasing can be identified with equipment that has been in service

– Phase tape can be wrapped around support

– Secondary wires checked with continuity as long as all conductors are isolated

– “Live” Bus or Line voltage can be used

– Phase between new and old secondary wires

– Metering screen on microprocessor relay


• AC Current Checks– Very important to be tested properly

– Primary loading with prediction current flow sheet is preferred method

– Proves CT ratio, CT circuit polarity, and CT circuit continuity in one test


• Primary Load testing– Double checks CT ratio for Line protection and Bus protection (if applicable)

– Double checks CT phasing for Line protection and Bus protection (if applicable)

– Double checks CT polarity from CT ratio, polarity, saturation test

– Creates a permanent record to be reviewed and duplicated in the future


• Primary Load testing– Breaker must be closed– Reference AC outlet must be identified– CT circuits made up completely to test switch(s)– Predicted results will easily show discrepancies– Isolate breaker fail – Isolate Bus Differential trip circuit– Test CT circuit to test switch– Test switch to relay tested during relay testing

Substation Commissioning• Equipment polarity

– All extension cords and plug strips must be proven to have proper polarity

– All hot legs and all neutral conductors must agree








• AC Current Checks– Secondary injection also viable test.• Only way to test transformer CT circuits

• Extreme care must be taken to get polarity correct

• Documented same as Primary load test

• Predicted results


• Secondary Injection Testing– Extreme care taken to the polarity of test connections

– Extreme care taken as to desired polarity of circuit under test

– Extreme care taken to land CT’s with correct ratio–Many CT errors are caused by testing the protection and metering circuits in this manner





• Relay Testing– Testing the relay is managed in different ways, but the goal is to prove the relay settings, relay logic, and relay functions are all working to “as set” settings

– Element testing can be accomplished via manual or automatic testing

– Strive to test relay logic with real dynamic testing


• Dynamic Logic Testing– Don’t just pulse/jumper contacts, create relay reaction by injecting values into the relay

– Use logic diagrams and yellow line them as they are tested is a great way to understand the relay logic

– Better yet, draw your own logic diagrams and test them

– Dynamic logic testing double checks DC checks



• Dynamic Logic Testing– Make breaker reclose or not reclose

– Block close by injecting false sync values

– Block transfer tripping with c/o switch

– Roll LOR with Breaker Failure or DTT RX


• Trip Checks– Vital to proving proper operation of all devices

– Electrical and mechanical


• Circuit Breakers– Trip from all known tripping sources

– Trip from mechanical devices such as low gas

– Test each trip coil individually

– Trip breaker failure back up devices

– Trip to/from remote sources if using Transfer Trip


• Transformers– Trip from all known

tripping sources– Trip from mechanical devices such as low oil and sudden pressure

– Trip from cooling related issues

– Trip breaker failure back up schemes

– Trip and lock out


• Communication Processor Programming

• Meter testing• TOP‐006 testing• Communication circuit testing

• End to end testing• Pre check alarm circuits


END‐TO‐END TESTING WORKSHEETSCHEME 120 ‐ BOEING AEROSPACE ‐ O'BRIEN #3 115kV

Initial Conditions: Breaker CLOSED; Reclose ON; Transfer Trip ON; Breaker Fail ISOLATED; Sync Check BYPASSED

SUB#1 TOTAL LINE LENGTH/IMPEDANCE SUB#2BAS 7449 1.705 Miles / 1.149 Ohms OBR 625

Reclose: 8 SEC Reclose: 5 SECPT: 1000:1 CT: 400:1 PT: 1000:1 CT: 400:1

BAS 7449FAULT #1 FAULT #2 FAULT #3 FAULT #4 FAULT #5

3LG FAULT 50% LINE 1LG 5% FROM SUB#1 L‐L 5% FROM SUB#2 L‐L REV FAULT FROM SUB#1 1LG REV FAULT FROM SUB#2PRE FAULT POST PRE FAULT POST PRE FAULT POST PRE FAULT POST PRE FAULT POST

TIME (cycles) 60 5 60 60 5 60 60 5 60 60 5 60 60 5 60VA 70 3.35 4.66 4.35 70 3.35 70 3.35 0.74 4.85 70 3.35 70 3.35 70.3 3.34 70 3.35 70 3.35 70.2 3.34 70 3.35 70 3.35 11.9 3.35 70 3.35VB 70 ‐117 4.66 ‐116 70 ‐117 70 ‐117 84.9 ‐131 70 ‐117 70 ‐117 35.7 ‐167 70 ‐117 70 ‐117 35.2 ‐175 70 ‐117 70 ‐117 80.1 ‐128 70 ‐117VC 70 123 4.66 124 70 123 70 123 85.4 138 70 123 70 123 35.7 173 70 123 70 123 35.1 ‐179 70 123 70 123 80.7 134 70 123IA 0 0 20.3 ‐78 0 0 0 0 15.6 ‐77 0 0 0 0 0.01 ‐86 0 0 0 0 0.01 ‐85 0 0 0 0 10.3 ‐79 0 0IB 0 0 20.3 162 0 0 0 0 0.19 ‐102 0 0 0 0 14.2 ‐169 0 0 0 0 30.5 9.92 0 0 0 0 0.12 ‐66 0 0IC 0 0 20.3 41.6 0 0 0 0 0.19 ‐98 0 0 0 0 14.2 10.7 0 0 0 0 30.5 ‐170 0 0 0 0 0.12 ‐61 0 0

RESULTS R1 R2 RESULTS R1 R2 RESULTS R1 R2 RESULTS R1 R2 RESULTS R1 R2A, B, C ‐ PHASE A‐PHASE & GROUND B, C ‐ PHASE NO TARGETS NO TARGETS

INST INST COMM PERMISSIVE RECV'D PERMISSIVE TRANSM'D

ZONE 1 ZONE 1 ZONE 2 ZONE 3 (Reverse)PERMISSIVE TRANSM'D PERMISSIVE TRANSM'D PERMISSIVE TRANSM'D

PERMISSIVE RECV'D PERMISSIVE RECV'D PERMISSIVE RECV'D

BREAKER R1 R2 BREAKER R1 R2 BREAKER R1 R2 BREAKER R1 R2 BREAKER R1 R2TRIP TRIP TRIP NO TRIP NO TRIP

RECLOSE? RECLOSE? RECLOSE? RECLOSE? N/A N/A RECLOSE? N/A N/AMILEAGE MILEAGE MILEAGE MILEAGE N/A N/A MILEAGE

R1 R2DTT

LATENCY (ms)

END‐TO‐END TESTING WORKSHEETSCHEME 120 ‐ BOEING AEROSPACE ‐ O'BRIEN #3 115kV

Initial Conditions: Breaker CLOSED; Reclose ON; Transfer Trip ON; Breaker Fail ISOLATED; Sync Check BYPASSED

SUB#1 TOTAL LINE LENGTH/IMPEDANCE SUB#2BAS 7449 1.705 Miles / 1.149 Ohms OBR 625

Reclose: 8 SEC Reclose: 5 SECPT: 1000:1 CT: 400:1 PT: 1000:1 CT: 400:1

OBR 625FAULT #1 FAULT #2 FAULT #3 FAULT #4 FAULT #5

3LG FAULT 50% LINE 1LG 5% FROM SUB#1 L‐L 5% FROM SUB#2 L‐L REV FAULT FROM SUB#1 1LG REV FAULT FROM SUB#2PRE FAULT POST PRE FAULT POST PRE FAULT POST PRE FAULT POST PRE FAULT POST

TIME (cycles) 60 5 60 60 5 60 60 5 60 60 5 60 60 5 60VA 70 3.35 10.2 2.49 70 3.35 70 3.35 20.1 2.93 70 3.35 70 3.35 70.3 3.34 70 3.35 70 3.35 70.2 3.34 70 3.35 70 3.35 2.41 2.04 70 3.35VB 70 ‐117 10.2 ‐118 70 ‐117 70 ‐117 78.7 ‐126 70 ‐117 70 ‐117 35.2 ‐175 70 ‐117 70 ‐117 38.5 ‐153 70 ‐117 70 ‐117 83.3 ‐130 70 ‐117VC 70 123 10.2 122 70 123 70 123 79.1 133 70 123 70 123 35.1 ‐178 70 123 70 123 38 160 70 123 70 123 83.8 137 70 123IA 0 0 44.5 ‐80 0 0 0 0 23.6 ‐79 0 0 0 0 0.01 93.9 0 0 0 0 0.01 94.4 0 0 0 0 10.3 101 0 0IB 0 0 44.5 160 0 0 0 0 0.19 77.9 0 0 0 0 46.9 ‐169 0 0 0 0 30.5 ‐170 0 0 0 0 0.12 113 0 0IC 0 0 44.5 40.4 0 0 0 0 0.19 82.1 0 0 0 0 46.9 10.8 0 0 0 0 30.5 9.91 0 0 0 0 0.12 120 0 0

RESULTS R1 R2 RESULTS R1 R2 RESULTS R1 R2 RESULTS R1 R2 RESULTS R1 R2A, B, C ‐ PHASE A‐PHASE & GROUND B, C ‐ PHASE NO TARGETS NO TARGETS

INST COMM INST PERMISSIVE TRANSM'D PERMISSIVE RECV'DZONE 1 ZONE 2 ZONE 1 ZONE 3 (Reverse)

PERMISSIVE TRANSM'D PERMISSIVE TRANSM'D PERMISSIVE TRANSM'D

PERMISSIVE RECV'D PERMISSIVE RECV'D PERMISSIVE RECV'D

BREAKER R1 R2 BREAKER R1 R2 BREAKER R1 R2 BREAKER R1 R2 BREAKER R1 R2TRIP TRIP TRIP NO TRIP NO TRIP

RECLOSE? RECLOSE? RECLOSE? RECLOSE? N/A N/A RECLOSE? N/A N/AMILEAGE MILEAGE MILEAGE MILEAGE MILEAGE N/A N/A

R1 R2DTT

LATENCY (ms)


• Point to Point– Complete final check of proper operation of all new devices in the substation

– Control points– Analog points– Alarm points– Verified to remote control center




• Energization Day– Expectations

• Could be a long day• Problems may arise• Plan to mitigate problems• Personal safety• Non field personnel in substation

• Confident• All protective devices in service


• Post Energization– Setting files– Red/Green prints– Complete all documentation

– “Honey do” list– Best commissioning jobs are the substations you never hear from


• Conclusions– A well thought out plan will guarantee the best chance for a successful commissioning job regardless of size of scope

– Strive for a plan that will “double check” yourself– Ask for help when it’s needed– Have confidence in your approach

Thank You

Documents

Substation Commissioning - etouches · PDF fileSubstation Commissioning •All commissioning tasks require a good plan. In order to prove proper operation, the technician must