Module 0 Commissioning & NETA Standard

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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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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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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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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



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



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



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



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




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




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




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




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




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




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 ?