Testing and Commissioning Manual.pdf

8/18/2019 Testing and Commissioning Manual.pdf

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Test and CommissioningManual

“This material is made available on the basis that it may be necessary fora Registered Professional Engineer of Queensland (RPEQ) to undertakeor oversee the engineering services to meet statutory obligations”.


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Test and Commissioning Manual

i Reference MN000301R171 Ver 1

Ergon Energy Corporation Limited ABN 50 087 646 062Ergon Energy Queensland Pty Ltd ABN 11 121 177 802

This material is made available on the basis that it may be necessary for a RegisteredProfessional Engineer of Queensland (RPEQ) to undertake or oversee the engineering servicesto meet statutory obligations.

Ergon Energy makes no representations, express or implied, as to the accuracy of thedocuments provided and accepts no liability howsoever arising for any loss resulting from theuse of the documents or reliance placed on them.

The recipient agrees to indemnify Ergon Energy and keep it indemnified against any liability forany losses (including liabilities of the recipient to third parties), costs and expenses arising out ofthe use or reliance on the documents by the recipient.

The documents provided are to be used as a guide only. Subject to any other statutoryobligation, to the extent practical, the recipient agrees to use reasonable endeavours to notifyErgon Energy of any errors or omissions it becomes aware of in the documents to enablecorrection/updating.


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ii Reference MN000301R171 Ver 1


Table of Contents

1. Purpose and Scope ................................................................................... 1

2. Responsibilities .......................................................................................... 1 3. Definitions, Abbreviations and Acronyms ................................................... 2

4. References ................................................................................................ 5

5. Role and Responsibilities of the Commissioning Officer / Engineer ........... 5

6. The Commissioning Process ..................................................................... 7

7. Single Point of Accountability for Commissioning ...................................... 7

8. Project Development Phase ...................................................................... 7

9. Project Implementation Phase ................................................................... 8

9.1. Handovers ......................... ............................ ............................. ................. 8

9.1.1 Primary Plant .................................................................................... 8

9.1.2 Design Handover .......................... ............................ ........................ 9

9.2. Drawing Management ............................. ............................. ....................... 9

10. Submission of Application for Work Requests and System Outages ....... 10

11. Commissioning Testing ............................................................................ 11

11.1. Primary Plant Testing............................................................................... 11

11.2. Testing Beyond that Specified In Ergon Energy Test Documentation ..... 11

11.3. Secondary Systems Testing ............................ ............................ ............ 12

11.4. Substation Communications System Testing ............................. ............. 12

11.5. Revenue and Statistical Metering Testing .......................................... ..... 12 11.6. Substation Miscellaneous System Testing ................................ .............. 12

11.7. Test Result Assessment .......................... ........................... ..................... 13

12. Reporting of Plant, Construction and Design Defects during theCommissioning Process .......................................................................... 13

13. Construction Release ............................................................................... 14

14. Site Acceptance Testing Release ............................................................ 14

15. Site Integration Testing Release .............................................................. 14

16. Pre-Connection Hold Point ...................................................................... 15

17. Commissioning Authority for Energising Electrical Plant .......................... 15 18. Customer Authority to Energise Customer Owned Plant ......................... 15

19. Commissioning and Decommissioning Notices ....................................... 15

20. Storage of Test Results ........................................................................... 15

21. Post Commissioning Closeout ................................................................. 16

22. Authorisation and Approval of Commissioning Documentation ............... 16

A1. Annex A – Commissioning Process Flowchart ......................................... 18

A2. Annex B – Commissioning Process Inputs and Outputs .......................... 19

A3. Annex C – Terms and Conditions of Use of Ergon Energy Developed

Automated Test Reporting Tools ............................................................. 20


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iii Reference MN000301R171 Ver 1


A4. Annex D – Terms and Conditions of Use of Ergon Energy DevelopedStandard Work Practices ......................................................................... 22

A5. Annex E – Terms and Conditions of Use of Protection Relay StandardTest Plans ................................................................................................ 24


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Page 1 of 25 Reference MN000301R171 Ver 1


1. PURPOSE AND SCOPEThis document defines the commissioning process in the context of the Ergon Energy capitalproject delivery process. This manual is applicable for all substation projects regardless of thedelivery mode.

It is not the intention of this manual to repeat, nor supersede information and guidelines which aredetailed in the Ergon Energy Test and Commissioning Standard Work Practices or Inspection andTest Plans. If a conflict exists between this document and the Ergon Energy published StandardWork Practice then the SWP is to be assumed correct.

The Scope of this manual includes:

i. Define the roles and responsibilities of the Test and Commissioning Officer/Engineer duringthe development and implementation phases of a project work.

ii. Define the required deliverables for the Test and Commissioning Team during projectdevelopment and implementation phases.

iii. Define the required level of primary plant testing to be performed during projectimplementation.

iv. Define the required level of secondary system testing to be performed during projectimplementation.

v. Define the required level of system integration testing to be performed during projectimplementation.

vi. Define the required quality assurance documentation that will be completed during projectimplementation.

vii. Define where, how and when quality control documentation is stored post test andcommissioning activities.

The information provided in this manual has been written with the intent of safely delivering the testand commissioning portion of Ergon Energy projects. The definitions and processes presented inthis manual have been written with a focus on test and commissioning works and do not cover norattempt to cover the definitions or processes of other project delivery groups. Where there existsuncertainty in the interpretation of the material presented within this document the reader shouldalways seek clarification from the assigned Commissioning Engineer/Officer or the CommissioningRepresentative for the project.

2. RESPONSIBILITIESThe Group Manager Works Enablement is the Process Owner responsible for approving thisReference.

The General Manager Substations is the Subject Matter Expert (SME) for the content and shallimplement and maintain this Reference.

The Manager Management Systems is the Management System Representative and isresponsible for the endorsement of this Reference prior to submission for approval.


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3. DEFINITIONS, ABBREVIATIONS AND ACRONYMSThe following terms and acronyms have been defined to provide clarity and consistency duringcommissioning activities.

Commissioning Authority to Energise: the Commissioning Authority for Energising ElectricalPlant Form (MN000301F174) is used to signify the completion of three critical stages of thecommissioning process. Sections 1 and 2 of this document are signed by the Testing Officerresponsible for Site Integration Testing (SIT) to signify that all site integration testing has beensuccessfully completed and that all personnel involved with this testing have surrendered access tothe listed plant and equipment. Section 3 is signed and issued by the Project Manager to theCommissioning Officer/Engineer to provide clearance that all required prerequisites have been metto allow the plant to be energised. Section 4 is signed by the Commissioning Officer/Engineer toprovide final clearance to energise the plant. Section 4 of this document also lists all outstandingitems affecting network operation and/or maintenance activities as well as any additional testingrequired before the plant is released for normal operation.

Commissioning Co-ordination Program: is a detailed technical document which specifies the

required steps to be performed on site to provide a final audit check of critical operations andfunctions. Under the commissioning co-ordination program all new plant/systems will be integratedand tested into the operational network.

Commissioning Officer/Engineer: is an experienced engineer or technician appointed to co-ordinate and control the testing and commissioning of new or refurbished plant and/or systems.The Ergon Energy P53 Operate the Network Enterprise Process defines this role as theCommissioning Co-ordinator. An Ergon Energy Contractor may take on the part of the role of theCommissioning Officer/Engineer provided they have the required skills and experience to performthe role. The portion of the Commissioning Officer/Engineer role that fulfils Ergon Energy’s non-delegable responsibility under the Electrical Safety Act to ensure that plant and systems are testedappropriately prior to energisation cannot be fulfilled by a contractor.

Commissioning Outage Plan: details primary plant and secondary system outages and switchingrequirements to achieve the commissioning outages as described in the Commissioning StagingPlan.

Commissioning Phase: is defined as set or suite of tests designed to prove that a plant item orsystem meets design specifications. For Ergon Energy commissioning purposes 5 phases havebeen defined, these being Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), SiteIntegration Testing (SIT), Pre-Energisation Testing and Post-Energisation Testing. A completedefinition of each of these phases is provided below.

Commissioning Schedule: is a time based representation of the tasks required to complete thecommissioning works including the resource requirements and resource skill/competenciesrequired to perform these tasks.

Commissioning Stage: is defined as the sequence of phases and/or works portions whichprogress a primary plant item or secondary system from manufacturers testing through to systemintegration and final commissioning testing. In general, a commissioning stage requires that all 5phases of testing be successfully completed culminating in the successful energisation of newplant or system into the Ergon Energy network.

Commissioning Staging Plan: is a plan developed by the Commissioning Officer/Engineer whichdetails the proposed substation, distribution and transmission/sub-transmission primary plantconfigurations during each of the proposed commissioning stages. This plan is developed to allowall key stakeholders to understand, review and comment on proposed staging during the projectdevelopment phase.

Construct ion Release: for the purpose of test and commissioning the Construction Release Form(MN000301F175) is used to provide a clear delineation between the completion of constructionactivities and testing phases. This form is completed and signed by the officer responsible for


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construction to signify that construction activities for the listed plant have been completed inaccordance with the quality control systems specified in the construction manual and that allpersonnel involved with the construction have surrendered access to the equipment. This cleardelineation is required to allow testing activities to be safely performed and to ensure that testedplant is not compromised by unauthorised access.

Where a partial construction release is used to provide improved efficiencies in project delivery thedetails of the partial release are to be recorded on the construction release form under the section“Conditions of Release” and conveyed to the officer responsible for testing upon handover. Forfurther details on the construction release handover process see section 13 of this document.

Testing Phase Release: the Testing Phase Release Form (MN000301F183) is used to provideclear delineation of a testing phase from subsequent phases. This form is to be completed andsigned by the officer responsible for the testing phase to signify that testing activities associatedwith the listed phase have been completed and that all personnel involved with this testing havesurrendered access to the equipment.

This form is also to be used when a testing entity completes an assigned portion of works whichdoes not complete a phase of testing. Under these circumstances those items required to completethe listed testing phase will be recorded on the Testing Phase Release Form to document that thetesting phase has not been completed at the documented release date.

Development Phase of a Project: The Project Development Phase is initiated on receipt of theProject Initiation Advice and is the time in which the detailed project planning is performed toproduce a project plan. During this phase, as part of the high level design performed by the designgroup, the commissioning officer/engineer will develop a commissioning staging plan andcommissioning schedule. The staging plan will be used to ensure that staged design requirementsare identified and that the final design outcomes reflect the need for commissioning staging. Thecommissioning schedule will be used by project manager to produce the Gate 3 Estimate (G3E) forcustomer approval.

Implementation Phase of Project: The Project Implementation Phase commences once Gate 3 Approval has been achieved. During this phase the construction and test and commissioningactivities are performed. The Implementation Phase ends on achievement of the Certificate ofPractical Completion (CPC) milestone.

Factory Acceptance Testing (FAT): is defined as the Testing Phase performed by themanufacturer on an independent item of plant or equipment to prove that the item operates inaccordance with its design specifications. Factory Acceptance Testing is commonly, but need notbe, performed at the place of manufacture prior to delivery of the plant or equipment.

In cases where the piece of equipment under test is comprised of a number of subsystems orcomponents then FAT may include the testing of individual components or of the system as awhole.

Inspection and Test Plan (ITP): is a Quality Control document which is used to specify the testingrequirements for a particular testing phase and plant/system item. The ITP is a high level technicaldocument which specifies test types which will be performed and is used in conjunction with therelevant test report documentation.

Maintenance Acceptance Criteria (MAC): is a joint workings document developed to define plantcondition acceptance criteria. The MAC is used to evaluate substation and distribution plantcondition and defines test acceptance criteria.

Post-Energisation Testing : is defined as the Testing Phase required to confirm that criticalsystem components are operating as per design requirements. This type of testing is generallycovered by a series of on-load tests to confirm system component operability and stability. Post-energisation testing cannot be delegated to contracted resources , however contracted resourcesmay carry out post-energisation testing tasks under the direction of Ergon Energy staff.


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Pre-Connection Hold Point: is defined as the point in time in which plant transitions from beingunder general access to requiring High Voltage Isolation and Access procedures to be followed inaccordance P53 Operate the Network Enterprise Process.

Pre-Energisation Testing: is defined as the Testing Phase required to provide final confirmationthat the system is safe to be energised. Pre-energisation testing can only be performed once the

item of plant or equipment has successfully passed SIT. Pre-energisation testing cannot bedelegated to contracted resources, however contracted resources may carry out pre-energisationtesting tasks under the direction of Ergon Energy staff.

Project Manager: is the person assigned with the accountability for overall delivery of a project. Asthe responsible person for project delivery, the project manager must be included in all decisionmaking processes that have a material effect on the project schedule, cost, quality or scope.

Site Acceptance Testing (SAT): is defined as the testing performed at the installation site of apiece of plant or equipment to prove that item operates in accordance with its designspecifications. This type of testing is required to ensure that no damage has resulted from the plantor equipment being transported or reassembled on site.

Site Integration Testing (SIT): is defined as the Testing Phase performed on site to prove that apiece of plant or equipment is correctly connected and integrated into the site to form a completeoperational system. In order for a plant item or piece of equipment to undergo SIT that item mustfirst have passed a FAT and/or SAT component of testing.

Whilst Site Integration Testing proves that plant and secondary systems operate correctly as anintegrated system, for commissioning purposes, the SIT component only provides integrationtesting of plant and systems not in service. Proof of system integration functionality with in serviceplant and/or systems will be performed during Pre-energisation testing under the control of aCommissioning Co-ordination Program.

Standard Work Practice (SWP): is a Quality Control document developed by Ergon Energy whichdetails the requirements and methodology to be followed when performing plant/system testing.

Test Report: is an approved Quality Control document used to record test result information.

Validation: Inspection, testing, measurement, simulations and audits to confirm that the installedplant and equipment and the system design is fit for the intended purpose and meets all regulatoryrequirements and the appropriate standards.

Verification: Inspection and testing to confirm that the installed plant and equipment complies withthe system design.

Works Portion: is any work performed by an entity to achieve an objective. This includes worksperformed under H.V.I.A. procedures. Works portions are commonly used to break down complexor lengthy works in manageable components.

Under Direction : When a task or work is performed under direction the entity providing directiondoes not assume responsibility for the safety obligations of those performing the works. It remainsthe obligation of the entity performing the works to ensure that all works are completed inaccordance with approved work practices and risk management strategies.


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4. REFERENCESMN000301R165. 8 Level Field Test Competency (Reference)

MN000301F175. Construction Release (Form)

MN000301F183. Testing Phase Release (Form)MN000301F123. Construction Safety Clearance – High Voltage Apparatus (Form)

MN000301F174. Commissioning Authority for Energising Electrical Plant (Form)

MN000301F176. Customer Authority to Energise Customer Owned Electrical Plant (Form)

EE STNW1160. Maintenance Acceptance Criteria (Standard)

P53. Operate the Network (Enterprise Process)

5. ROLE AND RESPONSIBILITIES OF THE COMMISSIONING OFFICER /ENGINEER

The role of the Commissioning Officer/Engineer with respect to the delivery of Ergon Energyprojects is to provide technical support and advice for the Project Manager regarding thecommissioning phases of the project and to co-ordinate outages required to achieve the outcomesdetailed in the Commissioning Staging Plan. To achieve these objectives the CommissioningOfficer/Engineer will be responsible for:

a) Developing and Maintaining Commissioning Staging Plans and a CommissioningSchedule – a Commissioning Staging Plan and Commissioning Schedule will be developedby the Commissioning Officer/Engineer during the project development phase. The stagingplan will detail the proposed substation, distribution and transmission/sub-transmissionprimary plant configurations during each of the proposed commissioning stages. TheCommissioning Schedule will detail the tasks required to complete the planned

commissioning works along with the expected timing of these tasks and the resourcesrequired. The skill and competency level required of the resources will also be included in theCommission Schedule. The competency and skill levels required to perform specificcommissioning and testing tasks are defined in MN000301R165: 8 Level Field TestCompetency Reference document.

At the project development phase the Commissioning Staging Plan and CommissioningSchedule will be used to convey the proposed commissioning staging and resourcerequirements to the Project Manager and the Project Design Manager. The commissioningstaging information is to be used when producing design specifications to ensure that allprimary plant, secondary systems and protection systems designs are produced for each ofthe proposed commissioning stages. The Commissioning Schedule information will be used

by the Project Manager to manage the resource requirements during the commissioningstages. Once developed, the Commissioning Staging Plan and Commissioning Schedule willthen be reviewed and modified as necessary to gain approval from the project KeyStakeholders.

The Commissioning Staging Plan is the overarching or high level document which describesthe proposed commissioning staging. It should be written for its intended target audience andthus should not contain a high level of detail which will divert focus from the intendedpurpose of the document. This document is supported by the more specific and detailedCommissioning Schedule and Commissioning Co-Ordination Programs.

As the project progresses towards its commissioning stage/s the Commissioning StagingPlan and Commissioning Schedule will be further refined by the Commissioning

Officer/Engineer to include and reflect more detailed information about outage requirements,anticipated works durations and resource requirements as this information becomesavailable. Where circumstances change such that a new or significantly revised staging plan


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is required, all commissioning works will cease until a new staging plan and schedule hasbeen developed and approved by the relevant stakeholders.

An example of a Commissioning Staging Plan and a Commissioning Schedule is availableon the Test and Commissioning Resource Centre website.

b) Production of Inspection and Test Plans (ITPs) and Test Reports – these are qualitycontrol documents which specify the testing requirements for primary plant and secondarysystems. Ergon Energy has developed a set of tools which automatically produceengineering approved standard ITPs and Test Reports for primary plant and secondarysystem Testing and Commissioning Works. These tools are available on the Test andCommissioning Resource Centre.

The Ergon Energy assigned Commissioning Officer/Engineer will be responsible forproducing the ITPs and test reports for each of the commissioning stages at the start of theproject implementation phase. Where non-standard ITPs are required these ITPs must beapproved in accordance with Section 22, “Authorisation and Approval of CommissioningDocumentation” of this document.

Where contractors are performing test and commissioning works the CommissioningOfficer/Engineer will forward the prepared ITPs and test reports to the project manager whowill pass these documents onto the contractor test and commissioning representative.

c) Development of a Commissioning Outage Plan – the Commissioning Staging Plan willprovide a high level detail of the primary plant and secondary system outages required toachieve the planned commissioning staging for the project.

The Commissioning Outage Plan will take the form of tentatively submitted Application forWork (AFW) requests entered into the Ergon Energy FeederSTAT system by thecommissioning officer/engineer for the planned outages. The AFW submission process isdefined in section 10 of this document.

d) Developing and Maintaining Commissioning Co-ordination Programs – theCommissioning Co-ordination Program is a detailed technical document produced by theCommissioning Officer/Engineer during the project implementation phase to detail therequired steps to be performed on site to energise or de-energise substation plant. Thisdocument will detail the following information:

1. A high level overview of secondary systems isolation requirements.

2. A high level overview of works to be performed.

3. A works co-ordination programme detailing the order in which works need to beundertaken to commission the plant and secondary systems. The order of worksdetailed in the commissioning co-ordination program will reflect and align with thecommissioning outages.

4. A high level overview of secondary systems testing and primary injection requirementsto prove system functionality and stability pre plant energisation.

5. Phasing checks required.

6. On-load or post-energisation checks required.


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6. THE COMMISSIONING PROCESSThe Commissioning Process is shown in the flowchart provided in Annex A. This process has beendivided into the Project Development and Implementation Phases to achieve alignment with theproject management phases of the project lifecycle. Within the project implementation phase thecommissioning activities have been further broken down into the commissioning phases to identifythe divisible portions of the test and commissioning lifecycle. The major components of thecommissioning activities in relation to their project lifecycle phases are further detailed in thefollowing sections of this document.

7. SINGLE POINT OF ACCOUNTABILITY FOR COMMISSIONINGErgon Energy has adopted a Single Point Accountability philosophy for the delivery of its projects.When applied to the Commissioning Process this philosophy means that the CommissioningOfficer/Engineer will be responsible for the delivery of all commissioning outcomes as detailed inthe Commissioning Staging Plan and Commissioning Schedule. In order for the CommissioningOfficer/Engineer to be able to deliver these outcomes all prerequisites as detailed in this manualmust be satisfied.

8. PROJECT DEVELOPMENT PHASE At the project development phase of the project lifecycle the project objectives will be fully definedhowever the project scope will not be clear. Until a Commissioning Staging Plan has beendeveloped and approved the project scope cannot be fully determined. In order for theCommissioning Officer/Engineer to develop a staging plan the Project Manager must provide thefollowing information to the Commissioning Officer/Engineer:

a) A single line protection diagram showing the final plant configurations for all effectedsubstations as defined by the project objectives.

b) A general arrangement drawing showing the final plant layout for all effected substations as

defined by the project objectives.c) A proposed transmission and distribution feeder arrangement layout for all effected

substations as defined by the project objectives.

Once the above information has been provided, the Commissioning Officer/Engineer will develop aCommissioning Staging Plan and Commissioning Schedule. The staging plan will detail theproposed substation, distribution and transmission/sub-transmission primary plant configurationsduring each of the required commissioning stages. Once developed, the project manager willarrange for a meeting to facilitate a review of the Commissioning Staging Plan with the followingkey stakeholders:

Project Design Manager – for confirmation and approval that the primary plant and

secondary systems infrastructure can be constructed to meet the Commissioning StagingPlan requirements and that all designs will be provided for each of the proposedcommissioning stages.

Protection Design Engineer – for confirmation and approval that all primary plant can beadequately protected during all proposed commissioning stages.

Regional Asset Manager – for confirmation and approval that network risk associated withthe commissioning staging is acceptable to the Asset Manager.

Area Operations Manager - for confirmation and approval that network risk and customerimpacts associated with the commissioning staging is acceptable.

Network Operations and Outage Co-ordination Groups – for confirmation and approval that

the proposed commissioning staging and required outages to achieve this staging will besupported by these groups and that any operational concerns have been identified andconveyed to the commissioning officer/engineer.


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Project Manager – for approval of the commissioning staging including resource and timerequirements to execute these plans.

On completion of the review stakeholder approval of the commissioning staging plan will beformalised by signing the approvals section of the commissioning staging plan document.

In addition to the Commissioning Staging Plan the Commissioning Officer/Engineer will alsodevelop a Commissioning Schedule which will detail the tasks required to complete the plannedcommissioning works along with the expected timing of these tasks and the resources required.The skill and competency level required of the resources will also be included in the CommissionSchedule.

Once the Commissioning Staging Plan and Commissioning Schedule have been completed andapproved, the Commissioning Officer/Engineer will provide a copy of the final documents to thekey Stakeholders and store a copy on the Ergon Energy shared drive.

9. PROJECT IMPLEMENTATION PHASE9.1. Handovers

9.1.1 Primary Plant

a) Vendor Primary Plant Handover

Where the Procurement Contract has specified that the plant vendor will install and test the primaryplant item then the primary plant handover will take the form of a vendor release document. Thevendor release will provide all test results as specified by the contract for that plant item and avendor signed authority to energise for the plant item.

A copy of the signed vendor release and associated test results will be issued to theCommissioning Officer/Engineer for verification at the time specified in the Commissioning StagingPlan.

b) Construction Handover At the completion of construction activities for a package of works a plant handover must takeplace prior to the start of Site Integration Testing. This handover will take the form of a signedConstruction Release Form (Form MN000301F175) which relinquishes construction access to theplant and acknowledges that the plant construction quality control documentation has beencompleted and assessed to be fit for purpose in accordance with the requirements detailed in theconstruction manual. This handover is required to ensure all tested plant and equipment not beinterfered with once site integration testing has commenced.

The signed Construction Release Form will be issued to the Commissioning Officer/Engineer or anapproved commissioning delegate for verification at the time specified by the CommissioningStaging Plan.

Where additional construction works are required on previously released plant these works mustbe performed in consultation with the officer responsible for SIT and a new construction releasemust be completed at the completion of the works. This process ensures that tested plant is notcompromised by construction activities and that the officer responsible for SIT can assess the needfor additional testing to prove disturbed plant. If required the officer responsible for SIT canrelinquish access to the plant returning control to the officer responsible for construction.

c) Site Acceptance Testing Handover

At the completion of Site Acceptance Testing (SAT) for a package of works a handover must takeplace prior to the start of Site Integration Testing. This handover will take place in the form of asigned Testing Phase Release Form (Form MN000301F183) which relinquishes access to thelisted plant items and acknowledges that SAT has been completed in accordance with theapproved SAT test schedules.


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Where SAT is not completed by a single testing entity then a signed Testing Phase Release Form(Form MN000301F183) will be completed at the conclusion of a testing entities’ portion of worksand it will be noted in the “Incomplete Items List” that that only those test specified under thecontracted scope of works have been completed.

9.1.2 Design Handover

At least six weeks prior to the start of execution of each of the commissioning stages the ProjectManager will call for a handover meeting. The purpose of the handover meeting is to ensure thatall Stakeholders receive the required documentation to allow the Commissioning Stage to proceed.Key handover documentation will include:

A complete Secondary System Design for the upcoming stage of work. This will include acomplete set of approved Secondary System Design Drawings, Remote Terminal Unit (RTU)Configuration Files, an RTU SCADA Points Test List and RTU Logic Drawings.

A complete Protection System Design for the upcoming stage of works. This will include anapproved set of all Protection Relay Setting Files, Protection Setting Requests (PSRs) andProtection Relay Logic Drawings.

A complete set of approved Inspection and Test Plans and Test Reports for the SAT and SITPhases of Testing.

Confirmation from the Project Manager that all resources have been scheduled and will beavailable as per the Commissioning Schedule.

The Design Handover will be called for in the Commissioning Staging Plan. It is the responsibilityof the Project Manager to ensure that all deliverable be made available to the appropriateStakeholders at the handover meeting.

9.2. Drawing Management

In accordance with Ergon Energy operational requirements a correct copy of Design Drawings is toremain on site at all times. This requirement holds true during commissioning activities and thusthe following guidelines have been developed to ensure that commissioning works can beperformed whilst meeting operation requirements.

a) Approved drawings must be available on site such that through a combination of the greenlined drawings, isolation sheets and switching sheets the active state of the substation canbe readily determined.

b) Where the substation state cannot be clearly identified in accordance with point a) above,design will be required to provide stage specific approved drawings.

c) The single line diagram for a substation must at all times accurately represent the operationalstate of the substation. Due to this requirement approved designs must be made availablewhenever primary plant is either commissioned or decommissioned. The only exception tothis requirement occurs when there is no resultant change to the single line diagram due tothe works being performed.

It is the responsibility of the Design Group to review the existing Substation Drawings and theproposed Commissioning Staging Plan to determine if the above requirements can be met andwhere new design drawings will be required. In general this decision will be made during theDesign Verification Process of the project.

In order for the commissioning process to align with the Ergon Energy Substation ControlledDrawing management process the following guidelines will be applied during on site testing andcommissioning activities;

i) The “Site Test Copy” (designated as copy number 12) will be used by the testing entity

during each of the testing phases to capture site mark-ups and record testing progress (referMN000301R167 Greenlining and Bluelining of Ergon Energy Substation Drawings). Wheredifferent testing entities are used to complete each of the testing phases then at the


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completion of a phase the entity in control of the drawings will make an electronic copy ofthese drawings for record purposes and then issue both the electronic copy and the originalset of drawings to the project manager for reissue to the testing entity performing thesubsequent phase of testing. On completion of commissioning activities these drawings willbe electronically stored on the network server \\ecasd01\Protection\Test Data - (Test-Commissioning-Maintenance) by the Officer Responsible for Testing as proof of completionof testing as prescribed in the relevant ITP documentation.

It is the responsibility of the Officer Responsible for Testing to ensure that all mark-upsrecorded on the “Site Test Copy” are transferred to the “Site Initial Record Copy” (designatedas copy number 13) and the “Master Copy” (designated as copy number 1) prior to returningthe drawings to the project manager.

When on site test and commissioning activities have been completed the “Site Test Copy”will be retained by the local test section such that they can perform operational responseduties.

ii) The “Site Initial Record Copy” (designated as copy number 13) will be retained on site withall mark-ups for use as the site copy until it is replaced with “Substation As Constructed”(designated as copy number 20) copy. The “Site Initial Record Copy” will not be used forcapturing testing progress.

The “Site Test Copy” will be retained by the local test section until the “Test Section AsConstructed” copy (designated as copy number 21) are issued to the test section.

10. SUBMISSION OF APPLICATION FOR WORK REQUESTS ANDSYSTEM OUTAGES

The commissioning officer/engineer will provide the initial draft of the Application for Work (AFW)request in the form a tentatively entered AFW in the Ergon Energy FeederSTAT system. Thecommissioning officer/engineer will initially record the Work Group Supervisor of the work group

performing the dominant portion of the works as the AFW applicant. It will be the responsibility ofthe supervisor to ensure that the AFW request is reviewed by the appropriate staff and that the AFW is submitted to the Network Operations and Outage Co-ordination Groups with sufficient leadtime to allow outages to proceed as detailed in the Commissioning Schedule.

Where planned field crews performing the work change due to unforeseen circumstances it is theresponsibility of the supervisor to ensure that newly appointed staff are provided sufficient time toreview and familiarise themselves with the AFW details.

Where contractors have been identified as the work group performing the dominant portion of theworks the AFW submission will be performed by Ergon Energy assigned Contracts Officer/ProjectDelivery Coordinator. Under these circumstances the commissioning officer/engineer will recordthe contracts officer/project delivery coordinator as the AFW applicant on the tentatively submitted

AFW. It will then be the responsibility of the contracts officer/project delivery coordinator to seekconfirmation from the contractor that the AFW details have been reviewed for correctness and thatthe contractor authorises submission of the AFW into the FeederSTAT system. Upon receivingwritten confirmation from the contractor the contracts officer/project delivery coordinator will thensubmit the AFW on the contractor’s behalf.

The commissioning officer/engineer will provide ongoing support as required to ensure that the co-ordination of multiple work groups is correctly reflected in the AFW.

Prior approval of the Commissioning Staging Plan from the Network Operations and Outage Co-ordination Groups will ensure that any operational issues associated with planned outages will beresolved well before AFWs are submitted.


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11. COMMISSIONING TESTINGThe Commissioning Testing philosophy adopted by Ergon Energy and detailed in this manual isdesigned to meet the following criteria:

1. Ensure personnel and public safety

2. Minimise risk to plant3. Ensure that substation plant and systems are verified in accordance with their design

4. Capture test results for baseline/benchmark recording and trending purposes

5. Provide an audit function of external service providers

In order to meet these requirements it may be necessary to repeat some tests throughout thecommissioning lifecycle.

It is important to note that during the commissioning phase/s of a project, the CommissioningOfficer/Engineer is responsible for the verification of the plant and systems in accordance with theapproved design. Where the Commissioning Officer/Engineer identifies issues with the suitability or

implementation of a design the Commissioning Officer/Engineer will raise these issues with theappropriate subject matter expert for design validation. It remains the responsibility of the subjectmatter expert to ensure that all designs are correct, fit for their intended purpose and meetregulatory requirements.

Commissioning Testing has been divided into the five distinct phases, these being Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), Site Integration Testing (SIT), Pre-Energisation Testing and Post-Energisation Testing. The standard testing requirements for each ofthese phases has been clearly defined within the Automated Test Generation Tools which areavailable on the Ergon Energy Test and Commissioning Resource Centre website. Standard WorkPractice documents which detail how testing is to performed are also available on the ErgonEnergy Test and Commissioning Resource Centre website. The legal obligations and requirementspertaining to the use of Ergon Energy developed Automated Testing Tools and Standard WorkPractices are detailed in Annexes B and C of this document.

All automated test generation tools have provision for the sign off of test results and/or check sheetlists. It is the responsibility of the lead person performing the testing works to sign the recordedresults to signify that the tests have been performed in accordance with the approved standardwork practice and that the results reported are a true and correct record of the test results. Wheremore than one entity performs the testing requirements detailed in the test tool then the leadperson performing the testing must ensure that signatures are recorded by the persons responsiblefor the reported test results.

An overview of the Test and Commissioning Process for primary plant and secondary systems forthe purpose of substation plant and secondary system commissioning is discussed in the following

sections.11.1. Primary Plant Testing

All primary plant testing is to be carried out in accordance with the relevant Standard Work Practice(SWP), Inspection and Test Plan (ITP) and Test Report documentation provided on the ErgonEnergy Test and Commissioning Resource Centre website. Prior to commencing testing it is theresponsibility of the entity performing the testing to ensure that the documentation version beingused is in alignment with that published on the Ergon Energy Test and Commissioning ResourceCentre website.

11.2. Testing Beyond that Specified In Ergon Energy Test Documentation

Where the manufacturer of, or procurement contract for a plant item specifies additional testingrequirements beyond that detailed in the Ergon Energy ITP/Test Report documentation providedon the Test and Commissioning Resource Centre website then the most stringent testing criteriashall apply. In these cases the reporting of test results shall be completed as follows:


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a. The plant manufacturer shall be responsible for performing, recording and assessing all testresults. The output will be the issue of a vendor release and a report detailing all test resultsfor the plant item. These documents will be received and processed by the ProcurementGroup. A copy of the signed vendor release will also be issued to the CommissioningOfficer/Engineer to verify the plant item is available to be energised.

b. In addition to the documentation provided in part a) the manufacturer will also provide acomplete set of test results as detailed by the Ergon Energy ITP and Test Reports providedon the Test and Commissioning Resource Centre website. These results will be issued toand processed by the Commissioning Officer/Engineer.

11.3. Secondary Systems Testing

All secondary systems testing is to be carried out in accordance with the relevant Standard WorkPractice (SWP), Inspection and Test Plan (ITP) and Test Report documentation provided on theErgon Energy Test and Commissioning Resource Centre website. Prior to commencing testing it isthe responsibility of the entity performing the testing to ensure that the documentation versionbeing used is in alignment with that published on the Ergon Energy Test and CommissioningResource Centre website.

For protection relays there will be no Factory Acceptance Testing required as this equipment isconsidered proven when procured by Ergon Energy. In some instances FAT equivalent testingmay be performed by the Protection Standards or Design Groups to ensure that a relay is suitablefor a proposed protection scheme. This type of testing is beyond the scope of this document andwill not be discussed further. In relation to commissioning activities within the project lifecycleprotection relay testing will start at the Site Acceptance Testing phase.

For protection relay Site Acceptance Testing, engineering approved Ergon Energy Standard TestPlans will be used where available. If an approved Standard Test Plan is not available then it willbe the responsibility of the testing entity to develop a suitable Test Plan and seek Ergon Energyengineering approval for the Test Plan. Standard Test Plan approval is to be performed inaccordance with the guidelines provided in the Protection Relay Testing for CommissioningStandard Work Practice document.

The legal obligations and requirements pertaining to the use and development of protection relayStandard Test Plans is detailed in Annex D of this document.

11.4. Substation Communications System Testing

Substation Communications Systems form an integral and essential part of Substation SCADA andProtection Schemes. Due to the dependency on substation communications paths it is often thecase that these paths will need to be established to allow commissioning testing to be performed.The Commissioning Officer/Engineer will specify these requirements in the Commissioning StagingPlan.

Whilst System Integration Testing which requires the use of a substation communications path willbe the responsibility of the Commissioning Officer/Engineer, the establishment and testing of thecommunications path remains the responsibility of the Communications Systems Groups. The co-ordination of these resources to meet the project needs as detailed in the Commissioning StagingPlan will be the responsibility of the Project Manager.

11.5. Revenue and Statistical Metering Testing

In situations where additional accuracy testing is required to prove Substation Metering Systemsthis will be co-ordinated by the Project Manager. Where required, the CommissioningOfficer/Engineer will schedule the metering testing into the Commissioning Schedule so that theProject Manager can arrange for these resources to be made available.

11.6. Substation Miscellaneous System TestingFor all substation system or plant not covered by Sections 9.1 through 9.4 above, testing is to becarried out in accordance with the relevant Standard Work Practice (SWP), Inspection and Test


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Plan (ITP) and Test Report documentation provided on the Ergon Energy Test and CommissioningResource Centre website. Prior to commencing testing it is the responsibility of the entityperforming the testing to ensure that the documentation version being used is in alignment withthat published on the Ergon Energy Test and Commissioning Resource Centre website.

11.7. Test Resul t Assessment

Test result assessment will be performed in accordance with the Maintenance Acceptance Criteria(MAC) document (EE STNW1160). Where test results are assessed as a fail or not fit to beenergised against the MAC criteria, or assessment criteria is not available, the commissioningofficer/engineer will seek engineering advice from a Senior Commissioning Engineer.

Primary plant oil test result assessment will be performed by Ergon Energy SubstationMaintenance Group. Based on the oil test results the Substation Maintenance group will provide aclearance to energise for the oil test acceptability component of the plant. Unless under thedirection of a Senior Commissioning Engineer no power transformer or oil filled reactor shall beenergised without this clearance being received from the Substation Maintenance Group.

12. REPORTING OF PLANT, CONSTRUCTION AND DESIGN DEFECTSDURING THE COMMISSIONING PROCESS

In order to improve Design, Plant Procurement and Construction processes Defect Recording andReporting will be carried out throughout the Commissioning Process. Defect information capturingwill be achieved using the Ergon Energy Defect Reporting Tool Form MN000301F171.

Ergon Energy has also developed a Project Variation Reporting Tool within its corporateinformation technology systems. The Defect Reporting Tool is to be used to support andcomplements the corporate system by allowing field data to be efficiency captured and reported tothe Project Manager. During the commissioning phases of a project the CommissioningOfficer/Engineer will be responsible for issuing the defect reporting tool to the responsible workcrew leaders. The work crews performing the works are responsible for entering and maintaining

the defect data within the reporting tool and reporting the information back to the CommissioningOfficer/Engineer. At the conclusion of each of the commissioning phases the CommissioningOfficer/Engineer is responsible for ensuring that all defect reporting tools are returned to theCommissioning Officer/Engineer and that the defect information, including rectification status andrectification hours have been completed.

Project time and/or cost variations resulting from the correction of reported defects will be reportedto the Project Manager by the Commissioning Officer/Engineer. The Project Manager will beresponsible for reporting and approving these changes in the project variation system andcoordinating with all effected resources to ensure that the commissioning works can progress asdetailed in the Commissioning Staging Plan.

It is the responsibility of the Commissioning Officer/Engineer to review all reported defects toassess the impact of these defects on the Commissioning Staging Plan and advise the ProjectManager should there be any impact on the planned commissioning dates. In addition to this theCommissioning Officer/Engineer will be responsible for reporting defects which they considersystemic to the project delivery process into the Ergon Energy eSafe system so that these issuescan be addressed by the appropriate Department Managers.

During the Project Close-Out Phase all collected defect information will be provided by theCommissioning Officer/Engineer to the Project Manager for entry into the project variation tool andfor use in providing ongoing improvement of procurement contracts, construction processes anddesign standards. This information will also be used to provide validation of cost escalation duringthe project implementation phases.


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13. CONSTRUCTION RELEASE A Construction Release Form (MN000301F175) is to be completed by the officer responsible forconstruction and returned to the Commissioning Officer/Engineer or an approved commissioningdelegate. It is the responsibility of the Commissioning Officer/Engineer/delegate to ensure that thisdocument is correctly completed and signed prior to the start of Site Integration Testing.

On receipt of this document the Testing Officer responsible for SIT becomes the responsibleperson for the released plant and/or systems and remains in control of this equipment until theTesting Officer responsible for SIT completes sections 1 and 2 of the Commissioning Authority toEnergise Electrical Plant and issues the completed form to the Project Manager or the officerresponsible for SIT relinquishes access to the plant. Commissioning control is required during thisperiod to allow test resources to complete all required testing without interference from otherparties. If outside parties infringe on this control then the officer responsible for testing will informthe Commissioning Officer/Engineer who will assess the need to repeat testing to prove thatpreviously tested systems/plant have not been compromised. If an infringement occurs then theCommissioning Officer/Engineer must immediately inform the Project Manager that a breach ofaccess has occurred and the anticipated impact on the delivery of the commissioning objectives.

14. SITE ACCEPTANCE TESTING RELEASE A Testing Phase Release Form (MN000301F183) is to be completed by the officer responsible forSAT testing and returned to the Commissioning Officer/Engineer. It is the responsibility of theCommissioning Officer/Engineer to ensure that this document is correctly completed and signedprior to the start of Site Integration Testing.

Where SAT is not completed by a singular testing entity then a signed Testing Phase ReleaseForm (Form MN000301F183) will be completed at the conclusion of a testing entities portion ofworks. Under these circumstances the “Incomplete Items List” on the Testing Phase Release Formwill be completed by the testing entity handing over the works detailing the outstanding itemsrequired to complete SAT testing.

On receipt of the Testing Phase Release Form (Form MN000301F183) and the ConstructionRelease Form (MN000301F175) the Testing Officer responsible for SIT becomes the responsibleperson for the released plant and/or systems and remains in control of this equipment until theTesting Officer responsible for SIT completes sections 1 and 2 of the Commissioning Authority toEnergise Electrical Plant and issues the completed form to the Project Manager. Commissioningcontrol is required during this period to allow test resources to complete all required testing withoutinterference from other parties. If outside parties infringe on this control then the Testing Officer willinform the Commissioning Officer/Engineer who will assess the need to repeat testing to prove thatpreviously tested systems/plant have not been compromised. If an infringement occurs then theCommissioning Officer/Engineer must immediately inform the Project Manager that a breach ofaccess has occurred and the anticipated impact on the delivery of the commissioning objectives.

15. SITE INTEGRATION TESTING RELEASEOn completion of Site Integration Testing the Testing Officer responsible for SIT is responsible forcompleting and signing off sections 1 and 2 of the Commissioning Authority for EnergisingElectrical Plant Form (MN000301F174). Completion of this form signifies that all SIT works havebeen completed and that the resources responsible for performing these works have beeninformed and have acknowledged that the equipment tested is now to be treated as ‘LIVE’.

Where SIT is not completed by a singular testing entity then a signed Testing Phase Release Form(Form MN000301F183) will be completed at the conclusion of a testing entities portion of works.Under these circumstances the “Incomplete Items List” on the Testing Phase Release Form will becompleted by the testing entity handing over the works detailing the outstanding items required tocomplete SIT testing.


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16. PRE-CONNECTION HOLD POINT A pre-connection hold point will be enforced by the Commissioning Officer/Engineer to ensure thatall pre-commissioning checks have been completed as per the Ergon Energy Project ITP Tool.Once these checks have been completed by the Commissioning Officer/Engineer theCommissioning Officer/Engineer will provide authorisation to perform plant H.V. connections. TheCommissioning Officer/Engineer’s authorisation will also signify that “Queensland Electricity EntityProcedures for Safe Access to High Voltage Electrical Apparatus” procedures are now enforced inorder to make any H.V. connections.

17. COMMISSIONING AUTHORITY FOR ENERGISING ELECTRICALPLANT

On completion of Site Integration Testing the Testing Officer responsible for SIT is responsible forcompleting and signing off sections 1 and 2 of the Commissioning Authority for EnergisingElectrical Plant Form (MN000301F174). Completion of this form signifies that all SIT works havebeen completed and that the resources responsible for performing these works have beeninformed and have acknowledged that the equipment tested is now to be treated as live and canonly be accessed in accordance with H.V.I.A. processes by authorised personnel. Whencompleted, the signed form is to be issued to the Project Manager to provide formal notificationthat the SIT component of works has been completed and that all testing resources no longer haveaccess to that equipment.

On receipt of the signed Commissioning Authority for Energising Electrical Plant Form from theTesting Officer responsible for SIT it is the responsibility of the Project Manager to ensure thatSection 3 is completed and signed. The Project Manager will then issue the Commissioning

Authority for Energising Electrical Plant Form to the Commissioning Officer/Engineer.

The Commissioning Officer/Engineer will be responsible for providing final authority to energise theequipment listed on the Commissioning Authority for Energising Electrical Plant Form and

complete Section 4 of this document. Once completed, this document will be stored by theCommissioning Officer/Engineer as per the instructions detailed on the document.

18. CUSTOMER AUTHORITY TO ENERGISE CUSTOMER OWNED PLANTThe Customer Authority to Energise Customer Owned Plant Form (MN000301F176) is the officialnotification from a customer to Ergon Energy that their plant is ready to be energised. Without acompleted Customer Authority to Energise Customer Owned Plant Form customer owned plantcannot be energised.

It is the responsibility of the Project Manager to ensure that the Customer Authority to EnergiseCustomer Owned Plant Form is completed and signed by a Responsible CustomerRepresentative.

19. COMMISSIONING AND DECOMMISSIONING NOTICES A Commissioning/Decommissioning Notice (Form MN000301F124) will be completed by theCommissioning Officer/Engineer and returned to the Asset Maintenance Officer within 5 workingdays of the commissioning/decommissioning date.

20. STORAGE OF TEST RESULTS All test result will be stored using the Ergon Energy automated ITP tools and transferred to thenetwork server \\ecasd01\Protection\Test Data - (Test-Commissioning-Maintenance) by the OfficerResponsible for Testing. Where addition test results files (as specified by the Ergon Energy

automated ITP tools) are required these files will be named in accordance with the format specifiedby Ergon Energy automated ITP tool and transferred to the network server


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\\ecasd01\Protection\Test Data - (Test-Commissioning-Maintenance) by the Officer Responsiblefor Testing.

It is the responsibility of the Commissioning Officer/Engineer to ensure that all test results arereviewed and correctly stored at the completion of each of the commissioning phases. In caseswhere the Officer Responsible for Testing does not have access to the network server, then the

test results will be provided to the Commissioning Officer/Engineer by the Testing Officer forcorrect storage.

21. POST COMMISSIONING CLOSEOUT At the completion of each of the commissioning stages the Commissioning Officer/Engineer will beresponsible for completing a stage close out. To complete a Stage Closeout the CommissioningOfficer/Engineer will:

a. Confirm that all test reports and results have been saved to the Ergon Energy shared drive.

b. Ensure that all defect reporting tools have been completed and saved to the Ergon Energyshared drive.

c. Perform a defect consolidation using the Ergon Energy Defect Summary tool (formMN000301F172) and forward the complete tool to the Project Manager.

d. Confirm that all Commissioning/Decommissioning notices have been completed andreturned to the Asset Maintenance Officer.

e. Storage of all commissioning documentation on the Ergon Energy shared drive.

f. Ensure that all systemic defects have been entered into eSafe.

g. Participate in the project close out debrief as arranged by the Project Manager.

22. AUTHORISATION AND APPROVAL OF COMMISSIONING

DOCUMENTATIONErgon Energy has developed a number of sophisticated systems and tools to provide a high levelof consistency and continuity of testing and management of its commissioning activities. Thesesystems have been RPEQ approved and are not to be modified without approval from the SeniorCommissioning Engineer.

It is the responsibility of the Engineering Manager to ensure that these systems and tools remainup to date and reflect the requirements detailed in the Standard Work Practice Documentation andMAC criteria.

A breakdown of the required Qualifications/Competencies for the development, approval andmodification of Ergon Energy Commissioning Documentation is provided below in Table 1.

Document Approval Level Contractor Approval Level

ITP developed from approved SWPs orapproved ITP templates

PP4/PP5/PM2/PM3 Level 6 Field TestCompetency

Non-standard ITP RPEQ Not Applicable

Application for Works tentative submission PP5/PM2/PM3 Level 6 Field TestCompetency

Co-ordination Plan PP5/PM2/PM3 Not Applicable

Test Results (where pass/fail criteria have been

defined)

PP4/PP5/PM2/PM3 Level 6 Field Test

CompetencyTest Results (no defined pass/fail criteria) RPEQ RPEQ


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Work Instruction, Standard Work Instruction,Inspection or Test Plan Template

RPEQ Not Applicable

Form Template PP5/PM2/PM3 Not Applicable

Table 1: Ergon Energy Commissioning Documentation Development, Approval and Modification

Authorisation Requirements.


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A3. ANNEX C – TERMS AND CONDITIONS OF USE OF ERGON ENERGYDEVELOPED AUTOMATED TEST REPORTING TOOLS


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A4. ANNEX D – TERMS AND CONDITIONS OF USE OF ERGON ENERGYDEVELOPED STANDARD WORK PRACTICES


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A5. ANNEX E – TERMS AND CONDITIONS OF USE OF PROTECTIONRELAY STANDARD TEST PLANS


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Documents

Testing and Commissioning Manual.pdf