-Pre-com. Procedure for Tertiray _415V SWGR

PROJECT / CONTRACT REF.:

2546 / GC07100300

ENGINEERING, PROCUREMENT, INSTALLATION AND COMMISSIONING (EPIC) FOR BERTHS AND PORT INFRASTRUCTURE FOR RAS LAFFAN PORT EXPANSION PROJECT DOCUMENT TITLE:

PRE-COMMISSIONING PROCEDURE FOR 415V SWITCHGEAR AT TERTIARY AND SECINDARY DISTRIBUTION SUBSTATIONS

15-JUN09

0

ISSUED FOR REVIEW / COMMENTS

DM

MAS

AI

PRE-COMMISSIONING PROCEDURE FOR 415V SWITCHGEAR AT TERTIARY & SECONDARY DISTRIBUTION SUBSTATIONS

DATE

REV. NO.

REASON FOR REVISION

DOCUMENT NUMBER:

-

PREPARED

CHECKED

APPD.

SHT 1 OF 0 1 2

Contents 1

Scope

3

2

Reference Documents

4

3

Pre-commissioning Check List

5

4

Risk Assessment

6

5

Pre-commissioning Procedure

7

5.1 5.2 5.3 5.4

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Test Procedure Punch List Precommissioning Test Forms List of Test Equipments

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Scope This scope describes the procedure for Pre-commissioning activities of the new 415V Switchgears located at either the Tertiary substations or at Secondary Distribution Substations of all P 965 – Berth & Port Infrastructure for Ras Laffan Port Expansion project. ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------++++++

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Reference Documents All pre-commissioning tests which are performed shall be in accordance with specifications of International Electrotechnical Commission (IEC) and the specifications listed below: 

RPGE-0-05-0041:

Pre-commissioning

&

Commissioning General Guide lines. 

RPGE-0-05-0247:

Pre-commissioning

&

Commissioning System/ Sub-system Definitions for Mile Stone - 1 

RPGE-0-05-0381:

Pre-commissioning

&

Commissioning Note.

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3

Pre-commissioning Check List

S/N

ACTIVITIES

1

Check all Safety devices such as display of warning sign, barrication of access limitation, key box for the panels and fire extinguishers are in compliance with HSC requirements prior to start performing pre-commissioning activity, as required.

2

Perform verification of equipment to full compliance to manufacturer drawings, and project specification & standards

3

Check the feeder labelling is correct. Verify all safety signs are in place.

4

Check the earthing bar and connections are firm & tight.

5

Check the Padlocking facilities for breakers are made available.

6

Check the cable terminations.

7

9

Check the mechanical closing and opening of incomer & outgoing breakers Rack each circuit breaker from TEST position to SERVICE position and back several times. Record fuse type and rating for the control circuits.

10

Perform Ductor test.

11

Perform CT testing

12

Perform PT testing

13

Perform IR test.

15

Check the operation of safety shutters of ACB are correctly functioning.

16

Perform ACB/MCCB testing

17

Perform Relay testing with final settings

18

Perform Functional test for the switchgear including the ATS, as applicable.

8

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Risk Assessment The risk assessment form is a safety management tool which identifies the major potential risk factors, preventive controls and additional control measures to be undertaken prior to performing a specific task or the whole task associated with the project subsystem activities during pre commissioning stages of work. This document is prepared by CCC/Subcontractor and submitted to project CCC/QP HSE personnel for their review prior to commencement of pre commissioning activities These features as prescribed in the risk assessment form will be regularly monitored and audited by the field safety personnel to ensure the pre commissioning activities are performed in a safe manner for the successful completion of the task.

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Pre-commissioning Procedure Introduction The procedure of Pre-commissioning test & checks are required to ensure LV Switchgear is properly installed, wired correctly, and the safety devices are tested to verify the performance and the function to confirm the suitability of the equipment for the application. This procedure will be applicable for site testing of LV Switchgear for readiness before the commencement of the Commissioning activities. The LV Switchgear and the control devices will be tested in accordance with the vendor approved procedures, applicable IEC standards and Project reference documents. General Visual check shall be carried out to confirm the correctness of the installation, and the equipment structure is free-of-damage. Mechanical tests shall be carried out to assure the operation/mechanize of the mechanical parts. Electrical tests shall be carried out to confirm either the conductivity or the quality of the insulation. Functional tests shall carried out verify the schematic/logic diagram. Protective relays shall be set and tested in accordance with the requirement of the system coordination and protective relay setting record. Punch list, if any, shall be prepared and submitted to the Vendor. Vendor will replace defective major components that are critical for the successful operation of the equipment. Following is the minimum checks that will be performed and confirmed:

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

Before performing any activity it shall be ensured that the equipment is properly isolated and the person can work safely.



Verify all fuse holders, fuses, and other protective devices are not damaged and are of proper size, type & rating in accordance with SLD.

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PRE-COMMISSIONING PROCEDURE FOR 415V SWITCHGEAR AT TERTIARY & SECONDARY DISTRIBUTION SUBSTATIONS



Check the bus bar ratings and the creepage and clearance distances of the bus bar.



Verify type & rating of instrument transformers.



Check the proper phase rotation N-R-Y-B counting from left to right, top to bottom, or front to rear when viewing from front.

All megger readings will be taken preferably during dry temperature weather. Verify the busbar joints of Separate transport sections are connected properly. Also check the tightness of busbar joints with proper torque in accordance with manufacturer recommended torque values. Ductor test will be performed at all joints of the bus bar on completion of torque. Verify the interpanel wiring wherever it is applicable.

is

connected

properly

Circuit breaker device that have adjustable settings such as MCCB shall be set in accordance with system protection coordination requirements. Tripping characteristic shall be tested in line with Vendor’s recommendation. Thermal overload relays shall be individually checked to ensure proper ampere range has been installed and set for the full load currents, where fuses are used their ampere ratings and types shall be checked for conformance with design requirements. Protective relay settings and adjustments shall be made in accordance with manufacturer instruction booklet. The integrity of the circuits between protective relays / meters and their associated CTs shall be verified. Check the relay gives the trip signal to circuit breakers. Following inspections and test shall be performed on all the 415V Switch gear prior to Commissioning:

5.1



Perform IR test for phase to phase, phase to neutral, phase to ground and neutral to ground.



Check all VT fuses are connected in the panel.

Test Procedure a.

VISUAL CHECKS:

The visual checks are filled in the check sheet forms.

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The visual checks will be carried out to ensure the installation work is done as per the approved layout drawings and vendor procedures, and the equipment is free-of-damage. b.

MECHANICAL CHECKS:

The mechanical checks are filled in the check sheet forms. The test is performed by operating the incoming and outgoing circuit breakers operation manually for free operation. The Mechanical Operation is performed for the interlock between incomers wherever it is applicable. c.

ELECTRICAL CHECKS:

The electrical checks are filled in the check sheet forms.

IR Test on Busbars: The IR test is to measure the insulation level of the equipment. This test is done by using a 1000V megger for 1 minute between each phase to Neutral, each phase to earth, phase to phase and neutral and earth. Ductor Test for Busbars: This test is to ensure the all the busbar joints are properly aligned jointed and connected firmly. It can be measured by using a Ductor tester. Keep the probes on both sides of the busbar joint and apply some pressure to be sure for better contact and press the test button. Wait for few seconds to get a stable reading. The measured values should be less than the specified values. Refer vendor requirements and table or FAT reports. CT & VT TESTS: CT POLARITY TEST: Connect +Ve 9V battery to P1 of CT and –Ve of 9V battery to P2 of CT. Connect the analog ammeter between S1-S2 of CT secondary.

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Check the ammeter needle goes towards forward direction. VT RATIO TEST: Connect the 3 phase supply to the P1 & P2 of VT Measure the secondary voltage between S1 & S2 Verify the VT ratio is inline with the name plate details. CT RATIO TEST: Connect the primary injection kit across the P1-P2 of CT. Connect the ammeter between S1-S2 of CT secondary. Inject the primary current and measure the secondary current in the ammeter. Verify the CT ratio is inline with the name plate details. PRIMARY INJECTION TEST: Connect primary injection kit across P1-P2 of CTs. Make sure that all the CTs secondary wirings are connected to the corresponding metering / protection circuit. Inject primary current and measure the CTs secondary current in the relay circuit, metering circuit, etc., Measure the relay current/meter current through display. VOLTMETER: Apply the voltage in the voltage terminal of the VT and check the voltage in the voltmeter/relay, the voltage measured should be in acceptance level. AMMETER: Inject the current to the CT terminals of meter/relay and check the current in the ammeter/relay the current measured should be in acceptance level. MULTI FUNCTION RELAY TEST: PICK UP TEST: Set the current set value in relay.

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Inject current into relay by a secondary injection kit after isolating CT. Increase current until assigned LED to glow for pick up test. Reduce the current value until LED disappears for drop off test. DEFINITE TIME ELEMENT (50/64) TEST: Set the current set value in relay and tipping time in relay. Inject current slightly more than set value in the relay. Relay contact to be connected to secondary injection test kit to stop the timer. IDMT ELEMENT TEST (51/51N/51G): Set the current set value in relay. Set the Operating curve and TMS in relay. Inject current two times and five times of the set value in the relay. Relay contact to be connected to secondary injection test kit to stop the time. Check the function of the existing shunt closing and shunt opening releases by electrical operation. Perform ACB/MCCB testing for trip conditions.

d.

FUNCTIONAL TESTS:

Functional tests shall be carried out to verify the schematic/logic diagram. ATS TEST For ATS logic, wherever it is applicable, operation check shall be carried out as following: Simulate power failure condition on incomer-1 and check that there is an automatic closing of bus-coupler breaker and transferring the load to the incomer-2. Resume the power back on incomer-1. Then, simulate power failure

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condition on incomer-2 and check that there is an automatic closing of bus-coupler breaker and transferring the load to the incomer-1. INTERLOCK TEST: Check the mechanical / electrical interlock whichever is applicable to the project. Ensure that only two breakers out of three breakers can be closed at any time. Check the operation of momentary synchronization if available.

paralleling

/

MOMENTARY PARALLELING: In manual mode, select the breaker to trip and give a close pulse to the third breaker which is in open position. Check that the third breaker closes first achieving paralleling and the selected breaker will trip within a short period (usually 1 to 3 seconds) as per the project specification & requirement. SYNCHRONIZATION: Check the possibility of closing both the incomers and bus-coupler breakers through synchronization relay. INTERTRIP TEST: Trip the incomer breaker through protection relay and check a inter trip signal is ready to go to the respective 11kV RMU outgoing breaker. GENERATOR FEEDER TEST: Generator feeder functional test shall be in line with the applicable schematic/logic diagram for Normal mode operation logic and Test Mode operation logic.

5.2

Punch List Exceptional punch list shall be created in line with the punch list definition of categories in order to identify and place in record the missing materials, pending engineering discrepancies, field modifications, pending

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vendor document which do not provide a hindrance for the commencement of commissioning activities 5.3

5.4

Precommissioning Test Forms 

IR Test (FM-106)



Ductor Test (FM-107)



CT test (FM- 109)



VT test (FM-110)



Multi Function Relay /IPR Test (FM-111)



ACB / MCCB Test (FM-112)

List of Test Equipments The test equipments used will comply with suitable accuracy, by proper validation by third party for the suitability of the device for the intended function prior to performing the testing activity 

0.5kV / 1kV megger



Multi meter



Clamp meter



Ductor Tester



Primary Injection Test Kit



AC High voltage Test Kit



Secondary Injection Test Kit / Protection Relay Test Kit



Laptop

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