SAKR POWER GENERATION

BOOK No.

TAB No.

COMMISSIONING MANUALS
E

DOCUMENT TITLE

17

DOCUMENT No.

REVISION

COMMISSIONING PROCEDURE:
11kV SWITCHGEAR

0
No. OF PAGES

APPENDICIES

9
PROJECT

LOCATION

AL-HORRIAH (PP-1), HFO Power Plant.

CLIENT/ ENGINEER

Ministry Of Energy

CONTRACTOR

SAKR Power Generation

00

ISSUED BY

Baghdad, IRAQ

JOB Ref.

ISSUE DATE

1005

July 15, 2010

These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met during testing or
commissioning. Should further Information be desired or should particular problems arise that are not covered sufficiently for the purchasers purpose, The matter
should be referred to OEM. This document contains proprietary information of SAKR, LEBANON and is furnished to its client solely to assist him in the testing and
commissioning of the equipment described herein. This Document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party
without the written approval of SAKR Power Group.
Note
The component level check sheets and test procedures referenced herein depict philosophies for minimum check out requirements. Other vendors or
subcontractors may have equivalent documentation that may be substituted for check sheets/forms with the concurrence of the site Commissioning Manager.

REV.

DESCRIPTION

APPROVED/ ISSUED

SAKR Power Group

Power Generation
Power Projects

DOCUMENT TITLE

Procedure No.

PP1-MVSW-TP-001

COMMISSIONING PROCEDURE
11KV SWITCHGEAR

0
PROJECT

CLIENT

AL-HORRIA POWER PLANT-PP1

LOCATION

Ministry Of Energy IRAQ

13

ISSUE DATE

Baghdad, IRAQ

15-07-2010

CONTENTS
1.0

SYSTEMS CONCERNED......................................................................................................................2

2.0

SCOPE......................................................................................................................................................2

3.0

REFERENCE DOCUMENTS................................................................................................................2

3.1
3.2

PROJECT REFERENCE DOCUMENTS.........................................................................................................2

TECHNICAL REFERENCES & STANDARDS...............................................................................................3

4.0

PRECAUTIONS AND LIMITATIONS.................................................................................................3

5.0

PREREQUISITES...................................................................................................................................3

6.0

APPLICABLE TEST FORMS & PROCEDURES..............................................................................4

7.0

TEST EQUIPMENT/TOOLS.................................................................................................................4

8.0

TEST EXECUTION................................................................................................................................4

8.1
8.2
8.2.1
8.2.2
8.2.3
8.3
8.4
8.5
8.6
9.0

INITIAL INSPECTION.........................................................................................................................4
SWITCHGEAR INSPECTION.............................................................................................................4
Inspection of the Power and Ground Bus........................................................................................4
Inspection of Control Wiring, Control & Protection Devices..........................................................5
Inspection of Cubicles......................................................................................................................5
PRE-COMMISSIONING CHECKS......................................................................................................6
OPERATIONAL TESTS........................................................................................................................7
FUNCTIONAL TESTS- (LOGIC TESTS).................................................................................................9
ENERGIZED TESTS...........................................................................................................................11

ACCEPTANCE......................................................................................................................................13

1.0 Systems Concerned

1.1
2.0

Scope
2.1

3.0

11kV switchgear.

The scope of the procedure is to perform inspection and tests to verify that the
equipment has been installed and will function according to design and
operation requirements.

Reference Documents
3.1

Project reference documents

Drawing WPKI-0705-EL-4020 Main single Line diagram

Drawing WPKI-0705-EL-4020-00 Main single Line diagram

Drawing WPKI-0705-EL-4020-02 33KV Switchgear And Generator

Transformers Metering and Relaying

Drawings Kale E200-160 11kV switchgear wiring diagrams

Drawing 0793-H 33 KV TR-1 Schema

Vendors O&M manuals.(11kv Switchgear, 3 - F650 - Relay TR, 4 - SR

489 - Relay GE, SR 745 - Relay TR)

3.2

Technical references & standards

IEC 60694
IEC 60298 (IEC 62271-200)
IEC 60129 (IEC 62271-102)
IEC 60420 (IEC 62271-105)

IEC 60265 (IEC 60265-1)

IEC 60694

4.0

Precautions And Limitations

4.1 Perform thorough inspection prior to any tests and or energizing being done.
4.2 Provide signs and barriers, where necessary, for safety.
4.3 Use electrical test equipment with caution and as per manufacturer instructions.
4.4 Make sure to remove any temporary (installed during tests), wiring or jumpers
after tests completion.
4.5 All personnel shall wear the appropriate PPE.

5.0

6.0

Prerequisites
5.1

The equipment installation is complete and turn-over done.

5.2

All mechanical checks, if any, are complete.

5.3

All the reference documents should be at hand. Instruction manuals, wiring

diagrams, protection settings etc.

5.4

Personnel performing the commissioning are expected to perform the attached

tests as minimum, in addition to any other tests and inspections that their
experience, training might require.

5.5

Test team should verify that the equipment can be safely energized as a part of
the whole plant electrical system.

Applicable Test Forms & Procedures

PP1-MVSW-TF-001 - Visual Inspection
PP1-MVSW-TF-002 Pre-Commissioning Checks
PP1-MVSW-TF-003 Functional Checks
PP1-MVSW-TF-004 Energized data- PMCC

7.0

Test Equipment/Tools

a) Digital multi-meter & clamp meter

b) Phase sequence indicator

c) Megger
d) Relay test equipment for secondary injection- ISA T/D series or equivalent
e) Unit relay primary injection- ISA KAM/ GE ODEN/Megger/ or equivalent.
f) Three phase adjustable transformer

8.0

Test Execution
8.1

INITIAL INSPECTION

1.1.1

Inspect the cubicles and breakers for damage

1.1.2
Check the equipment against applicable Electrical and Schematic
Drawings to be sure that the proper equipment has been installed in the proper
location.
1.1.3
8.2
1.1.1

Check equipment name plate and compare to design.

SWITCHGEAR INSPECTION
Inspection of the Power and Ground Bus.
a. Check power bus compartments for clearances, insulation, loose
debris, no exposed control wiring, damage, phasing.
b. Inspect all ground bus connections and ensure that the ground bus
is continuous throughout the switchgear and properly connected to
station ground.
c. After inspection, reinstall all power bus cover plates.
d. Complete PP1-MVSW-TF-001

1.1.4

Inspection of Control Wiring, Control & Protection Devices

a. Verify that all electrical connections are tight.
b. Check DC control circuit throughout the switchgear as per
drawings.
c. Check that the proper control and (control) power cables are
installed and terminated.

d. Check conformity of all circuits with drawings.

e. Check that the relays and associated parts are installed and
undamaged.
f. Perform visual check of all protection devices(MCB, Fuses etc).
g. Complete PP1-MVSW-TF-001

1.1.5 Inspection of Cubicles

a. Check the operation of cubicle: door, hinges, locks, locking bolts.
b. Inspect the cubicle door panels for proper arrangement of relays,
test switches, plugs indicating lights.
c. Check the Current and Voltage transformers for damage.
d. Verify proper operation of bus shutter assembly.
e. Check cubicle space heaters are working properly.
f. Verify the following:

o With the breaker closed, it cannot be moved between the

connected and disconnected positions.
o With the breaker closed, it cannot be moved into or out of
the cubicle.
o With the earth switch closed, the breaker cant be racked
in.
o Check interchange-ability of similar rating breakers and
the contrary for different ratings.
o Rack the breaker into the test, operate in its open, and
closed, positions and verify that the cell position
indicator is correct in all positions and that the insertion
and draw out mechanisms function smoothly throughout
the racking stroke
a.

1.1.1

Complete PP1-MVSW-TF-001

Inspection of Breakers
I. Check incoming/outgoing breakers as per manufacturers
instruction.

8.3

PRE-COMMISSIONING CHECKS

1.1.1

Perform all activities as per PP1-MVSW-TF-002.

1.1.2
Perform Bus insulation resistance check (Megger) with all CBs
closed and power cables and voltage transformers disconnected. PP1-MVSWTF-002
1.1.3
Perform insulation resistance check of control and auxiliary circuits.
PP1-MVSW-TF-002
1.1.6
Check power supply for the cubicle (control, auxiliary). Record data
in PP1-MVSW-TF-002.
8.4

OPERATIONAL TESTS

1.1.1

Perform primary/secondary injection and protection relay setting.

1.1.7 For the purpose of the test, install a temporary short circuit link

for if necessary. Refer to test equipment and protection relay

manufacturer instruction manual.
The injection test is designed to test the high current circuits in
switchgear. Current transformer ratios, meter circuits and protective
relay circuits are verified for proper operation by this test.
The current ranges are typically 50-5,000 AC amperes,
depending on the ratings of the switchgear. The test set is connected
to the three primary conducting phases in the switchgear and the
current levels are raised and monitored to check all applicable
instruments in the primary current path. The results will confirm and
verify that all relays and metering systems are performing within the
published times.
1.1.8

Perform solid state/thermal overload setting checks.

The test set for this is a low voltage, high current test device
used to test the performance of electromechanical overloads and
solid state trip devices in low voltage air circuit breakers. The test
set is rated for operation at 20,000 amps continuous and 100,000
amps instantaneous.
The air circuit breaker is connected to the test set directly by
use of the primary disconnects and current is raised to the proper
levels to test all circuit breaker functions and characteristics that will
ultimately trip the circuit breaker. All characteristics (long time,
short time and instantaneous) are verified to fall within original
manufacturer's published curves.
The above tests will confirm the ability of the air circuit
breaker to sustain high current, hot spots on the contacts and verifies
that the overloads or solid state package operate properly within a
given range of times.
N.B. It is up to the commissioning engineer to decide whether to do
primary or secondary injection tests OR conduct both tests as required.
1.1.9
8.5

Record results on PP1-MVSW-TF-003.

FUNCTIONAL TESTS- (Logic tests)

The functional tests are intended to test the control circuit of the Switchgear feeders
(Logic test). This will include testing of Start/Stop commands, feedback contacts,
local alarm and signalization in addition to any other interlocks. The tests shall be
based upon the wiring diagrams of the SWITCHGEAR. The test Engineer is expected
to test/simulate all the possible logic combinations and record the results. For the
signals to remote equipment (DCS, Local Control Panels LCP), the test will be
simulated/verified at the terminals of these signals.

8.6.1

Pre-Checks
a-

Check the schematic diagrams to determine the desired

control objective and verify that the control objective agrees
with the system design.

b-

Check the wiring and schematic diagrams and verify that the
wiring diagrams exactly mimics the schematic diagrams.

c-

Check the wiring and schematic diagrams to determine the

control circuit switching devices, such as: push button,
temperature, & relays, etc.

d-

Check the wiring and schematic diagrams to determine the

control circuit-energized devices, such as: solenoids,
contactors, starters, indicating lamps, alarms, relays, etc.

e-

Check the wiring and schematic diagrams for errors. Verify

that the diagrams, as shown, will accomplish the desired
control objective. Pay particular attention to the state of
switch contacts, normally open/normally closed.

f-

Check the wiring and schematic diagrams to determine the

number and the location of termination points, conduit
routing, etc.

1.1.10

8.6.2 Phase 1 - Pre-Commissioning (Preliminary Testing)

8.6.3

a-

Be
sure
to
have
the
CB/Switch
of
the
INCOMING/OUTGOING feeder compartment to be tested is
disconnected prior to test.

b-

Be sure that no external voltage is available in the circuit to

be tested.

c-

Trace the control circuit wiring from the circuit power source
through the switches to the output devices.

d-

Trace each wire point-to-point. Highlight (yellow line)

drawings as each conductor is traced.

e-

Confirm that the field wiring, ratings agree with the

applicable wiring diagrams.

f-

Verify that all the wiring at all intermediate terminal blocks,

final terminal blocks, relays, switches, PB are terminated
correctly.

Phase 2 Logic Tests (All the tests shall be done with the switchgear
denergized.)
a-

Perform electrical operation of the breakers; opening and

closing.

b-

Simulate functional test of all applicable relay and control

schemes. Local and remote closing/opening if applicable.

c-

Check the correct operation of all breaker status and alarm

schemes.

d-

Insulate any wires that are to be disconnected while performing

this test procedure.

e-

Insulate any wires that are to be disconnected while performing

this test procedure.

f-

Mark for identification all temporary jumpers and disconnected

wires while performing this test procedure and document
jumpers that are to be left in place for operational & start up
purposes and AS Built revision.

g-

Disconnect or isolate energized output device power.

h-

For each contact in the control circuit, change the state of each
contact, monitor the controlled devices, and verify that the
controlled devices respond, energize and de-energize, per
design.

i- Remove or replace any lifted leads, jumpers, fuses or grounds used in

testing.
j- Replace all the panels removed for inspection and testing purposes.
k-

Verify that the equipment is free of foreign materials.

l- Mark-up any modifications done for AS BUILT.

m8.6

Complete PP1-MVSW-TF-003.

ENERGIZED TESTS
i. Initial Conditions:
a.

Check that all incoming and outgoing feeder circuit

breakers are isolated open and locked off.

b.

All power cables are connected and identified and

meggered. Refer to PP1-CAB-TF-001/002/003.

c.

Bus bar insulation test done (Megger).

d.

33kV transformer commissioning and energized from the

grid if possible, if not one generator should be in service
and ready to energize.

b. Case 1- Supply from Grid

I. Make sure all other incoming/outgoing feeders are open and racked
out.
II. Close main feeder on BSDG to PMCC and hold for 5 Minutes to
soak test the power cable.
III. Check phase rotation of incoming feeder.

IV. Check that bus couplers are open and locked off - close main
feeder breaker and energize main bus system and soak for 30
minutes. After that close bus couplers to energize all the PMCC.
Repeat soak test for each newly energized section. Check phase
rotation for each section.
V. Check that all instrumentation reads correctly.
VI. Check system voltage value.
VII. Record results on PP1-MVSW-TF-004.
VIII. Measure the secondary voltages of the voltage transformers and
calculate the equivalent primary voltages/ratio.
IX. Record results on PP1-MVSW-TF-004.

i.

Case 2- Supply from transformers

I. Make sure all other incoming ACB from transformers are opened.
X. Energize one auxiliary transformer by closing the relevant switch
in 11kV PP1-MVSW, and hold for 5 Minutes to soak test the power
cable.
XI. Check phase rotation of incoming feeder cable.
XII. Check that bus couplers are open and locked off - Close main
feeder breaker 3200A and energize main bus system and soak for
30 minutes. After that close bus couplers to energize all the PMCC.
Repeat soak test for each newly energized section. Check phase
rotation for each section.
XIII. Check that all instrumentation reads correctly.
XIV. Check system voltage value.
XV. Record results on PP1-MVSW-TF-004.
XVI. Measure the secondary voltages of the voltage transformers and
calculate the equivalent primary voltages/ratio.
XVII. Record results on PP1-MVSW-TF-004.
i. Perform ACO if applicable.
1.1.11

8.6.1 ACCEPTANCE
8.7

Equipment physical integrity is sustained, associated devices are installed and

operating properly, and all electrical tests indicate satisfactory condition.

8.8

No failure of the insulation during the test.

8.9

Compare factory test to the PP1-MVSW design criteria to ensure all design
requirements are satisfied.

8.10 All control is according to design requirements.