Electrical Equipment Protection Safety Testing and Inspection

Introduction

Equipment readiness for commercial service is proven by testing all its functions under different conditions. ‘Do not believe, until it is proven’ is the key to successful testing and satisfactory operation of electric systems. Equipment is finally proven when it is energized and tested on load during the start-up (first energization). Errors missed in previous stages of the project are discovered in the commissioning. During testing, the engineers are exposed to high and low voltages and currents. To prevent injuries and damages, they must be trained to fully understand the processes and plan all steps of the commissioning.

The safe and efficient operation of modern electrical equipment and control systems requires the successful testing, start-up, and commissioning of this equipment, or system, to ensure correct operation, plus;

• Accurate troubleshooting
• Subsequent repair of this equipment, or system
• Ensuring continued productivity
• Commissioning planning, process, and procedures
• Commissioning inspections
• Commissioning /maintenance tests
• Start-up or first energization
• The safety aspect of commissioning

Objectives

Upon the successful completion of the workshop, each participant will be able to:-

• A better understanding of commissioning procedures
• A better understanding of troubleshooting procedures
• An improved capability in the use of test equipment
• A better understanding of failure modes and failure analysis
• Understand the testing process
• Plan and prepare for testing
• Plan and carry out inspections
• Perform primary and secondary injections
• Plan the first energization
• Perform phasing tests
• Consider safety aspects during testing
• A refreshed awareness of electrical safety concerns

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This training course is suitable for a wide range of professionals but will greatly benefit:

• Testing Engineers / Technicians
• Maintenance Engineers / Technicians
• Managers of Engineering departments
• Consulting Engineers / Technicians
• Project Engineers
• Safety Professionals
• Others who want a solid preparation in testing & commissioning

Course Outline

Importance of Start-Up, Commissioning, and Testing of Electrical Systems 

• Definition of Start-up, Commissioning, and Testing
• Pre-commissioning Procedures
• Reasons for Start-up, Commissioning, and Testing
• Substation Commissioning – Gas Insulated Substation
• Managing Commissioning with IEC 61850 and GOOSE
• Earthing System including Clean Earth, Intrinsic Safe Earth, and Planet Earth
• Major Components of GIS Substations
• GIS with Vacuum Interrupter

The Technology of Electrical Equipment

• Transformers – Power supplies (UPS) – Batteries
• Generators – Switchgear – Disconnect switches
• Neutral ground resistors (NGR)
• Motor control centers (MCC) – Variable frequency/speed drives (VFD/VSD)
• Programmable logic controllers (PLC) – Distributed control systems (DCS)
• Power monitoring
• Control relays/timers/switches – Motor/feeder protective devices
• Miscellaneous equipment – Heaters, solenoid valves, electric valve actuators, and signaling/alarm devices

Commissioning and Testing of Electrical Equipment

• Methods
• Principles – Special techniques
• NEC checklists

Commissioning Test Equipment (CPC 100, Omicron 356, CIBANO, ARCO, TESTRANO) and Circuit Breakers including Instrument Transformers

• Types of Tests and Equipment for Commissioning
• IR test, Primary Injection Test, Secondary Injection Test
• HV Test, AC Hipot Test, DC Hipot Test and Connections
• Infrared and Partial Discharge Monitoring
• Circuit Breaker Functional Tests
• Tests for SF6 Circuit Breaker
• SF6 Management
• Construction and Test for Current Transformer and Voltage Transformers

Troubleshooting of Electrical Equipment

• Methods – Terminology – Principles
• Special techniques
• Case studies/examples
• Single line drawings
• Group exercises

The Use of Test Equipment

• Digital voltmeter (DVM)
• Megger
• Frequency meter
• Temperature probes/pyrometers
• Ammeters, Power meters
• Load banks
• Digital hydrometers
• Cable fault locators

Commissioning Test for Earthing and Lightning Systems 

• Importance of Earthing
• Network Earthing
• Neutral Earthing Resistors
• Restricted Earth Fault
• Sensitive Earth Fault
• Lightning Protection Systems
• Commissioning Testing for Protection
• Numerical Relays Functionalities

The Interpretation and Use of Drawings

• Single-line electrical drawings
• Control schematics
• Wiring lists
• P&ID’s
• Logic and standard symbols

The Development of a Job Plan

• Identification of the troubleshooting step-by-step sequence
• Procedure preparation
• Follow-up
• Safety considerations and training

The Identification and Repair of Problems/Failures

• Common mode failures, Phase imbalance
• Electronic component failure, Fusing
• Fusing
• Motor windings/bearings/brushes
• Excitation circuits
• Battery cells, Inverters/rectifiers
• Inverters/rectifiers
• Bushings – Switches
• Control circuits
• Ground faults

First Energization and Commissioning Documentation

• Battery Charger Commissioning Tests
• Commissioning Switching Plans
• Managing the First Energisation
• Switching Plans
• Soak Tests and Phasing Tests

A review of Safety Requirements

• Area classifications
• NEC electrical codes, Safety Information