TESTING AND COMMISSIONING PROCEDURE
FOR
MV PANEL
EPCC MS CNG PROJECT - GROBOGAN
Company
PT ENERGASINDO HEKSA KARYA
EPCC CONTRACTOR
PT GLOBALINDO - PT AEMCO KSO
0
Rev.
Number
Document No.
GB-AEMCO-EPCC-QC-005
Authorized
QC Dept.
Issued Date
1 JU 2023
Issued for approval
Description
QC Officer
Prepared By
Project Manager
Approved By
PT. GLOBALINDO - PT AEMCO KSO
QC Officer
Reviewed By
Project Manager
Approved By
PT. ENERGASINDO HEKSA KARYA
Table of Content
1. Introduction .................................................................................................................................................... 3
2. Objectives of the Testing and Commissioning Works ....................................................................................3
3. Scope of the Testing and Commissioning Works ............................................................................................3
3.1.Tests and Inspections during Construction ...........................................................................................3
3.2. Statutory Test and Inspection .............................................................................................................3
3.3. Functional Performance Tests .............................................................................................................4
3.4.Documentation and Deliverables ......................................................................................................... 4
4. Refference Documents, Codes, and Standards .............................................................................................. 5
5. Test Rquirements ............................................................................................................................................ 5
5.1. Safety Guidelines
.............................................................................................................5
5.2. Responsibility and Qualified Personnel ............................................................................................... 5
5.3. Tools Required
.............................................................................................................5
6. Procedures ...................................................................................................................................................... 6
6.1. Design and visual check ....................................................................................................................... 6
6.2. Mechanical operation tests ................................................................................................................. 6
6.3. Test of auxiliary electrical .................................................................................................................... 6
6.4. Test on auxiliary and control circuits ................................................................................................... 6
6.6. Measurement of the insulation resistance ..........................................................................................7
7. ANNEX ............................................................................................................................................................. 7
1.
Introduction
The procedures stated in this Testing and Commissioning (T&C) Procedure cover the
activities in preliminary tests and inspections, functional performance tests and the
commissioning of newly completed installations. This procedure is applied by contractors
in the MS CNG Grobogan project.
This T&C Procedure is also intended to lay down the minimum testing and commissioning
requirements to be carried out by Electrical Contractor on a new Medium Voltage Cubicle
Switchboard Installation upon completion.
2.
Objectives of the Testing and Commissioning Works
The objectives of the T&C works are:(i)
To verify proper functioning of the equipment/system after installation;
(ii)
To verify that the performance of the installed equipment/systems meet with the
specified design intent and statutory requirements, if any, through a series of
tests, measurements and adjustments; and
(iii)
To capture and record performance data of the whole installation as the baseline
for future operation and maintenance.
3.
Scope of the Testing and Commissioning Works
3.1.
Tests and Inspections during Construction
The purpose of these tests is to ensure that all components and systems are in a
satisfactory and safe condition before start up. Preliminary adjustment and setting
of equipment at this stage shall also be carried out at the same time to pave way
for the coming functional performance tests.
Before carrying out any test, the Electrical Contractor shall ensure that the
Installations comply with all relevant statutory requirements and regulations. The
T&C works shall also comply with all site safety regulatory requirements currently
in force.
3.2.
Statutory Test and Inspection
The Electrical Contractor shall carry out tests for the Installations to meet statutory
requirements as specified in the Specification. After the proper testing and
commissioning of the Installations, the Electrical Contractor shall notify the
appropriate authority as specified in the Specification, through the Project Owner
at the completion of the Installations and its readiness for inspection and testing.
The Electrical Contractor shall arrange for the necessary inspections and tests as
required by the Authority.
3.3.
Functional Performance Tests
The purpose of functional performance tests is to demonstrate that the
Installations can meet the functional and performance requirements as specified in
the Specification.
Some of the tests may need to be carried out under the supervision of the supplier
according to the provisions of the Specifications.
Any performance deficiencies revealed during the functional performance tests
must be evaluated to determine the cause. After completion of the necessary
corrective measures, the Electrical Contractor shall repeat the tests.
If any test cannot be completed because of circumstances that are beyond the
control of the Electrical Contractor, it shall be properly documented and reported
to the Project Owner, who shall then liaise with the relevant parties to resolve the
situation. The Contractor shall resume his testing work immediately upon the
attainment of a suitable testing environment.
3.4.
Documentation and Deliverables
The Electrical Contractor shall submit his proposed T&C procedures to get Project
Owner for approval.
All inspection and T&C results shall be recorded by the Electrical Contractor in the
appropriate test record forms. A complete set of these forms can be found in Annex
of this document.
Data recorded in other formats may also be acceptable subject to prior approval of
the Project Owner. Upon completion of all the required T&C works, the Electrical
Contractor shall complete and sign the testing and commissioning certificate to the
effect that the agreed T&C works have been duly carried out.
Functional test reports covering all measured data, data sheets, and a
comprehensive summary describing the operation of the system at the time of the
functional tests shall be prepared and submitted to the Project Owner. Deviations
in performance from the Specification or the design intent should be recorded, with
a description and analysis included.
Where required in the Specification, the Electrical Contractor shall conduct a final
evaluation of the performance of the Installations, the results of which shall be
included in the commissioning report.
The Electrical Contractor shall sign work completion certificate(s) and issue to the
Project Owner after completion of the Installations or any work subsequent to
repair, alteration or addition to an existing installation. This should be done before
the installations are energized.
4.
Refference Documents, Codes, and Standards
EHK-GBA-0323-10501-ELC-DW-011
SNI 0225:2011
IEC 60038
IEC 62271
IEC 60060
IEC 60694
5.
General Arrangement Drawing and Wiring
Termination for MV Panel
Standar Nasional Indonesia. Persyaratan Umum
Instalasi Listrik 2011
IEC Standard Voltages
High Voltage Switchgear and Controlgear
High Voltage Test Techniques
Common Specification for High Voltage Switchgear
and Controlgear
Test Rquirements
5.1.
Safety Guidelines
(a)
(b)
(c)
(d)
(e)
(f)
(g)
5.2.
Responsibility and Qualified Personnel
(a)
(b)
(c)
5.3.
Always follow the project safety plan and policy
Safety sign, safety warning, and safe boundary must be arranged prior to
the every test sequence
Always assume that any exposed conductor and electrical equipment are
live or energized during the T&C
Do Not cross the test boundaries when the T&C is being carried out.
Visitors are advised not to wear loose clothing, necklaces or rings around
fingers which may impair safety as it can be a hazard during the mechanical
and electrical test.
Refrain from wearing any high platform footwear to prevent any injuries
from tripping when on the factory floor.
Refrain from using mobile phones or any other personal electrical devices
when the electrical test is being conducted.
Quality Control is responsible for conducting the Test and issue of Test.
Project owner and Third Party Inspector will witness the test.
Only qualified personnel can perform the tests
Only authorized person may engaged in this T&C
Tools Required
(a)
(b)
Continuity tester
Grounding/earth tester
6.
Procedures
6.1. Design and visual check
The switchgear shall be checked to verify its compliance with the purchase
specification. The specification should be verified consist of :
(a)
Type of designation
(b)
Rating
(c)
Dimension
(d)
Phisical Fitness
(e)
Completeness
(f)
Tightnes of busbar fixing
6.2. Mechanical operation tests
Operation test are made to ensure that switching devices and removable parts
comply with operating conditions and the mechanical interlock work properly.
Each switching device and removable part shall be tested 5 times in each direction.
Additional noted that these operation are tested in no voltage supply.
6.3. Test of auxiliary electrical
The electrical, pneumatic and other interlocks together with control devices having
a predetermined sequence of operation shall be tested 5 times in succession in the
intended conditions of use and operation and with the most unfavourable limit
values of auxiliary supply. During the test no adjustment shall be made.
The test are considered to be satisfactory if the auxiliary devices have operated
properly, if they are in good operating condition after the tests and if the effort to
operate them is practically the same before and after tests.
6.4. Test on auxiliary and control circuits
Inspection of auxiliary and control circuits, and verification of conformity to the
circuit diagram and wiring diagrams
(a)
visual check of the nature of the material, quality of assembly, installation &
the coating.
(b)
inspection of interlock, locks etc.
(c)
check the property mounting of component of auxiliary and control circuit
also the property connection & sufficiently wiring space.
(d)
check the property routing of conductor and cables.
(e)
to ensure that no mechanical damage can occur to conductors and cables
due to the promixity of sharp edges or heating elements, or to the
movement of moving parts.
(f)
verify the identification of component, terminal, cables and wiring (if
applicable).
(g)
check the conformity of auxiliary and control circuits to the
diagram/drawings
(h)
check the technical data provided by manufacturer (for example: number of
free auxiliary) contact and the class of each one, number, type and capacity
of contact other than auxiliary and control contact, electrical power of
shunt trip etc)
A functional test of all low-voltage circuits shall be made to verify the proper
functioning of auxiliary and control circuit in conjuction with the other parts of the
switchgear such as :
(a)
Current Transformer
(b)
Voltage Transformer
(c)
Switching device (DS, CB, LBS exct)
(d)
Metering Component (A-Meter, V-Meter, Watt & VAR meter, Energymeter,
ect)
6.6. Measurement of the insulation resistance
Megger test is made to measure insulation between phases and each phase to
ground.
For Main circuit of MV switchgear, the megger tension shall not exceed 10 kV dc
with duration maximum of 5 seconds
7.
ANNEX
EPC-04
EPC-20
INSPECTION FOR MV PANEL
TEST FOR MV SWITCHGEAR
EPC-04
Date
Page
Doc. No:
of
QC-EPC-04-
INSPECTION FOR MV PANEL
Project no :
Project
: MS CNG GROBOGAN
Erection by.
: PT GLOBALINDO-AEMCO KSO
Equipment Tag Number
:
Weather
:
Manufacture
:
Temperature
:
Rated Voltage
:
Product S/N
:
Reference drawing
:
Equipment Title
:
RESULT
OK
NOK
ITEM TO CHECK
1
Visual & dimensional
2
Board assembly and bolting
3
Busbars bolted connection
4
Fuse ratings and gauge rings
5
Cable glands, clamping and termination
6
Tag & wire number
7
Check grounding connections
8
Check rating and capacity of CT, PT.
9
The relays have complete final setting
10
Insulation resistance measurement
11
Mechanical operation test
12
Mechanical and functional operation test for protection & relay
13
FAT Report
DATE
ACCEPT
SIGN
REMARKS
14
Remarks :
Contractor
Inspector
PT Globalindo - Aemco KSO
PT Sertco Quality
Project Owner
PT Energasindo Heksa
Karya
Name
Signature
Date
QC QPCC MS CNG - 04 - Page 1 of 1
EPC-20
Doc.
QC-EPC-20-
TEST FOR MV SWITCHGEAR
Date
Page
of
Project no :
Project
: MS CNG GROBOGAN
Erection by.
: PT GLOBALINDO-AEMCO KSO
Inspection Item
: MV Switchgear
Weather
:
Manufacturer
: Schneider
Date of Inspection :
Reference drawing
:
MV SWITCHGEAR DATA
CUBICLE SERIAL NUMBER
DESCRIPTION
CUBICLE TYPE
CI-2022-W12-4-0006
INCOMING
IM
CI-2022-W11-4-0032
OUTGOING
QM
TAG NUMBER
VISUAL INSPECTION
CHECK ITEM
ACCEPTANCE CRITERIA
Name plate panel
As per project documents
Name plate CB
As per project documents
Name plate CT
As per project documents
Name plate VT
As per project documents
Label & sticker on panel
As per project documents
PANEL NO.
INCOMING
OUTGOING
WIRING AND INSTALLATION
CHECK ITEM
Component layout
ACCEPTANCE CRITERIA
As per project documents
Wire size
As per project documents
Panel arrangement
INSPECTION
OUTGOING
RESULT
As per schematic
Wire colour
Wiring tighness
INCOMING
No loose
As per project documents
Insulation Resistance
R-N
> 25 MW
S-N
> 25 MW
T-N
> 25 MW
R-S
> 25 MW
R-T
> 25 MW
S-T
> 25 MW
MECHANICAL TEST
CHECK ITEM
Interlocking MV Door with
ACCEPTANCE CRITERIA
INSPECTION
INCOMING
OUTGOING
MV door can be opened when the earthing switch close
QC QPCC MS CNG - 20 - Page 1 of 2
EPC-20
Page
Doc.
QC-EPC-20-
TEST FOR MV SWITCHGEAR
Date
of
Project no :
earthing switch
Not possible to open the MV door when the earthing
switch open
Interlocking DS with earthing
switch
Not possible to close Disconnecting Switch when the
earthing switch in close condition
ELECTRICAL OPERATION TEST
CHECK ITEM
INSPECTION
INCOMING
OUTGOING
ACCEPTANCE CRITERIA
DS close manually
DS can close manually properly
DS open manually
DS can open manually properly
Heater function
Heater in a good operational condition
Thermostat function
Thermostat can operate according to given temperature
Trip function
DS can close when receive trip signal
FINAL RESULT
Contractor
Inspector
Project Owner
PT Globalindo - Aemco KSO
PT Sertco Quality
PT Energasindo Heksa Karya
Name
Signature
Date
QC QPCC MS CNG - 20 - Page 2 of 2