Commissioning Testing and Start Up of Electrical Systems

Introduction

The successful operation of Electrical Systems ultimately depends on how well the Testing, Start-Up, and Commissioning is carried out on each system. Well-developed procedures will in the long run result in reduced 1) costs, 2) start-up delays, 3) parts requirements and 4) troubleshooting time. Delegates are encouraged to raise queries both during and at any time after attending the course. Delegates are also encouraged to bring with them any issues or experiences that they may have to this course. 

Following the attendance at this course, participants will return to their respective organizations equipped with new skills and knowledge to enable them to more effectively start-up and commission electrical systems and to solve problems that arise during these activities. This in turn will reduce downtime, improve equipment availability and reliability and allow the transfer of these skills to the participant’s co-workers.

Objectives

• To develop a structured approach to electrical systems using common terminology and to provide methods and solutions for various electrical systems start-up and commissioning.
• To develop a better understanding of various test equipment used in electrical testing.
• To develop a better understanding of various electrical equipment and control systems design, functionality, and failure modes.
• To better understand work practices, which allow for a successful start-up, commissioning, and troubleshooting including job plans.
• To provide examples of successful techniques and ‘hands-on experiences plus case studies and group problem solving exercises

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 course is intended for Electrical Maintenance Engineers, Supervisors, and Technicians working in a start-up, commissioning, or testing related roles that need either a greater awareness of, or to become more proficient in, the aspects of electrical systems and electrical maintenance activities. Because the methods and examples are generic, personnel from all industries will benefit.

Course Outline

Day 1: Definitions/Procedures

• Testing, Start-Up, Commissioning and Troubleshooting
• Electrical Systems: AC (High Voltage, Medium Voltage, Low Voltage)
• DC
• Emergency Power and/or Cogeneration Power
• HVAC
• Lighting
• Fire Detection, Alarm and Suppression
• Safety, Security and Surveillance

Industrial Electrical Symbols

• Circuit Interrupter, Disconnect, Circuit Breaker
• Overload, Contacts
• Switch
• Transformer
• Meter
• Motor
• Electrical Components and Logic Symbols

Drawings

• Single Line HV (Switchgear)
• Single Line MV (Switchgear)
• Single Line LV (MCC)
• Single Line Wiring Schedule
• Single Line MV (Distribution)
• Protective Device Schematic

Test Equipment

• Digital Volt Meter with Temperature and Frequency accessories
• Oscilloscope/ScopeMeter
• Megger
• Ohm Meter
• Ammeter
• Pyrometer
• Power Meter/Power Quality Analyzer

Day 2: AC Electrical System – High Voltage (7.5kV to 750kV)

Input Power from Local Utility Company

Power Transformer

• Bushings
• Mechanical Protection Devices and Indicators
• Electrical Protection Devices and Indicators
• Cooling Fans and Radiators
• Configuration
• Electrical Bus and Wiring Connections
• Current and Potential Transformers

Switch Gear

• Bus and Wiring Connections
• Knife Edges/Disconnects
• Insulators
• Fusing/Circuit Breaker/Tie Breaker
• Feeder Protection Relays
• Current and Potential Transformers

AC Electrical System – Medium Voltage (750V to 7.5kV)

Transformer

• Bushings
• Mechanical Protection Devices and Indicators
• Electrical Protection Devices and Indicators
• Cooling Fans and Radiators
• Configuration
• Electrical Bus and Wiring Connections
• Current and Potential Transformers

Switch Gear

• Bus and Wiring Connections
• Knife Edges/Disconnects/Contactors
• Insulators
• Control Metering/Indicators
• Fusing/Circuit Breaker/Tie Breaker
• Feeder Protection Relays
• Current and Potential Transformers

Motors

• Motor Protection Relays
• Vibration Analysis
• Hand-Off-Auto Functions
• Wiring Connections

AC Electrical System – Low Voltage (up to 750V)

Transformer

• Bushings
• Mechanical Protection Devices and Indicators
• Electrical Protection Devices and Indicators
• Radiators
• Configuration
• Electrical Bus and Wiring Connections
• Current and Potential Transformers

Motor Control Centre (MCC)

• Bus and Wiring Connections
• Fusing/Circuit Breaker
• Feeder Protection Relays
• Current and Potential Transformers
• Control Metering/Indicators
• Control Transformers
• Contactors
• Overloads
• Lighting Contactors
• Variable Frequency Drives (VFD)

Motors

• Motor Protection Relays
• Vibration Analysis
• Hand-Off-Auto Functions
• Wiring Connections

Miscellaneous Loads

• Heaters
• Pumps
• Wall Outlets
• Distribution Panel Boxes
• Distribution Transformers
• Solenoid Valves
• Electric Valve Actuators

 Day 3: DC Electrical System

Transformer

• Bushings
• Mechanical Protection Devices and Indicators
• Electrical Protection Devices and Indicators
• Radiators
• Configuration
• Electrical Bus and Wiring Connections
• Current and Potential Transformers

AC Motor Control Centre (MCC)

• Bus and Wiring Connections
• Fusing/Circuit Breaker
• Feeder Protection Relays
• Current and Potential Transformers
• Control Metering/Indicators
• Control Transformers
• Contactors
• Overloads

DC Motor Control Centre (MCC)

• Rectifier
• Bus and Wiring Connections
• Fusing/Circuit Breaker
• Wiring Connections
• Variable Speed Drives (VSD)
• Rectifier
• Control Metering/Indicators

Motors

• Motor Protection Relays
• Vibration Analysis
• Hand-Off-Auto Functions
• Wiring Connections

Miscellaneous Loads

• Heaters
• Solenoid Valves
• Electric Valve Actuators

Emergency Power and/or Cogeneration Power

Generation

Generator

• Wiring Connections
• Driver and Fuel Source

Transformer

• Bushings
• Mechanical Protection Devices and Indicators
• Electrical Protection Devices and Indicators
• Radiators
• Configuration
• Electrical Bus and Wiring Connections
• Current and Potential Transformers

Motor Control Centre (MCC)

• Bus and Wiring Connections
• Fusing/Circuit Breaker
• Feeder Protection Relays
• Current and Potential Transformers
• Control Metering/Indicators
• Control Transformers
• Contactors
• Overloads
• Lighting Contactors
• Static Synchronizing Switch

Motors      

• Motor Protection Relays
• Hand-Off-Auto Functions
• Wiring Connections

Miscellaneous Loads

• Heaters
• Pumps
• Wall Outlets
• Distribution Panel Boxes
• Distribution Transformers
• Solenoid Valves
• Electric Valve Actuators

Day 4: AC Uninterruptible Power Supply (UPS)

Rectifier

• Wiring Connections
• Circuit Breakers/Fusing
• Control Metering/Indicators

Batteries

• Wiring Connections
• Battery Fluids/Specific Gravity

Inverter

• Wiring Connections
• Circuit Breakers/Fusing
• Control Metering/Indicators

Static Switch

• Wiring Connections

Loads

• Wiring Connections
• UPS Wall Outlets
• Computer Controlled Equipment

DC Uninterruptible Power Supply (UPS)

Rectifier

• Wiring Connections
• Circuit Breakers/Fusing
• Control Metering/Indicators

Batteries

• Wiring Connections
• Battery Fluids/Specific Gravity

Loads

• Wiring Connections
• Specialized Wall Outlets
• ESD Valve Actuators
• Critical Switchgear Motorized Actuators

Heating, Ventilating and Air Conditioning (HVAC)

Power

• Wiring Connections
• Circuit Breakers/Fusing

Furnaces

• Fuel Supply
• Wiring Connections
• Temperature Control

Fans

• Wiring Connections
• Temperature/Air Flow Control

Air Conditioning

• Temperature Control
• Wiring Connections
• Compressor/Coolant Unit

LIGHTING 

Lighting Transformers

• Configuration
• Wiring Connections
• Cooling

Lighting Panels

• Wiring Connections
• Circuit Breakers

Lighting

• Wiring Connections
• Harmonics
• Lighting Ballasts
• Lighting Fixtures
• Lighting Dimmers

 Day 5: Fire Detection, Alarm and Suppression

Detection

• Sensors
• Wiring Connections
• Control Equipment

Alarm

• Audible
• Visual
• Wiring Connections
• Relays

Suppression

• Water Deluge
• CO2
• Wiring Connections
• Solenoids

Safety, Security and Surveillance

Toxic Gas

• Detectors
• Wiring Connections
• Control Equipment
• Alarms/Indicators

Explosive Gas

• Detectors
• Wiring Connections
• Control Equipment
• Alarms/Indicators

Entry Control

• Door/Window Switches
• Wiring Connections

Closed Circuit TV (CCTV)

• Cameras/Recorders
• Wiring Connections
• Control Equipment
• Alarms/Indicators

Regulatory Considerations

• Area Classifications
• Electrical Safety
• Electrical Codes