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Confidential. Not to be copied, distributed, or reproduced without prior approval.
TCR KURUKSHETRA WORKSHOP 3
SVC 33 - Introduction to Pre-Commissioning and Commissioning Testing
of TCR
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disclosures. Delete if not needed.
Pre-commissioning is a construction procedure that
includes checking the functional operability of elements within
the system in order to ensure the system is ready for
commissioning start-up.
Commissioning - the last phase of a construction project is the
commissioning phase, where the subsystems are integrated
together to form the desired plant process and tested as a system
to verify project specification requirements are met. .
PRE-COMMISSIONING
This presentation is based on Pre-CommissioningTest Program document No:TCR-
TCR-KUR-MVL-PET-00019-TR
15-07-2022
NAGENDRA YADAV
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Pre-commissioning checks/ tests are the
activities carried out to as certain the
correctness, completeness of installation and
healthiness of the equipment before its charging
 At Site Pre-Commissioning testing is required
prove that
– No Equiment / Cubicle Damage.
– Proper Installation.
– Protection & Control working as per specification.
– Equipments adjusted properly according to
design.
– Safe to Put in Service.
Pre-Commissioning
4
Why Pre-Commissioning Needed?
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After completion of erection in all respects, a Pre-commissioning team constituted (as per
procedures laid down in Works & Procurement Policy and Procedures, to oversee/
coordinate with erection agency/ manufacturer of the equipment for the pre-
commissioning tests and subsequently charging of the equipment's / Cubicles.
Pre-Commissioning Team:-
 I/C Substation.
 Pre-Commissioning Engineer.
 O&M Executive (Optional).
Note :-
 Testing Equipment's must be calibrated. Before start testing Pre-Commissioning Engineer must
read / Know the testing equipment's instruction.
 Commissioning Test Plan document should be filled during Pre-Commissioning and applicable
Customer site test reports filled and signed.
After all pre-commissioning checks and tests are found to be acceptable taking into account
permissible deviation limits, Next Substation handover to the commissioning team.
Pre-Commissioning 5
Pre-Commissioning Engineer
Responsibilities
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 All measures and precautions should be undertaken to
prevent occurrence of unsafe acts.
 All the personnel involved should be thoroughly
explained about the safe procedures to be adopted
while performing various activities including carrying out
tests in the switchyard.
 Adequate fire-fighting system as per procedures and
their healthiness is to be ensured before charging.
 Warning signs and Safety barriers should be positioned
in conformity to Safety rules as amended from time to
time.
Pre-Commissioning 6
General Safety
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 Work will be performed according to local regulations and safety procedures. All work concerning GE
personnel will be done according to GE safety regulations if they exceed the local regulations. GE
LOTO procedure shall be always followed.
 Capacitor units must be short circuited and grounded before working on them.
 Air core reactors may have induced voltage across their terminals if current flowing in a nearby busbar
or line.
 when working on thyristor valves since its terminals are close to each other and both terminals are
connected to air core reactors outside the valve room. Therefore, it is recommended to always apply
equipotential bonding and grounding to the thyristor valve terminals before working inside valve fence.
Pre-Commissioning 7
Equipment Safety
“All high voltage switching will be done by or under supervision of Customer”.
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Confidential. Not to be copied, distributed, or reproduced without
prior approval.
TCR-1
Branch
192Mvar
TCR-3
Branch
192Mvar
Control
Building
TCR-2
Branch
192Mvar
Single Phase
coupling
Transformer
500Mvar -
400/30kV
Single
Tunned
Filter – 5th
– 31Mvar
Single Tunned
Filter – 7th and
High Pass
45Mvar
Access
Road
Spare
Trfo.
Delta Bus
(”C”
Channel)
Grounding
Transformer
Auxiliary
Transformer
MAIN COMPONENTS AND LAYOUT OF TCR
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Verify correct
installation of each
components of the
Substation / TCR.
Equipment
Tests
Subsystem
Tests
Pre-Commissioning 9
Pre-Commissioning Tests
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GENERAL
INSTALLATION
AND WIRING
CHECK
REACTORS
CIRCUIT
BREAKERS
SURGE
PROTECTION
EQUIPMENT
INSULATORS
INSTRUMENT
TRANSFORMER
S
DISCONNECTOR
S AND
EARTHING
SWITCHES
POWER
TRANSFORMER
S
AUXILIARY AND
EARTHING
TRANSFORMER
TCR VALVES
COOLING UNIT
AUXILIARY
POWER SYSTEM
P&C CUBICLES EARTHING
SYSTEM
CIVIL SYSTEMS
Pre-Commissioning 10
Equipment Tests
“The inspection- and pre commissioning checklists provide general tests for each piece of
equipment. However, if a contractor or manufacturer of any device has also provided an
installation checklist, then that should also be filled”.
GENERAL INSTALLATION AND
WIRING CHECK
1
1
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Pre-Commissioning 12
Equipment Tests
GENERAL INSTALLATION AND WIRING
CHECK
 The complete installation is inspected visually. The
position and electrical connection of the TCR
equipment is cross-referenced with documentation.
 Equipment labels are checked for correct text and
fixing material ie. plastic on. valves and reactor noise
enclosure.
REACTORS
1
3
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Equipment Tests
REACTORS
 The complete installation is inspected
visually. The position and electrical
connection of the TCR equipment is cross-
referenced with documentation.
 Equipment labels are checked for correct
text and fixing material ie. plastic on. valves
and reactor noise enclosure.
Pre-commissioning Tests 14
.
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Equipment Tests
REACTOR CHECK LIST
Pre-Commissioning Tests 15
SURGE PROTECTION EQUIPMENT
1
6
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Equipment Tests
SURGE PROTECTION EQUIPMENT
 Verify the condition and installation of
all surge arresters and surge
capacitors in the TCR.
 The equipment and installation are
inspected visually and/or with
appropriate devices
Pre-Commissioning Tests 17
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Equipment Tests
SURGE PROTECTION CHECK LIST
Pre-Commissioning Tests 18
INSULATORS
1
9
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Equipment Tests
INSULATORS
– Verify the condition and installation of all
insulators in the TCR. These include
support and wall-bushing insulators.
– The equipment and installation are
inspected visually and/or with
appropriate devices.
– Wall-bushing nameplate values are
cross-referenced with appropriate
documents.
– Wall-bushing insulator electrical
connection tightness is checked with a
torque wrench.
– Insulators are cleaned if necessary.
– The earthing of the insulator base or
support structure is checked
Pre-Commissioning Tests 20
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Equipment Tests
INSULATOR CHECK LIST
Pre-Commissioning Tests 21
INSTRUMENTTRANSFORMERS
2
2
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Equipment Tests
INSTRUMENT TRANSFORMERS- CT &
VT
• Verify the condition and installation of all voltage
and current transformers in the Substation.
• The equipment and installation are inspected
visually and/or with appropriate devices. Voltage
and current transformer nameplate values are
cross-referenced with appropriate documents.
• The tightening torque of random electrical
connection is checked with a calibrated torque
wrench. The earthing of the equipment support
structure is verified visually and with appropriate
measurements. The equipment direction is
verified against single line diagram and
assembly drawings.
Pre-commissioning Tests 23
.
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Equipment Tests
INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST
Pre-Commissioning Tests 24
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Equipment Tests
INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST
Pre-Commissioning Tests 25
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Equipment Tests
INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST
Pre-commissioning Tests 26
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Equipment Tests
INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST
Pre-commissioning Tests 27
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Equipment Tests
INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST
Pre-commissioning Tests 28
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Equipment Tests
INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST
Pre-Commissioning Tests 29
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Equipment Tests
INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST
Pre-commissioning Tests 30
DISCONNECTORS AND EARTHING
SWITCHES
3
1
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Equipment Tests
DISCONNECTORS AND EARTHING SWITCHES
 The purpose of these tests is to verify the condition and
installation of all disconnectors and earthing switches in the
SVC
 Check that the Installation supervisor checklist and Site test
report has been filled and signed appropriately. Check
nameplate records
 Disconnector wiring and input and output signal checks are
done separately and confirmed with site testing report and
to be checked associated sequence and Interlocking
scheme.
 Mechanical operating tests ,Verification of Earthing function
 Dielectric test on the Main circuit
 Test on the Aux. and control circuits
Pre-commissioning Tests 32
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Equipment Tests
DISCONNECTORS AND EARTHING SWITCHES CHECK LIST
Pre-commissioning Tests 33
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Equipment Tests
DISCONNECTORS AND EARTHING SWITCHES CHECK LIST
Pre-Commissioning Tests 34
CIRCUIT BREAKERS
3
5
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Equipment Tests
CIRCUIT BREAKERS
 A Circuit breaker is a device which control (make or break)
a circuit automatically, manually or by remote control under
normal and fault conditions like over current, Short circuit,
etc. connected through circuit breaker. This way, it protect
the connected circuit by discounting it from power supply
during faults such as overload or short circuit currents
 Check that the Installation supervisor checklist and Site
test report has been filled and signed appropriately. Check
nameplate records
 The wiring and input/output signals of the circuit breakers
are checked, and the interlocking scheme is confirmed with
the site precomm report.
Pre-Commissioning Tests 36
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Equipment Tests
CIRCUIT BERAKERS CHECK LIST
Pre-Commissioning Tests 37
POWERTRANSFORMERS
3
8
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Equipment Tests
POWER TRANSFORMERS
Pre-commissioning Tests 39
 Check that the Installation supervisor checklist and
Site test report has been filled and signed
appropriately.
 Oil leakage, Vacuum & Pressure tests on
transformer tank.
 Polarity and Vector group.
 Voltage Ratio test.
 Winding Resistance measurement.
 No-load losses and currents (at 90%, 100% &
110% voltage)
 Oil samples (IEC 60567)
 Switching impulse test.
 AC Separate source withstand test, Induced
overvoltage test and partial discharge
measurement.
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Equipment Tests
POWER TRANSFORMERS
Pre-commissioning Tests 40
 Test of the Magnetic circuit insulation and
associated insulation(3 kV DC, one minute)
 Insulation resistance test for Auxiliary wiring at
2 kV RMS for one minute
 Bushing current transformer tests
 High voltage withstand test on auxiliary
equipment & wiring
 Magnetization characteristic test
AUXILIARY
AND
GROUNDINGTRANSFORMERS
4
1
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Equipment Tests
AUXILIARY AND GROUNDING TRANSFORMERS
Pre-commissioning Tests 42
AUXILIARY TRANSFORMER
Two Auxiliary transformer of 630 kVA shall feed Main switch boards. One of them shall be
fed from TCR MV Bus and other one from existing station 33 kV switchgear.
GROUNDING TRANSFORMER
(a) 33KV Earthing Transformer, ONAN Cooled, 3 ph, oil-immersed, class A insulated, fitted
with outdoor type bushings on HV side. Neutral of HV bushings shall be earthed for non
effectively earthed 33 KV system. Earthing transformer shall consist of a single winding
in which case this winding shall be connected inter-star (zigzag) in accordance with the
relevant IS group.
(b) INTERPHASE CONNECTION: HV :Inter-star (Zigzag) with neutral brought out through
Bushing for solid earth connection.
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Equipment Tests
AUXILIARY AND GROUNDING TRANSFORMERS
Pre-Commissioning Tests 43
AUXILIARY POWER SYSTEM
4
4
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Equipment Tests
AUXILIARY POWER SYSTEM
Pre-commissioning Tests 45
This system includes the LV AC, DC and UPS power systems with their associated batteries.
The equipment and installation is visually inspected. The tightness of the screw terminals is
checked. Earthing of the equipment frame is verified visually and with appropriate
measurements. Functionals tests are performed as per detailed commissioning instructions
• UPS/UPS Bypass for
• TCR cooling unit.
• Battery Charging.
• Protection& Control panels.
• Filter/Aux. Trafo & other branch Circuit breaker.
• Filter/Aux. & other branch Disconnector/Earth Switches.
• Essential building services(HVAC/emergency lights/Fire protection system etc.)
• Air conditioning units.
• Coupling Transformer cooling Fans
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Equipment Tests
AUXILIARY POWER SYSTEM
Pre-commissioning Tests 46
COOLING UNIT
4
7
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Equipment Tests
COOLING UNIT
Pre-Commissioning 48
The purpose of these tests is to verify the condition and installation of TCR valve cooling unit
,to be inspected visually . Nameplate values are cross-referenced with appropriate
documents. The tightness of the screw terminals is checked. The earthing of the equipment
support structure is verified visually and with appropriate measurements. The cooling unit is
filled with appropriate coolant and de-aired. Functional tests are performed, and
measurements are checked.
 Installation supervisor check-list has been filled
 Inspect equipment for physical damage,
proper mounting, and required clearances
 Check pump and piping alignment.
 The earthing of the equipment to be verified
 The cooling unit is filled with appropriate coolant and de-aired.
 Functional tests are performed, and measurements are checked.
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Equipment Tests
COOLING UNIT
Pre-Commissioning 49
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Equipment Tests
COOLING UNIT
Pre-Commissioning 50
THYRISTORVALVES
5
1
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Pre-Commissioning 52
Equipment Tests
• THYRISTOR VALVES
• TCR is a reactance which is connected in
series through the bidirectional thyristor
valve. The thyristor valve is phase-
controlled, and it gives the delivered
reactive power should be adjusted to meet
the varying system condition.
• Verify the condition and installation of all
thyristor valves in the Substation.
• The earthing of the equipment support
structure is verified visually.
• The resistance and capacitance of each
thyristor level is measured. Operation of
GLPS units is verified.
• Check that all the optical fibers between
the LEU boards and the fibers between
LEU boards and VBE are connected
according the Thyristor Valve Manual.
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Equipment Tests
Pre-Commissioning 53
TCR VALVES
 Inspect equipment (Valves and both GLPs) for physical damage, proper
mounting and required clearances.
 Record the manufacturing number of the valve
 Check that correct position labels (if any) are fastened on the equipment.
 Check electrical connection of the busbars connected to the valve: Verify
polarity, phasing and wiring of TCR valves.
 Verify that the polarity of TCR valves vs. the corresponding CTs is correct.
 Check clearances and creepage distances within valve.
 Check that all parts of equipment support structure are properly earthed,
and the earthing does not form loops. Use a multimeter to verify earthing
connection.
 Check tightness of all bus and cable connections with a calibrated torque
wrench. Write used torque values (in Nm) for each bolt size to this table.
 Measure the resistance over every thyristor level: TCR valves should have
resistance R > 100kΩ
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Equipment Tests
TCR VALVES
Pre-Commissioning 54
 Measure the capacitance of capacitor of every thyristor level and check they are
within tolerances.
 Measure capacitance over every thyristor level and make sure the measured values
are similar on each level. Differences in measured values may indicate wrong
connection.
 Check that all the optical fibres between the LEU boards and the fibers between
LEU boards and VBE are connected according the TCR Valve Manual.
 Check fiber connections are locked, not just pushed in.
 Perform GLPS power up test:
 Connect GLPS VBATT connection and all fiber connections but leave VOUT
connection unconnected.
 Start with the GLPS front panel circuit breaker in the “OFF” position.
 After closing the DC-distribution panel circuit breaker and thus applying power to
GLPS, measure and verify the voltage level and polarity at the VBATT connection
(dependent on substation battery used). Observe and verify that no lights on the
GLPS front panel are illuminated.
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Equipment Tests
TCR VALVES
Pre-Commissioning 55
 GLPS no load check:
 Switch the GLPS front panel circuit breaker from “OFF” to “ON”.
 Observe and verify that the GLPS front panel “INPUT POWER” (yellow) light is
illuminated.
 Observe and verify that the GLPS front panel “FAULT” (red) light is not illuminated.
 VBE controls check:
 The “RX1” fiber optic GLPS input will have a positive light signal when it is
commanded on by the VBE. Measure and verify that the GLPS has the correct VOUT
voltage (dependent on system design and setup) and that the “OUTPUT ON” (green)
light is illuminated.
 Check that all the optical fibres between the LEU boards and the fibers between LEU
boards and VBE are connected according the TCR Valve Manual
 Check fiber connections are locked, not just pushed in.
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Equipment Tests
TCR VALVES
Pre-Commissioning 56
 Perform GLPS power up test:
 Connect GLPS VBATT connection and all fiber connections but leave VOUT
connection unconnected.
 Start with the GLPS front panel circuit breaker in the “OFF” position.
 After closing the DC-distribution panel circuit breaker and thus applying power to
GLPS, measure and verify the voltage level and polarity at the VBATT connection
(dependent on substation battery used). Observe and verify that no lights on the
GLPS front panel are illuminated.
 GLPS no load check:
 Switch the GLPS front panel circuit breaker from “OFF” to “ON”.
 Observe and verify that the GLPS front panel “INPUT POWER” (yellow) light is
illuminated.
 Observe and verify that the GLPS front panel “FAULT” (red) light is not
illuminated.
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Equipment Tests
TCR VALVES
Pre-Commissioning 57
 System check:
 Remove power and connect the VOUT terminals of GLPS to the isolation transformer.
 Apply power and observe and verify that the GLPS has the correct VOUT voltage and that
the “OUTPUT ON” light is illuminated.
 Connect the Ground Level Power Supply (GLPS) and power all the LEU-boards and check
that the boards wake up (LEDs turn on). Verify that the voltage over the 4ET transformer
(black discs in the corner) on each level is between 4 – 7 VAC.
 Open the MCB of the active GLPS and check that backup GLPS will start up without
disturbances in the thyristor valve level electronics power supply
 All the levels should now have “communication OK” in the VBE panel if the data back fibres
between the valve and valve base are OK. A few fibres may be disconnected and checked
that the status is changed OK -> fail, then connected back and the status changes fail ->
OK.
 The optical fibres between TCR control system and the valve base should be tested by
checking the status from valve base cubicle (communication between CTRL systems and
VBE is OK).
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Equipment Tests
TCR VALVES
Pre-Commissioning 58
 Verify VBE software version and parameters.
 Verify that the checksum of the valve base
is OK (from VBE’s valve protection
parameter screen). Checksum match status
is shown on the first line (check sum fail/ok).
P&C CUBICLES
5
9
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Pre-Commissioning 60
Equipment Tests
P&C CUBICLES
 The purpose of these tests is to verify the
condition and installation of all specific
cubicles.
These include Control, Protection,
communication, valve base, repetition and
VT/CT/DCT connection cubicles.
 The equipment and installation are visually
inspected. The tightness of the screw
terminals is checked.
 The earthing of the cubicle is verified
visually and with appropriate
measurements.
 Supply voltages and current consumptions
are measured.
 Functional tests are performed for each
cubicle.
These include tests on protection relays,
control system and communication system.
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Equipment Tests
P&C CUBICLES
Pre-Commissioning 61
Control cubicles Test (KF1/KF2)
 Check that the Installation supervisor check-list has been filled and signed appropriately.
 Inspect equipment for physical damage and proper mounting.
 Verify nameplate information is correct.
 Check that cubicle is properly earthed and that earthing does not form loops.
 Randomly check tightness of screw terminals and wire connections.
 Energize the cubicles completely. Check every device power up normally.
 Measure DC supply voltages and currents and record them to table. Verify that there is no AC-
component in the DC-supply voltage
 Measure AC supply voltage and current and record them to table.
 Check that the PLC code goes to running state and correct LEDs are lit in the cubicle front
panel.
 Upload latest software to the control system.
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Equipment Tests
P&C CUBICLES
Pre-Commissioning 62
Control Field I/O Panels (KK-11/12/13,KK-21/22/23)
 Check that the Installation supervisor checklist has been filled and signed appropriately.
 Inspect equipment for physical damage and proper mounting, Verify name plate
information
 Check that cubicle is properly earthed and that earthing does not form loops.
 Randomly check tightness of screw terminals and wire connections.
 Randomly check jumper connections in terminals.
 Energize the cubicles completely.
 Measure DC supply voltages and currents and record them to table. Verify that there is no
AC-component in the DC-supply voltage.
 Measure AC supply voltage and current and record them to table.
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Equipment Tests
P&C CUBICLES
Pre-Commissioning 63
Communication Cubicle(UH1)
 Check that the Installation supervisor checklist has been filled and signed appropriately.
 Energize the cubicle completely. Check every device power up normally.
 Measure AC & DC supply
 Check GPS equipment Installation
 Check the clock has locked in respect of GPS signal and clock parameters are correct
 Change IP addresses and subnet of all communication devices as per IP address schedule
mentioned in CBD.
 Check that synchronization time signal is distributed to all necessary equipment: protection
relays, control system, DFR
 Verify that Local-HMI computer is energized from 230VAC UPS supply and verify that
local/Remote HMI programs appear to function properly
 Verify HMI single line diagram (correct components, component names).
 Check that DFR operating correctly and all modules are live and showing proper readings
 Check that DFR trigger signal settings are correct and showing correct timing of triggering.
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Equipment Tests
P&C CUBICLES
Pre-Commissioning 64
Valve Base Cubicles (KG1/KG2/KG3)
 Check that the Installation supervisor checklist has been filled and signed
appropriately.
 Check that cubicle is properly earthed and that earthing does not form
loops.
 Measure and record AC & DC supply of cubicles ,verify No AC
component in DC supply.
 Check that modules are configured as "VBA", "VBB", "VBC" from top to
bottom. (Rotary switch position 1,2,3 accordingly)
 Check that “power ok” –led is lit at the back of each module.
 Check that LCD backlight is lit when front panel disp-button is pressed
 Check VBE software version from all phases and mark them down.
 After installing fibre optics check communication between LEU-board.
The optical fibre between TCR control system and the valve base should
be tested by checking the status from valve base cubicle
 Verify that the parameter checksum of the valve base is OK.
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Equipment Tests
P&C CUBICLES
Pre-Commissioning 65
Repetition Cubicle (KK3)
 Check that the Installation supervisor checklist has been filled and signed appropriately.
 Check that cubicle is properly earthed and that earthing does not form loops.
 Randomly check tightness of screw terminals and wire connections.
 Randomly check jumper connections in terminals.
 Energize the cubicle completely.
 Measure and record AC & DC supply of cubicles ,verify No AC component in DC supply.
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Equipment Tests
P&C CUBICLES
Pre-Commissioning 66
Protection Cubicles (F11/F21)
 Check that the Installation supervisor checklist
has been filled and signed appropriately.
 Energize the cubicle completely. Check every
device power up normally.
 Check that cubicle is properly earthed and that
earthing does not form loops.
 Measure and record AC & DC supply of
cubicles .
 Check fiber and/or ethernet connections are
installed and connected.
 Check all protection relays tested and to be
verified parameters and settings.
EARTHING SYSTEM
6
7
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Equipment Tests
EARTHING SYSTEM
Title or Job Number | XX Month 201X 68
 The purpose of these tests is to verify the installation of the
earthing system in the substation area.
 The equipment and installation are inspected visually and/or
with appropriate devices.
 During the installation phase it is continuously verified that GE
instructions on earthing system are followed.
 Each piece of equipment shall be appropriately earthed but
closed loops in earthing shall not be approved.
 The same applies also to concrete reinforcement steel bars in
reactor foundations.
 Each earthing will be checked visually by GE afterwards to
ensure it is done properly. Also measurements will be done for
the earth grid and above ground earthing.
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Equipment
Tests.
Functional tests such as
testing interfaces between
control system and field
equipment, verification of
interlocking scheme and
SCADA communication.
Subsystem
Tests.
Pre-Commissioning 69
Pre-Commissioning Tests
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Pre-Commissioning 70
Subsystem Tests
“The purpose of subsystem tests is to verify that all major subsystems and interfaces between them
are working correctly. Subsystem tests end
with cold run tests where the TCR is operated without high voltage. After subsystem tests have been
completed, TCR is ready for energization”.
CABLING
MEASUREMENT
CIRCUITS
HARD-WIRED
DIGITAL IO
COMMUNICATION
LINKS WITHIN THE
TCR/ SUBSTATION
INTERFACE TO
SAS SYSTEM
INTERLOCKING COLD RUN TESTS
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Pre-Commissioning 71
Subsystem Tests
CABLING
 Verify the condition and installation of all cabling related to the Substation.
 All cables are visually inspected. Special attention is paid on the cable shield earthing. The
shield shall be earthed at one end only and the other end shall be properly insulated.
• The continuity of each core is checked with a multimeter and the correct connection point is
verified.
 The insulation of each cable is verified with insulation resistance measurement.
 It is verified that all optic fiber bundles are installed within trunking or equivalent mechanical
protection.
• A point-to-point test is performed on optic fibers
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Pre-Commissioning 72
Subsystem Tests
MEASUREMENT CIRCUITS
 The purpose of these tests is to verify the operation of measurement circuits related
to the TCR (CT- and VT-circuits).
 The earthing of each circuit is checked. The VSC current measurement circuit DC-
offset calibration sequence is performed.
 Appropriate current or voltage is injected to each CT- and VT-primary circuit.
 The polarity and magnitude are verified from each associated cubicle. Polarities and
magnitudes are also verified from HMI, protection relays and fault recorder.
 Note! - Hazardous voltages may appear on VT primary during injection if the VT is
not isolated from the secondary circuit.
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Pre-Commissioning 73
Subsystem Tests
HARD-WIRED DIGITAL IO
 The purpose of these tests is to verify the operation of the
hard-wired digital inputs and outputs of the TCR control,
protection and communication system.
–Digital Inputs: Both states of each P&C-system digital input
signal are tested.
 The activation and deactivation of each signal are from the
remote end mimicing as far as possible the actual operation
of the signal.
 The signal is observed from the HMI screen, protection
relay, cooling unit, fault recorder or other receiving device so
that the complete signal path gets verified.
–Digital Outputs: Digital outputs are tested similarly. The
output is activated and deactivated from the P&C-system.
 The signal is observed at the remote end by verifying that
the intended response is shown by the device.
 Again, it is recommended that the complete signal path is
verified.
See tutorial regarding confidentiality
disclosures. Delete if not needed.
 The purpose of these tests is to verify the
operation of all communication links & to
verify the operation of the interface between
TCR control and protection system and
SCADA system
 Digital signals are tested by activating and
deactivating them at the sending end and
observing the HMI screen & SCADA system.
 Analog signals are verified by comparing the
values shown on the sending device and HMI
screen and same for SCADA system
 It may be necessary to inject voltages or
currents.
Pre-Commissioning
74
Subsystem Tests
COMMUNICATION LINKS & INTERFACE
TO SCADA SYSTEM
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Pre-Commissioning 75
Subsystem Tests
INTERLOCKING
 To verify the installation and operation of safety interlocking system of the TCR.
 Interlocking scheme to be verified. Interlocking between each disconnector and its
associated earthing switch is tested.
 Key interlocking system between earthing switches and associated entry gates is
tested.
 The interlocking system between HV and MV side is tested.
See tutorial regarding confidentiality
disclosures. Delete if not needed.
Pre-Commissioning 76
Subsystem Tests
COLD RUN TESTS
 The purpose of these tests is to verify the operation of
the complete TCR without high voltage.
 Prior to the tests, all preceding pre-commissioning
documentation is thoroughly checked and validated.
 Check all applicable signals as per signal list by cold run
test (without HV voltage) has been tested with all control
cubicles and its associated.
 Activate all necessary signals for TCR to enter ready to
run state. It is recommended to actually operate the
disconnectors to achieve this.
 Verify that the HV disconnectors and MV disconnector
are open and cannot be closed during the cold run test.
 Each ready to run state and condition is tested.
Thank You !!
SVC 33- TCR WORK SHOP-3#Intro to PreComm & Comm.ppt

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SVC 33- TCR WORK SHOP-3#Intro to PreComm & Comm.ppt

  • 1. Confidential. Not to be copied, distributed, or reproduced without prior approval. TCR KURUKSHETRA WORKSHOP 3 SVC 33 - Introduction to Pre-Commissioning and Commissioning Testing of TCR
  • 2. See tutorial regarding confidentiality disclosures. Delete if not needed. Pre-commissioning is a construction procedure that includes checking the functional operability of elements within the system in order to ensure the system is ready for commissioning start-up. Commissioning - the last phase of a construction project is the commissioning phase, where the subsystems are integrated together to form the desired plant process and tested as a system to verify project specification requirements are met. .
  • 3. PRE-COMMISSIONING This presentation is based on Pre-CommissioningTest Program document No:TCR- TCR-KUR-MVL-PET-00019-TR 15-07-2022 NAGENDRA YADAV
  • 4. See tutorial regarding confidentiality disclosures. Delete if not needed. Pre-commissioning checks/ tests are the activities carried out to as certain the correctness, completeness of installation and healthiness of the equipment before its charging  At Site Pre-Commissioning testing is required prove that – No Equiment / Cubicle Damage. – Proper Installation. – Protection & Control working as per specification. – Equipments adjusted properly according to design. – Safe to Put in Service. Pre-Commissioning 4 Why Pre-Commissioning Needed?
  • 5. See tutorial regarding confidentiality disclosures. Delete if not needed. After completion of erection in all respects, a Pre-commissioning team constituted (as per procedures laid down in Works & Procurement Policy and Procedures, to oversee/ coordinate with erection agency/ manufacturer of the equipment for the pre- commissioning tests and subsequently charging of the equipment's / Cubicles. Pre-Commissioning Team:-  I/C Substation.  Pre-Commissioning Engineer.  O&M Executive (Optional). Note :-  Testing Equipment's must be calibrated. Before start testing Pre-Commissioning Engineer must read / Know the testing equipment's instruction.  Commissioning Test Plan document should be filled during Pre-Commissioning and applicable Customer site test reports filled and signed. After all pre-commissioning checks and tests are found to be acceptable taking into account permissible deviation limits, Next Substation handover to the commissioning team. Pre-Commissioning 5 Pre-Commissioning Engineer Responsibilities
  • 6. See tutorial regarding confidentiality disclosures. Delete if not needed.  All measures and precautions should be undertaken to prevent occurrence of unsafe acts.  All the personnel involved should be thoroughly explained about the safe procedures to be adopted while performing various activities including carrying out tests in the switchyard.  Adequate fire-fighting system as per procedures and their healthiness is to be ensured before charging.  Warning signs and Safety barriers should be positioned in conformity to Safety rules as amended from time to time. Pre-Commissioning 6 General Safety
  • 7. See tutorial regarding confidentiality disclosures. Delete if not needed.  Work will be performed according to local regulations and safety procedures. All work concerning GE personnel will be done according to GE safety regulations if they exceed the local regulations. GE LOTO procedure shall be always followed.  Capacitor units must be short circuited and grounded before working on them.  Air core reactors may have induced voltage across their terminals if current flowing in a nearby busbar or line.  when working on thyristor valves since its terminals are close to each other and both terminals are connected to air core reactors outside the valve room. Therefore, it is recommended to always apply equipotential bonding and grounding to the thyristor valve terminals before working inside valve fence. Pre-Commissioning 7 Equipment Safety “All high voltage switching will be done by or under supervision of Customer”.
  • 8. See tutorial regarding confidentiality disclosures. Delete if not needed. Confidential. Not to be copied, distributed, or reproduced without prior approval. TCR-1 Branch 192Mvar TCR-3 Branch 192Mvar Control Building TCR-2 Branch 192Mvar Single Phase coupling Transformer 500Mvar - 400/30kV Single Tunned Filter – 5th – 31Mvar Single Tunned Filter – 7th and High Pass 45Mvar Access Road Spare Trfo. Delta Bus (”C” Channel) Grounding Transformer Auxiliary Transformer MAIN COMPONENTS AND LAYOUT OF TCR
  • 9. See tutorial regarding confidentiality disclosures. Delete if not needed. Verify correct installation of each components of the Substation / TCR. Equipment Tests Subsystem Tests Pre-Commissioning 9 Pre-Commissioning Tests
  • 10. See tutorial regarding confidentiality disclosures. Delete if not needed. GENERAL INSTALLATION AND WIRING CHECK REACTORS CIRCUIT BREAKERS SURGE PROTECTION EQUIPMENT INSULATORS INSTRUMENT TRANSFORMER S DISCONNECTOR S AND EARTHING SWITCHES POWER TRANSFORMER S AUXILIARY AND EARTHING TRANSFORMER TCR VALVES COOLING UNIT AUXILIARY POWER SYSTEM P&C CUBICLES EARTHING SYSTEM CIVIL SYSTEMS Pre-Commissioning 10 Equipment Tests “The inspection- and pre commissioning checklists provide general tests for each piece of equipment. However, if a contractor or manufacturer of any device has also provided an installation checklist, then that should also be filled”.
  • 12. See tutorial regarding confidentiality disclosures. Delete if not needed. Pre-Commissioning 12 Equipment Tests GENERAL INSTALLATION AND WIRING CHECK  The complete installation is inspected visually. The position and electrical connection of the TCR equipment is cross-referenced with documentation.  Equipment labels are checked for correct text and fixing material ie. plastic on. valves and reactor noise enclosure.
  • 14. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests REACTORS  The complete installation is inspected visually. The position and electrical connection of the TCR equipment is cross- referenced with documentation.  Equipment labels are checked for correct text and fixing material ie. plastic on. valves and reactor noise enclosure. Pre-commissioning Tests 14 .
  • 15. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests REACTOR CHECK LIST Pre-Commissioning Tests 15
  • 17. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests SURGE PROTECTION EQUIPMENT  Verify the condition and installation of all surge arresters and surge capacitors in the TCR.  The equipment and installation are inspected visually and/or with appropriate devices Pre-Commissioning Tests 17
  • 18. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests SURGE PROTECTION CHECK LIST Pre-Commissioning Tests 18
  • 20. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests INSULATORS – Verify the condition and installation of all insulators in the TCR. These include support and wall-bushing insulators. – The equipment and installation are inspected visually and/or with appropriate devices. – Wall-bushing nameplate values are cross-referenced with appropriate documents. – Wall-bushing insulator electrical connection tightness is checked with a torque wrench. – Insulators are cleaned if necessary. – The earthing of the insulator base or support structure is checked Pre-Commissioning Tests 20
  • 21. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests INSULATOR CHECK LIST Pre-Commissioning Tests 21
  • 23. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests INSTRUMENT TRANSFORMERS- CT & VT • Verify the condition and installation of all voltage and current transformers in the Substation. • The equipment and installation are inspected visually and/or with appropriate devices. Voltage and current transformer nameplate values are cross-referenced with appropriate documents. • The tightening torque of random electrical connection is checked with a calibrated torque wrench. The earthing of the equipment support structure is verified visually and with appropriate measurements. The equipment direction is verified against single line diagram and assembly drawings. Pre-commissioning Tests 23 .
  • 24. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST Pre-Commissioning Tests 24
  • 25. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST Pre-Commissioning Tests 25
  • 26. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST Pre-commissioning Tests 26
  • 27. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST Pre-commissioning Tests 27
  • 28. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST Pre-commissioning Tests 28
  • 29. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST Pre-Commissioning Tests 29
  • 30. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests INSTRUMENT TRANSFORMERS- CT & VT CHECK LIST Pre-commissioning Tests 30
  • 32. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests DISCONNECTORS AND EARTHING SWITCHES  The purpose of these tests is to verify the condition and installation of all disconnectors and earthing switches in the SVC  Check that the Installation supervisor checklist and Site test report has been filled and signed appropriately. Check nameplate records  Disconnector wiring and input and output signal checks are done separately and confirmed with site testing report and to be checked associated sequence and Interlocking scheme.  Mechanical operating tests ,Verification of Earthing function  Dielectric test on the Main circuit  Test on the Aux. and control circuits Pre-commissioning Tests 32
  • 33. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests DISCONNECTORS AND EARTHING SWITCHES CHECK LIST Pre-commissioning Tests 33
  • 34. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests DISCONNECTORS AND EARTHING SWITCHES CHECK LIST Pre-Commissioning Tests 34
  • 36. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests CIRCUIT BREAKERS  A Circuit breaker is a device which control (make or break) a circuit automatically, manually or by remote control under normal and fault conditions like over current, Short circuit, etc. connected through circuit breaker. This way, it protect the connected circuit by discounting it from power supply during faults such as overload or short circuit currents  Check that the Installation supervisor checklist and Site test report has been filled and signed appropriately. Check nameplate records  The wiring and input/output signals of the circuit breakers are checked, and the interlocking scheme is confirmed with the site precomm report. Pre-Commissioning Tests 36
  • 37. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests CIRCUIT BERAKERS CHECK LIST Pre-Commissioning Tests 37
  • 39. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests POWER TRANSFORMERS Pre-commissioning Tests 39  Check that the Installation supervisor checklist and Site test report has been filled and signed appropriately.  Oil leakage, Vacuum & Pressure tests on transformer tank.  Polarity and Vector group.  Voltage Ratio test.  Winding Resistance measurement.  No-load losses and currents (at 90%, 100% & 110% voltage)  Oil samples (IEC 60567)  Switching impulse test.  AC Separate source withstand test, Induced overvoltage test and partial discharge measurement.
  • 40. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests POWER TRANSFORMERS Pre-commissioning Tests 40  Test of the Magnetic circuit insulation and associated insulation(3 kV DC, one minute)  Insulation resistance test for Auxiliary wiring at 2 kV RMS for one minute  Bushing current transformer tests  High voltage withstand test on auxiliary equipment & wiring  Magnetization characteristic test
  • 42. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests AUXILIARY AND GROUNDING TRANSFORMERS Pre-commissioning Tests 42 AUXILIARY TRANSFORMER Two Auxiliary transformer of 630 kVA shall feed Main switch boards. One of them shall be fed from TCR MV Bus and other one from existing station 33 kV switchgear. GROUNDING TRANSFORMER (a) 33KV Earthing Transformer, ONAN Cooled, 3 ph, oil-immersed, class A insulated, fitted with outdoor type bushings on HV side. Neutral of HV bushings shall be earthed for non effectively earthed 33 KV system. Earthing transformer shall consist of a single winding in which case this winding shall be connected inter-star (zigzag) in accordance with the relevant IS group. (b) INTERPHASE CONNECTION: HV :Inter-star (Zigzag) with neutral brought out through Bushing for solid earth connection.
  • 43. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests AUXILIARY AND GROUNDING TRANSFORMERS Pre-Commissioning Tests 43
  • 45. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests AUXILIARY POWER SYSTEM Pre-commissioning Tests 45 This system includes the LV AC, DC and UPS power systems with their associated batteries. The equipment and installation is visually inspected. The tightness of the screw terminals is checked. Earthing of the equipment frame is verified visually and with appropriate measurements. Functionals tests are performed as per detailed commissioning instructions • UPS/UPS Bypass for • TCR cooling unit. • Battery Charging. • Protection& Control panels. • Filter/Aux. Trafo & other branch Circuit breaker. • Filter/Aux. & other branch Disconnector/Earth Switches. • Essential building services(HVAC/emergency lights/Fire protection system etc.) • Air conditioning units. • Coupling Transformer cooling Fans
  • 46. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests AUXILIARY POWER SYSTEM Pre-commissioning Tests 46
  • 48. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests COOLING UNIT Pre-Commissioning 48 The purpose of these tests is to verify the condition and installation of TCR valve cooling unit ,to be inspected visually . Nameplate values are cross-referenced with appropriate documents. The tightness of the screw terminals is checked. The earthing of the equipment support structure is verified visually and with appropriate measurements. The cooling unit is filled with appropriate coolant and de-aired. Functional tests are performed, and measurements are checked.  Installation supervisor check-list has been filled  Inspect equipment for physical damage, proper mounting, and required clearances  Check pump and piping alignment.  The earthing of the equipment to be verified  The cooling unit is filled with appropriate coolant and de-aired.  Functional tests are performed, and measurements are checked.
  • 49. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests COOLING UNIT Pre-Commissioning 49
  • 50. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests COOLING UNIT Pre-Commissioning 50
  • 52. See tutorial regarding confidentiality disclosures. Delete if not needed. Pre-Commissioning 52 Equipment Tests • THYRISTOR VALVES • TCR is a reactance which is connected in series through the bidirectional thyristor valve. The thyristor valve is phase- controlled, and it gives the delivered reactive power should be adjusted to meet the varying system condition. • Verify the condition and installation of all thyristor valves in the Substation. • The earthing of the equipment support structure is verified visually. • The resistance and capacitance of each thyristor level is measured. Operation of GLPS units is verified. • Check that all the optical fibers between the LEU boards and the fibers between LEU boards and VBE are connected according the Thyristor Valve Manual.
  • 53. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests Pre-Commissioning 53 TCR VALVES  Inspect equipment (Valves and both GLPs) for physical damage, proper mounting and required clearances.  Record the manufacturing number of the valve  Check that correct position labels (if any) are fastened on the equipment.  Check electrical connection of the busbars connected to the valve: Verify polarity, phasing and wiring of TCR valves.  Verify that the polarity of TCR valves vs. the corresponding CTs is correct.  Check clearances and creepage distances within valve.  Check that all parts of equipment support structure are properly earthed, and the earthing does not form loops. Use a multimeter to verify earthing connection.  Check tightness of all bus and cable connections with a calibrated torque wrench. Write used torque values (in Nm) for each bolt size to this table.  Measure the resistance over every thyristor level: TCR valves should have resistance R > 100kΩ
  • 54. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests TCR VALVES Pre-Commissioning 54  Measure the capacitance of capacitor of every thyristor level and check they are within tolerances.  Measure capacitance over every thyristor level and make sure the measured values are similar on each level. Differences in measured values may indicate wrong connection.  Check that all the optical fibres between the LEU boards and the fibers between LEU boards and VBE are connected according the TCR Valve Manual.  Check fiber connections are locked, not just pushed in.  Perform GLPS power up test:  Connect GLPS VBATT connection and all fiber connections but leave VOUT connection unconnected.  Start with the GLPS front panel circuit breaker in the “OFF” position.  After closing the DC-distribution panel circuit breaker and thus applying power to GLPS, measure and verify the voltage level and polarity at the VBATT connection (dependent on substation battery used). Observe and verify that no lights on the GLPS front panel are illuminated.
  • 55. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests TCR VALVES Pre-Commissioning 55  GLPS no load check:  Switch the GLPS front panel circuit breaker from “OFF” to “ON”.  Observe and verify that the GLPS front panel “INPUT POWER” (yellow) light is illuminated.  Observe and verify that the GLPS front panel “FAULT” (red) light is not illuminated.  VBE controls check:  The “RX1” fiber optic GLPS input will have a positive light signal when it is commanded on by the VBE. Measure and verify that the GLPS has the correct VOUT voltage (dependent on system design and setup) and that the “OUTPUT ON” (green) light is illuminated.  Check that all the optical fibres between the LEU boards and the fibers between LEU boards and VBE are connected according the TCR Valve Manual  Check fiber connections are locked, not just pushed in.
  • 56. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests TCR VALVES Pre-Commissioning 56  Perform GLPS power up test:  Connect GLPS VBATT connection and all fiber connections but leave VOUT connection unconnected.  Start with the GLPS front panel circuit breaker in the “OFF” position.  After closing the DC-distribution panel circuit breaker and thus applying power to GLPS, measure and verify the voltage level and polarity at the VBATT connection (dependent on substation battery used). Observe and verify that no lights on the GLPS front panel are illuminated.  GLPS no load check:  Switch the GLPS front panel circuit breaker from “OFF” to “ON”.  Observe and verify that the GLPS front panel “INPUT POWER” (yellow) light is illuminated.  Observe and verify that the GLPS front panel “FAULT” (red) light is not illuminated.
  • 57. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests TCR VALVES Pre-Commissioning 57  System check:  Remove power and connect the VOUT terminals of GLPS to the isolation transformer.  Apply power and observe and verify that the GLPS has the correct VOUT voltage and that the “OUTPUT ON” light is illuminated.  Connect the Ground Level Power Supply (GLPS) and power all the LEU-boards and check that the boards wake up (LEDs turn on). Verify that the voltage over the 4ET transformer (black discs in the corner) on each level is between 4 – 7 VAC.  Open the MCB of the active GLPS and check that backup GLPS will start up without disturbances in the thyristor valve level electronics power supply  All the levels should now have “communication OK” in the VBE panel if the data back fibres between the valve and valve base are OK. A few fibres may be disconnected and checked that the status is changed OK -> fail, then connected back and the status changes fail -> OK.  The optical fibres between TCR control system and the valve base should be tested by checking the status from valve base cubicle (communication between CTRL systems and VBE is OK).
  • 58. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests TCR VALVES Pre-Commissioning 58  Verify VBE software version and parameters.  Verify that the checksum of the valve base is OK (from VBE’s valve protection parameter screen). Checksum match status is shown on the first line (check sum fail/ok).
  • 60. See tutorial regarding confidentiality disclosures. Delete if not needed. Pre-Commissioning 60 Equipment Tests P&C CUBICLES  The purpose of these tests is to verify the condition and installation of all specific cubicles. These include Control, Protection, communication, valve base, repetition and VT/CT/DCT connection cubicles.  The equipment and installation are visually inspected. The tightness of the screw terminals is checked.  The earthing of the cubicle is verified visually and with appropriate measurements.  Supply voltages and current consumptions are measured.  Functional tests are performed for each cubicle. These include tests on protection relays, control system and communication system.
  • 61. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests P&C CUBICLES Pre-Commissioning 61 Control cubicles Test (KF1/KF2)  Check that the Installation supervisor check-list has been filled and signed appropriately.  Inspect equipment for physical damage and proper mounting.  Verify nameplate information is correct.  Check that cubicle is properly earthed and that earthing does not form loops.  Randomly check tightness of screw terminals and wire connections.  Energize the cubicles completely. Check every device power up normally.  Measure DC supply voltages and currents and record them to table. Verify that there is no AC- component in the DC-supply voltage  Measure AC supply voltage and current and record them to table.  Check that the PLC code goes to running state and correct LEDs are lit in the cubicle front panel.  Upload latest software to the control system.
  • 62. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests P&C CUBICLES Pre-Commissioning 62 Control Field I/O Panels (KK-11/12/13,KK-21/22/23)  Check that the Installation supervisor checklist has been filled and signed appropriately.  Inspect equipment for physical damage and proper mounting, Verify name plate information  Check that cubicle is properly earthed and that earthing does not form loops.  Randomly check tightness of screw terminals and wire connections.  Randomly check jumper connections in terminals.  Energize the cubicles completely.  Measure DC supply voltages and currents and record them to table. Verify that there is no AC-component in the DC-supply voltage.  Measure AC supply voltage and current and record them to table.
  • 63. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests P&C CUBICLES Pre-Commissioning 63 Communication Cubicle(UH1)  Check that the Installation supervisor checklist has been filled and signed appropriately.  Energize the cubicle completely. Check every device power up normally.  Measure AC & DC supply  Check GPS equipment Installation  Check the clock has locked in respect of GPS signal and clock parameters are correct  Change IP addresses and subnet of all communication devices as per IP address schedule mentioned in CBD.  Check that synchronization time signal is distributed to all necessary equipment: protection relays, control system, DFR  Verify that Local-HMI computer is energized from 230VAC UPS supply and verify that local/Remote HMI programs appear to function properly  Verify HMI single line diagram (correct components, component names).  Check that DFR operating correctly and all modules are live and showing proper readings  Check that DFR trigger signal settings are correct and showing correct timing of triggering.
  • 64. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests P&C CUBICLES Pre-Commissioning 64 Valve Base Cubicles (KG1/KG2/KG3)  Check that the Installation supervisor checklist has been filled and signed appropriately.  Check that cubicle is properly earthed and that earthing does not form loops.  Measure and record AC & DC supply of cubicles ,verify No AC component in DC supply.  Check that modules are configured as "VBA", "VBB", "VBC" from top to bottom. (Rotary switch position 1,2,3 accordingly)  Check that “power ok” –led is lit at the back of each module.  Check that LCD backlight is lit when front panel disp-button is pressed  Check VBE software version from all phases and mark them down.  After installing fibre optics check communication between LEU-board. The optical fibre between TCR control system and the valve base should be tested by checking the status from valve base cubicle  Verify that the parameter checksum of the valve base is OK.
  • 65. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests P&C CUBICLES Pre-Commissioning 65 Repetition Cubicle (KK3)  Check that the Installation supervisor checklist has been filled and signed appropriately.  Check that cubicle is properly earthed and that earthing does not form loops.  Randomly check tightness of screw terminals and wire connections.  Randomly check jumper connections in terminals.  Energize the cubicle completely.  Measure and record AC & DC supply of cubicles ,verify No AC component in DC supply.
  • 66. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests P&C CUBICLES Pre-Commissioning 66 Protection Cubicles (F11/F21)  Check that the Installation supervisor checklist has been filled and signed appropriately.  Energize the cubicle completely. Check every device power up normally.  Check that cubicle is properly earthed and that earthing does not form loops.  Measure and record AC & DC supply of cubicles .  Check fiber and/or ethernet connections are installed and connected.  Check all protection relays tested and to be verified parameters and settings.
  • 68. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests EARTHING SYSTEM Title or Job Number | XX Month 201X 68  The purpose of these tests is to verify the installation of the earthing system in the substation area.  The equipment and installation are inspected visually and/or with appropriate devices.  During the installation phase it is continuously verified that GE instructions on earthing system are followed.  Each piece of equipment shall be appropriately earthed but closed loops in earthing shall not be approved.  The same applies also to concrete reinforcement steel bars in reactor foundations.  Each earthing will be checked visually by GE afterwards to ensure it is done properly. Also measurements will be done for the earth grid and above ground earthing.
  • 69. See tutorial regarding confidentiality disclosures. Delete if not needed. Equipment Tests. Functional tests such as testing interfaces between control system and field equipment, verification of interlocking scheme and SCADA communication. Subsystem Tests. Pre-Commissioning 69 Pre-Commissioning Tests
  • 70. See tutorial regarding confidentiality disclosures. Delete if not needed. Pre-Commissioning 70 Subsystem Tests “The purpose of subsystem tests is to verify that all major subsystems and interfaces between them are working correctly. Subsystem tests end with cold run tests where the TCR is operated without high voltage. After subsystem tests have been completed, TCR is ready for energization”. CABLING MEASUREMENT CIRCUITS HARD-WIRED DIGITAL IO COMMUNICATION LINKS WITHIN THE TCR/ SUBSTATION INTERFACE TO SAS SYSTEM INTERLOCKING COLD RUN TESTS
  • 71. See tutorial regarding confidentiality disclosures. Delete if not needed. Pre-Commissioning 71 Subsystem Tests CABLING  Verify the condition and installation of all cabling related to the Substation.  All cables are visually inspected. Special attention is paid on the cable shield earthing. The shield shall be earthed at one end only and the other end shall be properly insulated. • The continuity of each core is checked with a multimeter and the correct connection point is verified.  The insulation of each cable is verified with insulation resistance measurement.  It is verified that all optic fiber bundles are installed within trunking or equivalent mechanical protection. • A point-to-point test is performed on optic fibers
  • 72. See tutorial regarding confidentiality disclosures. Delete if not needed. Pre-Commissioning 72 Subsystem Tests MEASUREMENT CIRCUITS  The purpose of these tests is to verify the operation of measurement circuits related to the TCR (CT- and VT-circuits).  The earthing of each circuit is checked. The VSC current measurement circuit DC- offset calibration sequence is performed.  Appropriate current or voltage is injected to each CT- and VT-primary circuit.  The polarity and magnitude are verified from each associated cubicle. Polarities and magnitudes are also verified from HMI, protection relays and fault recorder.  Note! - Hazardous voltages may appear on VT primary during injection if the VT is not isolated from the secondary circuit.
  • 73. See tutorial regarding confidentiality disclosures. Delete if not needed. Pre-Commissioning 73 Subsystem Tests HARD-WIRED DIGITAL IO  The purpose of these tests is to verify the operation of the hard-wired digital inputs and outputs of the TCR control, protection and communication system. –Digital Inputs: Both states of each P&C-system digital input signal are tested.  The activation and deactivation of each signal are from the remote end mimicing as far as possible the actual operation of the signal.  The signal is observed from the HMI screen, protection relay, cooling unit, fault recorder or other receiving device so that the complete signal path gets verified. –Digital Outputs: Digital outputs are tested similarly. The output is activated and deactivated from the P&C-system.  The signal is observed at the remote end by verifying that the intended response is shown by the device.  Again, it is recommended that the complete signal path is verified.
  • 74. See tutorial regarding confidentiality disclosures. Delete if not needed.  The purpose of these tests is to verify the operation of all communication links & to verify the operation of the interface between TCR control and protection system and SCADA system  Digital signals are tested by activating and deactivating them at the sending end and observing the HMI screen & SCADA system.  Analog signals are verified by comparing the values shown on the sending device and HMI screen and same for SCADA system  It may be necessary to inject voltages or currents. Pre-Commissioning 74 Subsystem Tests COMMUNICATION LINKS & INTERFACE TO SCADA SYSTEM
  • 75. See tutorial regarding confidentiality disclosures. Delete if not needed. Pre-Commissioning 75 Subsystem Tests INTERLOCKING  To verify the installation and operation of safety interlocking system of the TCR.  Interlocking scheme to be verified. Interlocking between each disconnector and its associated earthing switch is tested.  Key interlocking system between earthing switches and associated entry gates is tested.  The interlocking system between HV and MV side is tested.
  • 76. See tutorial regarding confidentiality disclosures. Delete if not needed. Pre-Commissioning 76 Subsystem Tests COLD RUN TESTS  The purpose of these tests is to verify the operation of the complete TCR without high voltage.  Prior to the tests, all preceding pre-commissioning documentation is thoroughly checked and validated.  Check all applicable signals as per signal list by cold run test (without HV voltage) has been tested with all control cubicles and its associated.  Activate all necessary signals for TCR to enter ready to run state. It is recommended to actually operate the disconnectors to achieve this.  Verify that the HV disconnectors and MV disconnector are open and cannot be closed during the cold run test.  Each ready to run state and condition is tested.