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Test and Commissioning Manual V4 PDF
Test and Commissioning Manual V4 PDF
Test and Commissioning Manual V4 PDF
Commissioning
Manual
“This material is made available on the basis that it may be necessary for a
Registered Professional Engineer of Queensland (RPEQ) to undertake or
oversee the engineering services to meet statutory obligations”.
Test and Commissioning Manual
This material is made available on the basis that it may be necessary for a Registered
Professional Engineer of Queensland (RPEQ) to undertake or oversee the engineering services
to meet statutory obligations.
Ergon Energy makes no representations, express or implied, as to the accuracy of the
documents provided and accepts no liability howsoever arising for any loss resulting from the
use of the documents or reliance placed on them.
The recipient agrees to indemnify Ergon Energy and keep it indemnified against any liability for
any losses (including liabilities of the recipient to third parties), costs and expenses arising out of
the use or reliance on the documents by the recipient.
The documents provided are to be used as a guide only. Subject to any other statutory
obligation, to the extent practical, the recipient agrees to use reasonable endeavours to notify
Ergon Energy of any errors or omissions it becomes aware of in the documents to enable
correction/updating.
Table of Contents
1. Purpose and Scope ....................................................................................................... 1
2. Definitions, Abbreviations and Acronyms ...................................................................... 1
3. Role and Responsibilities of the commissioning officer / engineer ................................ 4
4. The Commissioning Process ......................................................................................... 5
5. Single Point of Accountability for Commissioning .......................................................... 8
6. Project Development Phase .......................................................................................... 8
7. Project Implementation Phase ....................................................................................... 9
7.1. Handovers .......................................................................................................................... 9
7.1.1 Primary Plant ............................................................................................................... 9
7.1.2 Design Handover ......................................................................................................... 9
7.2. Drawing Management ...................................................................................................... 10
8. Submission of Application for Work requests and System Outages ............................ 11
9. Commissioning Testing ............................................................................................... 11
9.1. Primary Plant Testing ....................................................................................................... 12
9.2. Testing Beyond That Specified In Ergon Energy Test Documentation............................. 12
9.3. Secondary Systems Testing ............................................................................................. 12
9.4. Substation Communications System Testing ................................................................... 13
9.5. Revenue and Statistical Metering Testing ........................................................................ 13
9.6. Substation Miscellaneous System Testing ....................................................................... 13
10. Reporting of Plant, Construction and Design Defects during the Commissioning
Process ....................................................................................................................... 13
11. Construction Release .................................................................................................. 14
12. Pre-Connection Hold Point .......................................................................................... 14
13. Commissioning Authority for Energising Electrical Plant ............................................. 14
14. Customer Authority to Energise Customer Owned Plant ............................................. 15
15. Commissioning and Decommissioning Notices ........................................................... 15
16. Storage of Test Results ............................................................................................... 15
17. Post Commissioning Closeout ..................................................................................... 15
18. Authorisation and Approval of Commissioning Documentation ................................... 16
A1. Annex A – Terms and Conditions of Use of Ergon Energy Developed Automated
TEst Reporting Tools ................................................................................................... 17
A2. Annex B – TERMS AND CONDITIONS OF USE OF ERGON ENERGY
DEVELOPED STANDARD WORK PRACTICES ........................................................ 18
A3. Annex C – Terms and Conditions of use of protection relay standard test plans ........ 19
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Start
Project Manager to provide Commissioning
from high level design - Develop
Single line protection FAT ITP
Stakeholder
diagram for the final Commissioning Design
Commissioning Commissioning Proceed approved Commissioning
configuration Develop Verificaion &
Staging Plan Schedule Commissioning schedule
General Arrangement Staging Plan Stakeholder
staging plan FAT ITPs
drawing and Schedule review
Proposed transmission
and distribution feeder
Staging plan requires review
arrangement
Project Manager
Implementation Phase
Reviewed
Commissioning Project Manager
Plan and Review
Schedule Prepare
Handover Final
Commissioning
Start (Gate 3 approval) Schedule
Commissioning meet Commissioning
with resource Commissioning Resource Develop Outage Plan
Ergon ITP PM to conduct
supervisors to review develop SAT& SIT schedulers to Review Commissioning
Approval design handover
Commissioning ITPs schedule works Schedule after
Schedule scheduler input
De-
Commissioning
ITP revision required Outage Plan
(if required)
Completed Sections
1 & 2 of Commissioning
Authority to energise Project Manager
form
Implementation Phase
Construction Unresolved
Construction Completed SIT
Release SIT resources to
Start resources complete ITPs
received
SAT and SIT
perform SIT
construction activities
New Plant Outstanding
supplied Issues
Completed SAT
Start ITPs
Commissioning Review
Completed FAT SAT and SIT Complete
FAT completed ITPs
PM to complete Section
3 of Commissioning
Pre & Post Authority to energise
Energisation form
ITPs
Pre-Energisation Completed Pre-
Start resources to perform Energisation Commissioning
Pre-Energisation ITPs Review
Commissioning testing
Commissioning
Develop ITP’s
Co-ordination
Pre & Post Energisation
Co-Ordination
programs
Implementaion Phase
Program
Outage Plan
HV
Pre-connections
checks complete
Completed
Commissioning No
Outage Plan
Yes
Completed Commissioning
Post- Review
Energisation Complete
ITPs commissioning
Perform HV Commissioning documentation
Post-Energisation
Commissioning and Authority to
HVIA process now Perform HV resources to perform
Co-ordination Secondary energise form
enforced energisation Post-Energisation
Program Systems completed Completed
testing
connections Commissioning Commissioning /
Co-ordination Decommissioning
program Notice
Legend Deliverable
Control Point File / Document
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9. COMMISSIONING TESTING
The Commissioning Testing philosophy adopted by Ergon Energy and detailed in this manual is
designed to meet the following criteria:
1. Ensure personnel and public safety
2. Minimise risk to plant
3. Ensure that substation plant and systems are verified in accordance with their design
4. Capture test results for baseline/benchmark recording and trending purposes
5. Provide an audit function of external service providers
In order to meet these requirements it may be necessary to repeat some tests throughout the
commissioning lifecycle.
It is important to note that during the commissioning phase/s of a project, the Commissioning
Officer/Engineer is responsible for the verification of the plant and systems in accordance with the
approved design. Where the Commissioning Officer/Engineer identifies issues with the suitability or
implementation of a design the Commissioning Officer/Engineer will raise these issues with the
appropriate subject matter expert for design validation. It remains the responsibility of the subject
matter expert to ensure that all designs are correct, fit for their intended purpose and meet
regulatory requirements.
Commissioning Testing has been divided into the five distinct phases, these being Factory
Acceptance Testing (FAT), Site Acceptance Testing (SAT), Site Integration Testing (SIT), Pre-
Energisation Testing and Post-Energisation Testing. The standard testing requirements for each of
these phases has been clearly defined within the Automated Test Generation Tools which are
available on the Ergon Energy Test and Commissioning Resource Centre website. Standard Work
Practice documents which detail how testing is to performed are also available on the Ergon
Energy Test and Commissioning Resource Centre website. The legal obligations and requirements
pertaining to the use of Ergon Energy developed Automated Testing Tools and Standard Work
Practices are detailed in Annexes A and B of this document.
An overview of the Test and Commissioning Process for primary plant and secondary systems for
the purpose of substation plant and secondary system commissioning is discussed in the following
sections.
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Contractor
Document Approval Level Approval Level
ITP developed from approved SWPs or PP4/PP5/PM2/PM3 Level 6 Field Test
approved ITP templates Competency
Non-standard ITP RPEQ Not Applicable
Outage Plan PP5/PM2/PM3 Level 6 Field Test
Competency
Co-ordination Plan PP5/PM2/PM3 Not Applicable
Test Results (where pass/fail criteria have been PP4/PP5/PM2/PM3 Level 6 Field Test
defined) Competency
Test Results (no defined pass/fail criteria) RPEQ RPEQ
Work Instruction, Standard Work Instruction, RPEQ Not Applicable
Inspection or Test Plan Template
Form Template PP5/PM2/PM3 Not Applicable
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