harar polytechnic college

ELECTRICAL/ELECTRONIC EQUIPMENT SERVICING

MANAGEMENT
LEVEL IV

Learning Guide

Unit of Competence: Commission Electrical/Electronic

Equipment
Module Title: Commissioning Electrical/Electronic
Equipment
LG Code: EEL EES4 M13 LO1- LG-52
TTLM Code: EEL EES4 TTLM0320V3

LO3: Complete and report commissioning activities

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Learning Guide
Version: 3 Revision: 1 Author: electrical electronics
 Instruction sheet Learning Guide#52

This learning guide is developed to provide you the necessary information regarding
the following content coverage and topics –

 Definition of commissioning
 OH&S Policies and procedures
 Selecting and using proper tools and equipment
 Procedures of commissioning
 Planning and preparing commissioning procedures
 Documenting final operating parameters and settings.

This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –

x Follow OH & S policies and procedures.

x Check Start-up and commissioning procedures of electronics and
communications systems against specifications and requirements.
x Carry out the start-up Tools, equipment and testing devices need to
commissioning work and check for correct operation and safety.
x Obtain Materials necessary to complete the work are in accordance with job
requirements.
x Follow electronics and communications systems standards in line with job
requirements.
x Plan and prepare Start-up & Commissioning procedures are in line with job
requirements
x Document final operating parameters and settings

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Learning Guide
Version: 3 Revision: 1 Author: electrical electronics
Learning Instructions:

1. Read the specific objectives of this Learning Guide.

2. Follow the instructions described in number 3 to 14.

3. Read the information written in the “Information Sheets 1”. Try to understand what
are being discussed. Ask you teacher for assistance if you have hard time
understanding them.

4. Accomplish the “Self-check 1” in page 10__.

5. Ask from your teacher the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 1).

6. If you earned a satisfactory evaluation proceed to “Information Sheet 2”. However, if

your rating is unsatisfactory, see your teacher for further instructions or go back to
Learning Activity #1.

7. Submit your accomplished Self-check. This will form part of your training portfolio.

8. Read the information written in the “Information Sheet 2”. Try to understand what are
being discussed. Ask you teacher for assistance if you have hard time
understanding them.

9. Accomplish the “Self-check 2” in page 23__.

10. Ask from your teacher the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 2).

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Learning Guide
Version: 3 Revision: 1 Author: electrical electronics
11. Read the information written in the “Information Sheets 3 ”. Try to understand what
are being discussed. Ask you teacher for assistance if you have hard time
understanding them.

12. Accomplish the “Self-check 3” in page _28_.

13. Ask from your teacher the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 3).

14. (if you are ready). Request your teacher to evaluate your performance and outputs.
Your teacher will give you feedback and the evaluation will be either satisfactory or
unsatisfactory. If unsatisfactory, your teacher shall advice you on additional work.
But if satisfactory you can proceed to Learning Guide #27.

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Learning Guide
Version: 3 Revision: 1 Author: electrical electronics
 Documenting adjustment settings
Information Sheet 1

3.1 Testing installation

Commissioning vs testing
It is important to understand the differences between the terms testing,
commissioning and performance testing, and to ensure that the programmed has
sufficient time within it to enable these activities to be undertaken. Unfortunately, with
this stage of the project being so close to handover, there is often pressure to gain time
by shortening the testing, commissioning and performance/environmental testing
programmed.
This should be strongly resisted. Rarely, if ever, after the project will such an
opportunity exist to fully test the services to ensure that they work individually, as a
system, and, that they work under part-load and full-load conditions. Many problems
with respect to the under-performance of services within an occupied building can be
related back to either insufficient quality in the testing and commissioning, or,
insufficient time to test and commission.
It should also be borne in mind that various statutory services will need to be
demonstrated to site inspectors, and insurers. Time should be allowed for within the
programmed since these activities are often taken as separate tests after the
main commissioning has been undertaken.
Testing

During services installation various tests will be undertaken known as “static testing”.
This testing is normally undertaken to prove the quality and workmanship of the
installation. Such work is undertaken before a certificate is issued to “enliven” (i.e. to
make live) services whether electrically or otherwise. Examples of this sort of testing
are:
 Pressure testing ductwork and pipework.

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Learning Guide
Version: 3 Revision: 1 Author: electrical electronics
 Undertaking resistance checks on cabling.

Commissioning

Upon completion of static testing, dynamic testing can be undertaken, this is

'commissioning’. Commissioning is carried out to prove that the systems operate and
perform to the intent and specification.
This work is extensive and normally commences by issuing a certificate permitting the
installation to be made “live”, i.e. electrical power on. After initial tests of phase rotation
on the electrical installation and checking fan/pump rotation (in the correct direction), the
more recognized commissioning activities of balancing, volume testing, load bank
testing, etc. begin.

Performance testing

Upon completion of the commissioning, performance testing can begin. Some may not
distinguish between commissioning and performance testing. However, fo r
programming purposes it is worth distinguishing between commissioning plant as
individual systems and undertaking tests of all plant systems together, known as
performance testing, (and including environmental testing).
Sometimes this performance testing is undertaken once the client has occupied the
facility, e.g. for the first year because systems are dependent upon different weather
conditions. In such cases, arrangements for contractor access after handover to fine-
tune the services in response to changing demands must be made.
However, for some facilities it may be necessary to simulate the various conditions
expected to prove that the plant systems and controls operate prior to handover, e.g.
computer rooms.

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Learning Guide
Version: 3 Revision: 1 Author: electrical electronics
INSPECTION AND TESTING AFTER INSTALLATION

After the instruments have been installed they shall be inspected and tested for correct
operation as part of the system. This procedure covers the complete inspection and
testing of all instruments and instrument systems received on site up to and including
the pre-commissioning.

The inspection and testing shall be carried out in accordance with the requirements of
following sections and paragraphs.

Visual Inspection

Field visual inspection shall ensure that each instrument:

 has the correct tag number, range, etc.;

 is in the proper place;

 is correctly and rigidly installed;

 is properly earthed where necessary;

 is suitably protected against adverse environmental conditions.

Attention shall also be paid to the final accessibility of the instrument and the free
space necessary for removal or partial disassembly.

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Learning Guide
Version: 3 Revision: 1 Author: electrical electronics
Testing of Impulse Lines

With the process and instrument isolating valve closed, all instrument impulse lines
shall be pressure-tested to a pressure of 1.5 times the intended upper operating
pressure.

Note:

Local regulations may specify a higher pressure, e.g., two times the intended
operating pressure.

Pressure testing shall be done with demineralized water. After pressure testing, the
impulse lines shall be disconnected from the process connections, then the instrument
impulse lines shall be carefully drained and blown out. For safety reasons stainless
steel tubes shall be used for testing purposes and not copper. Gas cylinders may be
used for high pressure testing.

Testing of Sampling Systems of Analyzers

Sampling systems for on-line process analyzers and impulse lines shall be blown
out, pressure-tested and leak tested using dry air or Nitrogen, after which the sampling
systems shall be disconnected from the process connections.

Testing of Pneumatic Tubing

Leak testing of pneumatic tubes shall be carried out using the bubble method and soap
test; after the test the pneumatic signal loops shall be subjected to a full operational

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Learning Guide
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test. Special attention shall be paid to the correct line-up between 3-way or 4-way
solenoid valves and the relevant final control element.

Testing of Instruments

All individual instruments shall be tested and (re)calibrated before installation, and a
detailed testing of the instrument is not necessary at this stage, unless the function
testing reveals an abnormal behavior.

Control valves and shut off valves equipped with actuators (complete with associated
tubing, solenoid valves quick exhausts, boosters and positioners) shall be tested for
full-stroke time.

Actuators for variable-pitch fans on air-cooled heat exchangers shall be tested for
smooth stroking in site before plant commissioning. Final adjustment shall be done
when the plant is operating at its design duty and the heat exchanger is at operating
temperature, such that:

- Minimum pitch (usually negative to compensate for air flow due to heat
conduction) shall cause zero air flow;

- Maximum pitch shall not cause the maximum allowable motor current to be
exceeded.

Testing of Instrument Loops

All instrument loops shall be fully tested for correct functioning, where necessary by
simulating the signals.

All controllers shall have their settings for proportional, integral and derivative actions
adjusted to a calculated value. Company approved loop check forms, shall be applied
for recording the results.

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Learning Guide
Version: 3 Revision: 1 Author: electrical electronics
Note: The following equipment shall also receive attention at this stage:

- Special high-signal or low-signal selectors calculating relays, etc. shall

be adjusted;

- The mechanical min/max stop on control valves shall also be adjusted;

- The position of limit switches shall be checked and adjusted; - Selector

switches shall be checked.

Self-Check 1 Written Test

Instructions: Answer all the questions listed below. Illustrations may be necessary to
aid some explanations/answers. W rite your answers in the sheet
provided in the next page.

1. what is the difference between testing & commissioning?

2. W hen performance testing can begin?

3. what are those tasks covered on field visual inspection?

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Learning Guide
Version: 3 Revision: 1 Author: electrical electronics
 Note: Satisfactory rating - 25 points Unsatisfactory - below 25
points
You can ask you teacher for the copy of the correct answers.

Answer Sheet Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

1._______________________________________________________________

_______________________________________________________________

2._______________________________________________________________

_______________________________________________________________

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Learning Guide
Version: 3 Revision: 1 Author: electrical electronics
 3._________________________________________________________________
______________________________________________________________

Complete and report commissioning activities

Information Sheet 2

\
3.1 Complete and report commissioning activities
Commissioning documentation shall include:

1. The Commissioning Plan, the master planning document for all commissioning activities and
deliverables, revised, refined, updated and reviewed at each stage of design development and
re-submitted for review by the Commissioning Manager.
2. The Building Management Manual, containing all documentation for the project and providing
a complete "paper trail" relating to project delivery.
3. Commissioning specifications. For details of requirements, Guide to the development and use of
Commissioning Specifications.
4. Training Plans. To the preparation of Training Plans.
5. Installation Check Lists for use during pre-start-up and pre-commissioning inspections.
6. Product Information (PI) report forms to document all details of equipment, components and
systems,
7. Performance Verification (PV) report forms and include thereon all Design Criteria, Design
Intents and other relevant design information.
8. "As-built" drawings and specifications: to be completed prior to, and available for,
9. Final evaluation report,
10. Any other documents and reports

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Learning Guide
Version: 3 Revision: 1 Author: electrical electronics
 Date: May 2020 Page 13 of 30
Learning Guide
Version: 3 Revision: 1 Author: electrical electronics