Test Specification

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 Test Specification

1. INTRODUCTION

1.1 OVERVIEW
This Test Specification is to verify and validate the functional configuration of the 2
x 265 Kw Generators located on the Zahara Desert Camp, Bidiya site and their
combined functionality in respect of the Synchronisation panel.
The aim of the tests is to show:
(a) That the synchronisation panel and generators is operating as expected
under normal working conditions.
(b) That the Synchronisation and generators will operate correctly in an
emergency/redundancy scenario
(c) That the Synchronisation and generators will operate in a load sharing
capacity.
See Figure 2 -1
The synchronisation tests will include
(a) The 265 KW Generator – D.G.1
(b) The 265 KW Generator – D.G.2
(c) Synchronisation Panel
(d) Electrical Load Simulator

1.2 OTHER TESTING

Tests not performed
A possible test is that both generators are left running and the load increased to a
value that cannot be supported by a single generator. In the event of a generator
failure, the remaining generator should shut down as it hasn’t got the capacity to
handle the total load.
Due to the potential damage to equipment, it has been decided that this test will
not be performed.

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 Test Specification

2. TEST CASES

2.1 FUNCTIONAL TESTS

2.1.1 Test Specification

Reference
Description of item(s) under test UEI Generators and Synchronisation panel
High level description of item(s) under test. For example, subsystem
name or program name.
Item(s) under test reference number(s) and issue(s) PMO Building 500KVA Genset G2 (serial no. C5H02106)
Define exactly which software, hardware or other item is being tested.
Use the most appropriate method, such as a list of source files and TTTF Building Genset G1 (serial no. SNW00263)
version numbers, or an overall version number or release note. This must
be sufficiently comprehensive so that the tests can be reproduced later if
Synchronisation Panel (Serial No. TTCWA1600-009)
required.
Electrical Load simulator (Serial no. TTCNJ1250-011)
Where a Test Log is raised in order to verify a CA or RM, the item being
tested is not the CA or RM but the item which has been changed by the
CA or RM. It is therefore not sufficient to simply enter a CA or RM number
here.
Where items do not yet have a formal version ensure that they can still be
identified; for example “version 2.1 plus CA/123”.
Test Overview and Procedure (a) That the synchronisation panel and generators
Define the objective of the test and a brief overview of the test. are operating as expected under normal working
conditions.
(b) That the Synchronisation and generators will
operate correctly in an emergency/redundancy
scenario.
(c) That the Synchronisation and generators will
operate in a load sharing capacity.
Test setup See Figure 2 -1
Details of configuration used for testing. For example, hardware used or
database version, plus any other relevant information.
This must include all items which are required to conduct the test, other
than the item under test, so that the tests can be reproduced later if
required.
Name of engineers running test Viju George (UEI)
Bill Clarke (UEI)
(TTC – Ramsey, Cruz, Mukutsaab, Varundas, Midhun Pius,
Ponnambalam Murgaraj, Senthil Kumar, Cat Engineer)

Date testing started 14th & 15th March 2013

All tests passed? All tests passed

Mark with X as appropriate. One or more tests failed
Query Note, CA or RM references None
If this test results in queries or changes to design items or standards
documents, enter the QN, CA or RM reference numbers here, with the
number of the test step which produced each query or change.
Otherwise, enter None.
Test Engineer
Signature of engineer performing tests and date tests completed.
Witness
Where tests have been witnessed, signature of person witnessing tests,
and date. Otherwise enter Un-witnessed.
Test Authority
Signature of Test Manager or other test authority, accepting results of
tests, and date accepted.

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 Test Specification

Test Data
Provide details of the test data to be used. This may take the form of a
description or a link.

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 Test Specification

FIGURE 2-1 SYNCHRONISATION – GENERATOR CONFIGURATION

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 Test Specification

2.1.2 Test Log

Reference (auto populated)
Step Action Expected result Actual Result Pass or fail Failure action
If using a Test Procedure, enter just the test step reference. Leave this blank if using a Test Ensure that any deviations from the If test fails, reference of
Otherwise, state the actions to be performed. Also state the Procedure. expected result are listed, plus any CA, RM or QN raised, or
purpose of the test step, if it is not obvious. observations which may be significant. Pass Fail explanation of failure.
1 Pre-requisites IT Systems are shut down or As expected, PASS
powered by standby
generator.
PMO Office is directly powered from the G1
Genset
TTTF is directly powered from the G2 Genset
Electrical load is on within both buildings
Key IT systems have been shut down (or
disconnected and powered by a standby
generator) to protect them from adverse testing.

2 Pre-requisite Generators disconnected and As expected PASS

no load.
Disconnect both buildings from the generators G1
and G2

3 Gensets G1 and G2 are connected to the Both generators are operating Connected as stated and no load PASS
Synchronisation panel. On no load. Load Bank is in sync
connected to the outgoing breaker of the Sync
Panel

4 Apply load on both synchronisation panel via load Both generators to run in sync
bank to the value of 66 KW in total (25%) and load share (half load on
______ KW load on simulator
each Genset)
Load & voltages are:
Note: load on each Genset

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 Test Specification

Reference (auto populated)

Step Action Expected result Actual Result Pass or fail Failure action
If using a Test Procedure, enter just the test step reference. Leave this blank if using a Test Ensure that any deviations from the If test fails, reference of
Otherwise, state the actions to be performed. Also state the Procedure. expected result are listed, plus any CA, RM or QN raised, or
purpose of the test step, if it is not obvious. observations which may be significant. Pass Fail explanation of failure.
should be: G1= ____ KW
G1= 33 KW (approx) G2= _____ KW
G2= 33 KW (approx) 3-phase volts = ___, ___ Hz
Voltage on 3 phase to be 415 Single phase volts = _____V
V
Voltage on single phase to be
240 V
5 Apply load on synchronisation panel via load bank Both generators to run in Load on load simulator was
to the value of 132 KW in total (50%) sync. and load share (half ______ KW
load on each Genset)
Note: Load on each Genset
Load & voltages are:
should be:
G1= ____ KW
G1= 66 KW approx.
G2= _____ KW
G2= 66 KW approx
3-phase volts =____V, ___ Hz
Voltage on 3 phase to be 415
V Single phase volts =______V
Voltage on single phase to be
240 V
6 Apply load on synchronisation panel via load bank Both generators to run in sync Load on load simulator was -
to the value of 198 KW in total (75%) and load share (half load on ______KW
each Genset)
Note load on each Genset
Load & voltages are:
should be:
G1= 99 KW
G1= 99 KW
G2= 99 KW
G2= 99 KW
3-phase volts =____V, __ Hz
Voltage on 3 phase to be 415
V

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 Test Specification

Reference (auto populated)

Step Action Expected result Actual Result Pass or fail Failure action
If using a Test Procedure, enter just the test step reference. Leave this blank if using a Test Ensure that any deviations from the If test fails, reference of
Otherwise, state the actions to be performed. Also state the Procedure. expected result are listed, plus any CA, RM or QN raised, or
purpose of the test step, if it is not obvious. observations which may be significant. Pass Fail explanation of failure.
Voltage on single phase to be Single phase volts =______V
240 V

7 Genset G1 is powered down and Genset G2 is Genset G2 is running on load Load & voltages are:
operating to a load of 198 KW. (75%) 198 KW without power
G1= _____ KW
interruption
G2= ____ KW
Note : Load on Genset G2
Voltage on 3 phase to be 415
V 3-phase volts = ____ V ___Hz
Voltage on single phase to be Single phase volts = ______V
240 V
8 With G2 still set to 198 KW, Genset G1 has power Genset G1 should Simulated load was 198 KW
restored synchronise and load share
with Genset G2. Half load so Load & voltages are:
that: G1= 99 KW
G1= 99 KW G2= 99 KW
G2= 99 KW 3-phase volts = ____ v ___Hz
Voltage on 3 phase to be 415 Single phase volts =239-240 v
V
Voltage on single phase to be
240 V
Note load on each Genset
and voltages
9 Genset G2 is powered down and Genset G1 is Genset G1 is running on load Load & voltages are:
operating to a load of 198 KW. (75%) 198 KW without power
G1= _____ KW
interruption
Note load on Genset G1 and
Voltages 3-phase volts =____ v ___ Hz

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 Test Specification

Reference (auto populated)

Step Action Expected result Actual Result Pass or fail Failure action
If using a Test Procedure, enter just the test step reference. Leave this blank if using a Test Ensure that any deviations from the If test fails, reference of
Otherwise, state the actions to be performed. Also state the Procedure. expected result are listed, plus any CA, RM or QN raised, or
purpose of the test step, if it is not obvious. observations which may be significant. Pass Fail explanation of failure.
Single phase volts =_____ V
10 With G1 still set to 198 KW, Genset G2 has power Genset G2 should
restored synchronise and load share
with Genset G1. Half load so Load & voltages are:
that: G1= _____ KW
G1= 99 KW G2= ______ KW
G2= 99 KW 3-phase volts = ____V,___Hz
Voltage on 3 phase to be 415 Single phase volts =______V
V
Voltage on single phase to be
240 V
Note load on each Genset
and voltages
11 Pre-requisite Parameter set
Set Syncronisation parameter, that determines G1 is powered down G1 = ______ KW
when a second generator is required to share the
load, to 185 KW G2 is at 132 KW G2 = ________KW

Set sync panel so that it is on AUTO Sync Parameter is set to 185 3-phase volts = ____V,___Hz
KW
Power down Genset G1 Single phase volts =______V

Reduce load on Genset G2 to 132 KW

12 Genset G1 is powered down. The load is increase The synchronisation panel Actual load on load simulator
on Genset G2 to 185 KW (75%) automatically starts Gensetwas ____ KW
G1 and distributes the load Load & voltages are:
over the two generators. The
load across the twoG1= _____ KW
generators is evenlyG2= ______ KW
distributed.
3-phase volts =____v, __ Hz

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 Test Specification

Reference (auto populated)

Step Action Expected result Actual Result Pass or fail Failure action
If using a Test Procedure, enter just the test step reference. Leave this blank if using a Test Ensure that any deviations from the If test fails, reference of
Otherwise, state the actions to be performed. Also state the Procedure. expected result are listed, plus any CA, RM or QN raised, or
purpose of the test step, if it is not obvious. observations which may be significant. Pass Fail explanation of failure.
Single phase volts =_____ v

13 Pre-requisite G2 is powered down Load & voltages are:

Power down Genset G2 G1 is set at 163 KW G1= _____ KW
Reduce load on Genset G1 to 163 KW (62%) G2= ______ KW
3-phase volts =____v, __ Hz
Single phase volts =_____ v

14 Genset G2 is powered down. The load is increase The synchronisation panel Load & voltages are:
on Genset G1 to 185 KW (70%) automatically starts Genset 2 G1=_________ KW
and distributes the load over
the two generators. The load G2= __________ KW
across the two generators is 3-phase volts =___ V, ___ Hz
evenly distributed.
Single phase volts = _____V
G1= 92 KW
G2= 92 KW
Voltage on 3 phase to be 415
V
Voltage on single phase to be
240 V
Note load on each Genset
and voltages

15 Pre-requisites G1 is now master Load & voltages are:

Gensets G1 and G2 are both running Total load on the sync panel G1= ______ KW
is 280 KW

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 Test Specification

Reference (auto populated)

Step Action Expected result Actual Result Pass or fail Failure action
If using a Test Procedure, enter just the test step reference. Leave this blank if using a Test Ensure that any deviations from the If test fails, reference of
Otherwise, state the actions to be performed. Also state the Procedure. expected result are listed, plus any CA, RM or QN raised, or
purpose of the test step, if it is not obvious. observations which may be significant. Pass Fail explanation of failure.
Set Genset G1 to be Master control generator G1= 92 KW G2= _______ KW
Using the Electrical Load Simulator set the load so G2= 92 KW 3-phase volts = ____v, ___Hz
that the sync panel is at 185 KW. (50%)
Single phase volts =____V

16 Reduce KW load on synchronisation panel to Genset G1 has the total load Load & voltages are: PASS
below 132 KW (50%) of 132 KW
G1= ____ KW
Genset G2 is automatically
G2= _____ KW
shut down after a time of 5
minutes to dormant state and 3-phase volts =____V,___ Hz
has no load
Single phase volts =____V

17 Pre-requisites G2 is now master As stated, but exact load above PASS

Gensets G1 and G2 are both running Total load on the sync panel ____KW not recorded accurately
must be above 185 KW recorded at this step.
Set Genset G2 to be Master control generator
Using the Electrical Load Simulator set the load so
that the sync panel is at above 185 KW(70%)
18 Reduce KW load on synchronisation panel to Genset G2 has the total load Load was reduced to 261 which
below 132 KW (50%) of 132 KW was sufficient for the test and G1
shut down.
Genset G1 is automatically
shut down after a time of 5 Load & voltages are:
minutes to dormant state and
G1= ____ KW
has no load
G2= _____ KW
3-phase volts =____V,___Hz
Single phase volts =_____V

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 Test Specification

Reference (auto populated)

Step Action Expected result Actual Result Pass or fail Failure action
If using a Test Procedure, enter just the test step reference. Leave this blank if using a Test Ensure that any deviations from the If test fails, reference of
Otherwise, state the actions to be performed. Also state the Procedure. expected result are listed, plus any CA, RM or QN raised, or
purpose of the test step, if it is not obvious. observations which may be significant. Pass Fail explanation of failure.
19 Pre-requisites G1 is now master As stated, but exact load above
Extra Test using Load Simulator Total load on the sync panel ____KW not recorded accurately
is above 185 KW recorded at this step.
Gensets G1 and G2 are both running
Set Genset G1 to be Master control generator
Using the Electrical Load Simulator set the load so
that the sync panel is above 185 KW.(70%)
20 Extra Test using Load Simulator Genset G1 has the total load Load & voltages are: PASS
of 132 KW
Reduce KW load on synchronisation panel to G1= ____ KW
below 132 KW Genset G2 is automatically
G2= _____ KW
shut down after a time of 5
minutes to dormant state and 3-phase volts =____V,___Hz
has no load
Single phase volts =_____V

G1 took the load and G2 shut

down, but this was an extra test
on the day and KW were not
recorded.

21 Extra Test using Load Simulator At 24:01 G2 should start and G2 started and had ___ KW load,
G1 should shut down G1 shut down
G2 is set to be Master on a Saturday.
The time should be set to 23:55 on Friday with G1
having a load of 132KW

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 Test Specification

Reference (auto populated)

Step Action Expected result Actual Result Pass or fail Failure action
If using a Test Procedure, enter just the test step reference. Leave this blank if using a Test Ensure that any deviations from the If test fails, reference of
Otherwise, state the actions to be performed. Also state the Procedure. expected result are listed, plus any CA, RM or QN raised, or
purpose of the test step, if it is not obvious. observations which may be significant. Pass Fail explanation of failure.
22 Extra Test using Load Simulator At 24:01 G1 should start and G1 started and had ___KW load,
G2 should shut down G2 shut down
G1 is set to be Master on a Monday
The time should be set to 23:55 on Sunday (__
Dec. 2020) with G2 having a load of 200 KW

23 Extra Test using Load Simulator G2 shuts down and G1 is the G2 shut down
running as Master with a load
G1 set to Master, Load on Sync Panel is 183 KW, G1 = _____KW
of 132 KW
both Gensets are running. Load is then reduced to
132 KW

24 Power down both generators & disconnect Load No load on the As stated PASS
Bank. synchronisation panel
Power cables from Sync Panel to be connected to
the Two DB (TTTF & PMO)

25 Pre-requisites Connections made As stated PASS

Gensets 1 and 2 are connected to the
Synchronisation panel

26 Gensets are powered up and are operating as per Both buildings are being Both buildings were being PASS
their correct specifications. powered from the powered and in sync
synchronisation panel.
Loads on generators,
synchronisation panel are
within normal specifications
and each share half the total
load

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 Test Specification

Reference (auto populated)

Step Action Expected result Actual Result Pass or fail Failure action
If using a Test Procedure, enter just the test step reference. Leave this blank if using a Test Ensure that any deviations from the If test fails, reference of
Otherwise, state the actions to be performed. Also state the Procedure. expected result are listed, plus any CA, RM or QN raised, or
purpose of the test step, if it is not obvious. observations which may be significant. Pass Fail explanation of failure.
27 Final Power up of Buildings The sync panel shares the G1 = 165 KW PASS
combined load.
The buildings are connected to the Sync Panel and G2 = 163 KW
are energised. The PMO building, Pump, External
lights and TTTF is powered up (not racks)

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 Test Specification

2.1.3 Additional Test log

To be used for additional steps.
Reference (auto populated)
Step Action Expected result Actual Result Pass or fail Failure action
If using a Test Procedure, enter just the test step reference. Leave this blank if using a Test Ensure that any deviations from the If test fails, reference of
Otherwise, state the actions to be performed. Also state the Procedure. expected result are listed, plus any CA, RM or QN raised, or
purpose of the test step, if it is not obvious. observations which may be significant. Pass Fail explanation of failure.
1

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 Test Specification

REFERENCES AND RELATED DOCUMENTS

No. Title General Reference ACONEX Reference
1.
2.
3.
4.
5.
6.
7.
8.
Note 1: Versions of standards and legislation current at the Base Date apply. Current versions of standards may be used for
reference purposes only, until approval is provided by Project Change Control..

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 Test Specification

INTERNAL CROSS REFERENCES

No. Title Cross Reference ACONEX Reference
1

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