10-b - Edc-100003-11-Aa-Commissioning Manuals Compilation of Electrical Commissioning Instructions

ENGINEER’S STAMP: CONTRACTOR’S STAMP:
Signature
AA For Approval E. Hümmer W. Raffel M. A. Khan 08.03.2013

REV DESCRIPTION PREPARED CHECKED APPROVED DATE
KINGDOM OF SAUDI ARABIA ‫اﻟـﻤﻤـﻠـﻜــﺔ اﻟﻌــﺮﺑـﻴــﺔ اﻟﺴــﻌـﻮدﻳـــﺔ‬

‫اﻟﻤـﺆﺳــﺴــــﺔ اﻟﻌــﺎﻣــﺔ ﻟﺘﺤــﻠـﻴﺔ اﻟـﻤــﻴــﺎﻩ اﻟـﻤــﺎﻟــﺤــﺔ‬
SALINE WATER CONVERSION CORPORATION
‫ﻣﺤﻄﺔ ﺗﺤﻠﻴﺔ اﻟﻤﻴﺎﻩ اﻟﻤﺎﻟﺤﺔ وﺗﻮﻟﻴﺪ اﻟﻄﺎﻗﺔ اﻟﻜﻬﺮﺑﺎﺋﻴﺔ رأس اﻟﺨﻴــﺮ – اﻟﻤﺮﺣﻠـﺔ اﻻوﻟـﻰ‬
RAS AL KHAIR POWER AND DESALINATION PLANT-PHASE 1
PÖYRY ENERGY AG
CONSORTIUM
AL - ARRAB CONTRACTING COMPANY LTD
SEPCOIII ELECTRIC POWER CONSTRUCTION CORPORATION
PROJECT: TITLE:
31002
LOCATION:
Commissioning Manuals
East Coast
PACKAGE:
Compilation of Electrical Commissioning Instructions
“P” Power Plant
SCALE: DOCUMENT No.: REV:
None 10 - B _ _ - EDC - 1 0 0 0 0 3 - 11 AA
Engineer of Record Sheet 1
Document No.: Orig./Ref. Document No.: SAP Rev: SAP UNID

SA1905-10B__-EDC-100003 A 488931131
PACKAGE “P” POWER PLANT
RAS AL KHAIR POWER AND DESALINATION PLANT – PHASE 1
Subject: Commissioning Manuals Page 2 of 2
Doc No.: 10 - C O M - E D C - 1 0 0 0 0 3 - 1 1 Rev. AA
CONTENTS
1 Compilation of Phase B and C Commissioning Instructions
System/ Component Program code

KKS
Main Unit Protection Primary Test Procedure CI-B-702.1
2 Compilation of Standard Commissioning Instructions
System/ Component Program code

KKS
Black Start Diesel Generator Set (BSDGS) CI-E02
Testing of the Current and Voltage Transformers CI-E03
Testing of the Electrical Measuring and Metering Devices CI-E04
Main Unit Protection Secondary Injection Tests CI-E05
Emergency Diesel Generator Set (EDGS) CI-E07
Commissioning of Low-Voltage Transformers CI-E13
Power Transformers CI-E17
CONSORTIUM
AL - ARRAB CONTRACTING COMPANY LTD
SEPCOIII ELECTRIC POWER CONSTRUCTION CORPORATION
Inbetriebsetzungs-Anweisung Seitenzahl: 1 of 10
No. of Pages
Commissioning Instruction
Ras al Khair SA1905 10/11 9332 DZ070

Kraftwerk/Power Plant KW-Nr./Plant Code Block/Unit Inhaltskennnzeichen / Contents Code DCC Zähl-Nr./Reg. No.
Handhabung/Handling: For Internal Use Only

System/Titel:
System/Title CI-B-702.1 Main Unit Protection Primary Test Procedure
Table of Contents
1 Task
2 Preconditions
3 Precautions
4 Scope
5 Execution
6 Documentation/Evaluation
7 Appendices
Item Aktivität Referenz

Activity Reference
1. Task
In order to prove the integrity of the overall protection system in live operation it is
necessary to carry out primary tests with the running machine. Stability of differential
protection functions can only be verified by primary tests. Activation of the individual
protection functions during primary tests is in general not required for digital protection
systems.
*) Nicht zutreffendes
streichen Erstellt Erstellt/Geprüft*) Geprüft/Freigeg.*) Geprüft/Freigeg.*)
*) Delete as appropriate Prepared by Prepared/Verified by Verified/Released by Verified/Released by
Dienststelle
Department
Name
Name
Datum
Date
Unterschrift
Signature
Geändert: Geprüft/Freigegeben:
modified by: Reviewed/released by:
Rev. Name/Kurzzeichen Dienststelle/Firma Datum Fachabteilung, Ibs-Leitung, Projektleitung

Index Name/Signature Department/Company Date Techn. Department, Com. Management, Project Management
Verteiler:
Copies to
Siemens Sector Energy Transmittal, reproduction, dissemination and/or editing of this document as well as utilization Electrical Commissioning
of its content and communication thereof to others without express authorization are prohibited.
Fossil Power Generation Offenders will be held liable for payment of damages. All rights created by patent grant or
Energy Solutions registration of a utility model or design patent are reserved.
Inbetriebsetzungs-Anweisung: Seite: 2 of 10
Commissioning Instruction Page
CI-B-702.1 Main Unit Protection Primary Test Procedure

Activity Reference
2. Preconditions
2.1 Work status
· For all equipment under test an ECC has been issued

· All permit to work for the equipment under test to be withdrawn
· Secondary tests of protection relays including testing of peripherals (trips/incouplings)
completed
· The turbo set is ready for start-up
· The procedure has been co-ordinated with the load control centre
· Site telephone line links are available.
· A telephone connection to the load control centre is available
2.2 Documentation
· Circuit documentation of the generator/transformer protection equipment

· Logic diagrams of the relevant fault alarms
· Product manuals of all relevant protection devices
· Check lists of the secondary tests
· Protection relay setting study
· Printout of actual relay settings
2.3 Personnel
· 1 Commissioning engineer: Engineer or technician with experience in commissioning

of generator protection systems
· 1 Helper: Technician or skilled worker with suitable on the job training
2.4 Measuring instruments
· 1 Multimeter (A;V;Ohms)
· 3 Voltmeters
· 3 fuseless Ammeters
· Adjustable Resistor of approx. 10kOhm, 10W
3. Precautions
· Inspect all barriers (operational and additional)
. Relevant isolations must be established
· Install equipment to allow emergency de-excitation from the protection cabinet
· Energised current transformers may not be open circuited on their secondary side
· Implemented simulations have to be checked regarding their validity and their
influence on the required test conditions prior to performing this test.
Fossil Power Generation Offenders will be held liable for payment of damages. All rights created by patent grant or CI-B-702.1Main Unit Protection Primary
Energy Solutions registration of a utility model or design patent are reserved. Test Procedure.doc

Activity Reference
4. Scope
· Short circuit tests
· Earth fault tests
· Voltage tests
· Excitation tests (not part of this CI)
· Additional Voltage tests
· Synchronizing tests (not part of this CI)
· Load tests (after synchronisation)
· Evaluation of results.
5. Execution
5.1 Preparations, General
· Where not otherwise expressly specified, the tests are performed using the original
settings of the protection relays.
· Communication between protection cabinet and excitation cabinet installed (via head
phone set)
· Communication between protection cabinet and HV substation installed (if applicable)
· Communication between protection cabinet and CCR installed
· Emergency push button for de-excitation at CHA - cabinet installed on spare trip
channel
· Temporary settings applied where necessary
· MV supplies established via BAT and BBT transformers.
. Record all results (checklists –if available- and/or print-out of protection test device).
· The protection relay setting study of the engineering department shall be regarded
during the tests.
· The protection relay manuals shall be regarded
5.2 Short circuit tests
If the stability of the Generator differential protection has been verified during SFC tests, a
three phase short circuit test at the generator terminals is not required
If the stability of the Generator differential protection could not yet be verified, the test
described under 5.2.1 is advisable. If a three phase short circuit test is not reasonably
practical, the stability of the generator differential protection may be tested on load as
described under 5.8.

Activity Reference
5.2.1 Generator side three phase short circuit tests

分离发电机断路器隔离
bac01gs009 Preparations
·启动机组额定转速
·励磁机分离（mkc01 · Isolate Generator circuit breaker isolator BAC01GS009
· Start up of turbo set to rated speed
gt001）或左心室兴奋CB为 · Isolate Excitation Feeder (MKC01 GT001) or LV Excitation CB as installed
安装 · Close shorting link at *BAA01GS081 or BAC01GS081 as installed
· Set the voltage regulator to “Manual“ operation (block “Automatic“ operation).
·接近短路链接* · Put MV/LV excitation feeder in service (defeat of interlock necessary)
baa01gs081或bac01gs081
· Switch on excitation in manual mode ( field current 0A)
· Check emergency de-excitation from the protection cabinet
安装
·设定电压调节器“手动”操作
（块“自动”操作）。 Check of Current Transformer circuits
·把MV / LV服务激励馈线 · Check the remanence current (excitation off) in all Generator CT-circuits (protection,
（解除联锁需要） metering, measuring)
·开关在手动模式下励磁
（励磁电流0A） Test of individual protection functions
·检查应急de激发从保护柜Generator differential protection
· Block relay. (for redundant protection both relays)

· Disable Generator Transformer Differential Protection and Overall Differential
· Protection (if installed) preferably by shorting the generator current in front of the
relay.
增加励磁发电机的额定电· Increase excitation to 10% generator rated current; the protection relay should not
流的10%；继电保护不应 pick up. Record the values of differential and stabilising currents shown by the
该接。记录的微分值和稳 protection relay.
定的保护继电器的电流。
· Check indication of currents in all connected devices
增加励磁发电机的额定电流
为30%；继电保护不应该动
· Increase the excitation to 30% generator rated current; the protection relay should not
pick up. Record the values of differential and stabilising currents shown by the
作。记录的微分值和稳定的 protection relay.
保护继电器的电流。
· De-excite the generator.
· Unblock relay(for redundant protection both relays)

· Enable Generator Transformer Differential Protection and Overall Differential
· Protection (if installed)
· Isolate Excitation Feeder (MKC01 GT001) or LV Excitation CB as installed
· Open shorting link at *BAA01GS081 or BAC01GS081 as installed

Activity Reference
Generator transformer differential protection
· Further tests to be carried out under “5.8 Load tests ”.
5.3 Earth fault tests
5.3.1 Earth fault on generator side
· Install a single phase earth fault (L1-E) at *BAA01GS081 (i.e. by closing one phase
only) or by other suitable means
Note: The earth fault connection must be able to withstand the expected earth fault
current which is to be determined before commencing the test.
90% Stator earth-fault protection
· Block protection relay

块保护继电器
·确认继电器动作在非励 · Block protection relay
磁状态发生器。 · Confirm that the relay picks up with the generator in an unexcited state.
· Connect the 20Hz generator to an external supply; with the supply switched off.
·20Hz的发电机连接到 · Increase the generator voltage until 90% Stator earth-fault picks up.
外部电源与电源断开。
· Switch on supply to 20Hz generator. The relay picks up immediately
·增加发电机电压至90% Record all voltage values, line to earth and open delta winding
定子接地动作。 · Record ISEF at 10% to 20% of the displacement voltage
· De-excite generator
· Unblock protection relay of 100%SEF
· Unblock protection relay of 90%SEF
Post test activities:
· Isolate MV excitation feeder or LV Excitation CB as installed

· Remove earth fault by opening *BAA01GS081
End of earth fault test

Activity Reference
5.4 Voltage tests
Preparations
· Set the voltage regulator to “Manual“ operation (block “Automatic“ operation).

· Put MV excitation feeder or LV Excitation CB as installed in service
· Switch on excitation ( field current If=0[A])
Check of VT circuits
· Increase generator voltage to 30% generator rated voltage

· Check indication of voltages in all devices with voltage measuring
· Check indication of phase sequence in all devices with voltage measuring
· Check indication of frequency in all devices with voltage measuring
· Increase generator voltage to 100%

· Repeat check of voltages
· De-excite the generator
Stator Earth fault protection 90%
· Record the displacement voltage on rated voltage and no load
· Record the earth resistance values on rated voltage and no load
Rotor Earth fault protection
· Block relay
· An earth fault is simulated via a resistor of approximately 90% of the trip
resistance.The resistor is placed in machines with excitation via slip rings between
one slip ring and earth.
· Excite Generator to the rated voltage
· Check the operational measured value Rearth and the pickup indication· („REF 1-
3Hz Fault“) and, after T-TRIP-RE<< (10 s on delivery) has expired, check the trip
indication („REF 1-3Hz Trip“).
· Set the resistance to approx. 90 % of the warning stage (RE< WARN).read out the
operational measured value „Re =“, and check the warning message („REF 1-3Hz
Warn“). If there is heavy interference from the excitation system, it may be necessary
to reduce the resistance set for the warning threshold.
· Remove the earthing resistor and check the operational measured values as well as
the measuring circuit supervision „REF 1-3Hz open“ under fault-free conditions. If
spontaneous indications are issued by the measuring circuit monitoring, reduce the
pickup value (Qc <) or deactivate the monitoring.
· For generators with excitation via slip rings, repeat test on the other slip ring.
· Deexcite generator.

Activity Reference
· Remove earth fault resistor.

· Activate the rotor earth fault protection: REF 1-3Hz = ON .
Post test activities
· Normalise all temporary settings (if applied)

· All protection and trip circuits must be enabled
5.5 Excitation tests
· On completion of the voltage test runs the voltage regulator can be released for
· optimisation in ”MANUAL” and „AUTOMATIC“ mode in accordance to
· Commissioning Instruction CI-B-703 (Excitation and Automatic Voltage Regulator
(AVR)Test Procedure).
5.6 Additional Voltage tests
Overvoltage protection
· Excite generator to maximum voltage limit in “AUTOMATIC” mode

· Determine the margin between highest phase voltage and protection setting
· Criteria: (U>set/Umax -1 ) x100% >3%
Overexcitation protection
· Excite generator to maximum voltage limit in AUTOMATC

· Decrease frequency to lower limit
· Determine the margin between excitation and protection setting
· Criteria: (U/f>set / U/f - 1 ) x100% >1 %
Frequency protection
· Excite generator to rated voltage

· Decrease frequency to lower limit
· Determine the margin between frequency and protection setting
· Criteria (f /f<set -1) x100% >0.5%
· Decrease frequency to upper limit
· Determine the margin between frequency and protection setting
· Criteria (f>set /f -1) x100% >0.5%
5.7 Synchronizing Tests (refer to CI-B-701.2)

Activity Reference
5.8 Load tests
Generator differential protection (Only required if no short circuit tests described

under 5.1.2.2 have been carried out)
· On-load measurements straight after first synchronisation of the unit will prove the
stability of the differential protection.
· Therefore, co-ordinate with the GT commissioning engineer the load jump after first
synchronisation. Ensure the load level after first synchronisation is below the trip
value of the differential protection.
· Ensure generator current is sufficient to prove stability and correct function.
· Measure and record voltage, load, earth and stabilising currents for the relevant
protection relays.
· Increase excitation to 10% generator rated current; the protection relay should not
pick up.
· Check indication of currents in the protection device
· Check indication of currents in Generator Transformer differential protection device
· Increase the excitation to 30% generator rated current; the protection relay should not
pick up.
· Record the values of differential and stabilising currents shown by the protection
relay.
· Normalise all temporary settings (if applied)
Generator transformer differential protection
· On-load measurements straight after first synchronisation of the unit will prove the
stability of the differential protection.
· Ensure generator current is sufficient to prove stability and correct function.
protection relays.
Unit auxiliary transformer differential protection
· On-load measurements on energisation of large consumers (i.e. feedwater pump

motor, cooling water pump motor) will prove the stability of the differential protection.
· Co-ordinate with the mechanical commissioning engineers the energisation of such
consumers.
· Ensure the load level is below the trip value of the differential protection.
· Ensure current is sufficient to prove stability and correct function.
protection relays.
Underexcitation protection
· Verify correct measurement and polarity of active and reactive power by comparing
the measured values of the I&C System and the protection relay.
· By reducing the generator voltage or operation of the generator transformer OLTC
check underexcitation limiter in excitation, no protection alarm should occur
· Pick up of protection function is not required if secondary testing has been completed

Activity Reference
Out-of-step protection
· Check direction on load by recording active load, reactive load and impedance
· Record load point in R/X diagram
Reverse power protection for ST
· Confirm during generator operation that the measured power is positive and plausible
· Adjust reactive power to approx. Q= 0MVA
· Block reverse power protection (both relays in case of redundant protection)
· Close the control valve fully by reducing the setpoint of the turbine controller;
determine smallest value of reverse power
Caution!
Operating the turbine without a minimum steam throughput (cooling effect) can cause
the turbine blades to overheat!
Input of reverse power is admissible with a turboset only for a short period.
The test must be coordinated with the responsible turbine engineer
· Record active Power P0 and reactive power Q0

· Increase reactive power to approx. 30% of rated apparent power of generator
(overexcited)
· Decrease reactive power to approx. 30% of rated apparent power of generator
(underexcited)
· Adjust CT correction angle
· Increase reactive power to approx. 0 MVA
· Trip value to be adjusted to ¼ (P1+P2)
· Unblock relay
· The relay picks up and turbine shuts down
Reverse power protection for GT (also applicable for Single Shaft )
· Confirm during SFC operation that the measured power is negative.

· Compare measured active power in the protection relay with the measured active
power in the I&C system.
· The activation of the reverse power protection on line is for gas turbines in general
not required.
Impedance protection
· Carry out a direction check on load with minimum 30% relay current
· Record measured resistance and reactance

Activity Reference
Stator Earth fault protection 100%
· Record the stator earth current and earth resistance values on load
Unbalanced Load protection
· Record the Negative Sequence Current I2 during load operation with minimum 50% of
rated current
· Calculate the unbalanced load I2/In extrapolated to In The unbalanced load should be
negligable (<5%)
Overcurrent protection
· Record phase currents during full load operation

· For directional overcurrent, check correct detection direction
· Check for sufficient margin to trip value
Thermal Overload Protection (Located in I&C)
· Record phase currents and temperature of cooling medium during full load operation
· Check for sufficient margin to trip value
6. Documentation/Evaluation
6.1 Documentation
· Refer to commissioning checklists.
6.2 Evaluation
· Compare measured results with protection relay setting study of engineering
department.
· Where necessary, amend settings after confirmation of engineering department.
· Where applicable, prepare/print off graphs and/or calculate values to support the
evaluation.
· Refer to relay manual.
7. Appendices
· None
Commissioning Instruction No. of Pages
STANDARD
Ras al Khair SA1905 10/11 9332 DZ070


System/Titel:
System/Title CI-E02 Black Start Diesel Generator Set (BSDGS)
Table of Contents
1 Task
2 Preconditions
3 Precautions
4 Scope
5 Execution
6 Documentation
7 Appendices

Activity Reference
1. Task
Commissioning of black start diesel generator unit itself and black start diesel generator
unit in an overall plant configuration.
NOTE: CI-E02 is valid for containerized and pre-tested units only!

Check with engineering department whether the BSDGS units have been
load tested at manufacturers works.
Dienststelle
Department
Name
Name
Datum
Date
Unterschrift
Signature

Verteiler:
Copies to
registration of a utility model or design patent are reserved.
Energy Solutions
STANDARD
CI-E02 Black Start Diesel Generator Set (BSDGS)

Activity Reference
2. Preconditions
NOTE: For the black start diesel generator function more than one diesel
generator is required (check overall SLD).
NOTE: No synchronizing of more than one BSDGS in test operation!

Check with engineering department.
2.1 Work status

- Erection has been completed for plant equipment involved.
- All checks in accordance with the Diesel-Gen-Set FQP are completed.
- The Erection Clearance Certificate [ECC] has been issued.
- Affected switchgears are in operation.
- All supply feeders have been checked.
- BSDGS has been workshop tested.
- Station in-house power supply is available.
- Closed cooling water system available.
- Air pressure equipment available (if applicable).
2.2 Documentation
- Circuit diagrams of black start diesel generator set.
- Logic diagram of diesel generator control.
- Product manuals of all affected equipment.
- Circuit diagrams of related switchgears.
- Commissioning checklists of related equipment/cables.
- Workshop test certificates/results.
- Settings for control and protection devices (manufacturer instruction/engineering
department).
2.3 Personnel
- 1 Commissioning engineer: qualified electrical engineer with experience in
commissioning of generator sets.
- 1 Helper: skilled worker who has received suitable training.

- secondary test device
- insulation resistance tester
- single-knob measuring bridge
- multimeter (A,V,Ohm)
- phase sequence indicator
- current injector
3. Precautions
- Observe standards for "Erection and operation of power installations".
- Before operating a synchronizing CB a local inspection shall be done.
Energy Solutions
STANDARD

Activity Reference
4. Scope
- Visual checks
- BSDGS tests
- Control centre
- Generator / Generator circuit breaker
- Cables
- Interface
- Sensors
- CT circuits
- Interlock
- Check of electrical protection circuits
- Synchronising equipment
- Initial start up
- Load tests / operation modes
5. Execution
NOTE: Since the BSDGS is a pre-assembled and tested component, workshop tests will
not be repeated on site. A list with workshop tests is available in the product
manual. IT IS MANDATORY TO OBSEREVE THE MANUFACTURER
INSTRUCTION.
NOTE:
Diesel engine supervisor shall be called to site when the tests have 5.1, 5.2.1 to
5.2.10 (including) have been performed successfully. Inform engineering department
of the anticipated date when above works are completed.
Tests 5.2.11 to 5.2.12.c) shall be performed in cooperation with the diesel engine
supervisor.
5.1 Visual Checks

The following visual inspection shall be carried out:
- correct labelling of devices and cables
- devices and cables are undamaged
- correct cable terminations (arcing distance)
- correct sealing of cable entries in terminal boxes and switchgears
- correspondence between rating plate data and design data
- correct protective conductor and grounding connections
5.2 BSDGS tests
5.2.1 BSDGS control centre
5.2.1.1 Incoming feeder

- switch off all incoming circuit breakers
- isolate starter battery charger (if applicable)
- switch on three phase AC supply feeder
- check voltage and phase sequence at incoming terminals
- switch on relevant circuit breaker
- switch on single phase AC supply feeder (if applicable)
- check voltage at incoming terminals
Energy Solutions
STANDARD

Activity Reference
- switch on DC supply feeder (if applicable)

- check indications on control panel for no faults
- check voltage of starter and control battery (if applicable)
- check function of battery chargers (if applicable)
5.2.1.2 Check of control centre functions

- air conditioning/ventilating system (if applicable)
- light & power sockets
- emergency lighting
- fire detection
- cooling water temperature (approx. 40°C) is achieved one day after energisation.
5.2.2 Generator
An insulation test for the stator and rotor windings of the generator shall be done, if no
manufacturer test certificate is available.
5.2.3 BSDGS generator circuit breaker (XKAxxGS001)

Commission the BSDGS generator circuit breaker (refer to CP-E18).
5.2.4 Power and control cables installed on site

Power and control cables shall be checked in accordance with the relevant checklists.
5.25 Commissioning of signal interface to I&C and commands from and to

BSDGS control centre
The signal interface to the I&C system shall be tested according to the relevant
drawings/logic diagrams.
All commands from and all feedbacks to the BSDGS control centre shall be checked (test
position of circuit breakers).
5.2.6 BSDGS sensors

BSDGS sensors (i.e. temperatures, limit switches) have undergone workshop testing.
Check indications for plausibility.
5.2.7 Commissioning of current transformer (CT) and CT circuits

Voltage and current transformer and voltage and current transformer circuits shall be
tested according to the relevant commissioning instructions (CI-E03).
Compare current transformer data of generator star point side and switchgear side. The
data shall be identical.
This test can be combined with test 5.2.9.
5.2.8 Interlock Tests

Interlock tests according to the drawings of the affected switchgears shall be done. Special
attention must be paid to the closing and re-closing interlocks of all incoming feeders of the
emergency switchgear.
To perform the interlock tests, the relevant circuit breakers must be brought to "TEST
POSITION".
Energy Solutions
STANDARD

Activity Reference
5.2.9 Test of electrical protection circuits

Check settings of protection and control equipment (reference: settings for control and
protection devices).
After test of the CT circuits (5.2.7), inject a current on the primary side of each CT (phase
and star point side) with sufficient magnitude to be indicated on the protection relay. Verify
correct indication.
The results are to be recorded in the relevant checklists .
In order to check the entire trip circuit from the BSDGS to the relevant circuit breaker,
initiate trip commands on the protection relay of the EDGS. Verify correct opening of
BSDGS generator circuit breaker.
Check of emergency stop of the diesel generator engine.
5.2.10 Test of synchronising equipment

The synchronising equipment shall be tested in accordance with the relevant manufacturer
instruction and commissioning instruction “Synchronising Equipment” and the relevant
“Synchronising Procedure”.
5.2.11 Initial start up/synchronising
NOTE: Only one generator shall be operated when synchronized with the grid!
In coordination with the mechanical engineer start up the BSDGS. Manufacturer

instructions shall be observed.
Excite the generator and check for correct phase sequence and voltage level. Local and
remote indications to be checked.
Perform synchronising checks (refer to commissioning instruction “Synchronising
Procedure for Plants with Generator Circuit-Breaker”) and synchronise generator to the
grid.
5.2.12 Load tests and test of operating modes

a) After initial synchronising load generator by raising the load set point. Leave
generator at low load (but sufficiently high to register on the relay -> approx. 10% of
full load current) and verify protection relays read/indicate currents/voltage correctly
(i.e. diff. protection stable). Record results (checklists).
b) Raise load set point to full load and verify again relays read/indicate currents/voltage
correctly. Record results (checklists).
c) Reduce load set point until BSDGS trips via reverse power. Record results
(checklists).
d) Automatic start of BSDGS with parallel operation (loading and unloading; trip the
BSDGS by one electrical protection function). Record results (chart recorder ->
BSDGS voltage, current and speed). Optimise settings where/if required. Consult
electrical engineering department where/if required. Observe BSDGS sensor
indication (i.e. temperature rise).
Energy Solutions
STANDARD

Activity Reference
e) Function emergency diesel generator

Perform mains failure function test to verify that the BSDGS and the BSDGS
automatic programme is functioning according to design. Verify that the MV busbar
voltage is not less than rated voltage. Record results (chart recorder -> BSDGS
voltage, current and speed). Optimise settings where/if required. Consult electrical
engineering department where/if required.
f) Parallel operation of several BSDGS units

Without grid start first BSDGS unit and supply MV switchgear, load the BSDGS by
process consumers.
Start second BSDGS unit and synchronise to MV switchgear. Check stable parallel
operation (frequency, voltage, active and reactive power).
Start further BSDGS units and synchronise them, see above
g) With the BSDGS units supplying the MV switchgear only, start and stop the drive or
drive group with the highest kW rating in emergency operation for verification of
• speed controller (check behaviour and compare with under-/overfrequency

detection settings)
• differential protection setting (in-rush detection and stabilising function)
• voltage controller (check behaviour and compare with under-/overvoltage
detection settings on protection relay and switchgear)
Record results (chart recorder -> BSDGS voltage, current and speed). Optimise
settings where/if required. Consult electrical engineering department where/if
required.
h) Function black start diesel generator

Initiate power plant unit black start by automation system.
Check sequence of BSDGS units, their synchronizing, MV voltage and frequency,
active and reactive power on individual BSDGS units, when sequentially loaded by
the process systems (especially during SFC operation )
Send test results (d, e, f, g, h) to electrical engineering department.
6. Documentation
- Commissioning Procedures
- Checklists
- Charts
- List of final settings
7. Appendices
- None -
Energy Solutions
STANDARD
Ras al Khair SA1905 10/11 9332 DZ070


System/Titel:
System/Title CI-E03 Testing of the Current and Voltage Transformers
Table of Contents
1 Task
2 Preconditions
3 Precautions
4 Scope
5 Execution
6 Documentation
7 Appendices

Activity Reference
1. Task
The measuring circuits for protection, synchronisation, closed-loop control and operational
instrumentation are to be tested.
Dienststelle
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Signature

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STANDARD
CI-E03 Testing of the Current and Voltage Transformers

Activity Reference
2. Preconditions
2.1 Work status

· Erection has been completed. (The Erection Clearance Certificate [ECC] has been
issued.)
· Labelling of the equipment and designation of live enclosed plant sections has
been carried out.
2.2 Documentation
· The circuit diagrams of the electrical equipment cabinets are available
· Commissioning checklists CL-E21 and CL-E22
2.3 Personnel
of types of the electrical equipment systems employed in the plant.
· 1 Helper: skilled worker with adequate on-the-job training.
2.4 Measuring instruments and tools

· Single-phase variable-voltage transformer (approx. 0 - 20 V secondary voltage),
· Single-phase test transformer (approx. 400 V secondary voltage),
· 1 Ammeter (AC),
· 1 Voltmeter (AC),
· Multimeter (A, V, Ohms).
3. Precautions
· Observe the rules for handling electronic components sensitive to electrostatic
discharge (ESD measures).
· The VDE Regulations for ”Erection and Operation of Electrical Power Installations”
are to be observed (VDE 0100/0101/0105).
· Special safety arrangements shall be made for all areas which are not explicitly
designated as ”electrical operating areas” when performing tests at voltages in
excess of 50 V.
4. Scope
· Testing of the plant side cable connections,
· Checking that the mounting position is correct,
· Checking of the phase and core assignment,
· Checking of correct earthing,
· Checking of the function.
5. Execution
5.1 Visual checks

· Checking of the cables for damage and that they are connected correctly,
· Checking of the mounting position of the current transformers (polarity),
· Checking of the labelling of the individual cores, checking of the phase/core
STANDARD

Activity Reference
assignment
· Inspection for cleanliness of voltage transformers, high voltage connections and
associated cable connections
· Inspection of isolators, support structures and earthing connections
5.2 Testing the current transformers
Testing by secondary injection
· Secondary spare cores have to be short -circuited

· In the case of multi core type current transformers each winding must be tested
individually.
· Enter the rating plate data in check list CL-E22 and compare the current transformer
data with the data contained in the circuit documentation.
· Where additional tests have been specified in the contract for current transformers
which were not tested at the manufacturer’s works, special testing equipment is
required.
· The burden in each core of each phase is determined by injection
of a current of 1 A at the secondary CT terminals (or 5 A as appropriate) in the
direction of the load and measurement of the voltage with respect to earth
The measured burden should be compared with the rated data of the current
transformer. The residual current of the current transformer can be neglected,
i.e. there is no need to open the current transformer terminals.
Testing by primary injection:
· Injection of a primary current and measuring of the secondary current in each winding
Record the values in CL-E22 and verify the CT ratio.
5.3 Testing of the voltage transformers

· Enter the rating plate data in check list CL-E21 and compare the voltage transformer
data with the data contained in the circuit documentation.
· Disconnect the primary-side connections at a suitable location and apply a voltage of
approx. 400 V AC to the primary side.
· Measure the primary and the secondary voltage at all connection points.
· Application of a single-phase voltage for determination of the phase, the phase
sequence and for verification of earth-fault detection (e-n winding).
· Test the mechanical stability of the secondary-side earth connection.
5.4 Checking the protective earthing

Current and voltage transformers must be earthed on the secondary side in order to
afford protection to human beings. In order to avoid circulating currents such earthing
is permissible at one point only of a galvanically connected system. (In the case of
physical separation of the phases the three earthing points should be regarded as
being one earthing point.)
· Meeting of both requirements is verified by opening the earthing link and checking
the isolation of the circuit to earth (by Ohmmeter, Megger or voltage source)
Subsequently the earth connection is to be restored.
STANDARD

Activity Reference
6. Documentation
A check list CL-E21 or CL-E22, as the case may be, is to be completed for each set of
instrumentation transformers. In the case of cascade-type voltage transformers a
separate check list is required for the top element.
7. Appendices
- None -
STANDARD
Ras al Khair SA1905 10/11 9332 DZ070


System/Titel:
System/Title CI-E04 Testing of the Electrical Measuring and Metering Devices
Table of Contents
1 Task
2 Preconditions
3 Precautions
4 Scope
5 Execution
6 Documentation
7 Appendices

Activity Reference
1. Task
The function of the measuring and metering equipment is to be tested.
Messungv *) Nicht
zutreffendes streichen Erstellt Erstellt/Geprüft*) Geprüft/Freigeg.*) Geprüft/Freigeg.*)
Dienststelle
Department
Name
Name
Datum
Date
Unterschrift
Signature

Index Name/Signature Department/Company Date Techn. Department, Com. Management, Project
Management
Verteiler:
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Energy Solutions
STANDARD
CI-E04 Testing of the Electrical Measuring and Metering Devices

Activity Reference
2. Preconditions
2.1 Work status

· Erection has been completed. (The Erection Clearance Certificate (ECC) has been
issued.)
· Labelling of the equipment and designation of live enclosed plant sections has been
carried out.
· Testing of the current and voltage transformers as per standard commissioning
instruction CI-E03 has been completed.
2.2 Documentation
· The circuit diagrams of the electrical equipment cabinets are available.
· The I&C equipment, the alarm printer and the control console are ready for service.
· The relevant logic diagrams and circuit diagrams are available for the I&C equipment.
. The product manuals are available for the types of equipment employed in the plant
· Commissioning checklist CL-E20
2.3 Personnel
of the type of electrical equipment systems employed in the plant.

· Three-phase secondary testing device (with current and voltage section),
· Multimeter (A, V, Ohms).
3. Precautions
· Observe the rules for handling electronic components sensitive to electrostatic
discharge (ESD measures).
· The VDE Regulations for ”Erection and Operation of Electrical Power Installations” are
to be observed (VDE 0100/0101/0105).
· Special safety arrangements shall be made for all areas which are not explicitly
designated as ”electrical operating areas” when performing tests at voltages in
excess of 50 V
4. Scope
· Checking of the technical data,
· Testing of the functions,
· Testing of the remote indications,
· Testing of the fault alarm signals.
5. Execution
5.1 Visual checks

· Check the cables for damage and that they are connected correctly.
· Compare the technical data of the measuring instruments and meters with the
Energy Solutions
STANDARD

Activity Reference
data contained in the circuit documentation
5.2 Testing of current, voltage and frequency measurements

· Injection of current or application of voltage as per the rated instrument transformer
data.
Important: Disconnect the voltage transformer. Voltage should not be fed into the primary
circuit of voltage transformers!
· Test the output signals of the measuring equipment and the indications at the cabinet,
in the I&C equipment and at the control console.
· Restore the equipment to its original condition.
5.3 Testing of the active and reactive power measuring equipment and meters
· Feed in a three-phase current and a three-phase voltage.
Important: Disconnect the voltage transformer, voltage should not be fed into the primary
circuit of voltage transformers!
· Employ a zero phase angle: The active power meter should be operating and the
reactive power meter should be at a standstill.
· Employ a phase angle of 90°: The active power meter should be at a standstill and the
reactive power meter should be running.
· Test the output signals of the measuring equipment and the indications at the
cabinet, in the I&C equipment and at the control console.
5.4 Testing the phase angle measurement

This test should be performed employing the same measuring circuit as that employed for
point 5.3.
· Phase angle 0°: Indication cos Φ = 1.

· Phase angle +60°: Indication cos Φ = 0.5.
· Phase angle -60°: Indication cos Φ = -0.5.
· Restore the equipment to its original condition
6. Documentation
The activities performed and any modifications made are to be documented in the circuit
documentation.
An individual check list CL-E20 is to be completed for each device.
Energy Solutions
STANDARD

Activity Reference
7. Appendices
- None -
Energy Solutions
Ras al Khair SA1905 10/11 9332 DZ070


System/Titel:
System/Title CI-E05 Main Unit Protection Secondary Injection Tests
Table of Contents
1 Task
2 Preconditions
3 Precautions
4 Scope
5 Execution
6 Documentation
7 Appendices

Activity Reference
1. Task
The purpose of the secondary tests is to ensure the functional integrity and the correct
operation of the protection system according to the design.
Dienststelle
Department
Name
Name
Datum
Date
Unterschrift
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Offenders will be held liable for payment of damages. All rights created by patent grant or
Fossil Power Generation registration of a utility model or design patent are reserved.
Inbetriebsetzungs-Anweisung: Seite: 2 of10
STANDARD
CI-E05 Main Unit Protection Secondary Injection Tests

Activity Reference
2. Preconditions
2.1 Work status

· The incoming auxiliary supplies for the protection cabinets (AC and DC) are available.
· Erection work in the region of the current and voltage
transformers has either been completed or is presently not in progress.
· The alarm annunciation system is ready for operation.
2.2 Documentation
· Circuit documentation of the generator protection equipment.
· Logic diagrams of the relevant fault alarms.
· Product manuals of all relevant protection devices.
· Protection relay setting study of engineering department
2.3 Personnel
of the types of protection devices employed in the plant.
· 1 Helper: Technician or skilled worker with adequate on-the-job training.
·· Three-phase secondary test set,

Multimeter A,V,Ohm
DC source (up to 10 A).
Adjustable Resistor of approx. 10kOhm, 10W
3. Precautions
· The VDE Regulations for „Erection and Operation of Electrical Power Installations
with rated voltage up to 1000 V“ (VDE 0100/0105) shall be observed.
· The rules for handling electronic components sensitive to electrostatic discharge
(ESD measures) shall be observed.
· Designation and locking of external plant sections, which are used for protection
purposes, must be checked prior to commencing work.
· If applicable, the voltage transformers must be short-circuited and earthed on the
primary side, the secondary-side MCB is to be opened
4. Scope
· Setting and testing of the relays,
· Checking of the interface signals,
· Checking of the tripping channels.
· Current Transformer and Voltage Transformer circuit testing (Not part of this CI)
STANDARD

Activity Reference
5. Execution
5.1 Testing of the relays
NOTE: Some of the protection functions might not be applicable for individual projects.
These deactivated functions will not be tested by secondary injection.
5.1.1 General
· Before commencing the tests the technical data of the relays should be noted as per
the relevant device cover sheet.
· All tests performed are to be documented in the corresponding check lists or by using
print outs of the protection software.
· The tests are to be carried out at the specified settings (if possible).
· Testing is to be carried out in an overlapped manner up to and including the trip
channels; if other commissioning activities are hindered by testing of the tripping
channels, the corresponding tripping channels have to be blocked.
· The relays should be injected at the input terminals of the cabinet, the response
values are to be documented in the corresponding check lists or by using print outs of
the protection software.
· The current circuits can withstand a continuous current of up to 4 x In and the voltage
circuits up to 2 x Un. Unnecessary use of the full overload capability should be
avoided.
· On completion of the tests all simulated signals must be removed and the equipment
must be restored to its original condition.
5.1.2 Setting values

The relays should be initially set to the values contained in the Protection relay setting
study of engineering department. Where not otherwise expressly specified, the tests
should be carried out using these relay settings.
5.1.3 Secondary tests
-Generator differential protection
· Connect the secondary test set to the input terminals of the starpoint current
transformers.
· Inject a test current into phase L1.
· Steadily increase the test current until the relay picks up, document the tripping
current.
· Measure the tripping time for an injected current of In.
· Repeat the procedure for phases L2 and L3 as well as for the three phases of the
generator line-side current transformers.
· Record the results.
STANDARD

Activity Reference
- Restricted earth fault protection
· Connect the secondary test set to the input terminals of the current transformers
· Steadily increase the test current until the relay picks up, document the tripping
current.
- Transformer/cable differential protection
· Connect the secondary test set to the input terminals of the HV current transformers.
· Steadily increase the test current until the relay responds, document the tripping
current.
· Repeat for all phases and for all sets of current transformers.
- Generator/ Transformer overcurrent protection
· Inject a single phase input to phase L1 of the relay.

· Increase the current until the relay picks up.
· With an input of 1.1 times the set point measure the tripping time.
· Repeat for phases L2 and L3.
- Unbalanced load protection
· Connect the secondary test set to the input terminals of the current transformers
· Inject a three phase current with swapped phases (alternatively a single phase test
can be performed )
The minimum test current required is calculated as follows:
(three phase) Itest = setting value x rated current / 100%

(single phase) Itest = √3 x setting value x rated current / 100%
Example: rated current 1A, setting value I2 > warn = 10%
(three phase) Itest = 10% x A / 100% = 0.1A

(single phase) Itest = √3 x 10% x A / 100% = 0.173A
STANDARD

Activity Reference
· Testing of the warning stage
· Testing of the definite –time trip stage
· Testing of the thermal replica:
Before commencing each test the thermal preloading of the relay must be cancelled
(refer to protection relay manual).
· Inject 2 test currents in the range between the maximum permissible continuous
unbalanced load (I2> warn setting ) and the independent trip stage (I2>> trip setting ).
· Document the measured values and compare to the calculated values; calculation
according to protection relay manual.
· When testing one phase at a time it is necessary to divide the injected current by
three in order to calculate the tripping time.
· Repeat for all phases (single phase test only)
- Impedance protection
· Connect the three-phase secondary test set to the input terminals for the 3 current
and 3 voltages at the cabinet.
· Without any voltage being applied, steadily increase the test current for phase L1,
noting the value at which the relay picks up. Repeat for the other phases.
· Inject a three-phase test current of 2 A.

· Determine the voltage at which changeover for long-time to short-time tripping occurs
for various values of power factor.
· Measure the tripping times.
- Underexcitation protection
· Connect a three phase 100 V supply to the relay input.

· At cos phi = 0 leading, inject a three phase test current until the relay picks up.
Record this value and repeat for a second power factor value.
· Repeat the above procedure for the other two characteristics
· Measure and record the tripping times of the 3 characteristics below and above
excitation voltage limit. Record excitation voltage limit value
· Record the results in Commissioning Checklist and the generator capability diagram.
- Reverse power protection
· Connect a three phase 100 V supply to the relay input.

· At cos phi = -1 slowly increase the current until the relay picks up
· Test the tripping delay with and without the emergency stop signal. Where necessary,
simulate the emergency stop signal in the protection cabinet.
STANDARD

Activity Reference
- 90% Stator earth-fault protection
· Apply a single-phase voltage at the relay input terminals

· Steadily increase the voltage until the relay responds.
· Measure the response value and the tripping time.
- 100% Stator earth-fault protection
DANGER: When the 20Hz generator is energised, voltage on the generator will appear!
The external 20 Hz bias voltage of the stator winding must be isolated before
commencing work on the generator at standstill.
The 100-% stator earth fault protection can be checked with the machine at standstill,
because the measuring principle for the earth resistance calculation is independent of
whether the machine is at standstill, rotating or excited. A prerequisite is, however, that
the 20 Hz generator 7XT33 must be supplied with a DC voltage or an external voltage
source
· Switch the 100-% stator earth fault protection toBlock relay).
· Under fault-free conditions (RE infinite) the measured current must be negative due to
the capacitive current. If it is not, the connection at the current input must be rotated.
The phase angle „ φSEF=“ should be about –90° due to the existing stator
capacitances. If it is not, the value to complement it to –90° must be determined and
set as PHI I SEF = –90° – φSEF. For a display value of e.g. „ φSEF =“ –75° PHI I SEF = –
15° is set. This will change the measured value to approx. –90°. The value displayed
for R SEF must be in fault-free condition the maximum possible value of 9999 . The
maximum value for the primary earth resistance R SEFp depends on the selected
conversion.
· A short-circuit (RE = 0 ) is created in the generator starpoint, and the measured fault
resistance (address „R SEF=“) read out from the operational measured values. This
resistance is set at SEF Rps.
· Insert now on the primary side a resistance which corresponds to the tripping value
(e.g. 2 k). Check the measured fault resistance („R SEF=“). If this resistance differs
very much from the value expected, modify SEF Rps accordingly and, if necessary,
make a fine adjustment with the correction angle (PHI I SEF). Read out finally the fault
resistance, and set this value as the tripping threshold at R<< SEF TRIP.
· Next, insert a fault resistance for the alarm stage (e.g. 5k on the primary side, and
read out the fault resistance („R SEF=“) from the operational measured values. This
value is set as R< SEF ALARM.
STANDARD

Activity Reference
· Switch off the voltage supply for the 20 Hz generator, or block the binary input. The
indication „SEF100 Failure“ will appear. This ensures that a failure of the 20 Hz
generator is reliably detected. If this indication occurs already with the 20 Hz generator
in operation, the monitoring threshold should be reduced. This can be the case if the
loading resistances are very small (< 1 ).
· Finally, a series of measurements is performed, starting with 0 k and proceeding in

steps of 1 k . If changes are made to the correction angle or to the contact resistance,
the settings for the trip stage (R<< SEF TRIP) and the alarm stage (R< SEF ALARM)
must be matched as required.
· Now the earth resistance is reduced to about 90 % of the resistance for the alarm
stage. After the delay time T SEF ALARM (10.00 s on delivery), the stator earth fault
protection issues an alarm.
· Further reduce the earth resistance to 90 % of what the trip stage pickup value would
be for the protection device. The protection issues a pickup indication and after T SEF
TRIP a trip indication.
· Remove the test resistor.
· Unblock Relay
- Rotor earth-fault protection
· Switch the Rotor earth fault protection to Block relay).
· Apply a 100 V AC auxiliary voltage to the input to the square wave generator located in
the panel.
· Apply a dead earth fault between one slip ring and earth. The device now measures as
earth impedance only the reactance of the coupling unit and the brush resistance (as
the case may be in series with a protection resistor for the coupling capacitors and a
current-limiting resistor with inductive/capacitive coupling). These values can be read
out with the phase angle of this complex resistance under the earth fault measured
values:
· Rtot = x.xx k
· Xtot = y.yy k
· φZtot = z.z °
STANDARD

Activity Reference
· Rtot corresponds to the series resistance (brushes plus protection and limiting resistor)
and Xtot to the coupling reactance. If both for Rtot as well as for Xtot values are
indicated as 0, then the connections of URE or IRE have wrong polarity. Change the
polarity of one of the connections and repeat the measurement.
· It must then be checked that the setting values R SERIES = xxx

X COUPLING = yyy correspond to the above values.
· Remove earth fault bridge.
· Now using a resistor of the size of the warning resistance (RE< WARN,) an earth fault
is simulated as above. The earth resistance calculated by the unit can be read out
under the Operational Measured Values as Rearth. If substantial deviation occurs
between the actual and the indicated earth resistances, the matching improvement can
be attempted by correcting the preset angle error for IRE PHI I RE. This angle error
correction is only effective for the rotor earth fault protection function. An earth fault is
now simulated as above using a resistor approximately 90% of the trip resistance
(RE<< TRIP). The rotor earth fault protection initiates a pickup signal and after T-TRIP-
RE<< a trip indication.
· Repeat test for the other slip ring.
· Remove earth fault resistor.
- Overvoltage protection
· Connect a three phase voltage supply to the relay

· Steadily increase the voltage until the relay picks up.
- Overexcitation protection
· Connect a three phase voltage supply to the relay

· Keeping the frequency constant, the voltage is increased until the relay picks up.
· Record the results for Warning stage, Trip stage and Thermal Characteristic in two
points
- Frequency protection
· Connect a 100V, 50 Hz three phase supply to the relay.

· Steadily increase the frequency until the relay picks up.
· Check U < blocking by temporarily assigning the blocking alarm to a LED and
reducing the voltage until the LED lights up.
· Restore original settings
STANDARD

Activity Reference
- Earth fault protection in DC-Circuit
· Connect a DC current source (max. 10A) to the input terminals of the earth measuring
circuit.
· Insert an ammeter in the measuring circuit.
· Inject a test current until the relay picks up.
· Measure the voltage across the measuring shunt.
· Measure the voltage at the input to the protection relay.
· Repeat the measurements with the polarity of the test current reversed.
- Inadvertent energisation
. Connect a three phase voltage and current supply to the relay

. Increase current until pick-up value. Relay picks up after time delay has expired.
. Reduce the voltage below the pick-up value.
- Breaker failure protection (BF)
. Increase current until the BF relay picks up.

. Simulate a trip signal to the CB.
- Out-of-step protection
· Connect the three-phase secondary test set to the input terminals for the 3 current
and 3 voltages at the cabinet.
· Adjust the voltages symmetrically to the level of the rated voltage, currents
o
symmetrically to 2 x In. The angle between currents and voltages: Φp = 0 .
· Slowly reduce the voltages symmetrically down to 0 V. Reverse polarity of
Voltages by adding 180° to the phase angle. Then increase voltages again. This
simulates one passing through the power swing polygon (characteristic 1) of the out-
of-step protection. When the polygon is left, pick-up of the out-of-step
protection occurs:
- Annunciation “O/S char. 1”.
- Annunciation “O/S det.ch. 1” .
· If one out-of-step cycle has been set for n1, trip will occur:
- Annunciation “O/S Trip ch.1” .
- Trip relay.
· If more than one out-of-step cycle has been parameterized, the procedure must
be followed as often until trip occurs.
o o o
· Repeat test for different phase angles (Φp = 30 ,60 ,90 )
· Record the results in Commissioning Checklist and R/X diagram
STANDARD

Activity Reference
- Undervoltage protection
· Apply a three phase voltage supply to the relay

· Steadily decrease the voltage until the relay picks up.
· Record the results
5.3 Interface signals

Each signal should be tested at least once under live conditions.
· External trip signals, which are directly routed to the protection relays (e.g. turbine
emergency stop, transformer, HV switchgear, etc.) and
· Signals, which effect interlocking by means of relays (plant checkback signals are to
be checked at the signal interface, avoiding simulated signals where possible.
5.4 Tripping channels

Each tripping signal is to be tested to the device which it is tripping. The device to be
tripped must be available in the ON position (circuit-breaker closed, the emergency stop
device latched, etc.).
5.5 Fault alarm signals

During relay function testing it is necessary to test the corresponding alarms to the
outgoing terminal and I&C system.
6. Documentation
The corresponding check lists are to be filled in for each relay and also for the entire
protection system.
7. Appendices
None.
STANDARD
Ras al Khair SA1905 10/11 9332 DZ070


System/Titel:
System/Title CI-E07 Emergency Diesel Generator Set (EDGS)
Table of Contents
1 Task
2 Preconditions
3 Precautions
4 Scope
5 Execution
6 Documentation
7 Appendices

Activity Reference
1. Task
Commissioning of EDGS unit itself and EDGS unit in an overall plant configuration.
Dienststelle
Department
Name
Name
Datum
Date
Unterschrift
Signature

Verteiler:
Copies to
STANDARD
CI-E07 Emergency Diesel Generator Set (EDGS)

Activity Reference
2. Preconditions
2.1 Work status

- Erection has been completed for plant equipment involved.
- All checks in accordance with the Diesel-Gen-Set FQP are completed.
- The Erection Clearance Certificate [ECC] has been issued.
- Affected switchgears are in operation.
- All supply feeders have been checked.
- EDGS has been workshop tested.
- Station in-house power supply is available.
- Closed cooling water system available (if applicable).
2.2 Documentation
- Circuit diagrams of emergency diesel generator set.
- Logic diagram of emergency diesel generator control.
- Product manuals of all affected equipment.
- Circuit diagrams of related switchgears.
- Commissioning checklists of related equipment/cables.
- Workshop test certificates/results.
- Settings for control and protection devices (manufacturer instruction/engineering
department).
2.3 Personnel
- 1 Commissioning engineer: qualified electrical engineer with experience in
commissioning of generator sets.
- 1 Helper: skilled worker who has received suitable training.

- secondary test device
- insulation resistance tester
- single-knob measuring bridge
- multimeter (A,V,Ohm)
- phase sequence indicator
- current injector
3. Precautions
- Observe standards for "Erection and operation of power installations" (VDE
0100/101/105 and IEC 364 respectively).
- Before operating a synchronizing CB a local inspection shall be done.
4. Scope
- Visual checks
- EDGS tests
- Control centre
- Generator/Generator circuit breaker
- Cables
STANDARD

Activity Reference
- Interface
- Sensors
- CT circuits
- Interlock
- Check of electrical protection circuits
- Synchronising equipment
- Initial start up
- Load tests/operation modes
5. Execution
NOTE: Since the EDGS is a pre-assembled and tested component, workshop tests will
not be repeated on site. A list with workshop tests is available in the product manual.
IT IS MANDATORY TO OBSEREVE THE MANUFACTURER INSTRUCTION.
NOTE:
Diesel engine supervisor shall be called to site when the tests have 5.1, 5.2.1 to
5.2.10 (including) have been performed successfully. Inform engineering
department of the anticipated date when above works are completed.
Tests 5.2.11 to 5.2.12.c) shall be performed in cooperation with the diesel engine
supervisor.
5.1 Visual Checks

The following visual inspection shall be carried out:
- correct labelling of devices and cables
- devices and cables are undamaged
- correct cable terminations (arcing distance)
- correct sealing of cable entries in terminal boxes and switchgears
- correspondence between rating plate data and design data
- correct protective conductor and grounding connections
5.2 EDGS tests
5.2.1 EDGS control centre
5.2.1.1 Incoming feeder

- switch off all incoming circuit breakers
- isolate starter battery charger
- switch on three phase AC supply feeder
- check voltage and phase sequence at incoming terminals
- switch on single phase AC supply feeder (if applicable)
- switch on DC supply feeder (if applicable)
- check indications on control panel for no faults
- check voltage of starter and control battery, check function of battery chargers
STANDARD

Activity Reference
5.2.1.2 Check of control centre functions

- air conditioning/ventilating system (if applicable)
- light & power sockets
- emergency lighting
- fire detection
- cooling water temperature (approx. 40°C) is achieved one day after energisation.
5.2.2 Generator
An insulation test for the stator and rotor windings of the generator shall be done, if no
manufacturer test certificate is available.
5.2.3 EDGS generator circuit breaker (XKAxxGS001)

Commission the EDGS generator circuit breaker (refer to CP-E17).
5.2.4 Power and control cables installed on site

Power and control cables shall be checked in accordance with the relevant checklists.
5.25 Commissioning of signal interface to I&C and commands from and to EDGS
control centre
The signal interface to the I&C system shall be tested according to the relevant
drawings/logic diagrams.
All commands from and all feedbacks to the EDGS control centre shall be checked (test
position of circuit breakers).
5.2.6 EDGS sensors

EDGS sensors (i.e. temperatures, limit switches) have undergone workshop testing.
Check indications for plausibility.
5.2.7 Commissioning of current transformer (CT) circuits

Voltage and current transformer circuits shall be tested according to the relevant
commissioning instructions (CI-E03).
Compare current transformer data of generator star point side and switchgear side. The
data shall be identical.
This test can be combined with test 5.2.9.
5.2.8 Interlock Tests

Interlock tests according to the drawings of the affected switchgears shall be done.
Special attention must be paid to the closing and re-closing interlocks of all incoming
feeders of the emergency switchgear.
To perform the interlock tests, the relevant circuit breakers must be brought to "TEST
POSITION".
5.2.9 Test of electrical protection circuits

Check settings of protection and control equipment (reference: settings for control and
protection devices).
After test of the CT circuits (5.2.7), inject a current on the primary side of each CT (phase
and star point side) with sufficient magnitude to be indicated on the protection relay. Verify
correct indication.
STANDARD

Activity Reference
The results are to be recorded in the relevant checklists .
In order to check the entire trip circuit from the EDGS to the relevant circuit breaker,
initiate trip commands on the protection relay of the EDGS. Verify correct opening of
EDGS generator circuit breaker.
Check of emergency stop of the diesel generator engine.
5.2.10 Test of synchronising equipment

The synchronising equipment shall be tested in accordance with the relevant
manufacturer instruction and commissioning instruction “Synchronising Equipment” and
“Synchronising Procedure for Plants with Generator Circuit-Breaker”.
5.2.11 Initial start up/synchronising

In coordination with the mechanical engineer start up the EDGS. Manufacturer
instructions shall be observed.
Excite the generator and check for correct phase sequence and voltage level. Local and
remote indications to be checked.
Perform synchronising checks (refer to commissioning instruction “Synchronising

Procedure for Plants with Generator Circuit-Breaker”) and synchronise generator to the
grid.
5.2.12 Load tests and test of operating modes

a) After initial synchronising load generator by raising the load set point. Leave generator
at low load (but sufficiently high to register on the relay -> approx. 10% of full load current)
and verify protection relays read/indicate currents/voltage correctly (i.e. diff. protection
stable). Record results (checklists).
b) Raise load set point to full load and verify again relays read/indicate currents/voltage
correctly. Record results (checklists).
c) Reduce load set point until EDGS trips via reverse power. Record results (checklists).
d) Automatic start of EDGS with parallel operation (loading and unloading; trip the EDGS
by one electrical protection function). Record results (chart recorder -> EDGS voltage,
current and speed). Optimise settings where/if required. Consult electrical engineering
department where/if required. Observe EDGS sensor indication (i.e. temperature rise).
e) Start up EDGS. With the EDGS supplying the emergency switchgear only, start and
stop the drive or drive group with the highest kW rating in emergency operation for
verification of
• speed controller (check behaviour and compare with under-/overfrequency
detection settings)
• differential protection setting (in-rush detection and stabilising function)
• voltage controller (check behaviour and compare with under-/overvoltage
detection settings on protection relay and switchgear)
Record results (chart recorder -> EDGS voltage, current and speed). Optimise settings
where/if required. Consult electrical engineering department where/if required.
STANDARD

Activity Reference
f) Perform mains failure function test to verify that the EDGS and the EDGS automatic
programme is functioning according to design. Verify that the emergency busbar voltage
is not less than rated voltage (e.g. 400V). Record results (chart recorder -> EDGS voltage,
current and speed). Optimise settings where/if required. Consult electrical engineering
department where/if required.
Send test results (d, e and f) to electrical engineering department.
6. Documentation
- Commissioning Programme
- Checklists
- Charts
- List of final settings
7. Appendices
- None -
STANDARD
Ras al Khair SA1905 10/11 9332 DZ070


System/Titel:
System/Title CI-E13 Commissioning of Low-Voltage Transformers
Table of Contents
1 Task
2 Preconditions
3 Precautions
4 Scope
5 Execution
6 Documentation
7 Appendices

Activity Reference
1. Task
These instructions comprise a description of the test to be carried out on commissioning
of the dry-type low-voltage transformers (GEAFOL transformers).
Dienststelle
Department
Name
Name
Datum
Date
Unterschrift
Signature

Verteiler:
Copies to
STANDARD
CI-E13 Commissioning of Low-Voltage Transformers

Activity Reference
2. Preconditions
2.1 Work status

· Erection has been completed (the Erection Clearance Certificate (ECC) has been
issued.
· The affected switchgears are in operation and have been released for service.
· The affected controlled feeders of the switchgears have been tested using check list
CL-E06.x.
2.2 Documentation
· Protection grading diagram (short-circuit calculations),
· Product manual of the transformer,
· Circuit diagrams and layout drawings of the corresponding switchgear.
· Commissioning checklist CL-E06.7
2.3 Personnel
· 1 Commissioning engineer: engineer or technician with experience in commissioning
of low-voltage transformers and authorised to carry out switching in medium-voltage
and low-voltage switchgears.

· Multimeter (A, V, Ohms)
· Insulation resistance tester
. Secondary testing device.
3. Precautions
· The safety regulations for working at electrical installations shall be observed.
· Before testing voltages are applied a check shall be carried out to ensure that
no unauthorised persons are working at the corresponding loads
(where necessary barriers should be provided)
4. Scope
· Visual inspection
· Insulation resistance test
· Functional test
· Initial switching-on
5. Execution
The following instructions are valid generally. There may be deviations in detail depending
on the type of transformer employed.
Only those points relevant to dry-type transformers in the check list CL-E06.7 should be
carried out.
Note: Refer to manufacturer instruction.
5.1 Checking of technical data

The technical data should be checked and entered in the check list CL-E06.7:
STANDARD

Activity Reference
Check data against design specifications.
5.2 Visual check

Prior to carrying out the electrical tests a visual check of the transformer should be carried
out paying particular attention to the following points:
· Correct labelling of devices and cables
· Equipment and cables are undamaged
· Correct execution of the cable sealing ends (clearances)
· Correspondence between the rating plate data and the ambient conditions
· Firm attachment of cable terminals and connections
· Transport support/protection removed
5.3 Insulation resistance test

Checking of the insulation resistance shall be carried out as per the standard ”Instruction
for Commissioning” No. 51, point 5.4. The results shall be entered in the check list CL-
E06.7 of the transformer.
5.4 Transformer protection equipment

· Test of the current transformers.
· Check the settings of the overcurrent time protection. The settings are to be taken
from the protection grading diagram and from the transformer rating plate.
· Test the overcurrent time/diff. protection by feeding in a current on the secondary side
of the current transformers by means of a secondary-side testing device.
Important: If the overcurrent/diff. protection relay forms part of the unit or generator
protection, it will be tested within the framework of the unit protection test runs.
· Check the temperature monitor (generation of alarm and trip signals).
It may be necessary to postpone checking of the fault alarms of the alarm
annunciation plant until a later stage.
5.5 Preenergizing test

· Connect three phase low voltage supply to the HV-side of the transformer with open
circuit at the LV-side of the transformer . Measure Voltage on HV and LV-side and
confirm transformer ratio
5.6 Switching-on of the transformer

· Switch on the incoming feeder.
· Measure the voltages on the primary and secondary side of the transformer.
· Check the rotating field.
· Check the secondary currents of the current transformers after loading the
transformer.
6. Documentation
The results of the individual tests and the data and measured values are to be
documented in the commissioning check list CL-E06.7.
Where appropriate, a list of activities performed, which are not listed in the check list, shall
be appended.
If applicable, corrections and amendments shall be entered in the circuit diagrams and the
STANDARD

Activity Reference
layout drawings of the electrical equipment documentation.
7. Appendices
- None -
STANDARD
Ras al Khair SA1905 10/11 9332 DZ070


System/Titel:
System/Title CI-E17 Power Transformers
Table of Contents
1 Task
2 Preconditions
3 Precautions
4 Scope
5 Execution
6 Documentation
7 Appendices

Activity Reference
1. Task
To ensure that transformers have been properly installed and the respective safety and
monitoring devices are in perfect working order.
This instruction is not applicable for LV transformers.
Dienststelle
Department
Name
Name
Datum
Date
Unterschrift
Signature

Verteiler:
Copies to
Energy Solutions
STANDARD
System/Titel:
System/Title CI-E17 Power Transformers

Activity Reference
2. Preconditions
2.1 Work status

· The transformer has been released for commissioning (Erection Clearance Certificate
issued).
2.2 Documentation
· The manufacturer instructions are available for component.
· The circuit diagrams are available.
· Commissioning checklist.
2.3 Personnel
· 1 Commissioning engineer: Engineer or technician with experience in
commissioning of electrical equipment.

· Multimeter (A, V, Ohms)
· Megger tester 5kV
· AC source
· DC source (if applicable)
3. Precautions
· The VDE Regulations for ”Erection and
Operation of Electrical Power Installations with rated voltage up to 1000 V” (VDE
0100/0105) shall be observed.
· Refer to manufacturer instruction.
4. Scope
· Check of safety and monitoring devices
5. Execution
· All tests shall be performed according to the manufacturer instructions.
6. Documentation
The activities performed shall be documented in the manufacture commissioning checklist
7. Appendices
- None -
Energy Solutions
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ENGINEER’S STAMP: CONTRACTOR’S STAMP:

AA For Approval E. Hümmer W. Raffel M. A. Khan 08.03.2013

KINGDOM OF SAUDI ARABIA ‫اﻟـﻤﻤـﻠـﻜــﺔ اﻟﻌــﺮﺑـﻴــﺔ اﻟﺴــﻌـﻮدﻳـــﺔ‬

Engineer of Record Sheet 1

Document No.: Orig./Ref. Document No.: SAP Rev: SAP UNID

Subject: Commissioning Manuals Page 2 of 2

Doc No.: 10 - C O M - E D C - 1 0 0 0 0 3 - 1 1 Rev. AA

1 Compilation of Phase B and C Commissioning Instructions

System/ Component Program code

2 Compilation of Standard Commissioning Instructions

System/ Component Program code

Testing of the Current and Voltage Transformers CI-E03

Testing of the Electrical Measuring and Metering Devices CI-E04

Main Unit Protection Secondary Injection Tests CI-E05

Emergency Diesel Generator Set (EDGS) CI-E07

Commissioning of Low-Voltage Transformers CI-E13

Power Transformers CI-E17

Ras al Khair SA1905 10/11 9332 DZ070

Handhabung/Handling: For Internal Use Only

Item Aktivität Referenz

Rev. Name/Kurzzeichen Dienststelle/Firma Datum Fachabteilung, Ibs-Leitung, Projektleitung

CI-B-702.1 Main Unit Protection Primary Test Procedure

Item Aktivität Referenz

2.1 Work status

· For all equipment under test an ECC has been issued

· Circuit documentation of the generator/transformer protection equipment

· 1 Commissioning engineer: Engineer or technician with experience in commissioning

2.4 Measuring instruments

CI-B-702.1 Main Unit Protection Primary Test Procedure

Item Aktivität Referenz

5.1 Preparations, General

5.2 Short circuit tests

CI-B-702.1 Main Unit Protection Primary Test Procedure

Item Aktivität Referenz

5.2.1 Generator side three phase short circuit tests

· Block relay. (for redundant protection both relays)

· Unblock relay(for redundant protection both relays)

CI-B-702.1 Main Unit Protection Primary Test Procedure

Item Aktivität Referenz

Generator transformer differential protection

· Further tests to be carried out under “5.8 Load tests ”.

5.3 Earth fault tests

5.3.1 Earth fault on generator side

90% Stator earth-fault protection

· Block protection relay

100% Stator earth-fault protection

Post test activities:

· Isolate MV excitation feeder or LV Excitation CB as installed

End of earth fault test

CI-B-702.1 Main Unit Protection Primary Test Procedure

Item Aktivität Referenz

5.4 Voltage tests

· Set the voltage regulator to “Manual“ operation (block “Automatic“ operation).

· Increase generator voltage to 30% generator rated voltage

· Increase generator voltage to 100%

Stator Earth fault protection 90%

· Record the displacement voltage on rated voltage and no load

100% Stator earth-fault protection

· Record the earth resistance values on rated voltage and no load

Rotor Earth fault protection

CI-B-702.1 Main Unit Protection Primary Test Procedure

Item Aktivität Referenz

· Remove earth fault resistor.