5. Functional Tests
5.2 Electrical Functional Testing
• Subchapter 5.3: Instruments functional testing Each subchapter contains:
• The applicable methodology
• The list and coding of basic functions and the scope of testing
• The support test sheets.
Are also included miscellaneous information depending on each discipline.
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5.2 Electrical Functional Testing
5.2.1 IntroductionThe purpose of the electrical functional testing is either to energise electrical equipment in order to check their proper operation, most of the time off-load, before multidiscipline on-load operational tests, or to verify the ability of the equipment to be energized safely during the operational tests.
The functional testing comprises mainly the tests of the electrical protections and interlocks/interfaces with other equipment with or without energization.
The insulation of the equipment as well as their proper connection have been tested during Precommissioning and corresponding check lists and test sheets have been produced to prove it. The fact remains that, some time could have elapsed before the Commissioning is started and that insulation has deteriorated.
Ultimately the person who energises equipment is responsible for it and has to ascertain that it can be done safely.
This is why the functional tests include simplified measurement of the insulation resistance which can be done in the feeding switchboard and do not require any disconnection of cable. In the unlikely event that insulation to earth is found not acceptable, the procedure of Precommissioning test shall be applied to the faulty equipment.
The HV tests could be detrimental to the life expectancy of equipment and shall not be repeated unduly.
In all cases the continuity of the circuits shall be visually checked as well as proper connection to earth before energisation.
These above electrical functional tests, power receiving and energizing will be performed and completed during Precommissioning stage, and the required maintenance works will be performed until the handover relevant electrical systems to Company.
5.2.2
5.2.3 Methodology
For the purpose of functional testing, the electrical installation has been divided into 11 different equipment categories titled Basic Function Types and numbered P1 to P11.
Certain Basic Function Types have been further sub-divided using codes indicated by letters.
This codification has been necessary due to various classifications within a Basic Function Type e.g. Basic Function Type P6 (electric motor) has been further divided into P6 A and B.
A specific Commissioning functional test sheet has been designed for each appropriate equipment type as described by a Basic Function Type/Code e.g. FP6 A is the Commissioning functional test sheet for HV electric motors.
For each basic function installed, a functional test sheet will be completed by the electrical Precommissioning Team and reviewed during Commissioning stage.
Further Commissioning functional test sheets, not dedicated to a basic function type, have been designed for:
• Protection relays associated with HV equipment
• Protection relays associated with LV equipment
• ESD inputs to MCC cubicles, intertrip signals between HV and LV circuit breakers, etc.
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These test sheets will be used completed by the electrical Precommissioning Team and used during the preparation of the Commissioning and depending on the type of equipment, attached to the related functional test sheets.
A full list and master forms of all Commissioning test sheets are available in paragraph 5.2.7.
The completion of the test sheets requires equipment tests, checks, calibrations, etc., after which the equipment is ready either for operational testing or putting into service, whichever is applicable.
5.2.4 List and coding of Electrical Basic Functions
• P1 – Emergency Generator
• P2 – UPS System
• P3 – DC System
• P4 – Switchboards - A - HV Switchgear - C – LV Switchgear
- K – Emergency Load Center
• P5 – Transformers
• P7 – Motor - A – HV motor - C – LV motor
• P10 – Heaters
- Directly fed from MCC or distribution board
- Controlled via step controller or Thyristor controlled
• P11 - Misc. User - Hoists
- Crane
• P12 – Lighting Small Power and Trace Heating
- A – Lighting and small power (by distribution board)
• P15 - Earthing Loop (Power only)
• P16 - ECS (Display Logic)
5.2.5 Description and Test of Basic Functions 5.2.5.1 Function P1, Emergency Generator 5.2.5.1.1 Description of Function
Alternator, Control panel, AVR and all associated power and control cabling Alternator CB and all associated electrical protection.
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5.2.5.1.2 Functional Testing
For functional testing purpose, functional test sheets have been designed and are included in 5.2.7:
5.2.5.2 Function P2, UPS system 5.2.5.2.1 Description of Function
Batteries, battery chargers, inverters, by-pass transformer, static switch and by-pass isolator.
Feeder CB’s and associated cabling from LV switchboard/MCC and associated protection.
5.2.5.2.2 Functional Testing
For functional testing purpose, test sheet P2 “UPS System” is to be used. It is included in 5.2.7.
5.2.5.3 Function P3, DC system 5.2.5.3.1 Description of Function
Batteries, battery charger, DC distribution board and associated protection Feeder CB’s and associated cabling from LV switchboard/MCC.
5.2.5.3.2 Functional Testing
For functional testing purpose, functional test sheet P3 “DC System” is to be used. It is included in 5.2.6.
5.2.5.4 Function P4, Switchboard/MCC 5.2.5.4.1 Description of Function
Incoming CB’s bus-bars, bus-section, all protection, auxiliary supplies and associated cabling.
Cable supplied switchboard/MCC to include feeder CB’s and associated cabling.
5.2.5.4.2 Functional Testing
For functional testing purpose, three different functional test sheets have been designed. They are included in 5.2.7.
In addition to the scope of work on the function test sheet it is also required to produce marked up drawings to indicate parameters of functions testing. Prior to energisation of the switchboard, a switching procedure is to be produced by the senior authorised or authorised person detailing the sequence of switching and events.
This is to be in the form of a signed document, the original retained by the Senior authorised or authorised person and a copy attached to the function test sheet.
Functional test sheets are:
• P4A: HV Switchboard
• P4C: LV Switchboard
• P4K: Emergency Load Center
For the testing of electrical protections on LV and HV switchboards the following will apply:
• Primary current injection tests will be performed in the Vendor’s premises according to a specific requirement in the purchase order. These tests will be supported by documents and witnessed by a OWNER representative.
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• Commissioning will only carry out secondary current injection tests. They will also check that the equipment conforms to the data sheet, especially characteristics of CT’s.
• If for any reason the factory tests have not been performed or are not properly documented Commissioning will verify the conformity of CTs cabling and current ratios by primary current injection tests and the relays by secondary current injection tests.
5.2.5.5 Function P5, Transformers 5.2.5.5.1 Description of Function
Transformer with its associated power and control cables. Feeder CB’s, protection, neutral earthing resistor and bus-duct where applicable.
5.2.5.5.2 Functional Testing
For functional testing purpose, functional test sheets have been designed. They are included in 5.2.7.
5.2.5.6 Function P7, Electric Motors 5.2.5.6.1 Description of Function
Motor with its power and control cabling including motor heater. CONTRACTOR panel or CB, all associated protection and field devices.
5.2.5.6.2 Functional Testing
For functional testing purpose, three different functional test sheets have been designed. They are included in 5.2.7.
They are:
• P7A: HV Motor
• P7C: LV Motor
5.2.5.7 Function P10, Heaters 5.2.5.7.1 Description of Function
Heater associated JB’s, field control device, feeder CB, protection and associated power and control cabling.
5.2.5.7.2 Functional Testing
For functional testing purpose, functional test sheet “P10: Heaters” is to be used. It is included in 5.2.7.
5.2.5.8 Function P11, Miscellaneous User 5.2.5.8.1 Description of Function
Feeder CB protection and associated cabling. Control panel, motors with local protection, cabling and all associated electrical equipment.
5.2.5.8.2 Functional Testing
For functional testing purpose, functional test sheet “P11: Miscellaneous User” is to be used. It is included in 5.2.7.
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5.2.5.9 Function P12, Lighting, Small power 5.2.5.9.1 Description of Function
Cabling, Luminaries, sockets, JBs and heating tapes.
5.2.5.9.2 Functional Testing
For functional testing purposes, two different functional test sheets have been designed. They are included in 5.2.7.
They are:
• P12A : Lighting and Small Power (completed by circuit) 5.2.5.10 Function P15, Power Earthing Loop
5.2.5.10.1 Description of Function
• Module earth bars and earthing ring within module (this is a pre-Commissioning task).
• Total earth ring including all cabling between modules and to main earth (this is a function testing task).
5.2.5.10.2 Functional Testing
For functional testing purpose, functional test sheet “P15: Earthing Loop” is to be used. It is included in 5.2.7.
5.2.5.11 Function P16, ECS Display Logic 5.2.5.11.1 Description of Function
Feeder CB’s, associated cabling, VDU’s and keyboard’s.
Note: Ref. Serial links in ECS System.
These are to be function tested using a J3 functional test sheet which appears in the Instrumentation Section of this specification.
5.2.5.11.2 Functional Testing
For functional testing purposes, functional test sheet “P16: ECS Display Logic” is to be used. It is included in 5.2.7.
5.2.5.12 Test Values to be used during Functional Testing
These values (Megger voltage, HV pressure test voltage, etc.) are to be defined for each project depending on the type of equipment used.
These parameters shall be taken from the relevant IEC, CENELEC or National Standard and in all cases shall not exceed the Vendor recommendation.
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5.2.6 Basic Functions:
Electrical basic functions are listed here below :
Basic function type Title P1 Emergency generator
P2 UPS System
P3 DC Systems
P4 Switchboard Load Center
P5 Power transformer
P7 Electrical motor HV and LV
P10 Heater
P11 Miscellaneous user
P12A Lighting and small power
P15 Power earthing loop
P16 ECS display
5.2.7 Electrical Functional Test Sheets
Appendix 1 gives the master forms of the electrical function test sheets listed here below : 5.2.7.1 Functional Test Sheets related to a Basic Function
Form No. Basic function type Equipment description FP1B P1 Emergency generator
FP2 P2 UPS System
FP3 P3 DC System
FP4A P4A HV Switchboard
FP4C P4C LV Switchboard
FP4K P4K Emergency Load Center
FP5 P5A and C HV Transformer
FP7A P7A HV Motor
FP7C P7C LV Motor
FP10 P10 Electrical Heaters
FP11 P11 Miscellaneous User
FP12A P12A Lighting and small power
FP15 P15 Earthing Loop
FP16 P16 ECS Display Logic
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