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FirstEnergy
Commissioning Practice
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Commissioning Handbook
Table of Contents
Section Page
1. Preface 4
2. Definition of Terms 4
3. Qualifications of a Commissioner 7
5. Workflow 9
7. Equipment Testing 16
8. Energization Policies 24
11. Attachments
i. Electrical Clearances 38
ii. In-service Load Angles Guide 39
iii. End-to-End Test Plans 41
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1.0 Preface
Checkout
A systematic approach to verify the installation and functionality of all equipment prior
to energization. Often used synonymously with Commissioning.
Commissioning
A systematic approach of placing equipment inservice with as little impact or risk to the
system as practical. Often used synonymously with Checkout.
Commissioner
A generic term referring to anyone approved to commission equipment on FirstEnergys
system. Commissioners who are not employees of the Transmission and Substation
Services (TSS) can only commission equipment at voltages less than or equal to 100 kV.
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the standards set by the commissioning agent and the equipment is energized and all in-
service readings are acceptable, the commissioner is responsible for approving its use by
Releasing it to the System Operator.
Commissioning Checklist
A detailed list of work tasks, substation modification specific and organized by
equipment type, that must be completed and signed off prior to a piece of equipment
being released for service. This list, which is prepared by the commissioner, is used by
both the commissioner and the field installation and test crews to keep track of required
testing during the modification and installation process. A master copy of this checklist,
showing line-item signoffs and completion dates is retained as an auditable document
upon completion of the work activity.
Commissioning Engineer
A specialized commissioner that is approved to checkout, commission and release all
substation equipment, regardless of service voltage or function. A commissioning
engineer is a field engineer or technician employed by the Transmission and Substation
Services (TSS) department of FirstEnergy. This employee can be either a fulltime
FirstEnergy employee or a contractor working directly for that department.
In-service Date
The date that the substation modification or new equipment installation has been
energized and is in use and useful. This can be either at the time of Release for Test or
at the time of Release for Service.
Manual of Operations
A collection of FirstEnergy Policies and Practices defining how the transmission and
distribution system will be switched. It defines the methods and controls for obtaining
clearances and operating conditions and the job duties and qualifications of individuals
allowed to perform switching activities.
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A Release for Service indicates that all post-energization checks are satisfactory and
any new substation equipment is now available to the Transmission System Operator or
Distribution System Operator to be used within its capabilities at the discretion of the
dispatching organization without limitation.
A "Release for Test" indicates that all pre-energization testing is complete and the
equipment is ready for the application of system nominal voltages and currents. The
individual authorized to grant a new equipment release shall retain authority over the
operation of the equipment since additional testing is required. The individual authorized
to grant the new equipment release is required to communicate to the Transmission
System Operator or Distribution System Operator what limitations are imposed on the
equipment while energized and Released for Test.
Verify
The Commissioner reviews the results of a work task and attests that the work was
completed in a satisfactory manner. The Commissioner is not required to be present
while the task is being completed.
Witness
The Commissioner is physically present as the task is being done, is directly engaged in
the activity and can attest that the work was performed in a satisfactory manner because
he/she was an active participant.
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Commissioning Engineer - For Equipment Greater than 100 kV, all Power Transformers
and new or portable substations, the following additional requirements apply.
Be employed within the Transmission and Substation Services Group
Be a licensed professional engineer or be working under the authority and
direct supervision of a licensed professional engineer.
V
O
L
T 345 kV
A
G
E 230 kV
115 KV
100 kV
ANY APPROVED COMMISSIONER
0 kV
Station CTs/PTs Switch DC Voltage Comm Relaying Reactor Capacitor Breakers Power Mod Subs SVC Portable
Power CCVTs Systems Regulator Transformer Sub
Substation Equipment
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Safety
A Commissioner is responsible for performing his duties and responsibilities in a safe
manner. This includes wearing proper PPE (hardhat, safety glasses, steel-toed shoes, FR
clothing), actively participating in job briefings (daily and whenever a change in the work
occurs including crew change, condition change, etc.), having a questioning attitude and
keeping vigil for the safety of himself/herself and those around him/her,
Test Leader
The Commissioner is considered the Test Leader on any construction job. Although not
expected to directly perform any test themselves, all tests and measurements are under
the Commissioning Agents direction (whether present or not at the time of the test) and
require his/her approval before considered complete.
Field Modifications
The Commissioner often initiates minor to moderate design additions and changes as a
result of discovered design errors or gaps in the prepared engineering package. In these
cases the Commissioner directs field crews in these modifications and ensures that
marked-up prints are sent in for revision (as-built).
Work Verification
The Commissioner, as an independent technical resource from the design, test and
construction groups at FirstEnergy, is responsible to challenge all aspects of the
substations design and construction in order to discover any mistakes and make sure that
they are corrected before the new substation or modification to an existing substation
goes into service.
Job Completion
A Commissioner is responsible for determining when a new substation or new/modified
equipment in an existing substation is ready for energization and when any new
equipment is fully functional and ready to be turned over to the appropriate dispatch
organization for use. Refer to the definitions of Release for Test and Release for
Service.
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5.0 Workflow
The following flow chart provides a generalized look at the typical work flow and key
job duties and responsibilities that a FirstEnergy Commissioner performs during the
course of a construction job. Although some tasks that a Commissioner performs may
occur out of the below sequence listed, or may be performed at different phases (e.g.
construction may have started prior to assignment of a commissioner to a job), the tasks
are required.
Flow Chart
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The following are required policies that a Commissioner must incorporate into the
checkout, testing and commissioning of a FirstEnergy Substation modification.
2. In-service Load Angles In-service Load Angles must be measured, verified and
approved for all new or modified relay analog (CT & PT) circuits. A
Commissioner must be physically present, witness and sign off that the measured
readings are appropriate. Also a copy of the measured values must be retained.
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Marking of Prints
The preferred method of documenting the DC functional testing is by marking up
a copy of the schematics utilizing a highlighter (or digital equivalent) to color
over every portion of the DC schematic that has been validated by testing.
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(with plans to trip all breakers) may not be possible due to outage constraints.
Accordingly, the full relay and control scheme cannot be tested, however it is
essential that all portions of the scheme that may have been impacted by the new
wiring changes are checked to ensure that the full functionality of the existing
scheme remains.
When deciding how much of the existing scheme to functionally test, the
commissioning agent is aided in the task of evaluating protection schemes
through the application of an analysis technique called Disturbed Node
Functional Testing (DNFT). This analysis method and testing process applies to
any modifications made to various types of existing wired schemes and is
performed using the DC schematic diagrams. The process is summarized below:
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5. Energization Plan
Substation modifications typically involve new or modified protective relay
schemes. Until these schemes can be validated under load, they are considered
unverified and cannot be counted on to perform correctly. As a result, decisions
must be made as to how the impact of an unverified relay scheme will impact the
transmission and distribution system and whether a protective relay scheme
should be enabled or disabled until operational measurements can be made and
the functionality of the scheme validated.
Accordingly, the commissioner must work with EDPP and systems dispatch to
discuss the options of energizing any piece of equipment to ensure that mis-
operations are minimized and that the extent of any outage from a mis-operation
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is minimized, while also ensuring that adequate fault clearing exists to promptly
isolate any equipment failures. This vetting of options and the final plan is
referred to as an energization plan. The plan, once approved, can then be used to
develop switching orders.
6. Final Relay Settings The Commissioner must review verify that the all as-left
relay settings set on a protective relay match the setting orders approved and
issued to the field from the FirstEnergy protection engineer. A copy of the
downloaded relay settings, after all calibration and testing has been completed,
will be retained.
8. Substation Control and Isolation Form The purpose of the Substation Control
and Protection Scheme Isolation Form is to ensure that all modifications made to
FirstEnergy owned substation control and protection schemes are properly
identified, tracked, and documented. The form is intended to capture information
regarding the change in status of any component of a control or protection scheme
that isolates that scheme and/or may affect the normal operation of that scheme.
The Substation Commissioner will ensure that during the modification process,
that field crews are tracking lifted wires, open test switches and other circuit
isolation methods through the use of this form (X-3710). See Attachment 4.
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1. Transformers
Acceptance Tests
1. Dew Point
2. Megger Core Ground
3. Impact Recorder
4. Inventory of Shipping Manifest
5. Fill out Transformer Receiving Report, FE Form X-729
Assembly
1. Lights/Heaters
2. Cooler Valves Open
3. Conduit Sealed
4. LTC Breather has oil in cup
5. Control Cabinet/External Boxes Grounded
Final Vacuum Oil Fill
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3. Circuit Switchers
1. Verify SF6 Gas is filled
2. Timing Tests
3. Ductor Micro-Ohmmeter
4. If Shunt Trip Device is Used, Verify Proper Operation during Functional
Testing and Timing
5. Hipot Open Interrupters at appropriate voltage (see manufacturers IB)
6. Perform Power Factor testing if equipped with grading or shunt capacitors
5. Power Fuses
1. Verify Proper Fuse Size/Type
2. Air-Flow Test (Only applicable to S & C)
3. Fuse Tube Condition
4. Fuse Switch-Alignment/Adequate Contact Pressure
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6. Capacitor Banks
1. Check cans for damage/leaks
2. Record Capacitance of each capacitor can
3. Record Capacitance of each Phase-Neutral String
4. Check Capacitor Fuses/Clips
5. Visually verify interconnects/grounds
6. Verify Reactor Size (if equipped)
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9. Switchgear/Busswork
1. Check Bolted Connections
2. Ductor
3. Hipot or Megger (Phase-Phase and Phase-Ground)
4. Verify Heaters
5. Verify Bushings are Sealed (After Rain)
12. CCVTs
1. Power Factor Tests (Per Instruction Manual)
2. Ratio/Polarity Test
3. Verify Voltage Switch Position before energization
4. Verify Carrier Switch Position before energization
5. Check secondary wiring for shorts and grounds
6. Check in-service phasing of secondary voltages
7. Verify Ground at CCVT
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17. Grounds/GRID
1. Grounds on all equipment
2. Fence Grounds
3. Ground grid point-to-point checks (Use 100 Amp microhm meter)
4. Fall of Potential Test (new installations/major changes) If EPRI Smart Ground
Meter is not used, all remote connections to ground (e.g. static lines) must be
disconnected prior to test.
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20. SCADA
1. Functional Test (coordinated with FE Network Services)
Trip
Close
Indication
Alarms
2. Calibrate Transducers
3. Verify all Metering Settings are Correct
4. Secondary Load all Metering
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Polarity
Proper Labeling
25. Miscellaneous
1. Rod Gap Alignment and Spacing
2. Yard Lighting
26. Pre-Energization
1. Verify Switching Orders
2. Verify Equipment Labeling
3. Clearances-Phase to Phase, Phase to Ground
4. Fence
Gates Secured/Lockable with Lock
Proper Height/Allowable Gaps
Proper Signage
5. All protective grounds removed
6. Final Walkdown/Checklist Reviewed
27. Energization
1. Release for Test
Correct Phasing
In-service Metering Matches Load
In-service Load Angle Readings of Line Relaying
Current/Voltage Contributions of Differential Relaying
Neutral Unbalance Measurements of Capacitor Banks
Verify SCADA Metering and Indication are correct
2. Release for Service
Thermography Scheduled (Requires Follow-up)
In-service Oil Tests of Transformer scheduled (e.g. DGA tests performed
one day, one week and one month following energization)
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57 2032 Set Up on All Relays - autoconfigure for ea. Relay Witness Verify proper setup of SEL2032
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Example #2
The following is an example of a checklist prepared for a 230 kV modular distribution
substation.
Manchester
230-13.2kV Mod Sub Checkout Guide
Central Jersey
Item Initial Date
1. Overall external inspection of equipment _____ __________
2. Yard
2.1.1. Fence
2.1.1.1. Fabric _____ __________
2.1.1.2. Gates _____ __________
2.1.1.3. Grounds _____ __________
2.1.1.4. Signs _____ __________
2.2. Oil containment system
2.2.1. Installation _____ __________
2.2.2. Connection _____ __________
2.2.3. Operation FE to witness _____ __________
2.2.4. Alarm FE to witness _____ __________
3. Grounding
3.1. Soil resistivity test (remote earth) Document test results _____ __________
3.2. Cadweld inspection prior to burial FE to inspect _____ __________
3.3. Ground grid point-to-point checks (before ground grid resistance test)
Document test results _____ __________
3.4. Ground grid resistance (on installed ground grid, after point-to point)
Document test results _____ __________
3.5. Grounds on all equipment, per construction prints _____ __________
3.6. Ground mats properly grounded _____ __________
4. 230kV Line Disconnect Switches w/ Interrupters
4.1. 1098 LB 2 (Southern States type EV-2, with LLS-II Interrupter, 230kV,
2000A)
4.1.1. Install arcing horns _____ __________
4.1.2. Alignment (do not pierce until witnessed)
FE to witness _____ __________
4.1.3. Contact resistance Document test results _____ __________
4.1.4. Hipot Interrupter, per instruction book
Document test results _____ __________
4.1.5. Operate FE to witness _____ __________
4.2. 1098 LB 6 (Southern States type EV-2, with LLS-II Interrupter, 230kV,
2000A)
4.2.1. Install arcing horns _____ __________
4.2.2. Alignment (do not pierce until witnessed)
FE to witness _____ __________
4.2.3. Contact resistance Document test results _____ __________
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The final activity of a Commissioner involves verifying that the commissioning checklist,
test data sheets, marked prints and other pertinent data have been retained and is ready for
retention within the document management system(s) employed.
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Attachment 7 (Continued)
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Attachment 7 (Continued)
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Attachment 7 (Continued)
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Attachment 7 (Continued)
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Attachment 7 (Continued)
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Attachment 7 (Continued)
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Attachment 7 (Continued)
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Attachment 7 (Continued)
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Revision History
1 4/21/2015 Front Page, New Section Removed Contractor from Title; Added Preface, Added entire
1 & Section 3, Section 6, "Qualifications of a Commissioning Engineer" section; Revised Checklist
Section 7, Section 10, to include throw-over schemes; Split "Commissioning Policies" section
Attachment 3 and into two sections, adding "Energization Policies" section; Expanded on
Attachment 7. Commissioning Checklist preparation; Added more detailed DC
functional testing requirements with nodal analysis; Added End to End
Testing Discussion; Expanded on Document Retention; Added End to
End Test Plan Attachment; Added Transformer Receipt , Testing and
Processing Attachment.
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