TEEE 4204 Part 5 Testing and Commissioning

PART 5: TESTING AND COMMISSIONING
TEEE 4204: SAFETY ENGINEERING AND MANAGEMENT
Outline
 Introduction. Purpose and steps. Works inspection.
Equipment, sub‐systems, protective and control devices,
energization, performance, acceptance, commissioning tests.
Site inspection and testing.
 Testing and commissioning methods for protective systems,
switchgear, transformers, cables, protection. Sequence,
interlock and protection systems.
 Commissioning aspects: documentation, safety features and
rules. Safety clearance notice. Observation, trail runs and
handing over to client operating staff.
5.1 Work Inspection
 Workplace inspections help prevent incidents, injuries and

illnesses.
 Through a critical examination of the workplace,
inspections help to identify and record hazards for
corrective action.
 Health and safety committees can help plan, conduct,
report and monitor inspections.
 Regular workplace inspections are an important part of the
overall occupational health and safety program and
management system, if present.
TEEE 4204: SAFETY ENGINEERING AND MANAGEMENT ‐ WEGULO JG 3
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5.1 Work Inspection…

 Every inspection must examine who, what, where, when and
how. Pay particular attention to items that are or are most
likely to develop into unsafe or unhealthy conditions because
of stress, wear, impact, vibration, heat, corrosion, chemical
reaction or misuse. Include areas where no work is done
regularly, such as parking lots, rest areas, office storage areas
and locker rooms.
 All workplace elements – the people, the environment, the
equipment and the process. The environment includes such
hazards as noise, vibration, lighting, temperature, and
ventilation. Equipment includes materials, tools and
apparatus for producing a product or a service. The process
involves how the worker interacts with the other elements in
a series of tasks or operations.
5.1.2 Purpose of Work Inspections

Inspections are important as they allow you to:
 Listen to the concerns of workers and supervisors
 Gain further understanding of jobs and tasks
 Identify existing and potential hazards
 Determine underlying causes of hazards
 Recommend corrective action
 Monitor steps taken to eliminate hazards or control the
risk (e.G., Engineering controls, administrative controls,
policies, procedures, personal protective equipment)
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5.1.3 Elements of Work Inspection

Types of workplace hazards include:
Safety hazards such as those caused by inadequate machine guards,
unsafe workplace conditions, unsafe work practices.
• Biological hazards caused by organisms such as viruses, bacteria,
fungi and parasites.
• Chemical hazards caused by a solid, liquid, vapour, gas, dust, fume or
mist.
• Ergonomic hazards caused by physiological and psychological
demands on the worker, such as repetitive and forceful movements,
awkward postures arising from improper work methods, and
improperly designed workstations, tools, and equipment.
• Physical hazards caused by noise, vibration, energy, weather, heat,
cold, electricity, radiation and pressure.
• Psychosocial hazards that can affect mental health or well‐being
such as overwork, stress, bullying, or violence.
5.1.4 Components of Work Inspection
• Basic layout plans showing equipment and materials used
• Process flow
• Information on chemicals
• Storage areas
• Work force size, shifts and supervision
• Workplace rules and regulations
• Job procedures and safe work practices
• Manufacturer's specifications
• Personal Protective Equipment (PPE)
• Engineering controls
• Emergency procedures ‐ fire, first aid and rescue
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5.1.4 Components of Work Inspection

• Incident and investigation reports
• Worker complaint reports regarding particular hazards in the
workplace, including psychosocial hazards
• Recommendations of the health and safety committee
• Previous inspections
• Maintenance reports, procedures and schedules
• Regulator inspection reports or other external audits
(insurance, corporate specialist)
• Monitoring reports (levels of chemicals, physical or biological
hazards)
• Reports of unusual operating conditions
• Names of inspection team members and any technical experts
assisting
5.2 Testing
 Testing is a process or system which is used to identify
characteristics or problems.
 Testing is the means by which the presence, quality or
genuineness of anything is determined, a means of trial.
 Testing is a procedure for critical evaluation
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5.2.1 Importance of Testing
The importance of testing include determining:‐

1. Whether a process, product, or service complies with the
requirements of a specification, technical standard,
contract, or regulation
2. Conformance to the specifications and performances,
3. The equipment’s ability to continue functioning properly
and to reduce the chance of failure.
Testing equipment allows manufacturers to ensure quality and

consistency in all facets of business, from incoming raw materials
to the finished.
5.2.2 Common of Tests
The major types of tests include;

1. Factory Acceptance Tests:
2. Site Acceptance Tests
3. Commissioning tests
a) Functional test
b) Performance test
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5.2.3 Common commissioning Tests
 Continuity testing; Continuity of protective conductors,

Continuity of ring circuit conductors
 Polarity
 Insulation resistance
 Earth loop impedance; Supply impedance Ze, Earth loop
impedance of circuits Zs
 Prospective fault current
 Operation of residual current devices
5.2.3 Testing Process
Before any testing is done, an initial general inspection should be

conducted that should reveal:
1. Any aspects of the installation that may impair the safety of
persons and livestock against the effects of electric shock and
burns.
2. That there are no installation defects that could give rise to
heat and fire, and hence damage property.
3. That the installation is not damaged or deteriorated so as to
impair safety.
4. That there is any defect or non‐compliance with the
applicable regulation identified, which may give rise to
danger.
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5.2.3 Testing Process…

The Sequence of tests should then be followed
1. Continuity of all protective conductors: All protective
conductors, including main and supplementary protective
bonding conductors must be tested for continuity using a
low‐resistance ohmmeter.
2. Continuity of ring final circuit conductors:
3. Insulation resistance: Performed to ensure that the
insulation of conductors, accessories and equipment is in a
healthy condition, and will prevent dangerous leakage
currents between conductors, as well as between
conductors and earth. It also indicates whether any short
circuits exist.
The Sequence of tests should then be followed…

4. Protection by SELV, PELV or Electrical separation.
Protection by separation of circuits. When separated extra‐
low voltage (SELV) or protective extra low voltage (PELV) is
used as a protective measure, then the separation from
circuits of a higher voltage has to be verified by an
insulation resistance test at a test voltage of 250V and
result in a minimum insulation resistance of 0.5MΩ. If the
circuit is at LV and supplied from, for example, a BS 3535
transformer, the test will be at 500V with a minimum value
of 0.555MΩ.
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5. Protection by barriers and enclosures provided during
erection: If, on site, protection against direct contact is
provided by fabricating an enclosure or erecting a barrier, it
must be ensured that the enclosure can provide a degree of
protection
6. Insulation of non‐conducting floors and walls: This is a rare
location and demands special equipment to measure the
insulation resistance between insulated floors and walls at
various points.
7. Polarity: The requirements are: All fuses and single pole
switches are in the line conductor, the centre contact of an
Edison screw‐type lamp holder is connected to the line
conductor and all socket outlets and similar accessories are
correctly wired.

8. Earth electrode resistance: In order to determine the
resistance of the earth return path, it is necessary to
measure the resistance that the electrode has with earth.
9. Earth fault loop impedance: Overcurrent protective devices
must, under earth fault conditions, disconnect fast enough
to reduce the risk of electric shock. This is achieved if the
actual value of the earth fault loop impedance does not
exceed the tabulated maximum values given in the IEE
Regulations. The purpose of the test, therefore, is to
determine the actual value of the loop impedance ( Zs) for
comparison with those maximum values.
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10. Operation of RCDs: Where RCDs/RCBO s are fitted, it is
essential that they operate within set parameters.
11. Prospective fault current: If this value cannot be measured
it must be ascertained by either enquiry or calculation.
12. Phase sequence: For multi‐phase circuits a check on the
phase sequence must be made using a phase‐rotation
instrument
13. Functional testing: A check should be made to ensure that
the operating mechanism of RCDs are functioning, using
the integral test button.
14. Voltage drop: A check on voltage drop should be made
wherever required. This is not normally required during
initial verification.
5.2.4 Periodic Inspection and Testing
These are test and inspection done on operationalized

equipment. This may result from any of the circumstance below:‐
1. Insurance
2. Mortgage
3. Licensing reasons
4. Change of use
5. Change of ownership
6. After additions or alterations
7. After damage
8. Change of loading and
9. To assess compliance with current Regulations.
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5.2.4 Periodic Inspection and Testing…
The general reasons for a periodic inspection and testing include:‐

1. To ensure the safety of persons and livestock.
2. To ensure protection of property from fire and heat.
3. To ensure that the installation is not damaged so as to
impair safety.
4. To ensure that the installation is not defective and
complies with the current Regulations.
5.3 Commissioning
 Commissioning is the process of assuring that all systems and

components of a building or industrial plant are designed,
installed, tested, operated, and maintained according to the
operational requirements of the owner or final client
 Electrical commissioning is essential to the start up of
any electrical system for the first time/after major
maintenance, regardless of size or industry.
 Once equipment is installed, perform visual, mechanical,
and electrical tests to help ensure trouble‐free energizing of
the equipment.
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5.3.1 Commission tests
 These tests are conducted after the system has been

energized.
 They are possibly the most significant for future safety. If
carefully interpreted, results will show:
1. The adequacy of earthing
2. Poor connections
3. Cross polarity at the supply or anywhere in the
installation
4. Continuity of ring circuit conductors
5. Correct positioning of switches
5.4 Transformer Test and Commissioning
Recall testing is conducted to determine:‐

1. Whether a process, product, or service complies with the
requirements of a specification, technical standard,
contract, or regulation
2. Conformance to the specifications and performances,
3. The equipment’s ability to continue functioning properly
and to reduce the chance of failure.
Some tests are done at a transformer manufacturer premises
before delivering the transformer, on receipt of the transformers
at site, before commissioning and also periodically in regular and
emergency basis throughout its service life.
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Tests done at factory include:‐
1. Type tests: Confirms main and basic design criteria of a

production lot
2. Routine tests: Confirming the operational performance of

the individual unit in a production lot. Routine tests are
carried out on every unit manufactured.
3. Special tests: Done as per customer requirement to obtain

information useful to the user during operation or
maintenance of the transformer.
Tests done at site include:‐
1. Pre‐commissioning tests: These tests are done to assess

the condition of transformer after installation and
compare the test results of all the low voltage tests with
the factory test reports.
2. Periodic/condition monitoring tests
3. Emergency tests
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Type tests of transformer includes

1. Transformer winding resistance measurement
2. Transformer ratio test.
3. Transformer vector group test.
4. Measurement of impedance voltage/short circuit
impedance (principal tap) and load loss (Short circuit test).
5. Measurement of no load loss and current (Open circuit
test).
6. Measurement of insulation resistance.
7. Dielectric tests of transformer.
8. Temperature rise test of transformer.
9. Tests on on‐load tap‐changer.
10. Vacuum tests on tank and radiators.
Routine tests of transformer include:‐

1. Transformer winding resistance measurement.
2. Transformer ratio test.
3. Transformer vector group test.
4. Measurement of impedance voltage/short circuit
impedance (principal tap) and load loss (Short circuit test).
5. Measurement of no load loss and current (Open circuit
test)
6. Measurement of insulation resistance.
7. Dielectric tests of transformer.
8. Tests on on‐load tap‐changer.
9. Oil pressure test on transformer to check against leakages
past joints and gaskets.
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5.5 Other Terminology
 Safety clearance notice:

 Observation:
 Trail runs:
 Handing over to client operating staff:
5.5 Other Terminology …
Safety clearance notice/Certificate of Occupancy/:

 A Certificate of Final Inspection is a statutory document issued
under the Building Act 1993.
 A Certificate of Final Inspection is issued for extensions or
alterations to existing buildings (including homes) as well as
other outbuildings that do not require an Occupancy Permit.
 a document issued by a local government agency or building
department certifying a building's compliance with
applicable building codes and other laws, and indicating it to
be in a condition suitable for occupancy
 See copy attached
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Safety clearance notice/Certificate of Occupancy/:
Observation/DLP:
 A defects liability period is a set period of time after a
construction project has been completed during which a
contractor has the right to return to the site to
remedy defects. A typical defects liability period lasts for 12
months.
 During the defects liability period, typically:
1. the contractor has the right to return to the site to rectify
defects or complete unfinished work;
2. the principal is entitled to continue holding security, to secure
the contractor’s obligations in respect of incomplete or
defective work; and
3. The superintendent continues to remain involved in the
project.
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Observation/DLP:
 Under some contracts, if the contractor rectifies a defect
during the defects liability period, there will be a new defects
liability period in respect of that rectification work.
Trail runs:
 In effect, trail running provides better strength training
benefits for the legs compared to road running. Trail
running also challenges coordination, agility and balance more
so than running on roads, especially if running on
technical trails full of rocks, roots and uneven terrain.
 In much simply terms, its test running the equipment and
exposing it with loadings as if it was in a production
environment but in a non production environment
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5.5 Other Terminology…

Handing over to client operating staff
The project may not be complete when delivered to the stakeholder.
Some final project areas that may need to be considered are:
1. Documentation requirements
2. Complete drawings
3. Final report
4. Provision of people trained on operating product of facility
5. Customer training
6. Project audit
7. Update risk and work registers
8. Settle all invoices
9. Equipment and hire returns
10. Warranties and guarantees settled
11. Update financial systems
12. Document lessons learned
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TEEE 4204 Part 5 Testing and Commissioning

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PART 5: TESTING AND COMMISSIONING

PART 5: TESTING AND COMMISSIONING

5.1 Work Inspection

 Workplace inspections help prevent incidents, injuries and

5.1 Work Inspection…

PART 5: TESTING AND COMMISSIONING

5.1.2 Purpose of Work Inspections

TEEE 4204: SAFETY ENGINEERING AND MANAGEMENT ‐ WEGULO JG 5

5.1.3 Elements of Work Inspection

PART 5: TESTING AND COMMISSIONING

5.1.4 Components of Work Inspection

TEEE 4204: SAFETY ENGINEERING AND MANAGEMENT ‐ WEGULO JG 7

5.1.4 Components of Work Inspection

PART 5: TESTING AND COMMISSIONING

 Testing is a process or system which is used to identify

 Testing is the means by which the presence, quality or

genuineness of anything is determined, a means of trial.

 Testing is a procedure for critical evaluation

TEEE 4204: SAFETY ENGINEERING AND MANAGEMENT ‐ WEGULO JG 9

5.2.1 Importance of Testing

The importance of testing include determining:‐

Testing equipment allows manufacturers to ensure quality and

PART 5: TESTING AND COMMISSIONING

5.2.2 Common of Tests

The major types of tests include;

TEEE 4204: SAFETY ENGINEERING AND MANAGEMENT ‐ WEGULO JG 11

5.2.3 Common commissioning Tests

 Continuity testing; Continuity of protective conductors,

TEEE 4204: SAFETY ENGINEERING AND MANAGEMENT ‐ WEGULO JG 12

PART 5: TESTING AND COMMISSIONING

5.2.3 Testing Process

Before any testing is done, an initial general inspection should be

TEEE 4204: SAFETY ENGINEERING AND MANAGEMENT ‐ WEGULO JG 13

5.2.3 Testing Process…

PART 5: TESTING AND COMMISSIONING

5.2.3 Testing Process…

The Sequence of tests should then be followed…

5.2.3 Testing Process…

PART 5: TESTING AND COMMISSIONING

5.2.3 Testing Process…

5.2.3 Testing Process…

The Sequence of tests should then be followed…

PART 5: TESTING AND COMMISSIONING

5.2.4 Periodic Inspection and Testing

These are test and inspection done on operationalized

TEEE 4204: SAFETY ENGINEERING AND MANAGEMENT ‐ WEGULO JG 19

5.2.4 Periodic Inspection and Testing…

The general reasons for a periodic inspection and testing include:‐

TEEE 4204: SAFETY ENGINEERING AND MANAGEMENT ‐ WEGULO JG 20

PART 5: TESTING AND COMMISSIONING

 Commissioning is the process of assuring that all systems and

5.3.1 Commission tests

 These tests are conducted after the system has been

TEEE 4204: SAFETY ENGINEERING AND MANAGEMENT ‐ WEGULO JG 22

PART 5: TESTING AND COMMISSIONING

5.4 Transformer Test and Commissioning

Recall testing is conducted to determine:‐

5.4 Transformer Test and Commissioning

Tests done at factory include:‐

1. Type tests: Confirms main and basic design criteria of a

2. Routine tests: Confirming the operational performance of

3. Special tests: Done as per customer requirement to obtain

PART 5: TESTING AND COMMISSIONING

5.4 Transformer Test and Commissioning