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3.

COMMISSIONING PRACTICE

3.1 Initial inspection

For each functional unit or system submitted for
commissioning, an initial visual inspection is
necessary to ensure completeness, comparing the
assembly to the latest documentation. Special
attention should be paid to observing any damage
due to transportation and installation. Scratches
are to be repainted as soon as possible. Any
corrosion observed on or inside cabinets or
apparatus should be examined and recorded,
listing the obvious or assumed reasons (e.g.
missing inertia vapourating pad).
Check that isolating distances are sufficient where
they may be considered critical. Check that the
switchgear and controlgear units are well
supported, fastened and earthed. Check that all
hinged and screwed lids, doors and locks are
functional and close well.
Cable and busduct intakes must be checked for
good cable routing, fixing, sealing and labelling.
Check site-mounted and main bolted joints for
proper tightening (spot-tests using a wrench). The
assemblies must be dry, clean and free of dust,
installation waste and other inappropriate
materials, and wire channel covers must be
fastened.
During this inspection, confirm that the rated values
of vital equipment and main equipment signs are
correct. Check the factory acceptance test reports
that parts originally missing have been installed.
See to that no fuel is let into systems surrounded
by classified areas until the installations have been
assessed and accepted for the appropriate zones.
A closer description on requirements for
supervision and assessment of installations in
hazardous zones is found in chapter 19.

3.2 Powering up
Before powering up, verify that the insulation
resistance values are sufficient as described in the
chapter INSULATION TESTS. Test that manually
controlled distributing isolators and switches are
operational and leave them open.. Isolate the
assembly to be tested from unauthorised staff and
equip it with warning signs; e.g. Voltage
connected.
Auxiliary voltages should be connected step by
step, closing MCBs and fuses while watching for
earth and polarity faults. Assemblies equipped with
their own control voltage supplies which are

powered from the main supply will have to be

connected to their main supplies before the control
circuits can be energised. In these cases special
attention must be attached to avoiding uncontrolled
energising of connected motors, heaters, units or
other external or internal equipment when
powering up and testing the controls.
Voltage supplies to delicate apparatus should be
checked for correct values immediately after being
energised. The reasons for MCB trippings,
overheating power supplies or any other fault that
appears should be examined and repaired before
proceeding from the faulty circuit.

3.3 Circuit functionality tests

Though the main idea of the commissioning work is
to ensure correct and full functionality, it should still
rely on the documentation and verify the latest
documents versus the installed circuitry. For this
reason the tests might well be based on the circuit
diagrams of the system which is being tested.
Thus the circuit diagrams will, to some extent,
constitute the checklist of all the functions which
are to be tested.
WARNING! For each controlled motor, valve or
other operated device, a primary check should
ensure that the device may be activated without
causing any danger to persons or equipment - or

whether it should be disconnected or locked to

make it inoperable even by false signals.
If any part of the circuitry or of the operational unit
is excluded from the test, you will have to test this
at a later opportunity when this can be done. A
completing test should be performed for sufficient
overlapping with earlier tested functions.
Each circuit and branch of a circuit should be
tested by activating each signalling or interlocking
element and ensuring that it will affect the operated
device as expected. The test should as far as
possible cover the complete function from pysical
influence to physical action.

Fig. 3.1: Circuit checkout method

The test must also include all the indications,
activity reports, alarm signals etc. caused by these
circuit activities directly or via a programmable

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controller, operator stations or other connected
systems.
A check mark or marker pen is recommended for
marking off the circuit elements on the drawings
after they are checked for correct function.

locations may also prove to be of another class

than assumed. Hotter, wetter, badly protected
locations may well need to be improved or the
apparatus may have to be relocated. When neither
is possible, the equipment must be modified or
upgraded to apparatus of an acceptable
classification.

3.4 Modifications
3.5 Test documentation
When the original technical solution is tested and
shown not to function well enough, it will have to be
improved before it is accepted. You will normally
need to make minor modifications, mainly to
improve reliability, and to revise the as-built
documentation; no further investigations will be
needed. In the case of major functional problems,
the designer should be contacted to establish his
reasons for such solutions before they are
modified. Corrective actions should also be agreed
with the designer when these are considered
necessary. Significant modifications must be
documented and approved like the original solution
before being implemented on site. Some of the

fig.3.2. Test protocols

The tests should always be recorded in a way that

every functionality mode can be proven as tested
and, if necessary, the testing method indicated.
Isolation test values, relay test and setting values
must also be recorded in these minutes. For these
reasons a test list should be prepared in advance,
and marked at each step when its function is
checked. Remarks concerning details not included
or deficient should also be entered in the test
protocol (see fig.3.2), as well as notes on repairs
which have been performed and tested. The test
list should also indicate the dates of the tests and
the persons responsible for performing them.