Electrical Commissioning Guideline
Electrical Commissioning Guideline
This engineering guideline defines the minimum requirements for the handover from electrical construction to electrical commissioning on Global Operations plants. This guideline also establishes uniform safe work practices that should be followed during the electrical commissioning phase of the project.
1. This guideline applies to all electrical commissioning activities on Global Operations plant projects, including existing operating assets which are undergoing extensions or modifications.
2. This guideline is intended to supplement and reinforce the Facility Safety During Construction, Commissioning, and Start-up document 25-011703. All Electrical personnel should familiarize themselves and refer to this document when performing electrical commissioning.
Construction Specification for Electrical Installations (IEC based)
1. Electrical commissioning shall only be performed by personnel authorized by Global Operations Electrical Engineering. In general, and to meet the electrical safety requirements, only personnel that are trained and certified in accordance.
2. Equipment handed over from construction should be in a de-energized state; all electrical equipment should be mechanically and electrically complete. Before handover, all contractor QA documentation, “as-built” drawings, and electrical installation test sheets shall be provided to the electrical commissioning lead from the electrical construction supervisor. After electrical systems are handed over to commissioning, it shall be the responsibility of the electrical commissioning lead to ensure that all construction paperwork is complete. Refer to the appropriate section of the relevant Construction Specification.
3. Equipment should be inspected in accordance with approved procedure and a rectification punchlist produced by the electrical commissioning engineer. The equipment shall not be energized until the MBS (mandatory before start-up) punchlist items have been completed and the electrical commissioning lead has deemed that it is safe to do so. Equipment shall only be energized by the electrical commissioning engineer. The punchlist shall be copied to the start-up leader, electrical construction engineer, and the electrical contractor representative.
4. Items which are raised on the punchlist that cannot be resolved at a local level should be addressed initially with the GEM project electrical engineer for clarification via telephone and confirmed by e-mail. GEM/GO Electrical Engineering Management should be consulted if a resolution cannot be reached.
5. Electrical equipment, where possible, should be handed over for commissioning as a system; where this is not possible, adequate provisions shall be adopted to ensure safe working conditions are maintained until the system is fully handed over. Close liaison between construction, start-up, and electrical commissioning will be vital to ensure safety is not compromised. Any doubts should be discussed initially at site level and raised with GEM and GO Electrical Engineering for technical input, if required.
6. The handover of electrical equipment for commissioning shall include all communications cables (for example, RS232), software driver programs and any vendor special tools. It is the responsibility of the electrical commissioning lead to ensure the safe storage of these tools during commissioning.
7. After electrical equipment has been handed over to electrical commissioning by construction, no further work is permitted by construction or contractor personnel. If access is required (for example, punchlist rectification work), a safety work permit will be required in accordance with procedure.
8. Control of the electrical padlocks for the purpose of, for example, isolations and earthing, shall be the sole responsibility of the electrical commissioning lead. The locks shall have unique keys and numbers. The keys for each lock shall be kept in a locked key safe within the switch room for which only the electrical commissioning engineer has access.
9. Before energizing the incoming supply, the electrical commissioning lead shall isolate and lock-off all incoming and outgoing ways from HV and LV switchboards, lighting and small power distribution boards, and instrument supplies distribution systems in accordance with approved procedure.
10. Prioritization of equipment handover to meet the start-up schedule shall be determined by the commissioning electrical lead, start up leader, and construction supervisor.
11. Before energization of electrical equipment in the switch room, all safety equipment and notices as defined in applicable standards and those required by national codes and regulations shall be installed. Examples are fire extinguishers, a copy of the Electrical Single Line Diagrams, resuscitation notices, and Arc Flash PPE task table.
12. At the time of energization of the electrical equipment/switch room, the area/room will be restricted to authorized people only. The control of access to the electrical equipment/switch room will be the responsibility of the electrical commissioning lead. All work within the electrical equipment/switch room will require a Safety Work Permit and this must be countersigned by the electrical commissioning engineer in the additional approval box.
13. On completion of pre-commissioning checks and immediately before energization, systems/equipment should be clearly labeled as “LIVE“and barriers erected around field electrical equipment. Barriers can be removed after the electrical system/equipment is fully commissioned, but the live labeling must remain in place.
14. A visual method of identifying the commissioned status of each individual piece of electrical equipment shall be utilized by the electrical commissioning engineer. Appendix A lists the colors and meanings of the markers on each piece of electrical equipment. A copy of Appendix A should be posted in the electrical switch room for reference. These markers should be easily removable at the end of the commissioning phase, when the equipment is handed over to operations.
15. On a daily basis, the electrical commissioning lead shall inform the start-up leader of progress made during that day and the status of the electrical energization. It shall be the responsibility of the start-up leader and construction manager to inform all contractors and personnel working under them of the current status.
16. After commissioning of individual items of equipment is completed, the control and operation may be handed over to the start-up leader. Equipment that has been handed over to the control of the start-up team shall be clearly identified as such; however, electrical isolations required for permitted activities shall still be performed solely by the electrical commissioning lead until the control of the equipment is handed over to operations.
17. During the commissioning phase, all high voltage electrical work will require a High Voltage Electrical Isolation Certificate (HVEIC). The HVEIC shall be completed by the electrical commissioning engineer and used as part of the Safety Work Permit system in accordance with approved drawing.
18. All electrical work shall be performed in accordance with electrical and facility safety procedures. No work shall be completed on live equipment and no electrical permits signed off until the electrical commissioning lead has performed the necessary isolation, lock out/tag out and the equipment has been proven to be de-energized. All requests for construction work to be performed on electrical equipment that has been handed over to the start-up team will require a permit counter signed by the electrical commissioning engineer.
19. In addition to the daily update given to the start-up leader, the electrical commissioning lead will complete on a weekly basis a list of energized equipment and a look ahead to the following week. The document should contain a summary of work completed within the week and any problems or milestones identified. This information shall be distributed to the start-up leader, projects, and Electrical Engineering.
20. The electrical commissioning lead will be responsible for ensuring accurate records are kept of all isolations during commissioning, in an isolation register within the switchroom.
21. The electrical commissioning lead will be responsible for ensuring electrical commissioning record sheets are completed for all electrical equipment.
22. The electrical commissioning lead will be responsible for ensuring as-built drawings are recorded accurately. One copy is to be sent back to projects with a transmittal document to be signed and returned, and one set left on-site which will be the “master set” and stamped accordingly with a red “Master” stamp. Both sets are to be stamped and signed as “as-built” drawings. Any “as built” changes to drawings are to be “clouded” in red ink then signed and dated accordingly.
23. On completion of commissioning, the electrical lead should complete a full report. This should identify any issues raised or identified during the commissioning which can be fed back to GEM to facilitate improvements in design.
MEANS OF IDENTIFICATION OF COMMISSIONING STATUS OF ELECTRICAL EQUIPMENT
Color of Markers
RED = Fully commissioned and energised.
GREEN = Fully commissioned ready to run.
LIGHT BLUE = Direction of user checked.
WHITE = Loop checked to the DCS.
PURPLE = Overload set and fuse sized checked.
DARK BLUE = Control circuit and Protection relay secondary injection tested.