Commissioning Testing: The Step By Step Procedure Posted on April 29, 2013 by David Manney Commissioning Testing is the on-premise intensive testing that confirms the protective setup of equipment and its functionality. This test is basically to ensure that all the equipment and methodology used is in compliance with the pre-defined standards. For certified equipment, the manufacturer generally mentions the tests that have been performed. For non-certified equipment however, the number of tests to be performed is greater. For Certified Equipment To check whether the installed equipment meets the regulations, there are three major tests that are performed on certified equipment. These include: 1) Field Based Verification for Protective functional settings In this test, minor voltages, frequencies and currents are introduced in the system to test the result of operation. The point at which the equipment trips, is noted and checked. 2) Non-Islanding Function In this test, the load is increased to check the point at which the connection breaks. Also the time delay after a restart is noted. 3) Non-Exporting Function In this test, the equipment is testing by reversing the power or lowering the power of operation of the equipment. For Non-certified Equipment For non-certified testing, the following tests are performed to ensure that it is safe to deploy a certain system in industrial operations: 1) Functional Testing This type of testing is performed to check whether components react in the expected manner. The sections to be covered may vary from process to process and from industry to industry. The major activities involve: • Testing the functionality of the equipment below and above the voltage levels • Testing the functionality of the equipment below and above the frequency levels • Testing whether the equipment is able to strengthen the Dead line. • Testing the time that it takes to stabilize when an equipment is restarted • System fault detection (wherever applicable) • Testing of Synchronization Controls(wherever applicable) • Testing Anti-islanding and non-export Functionality(wherever applicable) 2) Verification of Equipment Setting The installation of the equipment is checked and if all the above tests pass, the equipment is verified to be in accordance with the laid down standards. 3) Trip Testing This test ensures that the protective equipment placed with the devices for breaking the circuits are working correctly. The operating conditions are tested under reverse power mode and by introducing variable function parameters. The interlocked circuits along with the interjecting devices are also tested to verify their compliance with the standards in case they are non-certified. 4) In-service Testing This test is to ensure the proper circuitry of the system under operation. Thorough inspection of wiring, flow of current, polarity, orientation of circuits, CT/PT ratio, etc. is done. The magnitude of voltages, currents flowing and induced, power, phase-angle parameters and frequency is properly analyzed with this system.   Cable Testing; Check the Insulation Posted on August 8, 2014 by David Manney Routine cable testing on any type of electrical equipment ensures a high degree of safe operation. These tests not only confirm a safe operating area for an equipment operator, but also help recognize any potential issues which may lead to premature equipment failure. Testing the strength of the cable insulation is vital for the safety of people working in the area. The human body provides a natural ground source, and if the equipment is not properly insulated, the voltage seeks ground through the body. Methods of Cable Testing The following four methods of cable testing help to ensure that the insulation is operating at safe levels. Dielectric Withstand Test (also known as a hipot test)- This test places stress on the insulation that is beyond the ordinary use of the equipment. The purpose of this cable testing is to determine if the insulation can stand up under regular use by ensuring that it can stand up under a higher level of voltage. Placing more stress on the insulation makes it possible to determine if there are any material defects require repair. Those material defects may not be evident during normal operation because of various environmental factors, which would cause those issues to be less likely to be recognized. Line Leakage Tests – There is no electrical insulation that is 100% effective, but it is necessary for it to be within certain safety limits. In order to ensure that the leakage of current through the insulation is not reaching unsafe levels for the user of the equipment, cable testing for line leakage test may be done. Ground Bond Testing – In the event that the insulation within the products should become defective, it may be necessary for the safety ground circuit to handle the fault current. Ground bond testing is a standard in cable testing that helps to make that determination. It is a way of ensuring that the circuit breaker or fuse is doing its job to keep the user from experiencing an electrical shock if the insulation should happen to fail. Insulation Resistance – This type of cable testing can also be used to determine the resistance of the insulation system within electrical equipment. An IR test unit measures the distance between two points separated by insulation and determines the amount of resistance the insulation allows. A dielectric withstand test provides a more thorough examination of the insulation than an IR test, so IR tests are not performed very often. Cable testing may be done on existing equipment to ensure that the insulation is still meeting the standards that would help to keep it safe for the end-user. It may also be used on a variety of electrical equipment that is being manufactured to determine that it is safe for use and, therefore, can be shipped to the end-user.