Testing and Commissioning | APD Engineering

TESTING AND COMMISSIONING

TESTING AND COMMISSIONING OVERVIEW

APD provide a complete range of on-site field testing and commissioning services for power infrastructure. APD also offer tailored field engineering solutions and other niche services. For example, network audits, performance studies, troubleshooting and investigative support services.

The commissioning team comprises of electrical engineers and technicians with protection systems experience, proficient in conducting power system studies and the preparation of settings for Intelligent Electronic Devices (IED) for voltages up to 500kV. APD own a full suite of testing equipment covering the various tests commonly performed in an electrical environment.

Additionally, our engineers are very familiar with the design, operation and settings requirements for recognised device manufacturers, including GE, ALSTOM (formerly AREVA), SIEMENS, SEL, ABB, Schneider and RMS. This multi-relay skillset and design capability delivers project savings through the deployment of a single team.

To ensure our field engineers meet the project milestones, they are backed by our extensive pool of design and consulting engineers fully equipped with a comprehensive suite of engineering application and drafting software.

PROTECTION SYSTEMS TESTING AND COMMISSIONING

APD Testing and Commissioning Engineers have extensive experience in the setting and the testing of legacy analogue devices and Intelligent Electronic Devices (IED) and their respective sensing devices used for protection and control systems in substations for all voltages up to and including 500kV and including but not limited to devices manufactured by; GE, Alstom (AREVA & Schneider), ABB, Siemens (Reyrolle), SEL. Etc. Protection relays will be tested at the proposed setting points or any other points required by the client to confirm correct functionality of the relay. A completed test sheet will be provided for each relay tested including an independent review on the equipment suitability for the function it was installed to do.

APD Testing and Commissioning Engineers can provide immediate resolution of any protection programming or setting issues and any integration issues as they are also expert in power system and protection systems design.

APD have extensive capability in automation and control systems, and their supporting communications and security infrastructure with expertise in SCADA systems. We can provide SCADA/Protection testing and commissioning as an integrated service including DNP3, IEC 61850, IEC 60870, CANBUS & Modbus.

APD TEsting Bench

PRIMARY EQUIPMENT TESTING AND COMMISSIONING

APD Testing and Commissioning Engineers undertake comprehensive testing and commissioning tests on each item of primary plant. The results from these tests are compared to the manufacturer’s data sheets, the relevant standard and if required the client requirements with any non-conformance reported. The table below illustrates the routine site tests carried by APD Testing and Commissioning Engineers, however, non-routine tests and be tailored to satisfy the clients special needs.

PRIMARY DEVICE	TEST REGIME
Generator	Stator DC resistance, stator zero, positive and negative sequence impedance., Rotor AC and DC impedance, dissipation factor, insulation resistance, polarisation index, Partial discharge measurement.
Power Transformer	Winding ratio, Vector group, DC resistance, Impedance %, tap change continuity/ratio, Insulation resistance, dissipation factor (Tanδ), calibration of thermal sensors, frequency response analysis, oil test and analysis, dirana testing.
Current Transformer	CT ratio and phase error, CT magnetising curve, CT secondary DC resistance Test, CT secondary impedance test, CT primary and secondary Insulation resistance test, polarity & continuity test.
Voltage Transformer	VT ratio, VT secondary/primary Insulation resistance tests, polarity & continuity tests, HiPot test.
Earthing System	Step and touch voltages, system earthing resistance, system integrity.
Circuit Breaker	Contact resistance for all joints, Insulation resistance, HiPot testing, Trip close timing tests, dynamic resistance measurements.
Busbar	Partial discharge test, conductivity, insulation resistance.
Disconnector Switch	Contact resistance for all joints, insulation resistance
Surge Arrestor	Insulation resistance test, variable frequency dissipation factor measurement, discharge counter check.
Power Line Testing	Positive and zero sequence impedance measurements, ground fault current compensation factor, mutual coupling of parallel lines, coupling impedances between power lines, and signal cables and pipelines.
Cables	VLF testing, Partial discharge, insulation resistance, conductivity test.

SYSTEM INTEGRATION FUNCTION TESTING

APD Testing and Commissioning Engineers undertake comprehensive integration functionality tests to prove that all equipment functions as an integrated unit.

Primary equipment is injected and current/voltage is measured at the relay to ensure that relays are all connected to the correct CTs and VTs with the correct polarity.

Integrated functionality is checked for all devices including; Relay trip contacts, Equipment Interlocks, Logic sequences, Alarm and mimic functions, Transformer cooling system operation, AVR and paralleling systems, Voltage and current systems continuity, CBF busbar protection trips, Voltage selection schemes functionality, Site ancillary services functionality checks etc.

APD Testing and Commissioning Engineers have design expertise and are supported by a design team enabling any design or construction non-conformances to be analysed at site and solutions offered.

TEST EQUIPMENT AND SOFTWARE

TESTING EQUIPMENT:

HIOKI 3198 Power Analyser
Hioki 8860-50 Memory HiCorder
CPC100 Omicron Primary injection Kit
CMC356 Omicron Secondary Injection Kit
CP TD Omicron leakage reactance, insulation conditions and dissipation factor tester
CP CU Omicron Over Head Line Parameter and Earthing system analyser
CP CB Omicron 2KA Current injector
CIBANO 500 Omicron Test System for medium- and high-voltage circuit breakers
Thermal Imaging Camera
HVA 60 – Cable VLF tester
PD 30 Partial discharge analyser
Mitton LCI 2058 current injection test set
Megger DLRO10 micro-ohm meter
Megger DET2/2 soil resistivity tester

SOFTWARE:

GE EnerVista/UR/URPLUS
SIEMENS DIGSI4/5
ABB PCM600/Cap5
SEL AcSELerator
AREVA MICOM S1
Reyrolle Reydisp
Ingteam(Artche)
Sepam (SFT)
CDEGS
DIgSILENT PowerFactory
DIgSILENT StationWare
PSS Adept (or PSS Sincal as required)
ETAP
CYMCAP
PowerCAD
AGI32
Microstation V8i
Autocad
Poles & Wires
PLSCADD

PROJECTS

HUNTER WATER HV NETWORK UPGRADE AND FIELD SERVICES

Powerline Design, Power System Studies & cable/conductor selection, Protection Grading, Earthing Design & Site Testing.

UPGRADE OF MC254 OVERLAND CONVEYOR EMERGENCY STOP SYSTEM

APD was hired to perform detailed design and development in integrating the conveyor emergency stop system into the plant Process Control System (PCS) at BHP Mine Area C.

33KV SWITCHBOARD PMS INTEGRATION

The Roy Hill Ultrafine Iron Recovery Facility required the repurposing of a 33kV switchboard, originally from the thier Port, integrated into their Mine’s PMS.

TOMAGO TOWN WATER SUPPLY PLANT

APD were engaged by UGL to perform the testing and commissioning of the HV protection relays on the Tomago town water supply plant.

PERTH CBD ZONE SUBSTATIONS EARTHING DESIGN & TESTING

Site Inspection, Earthing Design & Drawings, EPR Hazard Assessment on 3rd Party Assets, Current Injection Testing.

YANDI MINE POTABLE WATER SUPPLY

APD was hired to perform detailed design and development in integrating two new potable water tanks and associated equipment into the plant Process Control System (PCS) at Yandi Mine.

VALES PT SWITCHBOARD REPLACEMENT

Complete design, procurement, testing and construction management for the replacement of an existing 6.6kV Switchboard. Existing switchboard was split into separate boards with a total of 25 panels. All works were carried out within a brownfield powerstation environment with limits on outages and construction schedules.

33KV JUNCTION CAPACITOR CIRCUIT BREAKER AND CT REPLACEMENT

33kV Junction Capacitor circuit breaker, CT and controller replacement.

66KV OIL CIRCUIT BREAKERS REPLACEMENT

APD was hired to perform detailed design and commissioning for the replacement of 66 kV Oil Circuit Breakers (OCB’s) at 5 different substations around Newman.

ARENA FUNDED SOLAR FARMS EARTHING DESIGN AND SITE TESTING

Soil Testing, Earthing Design, Conductor Sizing, Step & Touch Assessment, Earth Injection Testing.

MAC TLO WORKING PLATFORM SLIDING GATE CONTROL INTEGRATION

APD Engineering was hired to perform the control system integration of the MAC TLO Working Platform Sliding Gate.

CLAREMONT NORTH UNDERGROUND POWER PROJECT

Provision of distribution design, lighting design, detailed earthing assessments and subsurface location services for the retrospective undergrounding of Western Power overhead lines in the Town of Claremont. Part of the WA State Undergrounding Power Project (SUPP).

POWER LOAD MANAGEMENT CONTROL SYSTEM AND NETWORK UPGRADE

APD Engineering was hired to perform design & implementation of the Power Load Management Control System & Network Upgrade.

Yandi Substation BHP MINE AREA C GROWTH REACTIVE SUPPORT

MINING AREA C GROWTH REACTIVE SUPPORT

Concept design, detailed design for installation of 10MVAR of reactive support for Mining Area C.

SOLOMON ISLANDS PROTECTION RELAY TESTING AND TRAINING SUPPORT

Protection relay testing and commissioning as well as training support.

ALINTA LINE RECONFIGURATION SECONDARY SCOPE

Secondary scope to facilitate reconfiguration of 66kV transmission lines connecting to the Alinta Power Station on the BHP network, including Line protection relay upgrades.

BALGO NETWORK AND POWER STATION UPGRADE

Engineering, Procurement and Construction Management (EPCM).

PILGANGOORA LITHIUM PROCESS CONTROL SYSTEMS COMMISSIONING

PILGANGOORA LITHIUM PROCESS CONTROL SYSTEM COMMISSIONING

Site commissioning of the new plant’s process control systems, enabling automation of the new equipment & ensuring ramp-up for operations.

HIGH VOLTAGE AUGMENTATION FOR JIMBLEBAR MINE EXPANSION

APD Engineering was engaged by BHP Iron Ore to provide HV Testing, Commissioning, Engineering Support & Design Revisions for their Jimblebar Mine Expansion.

SILVERGRASS EAST HV SUBSTATION SCADA DESIGN AND COMMISSIONING

APD Engineering performed detailed HV substation SCADA design of the RTU panels for each substation, RTU & HMI development, testing & site commissioning.

PLC and SCADA Development of Bulk Lubrication and Fuel Facilities

APD Engineering delivered & integrated the control systems for the new lubrication racks for the HME service bays, LV Workshop & the Bulk Re-Fueling Facility

REMOTE ABORIGINAL COMMUNITIES

Provide network and power station capacity upgrades to remote aboriginal communities.

WHEELARA & OREBODY 18 (OB18) VENT FANS VSD REPLACEMENT

APD was hired to perform detailed design and Process Control System (PCS) integration for a Variable Speed Drive (VSD) replacement of two vent fan soft starters at Wheelara and OB18.

NAMMULDI WATER TRANSFER PUMP STATION (SUB02)

Soil testing, detailed EPR/LFI study, earthing design and injection testing.

CSIRO MURCHISON RADIO-ASTRONOMY OBSERVATORY (MRO) – HV SUBMISSION

Power System Studies, Protection Grading Analysis, Earthing System Design & Site Testing.

SARACEN MINERALS POWERLINE WORKS

Engineering, Procurement, Construction and Management (EPCM)

RIO TINTO WICKHAM ACCOMMODATION EXPANSION

APD Engineering were contracted by PLP to engineer and design three new 1.5MVA and one 1MVA 11/0.433kV kiosk substations, powerline modifications and power and fibre optic cable reticulation for the Rio Tinto Wickham Accommodation Expansion.

NAMMULDI AGRICULTURAL PROJECT (NAP) – PIVOT CONTROL SYSTEM SIMPLIFICATION

Review of the Agricultural Pivot Control System, implementation of the recommended simplification design and construction.

WASTEWATER TREATMENT PLANT EARTHING AND LIGHTNING PROTECTION TESTING

Visual inspection and testing of the lightning protection, earthing and bonding systems for the Point Lookout Wastewater Treatment Plant. The project came about due to multiple instrument and electric motor failures, attributed to insufficient earthing of the instruments.