EPC Journal Archive

EPC Services - Commissioning

27 August, 2022

Commissioning is a critical function that must be done correctly by professional personnel. It is absolutely essential that in times of failure, the system operates as intended.

The potential problems and remedies are outlined:

While schematics deal with functionality, wiring diagrams present the physical arrangement. It is important that identical equipment are not only "functionally identical" but "physically identical" too. Otherwise, this leads to problems identifying physical test points.
The inspection and test plan (ITP) has not been properly developed. In this case, the ITP only confirms functionality: does it start?, does it stop? etc. Even if were to work perfectly, we are only half way there. The plan needs to include fault scenarios.
The ITP is vague: e.g. verify xxx responds to magnitude yyy in zzz time. We need more than this. Describe the test set up or make reference to an external document. Often, its not included through lack of knowledge or lack of time to properly develop the ITP
The ITP includes fault scenarios, but have not been well thought out. This often happens when the ITP has been developed without strong inspection and test experience. In addition to verifying the equipment build complies with the design, we also need to confirm various failure modes, and record the results against the expected outcome. Is the outcome been accounted for in the design? the outcome is not surprising or is surprising? We need to redesign?
The last point, an experienced test engineer. In quite a few cases, the ITP does not cover all important scenarios. Here, the test engineer will use his experience and judgement to determine if any scenarios have not been accounted for, that might otherwise lead to an unexpected outcome.

A well prepared Inspection and Test Plan and an Experienced Test Engineer can mitigate problems that might otherwise compromise safety, performance, and damage to assets.

Contact us if you need advice on your commissioning needs. We are able to offer bespoke solutions without obligation.

Our scope covers

Grid connection
HV/MV/LV switchgear,
Transformers, reactors
VFD and motor control
Lighting and Grounding

Read more about our Commissioning Services here

EPC Services - Commissioning

20 August, 2022

Some time back, I was engaged in developing a "Health Care Plan" for critical vessels. One of these vessels was the Deep Blue, owned and operated by Technip (now TechnipFMC).
It included the inspections and testing of the principal components of the electrical system, including Generators, Medium and Low Voltage Switchgear, Transformers, Propulsion Drives, and Motors.
Shortly after starting my inspection and testing of the main generators, I was informed by the staff, that the #2 generator (forward engine room, if I recall correctly) just didn't seem to respond well when synchronized to the switchboard. I was told that a new AVR (Automatic Voltage Regulator) was fitted but no improvements were noted.
Inspections revealed damage to the exciter, which was supported by tests. All in all, nothing special, but what can we learn from this?

Routine Inspections: For critical installations, it is important to have a routine inspection and test plan that covers the major electrical equipment. The electrical system has in the past, been one of the weakest links that results in downtime. It is possible that a well-developed inspection and test plan could have identified problems early before they deteriorated into major problems.
Performance Audit: A performance audit can be scheduled to identify potential problem areas that could result in unscheduled outages. In this case, it could be observed that the original equipment selection and design, might not meet current industry practice, and that a few simple changes could have significant improvements on the reliability and availability of the system.
Intelligent Upgrade: In the case that a performance audit is performed and recommendations presented, additional measures could be implemented to make the system more intelligent to anomalies. Such changes could include on-line monitoring of the various parameters such as: (for generators) (a) Is the fuel consumption consistent with the power output? (b) Is the excitation current consistent with the active and reactive power output? (c) Is there any change in the harmonic signature of the machine? (d) Is there any unusual changes in prime mover cooling water temperature to generator active power output? (e) Is the generator winding temperature and ambient temperature consistent with the generator output? These are all very easy to monitor and flag, when the values deviate outside the predefined limits,

Intelligent Upgrades can be applied to generators (as described above) as well as other principal equipment, such as transformers, switchgear, drives and motors.

Nowadays, equipment monitoring has become very advanced, and new installations are normally well monitored and protected, although that does not necessarily mean they are intelligent. Sometimes basic algorithms, and added monitoring and protection, can fill an important void, and bring about an added layer of security.

After all, if we cant monitor it, we can't control it.

CSO Deep Blue, Tampa Drydock

What simple measures can be put in place to improve the Power Supply of Critical Installations? In this short article we discuss a simple three-step approach that will bring perspective to the question.

Contact us if you need advice on your commissioning needs. We are able to offer bespoke solutions without obligation.

Our scope covers

Grid connection
HV/MV/LV switchgear,
Transformers, reactors
VFD and motor control
Lighting and Grounding

Read more about our Commissioning Services here

EPC Services - Independent Project Reviews

9 August, 2022

EPCI Solutions provides Independent Project Reviews covering all major disciplines, with a focus on Electrical, Automation, Instrumentation and Telecommunications systems and equipment.
What is an Independent Project Review and why do I need one?
The IPR is an important project management mechanism to support project participants and sponsors towards performance excellence. The IPR is a second, unbiased, expert assessment of project health; the first being the ongoing project evaluation by project teams and sponsors. If conducted by a team of objective, fair, and diversely experienced project managers, specialists and consultants, the IPR adds value by identifying additional actions which, when implemented, will improve project performance.

Independent Project Reviews provide a low-cost means to ensure that no surprises will arise at critical times in teh project.

Contact us if you need advice on Project Reviews. We are able to offer bespoke solutions without obligation.

Our scope covers

Engineering and Design Review / Gap Analysis
Procurement of equipment and Services
Factory Works (Equipment FAT)
Fabrication Yard (Equipment installations)
Integration Yard (Commissioning)

Read more about our Independent Project Reviews here