The engine commissioning process takes account of all elements of the Design and Functional Specifications to ensure all elements of the system operate as designed, and interface with the entire system completely.
Whether the Scope of Supply includes a single generating unit, combined heat and power (CHP) plant or a full turnkey project, our Commissioning Team is responsible for the commissioning and setting into safe operation all equipment and services supplied as per the Scope of Supply.
We work closely with the suppliers of ancillary equipment to ensure:
- All equipment supplied meets the relevant specification
- Any suppliers completing Installation and Commissioning works demonstrate that such works can and is completed to the highest standards
- All equipment is installed correctly
- All individual equipment or elements of any system operate as designed and required
- All supplied equipment interfaces correctly with both the Edina Systems and the complete site systems as required
Dependent upon the Edina Scope of Supply the Commissioning Process normally falls into four key areas.
Many pieces of equipment or services are tested to ensure that energisation of a building or system can take place safely. These include:
- Electrical transformers, cabling and switchgear – Correctly installed, inspected and tested appropriately before being made ‘live’
- Pipeline Systems – Correctly installed, cleaned and tested before being filled with operating medium
- Fire, Gas, and Security systems – Correctly installed, inspected and tested appropriately to ensure that they offer the relevant protection when required
Dry or Static Commissioning
Commissioning of the generating unit or CHP plant is completed to ensure that all systems are safe to energise and are completed before the unit is started. These include:
- All relevant and required pre-running checks and set up procedures as determined by the generating unit manufacturer are completed
- Complete static inspection of the installed systems, including all oil, gas and cooling systems
- Complete testing of all PLC Programming and Binary and Analog I/O
- Static testing of the alternator / generator unit
- Static Testing of GCB Or HV Switchgear, Interfacing and controls,
- Testing of all valves & controls including operation and strategy
- Testing of all installed safety systems
Additionally, throughout this stage all systems and equipment external to the generating unit or CHP plant is inspected and tested to ensure all systems are safe to enter operation. This includes:
- Pre Heating Systems – checked and tested, to ensure the installation meets all regulatory, design and safety criteria
- Building Ventilation Systems – tested to ensure correct operation at the relevant times and that all safety interlocks are operational
- Gas Systems – all installed gas systems and equipment is tested in accordance with regulatory requirements
- Bulk Oil Supply Systems – installed correctly, tank level gauges and alarms operational
- Waste Heat Recovery Systems – Boiler or Heat Exchanger – installed correctly, complete relevant pressure testing, ensure all safety systems tested, ensure associated control systems operate correctly
Wet / Live or On Load Commissioning
The generating unit or CHP plant is started and all checks relevant to safe operation and synchronisation of the unit against the electrical grid are carried out to include:
- Initial Start / Stop Tests
- Verification of all protection elements and settings
- Initial synchronisation checks, to ensure the generator aligns with the electrical grid
- G59 / G10 (Mains Protection Tests) to Distribution Network Official satisfaction
Once the generating unit or CHP plant is capable of grid synchronisation, it is brought up in load stages according to recommendations set by MWM and Edina. The load stages are carried out in isolation from any site system to ensure the generating unit or CHP plant is capable of attaining full load capability.
During this process and at each load step, the engine, alternator and system pressures, temperatures, exhaust emissions and performance is checked with calibrated equipment and the results are recorded and verified against stated performance criteria.
The generating unit or CHP plant is then ‘opened up’ to the sites systems. At this stage, the performance and output of the each unit is checked against agreed performance criteria, thermally and electrically, and any adjustments or trimming of the control systems is carried out. This includes a period of ‘normal’ operation against all site systems.
Once complete, the generating unit or CHP plant is subjected to an internal ‘trial’ performance test to ensure that all Contractual Performance criteria is met, including:
- Electrical & Thermal Output Efficiencies
- Gas Usage
- Noise Specifications
- Exhaust Emissions
- Reliability over a pre-determined period
- Start-up & Load Ramp Tests
- Hot & Cold Start Capability Tests
In accordance with Contract Conditions in place, the generating unit or CHP plant is then subjected to the agreed Performance Tests. These would normally replicate the ‘Trial’ tests completed. The timing and duration may vary according to the individual customer requirements.
Providing all the necessary tests and inspections have been passed satisfactorily, the generating unit is considered to be ready to enter commercial operation. This may initially be in the form of an extended reliability test period, e.g. 28 days.
At the time of Handover to the End User, the Commissioning Team will complete the Operator familiarisation Training, the purpose of this is to, familiarise Site Staff and Operators in the Safe, Routine Operation of the Edina Supplied Equipment installed. This includes:
- Plant components and layout
- Electrical Schematics & P&ID’s
- Interface with client systems
- Pre start checks
- Start, stop, load change
- Manual and automatic control
- Fault recognition & diagnosis via TEM and ComAp systems
- Emergency stop & Protection systems (electrical, mechanical)
- Isolation of plant ancillaries – (electrical, mechanical)
- Draining and filling systems
- Daily and weekly operator checks
- Instruction manuals
Our Integrated Approach
Our Commissioning and Project teams are involved at the point of Sales handover. During the course of Project Progression, the Commissioning Manager, together with the Design and Project Teams, produce a dedicated Commissioning Documentation package to suit the individual project installation and meet your strategic requirements.
- Risk Assessment and Method Statement (RAMS) and procedures
- Commissioning checklist and documentation
- Inspection and Test Plan
- Full supporting document package