Commisiong Pro for Solar Sys VEN-3397-DGEN-2!05!0461_A.1.0 (1)

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COMMENTS RESOLUTION SHEET

[CRS]

CONTRACT NUMBER GC13100800 QP PROJECT NUMBER 3397

CONTRACT TITLE EPIC FOR WELLHEAD SCADA AND CATHODIC PROTECTION IN DUKHAN

QP EXTERNAL TRANSMITTAL REFERENCE EDD/GC13100800/EXT/TN/348л DATE нфπ03-2015

DOCUMENT NUMBER VEN-3397-DGEN-2-05-0461 DOCUMENT REVISION н

DOCUMENT TITLE PRE-COMMISSIONING AND COMMISSIONING INSTRUCTIONS / PROCEDURES FOR SOLAR POWER

SYSTEM

No. QP COMMENTS CONTRACTOR RESPONSE

1 Code-1: Approved. Works may proceed. Noted. Document issued AFC.

C)

Qatar Petroleum

PROJECT/CONTRACT REF 3397 I GC1 31 00800

ENGINEERING PROCUREMENT INSTALLATION AND COMMISSIONING

FOR WELLHEAD SCADA AND CATHODIC PROTECTION IN DUKHAN

DOCUMENT TITLE:

PRE-COMMISSIONING AND COMMISSIONING INSTRUCTIONS / PROCEDURES FOR SOLAR POWER SYSTEM

EPIC CONTRACTOR:

QATAR KENTZ W.L.L. Engineers & Constructors P.O. Box 3865 Doha, Qatar Tel.; +974 4402 5222 Fax: +974 4455 2153/54

I KENTZl

Engineers & Constructors

Member of the SNC-Lavalln Group

CONTRACTOR DOC. NO : MQAE621-V0E-9391

VENDOR I SUBCONTRACTOR: SunPower I Tenesol SAS 12 allee du Levant 69890 La Tour de Salvagny - France [email protected] Tel: +33 4 78 48 88 50

SUNPOWER M06£ £NE*GY FCf uff

rfe I .ft W® RR/TC 29-03-15 Apporved for Construction BJ/LM BD A QP

RR/TC BJ/LM BD 19-03-15 Re-issued for Comments 2 QP

RR/TC 25-02-15 Re-issued for Comments BJ/LM BD 1 QP

Issued for Comments RR/TC BJ/LM BD QP 26-01-15 0

PREPARED CHECKED APPRD. APPRD. REASON FOR REVISION DATE REV.

BY BY BY QP

SHT 1 OF REV A VEN-3397-DGEN-2-05-0461 23 DOCUMENT NUMBER:


TABLE OF CONTENTS

1. INTRODUCTION .................................................................................................... 3

2. OBJECTIVE ........................................................................................................... 3

3. ABBREVIATIONS AND DEFINITIONS ................................................................. 3

4. HEALTH, SAFETY AND ENVIRONMENT ............................................................ 3

5. APPLICABLE DOCUMENTS ................................................................................ 4

6. TOOLS & EQUIPMENT RECOMMENDED FOR COMMISSIONING ................... 4

7. PRE-COMMISSIONING RECOMMENDATIONS .................................................. 5

PRE-COMMISSIONING RECOMMENDATIONS FOR GROUND CONNECTION5

PRE-COMMISSIONING RECOMMENDATIONS FOR BATTERIES .................... 5

PRE-COMMISSIONING RECOMMENDATION FOR THE LOAD CONNECTION 5

8. PRE-COMMISSIONING INSTRUCTIONS FOR PV MODULES ........................... 5

TEST OVERVIEW .................................................................................................. 6

TEST PROCEDURE .............................................................................................. 6

TROUBLESHOOTING ........................................................................................... 7

RECORDS .............................................................................................................. 8

9. COMMISSIONING PROCEDURE ......................................................................... 8

10. APENDICES ........................................................................................................... 9

Doc.No.VEN-3397-DGEN-2-05-0461 Rev.A Page 2 of 23


1. INTRODUCTION

The scope of work is to provide the pre-commissioning and commissioning recommendation & instructions for the Off-grid solar power system of the project QP DUKHAN FIELD - WELLHEAD SCADA AND CATHODIC PROTECTION in Qatar.

2. OBJECTIVE

The target of this procedure is to define the commissioning procedure for the Off-grid solar system & related equipment installations.

The processes and methods detailed in this document adopt best practice associated with the commissioning of an off-grid solar power system with health and safety requirement

The pre-commissioning phase shall start when construction is successfully completed:

- Array construction completed

- Electrical cabinet installation completed

- Loads installation and connection completed

- Array equipment grounding complete

This document does include all electrical check to be performed during commissioning but does not cover visual inspection of the system (i.e. visual check of PV modules, structures and battery banks). It is assumed that visual inspection is performed during the construction phase of the project.

3. ABBREVIATIONS AND DEFINITIONS

- QP Qatar Petroleum

- VOC Voltage Open-Circuit

- ISC Short circuit current

- RISO Resistance isolation

- PPE Personal Protective Equipment

- PVS Photovoltaic Supervisor

4. HEALTH, SAFETY AND ENVIRONMENT

CONTRACTOR shall follow and execute scope of work as per CONTRACTOR’s and COMPANIE’s HSE Plan Documentation.

Prior to start of work, CONTRACTOR shall undergo CONTRACTOR’s HSE Induction.

Safety of personnel shall be of the utmost priority in the execution of the works and compliance with the required PPE will be strictly enforced (see below list of recommended PPE).

Before commencement of work a Toolbox Talk shall be carried out each day.

All tools to be utilized shall be pre inspected for fitness for use and shall be regularly checked in accordance with procedure to be defined by contractor.



Following PPE are recommended at minimum to perform pre-commissioning test procedure:

- Non-melting or untreated natural fiber long-sleeved shirt and pants

- Hard hat

- Safety glasses or goggles

- If necessary hearing protection

- Rubber insulating or heavy duty leather gloves

- Rubber-insulating steel-toe boots or shoes

5. APPLICABLE DOCUMENTS

This procedure shall be read along with following documents

- Installation Manual for Solar Power System ref. VEN-3397-DGEN-2-21-0460

- Single Line Diagram ref. VEN-3397-DGEN-2-54-0460

- Charge Controller Wiring Diagram Ref. VEN-3397-DGEN-2-71-0460

- Charge Controller Layout Drawing ref. VEN-3397-DGEN-2-50-0461

- Cathodic Protection Controller Wiring Diagram ref. VEN-3397-DGEN-2-61-0460

- Cathodic Protection Controller Layout Drawing ref. VEN-3397-DGEN-2-61-0461

- Load shedding philosophy ref. VEN-3397-DGEN-2-03-0460

- PV Module E20 datasheet

- “safety and installation instructions PV module” ref. Doc 001-15497 (provided with PV modules)

- Battery Saft documentation (installation manual, commissioning and storage instructions)

6. TOOLS & EQUIPMENT RECOMMENDED FOR COMMISSIONING

All tools listed below are recommended by Sunpower and shall be available at site to perform the commissioning.

Tools Pictures

Solar Installation Test kit (i.e PV150 – Seaward) including solar irradiation sensor

Digital Voltage Tester VAT (i.e Duspol Digital)

All usual electrician tools



7. PRE-COMMISSIONING RECOMMENDATIONS

This section includes all pre-commissioning instructions on components.

PRE-COMMISSIONING RECOMMENDATIONS FOR GROUND CONNECTION

Following minimum verification are required for grounding connections:

- Verify each PV module support structure is connected to the site ground

- Verify each electrical cabinet is connected to the site ground

- Verify with the solar installation test kit the continuity of each ground connection point.

- Verify with the solar installation test kit the resistance value of the site. It shall be compared to the CONTRACTOR acceptable value.

Please note that Ground connection shall be in accordance with the approved documents.

PRE-COMMISSIONING RECOMMENDATIONS FOR BATTERIES

Following minimum actions are required for batteries and battery cables:

- Batteries shall be fully charged prior to installation/ pre-commissioning

- First connect battery cables on regulation controller unit side in order to avoid any risk of short circuit.

- Once done, battery cables can be connected on the battery bank terminals

- Record the voltage of each battery cell with following format. A complete table is attached in appendix (template 1).

Cell 1 Cell 2 Cell 3 Cell 4 Cell 5 Cell 6

Voltage

- Verify that battery cells are in the acceptable range of voltage according to data coming from battery manufacturer.

- For more information and details on the battery pre-commissioning procedure, please refer to Saft documentation. Especially In case of a long time storage (more than maximum required by Saft).

PRE-COMMISSIONING RECOMMENDATION FOR THE LOAD CONNECTION

Following minimum verification are required for load connections:

- Verify the polarity connection of each DC output cable from the regulation unit to the CP

- Verify the polarity connection of each DC output cable from the regulation unit to the RTU

- Visually check the torque mark inside each electrical cabinet. If they are correct, please continue the test, if not, verification of torque shall be done.

8. PRE-COMMISSIONING INSTRUCTIONS FOR PV MODULES

This section includes all pre-commissioning instructions on PV modules supplied for this project.



TEST OVERVIEW

Each PV module except dummy modules will be verified during this phase. All this test must be done through solar cables of each modules.

In order to verify PV modules work correctly, this test consist in verifying the correct connection and recording short-circuit current and open voltage circuit of each module.

TEST PROCEDURE

# Test Step Detail Pass Value

Fail Value

1 Measure irradiance at the plane of the array >300 W/m2

<300 W/m2

2 If step 1 passes then proceed with the next step; if step 1 fails

Perform test at a different time with better sunlight

3 Set the PV tester to pair with the irradiance meter

Connect the negative lead of the multi-meter (of the PV tester) to the module frame or to the closest ground connection.

4 Connect the negative lead of the PV tester to the negative connector of the module connection.

Connect the positive lead of the PV tester to the positive connector of the module connection.

5 If PV tester indicates positive voltage, the module polarity is correct +V -V

Negative Connector

Positive connector



# Test Step Detail Pass Value

Fail Value

6 If step 5 passes then proceed to the next step.

If step 5 fails:

Perform rework / repair

Retest (from step 4)

If it fails again, please refer to “troubleshooting” section 8.3

7 Press button to start test on PV Tester. PV Tester will show values for VOC, ISC, RISO, and Irradiance. Press button to save record of values in PV Tester memory.

8 Repeat above test steps 4-7 for each module.

9 Export data from PV Tester to Excel.

Review test results of all module voltages

Calculate average VOC of all modules and compare each module to the average.

±5%

of avg.

Over ±5% of avg.

10 If step 9 tests pass, procedure is closed; if step 9 fails

Retest during stable irradiance

Investigate low voltage/current module

Perform rework / repair / replace

Retest repaired or replaced module

If it fails again, please refer to “troubleshooting” section 8.3

TROUBLESHOOTING

# Troubleshooting

(perform steps below as needed to resolve problem)

PV Module Low Voltage

1 Check that the wire insulation has been stripped back

Check that all connectors are properly seated for the module

Look for a panel with low voltage compared to the other panels

Replace any bad panels

Test each individual panel voltage

2 High resistance indicates a wire or connection problem

Repair connection or replace wire



# Troubleshooting

(perform steps below as needed to resolve problem)

3 Visually inspect module wiring for insulation damage including

Cuts

Scrapes

Pinched wire

4 Visually inspect all connections at

Module

Module Junction-Boxes

RECORDS

All measurements shall be recorded and saved in excel. Those measurements shall include all measured values and tests conditions. Please see an example of a Test Report performed on PV modules:

9. COMMISSIONING PROCEDURE

This section includes all commissioning instructions on the solar power system provided by Sunpower.

Each step to perform the commissioning is detailed in appendix (template n°2).



10. APENDICES

TEMPLATE 1: Battery Voltage Records.

Please refer to description page 10.

TEMPLATE 2: Commissioning procedure

Please refer to page 11.

TEMPLATE 3:

TEMPLATE 3-1 Cathodic protection commissioning form

TEMPLATE 3-2 Charge controller type 1 commissioning form

TEMPLATE 3-3 Charge controller type 2/3 commissioning form

TEMPLATE 4: Site acceptance certificate

TEMPLATE 5: The Micha Design Company Limited doc n° 802195-A.doc

Please refer to page 20





TEMPLATE 1- BATTERY VOLTAGE RECORDS - Measures

BANK 1

Site n° Site type

Global Battery Bank Voltage Bank 1


Voltage


Voltage


Voltage


Voltage

Cell 25 Cell 26 Cell 27

Voltage

BANK 2

Global Battery Bank Voltage Bank 2


Voltage


Voltage


Voltage


Voltage

Cell 25 Cell 26 Cell 27

Voltage



TEMPLATE 2: COMMISSIONING PROCEDURE

No. Switching Instruction Hazard Responsible Person Result Time/

Initials

1 Prerequisites for Energization- Prior to switching Order section

Pre-commissioning completed

All system ready to be energized

Please note that this section shall be done during day time (to get energy from PV)

2 Verify the site is clear from installation wastes and read carefully the safety

Date: Operator

SwitchingOrder: Docrev. 0

Siten° SiteType



instruction from CONTRACTOR and advises listed in section 4

3 Close fuse QF2

4 System energized by Battery bank n°1

5 Close fuse QF3

6 System energized by Battery bank n°2

7 Switch On Q1

8 PVS datalogger initialization

Please note that PVS will start in “night mode” as PV are not connected. PVS will check its inputs every 10 minutes, then for the following verification, please take into account this data.

9 Switch On breaker QA1

10 System energized by sub array n°1

11 Control PV voltage and current in the PVS (relay charger n°1)

If no current, please refer to comment on part 8









18 Switch On Q4

19 Verify it does energize the output of the DC/DC and verify that voltage appears at the top of breakers Q5 and Q6, it shall be 24V +/-5% (+/-1.2V)

20 Switch On Q7 (this is applicable only for type 2&3)

21 Verify that voltage appears at the top of breakers Q8 and Q9, it shall be equal to the battery voltage (around 36V)

22 Switch On Q5

23 RTU Load energized



Verify voltage at CP controller incomer. It shall be equal to the voltage mentioned in step 21 above

24 Switch On Q8

25 CP Load energized. Verify voltage at CP controller voltage. It shall be equal to the voltage mentioned in step 21 above.

26 Please follow the CP commissioning procedure attached in appendix of this document (The Micha Design Company Limited doc n° 802195-B.doc)

Please note that we have no information on how the Black Box interface is connected to the RTU, or how the MODBUS TCP/IP link can be tested and have therefore left this section blank. It shall be completed by RTU supplier.

27 Please test the communication of the regulation unit through Modbus TCP/IP link to Modbus poll software.



28 Perform functional test as applicable as per fully integrated system FAT procedure (use templates 3)

29 Once load is energized, simulate the CC failure test i.e load continue to feed from battery even charge controller failed

30 Disconnection/connection of the battery bank without affecting 50% of the output load.

Operator/Switchman:_________________________________________ Time: ____________________ Date: __________________

Checked by:_________________________________________________ Time: ____________________ Date: __________________



TEMPLATE 3-1 CATHODIC PROTECTION COMMISSIONING FORM

Date:

Tag number: Cathodic protection

OK NOK

Tag plate

Polarity check

Communication test

Constant voltage mode

Constant current mode

Disable input

Auxiliary input

Interrupt timer

Alarm relay

Remarks:



TEMPLATE 3-2 CHARGE CONTROLLER TYPE 1 COMMISSIONING FORM

Date:

Tag number: Charge controller

type: 1

OK NOK

Tag plate

Communication test

Powering of charging relays

Charging current measurements

Unpowering of charging relays

Output voltage of DL1

DL1 current measurement

Low voltage disconnection of DL1

Low voltage disconnection alarm

Low voltage alarm

High voltage alarm

Battery charging 1 off


Door open alarm

Common fault alarm

Remarks:



TEMPLATE 3-3 CHARGE CONTROLLER TYPE 2/3 COMMISSIONING FORM

Date:

Tag number: Charge controller

type: 2/3

OK NOK

Tag plate

Communication test

Powering of charging relays

Charging current measurements

Unpowering of charging relays







Low voltage disconnection alarm

Low voltage alarm

High voltage alarm



Door open alarm

Common fault alarm

Remarks:



TEMPLATE 4 - SITE ACCEPTANCE CERTIFICATE.

Site n° Date of commissioning

Batch n° Site type (1, 2 or 3)

Those verifications shall be conducted based on applicable drawings and manuals (see list of applicable drawings in the project vendor document list)

Visual inspection : TICK

PV array are correctly fixed to the support structure

No particular shadow is present on the PV array which can affect the daily PV production

No particular crack or scratch is present on the glass of the PV module

All part are clean Describe all present damages or scratch out on the support structures:

Electrical cabinets are well fixed on the skid

Cables are correctly routed, crimped and well protected against any damaged

Battery boxes and batteries are correctly installed and wired

All cable glands are correctly tightened on cables

Electrical inspection:

PV strings are verified following pre commissioning instructions

Batteries are commissioned following manufacturer recommendations List down alarms present on the RCU and CPC (if any question, please come back to Sunpower for further information)

-

Approved

Approved with comments

Rejected

Comments:

Date Kentz Team member + Name signature


Tenesol / Sunpower Qatar Petroleum 802195-B.doc

CP Commissioning Procedure

MF Page 1 of 4 The Micha Design Company Ltd

1. Revision Status

Issue Description of Change Date Approved A First Issue 5 Jan 2015 MF/LH B Add Interrupt Timer Test and Alarm Relay Test 23 Jan 2015 MF/LH

Table 1 : Revision Status

2. Introduction

This document describes the commissioning of the CP Controller.

2.1. Typical System Wiring for Cathodic Protection Systems

As a CP system works by passing current through ‘ground’, it is essential that the system Common (the Positive potential) is only grounded at the output of the CP Controller. If a ground connection is made at any other point in the system, it is possible that the CP Controller will not be able to monitor or control the output current and voltage correctly, particularly if a reference electrode is used.

CHARGE CONTROLLER

CONTROL

SOLAR ARRAY BATTERY

+

COMMON POSITIVE

GROUNDBED

PROTECTED STRUCTURE

CATHODIC PROTECTIONCONTROLLER

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

CONTROL

MCBMCB

Grounding of Enclosures

The grounding of enclosures and structures is acceptable, but under no circumstances should a connection be made from the system common to a metal enclosure or structure otherwise the protective current is liable to have an adverse effect on these parts, and in some cases may accelerate corrosion.

TEMPLATE 5





3. Commissioning

3.1. Input Power

On the CPC Control PCB Assembly, ensure the Enable/Disable switch is set to the DISABLE position.

Turn on the power to the CP Input terminals.

On the CPC Control PCB Assembly, ensure the green Status LED is illuminated.

3.2. Initial Output Set-points

To start with Constant Voltage Control:

Navigate to Menu 0 Screen 1 and set the Output Voltage Set-point = 0.0V (minimum)

Navigate to Menu 0 Screen 2 and set the Output Current Set-point = 5.0A. This is given as an example of the required output current – set it to the output current desired.

Navigate to Menu 0 Screen 3 and set the Half-Cell Voltage Set-point = 5.0V. Setting the Half-Cell Voltage at its maximum ensures that the half-cell control will not interfere with Constant Voltage Control.

3.3. LCD Display

Verify the LCD display indicates the following ± 0.3 (assuming there is no half-cell fitted):

Voltage Current H-Cell

00.0V 00.0A 0.0V Actual

00.0V 5.0A 5.0V Set-Points

Note: If a Half-Cell (Reference Electrode) is fitted, the indication on the Half-Cell meter should match the structure to soil potential (as measured by a portable half-cell and meter).

Note: If a Half-Cell is not fitted, then ensure a wire link is fitted across the Half-Cell input terminals.

3.4. Constant Voltage Control

On the CPC Control PCB Assembly, ensure the Enable/Disable switch is set to the ENABLE position.

The Cathodic Protection Controller can now be set up to operate at the required level in the appropriate operating mode.


00.0V 00.0A 0.0V Actual


Increase the Output Voltage Set-point (Menu 0 Screen 1). The voltage and current actual values should indicate an increase as the set-point is increased. The CP Controller is operating in Constant Voltage Mode (readings dependant on ground conditions – example shown is 1.0 ):


4.0V 4.0A 0.0V Actual






3.5. Constant Current Control

Continue to increase the Output Voltage Set-point (Menu 0 Screen 1) until the voltage and current actual values indicate no further increase. The current actual value should equal the current set-point value (e.g. 5.0A). The CP Controller is operating in Constant Current Mode (readings dependant on ground conditions – example shown is 1.0 ):


5.0V 5.0A 0.0V Actual


3.6. Half-Cell Voltage Monitoring

This is only applicable if there is a Half-Cell (Reference Electrode) connected.

Note: If no Half-Cell is fitted, a wire link should be fitted to short out the Half-Cell terminals.

With the supplied software for this project, no Half-Cell control is available, but the value on the input terminals is sampled with the value displayed on the screen. The set-point should be set to 5.0V.

3.7. Disable Input

Connect a wire link across the Disable Input terminals and note that the CP Output Current drops to zero.

Remove the wire link across the Disable Input terminals and note that the CP Output Current goes back to its previous value.

3.8. Interrupt Timer

Navigate to the Interrupt Timer Set-up Screen (Menu 2) and ensure that the Interrupt Timer is set for 10 seconds on and 10 seconds off.

Navigate to Menu 2 Screen 1: “Int Tim: Disabled Select to change”. Activate the Interrupt Timer by pressing Select.

Navigate to Menu 0 Screen 0. Check that during the OFF time, the Output Current indicated on the LCD Display falls to zero, and LED6 (Disable Input) illuminates. Check that during the ON time, the Output Current indicated on the LCD Display returns to the Output Current Set-point and LED6 extinguishes.

Navigate to Menu 2 Screen 1 and de-activate the Interrupt Timer by pressing Select.

3.9. Alarm Relay Test

Navigate to Menu 3 Screen 3 and press Select to change the state of Alarm Relay 1



Use a continuity meter or a DVM set to resistance to check the change in status of the Relay contacts.

3.10. Communications

TBA

3.11. End of Procedure





4. Commissioning Record

Site:

Date:

Commissioned By:

Signed:

Section Description Voltage Current Half-Cell OK

3.1 Input Power

3.2 Initial Output Set-points 0.0V 5.0A 5.0V

3.3 LCD Display 0.0V 5.0A 5.0V

3.4 Constant Voltage Control 5.0V

3.5 Constant Current Control 5.0A

3.6 Half-Cell Voltage

3.7 Disable Input

3.8 Interrupt Timer

3.9 Alarm Relay Test

3.10 Communications

3.11 End of Procedure


Documents

Commisiong Pro for Solar Sys VEN-3397-DGEN-2!05!0461_A.1.0 (1)