Attachment_11_-Switchboard_System_Operational_Test_WT_PM.docx

IMPROVED NAVY LIGHTERAGE SYSTEM (INLS)

CONTRACT NO.

CDRL DATA ITEM NO:

Revision:

Hull:

TEST PROCEDURE PREPARATION/APPROVAL

PREPARED BY:

K. Fischer

DATE:

July 2015

APPROVED BY:

DATE:

TEST PROCEDURE CONDUCT

REVISION RECORD

PAGES

Original Issue

TEST OBJECTIVE:

The objective of this test is to demonstrate satisfactory SSDG control features and paralleling in manual and automatic modes.

EQUIPMENT INVOLVED:

1. Ship Service Generator #1

2. Ship Service Generator #2

3. Ship Service 460V Distribution Switchboard

REFERENCES:

1. IEEE – 45, section 34.2.1, Ship Test, New Installations, Circuits

2. Electrical One Line diagram, NAVFAC Dwg 1600428

3. WT/PM Switchboard drawing

SAFETY PRECAUTIONS:

1. Test personnel shall strictly adhere to all shipyard safety precautions including, but not limited to all CAUTION and WARNING notes contained in this test procedure and applicable documents.

2. All unauthorized personnel shall be kept clear of test areas for duration of test. Persons in adjacent areas shall be notified of testing being done.

3. Arc Flash safety gear must be worn when exposed to energized circuits above 230 VAC.

4. Ensure all power sources are de-energized during insulation resistance tests.

5. Observe Wattmeter and Ammeter during voltage adjustment demonstration to prevent overloading generator.

6. In the event of unusual noise or vibration, shut down the unit.

PREREQUISITES:

1. Generator and Switchboard System Cable Test

2. Generator and Switchboard System Input Output Test

3. Generator System Operational Test WT/PM

ADDITIONAL INSTRUCTIONS:

1. Prior to the performance of this test, ascertain that the minimum requirements necessary for the start of this test have been met. Enter all deviations from the minimum requirements on the comment sheet. Verify test equipment is in current calibration and record the information on the Test Equipment data Sheet.

2. The test conductor will list on comment sheet, any discrepancies requiring corrective action, any unusual response observed while performing test or any significant events and observations occurring during performance of the test. If hazardous conditions exist, test is to be stopped until conditions are corrected.

3. Verify calibration of installed instruments and equipment to be used during test is complete.

4. All breakers on switchboard shall be secured during test. Vessel lighting electrical loads should be fed from a shore power supplied source the duration of the test.

5. Controls and indicators not specifically mentioned in this procedure shall be observed for proper operation.

6. Read the entire test procedure prior to initiating the tests described herein. Verify test equipment calibration is current and record equipment used on Test Equipment Log Sheet in this test procedure.

TEST EQUIPMENT REQUIRED TO ACCOMPLISH THIS TEST PROCEDURE:

QTY DESCRIPTION DESIGN TEST READING (DTS)

PERSONNEL REQUIRED TO ACCOMPLISH THIS TEST PROCEDURE:

1. Two Electricians and one Machinery Installer

GOVERNMENT SUPPORT PERSONNEL:

1. Subject Matter Expert (SME): One SME, ISEA/SSA/PE or equivalent to witness and sign off on testing as Government Representative.

2. Ship’s Force personnel to stand by as safety watch, as necessary.

3. Ship’s Force engineer to align machinery as required.

4. Ship’s Force ET to support electrical checks and system alignment.

5. Contractor will require 4 hours of ISEA or SSA support. This support must be scheduled with the ISEA or SSA at least two weeks in advanced.

EQUIPMENT CONFIGURATION:

1. Propulsion engines and marine gears shall have all fluids checked and filled to their service levels.

2. Ensure starting batteries have been charged.

3. Align fuel oil system for normal operation.

4. Ensure MCS and LOS panel is turned on and ready for operation.

TEST INSTRUCTIONS:

1. Disconnect all generator terminations and remove all fuses at the switchboard.

2. Test the insulation resistance of each phase of the bus to ground and phase to phase at 500 VDC. Record the readings on the data sheet.

3. Reconnect all generator terminations and reinstall the fuses at the switchboard.

5. Align all auxiliary equipment to support the SSDG under full load conditions.

6. Inspect all relays, circuit breakers and fuses. Ensure they are clean and properly installed.

A-PHASE BUS TO GROUND

B-PHASE BUS TO GROUND

C-PHASE BUS TO GROUND

A-PHASE BUS TO B-PHASE BUS

B-PHASE BUS TO C-PHASE BUS

A-PHASE BUS TO C-PHASE BUS

1. Place the SSDG MODE switch in the MANUAL position and verify the 1MSR relay has energized.

2. Rotate the MODE switch to AUTO and verify the 1ASR relay has energized and input 1 on the PLC Input module has energized.

3. Rotate the MODE switch to PM and verify the 1PMR relay has energized and input 2 on the PLC Input module has energized.

4. Using an ohmmeter, verify contact closure between 1FTB1 terminals 9 and 14 when the speed adjust switch is in the raise position and terminals 10 and 14 when the speed adjust switch is in the lower position.

5. Using an ohmmeter, verify the change of resistance between 1FTB1 terminals 11 and 12 when the voltage adjust switch is in raise position then lower position.

6. Repeat steps 1 through 5 for Generator #2. Verify status of 2MSR (Step 1), 2 ASR and PLC input 7 (Step 2), 2PMR and PLC Input 8(Step 3) and 2FTB1 terminals (Step 4 and 5).

1. Manually start the generator and bring up to rated speed.

2. Verify proper operation of the following devices:

3. At the main switchboard, verify the proper operation of the SPR (Switchboard System) metering functions.

4. Place the MODE switch in the MANUAL position.

5. Push the circuit breaker CLOSE push button and verify the following:

6. Push the circuit breaker OPEN push button and verify the following:

7. Repeat steps 1 through 6 for Generator #2.

8. Record satisfactory or unsatisfactory performance on the data sheet.

460 VAC CIRCUIT BREAKER AND METER OPERATION

VOLTMETER AND SWITCH

FREQUENCY METER

POWER AVAILABLE LIGHT

CIRCUIT BREAKER OPEN LIGHT

SPR METERING FUNCTIONS

CIRUIT BREAKER CLOSES

CIRCUIT BREAKER CLOSE LIGHT ILLUMINATES

CIRCUIT BREAKER OPEN LIGHT EXTINGUISHES

CIRCUIT BREAKER OPENS

CIRCUIT BREAKER CLOSE LIGHT EXTINGUISHES

CIRCUIT BREAKER OPEN LIGHT ILLUMINATES

1. Connect a 120VAC, 1 Ø power source at terminals 1 and 2 of 1FTB for #1 SSDG and 2FTB for #2 SSDG. Turn the GENERATOR HEATER switch to the ON position.

2. With the #1 SSDG circuit breaker open the GENERATOR SPACE HEATER light should be illuminated.

3. Close the generator circuit breaker; the GENERATOR SPACE HEATER light should be extinguished.

4. Repeat steps 2 and 3 for #2 SSDG.

5. Remove the power source from 1FTB and 2FTB.

1. Connect a 120 VAC, 1 Ø power source at TB1 terminals 1 and 2. Turn the switchboard heater to the ON position and verify 120 VAC is available at the cabinet heater.

2. Use a heat gun to warm the element on the cabinet heater thermostat and verify the thermostat de-energizes the cabinet heater.

3. Turn the heater switch to the OFF position and remove the power source.

1. Place Generator #1 and Generator #2 on line.

2. Raise the speed of Generator #1. Generator #1 breaker should trip. Verify relay status on the Switchboard System.

3. Repeat step 1 and step 2 with Generator #2 speed change.

1. Place all modes switches in MANUAL and start both generators; adjust the generators to 460 VAC and 60 Hz.

2. Close #1 SSDG circuit breaker.

3. Place synchroscope in GEN 2 position and verify proper operation of the synchroscope. Close #2 SSDG circuit breaker and open #1 SSDG circuit breaker.

4. Place synchroscope in GEN 1 position and verify proper operation of the synchroscope. Close #1 SSDG circuit breaker and Open #2 SSDG circuit breaker. Open #1 SSDG circuit breaker.

1. Place #1 SSDG mode switch in AUTO. #1 SSDG circuit breaker should close automatically.

2. Turn #2 SSDG mode switch in AUTO. #2 SSDG should automatically parallel with the bus and close the circuit breaker.

3. Open both generator circuit breaker and repeat step 1 and 2 with #2 SSDG being the first on-line.

1. Place #1 SSDG mode switch in PM. Close the breaker from MCC/LOS console. #1 SSDG circuit breaker should close automatically.

2. Place #2 SSDG mode switch in PM. Close the breaker from MCC/LOS console. #2 SSDG should automatically parallel with the bus and close the circuit breaker.

3. Activate the 1PM1 relay; #1 SSDG circuit breaker should open.

4. Activate the 1PM2 relay; #2 SSDG circuit breaker should open.

5. Repeat step 1 through 4 with #2 SSDG being the first on-line.

1. With either of the generators on-line verify that all ground phase green LED lights are flashing and all red LED lights are off.

2. Using a jumper, ground the Phase A bus of the switchboard. The Phase A green LED should go out and the Phase A red LED should flash. Remove the ground wire and press the LAMP TEST pushbutton. Verify the LED lights return to the pre-test condition.

3. Repeat step 2 on the Phase B bus.

4. Repeat step 2 on the Phase C bus.

NOTE: This test is conducted in a NO LOAD condition. Place the AUTO/MANUAL switch on the circuit breaker to MANUAL. The generator circuit breakers should remain open.

1. Manually start SSDG and bring it up to rated speed.

2. Verify the line voltage is 460 VAC and the frequency is 60 HZ.

3. Adjust the voltage to the minimum and maximum limits and record on data sheet. Reset the voltage adjustment to 460 VAC.

4. Adjust the speed control to the minimum and maximum limits and record on data sheet. Record the elapsed time from minimum to maximum on the data sheet.

5. Repeat steps 1 through 4 for #2 SSDG.

426.5 VAC MINIMUM

481.5 VAC MAXIMUM

SPEED CONTROL OPERATION

MINIMUM FREQUENCY

MAXIMUM FREQUENCY

ELAPSED TIME FROM MINIMUM TO MAXIMUM

SHUTDOWN PROCEDURES:

1. Return all machinery and switchboards to pre-test conditions.

2. Perform a visual inspection of the generator sets for liquid leaks, loose fittings, or loose connections.

TEST EQUIPMENT

NUMBER

SERIAL

NUMBER

CALIBRATION

DUE DATE

REMARKS/WITNESS

TEST TITLE: TEST NO: REV

Switchboard System Operational Test WT/PM

This test was conducted in accordance with this test procedure; no adjustments were made to equipment under test except as required by the test procedure, and the results of the test are as stated in this report.