Ethiopian TVET-System

Electro Mechanical Equipment Operation and

Maintenance

Level –IV
Based on March, 2017G.C. Occupational Standard

Module Title: Commissioning Electro

Mechanical Equipment
and All Auxiliary System

TTLM Code: EIS EME4TTLM0820 v1

August, 2020
This module includes the following Learning Guides

LG 40: Plan and Prepare Commissioning

Activities
LG Code: EIS EME4 M09 L0 01-LG-40
LG 41: Commission Electro Mechanical
Equipment/ Systems
LG Code: EIS EME4 M09 L0 02-LG-41
LG 42: Turn-over Electrical
Equipment/Systems
LG Code: EIS EME4 M09 L0 03-LG-42

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 2 of 125
and Maintenance
Agency June, 2020
Level-IV
 Instruction Sheet Learning Guide #40: Plan and Prepare
Commissioning Activities

This learning guide is developed to provide you the necessary information regarding
the following content coverage and topics

 Confirming works instruction

 Planning commissioning procedures
 Obtaining materials and PPEs
 Obtaining, estimating and inspecting tools, equipment and testing
devices
 Identifying and preventing potential hazards and/or selecting control
measures
 Coordinating commissioning activities
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –

 Confirm works instructions

 Plan commissioning procedures
 Obtain materials and PPEs
 Obtain, estimate and inspect tools, equipment and testing devices
 Identify and prevent potential hazards and/or select control measures
 Coordinate commissioning activities
Learning Instructions:

1. Read the specific objectives of this Learning Guide.

2. Follow the instructions described in number 3 to 20.

3. Read the information written in the “Information Sheets 1”. Try to understand what
are being discussed. Ask you Instructor for assistance if you have hard time
understanding them.

4. Accomplish the “Self-check 1” in page __.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 3 of 125
and Maintenance
Agency June, 2020
Level-IV
5. Ask from your Instructor the key to correction (key answers) or you can request
your Instructor to correct your work. (You are to get the key answer only after you
finished answering the Self-check 1).

6. If you earned a satisfactory evaluation proceed to “Information Sheet 2”.

However, if your rating is unsatisfactory, see your Instructor for further instructions or
go back to Learning Activity #1

7. Submit your accomplished Self-check. This will form part of your training portfolio.

8. Read the information written in the “Information Sheet 2”. Try to understand what
are being discussed. Ask you Instructor for assistance if you have hard time
understanding them.

9. Accomplish the “Self-check 2” in page __.

10. Ask from your Instructor the key to correction (key answers) or you can request
your Instructor to correct your work. (You are to get the key answer only after you
finished answering the Self-check 2).

11. Read the information written in the “Information Sheets 3 and 4”. Try to
understand what are being discussed. Ask you Instructor for assistance if you have
hard time understanding them.

12. Accomplish the “Self-check 3” in page __.

13. Ask from your Instructor the key to correction (key answers) or you can request
your Instructor to correct your work. (You are to get the key answer only after you
finished answering the Self-check 3).

14. If you earned a satisfactory evaluation proceed to “Operation Sheet 1” in page _.

However, if your rating is unsatisfactory, see your Instructor for further instructions or
go back to for each Learning Activities.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 4 of 125
and Maintenance
Agency June, 2020
Level-IV
 Information Sheet-1 Confirming Works Instructions

Introduction
Have you ever had something not to work but only discovered long after start-up? Do
you have an uneasy feeling that something might not be installed correctly, but don’t
know how to verify? Then try commissioning. Actually, Commissioning is nothing
new. What good engineer would not confirm an installation works? But if
commissioning is documented poorly, it is inadequate. If it is done improperly, it is
inadequate. Projects routinely have problems. One part of the solution to minimizing
project problems is to have a robust and documented Commissioning process
(assuming the design is robust in the first place). However, we can go to far and judge
success by the weight of the paper generated. How can Commissioning be
implemented meaningfully in the real world? This course will attempt to answer this
question.

The Developer has been an instructor in the commissioning electromechanical

equipment and all auxiliary system in the application of documented Commissioning
to minimize the regulated paperwork required for Validation/Qualification. He shares
his learned experience in this course in the practical application of commissioning,
whether in a regulated industry or not. This course is to a general audience – see
separate material for specific applications to the commissioning electromechanical
equipment and all auxiliary system.

1. Commissioning Content
1.1. What is commissioning?
1. Commissioning is to effect the safe and orderly handover of the unit from the
constructor to the owner, guaranteeing its operability in terms of performance,
reliability, safety and information traceability
2. Commissioning activities, in the broader sense, are applicable to all phases of
the project, from the basic and detailed design, procurement, construction and
assembly, until the final handover of the unit to the owner, including sometimes
an assisted operation phase

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 5 of 125
and Maintenance
Agency June, 2020
Level-IV
 1.2. Why Commission?
Commissioning is necessary to ensure facilities, equipment, and systems are
installed and function properly, and are successfully turned over. A documented
Commissioning approach offers traceable verification, and ensures a systematic
approach that minimizes commissioning oversights. Effective Commissioning
minimizes punchlist items, and improves startup by eliminating problems up-front.
Further, certain Commissioning activities may be used to support documentation
requirements for regulated industries.

1.3. Commissioning detail description

Commissioning is a well planned, documented, and managed engineering approach
to the start-up and turnover of facilities, systems, and equipment to the End-User that
results in a safe and functional environment that meets established design
requirements and stakeholder expectations. That is, Commissioning verifies what
was specified was installed; that it functions properly, and it was successfully turned
over to the user and reasonably ensures the next step verification for regulated
industries will be successful.

Given this definition, engineers have always commissioned projects to a degree. For
example, when a new pump is installed, the proper rotation and flow rate is verified.
Before it is installed, the model number and materials of construction are confirmed.
The controls are tested. At the end, a test and balance contractor adjusts circuit
setters for proper water flow rates, and to adjust gauges for proper water flow. At the
end of a project, the operators and maintenance staff are trained. To have a record
of what was installed, as-built drawings and Operations and Maintenance manuals
are developed. This is commissioning. All these activities can be summarized in
distinct Commissioning categories: Pre-Commissioning activities, Setting-to-Work,
Inspections, Testing, and Turnover. (Note: Setting to Work is a potential fourth
category, but may be included under Inspection or Testing as needed.)

1.4. Pre-Commissioning
Pre-commissioning activities are Site Acceptance Tests (SAT) and Factory
Acceptance Tests (FAT) as well as other similar activities. FAT’s are useful in
protecting the business aspect of an investment, by testing the equipment or system
at the factory. This allows the system to be tested and deficiencies corrected in a
manufacturing environment before it arrives on-site with surprises. The SAT verifies
proper equipment and operation on-site. For many projects, especially those with

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 6 of 125
and Maintenance
Agency June, 2020
Level-IV
single equipment systems, the SAT may constitute the majority if not all the
Commissioning inspection and testing requirements. Further, SAT’s (and FAT’s with
caution) may include elements sufficient for aspects of a regulated activity
verification. If a FAT is provided, the SAT could be a reduced regimen. However, be
careful in that changes made after the FAT in the factory (outside a controlled setting)
could affect acceptable outcomes.
The following are typical elements of FAT’s/SAT’s, as applicable:
a Confirm fundamental scope definitions (or Acceptance Criteria) and
Specifications
b Functionality –operate equipment/systems during test
c Alarms and safeties
d PLC/Controls thorough checkout/challenge
e Utilities
f Maintenance needs
g Calibration
h Labeling
i Training and turnover

1.5. Setting-to-Work
Setting-to-work and other regulation and adjustments are needed prior to energizing
the system or full startup. This could include factory representative start-up,
calibration, and other considerations needed before fully operating the equipment
and beginning other aspects of Commissioning.

1.6. Inspection
Inspection is the process by which the construction and installation is verified as in
accordance with the detailed design, specified construction standards and materials
and any relevant legal or regulatory demands related to these areas. From the
examples above, confirm the pump model number and verifying the air handler was
properly leveled are Inspection activities. Inspection activities generally do not
include testing, and often are better handled on forms separate from testing. (There
are exceptions when for succinctness or clarity Inspection items are included with
Tests.) Inspections are usually visual confirmations. The questions to ask when
developing an Inspection checklist are:
What needs observing to ensure the equipment is properly installed?
What needs inspecting to ensure project definition requirements,
Acceptance Criteria and other regulatory issues are met?
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 7 of 125
and Maintenance
Agency June, 2020
Level-IV
 What inspections are needed to reasonably ensure any subsequent
regulated verification will pass?
How will Inspection activities be structured/documented so repetition
during any regulated verification is not required?

When these basic questions are answered, commonsense will prevail. There is no
need to create volumes of documents of marginal value. Yet, documentation must
be adequately thorough. The key is to be specific with Inspection line items to ensure
documentation is traceable.

1.7. Testing
Testing is the process by which adjustments to, and regulation of, individual systems
are demonstrated as within the required tolerances, system components are
demonstrated as delivering the required capacity or duty, the functions of the systems
are demonstrated as delivering the required capacity of duty, the functions of the
system are demonstrated to be as specified and appropriate.iii Referring again to the
commissioning examples earlier in the article, checking the pump’s flow rate and
performing test & balance on the HVAC system are all testing activities. Essentially,
testing is needed on what was installed to ensure the equipment or system operates
as specified and required. The questions to ask when determining test requirements
are,
What level of testing is needed to ensure the equipment is
properly functioning as specified?
What tests are needed to ensure fundamental design
requirements, Acceptance Criteria, and other regulatory issues
are met?
What testing is needed to ensure (within reason) any required
regulatory verification will pass?
How can the testing be documented/structured so it will not need
to be repeated during any regulated verification?

As with Inspection, when the basic questions are answered, commonsense will
prevail. There is no need to create volumes of useless test documents when the
documentation is adequately thorough. As with Inspection, a documented paper trail
is recommended to demonstrate (and document) that equipment and systems are
adequately tested.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 8 of 125
and Maintenance
Agency June, 2020
Level-IV
The project is not fully commissioned until Turnover is also completed. Training,
Project Closeout (documentation), and Commissioning Documentation are parts of a
successful project turnover as follows:

1.8. Training
Unless staff is properly trained, they will be unable to safely and efficiently operate
and maintain the facility, equipment, or system. The commonsense questions to ask
before determining training requirements are:
1. On which equipment/systems is training required?
2. Who needs to be trained?
3. What training do they need? (Not everyone needs the same training).
4. How must training be recorded?
5. What are the required qualifications of the trainer?

1.9. Project Closeout, Documentation

A project is not complete until all associated documentation is completed and turned
over to appropriate individuals. This includes as-built drawings and specifications,
Operations and Maintenance Manuals, etc.

1.10. Commissioning Documentation

Good commissioning is well documented commissioning. Commissioning
documentation could be included in a Commissioning Report for more complex
projects. For more complex projects, a formal Commissioning Plan is helpful to define
the commissioning process. But before we discuss the elements for a higher
documented Commissioning process, let’s ensure we InVEST wisely in
Commissioning.

2. InVEST Wisely in Commissioning

When establishing Commissioning requirements, it is important to remain
focused on commonsense objectives to make the effort meaningful and cost
effective. The acrostic InVEST is helpful in establishing the focus:
Integrate: Integrate Commissioning with any other documentation
required for a regulated industry if permitted. Don’t automatically do
things twice. Integrate also means to include commissioning activities
in various vendors’/subcontractors’ scope of work, as well as design
documents.
Verify: Ask: does the Commissioning activity adequately verify the
equipment or system is what was specified and works as it should?
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 9 of 125
and Maintenance
Agency June, 2020
Level-IV
 Ensure Regulated Documentation Success: Ask: does the
commissioning effort sufficiently ensure any regulated testing or
inspection activities will be successful – first time?
Sensible: Do enough but don’t over do it
Traceable: Document it. Remember the saying, “If you don’t document
it, you didn’t do it.”

3. Establishing Commissioning and Documentation Requirements

Before developing Commissioning Documentation, establish the extent of
Commissioning needed, and design efficient and effective Commissioning around
the needs of the project (hopefully as expressed in well-written and thorough project
definition documentation. Typical Commissioning Documents may include the
following, depending on project complexity.
Overall Commissioning Plan – for large and more complex projects,
especially those in regulated environments – this is a master plan for
Commissioning when the approach needs preplanning and structure. On
smaller projects/single equipment, consider relying on Standard Operating
Procedure (SOP) requirements rather than a separate overall Plan.
Pre Commissioning: Includes Factory Acceptance Test (FAT), Site
Acceptance Test (SAT), and possibly other early inspection/test activities.
These are usually structured for individual systems, and can be included in
or required by Commissioning Plan or Test Plans. These could be stand
alone for individual equipment/systems, and/or include essential elements
of the Commissioning Test/Inspection Plans
Commissioning Test and Inspection Plans: These could be stand alone for
individual equipment/systems. These may also supplement areas not
covered by FAT’s/SAT’s. Further, self-contained Commissioning Checklists
can be used for simple/small work. Don’t create unnecessary volumes of
documentation.
Commissioning Checklists: For smaller/simpler projects, consider a single
Commissioning Checklist in lieu of more extensive documentation above.
These overall checklists may include the following:

o Verify item specified was installed o Utility connection

o Functionality checkout
o Verify calibration completed
o Verify closeout documentation completed o Verify
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 10 of 125
and Maintenance
Agency June, 2020
Level-IV
 training or orientation completed
o CMMS (Computerized Maintenance Management
System) entry o Other internal requirements

Figure 1.1 hierarchy diagram of typical commissioning documentation

Note: When sufficient Commissioning direction is provided, in specifications or in

drawings and for non-regulated applications, at a minimum consider developing a
detailed checklist to ensure commissioning is completed, and documentation is
turned over. This is especially useful in non-regulated applications where a high-level
of documentation is not required.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 11 of 125
and Maintenance
Agency June, 2020
Level-IV
The following is a hierarchy diagram of typical commissioning documentation: Now
that we’ve reviewed the typical Commissioning documentation, we need to consider
values to which we will Commission. When we perform Commissioning, we need to
evaluate equipment and systems to specific quantifiable criteria.

4. SMART Commissioning Acceptance Criteria/Ranges

Another helpful acrostic is SMART, which should be considered when assigning
values for Commissioning verification. Often, limits can be set that are not attainable
by the installed equipment, nor are needed for the operation. The acrostic SMART
as follows can assist us in making meaningful acceptance criteria:
Sensible: Be practical when assigning commissioning acceptance ranges. Is
the range really needed? What does the project really require? Can the
equipment deliver this range consistently? Do the ranges also meet
business/payback objectives? Energy efficiency?
Maintainable: Will the range be maintained over time?
Accurate: Is the range measurable? Are realistic tolerances considered? Can
equipment consistently meet this target?
Range: Is a reasonable range assigned? Rarely can point values be
maintained. Design values must be well within commissioned ranges to
minimize nuisance alarms.
Traceable: Has/can the attainment of the range be verified and documented?
Can it be verified later?

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 12 of 125
and Maintenance
Agency June, 2020
Level-IV
 Figure 1.2 Chart showing how the part of the primary scope definition document against
which final Commissioning documents are drafted

So far, we have reviewed practical approaches to Commissioning, as well as its

definition. The following section offers a few practical examples of how
Commissioning might be applied. (Obviously, you will need to craft approaches
specific to your applications.)

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 13 of 125
and Maintenance
Agency June, 2020
Level-IV
 Self-Check 1 Written Test

Directions Answer all the questions listed below and write your answer on the space
provided
1. Give definition/description for the following commissioning activities? (13.pts)
 Electromechanical equipment commissioning
 Pre-commissioning
 Energizing commissioning system
 Inspection in commissioning
 Testing in commissioning
 Training after commissioning
 Commissioning checklists
 Commissioning acceptance criteria

2. Why commissioning? (4pts)

Note: Satisfactory rating –6 and above points Unsatisfactory - below 6points

Answer Sheet
Name: ______________ Date: _______________
Short Answer Questions

1. _______________________________________________________________
_______

2. __________________________________________________

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 14 of 125
and Maintenance
Agency June, 2020
Level-IV
 Information Sheet-2 Planning Commissioning Procedures

1. The Commissioning Procedures

1.1. General
The commissioning procedures should be initiated in the program phase of a project
and completed after the post-functional performance phase. As part of this process
a commissioning plan needs to be prepared. The plan should address the specific
objectives, details and parties involved in each individual project.

a. Commissioning plan: The commissioning process applies to all phases of a

system’s life-cycle and can be applied throughout the life of fixed facilities. A
commissioning plan shall be prepared and shall provide for all activities
associated with commissioning. These activities include the following.
1. Developing a design basis document.
2. Establishing the commissioning team and their responsibilities.
3. Listing the systems involved.
4. Providing for project cost and schedule impact resulting from
commissioning activities.
5. Providing a pre-functional test plan with procedures for testing each
system.
6. Providing a functional performance test plan with system test
procedures including deferred test procedures for each system.
7. Providing a corrective action plan with procedures.
8. Providing a commissioning documentation filing procedure.
9. Providing a commissioning tracking procedure.
10. Providing requirements for a commissioning final report.
11. Providing training modules for the operating and maintenance (O &
M) staff on each system.
12. Providing a training plan and procedures.
13. Providing a system course for each mechanical system.
14. Recommending test and calibration equipment for maintenance.

b. The Commissioning Process: In this section one explains first that

commissioning shall be seen has a process, i.e. as a list of coordinated tasks
which shall be performed in a structured manner. The different possible
organization to perform commissioning tasks as well as their pro’s and con’s
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 15 of 125
and Maintenance
Agency June, 2020
Level-IV
 are then presented. Then three types of tools which can be used to structure
the commissioning process are described and compared, they go from
simple check lists to an extended matrix for quality control. Finally a short
introduction is given to document produced within the annex to describe the
approach of commissioning in different countries.

2. Commissioning Should be Seen as a Process

Commissioning is a quality-oriented process for achieving, verifying, and
documenting whether the performance of an equipment/system and assemblies
meet defined objectives and criteria. Commissioning too often is viewed as a task
performed after a equipment/system is constructed and before it is handed over to
the equipment/system owner to check operational performance. We clearly favored
a broader view which starts at the pre design phase goes through the construction
process and continues during operation. This broader view aims at bridging the gaps
between 4 different visions: the expectations of the equipment/system owner, the
project of the designer, the assembled system of the contractor, and the running
system of the operator.

Bridging these gaps will consist for example in:

Clarifying the expectation of the equipment/system owner to obtain the

owner’s project requirements so that the owner and designer understand one
another and are in agreement;

Translating the project of the designer to specifications which can be

understood and realized and verified by the contractor;

Applying functional performance testing procedures which will enable the

contractor the equipment/system owner and the designer to verify that the
system is clearly operating as expected;

Producing system manuals which will enable the operator to take best profit
of the ideas of the designers and of the system realized by the contractor to
fulfill owner requirements;

Producing at regular interval report which will enable the operator and the
equipment/system owner to check that the operation continue to fulfill these
requirements.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 16 of 125
and Maintenance
Agency June, 2020
Level-IV
In this broader view the Commissioning Process begins at project inception during
the pre-design phase and continues for the life of the unit through the occupancy &
operation phase. This global view aims at providing a uniform, integrated, and
consistent approach for delivering and operating facilities that meet the owner’s on-
going requirements.

This broad view could appear to many users as a dream which could be realized in
Table 1: The 4 different types of commissioning

a few project but which is too far from their day to day practice to be applicable to
their projects. In practice one applies often only one part of the full process.
In practice one can differentiate 4 types of commissioning which are represented on
Table-1:

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 17 of 125
and Maintenance
Agency June, 2020
Level-IV
 3. Commissioning applicability to project phases
All phases of a system’s life cycle should be addressed in a commissioning plan. The
requirements to be addressed in the plan for each phase are discussed below.

a. Program phase: During the program phase certain tasks need to be

accomplished to initiate the commissioning process. These tasks are part of the
commissioning plan and include the following activities.
1. Establish a commissioning team. This team needs to have a
representative from quality control; the electromechanical contractor
(the mechanical contractor; the electrical contractor); the testing,
adjusting and balancing (TAB) contractor; the controls contractor; the
design agent; the contracting officer and the using agency. If
contractors are to do a large portion of the testing, a witness of sorts
should be employed to represent the owner.
2. Define the responsibilities of each team member.
3. Establish the team member with authority to coordinate the
commissioning process, the commissioning authority (CA).
4. Develop a list of the systems involved. This is the first step in
preparing a system course for each system.
5. Prepare a design basis document to document commissioning
requirements. The requirements establish what is needed by the
owner and therefore what is to be obtained from commissioning
activities in the project. They establish the desired goal of
commissioning which is to provide the system manager information
necessary to achieve, verify, test, accept and document that the
performance of mechanical systems meet design intent and the
owner and occupant needs. Included in the design basis document is
weather data, interior environmental criteria, other pertinent design
assumptions, cost goals, and references to applicable codes,
standards, regulations and guidelines.
6. Discuss possible impact resulting from commissioning activities. The
commissioning process will require human resources, materials and
equipment to be implemented.
7. Plan for the total impact of commissioning. Planning needs to include
the impact on schedule, equipment, system, manpower,
documentation, supplies, expendables, cost and objectives of the
project.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 18 of 125
and Maintenance
Agency June, 2020
Level-IV
 b. Design phase: For continued development of the commissioning plan, the
following needs to take place during the design phase.
1. Review and update the design basis document.
2. Confirm the systems involved as design progresses as the systems,
equipment, components, instruments and their particulars will change
during design. The commissioning plan needs to be updated as
applicable systems change.
3. Establish pre-functional testing criteria defining the checks and
inspections of system equipment and components which need to take
place before functional performance testing can start.
4. Develop the pre-functional test plan and include a pre-functional test
procedure for each system using the criteria established above. The
procedures include checks and inspections which need to be
conducted to insure that the equipment, components, instruments,
and entire system is ready for functional performance testing.
Procedures need to include forms indicating test results, deficiencies
found, dates and signature sheets and any other documents needed
to authorize commissioning of the system. A comparison of the
installed system against design schematics and piping and
instrumentation diagrams (P&ID) and a review of as-built documents
needs to be included in the procedures.
5. Define functional performance testing criteria for mechanical system
equipment and components during this phase as the technical
aspects of the mechanical systems are being established at this time
and the resources to develop these criteria are readily available.
6. Develop the functional performance test plan using the criteria
established above. Functional performance test procedures for each
system must be prepared. The functional performance test with sign-
off authorization is required for official system acceptance by the CA.
The functional performance test plan incorporates all functional
performance test procedures including deferred functional
performance test procedures. Procedures need to include forms
indicating test results, deficiencies found, dates and signature sheets
and any other documents needed to authorize acceptance of the
system.
7. Identify deferred functional performance test procedures and include
them in the functional performance test plan. Functional performance
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 19 of 125
and Maintenance
Agency June, 2020
Level-IV
 tests which require seasonal conditions or startup of other systems
as prerequisites need to be deferred until the conditions are met
and/or the systems are available and functioning properly. Once
systems requiring deferred tests are identified, a deferred functional
performance test procedure needs to be prepared for each and
included in the functional performance test plan. Procedures need to
include forms indicating test results, deficiencies found, dates and
signature sheets and any other documents needed to authorize
acceptance of the system.
8. Define recommended test and calibration equipment for maintenance
needs. This equipment is most easily defined during the design phase
because the technical aspects of the mechanical systems are being
established at this time and technical resources are readily available.
9. Develop a corrective action plan to handle pre-functional, functional
performance, and deferred functional performance testing
deficiencies discovered during commissioning. These deficiencies
need to be recorded, corrective actions taken, corrective actions
Prepare a design basis document to document commissioning
requirements. The requirements establish what is needed by the
owner and therefore what is to be obtained from commissioning
activities in the project. They establish the desired goal of
commissioning which is to provide the system manager information
necessary to achieve, verify, test, accept and document that the
performance of mechanical systems meet design intent and the
owner and occupant needs. Included in the design basis document is
weather data, interior environmental criteria, other pertinent design
assumptions, cost goals, and references to applicable codes,
standards, regulations and guidelines.
10. Develop a commissioning documentation filing procedure to retain
commissioning process plans, procedures, tests, test reports,
corrective actions, verification reports, tracking reports, training
modules, training status reports, other status reports, deficiencies, the
final commissioning report, and many forms, reports, drawings,
sketches, signature sheets, sign-offs and other documents for all
systems at all phases and steps in the process. This procedure will
provide a method of filing/retaining/retrieving documents and a
schedule for their retention. It will also establish the individual having
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 20 of 125
and Maintenance
Agency June, 2020
Level-IV
 authority for the system and location and conditions of storage.
11. Develop the commissioning tracking procedure as part of the
commissioning plan to track the status of all commissioning plans and
procedures, tests, test reports, corrective actions, verification reports,
tracking reports, training modules, training status reports, other status
reports, deficiencies, the final commissioning report, and any forms,
reports, drawings, sketches, signature sheets, sign-offs and other
documents for all systems at all phases and steps in the process. This
procedure will track all activities and documents in the commissioning
process and at any time provide readily generated reports on the
status of any item, system or process.
12. Develop the commissioning final report outline and include an
introduction; description of the system; purpose of commissioning
system systems; description of how through commissioning the
requirements of the design basis document have been achieved;
summary of commissioning activities; summary of commissioning
results and official authorization that the system has been turned over
to the owner to be managed by the system manager. The report shall
have a signature page.
13. Develop training modules for the O & M staff as part of commissioning
training. Training modules on maintenance and operation must be
prepared for each system.
14. Develop the training plan in order to insure that O & M staff are
properly trained on mechanical systems and that their training
remains current. For the purpose of commissioning and the systems
involved, procedures are needed for defining training requirements,
developing modules, updating training modules, conducting training,
tracking the status of trained staff and modules and maintaining
current training modules and records for each system. These
procedures need to be prepared during the design phase and
included as part of the training plan.
15. Prepare an initial system course for each mechanical system. Each
system course shall include a drawing and equipment list; drawings;
equipment specifications; and manufacturers’ equipment installation,
maintenance and operating instructions.
16. Adjust the project’s schedule and cost resulting from development
and refinement of commissioning activities. The impact on the project
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 21 of 125
and Maintenance
Agency June, 2020
Level-IV
 must constantly be adjusted for changes resulting from
commissioning activities as the commissioning process evolves.

c. Construction phase: Most of the commissioning activities defined in the

design phase can be conducted in the construction phase; however, the
technical staff required is more readily available in the design phase. Based
on as-built systems the following need to be confirmed in the construction
phase.
1. Design basis document.
2. List of systems involved.
3. Pre-functional test plan and procedures.
4. Functional performance test plan and procedures.
5. Deferred functional performance test procedures.
6. Recommended test and calibration equipment for first and second
echelon maintenance.
7. Corrective action plan.
8. Commissioning documentation filing procedure.
9. Commissioning tracking procedure.
10. Commissioning final report outline.
11. Training modules for the O & M staff.
12. Training plan.
13. Commissioning team and responsibilities.
14. Contents of system courses.
15. Impact to the projects schedule and cost resulting from development
and refinement of commissioning activities and construction activities
must be accounted for with revised schedules and costs.

d. Functional performance phase: The functional performance phase is when

tests are conducted and results recorded. Some overlap may be possible
allowing pre-functional tests to be conducted as systems are completed and
as-built documents are being prepared. Functional performance tests may be
conducted on some systems as construction on other systems is being
completed. After completion of the functional performance phase the project
is closed. Mechanical systems necessary for immediate operation of the
system have been functional performance tested and signed off. The system
will be turned over to the owner with some exceptions. Completion of some
deferred tests, some guarantee/warrantee work, and/or some corrective
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 22 of 125
and Maintenance
Agency June, 2020
Level-IV
 actions may remain to be conducted in the post functional performance phase.
During the functional performance phase the following need to be
implemented.
1. Pre-functional test plan and procedures.
2. Functional performance test plan and procedures.
3. Deferred functional performance test procedures.
4. Corrective action plan.
5. Commissioning documentation filing procedure.
6. Commissioning tracking procedure.
7. Commissioning final report preparation – first draft.
8. Training of the O & M staff.
9. Training plan.
10. Review of the design basis document.
11. Preparation of system courses

e. Post-functional performance phase: The post-functional performance

phase may take up to one year after project-close-out occurs. Final functional
performance comes at completion of the post-functional performance phase.
Tests conducted for re-commissioning are conducted after the post-functional
performance phase of the commissioning process to re-confirm the readiness
of systems or modified systems to meet their design or modified design intent.
To conduct re-commissioning activities, commissioning activities on the
original system must be complete. To conduct retro-commissioning activities,
a system which has been in operation but never commissioned must go
through the commissioning process. Post-functional performance includes the
following.
1. Completion and functional performance sign-off of remaining deferred
tests, guarantee/warrantee work, and/or corrective actions.
2. Implementing the commissioning documentation filing procedure.
3. Preparing the commissioning final report – final draft.
4. Issuing the commissioning final report.
5. Completing training of the O & M staff.
6. Implementing the training plan.
7. Preparation of an updated/revised final design basis document.
8. Preparation of final system courses.

4. Implementing Commissioning
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 23 of 125
and Maintenance
Agency June, 2020
Level-IV
The first step in implementation is to draft a robust Commissioning Plan or have a
predefined approach. For Commissioning to be successful, and more importantly,
meaningful, the process must be properly defined. Start by assigning a single
responsible individual, a Commissioning Team Leader. Establish a multidiscipline
team to be a part of the commissioning documentation approval and development.
But the Commissioning Team Leader (CTL) cannot do it by himself or herself. Even
if time were not an issue, no one can have the technical expertise in all areas to
develop meaningful tests and procedures. Much of the administrative aspects can be
typical or require only minor modifications, and other templates/formats are useful.
Including the development of Inspection Checklists and testing requirements in
Architectural/Engineering consultant’s or equipment integrator’s scope of work can
be effective financially and technically. The design engineers of record are most
qualified to know what needs to be Inspected and Tested. However, the engineers of
record must be familiarized on basic procedures as to how to develop proper formats
for the specific Client, which can be accomplished by examples and written
procedures. Much of the test requirements are routinely identified as part of the
project specifications, which must be referenced or included in the Commissioning
Plan or confirmed as part of a verification checklist.

Writing the entire Commissioning documentation can be accomplished completely

by outside consultants, but they must be adequately trained on the Owner’s
procedures. Complete outsource plan writing can be less effective than having an
internal CTL at the Owner to at least develop the backbone of the document and
coordinate/insert outsourced Inspections and Tests forms and requirements.

Once the Commissioning documentation is written, who will do the Inspections and
Tests? Again, the CTL cannot do all inspecting and testing (nor will be qualified to do
so) by himself/herself. Assistance is needed. For Inspections, Construction
Managers or integrators can provide cost effective support in this area. They often
appreciate the opportunity to have Inspection checklists upfront, since it minimizes
punch list items later. This approach usually adds minimal additional cost to the
project. Most testing is typically performed by traditional testing agencies, such as
geotechnical consultants, test and balancers, particulate monitoring companies, etc.
as routinely defined in a project’s specifications. However, specialized tests often
require extra assistance/guidance. A good example is a computerized system; it is
often best to require the design engineer of record to write and witness the sequence
challenge test. He or she best understands the acceptable outputs of the system and
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 24 of 125
and Maintenance
Agency June, 2020
Level-IV
the logic needed.

Commissioning for each project must be tailored to its needs, considering internal
resource constraints. Another alternative (and usually more costly) is to outsource
the complete commissioning implementation to a commissioning consultant.
However, as with all outsourcing, careful scrutiny by qualified internal resources is
needed to ensure Owner-specific requirements are met.

Below is a graphic of an example of an efficient Commissioning Process that has

worked well for building projects (there are others) which relies on the Engineering
Consultant and Construction Manager (CM) to perform much of the Commissioning
activities, while maintaining a CTL to coordinate the process (this example has a
dedicated Commissioning Team Leader (CTL) who develops the Commissioning
Plan and directs the Commissioning process, relies on the Engineering Consultant
to produce Inspection and Testing requirements, and acquires Commissioning
execution through the Contractor/Construction Manager.

The commissioning approach is essentially a 5-stage process.

1. The consultant develops essential inspection and testing requirements for the
CTL.
2. The CTL assembles the above and supplements as needed, completing other
commissioning documents such as a Commissioning Plan if required.
3. Testing vendors provide standard test results to the CM.
4. The CM completes other Commissioning requirements, assembles 3 and 4,
and forwards to the CTL. Outsourced Commissioning activities are under the
direction of the CTL.
5. The CTL reviews, approves, and assembles the materials into a
Commissioning Report.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 25 of 125
and Maintenance
Agency June, 2020
Level-IV
 Figure 1.2 Graphic of an example of an efficient Commissioning
Process
5. Timing of Commissioning
Sufficient scope detail should be included in Requests for Proposals/Quotes
(RFP/Q’s) to enable consultants and contractors to include scope and pricing in their
quotations. At a minimum, a draft of the Commissioning Plan should be issued with
bid documents. The cost of specialized tests or inspections will be less if captured
under a competitively bid environment. A Commissioning Plan or other suitable
documented commissioning directives should be approved by the Commissioning
Team Members and issued prior to construction beginning.

The implementation of Commissioning should begin concurrently with construction.

There will be items on the Inspection Checklists and Test requirements that will be
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 26 of 125
and Maintenance
Agency June, 2020
Level-IV
concealed by construction and cannot be viewed later.

Commissioning Checklist application

Adhering to pre-commissioning and commissioning procedures can be challenging
and drafting the commissioning report can be time-consuming. The managers,
contractors, and construction engineers perform trouble-free pre-commissioning and
commissioning activities through:
1. Capturing photo evidence of detected failures and assign corrective actions
2. Easily creating and using checklists anytime, anywhere, and on any computer
or mobile device
3. Send/receive notifications for scheduled installation, functional, and
operational checks on websites or software
4. Automatically generate and share commissioning reports before leaving the
facility. Preview sample report.
5. Use for free with small teams. Unlimited reports and storage, integrations, and
real-time analytics for premium accounts.

The Possible Collection of Electromechanical Commissioning Checklists

1. Commissioning Checklist
A commissioning checklist is used to ensure the safety and functionality of new or
modified systems in a facility. Efficiently validate the performance of HVAC, pumping,
piping, and lighting systems using this comprehensive checklist. This checklist
includes installation checks and testing, adjusting, and balancing (TAB) items.
Commissioning teams should take advantage of this ready checklist documents to
easily perform the following:
Specify the project details
Check systems installation and operation
Take/attach photos of compliance, detected failures, and more
Assign corrective actions with a due date and priority level
Sign off with digital signatures and auto-generate the commissioning
report

2. Pre-commissioning Checklist
A pre-commissioning checklist aims to prepare a manufacturing plant for start-up, or
when all new or modified systems are going live. Use this checklist to easily inspect
control systems, wiring, sensors, field control devices, and the site communications
network. Identify non-compliance, address systemic issues, and lessen start-up
problems with this pre-commissioning checklist.
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 27 of 125
and Maintenance
Agency June, 2020
Level-IV
 3. Electrical Commissioning Checklist
This electrical commissioning checklist is used for the commissioning of low voltage
installations in a building. Use this checklist to verify the compliance of the
switchboard, main switch and circuit breaker, distribution board, and final circuits with
client specifications. This checklist has been designed to make it easier for inspectors
to check the working space and facilities and conductors, cables and wiring.

4.1. Electrical Commissioning Checklist

Adequacy working space and safe access provided for switch room and /or electrical
facilities.
Compliant Non-compliant N/A
Entrance /exit to switch room and/or electrical facilities are free of obstruction.
Compliant Non-compliant N/A
Suitable locking facilities provided for switch room and /or electrical facilities.
Compliant Non-compliant N/A
Suitable lighting provision provided for switch room and /or electrical facilities.
Compliant Non-compliant N/A
Suitable ventilation provision provided for switch room and /or electrical facilities.
Compliant Non-compliant N/A
Suitable tools for withdrawal of fuses at fuse board provided.
Compliant Non-compliant N/A
A warning notice ‘DANGER—UNAUTHORISED ENTRY PROHIBITED’ provided at every
entrance of switch room.
Compliant Non-compliant N/A
Fire barriers and other measures for protection against thermal effects are properly installed.
Compliant Non-compliant N/A
Danger notices, warning notices, schematic diagrams, instructions and similar information
are correctly and adequately provided.
Compliant Non-compliant N/A
Warning notices for substations and switch rooms provided in compliance.
Compliant Non-compliant N/A
Warning notices for earthing and main bonding connections provided in compliance.
Compliant Non-compliant N/A
All switchgears, distribution boards and electrical equipment properly labelled.
Compliant Non-compliant N/A

4.2. Switchboard, Main Switch and Circuit Breaker

An up-to-date notice of periodic inspection and testing provided at point of supply (i.e. a switchboard,
a circuit breaker or a distribution board) of the installation.
Compliant Non-compliant N/A
Circuits, fuses, switches, terminals, etc. are provided with a legible and durable identification label.
Compliant Non-compliant N/A
No visible damage to impair safety.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 28 of 125
and Maintenance
Agency June, 2020
Level-IV
 Compliant Non-compliant N/A
Work done properly recorded in logbook.
Compliant Non-compliant N/A
An up-to-date schematic diagram displayed.
Compliant Non-compliant N/A
All accessible live parts screened with insulating plate or earthed metal.
Compliant Non-compliant N/A
All exposed conductive parts effectively earthed.
Compliant Non-compliant N/A
Earthing system effectively connected.
Compliant Non-compliant N/A
Warning notice displayed at main bonding connections.
Compliant Non-compliant N/A
All protective devices are functioned properly and correctly set.
Compliant Non-compliant N/A
Suitable interlock scheme provided to prevent parallel operation of two or more sources of supply and
4-pole incoming and interconnecting circuit breakers provided for supply to be taken from more than
one source and is interconnected.
Compliant Non-compliant N/A
Electrically and mechanically interlocked 4-pole changeover device(s) where standby generator set(s)
is installed.
Compliant Non-compliant N/A
The breaking capacity of all circuit breakers /interconnection devices are able to withstand the
prospective fault current.
Compliant Non-compliant N/A
Protective relays have been correctly set and overcurrent protective devices suitably set for all circuits.
Compliant Non-compliant N/A
Protective type current transformers are used for protective relays.
Compliant Non-compliant N/A
A means of isolation provided for every circuit.
Compliant Non-compliant N/A
Operation of circuit breakers and main switches checked.
Compliant Non-compliant N/A
Control, indication and alarm functions checked.
Compliant Non-compliant N/A
No undersized conductor used between the main busbar and fuse/MCB’s.
Compliant Non-compliant N/A
Fuses/MCB’s matching the lowest rated conductor in the circuit.
Compliant Non-compliant N/A
Suitable cable terminations provided.
Compliant Non-compliant N/A

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 29 of 125
and Maintenance
Agency June, 2020
Level-IV
Cable conductors of correct phases connected.
Compliant Non-compliant N/A
Single-pole devices for protection or switching connected in phase conductors only.
Compliant Non-compliant N/A
Distribution Board
A warning notice ‘DANGER’ provided on the front panel of every distribution board.
Compliant Non-compliant N/A
A notice of periodic testing provided at or near the main distribution board incorporating a residual
current device.
Compliant Non-compliant N/A
Distribution boards securely mounted on suitable supports.
Compliant Non-compliant N/A
A suitable switch provided to control each distribution board.
Compliant Non-compliant N/A
Phase barriers for 3-phase distribution board provided, where necessary.
Compliant Non-compliant N/A
The breaking capacity of MCB is compliant.
Compliant Non-compliant N/A
Suitable tools for withdrawal of fuses at a fuse board provided, where necessary.
Compliant Non-compliant N/A
Circuits connected to MCB or fuse in accordance with the schematic diagram.
Compliant Non-compliant N/A

4.3. Conductors, Cables and Wiring

No visible damage to impair safety.
Compliant Non-compliant N/A
All live conductors and their methods of insulation, in relation to design currents of circuits and to the
operating currents of the protective devices, are properly selected and erected.
Compliant Non-compliant N/A
All cables, flexible cords, switches, plugs and socket outlets, accessories and equipment are found to
be in good working conditions.
Compliant Non-compliant N/A
All conductors are correctly and securely connected and identified.
Compliant Non-compliant N/A
Armored cables properly terminated to metal casing or trunking by proper cable glands.
Compliant Non-compliant N/A
Cables passing through smoke lobby protected by enclosures of adequate fire rating.
Compliant Non-compliant N/A
Non-sheathed cables protected by conduit, trunking or ducting.
Compliant Non-compliant N/A
Cables and ductings adequately supported.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 30 of 125
and Maintenance
Agency June, 2020
Level-IV
 Compliant Non-compliant N/A
Cables at distribution board or busbar terminated with cable lugs
Compliant Non-compliant N/A
Main cables connected up with correct polarity.
Compliant Non-compliant N/A
Cables protected against mechanical damage and suitably supported.
Compliant Non-compliant N/A
All exposed metal parts including the armor effectively earthed.
Compliant Non-compliant N/A

4.4. Final Circuits

All fuses and single pole switches connected to the phase conductors only with correct polarity.
Compliant Non-compliant N/A
Wiring for emergency lightings and fire services installation segregated from other wirings.
Compliant Non-compliant N/A
Low voltage circuits segregated from extra low voltage circuits.
Compliant Non-compliant N/A
Cables of all phases and neutral of the circuit bunched and contained in the same conduit.
Compliant Non-compliant N/A
Exposed insulated non-sheathed cables protected.
Compliant Non-compliant N/A
Wiring inside false ceiling protected by conduit/trunking or metallic sheath.
Compliant Non-compliant N/A
Socket outlets installed below 1.5m from floor being shuttered type complying with the prescribed
requirements.
Compliant Non-compliant N/A
No socket outlet installed close to water tap, gas tap or cooker so as to avoid danger.
Compliant Non-compliant N/A
Floor socket outlets protected with suitable cover.
Compliant Non-compliant N/A
No 2-pin sockets installed. All socket outlets connected with protective conductors and live conductors
terminated at correct terminals.
Compliant Non-compliant N/A
Radial final circuits using 5A/15A socket outlets in compliance.
Compliant Non-compliant N/A
Circuit protective conductor is formed by the enclosure and a separate protective conductor between
the earthing terminal of socket outlet and its associated metal box provided.
Compliant Non-compliant N/A
Circuit protective conductor is not formed by the enclosure and a separate protective conductor to the
earthing terminal of socket outlet provided.
Compliant Non-compliant N/A
Residual current device having a rated residual operating current not exceeding 30mA provided for all
socket outlets.
Compliant Non-compliant N/A
Minimum sizes of protective conductors are provided as per requirement for limitation of protective
conductor impedance.
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 31 of 125
and Maintenance
Agency June, 2020
Level-IV
 Compliant Non-compliant N/A
Means of isolation provided for every fixed appliance.
Compliant Non-compliant N/A
All chokes, starters and capacitors of discharge lamps enclosed in earthed metal box(es) and suitably
ventilated.
Compliant Non-compliant N/A
Phase conductors connected to the center contact of the Edison-type screw lamp holders.
Compliant Non-compliant N/A
No switches other than a switch fed from a safety source or operated by an insulation cord or rod or
a push-button type of switch having an insulated button of a large surface area provided in bathrooms.
Compliant Non-compliant N/A
Shaver supply unit is compliant
Compliant Non-compliant N/A
No fixed luminaire nor fixed heater having unguarded heating elements installed within reach of a
person using the bath or shower.
Compliant Non-compliant N/A
Appliances exposed to weather being splash-proof type.
Compliant Non-compliant N/A
Luminaires, switches, sockets and plugs, cable couplers installed outdoor, being splash proof type.
Compliant Non-compliant N/A
General/site lighting readily accessible to the public supplied from a safety source.
Compliant Non-compliant N/A
General/site lighting not readily accessible to the public and not supplied from a safety source,
protected by RCD having a rated residual operating current not exceeding 30mA.
Compliant Non-compliant N/A

4. Equipment Commissioning Checklist

This equipment commissioning checklist is used for the commissioning of
electromechanical equipment/system in an industrial or commercial power plant.
Easily customize or build your own checklist using sample or standard template to
meet specific equipment design requirements and fulfill company needs. Each
inspection item can also be set to “mandatory” to make sure that every detail about
the equipment commissioning is checked.

5. Substation Commissioning Checklist

A substation commissioning checklist is used by commissioning engineers to test
and evaluate the safety and operation of high voltage electrical systems. This
checklist has been built to make it easier for inspectors to check transformers/motors,
direct current (DC) battery system, and the operation and testing tools and equipment
and perform efficient lightning protection system, busbar trunking system, circuitry
checks, and more.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 32 of 125
and Maintenance
Agency June, 2020
Level-IV
 6. Piping Pre-commissioning Checklist
This piping pre-commissioning checklist can be used by pipeline engineers to
perform water supply installation set-up (dry commissioning), pipeline control valve
launching sequence (wet commissioning), and pipeline flows, controls, gauging, and
distributions erecting (commissioning).

7. Pump Commissioning Checklist

A pump commissioning checklist aims to validate the operation of pumps through
correct installation, proper lubrication, and simulation of instrumentation and
protection devices. This pump commissioning checklist includes inspection items
such as “Is the pump/engine rotating direction correctly?” and “Are oil coolers, oil
pipes, and pressure water pipelines installed properly as per Piping and
Instrumentation Diagram (P&ID) and General Arrangement (GA)?”

8. Checklist for surface Water Pump Installation

During the last 20 years, the common understanding that new industrial pumps
require some basic checks and adjustments prior to installation and startup has been
supplanted by a new notion that pumps arrive from the factory ready to go, a
phenomenon known as "plug-and-play."

All, commonly surface water, pump installations require some basic action steps
from a well-thought-out checklist to yield a successful startup. Refer to figure below.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 33 of 125
and Maintenance
Agency June, 2020
Level-IV
Figure 2.2 Common surface water pumps commissioning checklist

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 34 of 125
and Maintenance
Agency June, 2020
Level-IV
 Self-Check 4 Written Test

Directions Answer all the questions listed below and write your answer on the space
provided
Q1. What is the definitions for: (8pts)
1. Commissioning procedures/ process? 5. Commissioning procedures at project
(2pts) phase?
2. Commissioning plan? 6. Implementing commissioning?
3. The relations that commissioning does 7. Timing of commissioning works?
have with process? 8. Commissioning checklists?
4. Types of commissioning?

Q2. Discuss on each one of main electrical and mechanical (pump, generator,
engines) commissioning checklists.(6pts)
Q3. Explain for the commissioning procedures against commissioning process
activities?(5pts)

Note: Satisfactory rating –10 and above points Unsatisfactory- below 10points

Answer Sheet
Name: __________________ Date: _______________
Short Answer Questions
Q1. 1) __________________ 5) ___________________
2) __________________ 6) ___________________
3) ___________________ 7) __________________
4) ___________________ 8) __________________
Q2 _______________________________________________________________

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 35 of 125
and Maintenance
Agency June, 2020
Level-IV
 Operation Sheet 2 Planning commissioning procedures

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Direction: Select any of appropriate materials, tools and equipment used for planning
commissioning procedures that are nearby you

Procedures:

Step 1- plan commissioning procedures

Step 2- Formulate checklists for electromechanical machines and equipment

parts
Electrical and Control systems
Pumping (submersible and surface water ) systems
Gene-sets installation and commissioning

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 2 of 125
and Maintenance
Agency June, 2020
Level-IV
 Information Sheet-3 Obtaining Materials and PPEs

1. Personal Protective Equipment (PPEs)

Where it is not possible for emissions to be controlled at their source, or removed or
reduced through effective ventilation, extraction or diversion, the use of personal
protective equipment (PPE) as a final measure must be considered to ensure safety.

PPE is a lower order control and can only be used where higher order controls are
not possible or are not totally effective.
Selection and use of PPE requires careful consideration, as there are many different
types that reduce the risk of injury of contact or exposure to a hazard.
Incorrect use of PPE, or purchasing inappropriate PPE, can contribute to serious
workplace incidents.

PPE that is uncomfortable, restrictive or heavy may create secondary hazards, and,
as a result, constant supervision may be necessary to ensure it is used effectively.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 3 of 125
and Maintenance
Agency June, 2020
Level-IV
Safety Items

Safety Glasses

Face Shield
Usage: While in the lab area students and instructors should always
wear protective clothing and eye protection. Students will not be
allowed to be in the lab without safety glasses!

Latex Gloves

Leather Gloves

Ear Plugs
Usage: Because of the wide variety of tools used in the labs, there will
be high decibel levels at times, it is advisable to protect your hearing by
using ear plugs during those times.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 4 of 125
and Maintenance
Agency June, 2020
Level-IV
 Self-Check 3 Written Test

Directions Answer all the questions listed below and write your answer on the space
provided
1. List down for PPEs that are essential while carrying out electromechanical
equipment commissioning. (3pts)
2. What is the use of using PPEs? (4pts)

Note: Satisfactory rating –4 and above points Unsatisfactory - below 4points

Answer Sheet
Name: __________________ Date: _______________ Score: 7Pts
Rating:_________
Short Answer Questions
1. _____________________________________________________________
_____________________________________________________________
__________
2. _____________________________________________________________
_____________________________________________________________
_______

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 5 of 125
and Maintenance
Agency June, 2020
Level-IV
 Information Sheet - 4 Obtaining, Estimating and Inspecting Tools,
Equipment and Testing Devices

1. Pliers, Snips, & Vice Grips

Pliers and Snips

Usage: These electrical pliers have a wire cutting edge and wide jaws.
The handle is insulated for shock resistance.

Channel Lock Pliers

Usage: Channel lock pliers are easily adjusted to fit all sizes of pipe or
bolts.

Needle Nose Pliers

Usage: Needle nose pliers are used in hard to reach areas; side cutters
are used to cut wire.

Side Cut Pliers

Usage: Needle nose pliers are used in hard to reach areas; side cutters
are used to cut wire.

Assorted Vise Grips

Usage: Vise grips have a locking handle that will grip with out being
held, they are used to hold metal pieces together for welding, bolting, or
alignment process.

2. Testing Devices

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 6 of 125
and Maintenance
Agency June, 2020
Level-IV
Present day voltage testers (duly approved types), when correctly handled, are safe live-
testing devices due to their impedance and rating that a user cannot even mistakenly
cause a short-circuit.

One such voltage tester available in the market is known as the high-impedance tester, as
shown in Figure 4.8. This device gives an audible visual indication on detection of the
presence of voltage.

A common handy device that is used by technicians for detection of voltage is the Neon
Tester. This consists of a neon indicator with current-limiting resistor in series. When you
put its conductive front portion over an active conductor, it will give an indication.
However, in most cases, this indication is faint and this confuses the user. In addition, it
cannot be assumed that a lack of indication is the result of a lack of supply. In that case, a
neon bulb may be inoperative.

A device used for the detection of electrical potential or for a polarity test is the neon test
pencil. It is manufactured in a variety of types and designs. The intensity of glow will
increase if a finger is placed on the cap or if the cap is earthed.
Therefore, it is advisable to use a good-quality neon
tester from a safety and reliability point of view. It should
be noted that the neon tester indicates the voltage of a
conductor with reference to earth (because it has only
one test lead and the circuit gets completed through the
body of the person using it and earth). This test is
sometimes not conclusive because an open circuit may
exist in the neutral and remain undetected by this test.
Also, neon testers sometimes give a glow at very low
voltages and results are thus erratic. A proper voltage
measurement using a voltmeter or multimeter is always
more reliable and conclusive.

A comparison between analog and digital instruments is as follows:

 An analog meter shows reading by the movement of a pointer on a calibrated

scale, whereas a digital meter shows a digital readout for the measurement
directly.
 It is easier for a user to differentiate between readings in analog meters rather
than in the digital one.
 In an analog meter, the reading is subjected to parallax error, while in a digital
one there is no such possibility.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 7 of 125
and Maintenance
Agency June, 2020
Level-IV
  For testing continuity, analog meters are a better choice.
For example, for an open-circuit full-scale deflection of the needle of an ohmmeter will
show infinite reading. While for a closed circuit, it will show zero-resistance reading,
thereby misleading the user.

1.1. Voltmeters and ammeters

For the measurement of voltage (potential difference) between two points, a device known
as a voltmeter is used. This is a device used in live testing of a circuit.
Voltage measurement is conducted by connecting the voltmeter across the test points in a
circuit.
A voltmeter can be used to measure AC/DC voltages of different ranges. Therefore, AC
voltages should be measured by selecting AC and vice versa.
A voltmeter is always connected in parallel or shunt with respect to test points.
While operating a voltmeter, ensure that proper range of voltage is selected before
conducting the measurement, because an instrument is designed for a particular range.
Failure to maintain the above-mentioned precautions results in safety hazards to both the
user and the instrument.
When high-voltage measurements are required, then the measuring range of a voltmeter
can be extended further by the addition of a voltage transformer (step down) with the
meter.
Accordingly, the measurement scale requires a multiplication factor.
Currently, digital multimeters (DMM) with voltage measurement have auto range system.
This enables the instrument to automatically get the correct range in spite of the users
incorrect selection of range.
A voltmeter is used for the following purposes:
 Test continuity of power in a electrical circuit
 Check integrity of single-three-phase power
 Check integrity of devices such as relays and timers
 Check integrity of earthing.
An ammeter is the other device used to measure current flowing through closed low-
voltage electrical circuits.
In addition, it is used in the live testing of an electrical circuit. Connecting the ammeter in
series with the close electric circuit always does measurement of current. AC/DC currents
of different (LV) ranges can be measured using an ammeter.
When connected in series with load (motor, fan), an ammeter will indicate the current
consumed by the load. The current shown depends upon the exact connection of the
ammeter.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 8 of 125
and Maintenance
Agency June, 2020
Level-IV
In order to extend the range of measurement done by an ammeter, a CT is connected
along with the meter. Accordingly, a multiplying factor will come into the picture.
Figure 1.4 shows the connection of an ammeter and voltmeter used for inspecting and
testing a motor starting circuit. As explained earlier, an ammeter is connected in series with
the path, while a voltmeter is
connected across the test
points.
For very-high voltage circuits, it
is unfeasible to disturb the
circuit or take physical
connection risks with the
meters.
To avoid physical connection of
an ammeter with the circuit,
another handy device known as
the clip-on meter is available in
the market (Figure 1.5).
A clip-on meter, as the name
suggests, is a handheld device
that requires to be clamped
with an active current carrying
conductor in a circuit (Figure
1.6). The basic principle
remains the same —a CT
transfers high-rating current to
a low-rating meter, which
shows the reading on a
calibrated scale.

This device works for AC/DC

ranges with an option of various current ranges. It also has a hold system, which helps in
value storage after a reading is taken. Moreover, this device has the facility to be used as a
voltmeter. It can be turned into a voltmeter by using the extra probes provided for testing.
Therefore, it is a versatile measuring device. It can be used for rough and ready
measurement of current flow in locations where individual phase leads are accessible.
However, it cannot measure current in multi-core power cables where all three-phase
conductors run bundled into a single cable. When using a clip-on ammeter care should be
taken to see that the CT clamp is fully closed without any air gap because the readings can
be quire erroneous in the event of improper closing of the clamp.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 2 of 125
and Maintenance
Agency June, 2020
Level-IV
 1.2. Multimeters and ohmmeters
To perform various tests to check AC/DC voltage, current, resistance, frequency, continuity
of circuit, or device integrity, the multimeter is a very useful device (Figure 1.7).
Various companies have different models with different functions. A multimeter consists of
an ammeter, voltmeter, and an ohmmeter combined, with a function switch to connect the
appropriate function.
The ohmmeter is essentially a current-measuring device. However, the scale is calibrated
in ohms, enabling resistance values to be read directly.
This combination of volt—ohm—milliammeter is a basic tool for inspecting and testing. The
proper use of this instrument increases its accuracy and life. The following precautions
should be observed during its usage:
o To prevent meter overloading and possible damage when checking
voltage or current, start with the highest range of the instrument and move
down the range successively.
o For higher accuracy, the range selected should be such that the
deflection falls in the upper half of the meter scale.
o Verify the circuit polarity before making a test, particularly when
measuring DC current or voltages.
o When checking resistance in circuits, power supply to the circuit has to
be switched off; otherwise, the voltage across the meter may damage the
meter.
o Renew multimeter batteries frequently to ensure accuracy of the
resistance scale.
o Recalibrate the instrument at frequent intervals.
o Protect the instrument from dust, moisture, fumes, and heat.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 3 of 125
and Maintenance
Agency June, 2020
Level-IV
Digital multimeter
The features of a multimeter (Figure 1.7) are listed as follows:
 Functionally easy
 Directly indicates the
numeric value of
measurement on an LCD
display
 Measurement-variable
—voltage, current, resistance
can be selected using the
function button
 Auto range feature
provides automatic
adjustment of internal circuits
to appropriate current,
voltage, or resistance
 Hold feature allows
storage of reading of quantity
Figure 1.8 Hand-driven insulation and continuity
measurement in memory for
tester
future viewing
 Auto polarity feature automatically displays + or —sign on display to indicate polarity
of DC measurements
 Some meters also provide Min/Max value indication for measurement
 Peak hold feature holds the peak value of measured quantity
 Quick check features such as diode test, transistor test, capacitor test, etc. are also
available.

Operating DMM
To operate the DMM, please perform the following steps:
 Before connecting the test probe that leads to the circuit, ensure proper function has
been selected as per measured quantity.
 Check the correct insertion of test probes in proper plugs —this will avoid possible
damage to the multimeter due to an incorrect function selection or an incorrect probe
insertion.
 If the multimeter does not have an auto range feature then check for the range
selector switch position —now, the variable can be measured.
If the measuring position/location is awkward, data can be stored using the hold function for
later viewing. The data can be viewed even after the probes are disconnected from the
circuit.
o The Y shift allows you to 9shift the waveform displayed vertically (up/down).
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 4 of 125
and Maintenance
Agency June, 2020
Level-IV
 o The X shift allows you to shift the waveform displayed horizontally left or right.
o The Volts/Div switch is
used to vary the magnitude of
the voltage variable
o displayed on the screen.
It is calibrated in Volts/Div of the
vertical scale. A control knob is
provided in the center to adjust
amplitude between calibrated
settings.
o To find the amplitude of a
signal multiply the Y-axis
reading with the Volts/Div
setting.
o The Time/Div is used to
Figure 1.10 Installation tester control the span of the X-axis.
o Physical markings
between two points can be used to calculate the time span. The same time span
can be used to measure the frequency of the waveform displayed.
o A control knob is provided at the center
for the same purpose as in Volts/Div.
o To find the time duration of a waveform,
measure the signal span reading
difference. When this is multiplied by
Times/Div it will give the time duration of
the signal.

1.3. Safety standards for

measuring instruments
While a person is conducting tests with an
instrument on live line supply, there is a
possibility of a sharp rise in voltage for a
short duration. This may result in an arc
or flash between measurement terminals
of the testing device. In addition, if a
heavy flash occurs, it may critically injure
a person handling the instrument.
To safeguard the person using the
Figure 1.9 Installation tester measuring instrument and to classify the

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 5 of 125
and Maintenance
Agency June, 2020
Level-IV
various instruments as per the application they are used in, the IEC has classified
instruments in the following categories:
 Category IV: Distribution systems, service connections, and primary over-current
protection for larger installations
 Category III: Three-phase and single-phase distribution within a premises
 Category II: Appliances, lighting points, socket-outlets
 Category I: Transient-protected electronic equipment.
The IEC Standard 61010 provides guidelines for manufacturers to follow safety norms for
testing devices. It is to be noted that irrespective of their maximum voltage rating, a
Category IV device provides a greater degree of transient protection than Category III, etc.
The Category III device is suitable for most of the testing undertaken by electricians.

1.4. Insulation-resistance
testers or meggers
Another common method of
measuring resistances ranging 0-
1000 MΩ is by using meggers or
insulation-resistance testers. This
is the usual ohmmeter with a
battery used for voltage source.
This instrument is used to
measure very high resistances,
such as those found in cable
insulations, between motor
windings, in transformer
windings, etc.
Figure 1.11 Battery-operated insulation—
resistance tester Normal multimeters do not
provide accurate indications
above 10 MΩbecause of the low voltage used in the ohmmeter circuit. Meggers can apply a
high voltage to a circuit under test and this voltage causes a current if any electrical leakage
exists. This makes it useful as an insulation tester.

Some laboratory test meters have a built-in high-voltage source. The high voltage permits
accurate high-resistance measurement, but such meters are usually not portable.
The megger is essentially a portable ohmmeter with a built-in high-voltage source. The built-
in high-voltage source may be derived from a magnet-type DC generator or battery.
In a DC generator-type megger, a hand crank is used to turn the armature to produce
voltages up to 500, 1000, and 2500 (depending on the model used).

1.5. Testing accessories

Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 6 of 125
and Maintenance
Agency June, 2020
Level-IV
Depending upon specific applications, special testing devices are used specifically to
improve the accuracy and efficiency of testing an installation. Some of these devices are
shown in the figures given here. Figure 1.10 shows a hand operated insulation tester
(commonly called as Meg. Ohm Meter or Megger).

Self-Check 4 Written Test

Directions: Answer all the questions listed below and write your answer on the
space provided

1. What are the tools and equipment and materials used to carry out commissioning?
Describe how to check them? (at least five of them) (5pts)

2. List down electromechanical equipment commissioning testing devices. Describe

purpose use of at least five of these testing devices?(5pts)

3. What are electromechanical commissioning inspection tools and their use of

purposes in commissioning? (3pts)

Note: Satisfactory rating –7 and above points Unsatisfactory - below 7points

Answer Sheet
Name: __________________ Date: _______________ score: 13pts
Rating:_________
Short Answer Questions
1. __________________________________________________________
2. __________________________________________________________
3. _________________________________________________

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 7 of 125
and Maintenance
Agency June, 2020
Level-IV
 Information Sheet - 5 Identifying and Preventing Potential Hazards
and/or Selecting Control Measures

1. Key principles of machinery and equipment safety

1.1. Mechanical hazards

Machinery and equipment have moving parts. The action of moving parts may have
sufficient force in motion to cause
injury to people. When assessing
machinery and equipment for
possible mechanical hazards,
consider:
3. machinery and equipment
with moving parts that can be
reached by people
4. machinery and equipment
that can eject objects (parts,
components, products or waste
items) that may strike a person
with sufficient force to cause harm
5. machinery and equipment
with moving parts that can reach
people, such as booms or
mechanical appendages (arms)
6. mobile machinery and
equipment, such as forklifts, pallet
jacks, earthmoving equipment,
operated in areas where people
may gain access.

Common mechanical hazards and associated risks for machinery and equipment are
shown below.

1.2. Non-mechanical hazards

Non-mechanical hazards associated with machinery and equipment can include
harmful emissions, contained fluids or gas under pressure, chemicals and chemical
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 8 of 125
and Maintenance
Agency June, 2020
Level-IV
by-products, electricity and noise, all of which can cause serious injury if not
adequately controlled. In some cases, people exposed to these hazards may not
show signs of injury or illness for years. Where people are at risk of injury due to
harmful emissions from machinery and equipment, the emissions should be
controlled at their source. When assessing machinery and equipment for possible
non-mechanical hazards, consider how machinery and equipment can affect the area
(environment) around them.

1.3 Access hazards

People must be provided with safe access that is suitable for the work they perform
in, on and around machinery and equipment. A stable work platform, suited to the
nature of the work that allows for good posture relative to the work performed, sure
footing, safe environment and fall prevention (if a fall may occur), is a basic
requirement. When thinking about safe access to machinery and equipment,
consider the following:
who will be working on or around the machinery and equipment
people who are required to work in enclosed areas where the atmosphere
could be harmful, such as pits, tanks or storage vessels
what equipment or materials need to be carried to undertake the task
where and when is access required for operation, maintenance and cleaning
how will people gain safe access (walkway, gantry, elevated work platform or
ladder)
what work will be carried out
during access
will people be near or
exposed to an unidentified mechanical
or non-mechanical hazard at the time
of access
has consultation occurred
with workers or contractors regarding
how they intend to gain access, and
what equipment and work platform or
structure is best suited for the
intended task.
1.3. Access
Access needs can be predicted and
planning must occur in advance. People need access to machinery and equipment
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 9 of 125
and Maintenance
Agency June, 2020
Level-IV
in the workplace (either continually or occasionally) for predictable tasks such as
operation, maintenance, repair, installation, service or cleaning. Access may vary
during each stage of the machinery and equipment life cycle. For example:
 Installation or removal: complete access from every area may be required and
involve disconnection or connection of services, such as water, air, pipes,
installation of electrical cable to switch board
 Operation: access for set up, operation and adjustment
 Maintenance, repair, cleaning, alteration or adaptation: access to remote
areas may be required.

Protection against electrical hazards, faults and mis-operations in electrical

installations:

The subject of protection in the industry and electrical installations is vast.

It covers many aspects:
Protection of the persons and animals against electrical shocks
Protection of the equipment and components against the stresses
generated by short-circuits, lightning surges, power-system instability, and
other electrical perturbations
Protection of the property and equipment against damages and
destructions
Protection against the production losses
Protection of the workers, the surrounding population and the environment
against fire, explosions, toxic gases, etc.
Protection of the operators and of the electrical equipment from the
consequences of incorrect operations. This means that the switching
devices (Load break switches, disconnectors, earthing switches) must be
operated in the right order. Suitable
Interlocking ensures strict compliance with the correct operating sequences. Four
aspects of the protection are detailed in the scope of this guide:
Protection against electrical shocks
Protection of the transformers against external constraints and internal faults
Improvement of MV/L- transformer protection with circuit breaker associated
to self powered relay
Protection of the operators against the consequences of incorrect operations
by appropriate interlocks.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 10 of 125
and Maintenance
Agency June, 2020
Level-IV
2. General principle of protection against electrical shocks in electrical
installations

Protective measures against electric shocks are based on two well known dangers:

2.1. Direct contact: contact with an active conductor, i.e. which is live with respect
to the earth in normal circumstances.

2.2. Indirect contact: contact with a conductive part of an apparatus which is

normally dead and earthed, but which has become live due to an internal
insulation failure.

2.3. Touching the part with hand would cause a current to pass through the hand
and both feet of the exposed person. The value of the current passing through
the human body depends on:- The level of the touch voltage generated by the
fault current injected in the earth electrode

2.4. Direct-contact protection or basic protection

There are four main principles of protection against direct contact hazards:
By containing all live parts in housings made of insulating material or in
metallic earthed cubicles. Furthermore, the metallic cubicles has to
demonstrate an electrical continuity between all inside and outside metallic
parts.
By placing live parts out of reach.
By installations of barriers also used in AIS substations
By insulation. The best example of protection by insulation is the electrical L-
and H- cables.

2.5. Indirect-contact protection or fault protection

As described above, a person touching the metal enclosure or the frame of an
electrical apparatus affected by an internal failure of insulation is subject to an indirect
contact. Extensive studies have demonstrated that a current lower than 30mA
passing through the human body can be considered as not dangerous. It correspond
to a touch voltage of about 50V.

This means that the operation of installations may continue in presence of any phase
to earth fault if the touch voltages can be maintained below 50V. In all other situations
where the expected touch voltages are above 50 - the interruption of the supply is
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 11 of 125
and Maintenance
Agency June, 2020
Level-IV
mandatory. The higher the expected touch voltages are, the lower the interruption
time must be. Case of fault on L.V. system. Only the isolated neutral system (IT)
allows maintaining touch voltages below 50 - and does not require the interruption of
the supply in presence of phase to earth faults.

2.6. Indirect-contact hazard in the case of a M- fault

In M- electrical systems, the expected touch voltages may reach values requiring
interruption of the supply within much shorter times than the quickest opening time
of the breakers. The principle of protection used for the L- systems cannot be applied
as such for M- systems. One possible solution for the protection of the persons it to
create equipotential systems by means of bonding conductors interconnecting all the
metallic parts of the installation: enclosures of switchgears, frames of electrical
machines, steel structures, metallic floor pipes, etc. This disposition allows to
maintain the touch voltages below the dangerous limit.

3. Protection of transformer and circuits

The electrical equipment and circuits in a substation must be protected in order to
limit the damages due to abnormal currents and over voltages. All equipment
installed in a power electrical system have standardized ratings for short-time
withstand current and short duration power frequency voltage. The role of the
protections is to ensure that these withstand limits can never be exceeded, therefore
clearing the faults as fast as possible. In addition to this first requirement a system of
protection must be selective. Selectivity or discrimination means that any fault must
be cleared by the device of current interruption (circuit breaker or fuses) being the
nearest to the fault, even if the fault is detected by other protections associated with
other interruption devices. As an example for a short circuit occurring on the
secondary side of a power transformer, only the circuit breaker installed on the
secondary must trip. The circuit breaker installed on the primary side must remain
closed. For a transformer protected with M- fuses, the fuses must not blow. They are
typically two main devices able to interrupt fault currents, circuit breakers and fuses
:
 The circuit breakers must be associated with a protection relay having
three main functions: - Measurement of the currents - Detection of the
faults - Emission of a tripping order to the breaker
 The fuses blow under certain fault conditions.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 12 of 125
and Maintenance
Agency June, 2020
Level-IV
 Self-Check 5 Written Test

Directions Answer all the questions listed below and write your answer on the space
provided
1. What are the possible hazards in electromechanical equipment
commissioning? (at least five of them)(5pts)
2. Discuss on how to protect hazards in equipment commissioning? (4pts)

Note: Satisfactory rating –5 and above points Unsatisfactory - below 5points

Answer Sheet
Name: __________________ Date: _______________
Short Answer Questions
Q1._______________________________________________________________
______________________________________________________
Q2._______________________________________________________________
______________________________________________________

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 13 of 125
and Maintenance
Agency June, 2020
Level-IV
 Information Sheet - 6 Coordinating Commissioning Activities

2) Coordination of Commissioning During Construction

In general, the Commissioning Authority coordinates the commissioning activities
and reports to the owner. The Commissioning Authority’s responsibilities, along with
all other contractors’ commissioning responsibilities are detailed in the specifications.
The Specifications will take precedence over the Commissioning Plan. All members
work together to fulfill their contracted responsibilities and meet the objectives of the
Contract Documents.
3) Possible Organizations for Commissioning
When the ultimate object of commissioning is considered, three main different
organizations for commissioning can be supposed and differentiated as follows.
In the first approach the commissioning tasks are performed by a commissioning
authority which depends only of the building owner and which is fully independent of
the other players in the construction process. This first approach insures that a new
eye is looking at all aspects especially taking into account operation and maintenance
issues. It gives a maximum security to the owner. The main disadvantages are the
extra costs for this new activity and the risk of lower involvement of the other players
in the quality aspects. Commissioning advocates consider that these costs lead to
high savings and that the cost benefit ratio is very good.
This approach would only guarantee a commissioning as a series of processes to
define and realize owner’s project requirements from the program step to the post-
acceptance step and hopefully through the lifecycle of a building, if well certified
commissioning authority is directly hired by the building owner.
In the second approach commissioning tasks are performed by the usual players:
architects, engineers, installers… This lead to a commissioning process much more
embedded in the day to day practice of these players. The challenge here is to well
differentiate the commissioning tasks from the usual design, installation, testing and
balancing tasks. It is also important to make the building owner confident that these
tasks are really performed.
This confidence could be obtained through a certification of the players by a third
party. Different certification procedures can be used. For single family houses the
certification can be a certification of the house itself. For larger project it is not
manageable to certify the building which is the final product, process certification
seems to be an efficient way to get confidence.
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 14 of 125
and Maintenance
Agency June, 2020
Level-IV
The third approach is an intermediate one and consists in having most of the actions
performed by the usual players and to have a commissioning authority in charge of
verifying that they are effectively performed.
In a long term view the two first approaches could lead to very different perspectives.
With the first approach commissioning will become a work in itself with
commissioning specialists. So the success of people working in the commissioning
field would rest on having their work recognized by the market. In the second
approach commissioning could become a part of each parties work as a way to
improve quality. Commissioning work will in this second approach disappear as such
and will only become common practice.
It is probably not possible to define which approach could be the best one. Depending
of the national experiences, project size, owner wishes one approach or the other
could be used.
4) Tools to Help Structuring the Commissioning Process
Whatever organization approach is chosen, the key challenge to commission a
building or system is to follow a well managed process. A central document for that
purpose is the Commissioning Plan which defines the actions to be performed. The
Commissioning Plan is the key tool that gives the different players an understanding
of what is meant by commissioning on a specific project, what amount of effort and
money will be required and how it will be managed. The global content of this
Commissioning Plan will be defined at the beginning of the project and will be refined
all along the project.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 15 of 125
and Maintenance
Agency June, 2020
Level-IV
 Self-Check 6 Written Test

Directions: Answer all the questions listed below and write your answer on the space
provided

1. What are the organizing activities of electromechanical equipment

commissioning? (Describe least five of them)(5pts)

2. What is the purpose organizing electro-mechanical equipment

commissioning activities (4pts)

Note: Satisfactory rating –5 and above points Unsatisfactory - below 5points

Answer Sheet
Name: __________________ Date: _______________
Short Answer Questions
Q1._______________________________________________________________
_______________________________________________________________
Q2._______________________________________________________________
_______________________________________________________________

Plan and prepare for commissioning

LAP Test

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Direction: complete the following job and report to your instructor

Job 1: Carry out complete planning and preparation that help to carry out
electromechanical equipment commissioning works

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 16 of 125
and Maintenance
Agency June, 2020
Level-IV
 Instruction Sheet Learning Guide #41: Commission electro
mechanical equipment/systems

This learning guide is developed to provide you the necessary information regarding
the following content coverage and topics

Following Safety policies and procedures

Following electromechanical equipment testing criteria
Commissioning electromechanical equipment/systems
Responding unforeseen events
Revising/updating records, electrical plans and schematic diagram
Filling out and submitting tests data and forms
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –

Follow Safety policies and procedures

Follow electromechanical equipment testing criteria
Commission electromechanical equipment/systems
Respond unforeseen events
Revise/update records, electrical plans and schematic diagram
Fill out and submit tests data and forms
Learning Instructions:

1. Read the specific objectives of this Learning Guide.

2. Follow the instructions described in number 3 to 20.

3. Read the information written in the “Information Sheets 1”. Try to understand
what are being discussed. Ask you Instructor for assistance if you have hard
time understanding them.

4. Accomplish the “Self-check 1” in page __.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 17 of 125
and Maintenance
Agency June, 2020
Level-IV
 5. Ask from your Instructor the key to correction (key answers) or you can request
your Instructor to correct your work. (You are to get the key answer only after
you finished answering the Self-check 1).

6. If you earned a satisfactory evaluation proceed to “Information Sheet 2”.

However, if your rating is unsatisfactory, see your Instructor for further
instructions or go back to Learning Activity #1

7. Submit your accomplished Self-check. This will form part of your training
portfolio.

8. Read the information written in the “Information Sheet 2”. Try to understand
what are being discussed. Ask you Instructor for assistance if you have hard
time understanding them.

9. Accomplish the “Self-check 2”

10. Ask from your Instructor the key to correction (key answers) or you can request
your Instructor to correct your work. (You are to get the key answer only after
you finished answering the Self-check 2).

11. Read the information written in the “Information Sheets 3 and 4”. Try to
understand what are being discussed. Ask you Instructor for assistance if you
have hard time understanding them.

12. Accomplish the “Self-check 3”

13. Ask from your Instructor the key to correction (key answers) or you can request
your Instructor to correct your work. (You are to get the key answer only after
you finished answering the Self-check 3).

14. If you earned a satisfactory evaluation proceed to “Operation Sheets”.

However, if your rating is unsatisfactory, see your Instructor for further
instructions or go back to for each Learning Activities.
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 18 of 125
and Maintenance
Agency June, 2020
Level-IV
 Information Sheet-1 Following Safety Policies and Procedures

Introduction
A guide to machinery and equipment safety is provided to assist persons conducting
a business or undertaking (PCBU) and workers to comply with their duties under the
Work Health and Safety Act 2011 (the Act) and the Work Health and Safety
Regulation 2011 (the Regulation).

This guide is an introduction to managing the risks associated with use of machinery
and equipment in the workplace.
Relevant persons can use this guide to:
Identify machinery and equipment hazards in the workplace
Eliminate or reduce the risk of those hazards causing harm.
The guide will also be useful to anyone else who is interested in machinery and
equipment safety, such as workers and Workplace Health and Safety
Representatives (WHSRs).
Workplace Health and Safety Queensland (WHSQ) also has additional information
and guidance supporting topics introduced in this document.

1. Consulting workers and workplace health and safety representatives

Consultative processes allow people to provide input and raise potential safety
concerns about the work they undertake. Although hazards associated with
machinery and equipment are often easily identified, the ways in which people can
gain access to, or may be exposed to, hazards require a detailed understanding of
how they do their job.

2. Managing Danger Areas

The following signs and activities are used in managing danger areas:
Warning signs (in appropriate positions)
Barriers / tapes
Lock off switches / valves / etc
Inform nearby or affected personnel
Clean up work areas
Spillage plan

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 19 of 125
and Maintenance
Agency June, 2020
Level-IV
 spill kit
absorbent material
detergents and solvents
Safe waste disposal
Fire equipment
Risk assessments
COSHH assessments
Safety personnel
Competent personnel
Supervision

Self-Check 1 Written Test

Directions Answer all the following choose questions and write your answer on the space
provided
1. What are the safety definition and policies and procedures for
electromechanical equipment commissioning? (7pts)
2. Discus on the important points that helps on managing danger areas
while commissioning electromechanical equipment (4pts)

Note: Satisfactory rating –6 and above points Unsatisfactory - below 6points

Answer Sheet
Name: __________________ Date: _______________
Short Answer Questions
1. ___________________________________________________
2. _________________________________________________

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 20 of 125
and Maintenance
Agency June, 2020
Level-IV
 Operation Sheet 1 Safety Policy and Procedures

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Direction: carry out electromechanical safety policy and procedures

Materials: - Manufacturers electromechanical equipment commissioning manual,

water supply pressure safety PPEs and appropriate hand tools.

Procedures: Think safety!!!!

 Ensure system is set in a safe condition
 Check security of attachments
 Check mechanical connections
 Check pipe work and connections
 Check electrical connections
Start up system / machine slowly
 Continue to build up to full operating pressures, loads, speeds and ranges
 Compare established system / machine to required operating and
manufacturer’s specifications
Thinking Safety: thinking safety is the priority that any equipment commissioning
person take care. This includes some of
the following activities to be considered.
Such as:
Most electromechanical equipment
commissioning has the ability to maim or
kill
Legislation (HSAW and associated
regulations) dictates employers and
employees responsibilities
Think of the implications of what you
Figure 2.1 Some of safety signs
are about to do
Think about danger areas
Permits to work

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 21 of 125
and Maintenance
Agency June, 2020
Level-IV
 Following Electromechanical Equipment
Information Sheet #-2 Testing Criteria

1. General system testing requirements

To perform the testing, the plan lists all required tests in order of performance and
gives a schedule for each test. The work items and schedule depend on many issues
including the importance and cost of the equipment, consequences of failure, age of
equipment, past and future frequency of service, hours of operation, future
maintenance availability, environmental conditions, and safety requirements.

1.1. Mechanical
The purpose of mechanical systems commissioning is to increase the reliability of
mechanical systems after installation by identifying problems and providing a set of
baseline values for comparison with subsequent routine tests. A procedure should
be developed to include a planned approach (road map) of what should be done in
order to verify the proper system installation. This procedure is the commissioning
plan. Specific areas addressed in a commissioning plan include the verification of the
installation of all equipment/components, interface connections between equipment
and individual systems, and interconnection drawings. The development of this plan
specific to each system and/or component is key to the usefulness of any
maintenance program. The plan consists of the schedule of when acceptance and
routine tests should be performed, test forms to be used to record the outcome of the
tests which are retained for comparison with previous and subsequent tests, and a
listing of the required test devices. Since the results of the commissioning tests
become baseline test values to compare with later tests and the results of the routine
maintenance tests are compiled to identify any downward trend in performance, it is
vital to the maintenance program to have accurate and complete records.

1.2. Electrical
The purpose of electric systems commissioning is to increase the reliability of
electrical power systems after installation by identifying problems and providing a set
of baseline values for comparison with subsequent routine tests. A procedure should
be developed to include a planned approach or road map of what should be done in
order to verify the proper system installation. This procedure is the commissioning
plan. Specific areas addressed in a commissioning plan include the verification of the
installation of all equipment/components, interface connections between equipment
and individual systems, and interconnection drawings. The development of this test
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 22 of 125
and Maintenance
Agency June, 2020
Level-IV
plan specific to each system and/or component is key to the usefulness of any
maintenance program. The plan consists of the schedule of when acceptance and
routine tests should be performed, test forms to be used to record the outcome of the
tests which are retained for comparison with previous and subsequent tests, and a
listing of the required test devices. Since the results of the commissioning tests
become baseline test values to compare with later tests and the results of the routine
maintenance tests are compiled to identify any downward trend in performance, it is
vital to the maintenance program to have accurate and complete records.

Self-Check 2 Written Test

Directions Answer all the questions listed below and write your answer on the space
provided

1. What are the criteria for electromechanical equipment testing criteria?(3pts)

2. Discuss and answer on the general electromechanical equipment system

testing criteria. (2pts)

Note: Satisfactory rating –3 and above points Unsatisfactory - below

3points

Answer Sheet
Name: __________________ Date: _______________
Short Answer Questions
1. _____________________________________________________________
_____________________________________________________________
___________
2. _____________________________________________________________
_____________________________________________________________
__________

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 23 of 125
and Maintenance
Agency June, 2020
Level-IV
 commissioning Electromechanical
Information Sheet-#3 Equipment/Systems

1. Commissioning, testing, energizing

When required by the local authority, commissioning tests and checking must be
successfully completed to get the authorization to energize a new installation.

The following tests and checking are generally mandatory and applicable to the whole
installation:
Verification that the main substation complies with all the requirements
expressed by the utility
Measurement of earth-electrodes resistances
Electrical continuity of all equipotential and bonding conductors
Inspection and functional testing of all M- components
Dielectric test of switchgears and transformers
Inspection and testing of the L- parts of the installation
Mechanical and electrical interlocks checking
Protective-relays checking
Other additional tests and checking mat be required.
As soon as the conformity official document is issued, the utility proceeds with the
energizing of the installation.

2. Commissioning Electromechanical Equipment/Systems

2.1. System commissioning testing
Checking of equipment such as fuses, lights, and breakers for continuity, equipment
calibration and settings, and investigating for faulty equipment or connections should
be the first troubleshooting steps. Examples of the possible causes to common
problems are shown for each system in the chapters that follow.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 24 of 125
and Maintenance
Agency June, 2020
Level-IV
 a) Mechanical
Mechanical systems commissioning on new projects is critical to insure that a system
is installed properly, is operating properly and efficiently, and that it will remain in
service for its projected life cycle.

The commissioning of a system encompasses the individual testing of the related

components, the verification of the component interconnection against the drawings,
and the functional testing of the system as a whole. An understanding of the
equipment involved and the modes of operation for a system are essential to the
development of the system commissioning plan. A survey of the equipment of the
system and listing the equipment in order of importance and startup is the first step
in developing the commissioning plan. The schedule of the tests and inspections is
dependent on many aspects of the equipment such as its importance and cost, the
frequency of service, hours of operation, environmental conditions, accessibility, and
safety requirements. The inspection, testing, and startup plan is then developed in
conjunction with this schedule with instructions and procedures for the test plan.

b) Electrical
Electrical systems commissioning on new projects is critical to ensure that a system
is installed properly and that it will operate as designed. The commissioning of a
system encompasses the individual testing of the related components, the
verification of the component interconnection against the drawings, and the functional
testing of the system as a whole. An understanding of the equipment involved and
the modes of operation for a system are essential to the development of the system
commissioning plan. A survey of the equipment of the system and listing the
equipment in order of importance and startup is the first step in developing the
commissioning plan. The schedule of the tests and inspections is dependent on many
aspects of the equipment such as its importance and cost, the frequency of service,
hours of operation, environmental conditions, accessibility, and safety requirements.
The inspection, testing, and startup plan is then developed in conjunction with this
schedule with instructions and procedures for the test plan. Problems may arise
during the testing of the equipment and systems. In order to identify and correct these
problems, troubleshooting techniques should be developed.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 25 of 125
and Maintenance
Agency June, 2020
Level-IV
 2.2. Installation and commissioning of electro-mechanical
equipment
The main and optional tasks for installation and commissioning of electro-mechanical
equipment on site/indoors include at least the following:

Assembly and dismantling of electro-mechanical equipment;

Fault detection and review of stator and rotor;
Current condition data download and analysis;
Machining and processing on-site activities;
Winding isolation restoration and repair;
Repair of hydro generators;
Repair of pumping systems and station;
Repair of control panel system;
Repair of high-voltage electric motors;
Technical support in damage failure situations;
Centering and balancing;
Installation and commissioning of hydro generators;
Installation and commissioning of pumping systems and station;
Installation and commissioning of control panel system;
Installation and commissioning of electric motors

2.3. Component testing

These common tests are described in detail later in this course. Sufficient time should
be allocated to define the inspections required, perform the check, and document the
results. A review of the system drawings will show major pieces of equipment.
Specific procedures should be developed for each test referencing the equipment to
be used, drawings to be followed, and step by step procedures with readings to be
recorded and forms for the results.

a) Mechanical
The reliability of any system is dependent on the interconnection of the equipment
and the equipment itself. This course’s content is predominately for testing of
mechanical systems themselves. It is assumed that the detailed and comprehensive
individual testing of equipment has been completed before the commencing of
commissioning of the system. However, general testing procedures for the
components of the systems described in this course are addressed in chapter 3.
Commissioning requirements for the system components must be provided with the
original proposal for the procurement of the equipment. The requirements provided
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 26 of 125
and Maintenance
Agency June, 2020
Level-IV
by the equipment manufacturer should be adhered to in addition to the recommended
testing herein. Although there are many different components to any mechanical
system, there are some tests that are common among the equipment. Examples of
the common testing procedures include the assembly check, alignment check,
grounding verification, insulation resistance tests and polarization index to name a
few.

b) Electrical
The reliability of any system is dependent on the interconnection of the equipment
and the equipment itself. This course predominately provides guidance for testing of
electrical systems. It is assumed that the detailed and comprehensive individual
testing of equipment has been completed before the commencing of commissioning
of the system. Commissioning requirements for the system components are typically
provided with the original proposal for the procurement of the equipment. The
requirements provided by the equipment manufacturer should be adhered to in
addition to the recommended testing herein. Although there are many different
components in any electrical system, there are some tests that are common among
the equipment. Examples of the common testing procedures include the assembly
check, alignment check, grounding verification, insulation resistance tests and
polarization index to name a few.

3. Cost of commissioning
New water supply construction and installation, renovation of an existing system, or
the modernization also will affect the cost of commissioning. Experience has shown
that the initial commissioning cost is more than offset by increased system reliability
and reduced operating costs.

3.1. Mechanical
The cost of commissioning for a mechanical system is dependent upon many factors
including the system size, complexity and the level of reliability desired.

3.2. Electrical
The cost of commissioning for an electrical system is dependent upon many factors
including the system size, complexity and the level of reliability desired.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 27 of 125
and Maintenance
Agency June, 2020
Level-IV
4. Initial Electrical testing of an installation
Before a utility will connect an installation to its supply network, strict pre-
commissioning electrical tests and visual inspections by the authority, or by its
appointed agent, must be satisfied.

These tests are made according to local (governmental and/or institutional)

regulations, which may differ slightly from one country to another. The principles of
all such regulations however, are common, and are based on the observance of
rigorous safety rules in the design and realization of the installation.
The standards included in this guide are based on an international consensus for
such tests, intended to cover all the safety measures and approved installation
practices normally required for electromechanical equipment commissioning. Many
industries however have additional regulations related to a particular product
(petroleum, coal, natural gas, etc.). Such additional requirements are beyond the
scope of this guide.

The pre-commissioning electrical tests and visual-inspection checks for installations

in buildings include, typically, all of the following:
Electrical continuity and conductivity tests of protective, equipotential and
earth-bonding conductors
Insulation resistance tests between live conductors and the protective
conductors connected to the earthing arrangement
Test of compliance of SELV- (Safety Extra Low Voltage) and PELV-
(Protection by Extra Low Voltage) circuits or for electrical separation
Insulation resistance/impedance of floors and walls
Protection by automatic disconnection of the supply

Additional protection, by verifying the effectiveness of the protective measure and

polarity test-where the rules prohibit the installation of single pole switching devices
in the neutral conductor:
Check of phase sequence in case of multiphase circuit
Functional test of switchgear and control-gear by verifying their installation and
adjustment
Voltage drop by measuring the circuit impedance or by using diagrams

These tests and checks are basic (but not exhaustive) to the majority of installations,
while numerous other tests and rules are included in the regulations to cover

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 28 of 125
and Maintenance
Agency June, 2020
Level-IV
particular cases, for example: installations based on class 2 insulation, special
locations, etc.

Drawing attention to the particular features of different types of installation, and

indicating the essential rules to be observed in order to achieve a satisfactory level
of quality will ensure safe and trouble-free performance. The methods recommended
in this guide, modified if necessary to comply with any possible variation imposed by
a utility, and are intended to satisfy all pre-commissioning test and inspection
requirements. After verification and testing an initial report must be provided including
records of inspection, records of circuits tested together with the test result and
possible repairs or improvements of the installation.

5. Put in out of danger the existing electrical installations

This subject is in real progress cause of the statistics with origin electrical installation
(number of old and recognized dangerous electrical installations, existing
installations not in adequation with the future needs etc.)

6. Installation and commissioning of common electro-mechanical equipment

6.1. Typical Submersible pump Installation

Pump Installed as an Automatic Pressure System Incorporating Pressure Tank
and Pressure Switch.
Various switching devices and the use of these products is recommended.
Alternative systems may be connected directly into the supply line to 240 volt motor
control boxes, provided the switching device used has an adequate current rating. If
the current rating of the switch is not adequate, a contactor must be wired into the
supply and the switching device used to control the contactor’s coil. In any case,
where a single phase motor has a control (starter) box, no additional switching
devices should be wired between the motor and box.

In the case of three phase motors, all switching devices should be wired to the
starter’s control coil, and on no account should they be used to directly break the
supply circuit to the pump.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 29 of 125
and Maintenance
Agency June, 2020
Level-IV
 6.2. Generators and Ancillary Equipment
Description of generator ancillary equipment, diesel fuel, and lube oil systems
Generators are used to supply primary power, standby power and emergency power.
The generators used at most facilities are often powered by diesel engines. This
course material will address the ancillary equipment consisting of a typical diesel fuel
and lube oil system.
Diesel fuel system: A diesel fuel system is shown in figure 3.2, Schematic of a
typical diesel fuel system. The system consists of a storage tank, strainer, motor
driven pump, filter, expansion tank, heater, day tank, cooler, engine mounted duplex
filter and engine mounted pump.

Figure 3.2 Schematic of a typical fuel system

b. Lube oil system: A lube oil system is shown in figure 3.3, Schematic
of a typical lube oil system. The system consists of a clean lube oil tank, dirty
lube oil tank, pumps, lube heaters, cooler, centrifuge, duplex filter and duplex
strainer.
c. Diesel fuel and lube oil systems: More information on design,
maintenance, and testing of diesel fuel and lube oil systems and generators is
found in the American Society of Mechanical Engineers (ASME): B 31.3.
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 30 of 125
and Maintenance
Agency June, 2020
Level-IV
Operation of diesel fuel system and lube oil systems
Basic operations of a diesel fuel and lube oil systems are presented in the following
paragraphs.

a. Diesel fuel system operation: The diesel fuel storage tank shown in figure 3.2,
Schematic of a typical diesel fuel system, must be a double wall tank or, when located
above ground, a single wall tank surrounded by a dike for containment of a leak, can
be used. For underground installations, the tank must be double wall with a leak
detection system monitoring the annulus between walls. The tank is provided with
level indication, either local, remote, and/or is interlocked to shut off fill flow. The tank
is provided with a fill line, man access port, return line and two suction lines. The tank
may be provided with suction line heaters or a tank heater (not shown) depending on
the engine’s fuel requirement and type of diesel fuel selected. The fill line and the
return lines are provided with traps to minimize the formation of vapors in the tank.
One suction line is located higher than the other. Normally the pump will draw from
the low suction line. As water separates from the fuel it will approach the lower
suction line. If water is picked up in this line, the pump can be switched to the upper
suction line until the water is removed through the man access port. A strainer
provides a coarse means of particulate removal upstream of the pump. A coalescing
filter provides for water and fine particulate removal downstream of the pump. An
expansion tank may be installed to prevent expanding fuel oil from leaking from joints
and shaft seals. An oil heater may be installed depending on the type of oil and
climate, to reduce oil viscosity to the atomizing range. The fuel oil then enters the
day tank and is discharged through a trap. The day tank holds a four- to eight- hour
supply of fuel and is mounted above, or in close proximity to, the generator’s diesel
engine. It is provided with a vent, overflow, return line; gravity feed line to the duplex
engine filters, a pump and a level indication, local, remote and/or interlocked to shut
off supply flow. The engines positive displacement pump raises the diesel fuel to the
correct pressure for engine operation and distributes it to the fuel injectors. An oil
cooler is provided, when needed, in the return line to minimize flashing and formation
of vapors. Oil lines may be electrically or steam heat traced for winter service
depending on the type of fuel, climate and installed pipe location.

b. Lube oil system operation: As shown in the lube oil system in figure 3.3,
Schematic of a typical lube oil system, new lube oil passes through a strainer before
entering the clean lube tank. The tank is provided with level indication, either local,
remote and/or is interlocked to shut off fill flow. The tank is also equipped with a vent
and a heater if required. The dirty lube tank incorporates a drain, level indication,
vent, return line and suction line.

(1) Pump draws lube oil through a strainer and foot valve in either tank. The foot valve
prevents the line from emptying when not in use. From this pump, lube oil can flow

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 31 of 125
and Maintenance
Agency June, 2020
Level-IV
 to the engine lube oil sump, to a tanker truck for hauling to an oil recycle center, or
it can be heated and cleaned through a centrifuge. From the centrifuge, water/oil
discharge is sent to a separator, sludge is sent to treatment for disposal and the
treated lube is sampled. The treated lube if clean is pumped to the engine lube oil
sum, or if dirty it is pumped to the dirty lube oil tank.

(2) From the engine lube oil sump, lube oil is pumped through a duplex strainer by a
motor driven pump or an engine driven pump. As with duplex filters, duplex strainers
provide for continuous operation. Switching from one strainer to the other can take
place without impeding oil flow by switching the inlet and outlet three-way valves
simultaneously. This permits cleaning of one strainer while the other is in service.
When the standby power engine requires warm engine lube and a warm engine
block for startup, the electric motor driven pump continuously circulates engine lube
through a heater. Once the engine is started the engine driven lube oil pump will
take over and lube will flow through a thermostatic valve to a cooler and by-pass
line to maintain correct engine lube temperature for operation. The lube oil flows
through a duplex filter before entering the engine. The electric motor driven pump
can also be used as a pre-lube pump to circulate lube prior to starting the engine
and after the engine shuts down for controlled cooling. The pump also transfers
dirty lube from the engine lube oil sump to the dirty lube oil tank.

(3) The lube oil system may be integral with the engine or may be provided as a separate
skid mounted unit. Lube oil tanks, pipes, and lines may be heated or heat traced.
Controls, alarms and engine shutdown interlocks are provided as needed and
include alarms for low oil flow, low oil level, low oil pressure, low oil temperature,
high oil temperature or high filter differential pressure.

6.3. Protection System Devices

The protection system includes protective relays, associated communications
systems, voltage and current sensing devices, station batteries, and direct current
control circuitry.

For transmission protection systems this includes, but is not necessarily limited to:
Distance Relays
Directional and Non-directional Ground Relays
Directional and Non-directional Over Current Relays
Transformer Differential Relays
Bus Differential Relays
Phase Balance Relays
Breaker Failure Relays
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 32 of 125
and Maintenance
Agency June, 2020
Level-IV
 Auxiliary Tripping Relays (a.k.a. 86 relays)
Transfer Tripping Relays including Fiber Optic, Micro Wave, Carrier Current Relay
and Pilot Wire Relays

For generation protection systems this includes, but is not necessarily limited to:
Generator Fault Protection Functions Similar to Above
Loss of Field Relays
Stator Ground Relays
Reverse Power Relays
Volts-per-hertz Relays
Negative Sequence Over-Current Relays
Generator Differential Relays
Generator Bus Differential Relays
Frequency Relays
Out-of-step Relays, and
Breaker Failure Relays

Other equipment condition sensing devices such as temperature control devices,

pressure switches, level switches, limit switches, low vacuum, low fuel pressure, fire
protection, explosion diaphragms, etc., if they are wired to initiate a relay protection
action are considered to be included in the scope of the protection system.

6.4. Basic principles in using a drawing and meter in

troubleshooting circuits
To identify a faulty section, follow the guidelines given below, along with a drawing
and a meter:
Check the incoming supply voltages first
Check for voltages at the specific test points in circuit (as per manufacturers
test point data sheet)
Do dead test of circuit for integrity of protection devices and others
In dead test, check for continuity of circuits, as intended, and check for
insulation resistance
If its not possible to perform a dead test, connect the supply to the circuit and
do a live test of circuit.
Generally, any electrical circuit can be differentiated in two sections:
Power circuit
Control circuit.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 33 of 125
and Maintenance
Agency June, 2020
Level-IV
It is always advisable to first check the power circuit. So, if the power circuit works,
as it should, then troubleshoot the control circuit.

Power circuit check list:

Incoming power to circuit and its integrity
Check for correct functioning of protection devices
Check visual cable continuity
Check for any signs of flash or burning smell of devices.
Control circuit check list:
Control circuit power first
Check for proper functioning of relays, timers, and switches
Check visual cable continuity
Check for wire interconnections and terminal connections of circuit
Check logical operational sequence of contactor switching
Check for timer duration settings.

If the above criteria are checked and still the motor (final device) is not working, then
test the motor (final device).

6.4.1. Checks for circuit continuity with disconnected

supply
Dead circuit testing is testing performed with the power disconnected from the circuit.
The main benefit of disconnecting power supply while tests with an external energy
source are performed is to eliminate hazardous risks to the environment or the person
conducting the test. A continuity test, as well as, an insulation test can be performed
in the dead circuit test.

a) Continuity test
This is to be performed on a dead circuit for checking continuity. Using an Audible
Continuity Tester can do it. This tester consists of a battery as a source of energy,
an audible device, and two test leads. Figure 3.4 shows an example of this test with
an audible continuity tester.
By this test, the continuity of an electrical circuit is checked to ensure that the
electrical path is complete. If the path is continuous, then an audio sound is emitted
to confirm path continuity and the non-existence of an open circuit.
In some devices, along with the audio indication, an LED or some other visual
indication is provided.
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 34 of 125
and Maintenance
Agency June, 2020
Level-IV
Similarly, an ohmmeter or multimeter can also be used to check continuity. An
ohmmeter or multimeter consists of a battery as a source of energy, along with a
meter to display the value of resistance. Figure 3.5 shows an example of this test
with an ohmmeter.

In an ohmmeter, the scale is calibrated from zero to an infinite range of resistance.

When the meter shows a zero reading, it indicates that the path between two test
leads has zero resistance. This, in turn, indicates that the path is a continuous one.
If the path or the conductor is open, then it will show resistance value as infinite.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 35 of 125
and Maintenance
Agency June, 2020
Level-IV
 In short, continuity
testing is used to check
the following purposes:
 Integrity of cables
 Integrity of electrical
circuit path
 Integrity of the earthing
system (i.e., electrical
continuity and low-
resistance value to
earth)
 Accurate wiring of a
control and power circuit
to the correct terminals
Differentiate active and
neutral conductors
before connecting them
to a device
Figure 3.4 Continuity test with audio tester
 Check for wrong wiring
interconnections
between different
control and power
circuits; thus indirectly,
checking for short-circuit
paths
 Integrity of switches,
fuses, and other
devices.
A few words of caution
are warranted here.
Checking for continuity
in a control circuit can
give erratic results due
Figure 3.5 Continuity test with ohmmeter to the existence of
parallel circuits. It is
better to disconnect appropriate terminals to ensure correct results. Continuity test in
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 36 of 125
and Maintenance
Agency June, 2020
Level-IV
power circuits can be tricky. Often, a circuit where there is an open circuit fault can
register excellent continuity with a low power tester or ohmmeter. But when a voltage
is applied, current may not flow. The reason for this is that the circuit may be partially
continuous (Example: a partially burnt cable where one or two conductor strands may
be making contact) but when
feeding a heavy load it will
behave as a high impedance.

This type of fault will be

detected by testing on load
using voltage measurements
(as illustrated later in this
chapter).
(b) Insulation test
This is another test performed
on a dead circuit only. The
objective is to check for
insulation of cables or a power
circuit. The device used to
check integrity of insulation is
known as an Insulation-
Resistance Tester. Generally,
this is used during the
installation of high-voltage
power cables and terminations.
Figure 3.6 Insulation test with insulation- In Figure 3.6, a general motor
resistance tester
circuit is shown with breaker,
fuses, and overload relay. To check insulation of the circuit (excluding motor),
disconnect the power supply by opening the breaker.

Then, isolate the motor from the circuit through terminals T1, T2, and T3. First
checking insulation resistance between earth and T1, then earth and T2, and finally
earth and T3 checks insulation resistances of conductors, as well as other devices.
If the insulation resistance of any branch shows zero or a very low reading, then it
can be concluded that there is an insulation failure.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 37 of 125
and Maintenance
Agency June, 2020
Level-IV
This test is also used in fault finding, to check for earthed motors or cables and for
checking insulation failure of conductors. Individual phases of three-phase motor
winding can be insulation-tested only if all six leads of the winding are brought out.
The winding being tested should be connected to the testers output with the other
two windings connected together and to the earthed frame of the motor. Where only
three leads are available, the insulation of the machine winding as a whole can only
be tested with reference to the earthed frame of the motor.

These insulation testers are also called Meggers and have a built-in energy source
(either DC generator or battery) to produce test voltages of rating 500 V DC or more.
This is required since the electrical circuit to be tested applies voltage of different
ratings.

For example, when the insulation resistance of HV cables is checked, 1000 V minimal
voltage is applied, whereas for a domestic circuit 500 V is sufficient for testing.
Testing on a live circuit requires extreme caution and should be restricted to LV
circuits. Precautions should be taken to prevent inadvertent contact of the technician
with live parts.

The probes and tools must be insulated with minimum exposure of conducting parts.
This will minimize inadvertent bridging of two terminals which are at different
potentials which can cause a short-circuit and arcing leading to burn injuries to the
technician.

6.4.2. Checks for circuit continuity with live supply

Generally, if possible, inspecting and testing is done with a disconnected power
supply, but in some circumstances, faultfinding is only possible if the circuit is live.
Therefore, the circuit under testing remains connected with the power supply. This
uses the circuit power supply itself as a source of energy for testing.

This kind of testing should be done with extreme care following safety precautions.
As shown in Figure 3.7, the integrity of a power supply or continuity of electric path
can be checked by using test lamps. Test lamps are connected in between two
phases. Thus, as with the dead circuit test, a continuity test can be performed. In
addition, a lamp-type visual tester can be used for simple continuity testing.
Alternatively, voltage indicators or multimeters can be used for checking voltage and
the continuity of the conductors or electrical path.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 38 of 125
and Maintenance
Agency June, 2020
Level-IV
While checking three-phase voltage, use two lamps connected in series and not a
single lamp. Currently, most manufacturers give test voltage a detail for test points
that helps to check the integrity of a particular section. Generally, equipments
consisting of electronic cards follow this kind of practice.

While checking the voltage at these test points, measuring instruments must be
accurate. Therefore, a comparison of voltages at these test points is sufficient to draw
conclusions.

Diagnostics for a single-phase motor can be undertaken with this kind of visual
indicators. This requires a sound knowledge of circuit and wiring arrangements —
depending upon the test done, interpretation varies and so does an accurate fault
diagnosis.

It is always advisable to check voltage between line-to-line than line-to-earth, since

for the latter, the results may be misleading.
Testing on a live circuit
requires extreme caution and
should be restricted to LV
circuits. Precautions should
be taken to prevent
inadvertent contact of the
technician with live parts.

The probes and tools must be

insulated with minimum
exposure of conducting parts.
This will minimize inadvertent
bridging of two terminals
which are at different
potentials which can cause a
short-circuit and arcing
leading to burn injuries to the
technician.
Figure 3.7 Continuity test with series test lamps

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 39 of 125
and Maintenance
Agency June, 2020
Level-IV
 6.5. Tests and methods
Although most of the tests have been detailed above, there still remain certain tests
that are common and critical to an electrical system. Parameters such as the
resistance of leakage paths and resistance of a conductor have to be known for some
applications.

The tests include the following:

Effectiveness of the power earth Effectiveness of the electronic earth
Continuity of the earthing system and the required equipotentiality (so as to check the
possibility of earth current loops)
Earth pit locations, resistance of earth conductor, material, and size
Location of protection devices, so that the path taken by fault current is minimum and
insures the activation of a protection device under fault conditions
Ratings of fuse and other protection devices
Selection of suitable cable types with proper current ratings keeping in mind
environmental conditions and length of run
Materials prone to environmental hazards which may be mechanical or chemical,
which might be present, such as dampness, high temperature, explosive gases,
vapors
Electrical equipments, to ensure that its operation will not cause overload conditions
Location of installation of electrical equipment and accessories.
If all the above points are considered during the installation of an electrical system,
there will be a reduced need for inspecting and testing. The quality of the system will
also be good.

6.5.1. Testing devices

To successfully troubleshoot in a short time, an understanding of the measurement
meters that can be used and their various functions is mandatory. This is detailed in
the following few sections.

a) Lamp indicators
A lamp indicator is the most basic tool used for inspecting and testing by a practicing
electrician. It is also known as a Voltage Tester. It consists of two 240 V lamps
connected in series.
b) Description
As shown in Figure 3.8, both lamps are connected in series along with the fuse and
probe that form a testing set. The low-wattage lamps comprise of equal power rating,
not greater than 25 W per lamp. Use of two lamps is advisable as the tester may at
times be subjected to line voltage (380/400/480) during testing. Single lamp if used
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 40 of 125
and Maintenance
Agency June, 2020
Level-IV
may fail and erroneously indicate that the circuit is not live. As a precaution, all
voltage testers should be checked before and after the test using a known live source.

For testing extra low voltages such

as 12 or 32 V systems, one may use
a single-lamp type.
Applications
Lamp indicator applications are
listed below:

 For detecting the presence of

a live potential
 For polarity of supply, i.e., the
location of active points, neutral, and
earth terminals or supply points
 For checking like or similar
Figure 3.8 The two 240 V lamps housed in
the housing phases when phasing out
preparatory to paralleling two
supplies
 Blown fuses
 Integrity of motor and three-phase supply system.

6.5.2. Testing of a motor

To check the earth condition, one lead of test lamps is connected to a live terminal of
a single-phase supply and the second lead to a winding terminal. If the winding is
earthed, the lamps will glow, else they will not glow.

6.5.3. Checking a three-phase supply voltage

To ensure there is no missing phase, connect both leads across the two phases. One
of the following three instances will occur:
If there is no supply then lamps will not glow
If any one phase is missing then the lamps will glow at half brightness
If both phases are connected then the lamps will glow at full brightness.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 41 of 125
and Maintenance
Agency June, 2020
Level-IV
7. Circuits
The previous chapter has listed the symbols representing electrical and electronic
components. Symbols make a drawing or circuit more readable.
Generally, a schematic consists of a control and a power circuit. The power circuit
provides power to the motors through contactors, whereas a control circuit controls
these contactors through safety interlocks.

7.1. Reading a circuit

 All control devices such as switches and relay contacts are either NO or
NC contacts.
 The switch position normally shown in any circuit diagram is the default de-
energized condition state.
 For denoting sensor contacts notations such as LS, PS, TS are used.
 A relay coil is denoted with a symbol inside a circle and contacts of relay
used in the circuit are represented with the same tag as the coil. If a relay
coil has multiple NO and NC contacts then the contact identification
numbers, as shown on relays, are mentioned in the drawing.
 In between the control supply lines L1 and L2 you will find either the relay
coil or a solenoid coil or the lamp load.
 If several devices are to be turned Onat the same condition then you will
find them connected in parallel between L1 and L2.
 If wires are common for two devices then in the diagram they are shown
with the same identification number.
 Generally, power circuit conductors are shown with thick lines while thin
lines are used for control circuits.
 A broken line indicates a mechanical function. Generally, it is used to show
linkage between two different contacts of the same push button.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 42 of 125
and Maintenance
Agency June, 2020
Level-IV
 7.2. Different wiring diagrams
In order to troubleshoot electrical equipments two things are required. One is the
location of the equipment to be tested and the other is the interconnection between
all the devices (contactors, timers, relay).
The wiring diagram of electrical equipment gives information as stated above. In
addition, it shows the identification tags of wires, connectors, relays, etc.
In Figure 3.9, the wiring diagram of a DOL starter is shown along with the physical
location of the devices. The terminal numbers of overload relays are also shown in
the wiring diagram. This enables
accurate device wiring and wire
tracing during inspecting and
testing.
Generally, this kind of wiring
diagram is given inside an
electrical equipment panel cover.
This diagram shows the actual
position of different devices as
closely as possible. The bold line
indicates the heavy current
carrying conductors, while the
thin line indicates the control
circuit.

8. Accurate wiring of circuits

and connections
While inspecting and testing
electrical equipments, continuity
tests of circuits and wiring are
done by performing the following
procedure:
o Checking correct polarity and
ensuring that supply polarity
follows the correct circuit route.
Figure 3.9 Simple motor circuit
o Ensuring that there are no
short-circuits in supply due to a wrong connection or termination of wires.
o Identifying different conductors before making connections to a device to
ensure correctness of circuits and connections.
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 43 of 125
and Maintenance
Agency June, 2020
Level-IV
 o Ensuring that there are no interconnections between two different circuits.
o Correctly identifying circuit loads such as contactors, relays, and their
contacts.
o Identifying active conductors and their corresponding neutral conductors
to check the integrity of the circuit.

A continuity test is particularly useful to help detect a short-circuit condition, which is

a result of cross-linking of wires between two different circuits.
An interconnection between circuits is likely to be due to the following reasons:
o Incorrect termination of wires
o Result of insulation breakdown
o Incorrect connection at field junction box.

Figure 3.10 is an example of an electrical appliance connected with a supply system.

If, due to any reason, a fault occurs within the appliance causing current flow in its
body, the fault current flows back to the mains supply. The circuit shown here is a
TN-C-S type of supply where the earth is derived from the supply neutral at the
service entrance. In the case of other supply systems the earth lead may not be
interconnected at service entrance but go right back to the source (TN-S). However
the general principles are still valid.

It is required to conduct tests

between neutral conductors of
all other circuits and the active
conductor of the same circuit at
the mains supply distribution to
reveal any interconnection
faults.

Before conduction of tests,

perform the following steps:

Figure 3.10 Earth fault within an installation

o Disconnect neutral link from circuit
o Keep circuit protective
o Close all contactors or switches.
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 44 of 125
and Maintenance
Agency June, 2020
Level-IV
Check all direct interconnections with the low-range ohmmeter. If resistance shown
in the ohmmeter is very low then it indicates a short-circuit condition. Suppose, the
load is connected with an active phase and is neutral from different circuits, then it
can be detected only with connected loads. If these steps are performed prior to the
start of the test, then check the resistance between the neutral and the active
conductors.

To check for insulation resistance of cables, take insulation resistance with megger
or insulation-resistance tester, especially if insulation breakdown is suspected. If the
resistance shown is less than 1 MΩthen it can be said that the wiring or device
terminal has an insulation problem.
To identify each electrical circuit and its active and neutral conductors, calculate load
resistance with the ohmmeter and accordingly, identify each active and neutral
conductor.

9. Conducting an insulation-resistance test:

To conduct an insulation-resistance test, perform the procedure listed below:
Check the insulation tester by shorting its test leads. It should show
zero resistance. If test leads are kept open, it should show infinite
resistance.
Isolate the section to be tested from the power supply.
Disconnect all lamps or electronic devices from the circuit to be tested.
Select the proper operating voltage for conducting the test, depending
upon the rating of the system.
Check for connections while conducting tests so that only the section
to be tested is included in the test.
There should not be any stray parallel leakage paths.
Check the instrument for pointer index or any other pre-adjustment
necessary.
Test leads to be used should have good-quality insulation.
Before starting the test, insure that all the capacitors in the circuit are
discharged by shorting their two leads together. Similarly, after the test
ensure that they are in discharge condition. If this is not done they may
give false readings.
Before touching cable ends after testing, discharge any energy that
might have been stored in the cables during the test. This is most likely
to occur in long runs of larger cables due to their capacitance.
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 45 of 125
and Maintenance
Agency June, 2020
Level-IV
 Checking continuity of an earthing system requires the use of low-
reading ohmmeters, which should be zero-adjusted before each test
and calibrated on regular intervals.
Where the testing of the earth electrode resistance is required (i.e., the
resistance between the electrode and the general mass of earth), one
of the special types of earth-resistance testers must be used.

10. Optional tests

There still remain a few useful tests using the measuring devices. These tests are
used for checking single- or three-phase systems and other electrical devices. Some
of the tests we have discussed the next few sections. These can be used to
strengthen inspecting and testing techniques.

10.1. Megger testing cables and auxiliary devices of a single-

phase system
Disconnect P and N from the supply side, as well as from the other end.
Now we have isolated our test circuit, making it dead. Short P and N with a temporary
short link. Close switch and protection devices.

As shown in Figure 3.12, open motor terminals, so that the motor remains isolated
from the test circuit. Check resistance with the insulation tester between the neutral
link and earth. If the value shown in the meter is
less than 1 MΩ, then there is a fault with either
the cable insulation or device terminals.

Figure 3.12 Megger of a single-

phase system

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 46 of 125
and Maintenance
Agency June, 2020
Level-IV
 10.2. Megger testing cables and
auxiliaries of a three-phase
system
Disconnect L1, L2, and L3 from the
supply side, as well as from the
other end. This makes it a dead
circuit. Short L1, L2, and L3
terminals with a temporary link.
Close the breaker device and
protection devices. As shown in
Figure 3.13, open motor terminals
T1, T2, and T3, so that the motor
remains isolated from the test
circuit. Check resistance with
insulation tester between each
conductor and earth.
If the meter shows a low value less
than 1 MΩ, there is a fault in either
cable insulation or device terminals.
Figure 3.13 Megger of a three-phase system
10.3. Megger testing of motor
A pre-condition for megger testing of a motor is to isolate the motor from the supply
totally. Take the megger value of a motor
between each conductor and earth, as
shown in Figure 3.14, to check the earthing
of the stator winding. This will help us to
conclude on earthing status of the stator
winding. Similarly, check for shorting
between two windings by checking the
megger value between two stator-winding
terminals, as shown in Figure 3.15. Thus, a
low reading can identify insulation failure of
any winding inside the motor.

10.4. Fault finding on an underground

Figure 3.15 Megger testing for cable
winding-to-winding short condition

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 47 of 125
and Maintenance
Agency June, 2020
Level-IV
Generally, underground cables are prone to insulation failure, although due care is
taken. Since they are buried underground, it is difficult to exactly pinpoint the fault
location. Resistance values between earth and a conductor from the two ends can
be checked. If the value reduces drastically, then the faulty location can be isolated.

10.5. Tests for installation and inspecting and testing

The following are a few tests used during commissioning and inspecting and
testing:
Insulation test: This is the most important test for inspecting and testing
of any electrical equipment. Depending on the system, a suitable test
voltage is applied to check the insulation resistance between the live
conductors and earth.
Earth continuity test: For electrical equipment, continuity between the
exposed portion (metallic) of earthed equipment and the earth terminal
is checked. Resistance value should be low. If resistance value is high,
then it is indicative of poor earthing.
Flash test: To check the insulation strength of cables, a high voltage
(as specified by the cable manufacture) is applied in the same way as
for the insulation test. This determines the withstand capability of the
cable insulation.
Electronic earth test: Generally, for microprocessor-based or electronic-based
sensitive devices, separate earthing is provided. This is called electronic earth. The
voltage between the electronic earth and the power earth should be lower than 2 V.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 48 of 125
and Maintenance
Agency June, 2020
Level-IV
 Self-Check 2 Written Test

Directions Answer all the questions listed below and write your answer on the
space provided
1. When you arrive to troubleshoot a D. Cutter
defective machine you should? 6. A piece of personal protective
A. Switch on the start push button equipment or PPE.
switch A. Prevents heavy equipment
B. Open the enclosure and make a B. Prevents injuries
visual inspection C. Prevents accident
C. Reset the overload relay D. Prevents short circuit
D. Talk and inquire the operator 7. A ground conductor in a three-way
2. A noisy operator of an electric motor system shall not be protected by a fuse
is caused by? since?
A. Winding A. Fuse is expensive
B. Open centrifugal switch B. A blown fuse in the ground
C. Rotor and stator touched each other conductor will make the circuit
D. Open capacitor unbalance
3. The advantage of a squirrel cage C. Fuse is not necessary
rotor is that it has D. Fuse will not protect
A. No copper bars 8. It is not advisable to put a copper or
B. No laminated iron core jumper wire instead of a fuse since
C. No commutator and carbon brushes A. A copper wire will explode
D. No bearings B. The circuit cannot be protected in
4. A device which is used to test short case of overload or short circuit
circuit and ground fault of an armature C. A copper wire is expensive
is D. A copper wire is long
A. Grounder 9. The capacitor can correct power
B. Grower factor because?
C. Growler A. It can carry current
D. Grounding B. It can charge electricity
5. A device which is used to removes C. It can handle power factor
rough edges of the conduit is called ? D. It can create short circuit
A. Bender 10. The standard unit of power is
B. Reamer A. Volt
C. Grinder B. Ampere
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 49 of 125
and Maintenance
Agency June, 2020
Level-IV
C. Watt B. Stop working
D. Ohm C. Continue working as much as you
11. The actual power consumption is can
expressed in D. Skip the unnecessary
A. KVA 16. The use of friction tape over the
B. KW plastic tape is required in every
C. KWA electrical splice?
D. KHz A. To make splice beautiful
12. Prevented maintenance of an B. To make the splice smaller
equipment? C. To avoid disconnection
A. Prolongs life D. To have more resistance
B. Keeps the equipment in good 17. The cabinet of lightning installation
condition shall have a grounding conductor?
C. Makes beautiful A. To have a connection
D. Makes someone safety B. To make installation
13. A device that automatically cut off C. To prevent electric shock
the circuit without damage during D. To carry current
abnormal condition is? 18. The markings are there inflexible
A. Sun breaker non-metallic conduits are?
B. Growler A. 1
C. Circuit breaker B. 2
D. Fuse C. 3
14. A rating of a feeder line in relation D. 4
to a protective device must be ? 19. A switch is used in the installation
A. Less than the protective device of one lamp controlled by two locations
B. Equal or greater than the protected is three-way.
device A. One way switch
C. Lower than the protective device B. Two way switch
D. Without rating C. Three way swicth
D. Four way switch
20. Pull down the fuse cut off of a
15. When you are given a job with a transmission line before
time limit and after working for a minute A. Cutting the wires
you noticed that it will not be finished in B. Working on electrical
a given time you should? C. Climbing the electrical pole
A. Notify the supervisor D. Disconnecting

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 2 of 125
and Maintenance
Agency June, 2020
Level-IV
 Note: Satisfactory rating –11 and above points Unsatisfactory - below
11points

Answer Sheet
Name: __________________ Date: _______________
Short Answer Questions
1. ________ 8. ________ 15. ________
2. ________ 9. ________ 16. ________
3. ________ 10. ________ 17. ________
4. ________ 11. ________ 18. ________
5. ________ 12. ________ 19. ________
6. ________ 13. ________ 20. ________
7. ________ 14. ________

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 2 of 125
and Maintenance
Agency June, 2020
Level-IV
 Commissioning electromechanical
Operation Sheet 2
equipment/ systems
Name: _____________________________ Date: ________________
Time started: ________________________ Time finished: ________________

Direction: carry out electromechanical equipment commissioning

Equipment, tools and materials:

Electrical systems testing devices and measuring instruments, paper, pen, pencil,
learning guide

Materials: - Manufacturers electromechanical equipment commissioning manual,

water supply pressure measuring gauge and flowrates measuring instruments and
appropriate hand tools.

Procedures:
One of the primary tasks for the commissioning authority/trainee is reviewing the
design documents to facilitate commissioning during commissioning. Many of the
features that facilitate commissioning will also enhance ease of electromechanical
equipment operation. All items from the list below shall be considered for
incorporation into the operation.
If Commissioning Facilitation is checked beforehand, Commissioning
Authority/trainer design submittal reviews will include the following:
1. Clear and rigorous design/manufacturer's documentation, including detailed
and complete sequences of operation.
2. An electromechanical equipment- generator sets, pumps, control boards and
protective devices-that lists all equipment and components etc.. with their
status and action during commissioning.
3. Access for reading gages, entering doors and panels, observing and replacing
filters, coils, etc.
4. Required isolation valves, dampers, interlocks, piping, etc. to allow for manual
overrides, simulating failures, seasons and other testing conditions.
5. Sufficient monitoring points in the building automation system (BAS), even
beyond that necessary to control the systems, to facilitate performance
verification and O&M.
6. Adequate trending and reporting features in the BAS, EMCS graphics.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 2 of 125
and Maintenance
Agency June, 2020
Level-IV
 7. Pressure and temperature (P/T) plugs close to controlling sensors for verifying
their calibration.
8. Pressure gages, thermometers and flow meters in strategic areas for verifying
system performance and ongoing O&M.
9. Pressure and temperature (P/T) plugs at less critical areas or on smaller
equipment where gages and thermometers would be over-kill.
10. Specification of the location and criteria for the VAV duct static pressure sensor
and chilled water and/or hot water differential pressure sensor.
11. Adequate balancing valves, flow metering and control stations and control
system functions to facilitate and verify reliable test and balance.
12. Uniform inlet connection requirements to VAV terminal boxes.
13. Clear and complete commissioning specifications for the construction phase.
14. Complete O&M documentation requirements in the specifications.
15. Complete training requirements in the specifications.
16. Review entire document and building information management plan from design
through construction and turnover to ensure adequacy and compliance with the
owner’s program.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 3 of 125
and Maintenance
Agency June, 2020
Level-IV
 Information Sheet-3 Responding Unforeseen Events

Pre-functional test plan and functional performance test plan for diesel fuel and
lube oil systems
This course assumes that individual components and packaged equipment have
been tested by the manufacturer. As part of the commissioning effort each
component should be checked for damage, deterioration, and failures by a procedure
using inspections and tests as defined by the specific equipment manufacturers.
Equipment manuals from manufacturers identify the minimum required receipt
inspections, handling and installation procedures, drawing and wiring verification,
field inspection and installation checks, verification of removal of shipping braces,
inspection of installation against drawings and nameplates, inspection of
components for damage and cleanliness, inspection of insulators and grounding,
inspection of anchorage and alignment, adjustment checks, mechanical operation
and interlock checks, lubrication application and verification that local safety
equipment is in place.

a. Safety, diesel fuel and lube oil systems. Many tests on equipment involve
the use of high voltages, high currents, pressurized fuel and rotating or moving
equipment. These can be dangerous to personnel and damaging to
equipment. A procedure should be followed to insure adequate safety rules
are instituted and practiced to prevent injury to personnel performing the tests
and other personnel who might be in the local area.

b. Test equipment, diesel fuel and lube oil systems. It is important that in any
test program the proper equipment is used. The equipment should be
calibrated, in good condition, and used by qualified operators as required by
a procedure. Any test equipment used for calibration shall have twice the
accuracy of the equipment to be tested. All equipment should be operated in
accordance with its instruction manual. A procedure defining installation
inspection and a system test needs to be provided.

c. Inspection checklists, diesel fuel and lube oil systems. Inspection

checklist(s) for fuel oil systems are presented in figure(s) 3.1, and 3.2. They
are filled out to serve as examples of typical equipment conditions. For
convenience, these checklists are included unpopulated at the end of the
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 4 of 125
and Maintenance
Agency June, 2020
Level-IV
 course manterial.
Possible failures and corrective measures for diesel fuel and lube oil syste
Table 3.1 lists general problems that may arise during the testing of equipment and
systems along with possible troubleshooting techniques. For all problems, consult
equipment and component manuals for troubleshooting directions. Check
fuses/lights/breakers/etc., for continuity, check equipment calibration and settings,
check for clogged filters and strainers, check for closed manual shutoff valves and
dampers, check for improperly adjusted valves and equipment, and look for faulty
equipment and connections.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 5 of 125
and Maintenance
Agency June, 2020
Level-IV
Table 3-1 Possible Failures and Corrective Actions for Diesel Oil and Lube Oil Systems

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 6 of 125
and Maintenance
Agency June, 2020
Level-IV
 Self-Check 3 Written Test

Directions: Answer all the questions listed below and write your answer on the space
provided

Q1. What is responding to commissioning unforeseen events? (3pts)

Q2. List down possible events that may be unforeseen in carrying out
electromechanical equipment commissioning? (3pts)

Q3. After carrying out commissioning, describe for the possible failure of
electromechanical equipment- (at least describe for three equipments)? How to
inspect them? Give two samples of inspections checklists. (5pts)

Note: Satisfactory rating –6 and above points Unsatisfactory - below

6points

Answer Sheet
Name: __________________ Date: __________
Short Answer Questions
Q1._______________________________________________________________
_______________________________________________________________
__________
Q2._______________________________________________________________
_______________________________________________________________
_______________
Q3._______________________________________________________________
_______________________________________________________________
_________

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 7 of 125
and Maintenance
Agency June, 2020
Level-IV
 Operation Sheet 3 Unforeseen events

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Direction: Select any of appropriate village or groups of community nearby you

Equipment, tools and materials:

Procedures, paper, pen, pencil, learning guide

Materials: - Manufacturers repair manual, Feeler gauge and appropriate hand

tools.

Procedures:

Step 1- Carry out basic activities regarding identifying for unforeseen events in the
commissioning equipment

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 8 of 125
and Maintenance
Agency June, 2020
Level-IV
 Revising/updating records, electrical plans
Information Sheet-4
and schematic diagram

General
As-built drawings are an essential part of every construction project. The main
purpose of an as-built drawing serves is to replicate how the contractor built the
project and identify what changes were made throughout the course of constructing
the project. The final sets of as-built drawings hold important information; such as
shop drawing changes, design changes, field changes, approved and disapproved
changes during construction, and any minor or major modification to the final resulting
project. At any given point in the duration of the project, there should be an up-to-
date version of the as-built drawings available for reference.

As you can imagine, any construction project goes through many changes and
modifications before reaching completion, no matter how minor these modifications
are, recording as-built drawings visualizes the changes being made and how it will
affect the remainder of the project. It also shows what the previous plans were before
any modifications were made, which can be useful in seeing the difference in the
project as time goes on.

What is an “as-built” drawing?

By definition, an as-built drawing is a revised set of drawings submitted by a
contractor upon completion of a construction project. As-built drawings show the
dimensions, geometry, and location of all components of the project. These 2D floor
plans commonly include details such as walls, doors, windows, and plumbing
fixtures. One of the main purposes of an as-built drawing is to be able to document
any changes made during the construction of the project that strays away from the
original design. As-built drawings are sometimes referred to as just “as-builts”, “Red-
Line Drawings,” or “Record-Drawings.” There are technical differences between all
three of these terms, even though they may be used interchangeably. IF a contractor
wants to be extremely precise, they will refer to the drawings as “As-Built Drawings”
to avoid any confusion.

These drawings are typically created by architects and designers. They are the ones
to create the drawings because they have the most training and talent in doing so.
However, they are not always on-site to see the work being done first hand. This
means that they can sometimes be liable for inaccuracies in the completion of the
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 9 of 125
and Maintenance
Agency June, 2020
Level-IV
project. There sometimes is a lack of communication between the two, which is when
the inaccuracies come about and issues occur. Having greater communication
between the job site and the designers or architects can lead to a more accurate
drawing and can stay more up-to-date on any changes.

Recording an as-built drawing:

Because as-built drawings contain important information, it is crucial that every
construction site has at least one set of the completed sets of as-built drawings
available at all times. When handling as-built drawings, whether you are on or off the
construction site, keep in mind these few factors:

Always record exact details of changes or additions to previous information, some

examples of this would be sizing, materials used, dimension measurements, or
installation. If any of these details change throughout the course of construction, be
sure not to remove them from the as-built documentation. Crossing out old details
and writing updated information is the best way to document changes being made,
this way anyone can look back at as-built drawings and see exactly what details were
made and where the changes stemmed from. It is crucial not to remove any old
details because having the original plans can be important in making changes in the
future.

If possible, as-built drawings should be color-coded for ease of use. Red is used for
deleted items, green for added items, and blue can be used for special instructions,
information, or details. When adding in these details, be sure to use the same scale
as the original drawing, to avoid any confusion or mistakes. Another tip to keep your
as-built drawing organized is by avoiding the use of abbreviations. To ensure that
everyone looking at the drawing understands what is happening, it is useful to write
out everything instead of using abbreviations. This is important to avoid any
miscommunications between the abbreviations and explains in full what is changing
and why.

It is also important that your as-built drawings include:

written explanations to describe modifications being made
written dates in the corner of all as-built drawing sheets
clear and concise handwriting
using the same scale when adding to as-built drawings or recreating as-
built drawings on different sheets

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 10 of 125
and Maintenance
Agency June, 2020
Level-IV
 Primary colors, if applicable, to color code when items are added, deleted,
or important changes.

Self-Check 4 Written Test

Directions: Answer all the questions listed below and write your answer on the space
provided
1. How to revise electrical diagrams in electromechanical equipment commissioning
performances? (5pts)

Note: Satisfactory rating –3 and above points Unsatisfactory - below

3points

Answer Sheet
Name: __________________ Date: _______________
Short Answer Questions

Q1._______________________________________________________________
__________________________________________________________________
_______

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 11 of 125
and Maintenance
Agency June, 2020
Level-IV
 Revising/ updating electrical plans ,
Operation Sheet 4
records and schematic diagram
Name: _____________________________ Date: ________________
Time started: ________________________ Time finished: ________________

Direction: Select any of appropriate materials and tools and equipment

Equipment, tools and materials:

Procedures, paper, pen, pencil, learning guide

Materials: - Manufacturers repair manual,

Procedures:

Step 1- Revise/record, update electrical plans and schematic diagrams in

commissioning

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 12 of 125
and Maintenance
Agency June, 2020
Level-IV
 Filling Out and Submitting Tests Data and
Information Sheet-5
Forms

Standardized and Sample Commissioning Forms

The following forms are included:
Pre-Installation Check Sheet
Equipment/ System Start-Up Notification
Training Plan/ Sign-In
Duct Leak Test Report
Pre start check list (sample)

As shown in the following table 5.1- sample form of Diesel engine inspection
checklist and figure 5.1 is sample filled form of diesel engine inspection checklists.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 13 of 125
and Maintenance
Agency June, 2020
Level-IV
 Table 5.1 DIESEL FUEL SYSTEM INSPECTION CHECKLIST
SECTION A - CUSTOMER DATA
1. PLANT 2. LOCATION 3. JOB NUMBER
6. DATE
4. EQUIPMENT 5. SYSTEM DESIGNATION (YYYYMMDD)
7. TEST EQUIPMENT 8. TESTED BY
SECTION B - EQUIPMENT DATA
10. MODEL 12. FLOW RATING
9. PUMP MANUFACTURER NO 11. SERIAL NO GPM

15.
13. TYPE 14. HP @ RPM PRESSURE RATING PSIG
16. HEATER MODEL
MANUFACTURER 17. NO 18. SERIAL NO 19. FLOW RATE GPM

20. COOLER 21. MODEL

MANUFACTURER NO 22. SERIAL NO 23. FLOW RATE GPM

SECTION C - VISUAL
AND MECHANICAL INSPECTION
CHECK
2 4 . POINT CHECK
COND* NOTES POINT COND* NOTES
EXTERIOR OF EQUIPMENT EQUIPMENT IDENTIFICATION
COMPLETENESS OF ASSEMBLY BRACING
EQUIPMENT ROTATION LABELING AND TAGGING
ELECTRICAL/MECHANICAL
INTERLOCKS SAFETY INTERLOCKS
INSTRUMENTS WORKING SPACE
PROPER GROUNDING ANCHORAGE
PROPER INSULATION LEAKS
TIGHTNESS OF BOLTED
CONNECTIONS COMPARISON TO DRAWINGS
PROPER LUBRICATION CONTROL SYSTEM
SECTION -
D CALIBRATION AND SET POINT
2
DESCRIPTION NOTES
SENSORS
CONTROLLERS
ACTUATORS
SECTION E - DIESEL FUEL SYSTEM TESTS
2 OPERATING
MODES TEMPERATURES PRESSURES FLOWS LEVELS NOTES

PUMP
HEATER
COOLER
ENGINE
HYDROSTATIC TEST
SYSTEM TEST
27. NOTES
*CONDITION: A = ACCEPTABLE; R= NEEDS REPAIR, REPLACEMENT OR ADJUSTMENT; C = CORRECTED; NA =NOT
APPLICABLE

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 14 of 125
and Maintenance
Agency June, 2020
Level-IV
Figure 5.1 diesel engine inspection sample checklist
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 15 of 125
and Maintenance
Agency June, 2020
Level-IV
 Self-Check 4 Written Test

Directions Answer all the questions listed below and write your answer on the space
provided
1. What are the activities we apply when filling out and submitting commissioning
and testing data and discuss on the forms? (5pts)

Note: Satisfactory rating –3 and above points Unsatisfactory - below

3points

Answer Sheet Score = 5pts

Name: __________________ Date: _______________
Rating: _________
Short Answer Questions
Q1._______________________________________________________________
_______________________________________________________________
__________

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 16 of 125
and Maintenance
Agency June, 2020
Level-IV
 Filling out and submitting
Operation Sheet 4 commissioning and testing data's and
forms
Name: _____________________________ Date: ________________
Time started: ________________________ Time finished: ________________

Equipment, tools and materials:

Testing devices, paper, pen, pencil, learning guide

Materials: - Manufacturers repair manual, pressure gauge and appropriate

electromechanical commissioning hand tools.

Direction: Fill out and submitting commissioning and testing data and using
samples/standard forms while you carry out commissioning on:

Surface water pumps installation

Submersible water pumps installation
Genesets installation and testing
Inspection of the above electromechanical equipment drives control
systems

LAP Test Commissioning electromechanical

equipment/systems
Name: _____________________________ Date: ________________
Time started: ________________________ Time finished: ________________
Direction: complete the following job and report to your instructor
Job1: Carry out complete electromechanical equipment/systems commissioning.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 17 of 125
and Maintenance
Agency June, 2020
Level-IV
 Instruction Sheet Learning Guide #42: Turn-over Electrical
Equipment/ Systems
This learning guide is developed to provide you the necessary information regarding
the following content coverage and topics

 Undertaking final inspection

 Cleaning, checking and returning tools, equipment and any excess
resources and materials
 Preparing and submitting written report
 Accomplishing monitoring data sheet for newly installed systems
 Providing orientation and technical assistant

This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –

o Undertake final inspection

o Clean, check and return tools, equipment and any excess resources
and materials
o Prepare and submit written report
o Accomplish monitoring data sheet for newly installed systems
o Provide orientation and technical assistant
Learning Instructions:

1. Read the specific objectives of this Learning Guide.

2. Follow the instructions described in number 3 to 20.

3. Read the information written in the “Information Sheets 1”. Try to understand
what are being discussed. Ask you Instructor for assistance if you have hard
time understanding them.

4. Accomplish the “Self-check 1” in page __.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 18 of 125
and Maintenance
Agency June, 2020
Level-IV
 5. Ask from your Instructor the key to correction (key answers) or you can request
your Instructor to correct your work. (You are to get the key answer only after
you finished answering the Self-check 1).

6. If you earned a satisfactory evaluation proceed to “Information Sheet 2”.

However, if your rating is unsatisfactory, see your Instructor for further
instructions or go back to Learning Activity #1

7. Submit your accomplished Self-check. This will form part of your training
portfolio.

8. Read the information written in the “Information Sheet 2”. Try to understand
what are being discussed. Ask you Instructor for assistance if you have hard
time understanding them.

9. Accomplish the “Self-check 2” in page __.

10. Ask from your Instructor the key to correction (key answers) or you can request
your Instructor to correct your work. (You are to get the key answer only after
you finished answering the Self-check 2).

11. Read the information written in the “Information Sheets 3 and 4”. Try to
understand what are being discussed. Ask you Instructor for assistance if you
have hard time understanding them.

12. Accomplish the “Self-check 3” in page __.

13. Ask from your Instructor the key to correction (key answers) or you can request
your Instructor to correct your work. (You are to get the key answer only after
you finished answering the Self-check 3).

14. If you earned a satisfactory evaluation proceed to “Operation Sheet 1” in page

_. However, if your rating is unsatisfactory, see your Instructor for further
instructions or go back to for each Learning Activities.
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 19 of 125
and Maintenance
Agency June, 2020
Level-IV
 Information Sheet#1 Undertaking Final Inspection

Acceptance
When a system’s readiness for operation has been demonstrated, verified,
documented, and authorized.

Acceptance test
Functional performance test has replaced this terminology.

Authority having jurisdiction

An individual designated by government, the insuring institution and/or the company,
who has knowledge of company operations, fire protection systems, and liability to
life and property and who has the authority to stop operation of the facility when
certain fire protection requirements are not met.

Commissioning
The systematic process of verifying, documenting, and ensuring that the systems in
a new system are designed, installed, functionally tested, and capable of being
operated and maintained to perform according to the original design intent and
owners’ requirements. The process begins in the facilities program phase and
progresses through design, construction/start-up, functional performance testing,
and post functional performance phases, and lasts at least one year after project-
closeout. Commissioning activities include training of operations and maintenance
staff. During commissioning, functional performance tests and deferred functional
performance tests are conducted on each system. These tests require written
authorization for the systems to be accepted as ready for operation in the
commissioning process. The commissioning process can be applied throughout the
life of the system (see re-commissioning). Commissioning requires the participation
of all parties involved in the system delivery cycle from the program phase to the post
acceptance phase.

Deferred functional performance tests

Functional performance tests which cannot be accomplished immediately and need
to be deferred to a later time because of seasonal reasons, lack of occupancy,
deficiencies in other systems, or structures impacting the system under consideration
or other reasons. A comprehensive acceptance test schedule including deferred
acceptance tests should be developed as part of the acceptance test plan.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 20 of 125
and Maintenance
Agency June, 2020
Level-IV
Design basis document
All information necessary to accomplish the design intent, including weather data,
interior environmental criteria, other pertinent design assumptions, cost goals, and
references to applicable codes, standards, regulations, and guidelines.

Design intent
A detailed explanation of the ideas, concepts, and criteria that are defined by the
owner to be important. This typically is an expansion of the information provided in
the owner’s program.

Final acceptance
When all requirements of the commissioning process/plan have been completely
satisfied, documented, and authorized as accepted. At this point all of the systems in
a system are deemed ready for operation. Final acceptance occurs at the completion
of the post acceptance period and may take one year in duration.

Functional performance test

The full range of checks and tests carried out to determine whether all components,
subsystems, systems, and interfaces between systems function in accordance with
the contract documents. In this contest, “function” includes all modes and sequences
of control operation, all interlocks, and conditional control responses and all specified
responses during design day and emergency conditions

Post acceptance
The period of time occurring after project-closeout and before final acceptance. The
post acceptance period may last for one year. It includes time for remaining or all
deferred acceptance tests and the guarantee/warrantee period.

Pre-Functional Performance Test

A series of tests for specified equipment or systems, which determine that the
systems are installed correctly, start up, and are prepared for the functional
performance tests. Often these tests are in a checklist format. The pre-functional test
checklists may be completed as part of the normal contractor start-up test

Project-closeout
The point in time when the systems are considered acceptable for the owner and/or
his operating and maintaining contractor (O & M) take over operation of the facility
and its systems. At this time some or all deferred acceptance tests and
guarantee/warrantee work will remain to be completed. The post acceptance period
begins at project-closeout.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 21 of 125
and Maintenance
Agency June, 2020
Level-IV
Re-commissioning
A detailed condition assessment/retesting of an existing facilities’ systems. During
re-commissioning, functional performance tests are conducted on systems to
establish acceptability. Re-commissioning requires subsequent "tune-ups" and fixes
to bring systems back to design or current operating requirements. It includes all
aspects of commissioning. Re-commissioning can occur only if a building or system
had been previously commissioned. Re-commissioning involves the continued
adjustment, optimization, and modification of systems to meet specified
requirements. It includes updating documentation resulting from minor set point
adjustments, system maintenance and calibration, major system modifications, and
provides for ongoing training of operations and maintenance personnel. As in
commissioning, re-commissioning requires authorization of satisfactorily completed
tests for the systems to be considered acceptable and ready for operation.

Retro-commissioning
A detailed condition assessment/testing of an existing equipment/systems, after the
system has been in operation and for which no commissioning activities have been
conducted. Retro - commissioning requires all commissioning activities be performed
and may require field work for preparation of drawings and documentation of
equipment specifications.

Systems Manual
A document developed for a system that includes as-built drawings, equipment
specifications, and equipment manuals which include installation instructions,
operating instructions, maintenance instructions, and approvals from fire department
inspectors, city, state, regulatory, and insurance officials. The system manual also
includes pertinent information gathered during the commissioning process such as a
copy of the signed commissioning sign-off sheet, a table of contents, and a list of all
items in the manual.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 22 of 125
and Maintenance
Agency June, 2020
Level-IV
 Self-Check 1 Written Test
Directions: Answer all the questions listed below and write your answer on the space
provided
1. What are the activities that are undertaken in carrying out the
electromechanical equipment final commissioning inspections? (4pts)
2. Give definitions for: (5pts)
 Acceptance tests
 Functional tests
 Final inspection tests
 Re-commissioning tests
 Post commissioning testing


Note: Satisfactory rating –5 and above points Unsatisfactory - below

5points

Answer Sheet
Name: __________________ Date: _______________
Short Answer Questions
1. _____________________________________________________________
_____________________________________________________________
_______________
2. _____________________________________________________________
________

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 23 of 125
and Maintenance
Agency June, 2020
Level-IV
 Operation Sheet 1 Undertaking final inspections

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Direction: Select any of appropriate village or groups of community nearby you

Equipment, tools and materials:

Procedures, paper, pen, pencil, learning guide

Materials: - Manufacturers repair manual, Feeler gauge and appropriate hand

tools.

Procedures:

Step 1- Determine their water need as per standard

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 24 of 125
and Maintenance
Agency June, 2020
Level-IV
 Cleaning, Checking and Returning Tools,
Information Sheet-#2 Equipment and Any Excess Resources
and Materials
a. Housekeeping
Poor housekeeping can result in an increased risk of injury and a decrease in work
efficiency.

By implementing a good housekeeping plan, areas are kept clean and free of waste
and the risk of injuries occurring due to slip, trips and falls, together with injuries
resulting from hitting stationary objects, are reduced. Items should be stored correctly
with no parts protruding onto walkways.

Electrical cords should not be on the floor, tools should have designated areas for
storage and bins for waste should be readily available and be easy to empty.

Structured programs that focus on organization, cleanliness and standardization can

be introduced to the workplace to assist with this. Cleanliness can be maintained in
a ‘clean as you go’ manner or the need for constant housekeeping can be eliminated
from the source e.g. leaks, etc.

Self-Check 2 Written Test

Directions: Answer all the questions listed below and write your answer on the
space provided
1. How to carry out cleaning tools, equipment and extra resources after you carry out
electromechanical equipment commissioning? (3pts)
2. What is housekeeping in electromechanical equipment commissioning concept?
(2pts)

Note: Satisfactory rating –3 and above points Unsatisfactory - below

3points

Answer Sheet
Name: ____________ Date: _______________
Short Answer Questions
1. _______________________________________________________________
2. _________________________________________________
Electro-Mechanical Equipment Operation
Author/Copyright: Federal TVET Version -1 Page 25 of 125
and Maintenance
Agency June, 2020
Level-IV
 Cleaning, Checking and Returning Tools,
Operation Sheet 2 Equipment and Any Excess Resources and
Materials

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Direction: Select any of appropriate village or groups of community nearby you

Equipment, tools and materials:

Procedures, paper, pen, pencil, learning guide
Materials: - Manufacturers repair manual, Feeler gauge and appropriate hand
tools.

Procedures:

Step 1- Determine their water need as per standard

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 26 of 125
and Maintenance
Agency June, 2020
Level-IV
 Information Sheet-3 Preparing and Submitting Written Report

Report Content
• Location of work
• Work undertaken (planned and unplanned)
• Dates and times of work
• Parts and consumables used
• Safety practices followed (Permits to Work)
• Tests carried out and data collected

• Details of design and construction

• Rated conditions of operation
• All foreseeable faults and operation of
safety devices
• Maintenance Schedule
• Latest periodic report of examination
• Previous reports linked to safety issues
• Details of all faults and modifications
• List of machine malfunctions
– Most shift staff see approx. quarter of faults
• Record of work carried out
• Personnel involved
• Technical file for new system or machine

Technical File
• The technical file contains:
• Information on design, construction
• How essential requirements have been met
• Conformity Assessment Procedure
• Conformity Certificate
• User Instructions
• Relevant research and test results
• Quality systems for a series of products

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 27 of 125
and Maintenance
Agency June, 2020
Level-IV
 Self-Check 3 Written Test

Directions: Answer all the questions listed below and write your answer on the space
provided
1. What is the final report contents? (5pts)

2. What does mean for technical file in electromechanical equipment

commissioning? (5pts)

3. What are methods for preparing and submitting written reports in

electromechanical equipment commissioning? (5pts)

Note: Satisfactory rating –8 and above points Unsatisfactory - below

8points

Answer Sheet
Name: __________________Date: _______________
Short Answer Questions
1. ______________________________________________________________
______________________________________________________________
2. ______________________________________________________________
______________________________________________________________
3. _____________________________

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 28 of 125
and Maintenance
Agency June, 2020
Level-IV
 Operation Sheet 3 Preparing and Submitting Written Report

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Direction: Select any of appropriate electromechanical equipment commissioning

Equipment, tools and materials:

Procedures, paper, pen, pencil, learning guide

Materials: - Manufacturers repair manual, metering and pressure gauge and

appropriate commissioning hand tools.

Procedures:

Step 1- prepare written commissioning reports

Step-2 - submitting reports for electromechanical equipment commissioning

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 29 of 125
and Maintenance
Agency June, 2020
Level-IV
 Information Sheet-4 Accomplishing Monitoring Data Sheet for
Newly Installed Systems

Standard O&M Manuals

(Commissioning Authority review of O&M manuals and equipment warranties is
recommended but is not a requirement for Fundamental Commissioning)
The Commissioning Authority reviews the O&M manuals, documentation and red line
as-builts for systems that were commissioned to verify compliance with the
Specifications. The Commissioning Authority recommends approval and acceptance
of these sections of the O&M manuals to the Commissioning Engineer. The
Commissioning Authority also reviews each equipment warranty and verifies that all
requirements to keep the warranty valid are clearly stated.

Commissioning Record
The Commissioning Authority will compile, organize and index the following
commissioning data by equipment into labeled, indexed and tabbed, three-ring
binders and deliver it to the GC, to be included with the O&M manuals. The
correspondence, meeting minutes and progress reports, miscellaneous notes, etc.
kept in the Commissioning Record Book during construction will not be retained into
this record and the O&M manuals. The format of the manual follows:
a. Commissioning Plan
b. Final Commissioning Report
c. Issues Log (record of deficiencies)
d. Progress Record

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 30 of 125
and Maintenance
Agency June, 2020
Level-IV
 Self-Check 4 Written Test

Directions: Answer all the questions listed below and write your answer on the space
provided
1. How to manage wastes, cleanness and recycled materials when we perform
commissioning? (3pts)
2. What if we don't keep cleaning and wastes after or when we carried out
commissioning activities? (2pts)

Note: Satisfactory rating –3 and above points Unsatisfactory - below

3points

Answer Sheet
Name: ________________ Date: _______________

Short Answer Questions

1. _____________________________________________________________
_____________________________________________________________
_____________
2. _____________________________________________________________
_____________________________________________________________
____________

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 31 of 125
and Maintenance
Agency June, 2020
Level-IV
 Information Sheet-5 Providing Orientation and Technical
Assistant

Training and Orientation of Owner Personnel

The following training will be provided in electromechanical commissioning:
Electrical system ___video ___class ___hands-on
Generator power system ___video ___class ___hands-on
Control panel systems ___video ___class ___hands-on
Surface water Pumping system ___video ___class ___hands-on
Submersible water pumping system ___video ___class ___hands-on
Gene set operating system ___video ___class ___hands-on
__________________________________video ___class ___hands-on
__________________________________video ___class ___hands-on

Self-Check 5 Written Test

Directions: Answer all the questions listed below and write your answer on the space
provided

1. Describe how to orient end-users of commissioning? (5pts)

2. How to document technical files of electromechanical commissioning? (4pts)

Note: Satisfactory rating –5 and above points Unsatisfactory - below

5points

Answer Sheet
Name: __________________ Date: _______________
Short Answer Questions
1. _____________________________________________________________
______
2. _____________________________________________________________
_______

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 32 of 125
and Maintenance
Agency June, 2020
Level-IV
 Provide Orientation and Technical
Operation Sheet 5
Assistant
Name: _____________________________ Date: ________________
Time started: ________________________ Time finished: ________________

Direction: provide orientation and technical assistance to the commissioning owner

Equipment, tools and materials:

Procedures, paper, pen, pencil, learning guide

Materials: - Manufacturers repair manual, testing devices, metering and pressure

gauge and appropriate hand tools.

Procedures:

Step 1- prepare O&M manual to the electromechanical equipment commissioning

you carried out previously

Step-2- provide orientation to users

Step-3-provide technical assistance to the users

LAP Test Carry out Turn-Over electrical equipment

commissioning

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Direction: complete the following job and report to your instructor

Job1: Carry out complete turn-over of electrical equipment commissioning.

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 33 of 125
and Maintenance
Agency June, 2020
Level-IV
References
1) Instructor: George E. Thomas, PE Commissioning Mechanical Systems-PDHonline
Course M353 (6 PDH)-2012
2) PDH online Course E409 (6 PDH)-Commissioning Major Electrical Systems-
Instructor: George E. Thomas, PE 2013
3) Mechanical and Electrical Design Of Pump Stations -EM 1110-2-3105-30 April 2020
4) Commissioning Plan-University Of Michigan-July 2016
5) Basic Tools-Pdf…..
6) Practical Troubleshooting of Electrical Equipment and Control Circuits- by-Mark
Brown Pr.Eng, DipEE, B.Sc (Elec Eng), Senior Staff Engineer, IDC Technologies,
Perth, Australia-2005.05.26

Developed by: Ferede Lemi (BSC degree in Mechanical Engineering, and Instructor
with Ath. Kenenisa Poly Technique College, Elecro-Mechanical
Equipment Operation and Maintenance Dept’)

Electro-Mechanical Equipment Operation

Author/Copyright: Federal TVET Version -1 Page 34 of 125
and Maintenance
Agency June, 2020
Level-IV