Start-Up, Commissioning and Testing of Electrical Systems

Many electrical start-up problems have simple causes. Test plans are written late and copied from previous projects, factory and site tests are not linked, protection settings arrive after the relays are installed, and nobody owns the interfaces between contractors. Safety isolation during testing is informal, results are recorded in different formats, and the operator receives a system without the evidence needed to run and maintain it with confidence.

This programme follows the commissioning sequence from planning to handover. It moves through five stages: organising the commissioning process and its documentation, working safely on partly energised systems, testing equipment off load, planning and carrying out first energisation, and completing on-load tests, performance checks and handover. Each stage links the test to the fault or risk it is meant to detect, so participants understand why a result matters and what to do when it fails.

Built on recognised practice. The programme references widely used international standards and specifications, including IEC 60364-6 for initial verification of low-voltage installations, the IEC 62271 series for high-voltage switchgear, the IEC 60076 series for power transformers, the IEC 60255 series for protection relays, IEC 61850 for substation communication, the ANSI/NETA Acceptance Testing Specifications and NFPA 70E for electrical safety in the workplace. Participants learn how to apply them to test procedures and acceptance criteria.

Decisions this programme improves. Which tests are needed for each type of equipment and at what stage; whether a test result is acceptable, needs investigation or should stop energisation; how to sequence first energisation safely; when a system is ready for handover; and what records the operations and maintenance team must receive.

How it is delivered. Twenty hours across five sessions, built around one running case: a medium-voltage substation with transformers, switchgear, LV distribution, a standby generator and motor loads. Participants prepare an inspection and test plan, interpret sample test results, review a protection coordination check, write an energisation procedure and compile a handover dossier.

In-house option. For organisations, the programme can be tailored to your own equipment, test forms, permit-to-work system and commissioning procedures, and delivered to owner, contractor and operations teams together so that everyone applies the same acceptance criteria.

Who Should Attend

Testing and commissioning engineers and technicians working for owners, contractors or specialist testing companies

Maintenance engineers and technicians who will operate and test the systems after handover

Project and site engineers responsible for electrical packages on construction and upgrade projects

Consulting engineers who review test procedures and witness tests

Engineering managers responsible for commissioning teams and handover decisions

HSE professionals who oversee electrical safety during testing and energisation

Objectives

Explain the purpose and sequence of factory acceptance, site acceptance, pre-commissioning, commissioning and start-up

Prepare an inspection and test plan with clear hold points, responsibilities and acceptance criteria

Apply safe isolation, earthing, permit-to-work and test-zone controls during commissioning

Select and carry out insulation resistance, winding resistance, ratio, polarity and contact resistance tests and interpret the results

Verify current and voltage transformer circuits, secondary wiring and protection relay operation by secondary injection

Check phasing and phase rotation before connecting sources or paralleling supplies

Plan and supervise first energisation of transformers, switchgear and distribution boards

Perform on-load checks on protection, metering, generators, motors and changeover schemes

Record test results, manage punch lists and deficiencies, and decide when equipment is ready for service

Compile a handover package that supports safe operation and future maintenance testing

Course Outline

Organising Commissioning: Scope, Roles and the Test Plan

Why electrical systems fail at start-up: typical causes and their costs
The commissioning life cycle: factory acceptance, site acceptance, pre-commissioning, commissioning and start-up
Roles of owner, consultant, contractor, vendor and operator
Inspection and test plans, hold points and witness points
Test sheets, records and digital commissioning management tools
Interfaces with mechanical, control and building management systems

Working Safely While Systems Are Being Energised

Electrical hazards during testing: shock, arc flash and back-feed
Isolation, lock-out, tag-out and proving dead
Temporary and permanent earthing arrangements
Permit-to-work, test zones and control of partly energised systems
Test equipment selection, calibration and safe use
Communication and emergency arrangements during energisation

Testing Equipment Before Energisation

Visual and mechanical inspection of switchgear, transformers, cables and busbars
Insulation resistance, polarisation index and dielectric withstand testing
Transformer tests: ratio, vector group, winding resistance and magnetic balance
Circuit breaker timing, contact resistance and interlock checks
Current and voltage transformer tests: ratio, polarity and burden
Cable testing and termination checks for MV and LV circuits
Low-voltage verification: continuity, earth fault loop impedance and RCD tests

Protection, Control and First Energisation

Reviewing protection studies and relay settings before testing
Secondary injection and functional testing of protection schemes
Trip circuit, alarm and interlock verification
Checks on substation automation and IEC 61850 communication
Phasing, phase rotation and synchronising checks
Writing and rehearsing the first energisation procedure
Energising transformers and switchboards in a safe sequence

On-Load Testing, Performance and Handover

On-load checks: stability, directional protection and metering
Generator, UPS and automatic transfer scheme testing
Motor start-up, rotation and load tests
Thermographic surveys and power quality measurements
Punch lists, deficiency management and acceptance certificates
Handover documentation and baseline data for maintenance testing
Lessons learned and improving the next commissioning project

Competencies

Commissioning planning and inspection and test plans

Safe isolation and permit-to-work for testing

Pre-commissioning tests on HV and LV equipment

Transformer and switchgear test interpretation

Protection relay and secondary circuit testing

Phasing and first energisation procedures

On-load testing and performance verification

Commissioning records and handover documentation

Barcelona

Explore professional training in Barcelona across Elite Academy’s full range of disciplines. The city’s position as a globally connected Mediterranean city with an active business and professional environment makes it an attractive international setting for scheduled courses and programs arranged to your preferred topic and dates. Elite Academy can deliver its full range of professional training programs in Barcelona, Spain. Because the city is a globally connected Mediterranean city with an active business and professional environment, it provides a strong international environment for participants from organizations as well as individual professionals. The courses shown on this page represent the programs currently scheduled in Barcelona; they do not limit what can be delivered there. If your preferred course or date is not listed, you can request any program from our portfolio to be arranged in Barcelona, subject to scheduling and delivery requirements.