Electrical Engineer's Report: ROGC Main Substation Commissioning, CE1

This report details the installation, commissioning, testing, and charging of the ROGC Main Substation project undertaken for Reliance Industries Ltd in Jamnagar, Gujarat, India. The project, completed from July 2016 to January 2017, involved the commissioning of electrical systems, revalidation of panels, and the implementation of innovative technologies. The author, an Electrical Engineer, describes their responsibilities, which included testing, report generation, and coordination with other departments. The report highlights the application of engineering knowledge, problem-solving skills, and adherence to safety standards, including addressing issues related to equipment installation and relay configuration. The project's successful completion within the given timeframe, with a focus on quality and safety, is emphasized, along with the use of various software tools and the importance of collaborative work. The report also includes project reviews, challenges, and solutions, demonstrating the engineer's contribution to the project.

Competency Demonstration Report
Career Episode 1

CE 1.1 Project Information
Name of the project: Installation, Commissioning, Testing and Charging of ROGC Main
Substation
Location of the project: Jamnagar, Gujarat, India.
Project Duration: July 2016 – January 2017
Organization: Reliance Industries Ltd
Role and Designation during the time: Electrical Engineer
CE 1.2 Project Background
CE 1.2.1 Characteristics of the project
I have chosen the project installation, commissioning, testing and charging ROGC main
substation for the Reliance Industry in Gujrat, India. I was liable for the ROGC electrical
commissioning and for the development of the world class refining unit. I was responsible for the
commissioning and modification of the plat automation and distribution equipment and testing
them. I have previous experience in petrochemical sector for performing maintenance and
commissioning activities but an additional one month training was provided to me regarding the
safety and the hazards related with the project. The project is developed for exporting petroleum
products to different countries and processing capacity of 1.24 million barrels per stream day
(BPSD). New innovative technologies are implemented in the project such as power electronics
pulse firing based sensitive drives.

CE 1.2.2 Objectives developed for the project
Following are the objectives of this particular project work:
 To test and commission of electrical system and generate report
 To revalidate all the PMCC, MCC panels in conjunction with 2.5MVA distribution
transformers
 To assign 1010KVA AMF DG Synchronizing panel for power backup in case of blackout
analyse the working principle of DC motor
 To check Auto Change-Over (ACO) Scheme witness and Fast Bus Transfer (FBT)
 To record the daily activities and discuss problem with the higher management
 To co-ordinate with other departments to avoid work isolation.
 To find out the drawing related issues and to modify the installed system as per
requirements.
CE 1.2.3 My area of work
I was concerned about the commissioning and testing of the power and distribution using
the transformers. I carried out testing for measuring and protection and of the equipment’s and
prepared reports. I also revalidated the 6.6. KV HT Motor and the transformer feeders and
checked the configuration for all protection IED’s and checked the soft logic. I used GOOSE
(Generic Object Oriented Substation Events) communication system for checking the Auto
Changeover (ACO) scheme. I rectified the design related issues and for the distribution and the
automation system. I used FBT (Fast Bus Transfer) for functional checking and system
commissioning. I followed the quality and the safety standards while commissioning the

Maintenance Head
J3 Electrical Head
Senior Manager
(Maintenance)
activities. I also checked and verified the relay settings for the HT motor feeders. I always
ensured effective communication between the team members and the other departments.
CE 1.2.4 Project Group
I has undertaken the project under the maintenance head of the department and he
supported me for avoiding the work isolation. I discussed the problems with him for
communicating with the other departments and checking the function of the interfacing system.
Under me senior manager worked and I choose skilled workforce for carrying out complex
project work activities by evaluating their technical skills and work experiences in relevant field.
Figure 1: People involved in the project
CE 1.2.5 My responsibilities throughout the project
I had concerned in studying the principles of motor, back EMF and DC motor as
a load to conduct the project work. I had analyzed DC-DC converter operation and switch mode

buck and boost converter circuits. I had evaluated the electrical systems, components and also
applications by design and conduct of research problems. I had developed the electrical products
by study the customer’s requirements and assembly of mathematical models. I had assured the
quality of the electrical equipments and DC motor by designing of electrical testing methods and
capabilities of system.
CE 1.3 Distinctive Activity
CE 1.3.1. Comprehending the theory of the project
As a part of building project work strategy, I performed visual inspection and
identification of all installed substation equipment. On the basis of this, I constructed system
related checklists to enhance the consistency and thoroughness of commissioning activities.
Distribution system was fully automated and equipped with multifunction IED’s, controllers,
load shedding modules in conjunction with auto synchronization system. The ISO 901 standard
was maintained for the installation of the sub system and the systems. I split the work into two
phases i.e. commissioning, testing and modification of the relays based on the microprocessor
and Ethernet switch testing and the auto change over scheme. In the second phase the interfacing
system was commissioned along with the fats bus transfer (FBT) and testing the logics of the
transformers. I selected the employees based on their skills and knowledge and organized a
status update meeting for discussing the issues and work related activities for ensuring the
quality of the work. I also contacted the department of procurement for checked the quality
standards of the tools and inspected all the portable tools and ensured third party certificate for
all portable electrical tools and tackles. I also attended interdepartmental meetings, where I have
to give presentation about the steps taken by me for avoiding and accomplishing the goals and

objectives of the project. This meeting proved to be beneficial in ensuring effective co-ordination
with concerned departments for smooth and seamless commissioning.
CE 1.3.2 Engineering knowledge and skills applied in the project
In order to ease the work complexity and systemisation tracking of commissioning work,
I constructed work flow sheets in Excel Tool where complete description of every activity and its
given deadlines were mentioned. I conducted brief meetings with construction team and
Schneider vendors, where I gave them assurance for providing our support and help in all
commissioning stages. Job planning was completed successfully, but it was most challenging for
me to allocate commissioning task to the technicians. So for assigning right task to the employee,
first of all I evaluated the risk factor and job complexity. Then I considered the experience,
proficiency and personal readiness of every individual and allocated the commissioning tasks
accordingly.
CE 1.3.3 Accomplishment and task performed
I started from commissioning of distribution transformers and power
transformers. I thoroughly inspected the alignment of all oil based tripping devices and
accessories. In a distribution transformer, Bucholz relay was mounted at an angle of 5degree
between conservator and main tank pipe with arrow marked towards main tank, which was not
acceptable. It was in the scope of L&T to rectify the issue, so I highlighted this issue to their site
in charge and Bucholz was reinstalled by turning the arrow direction towards conservator tank. I
carried out BDV and PPM testing on all transformers oil samples. In conjunction with this I
performed some routine testing and type testing i.e. ratio testing, DGSA, vector group testing and
made calculations as per the mathematical derived equations .Moreover, I generated the site
acceptance test reports and kept the records for dossier completion at the end phase of project

execution and send the copies of these reports to all concerned departments .Transformers pre
commissioning was almost completed by performing functional tests of Bucholz relay (by
injecting air in test pockets), OTI, WTI, MOG, and PRV.
CE 1.3.4 Identified issues and their solutions
1.3.4.1 Issues
I faced problem during the installation of the electrical equipment because the sparkle
inside the electrical equipment can result in fire because the project is carried in the
petrochemical sector. Another problem faced was to commission 6.6Kv and 440 v distribution
switchboards and all the distribution needs to be reconfigured and the health of the explosion
proof vents were needed to be checked.
1.3.4.2 Solutions
I strictly followed the commissioning standards of petrochemical sector to ensure zero
fire incidents due to sparking inside the installed electrical equipment. While performing
commissioning activities, I followed the IEC safety standards for safe commissioning of
electrical equipment. First of all I checked and verified Zone classifications, temperature classes,
and flame proof enclosures of the installed equipment .Some deviations from safety standards
were observed in power cables glanding, where non flame proof glands were used. Without any
delay, I informed to the sub-contractor for immediate replacement of material installed. I made
some changes in installed system by utilising my skills and technical expertise. I interlocked the
second stage over current (I2) tripping with “START IN PROGRESS” so that motors should not
be tripped during inrush current flow at the time of motor starting .Also, I routed Thermal
Overload Trip (49-2) directly to trip coil of breaker instead of master trip relay (86), to avoid any

serious damage to the motor in case of IED malfunctioning. Moreover, I disabled 2nd harmonic
from system configuration and also removed 2H block from O/C and SEF protections for safe
and reliable operation of equipment. For MCOMP (L&T) motor protection relay configuration, I
used MCOMP SUITE software tool and uploaded the verified settings.
CE 1.3.5 Plan to produce creative and innovative work
I revalidated the motor feeders and the distribution for examining the health of the vents
and commissioned the 6.6. KV and 440 V distribution switchboards. During re-validation, I
detected some operational issues in anti-condensation heaters, door interlocks and padlocking
arrangements. I rectified such issues on the priority basis and conducted HI Pot and CRM tests
on to the panel bus bars and results were absolutely normal. Then for system protection from
dust and harmful liquids, I scrutinized the ingress protection standards stencilled on switchgear,
Junction boxes and transformers. All systems and subsystems were adhered to IP66 standard for
ingress protection, which was accurate as per the surrounding environmental and soil conditions
of J3 site. Relay configuration part was quite challenging due to complex operational logics and
protection parameters. Prior to the relay configuration, I personally derived some simple setting
calculation methods for relay settings rather than using complex and time consuming
calculations. Also I made use of Excel Tool to formulate some simple operational and tripping
logics Moreover I made some changes in the existed protection settings, plug setting and time
multipliers parameters by incorporating mathematical derived calculation techniques as per IEEE
standards to deal with system contingencies. Then I used MICOM S1 STUDIO software tool for
fast and error free updating of PX 40 series relay parameters with modified settings. I uploaded
PSL (Programmable Scheme Logic), MCL (Micom configuration Binary Files) and SET files in
all IED’s .Also download the templates from IED’s and verified with settings given by

engineering department. To avoid any setting parameters conflict in future, I forward the
modified setting, user manuals and test reports to engineering department to update in their
system.
CE 1.3.6 Collaborative work
My focus was on the time schedule of the project and I completed the project within a
period of 6 months. I prepared project related documents and shared it with the senior authorities
for getting their valuable feedbacks. I attended inter-departmental meetings for understanding the
work flow process and demonstrated the status of the work. I conducted regular walk down for
analysing the limitation or barrier in the project development and integrated the results with the
project documents.
CE 1.4 Project Review
CE 1.4.1 Project Overview
The project is to for ROGC electrical commissioning of the main distribution substation
and management of the field equipment. The distribution and the plat automation are required to
be modified and plant automation related equipment are installed with testing and functional
checking. As an experienced employee I was appointed after one month training for the
commencement of the project.
CE 1.4.2 My contribution to work
I had done my works with 100% accuracy and within or before the deadline that was
assigned to me. I got appreciation from ROGC management team and new project was offered to

me. I had worked hard on the project and reviewed the fault in the project for increasing the
accuracy and circulated the test reports to the senior managers.