gtgb_start up_ric8955863 rev 0.1 (1)

SITE QUALITY START-UP CHECK LIST

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2 / 3 ISSUED 0 g GE Oil & Gas N° RIC8955863/4

TAV/SH DESCRIPTION REV DESCRIPTION REV This document is the property of General Electric Company. All rights are reserved according to law.

INDEX

Contents Page

1. INTRODUCTION NOTE START-UP CHECK LIST............................................................................................................................................................................................................................................................................. 3 1.1 PURPOSE: ......................................................................................................................................................................................................................................................................................................................................... 3 1.2 ACTIVITY OF THE INSPECTOR:................................................................................................................................................................................................................................................................................................ 3 1.3 CERTIFICATION: ............................................................................................................................................................................................................................................................................................................................ 4 1.4 CONTROL PROCEDURES AND REFERENCE DOCUMENTS:....................................................................................................................................................................................................................................... 4 1.5. REFERENCE DRAWINGS:............................................................................................................................................................................................................................................................................................................... 5

2. INSTRUCTION FOR USERS .................................................................................................................................................................................................................................................................................................................... 6 3. CHECK DURING START-UP AND INITIAL OPERATION............................................................................................................................................................................................................................................................... 7

3.1 START-UP ON CRANK MODE..................................................................................................................................................................................................................................................................................................... 7 3.2 START-UP ON FIRE MODE WITH IBH CLEANING TEST................................................................................................................................................................................................................................................. 12 3.3 START-UP ON AUTO/REMOTE AND CHECKS TO BE DONE AT FSNL ...................................................................................................................................................................................................................... 19 3.4 EXCITATION SYSTEM (AVR) FUNCTIONING AT FULL SPEED NO LOAD.................................................................................................................................................................................................................. 22 3.5 SHORT CIRCUIT TEST OF GENERATOR PHASES.............................................................................................................................................................................................................................................................. 28 3.6 MANUAL/AUTO SYNCHRONIZATION TEST & PRIMARY/SECONDARY FUEL GAS STRAINER CLEANING TEST ...................................................................................................................................... 32 3.7 DLN TUNING/MAPPING ........................................................................................................................................................................................................................................................................................................... 40 3.8 FINAL VERIFICATIONS............................................................................................................................................................................................................................................................................................................... 42


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1. INTRODUCTION NOTE START-UP CHECK LIST

1.1 PURPOSE:

This document describes the check list for the typical start-up of gas turbine and electric generator on GNL3Z PLANT, ARZEW – ALGERIA .

This document summarizes the standard installation and testing stages for the major components of the product in subject. this is a reference document for:

-Definition of the type of quality documentation to be given to the customer or his engineering company as final documentation or for preliminary approval.

-Definition of the installation or testing procedures to be witnessed by inspectors.

All the related auxiliary systems shall be function tested prior to the test runs. the following paragraphs require that all installation (auxiliary equipment coupling alignment, piping alignment

and tolerance check, soft foot checks etc) and pre-commissioning requirements have been successfully completed, witnessed, signed-off and the documents are readily available for review

if needed. it is also required that all instruments, electrical devices and circuits, and process systems are calibrated and loop checked prior to each function or run-in test. the activities are in

each clause below are written in the preferred chronological order. however, the order may be altered, if deemed necessary by the appropriate qualified start-up engineer.

1.2 ACTIVITY OF THE INSPECTOR:

For all parties involved in site activities, different levels of attendance may be specified in the space provided for this purpose in the document.

The following activities are possible:

-W (WITNESSED): This is a binding request to witness a installation or testing phase

-O (OBSERVED): This is a request for optional witnessing of an installation or testing phase

-R (REVIEWED): Inspector will perform a documentation review of the inspection or test.

Note: GE OIL&GAS inspector attendance is regulated by contractual terms and conditions. advance notification is defined in accordance with mobilization requirements.


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1.1.1GENERAL NOTE:

These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met during installation, testing or commissioning. should

further information be desired or should particular problems arise that are not covered sufficiently for the purchaser’s purpose, the matter should be referred to GE OIL & GAS Firenze 50127

Italy. this document contains proprietary information of GE OIL & GAS and is furnished to its client solely to assist him in the installation, testing and commissioning of the equipment

described here in. The UCS is composed of:

MKVI-e PLC’s and I\O cards, Bently Nevada vibrations monitor and fire & gas monitor and I\O cards.

1.3 CERTIFICATION:

The certification issued for the tests performed is listed in this document in the appropriate space provided for this purpose, and is defined by ITN 07771 (certificate type a-b-c equivalent to

EN10204 norm respectively type 2.1, 3.1.b, 3.1.c). said certification will be included in the final documentation dossier (m.d.r.) the final dossier will be compiled according to GE standard.

1.4 CONTROL PROCEDURES AND REFERENCE DOCUMENTS:

The acceptance criteria drawn from the single procedures valid on issuing this document are an integral part of said document and are enclosed for reference.

The aforementioned acceptance criteria to be checked prior to carry out the single test with reference to the original documents which could have been revised after issue of this document.

The documents (specifications or drawings) mentioned in this document can be consulted, on request, at GE OIL & GAS site management team office and are the official references for all

intents and purposes.


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1.5. REFERENCE DRAWINGS:

DESCRIPTION DWG NUMBER DESCRIPTION DWG NUMBER

P&I Diagram (cover and legend) SOM5106401 Unit control system cause & effect diagram SOM6623681 Fuel gas system on baseplate P&I diagram SOM5106410 Field Instrument list SOM5461138 Filter house control board functional dwg and component list SOM6666153 Control system electrical grounding guideline SOM6614381 P&ID - Fuel gas treatment skid SOM5106413 Battery Charger & DC Panel Single Line Diagram SOM6669064

P&ID - Cooling & sealing system SOM5106420 Control system electrical grounding guideline - part2 -safety instruction site preparation SOM6614380

P&ID - Control device system SOM5106421 UCS Sw changes tracking operating instructions SOM6614107

P&ID - Mineral lube, hydraulic, ratchet & control oil on baseplate SOM5106430 SOM5106431 Unit control system interconnecting wiring diagram SOM5461056

P&ID - Synthetic &/or mineral oil mist eliminator SOM5106434 Serial communication list SOM5461058 P&ID - Mineral oil cooler SOM5106436 Unit control system hardwired I/O list SOM5461050 P&ID –Electric generator SOM5106440 Generator control protection panel SOM6702866 P&ID Pulse jet filter house SOM5106471 Generator single line SOM6623894 P&ID - Ventilation system SOM5106480 Control system functional description SOM5461051 P&ID - Fire fighting system on package SOM5106481 MCC single line SOM6701962 P&ID - CO2 fire fighting skid SOM5106490 Generator wiring diagram SOM6701781 P&ID - Legs and flame detector system SOM5106492 Generator protection table SOM6701795 P&ID - Air/water cooling system SOM5106493 P&ID - Combined on/off washing trolley SOM5106494

Warning: Before beginning the start-up, it’s necessary to verify that the above listed documentation has no other revisions successive to those specified. If some of these documents have been revised, the relative modifications must be considered.


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2. INSTRUCTION FOR USERS

The present check list is a document where are reported the main steps of activity needed to proceed with the completion of a new unit installation (instrumental installation).

The purpose of the document is not intend to provide a complete list of activities nether an installation detailed instruction, but it is a useful tool for the installation activity completion check

and for their certification in agreement with all the party involved. the activity listed means that check will be executed according to the information, instruction, values, or other data provided

by relative job/project documentation. the signature beside the verification description, means that activity has been executed with positive result according to the information, instruction,

values, or other data provided by relative job/project documentation. the signature also means that the activity has been accept by the party who sign it. in the “note” field can be reported

any comment or reference regarding the mentioned activity.

Example:

Activity description The signature means that the activity has been correctly accomplished and cheched according to the relative job/project documentation

Parties involved in site activities

Visual or dimensional check

Applicable job document

Applicable procedures for check

execution


LEGEND: CU : CUSTOMER GE : GENERAL ELECTRIC TP : THIRD PARTY

CHECK TYPE: V : VISUAL D : DIMENSIONAL CHECK NDT: NON DESTRUCTIVE TEST

INSPECTORS LEGEND: W : WITNESSED O : OBSERVED R : REVIEWED

GENERAL NOTES:

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3. CHECK DURING START-UP AND INITIAL OPERATION

3.1 START-UP ON CRANK MODE

DESCRIPTION GE Oil & Gas Signature

CU Signature

GE Oil & Gas CU Ref.Doc. Procedure Acceptance

Criteria Check Type

Service report NOTE

WARNING: DURING ALL TESTS NEVER EXCEEDS MAX RUNNING TIME OF THE STARTING SYSTEM, PARTICULARLY AT ACCELERATION SPEED (REFER TO SUPPLIER MANUAL).

Warning: Before forcing any logic signals, verify their correctness and pay attention on the logic involved, in order to avoid problems for safety of plant.

Inhibit the fire fighting system (local portable extinguishers on auxiliary turbine compartment shall be available) and bypass ventilation system in the MKVI Toolbox interface in order to allow entrance inside the enclosure for visual inspection without stopping the normal sequence.

W W SOM5106401 - - V -

From the HMI interface, move the master selector on CRANK position. W O SOM5461051 - - V -

Verify permissions to start from customer ENMC-RTS (XS-5298). W O SOM5461051 - - V -

Verify ready to start from auxiliaries system (L3ARS) W O SOM5461051 - - V -





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Verify “Unit ready to start” conditions (L3RS=1) W O SOM5461051 - - V -

From the HMI interface, give “START” command. W O SOM5461051 - - V -

Verify the correct starting of auxiliaries system : -Mineral Lube Oil -Oil Mist Eliminator -Auxiliary Hydraulic Oil Pump -Jacking Oil Pump -Ventilation system (temporarily by-passed)

W O SOM5461051 - - V -

Verify the correct fuel gas sequencing: -20FB-1 Open -20FV-1 Close

W O SOM5461051 - - V -

Verify the activation of ratchet and starting system. W O SOM5461051 - - V -

As soon as the turbine shaft breakaway, from the proper graphic screen on HMI interface give the stop command. Check for unusual noise close to the turbine axial compressor , close to gear box and on generator.

W O - - - V -

Once the turbine is at zero speed, from the HMI interface, give “START” command. W O SOM5461051 - - V -

Verify when the turbine speed is over about 380 rpm of rated speed, the jacking oil pump (88QS-1A/B) is automatically stopped.

W O SOM5106401 - - D -

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Check the acceleration from zero speed to crank speed (about 20%). Eventually tune XEV-5249 (20TU-1) variable orifice on torque converter solenoid .

W O SOM5106440 - - D -

Record vibration and temperature on Starting Motor (88CR). W O SOM5106440 - - D Reading form

Check the gas turbine, accessory/load gear and generator for unusual noise or vibration. W O SOM5106401 - - V -

Check that the bearings (journal / thrust) metal temperature (gas turbine, accessory/load gear and generator) are within normal range.

W O SOM5106401 - - V -

Check for unusual noise or vibration of the lube oil and hydraulic main pumps driven by accessory gear : 51-MJ01-A-MJ38 (PL-1) 51-MJ01-A-MJ33 (PH1-1)

W O SOM5106431 SOM5106430 - - V -

Check for lube oil header pressure set point is 1.72 Bar G., regulate pressure by means PCV-5164 (VPR-2) if needed.

W O SOM5461051 SOM5106431 SOM5461138

- - V -

Verify the pressure relief valve VR-21 (PRV-5130) setting, increasing the set of hydraulic main oil pump discharge valve VPR3-1 (PCV-5136). The set pressure is 90 Bar G

W O SOM5106430 - - D -

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Check that the hydraulic main oil system pressure is around 80 Bar G and adjust via PCV-5136 (VPR3-1) if necessary.

W O SOM5106430 - - D -

Check that the main hydraulic oil filter (FH2-1) is full with oil looking at the overflow of oil through the sight glass devices and check the differential pressure across the hydraulic oil filter by indication of PDG-5133 (PDI-4) and that no alarm is activated by PDIT-5132 (96HF-1) on MKVI.

W O SOM5106430 - - V -

Open the filling valve of the stand-by hydraulic oil filter (FH2-2) and check when the filter is full with oil, looking at the overflow of oil through the sight glass.

W O SOM5106430 - - V -

Leave open the stand-by lube oil filter filling valves. Move the hydraulic oil filters transfer valve and leave it in the position of main filters (FH2-1) in service.

W O SOM5106430 - - V -

Check that the main lube oil filter (FL-1A) is full with oil looking at the overflow of oil through the sight glass devices and check the differential pressure across the lube oil filter by indication of PDG-5156 (PDI-1) and that no alarm is activated by PDT-5157 (96QQ-1) on MKVI.

W O SOM5106431 - - V -

Force on Mark VI the lube oil header pressure low low status (L63QTX) to zero logic, to avoid the turbogenerator trip during the test.

W O SOM5461051 - - V -





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Following activities to be executed 3 times, for transmitters A-B, B-C, A-C. Only then, checks can be signed-off.

Physically simulate oil Header Pressure Low Low (L63QT), partially closing PT-5190A÷C (96QT1A÷C) manifolds inlet and slowly opening relevant drain , to achieve 51-MJ01-A-MJG-37-B-M (88QE-1) start-up (0.8 Bar G).

W O SOM5461051 SOM5106431 SOM5461138

- - V -

From the proper graphic screen on HMI interface, verify the lube oil emergency pump 51-MJ01-A-MJG-37-B-M (88QE-1) is started by feedback signals from XS-5331 (42QE).

W O SOM5461051 SOM5461050 - - V -

Physically simulate oil Header Pressure High, slowly closing PT-5190A÷C (96QT1A÷C) manifolds drain , to achieve (88QE-1) stop (1.4 BarG).

W O SOM5106431 SOM5461051 SOM5461138

- - V -

From the proper graphic screen on HMI interface, verify the lube oil emergency pump (88QE) is stopped.

W O SOM5106431 SOM5461051 SOM5461138

- - V -

Restore PT-5190A÷C (96QT1A÷C) manifolds to operating condition (Inlet fully open, drain fully closed), then remove the logic forcing.

W O SOM5106431 SOM5461051 SOM5461138

- - V -

Push the emergency push button and check how much time the unit employs to come to zero speed, and if the zero speed is reached in a smooth way.

W O SOM5461051 - - V -





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3.2 START-UP ON FIRE MODE WITH IBH CLEANING TEST


CU Signature


Criteria Check Type

Service report NOTE

Warning: In order to remove preservation coating treatments from within the turbine, detergent based Water Wash sequences will be executed prior to bring unit to Firing.

Note: During the first start-up could be necessary the presence of DLN mapper specialist, in order to support the start-up team in this phase.

Inhibit the fire fighting system (local portable extinguishers on auxiliary turbine compartment shall be available) and bypass ventilation system in the MKVI Toolbox interface in order to allow entrance inside the enclosure for visual inspection without stopping the normal sequence.

W O SOM5106431 - - V -

Warning: Verify the spool with orifice, strainer and differential pressure transmitter are installed instead the bleed heating valve XV-5031A (VA20-1) to proceed with bleed heating cleaning line test.

W O SOM5106420 - RIC8954760 D RIC8954760

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Prepare the circuit of fuel gas for a flanges leakage test, using adhesive tape around it and then a portable gas analyzer to verify that there are no leaks. Before to begin the test establish a proper safety plan, that shall be also in accordance with the safety regulations of the plant and all safety applicable rules.

W O SOM5106410 - - V -

De-activate spark plug from M.C.C. W O SOM6701962 - - V -

Using trend recorder function on proper graphic screen on HMI interface, configure and start a trend with the parameters relevant to the fuel gas system (at least SRV and GCV command and feedback signals, inter-valve pressure).

W O SOM5106410 SOM5461051 - - V -

Inhibit the synchronization function by GCPP. W O SOM6702866 - - V -

From the HMI interface, move the master selector on FIRE position.

W O SOM5461051 - - V -

Verify “Ready to start” conditions (ready to start conditions from process system are by-passed for this mode of start up).

W O SOM5461051 - - V -






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At the end of Purge timer, verify that the ignition sequence is activated (closing of Vent valve (20VG-1) and opening of Stop/Ratio valve (SRV) and Gas Control valve (GCV). Once the ignition timer is expired, verify that the “Fail to ignite alarm” is activated.

W O SOM5461051 - - V -

From the proper graphic screen on HMI interface change master selector from “Fire mode” to “Crank mode”. Wait at least 2 minutes with the unit cranking in order to evacuate the residue of gas inside exhaust path.

W O SOM5461051 - - V -

Reactivate Spark-plugs from M.C.C. and on HMI screen change Master Selector to Fire Mode; then check for ignition.

W O SOM6701962 - - V -

Verify all flame detectors are working fine, looking at their intensity from the relevant graphic screen on HMI interface. (4 Primary’s ON, 4 Secondary’s OFF). BE-5116B/C (28FD-3P/7P) BE-5142B/C (28FD-8S/2S) BE-5116D/A (28FD-8P/2P) BE-5142D/A (28FD-9S/1S)

W O V

When the flame is detected (L28FDX) verify the activation of the Lube oil cooling system

W O SOM5461051 - - V -

Verify there is no gas into de enclosure by monitor system.

W O SOM5461051 - - V -





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Stop the ventilation fan system by logic forcing on MarkVI tool box interface of the proper signals, and inhibit the relative “enclosure ventilation differential pressure low” condition.

W O SOM5461051 - - V -

Verify there are no gas leaks around the fuel nozzle, gas manifold on VSR-1, VGC-1/2 valves and associated piping, by using a portable gas analyzer. Note: Minimize the time for the check inside the enclosure.

W O SOM5106410 - - D -

Use mirrors to view the sight ports in the combustion chambers to visually check that each chamber is fired and that the flame zone is centered within the liner. In addition, assure that the crossfire tube end is not glowing. Plug and stake sight ports once satisfactory flame conditions are obtained (at first opportunity, while the GT is not running).

W O - - - V -

Re-enable the enclosure ventilation fan system and remove any logic forced on ventilation signals.

W O SOM5461051 - - D -

Check that the bearings (journal / thrust) metal temperature (gas turbine, accessory/load gear and generator) are within normal range.

W O SOM5461051 SOM5461138 - - V -

Check that the wheel space and exhaust turbine temperatures are within normal range.

W O SOM5461138 - - V -

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STEP ON AUTO (CONTINUE FROM FIRE MODE)

ON GCPP make sure S8 (43A-M) is on center (OFF) position. ON GEP make sure S5 (LOCAL) and S3 (AVR MANUAL), are selected, and Excitation is OFF.

W O SOM6702866 SOM6701781 - - V -

From the proper graphic screen on HMI interface, force the auxiliary lube oil pump 51-MJ01-A-MJ37-A-M (88QA-1) to run (select START button).

W O SOM5461051 - - V -

From the HMI interface, move the master selector on “AUTO” position to accelerate the gas turbine up to full speed no load condition.

W O SOM5461051 - - V -

Verify at self-sustain turbine speed (about 60%), the starting system is stopped.

W O SOM5461051 - - V -

Verify the axial compressor antisurge valve close at 96.4%, it should be confirmed on proper graphic screen on HMI interface by feedback signals from field: XZSO-5084A/B (33CB-2/1)

W O SOM5461051 SOM5461050 - - V -

Check for main lube oil pump pressure regulation: PRV-5438 (VR1-1) The set pressure is 8.5 Bar G

W O SOM5106431 - - D -





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When the main lube oil pump discharge pressure is confirmed by reading pressure on manometer PG-5174 (PI-1), from the proper graphic screen on HMI interface, stop the auxiliary lube oil pump (select AUTO or STOP button).

W O SOM5461051 - - V -

From the proper graphic screen on HMI interface, verify the auxiliary lube oil pump (88QA-1) is stopped by feedback signals from MCC XS-5179R (52QA-1)

W O SOM5461051 SOM5106431 SOM5461138

- - V -

As soon as possible re-enable the fire fighting system (local portable extinguishers on auxiliary turbine compartment, shall be available).

W O SOM5106401 - - V -

Verify the absence of any alarms for gas presence and check the correct functioning of fire fighting system.

W O SOM5461051 SOM5106401 SOM5461138

- - V -

Run the turbine at full speed no load condition for 5 min. Note: Do not exceed running time in order to avoid any damage to the temporary strainer on IBH line.

W O SOM5461051 - - V -

Shutdown the turbine testing any normal shutdown causes.

W O SOM6623681 - - V -

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Monitor PDG installed on temporary IBH strainer and verify that differential pressure do not exceed 1.8 barg. Shut down the unit if pressure exceed the above value.

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Verify the auxiliary lube oil pump (88QA-1) and hydraulic oil pump (88HQ-1) automatically start when turbine speed drop below minimum operating speed (94% of speed)..

W O SOM5461051 SOM5461050 - - V -

Verify that the turbine speed decreases slowly down to 20-30% speed then the fuel gas valves are closed to stop the turbine.

W O SOM5461051 - - V -

Verify the jacking oil pump (88QS-1A/B) automatically start when HP speed is below about 6,6% of rated speed.

W O SOM5461051 - - V -

After the gas turbine has come down to zero speed, verify the start of cool down timer.

W O SOM5461051 - - V -

Verify the proper starting of the hydraulic ratchet system 51-MJ01-A-MJ10-M (88HR-1).

W O SOM5461051 SOM5461050 - - V -

Verify the temporary strainer installed for IBH cleaning test is free of visible contamination and debris, if not, clean the strainer and repeat an turbine start-up at minimum operating speed for 5min, then check again.

W O SOM5461051 - - V -

Remove the temporary spool with orifice, strainer and differential pressure transmitter, restore the inlet bleed heating valve XV-5031A (VA20-1), and check its functionality again.

W O SOM5461051 - - V -





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3.3 START-UP ON AUTO/REMOTE AND CHECKS TO BE DONE AT FSNL


CU Signature


Criteria Check Type

Service report NOTE

Warning: Before forcing any logic signals, verify their correctness and pay attention on the logic involved, in order to avoid problems for safety of plant.

ON GCPP make sure (43A-M) is on center (OFF) position. ON GEP make sure S5 (LOCAL) and S3 (AVR MANUAL), are selected, and Excitation is OFF.

W O SOM6702866 SOM6701781 - - V -

From the HMI interface, move the master selector on “AUTO” position. W O SOM5461051 - - V -

Verify “Ready to start” conditions. W O SOM5461051 - - V -

From the HMI interface, give “START” command W O SOM5461051 - - V -

Check any abnormalities during acceleration to full speed no load condition. W O SOM5461051 - - V -

Verify at minimum operating speed (96,4% of speed), the auxiliary lube oil pump (88QA-1) and hydraulic oil pump (88HQ-1) automatically stop without generate oil header pressure low alarm.

W O SOM5461051 SOM5461050 - - V -





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Verify the turbine complete sequence (L3). W O SOM5461051 - - V -

Demonstrate the auto start of the auxiliary lube oil pump (88QA-1) by simulating low pressure value on PT-5190A÷C (96QT1A÷C) pressure set point is 1 Bar G (aux lube oil pump start). Remove the simulation on PT-5190A÷C (96QT1A÷C) and verify that the auxiliary lube oil pump automatically stops.

W O SOM5461051 SOM5106431 - - D -

Verify the gas turbine is thermally stable and then verify that readings are compliant with the expected values.

W O SOM5461051 SOM5106401 SOM5461138

- - D -

Verify stability of control loops (SRV, GCV, IGV, speed).

W O SOM5106410 - - V -

Check and record gas turbine, load gear and generator parameters (temperatures, pressures, vibrations, etc.)

W O SOM5106401 - - D Reading form

Check and in case adjust the mineral oil vapour separator (88QV-1/2) by-pass line to have in the lube oil reservoir the pressure shown in the schematic piping diagram (-20 mmH2O).

W O SOM5106434

(See note 4) - - D -

Verify no air presence inside the oil coolers piping, slightly open the local vent valve on oil coolers.

W O SOM5106436 - - V -





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Verify Lube Oil Header Temperature and (TCV-5184) VTR-1 proper functioning.

W O SOM5106436 - - V -





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3.4 EXCITATION SYSTEM (AVR) FUNCTIONING AT FULL SPEED NO LOAD


CU Signature


Criteria Check Type

Service report NOTE

NOTE: the GT is supposed to be already running, if not it shall be started up to FSNL, following the initial steps listed at CHECKS TO BE DONE WHILE TURBINE RUN AT FULL SPEED NO LOAD

Confirm that on GECPP (Generator Excitation Panel) the excitation is set to “OFF” and the AVR control is set to ”LOCAL” and “MANUAL”.

W O SOM6702866 - - V -

Measure the voltage produced by the permanent magnets generator (PMG), on the input terminal board on the excitation panel.

W O SOM6702866 SOM6701781 - - D -

Verify the absence of localized overheating, absence of vibrations, according to the requirements set by the manufacturer.

W O SOM6702866 SOM6701781 - - V -

On driver PLC force (disable) electrical trips from GEP\GCPP. W O SOM6702866

SOM6701781 - - V -

As a pre-check, on TV’s secondary, measure residual phase-phase Voltage, phase-neutral Voltage and phase sequence.

W O SOM6702866 SOM6701781 - - D -





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Activate the manual function on the voltage regulator used by default (AVR-A), so as to manually manage the closure of the field contactor (41), and the adjustment of the excitation supplied to the brushless exciter. Then, still in manual mode, excite the generator until reading the nominal voltage on its terminals.

W O SOM6702866 SOM6701795 - - V -

Record TV’s secondary, phase-phase Voltage, phase-neutral Voltage and phase sequence. W O SOM6702866

SOM6701795 - - D Reading form

Repeat test with AVR-B, then go back to A. W O SOM6702866 - - V -

Based on the Vendor’s procedure, verify performance of the Exciter Manual Voltage Control through switch S6\S7 and record the results.

W O SOM6701781 - - D -

Based on the generator Vendor’s procedure, increase (S6) the generator voltage slowly beyond it’s over voltage set to verify transformer stability and then electrical trip from GCPP Relay 59, 86G2. Reset the systems.

W O SOM6702866 SOM6701781 SOM6701795

- - V -

Test 59 Overvoltage. Delay and thresholds as per spec.

Force Driver PLC 52G generator breaker close feedback then, based on the generator Vendor’s procedure, decrease (S7) the generator voltage slowly beyond it’s under voltage set and then electrical trip from GCPP Relay 27, 86G1. Remove forcing and reset the systems.

W O SOM6702866 SOM6701781 SOM6701795

- - V -

Test 27 Undervoltage Delay and thresholds as per spec.





GENERAL NOTES:

ITEM LINGUA/LANG.

A



Taking care of maintaining nominal voltage (S6\S7), based on the generator Vendor’s procedure, slowly increase turbine speed (43-S) beyond it’s over-frequency set and then electrical trip from GCPP Relay 81, 86G1. Reset the systems.

W O SOM6702866 SOM6701781 SOM6701795

- - V - Test 81O OverFrequenc

Force Driver PLC 52G generator breaker close feedback then, taking care of maintaining nominal voltage (S6\S7), based on the generator Vendor’s procedure, slowly decrease turbine speed (43-S) beyond it’s under-frequency set and then electrical trip from GCPP Relay 81, 86G1. Reset the systems.

W O SOM6702866 SOM6701781 SOM6701795

- - V - Test 81U UnderFrequency

On GEP 64R Protection Relay Module, push test button and check alarm is activated on Driver PLC HMI & DCS

W O SOM6702866 SOM6701781 SOM6701795

- - V - Test 64R Rotor earth fault

Refer to Vendor’s commissioning procedure for Prismic A50 Excitation Controller at no load rated speed condition and follow the steps to carryout parameter settings verifications on main and standby controllers, verify/note display of measured parameters, changeover between main and standby controllers, changeover between main and standby power circuits, controller soft start etc. and record the commissioning test results (attach the vendor’s procedures).:





GENERAL NOTES:

ITEM LINGUA/LANG.

A



At no load condition, carry out calibration of exciter field current as per the reference document section and ensure relevant parameters are set to adjust the exciter field current sensor

W O See Brush

manual - - D -

At no load condition, carry out calibration of exciter field voltage as per the reference document section and ensure relevant parameters are set to adjust the exciter field voltage sensor.

W O See Brush

manual - - D -

At no load condition, carry out calibration of generator terminal voltage sensing as per the reference document section and ensure relevant parameters are set to adjust the exciter terminal voltage sensor.

W O See Brush

manual - - D -

Stop the turbine using Normal Stop button from the proper graphic screen on HMI interface. Ensure that the turbine speed decreases smoothly down to 20% speed, then the fuel is cut and the turbine shuts down to zero speed.

W O SOM5461051 - - V -

Set on GEP (Generator Excitation Panel) the excitation “ON” and the AVR control on “AUTO”. W O SOM6701781 - - V -

Re-start the turbine up to FSNL, as per normal startup sequence W O SOM5461051 - - V -

Verify at field flashing speed (90% of speed), the AVR control should close the excitation contactor (41).

W O SOM5461051 - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



At no load condition, carry out verification per the reference document section to ensure that soft start causes excitation to reach the correct level (80% of terminal voltage) at the correct rate and ensure quality of the regulation.

W O SOM5461051 - - V -

Change AVR control from Auto to Manual W O SOM6701781 - - V -

At no load condition, carry out verification per the reference document section to ensure generator voltage reference range and ensure the rate of change of voltage reference.

W O SOM6701781 - - V -

At no load condition, carry out step response verification per the reference document section to ensure the correct level of transient response of the excitation control system to step changes and ensure the quality of regulation.

W O SOM6701781 - - V -

At no load condition, carry out verification per the reference document section to ensure smooth transfer between the channels and between the operation states

W O SOM6701781 - - V -

At no load condition, carry out verification of the V/f limiter as per the reference document section to ensure that V/f limiter operates at the correct level and ensure quality of the limiter action.

W O SOM6701781 - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



At no load condition, carry out verification of the terminal voltage limiter as per the reference document section to ensure the steady state limit level of the generator terminal voltage when terminal voltage limiter is active and ensure quality of the limiter action.

W O SOM6701781 - - V -

Connect the sequence meter to the generator side voltage regulator secondary (VT-G) on the control panel and record the cyclic sense of the generator phases.


The cyclic sense of the generator phases must correspond to the cyclic sense of the external line, as recorded during generator commissioning. If the cyclic sense does not correspond, invert the two phases either on the generator or on the external network.

W O - - - V -

Shutdown the turbine testing any normal shutdown causes. W O SOM6623681 - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



3.5 SHORT CIRCUIT TEST OF GENERATOR PHASES


CU Signature


Criteria Check Type

Service report NOTE

Prepare some copper bars with appropriate thickness/size, so as to support the circulation of the machine nominal current (I<10A\mm2) . The short circuit between phases shall be carried out as close as possible to the alternator terminals.

W O - - - V -

Connect the three generator phases in short circuit between them. W O - - - V -

Set on GEP (Generator Excitation Panel) the excitation “ON” and the AVR control on “LOCAL” and “Manual”.

W O SOM6701781 - - V -

On driver PLC force (disable) electrical trips from GEP\GCPP. W O SOM6701781

SOM6702866 - - V -

Set the manual control voltage regulator to ZERO. W O SOM5461051 - - V -

Re-start the turbine up to FSNL, as per normal startup sequence W O SOM5461051 - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



When the turbine is at field flashing speed (98% of speed), close the excitation contactor and activate the voltage regulator, step increase (S6) excitation of the generator and each time record all CT’s current readings, checking for equality, until rated value is achieved.


Verify the absence of intervention of any protection relays W O SOM6701781

SOM6701795 - - V -

This test shall be considered complete once the generator thermal stabilization has been reached.

W O - - - V -

Verify the correct functioning and data tag of current transformers (CT1÷CT7). Carry out adjustment to calibrate generator terminal current sensing as per the reference document section and ensure relevant parameters are set to adjust the sensor.

W O SOM6623894 - - D -

When possible, disable G60 voltage restrained feature and lower its threshold, for this relay set is higher than “real” overcurrent.

W O SOM6702866 - - D - Test 51V

Voltage restr. Overcurrent

Further increase excitation (S6) to reach overcurrent protection set and then electrical trip from GCPP Relay 51V, 86G2. Reset the systems.

W O SOM6701781 SOM6701795 - - V -

Verify the absence of abnormal overheating inside windings. W O - - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



Shutdown the turbine. W O SOM6623681 - - V -

The Generator Differential Protection 87G is usually tested during commissioning, through secondary current injection, however a real test of this protection can be done, if required by Customer, in this phase. While the turbine is stopped, remove one

of the short circuit bars from one phase and leave it open, either at line or neutral side.

Set on GEP (Generator Excitation Panel) the excitation “ON” and the AVR control on “Manual”.

Set the manual control voltage regulator to ZERO.

Restart the unit up to FSNL Activate excitation system, increase slowly

the control voltage regulator, monitoring the current circulating through the two phases left shorted. Increase the current up to the

activation of 87G, 86G2 protection relay.

W O SOM6701795 - - V -

Test 87G Differential.

Disable Relay 46 in case its setting would

anticipate 87G

Alternate 87G test method: Rather than opening one Short circuit bar, simply short to ground one phase CT’s secondary. This is much easier, (but not real) and allows test repetition on all 3 phases.

W O - - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



With excitation OFF, on GCPP knife-link terminals, install jumpers end open them in order to invert CT’s currents toward G60

W O SOM6702866 - - V - Test 46

Negative Phase Seq.

Start and increase excitation until electrical trip 46 , 86G1. W O SOM6701795 - - V -

Delay and thresholds as

per spec. Remove Driver PLC, Electrical trip, logic forcing, set GCPP and G60 back to operating conditions and trip turbine on 87G test repetition through alternate method.

W O SOM6701795 - - V -

Remove the copper bars used to carry out the tests and reconnect all cables to the external network.

W O - - - D -

Connect one generator phase to ground by means of a <= 2.5 mm2 jumper (fuse-like for rough-times) .

W O - - - V - Test 51G

Stator Earth Fault

GEP AVR “LOCAL” and “MANUAL”, Start unit and at FSNL increase excitation up to electrical trip 51G, 86G2. W O SOM6701795

SOM6701781 - - V -

Often, trips without

excitation because of

residual.





GENERAL NOTES:

ITEM LINGUA/LANG.

A



3.6 MANUAL/AUTO SYNCHRONIZATION TEST & PRIMARY/SECONDARY FUEL GAS STRAINER CLEANING TEST


CU Signature


Criteria Check Type

Service report NOTE

Install, outside of the enclosure, temporary differential pressure manometers connected to fuel gas primary/secondary/transfer temporary strainers (to be removed at the end of test). Monitor the DP during the fuel gas lines cleaning period, stop the turbine and clean the strainer if it is higher than 1,0 Bars.

W O SOM5106480 - - D -

Ensure that the generator circuit breakers in Customer supply has been Locked Out and Tagged Out.

W O - - - V -

With the excitation system on LOCAL MANUAL mode, start up the turbine and bring it to rated speed.

W O SOM5461051 - - V -

When the turbine is at field flashing speed (98% of speed), close the excitation contactor and excite the generator to reach the rated voltage.

W O SOM5461051 - - V -

Verify and confirm phase rotations are same on the VT secondaries at the GCPP\GEP panel and customer panel (Customer activity)

W O SOM6702866 SOM6701781 - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



2 modes for carrying it out: 1) With dead-bus condition, close

generator breaker and measure voltage between same phase VT’s. If 0 in all cases, VT’s are properly wired. (Safer Way)

2) No dead-bus condition, achieve synchro conditions (Nominal VG=VL, nominal Hz., Synchronoscope at 12 hrs. If voltages across breaker are 0, VT’s are properly wired.

W O - - - V -

Change speed slowly until frequency and phase of line and generator output are equalized within the narrow range allowed by synchronazing relay.

W O - - - V -

When the required conditions are met, manually give the closing command to generator circuit breaker. Verify excitation of breaker command relay (no actual breaker closure will happen due to the locked out tagged out breaker in Customer Power Center.

W O - - - V - Set MCB on Test mode if

avail.

Verify the absence of intervention of any protection relays. W O SOM6701795 - - V -

Change speed set point in order to exit from synchronization conditions. W O SOM5461051 - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



Perform again closing command to MCB, out of synchro conditions, and verify no closure command is issued.

W O - - - V -

After having ensured that this operation can be done safely, remove lock and tag from MCB in Customer Panel. Ensure that disconnector is CLOSED corresponding to 52G circuit breaker, depending on which has been selected for synchronization. (Customer activity)

W O SOM6702866 - - V -

Change speed slowly until frequency and phase of line and generator output are equalized within the narrow range allowed by synchronizing relay.

W O SOM5461051 - - V -

When the required conditions are met, manually give the closing command to generator circuit breaker. Verify the closure of circuit breaker 52G on the proper graphic screen on HMI interface.

W O SOM6702866 - - V -

Verify the initial load (spinning reserve) without the intervention of protection against reverse power (32).

W O SOM6701795 - - V -

Stay at minimum load for 15’, verify stability of control loops and monitor turbine and generator running parameters. At the end take a set of readings.

W O SOM5106401 SOM5461051 - - D -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



Refer to Vendor’s commissioning procedure for Prismic A50 Excitation Controller at loaded condition and follow the steps to carryout parameter settings verifications on main and standby controllers, verify/note display of measured parameters, changeover between main and standby controllers, changeover between main and standby power circuits, controller soft start etc. and record the commissioning test results (attach the vendor’s procedures).

W O SOM6702866 - - D -

At generator loaded condition, carry out verification of the over excitation limiter as per the reference document section to ensure that limiter operates at the correct level and ensure quality of the limiter action.

W O - - - V -

At generator loaded condition, carry out verification of the stator current limiter as per the reference document section to ensure that limiter operates at the correct level and ensure quality of the limiter action.

W O - - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



At generator loaded condition, carry out verification of the under excitation limiter as per the reference document section to ensure that limiter operates at various power levels and ensure quality of the limiter action. NOTE: this test will only be feasible absorbing reactive power from the external grid or from a second generator. Therefore, no test can be done while running a single generator on an isolated busbar.

W O - - - V -

At generator loaded condition, carry out verification of reactive load rejection as per the reference document section to ensure that generator terminal voltage variations subsequent to rejection of rated reactive load does not exceed the acceptable design limits (maximum 15%). NOTE: the execution of this test can be done through the availability of suitable loadbank and inductive load (to be provided by Customer)

W O - - - V -

Verify the excitation system, by quickly increasing manually the excitation current set point, causing a quick change on reactive power.

W O - - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



With the variation of the reactive load, the excitation current must increase or decrease to the required values without hunting.

W O - - - V -

Shutdown the turbine. W O SOM6623681 - - V -

Set the AVR system and synchronization on automatic mode. W O SOM6702866 - - V -



Warning: From the HMI interface, select “LEAN-LEAN MODE ON” to avoid premix mode operation until the primary/secondary strainers cleaning test is completed.

W O SOM5461051 SOM6701795 - - V -

When the turbine is at full speed no load, verify the synchronization phase and the closure of circuit breaker (52G-1 or 52G-2) on the proper graphic screen on HMI interface.

W O SOM5461051 - - V -

Verify the initial load (spinning reserve) without the intervention of the protection against reverse power (32).

W O SOM6701795 - - V -

Ramp the unit to maximum primary fuel flow (about TTRF1=1600 degF) stopping 10/15 degF before the setting point, to no activate the LEAN-LEAN mode.

W O - - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



Run for one hour and verify that the differential pressure across the primary strainer don’t increase above 100 KPa. In case shutdown the turbine, clean the strainer and repeat again. Continue operation at this load until during one hour the differential pressure doesn’t increase above 100 KPa.

W O SOM5106401 - - D -

During this test, the temperature values of thermo elements on copper and iron, the bearings temperature and the values of vibrations of generator shall be acquired.

W O SOM5106401 - - D -

Check and record gas turbine, load gear and generator parameters (temperatures, pressures, vibrations, power, etc.).

W O SOM5106401 - - D -

Ramp the unit to maximum fuel flow with inlet bleed heating off (about TTRF1=2010 degF), stopping 10/15 degF before the setting point, to no activate the EXTENDED LEAN-LEAN mode).

W O - - - V -

Run for one hour and verify that the differential pressure across the primary strainer or secondary strainer don’t increase above 100 KPa. In case shutdown the turbine, clean the strainer and repeat again. Continue operation at this load until during one hour the differential pressure doesn’t increase above 100 KPa.

W O SOM5106401 - - D -

105039846

Line

105039846

Line

105039846

Line

105039846

Text Box

After 1 hour without exceeding delta pressure of 100 Kpa remove all strainers, inspect and clean. Re-install the cleaned strainers and permanently remove them only when 10 hours of "clean" operation at this mode is achieved.

105039846

Polygon

105039846

Reviewed

105039846

Text Box

Site Mark-Up as per Doc.357A1862





GENERAL NOTES:

ITEM LINGUA/LANG.

A



Shutdown the turbine, remove and clean the strainers, then re-install and start up again the turbine.

W O SOM5106401 SOM5461051 - - V -

Ramp the unit to maximum fuel flow (EXTENDED LEAN-LEAN with turbine on control temperature). Permanently remove the strainers when 10 hours of clean operation at this mode is achieved.

W O - - - V -

Verify the gas turbine is thermally stable and then verify that readings are compliant with the expected values.

W O SOM5106401 SOM5461051 SOM5461138

- - V -

Verify stability of control loops (VSR-1, VGC-1/2, IGV, speed). W O SOM5106410 - - V -


W O SOM5106401 - - D -

Perform a lower command, unloading unit reverse power occurs. 32, 86G1. W O SOM6701795 - - V -

Test 32 Reverse power.

After turbine shut down, remove the temporary primary/secondary/transfer strainers and differential pressure manometers, restore the fuel gas manifold lines.

W O - - - V -

105039846

Line

105039846

Line

105039846

Line

105039846

Line

105039846

Line

105039846

Line

105039846

Polygon

105039846

Reviewed

105039846

Text Box

Site Mark-Up as per Doc.357A1862





GENERAL NOTES:

ITEM LINGUA/LANG.

A



3.7 DLN TUNING/MAPPING


CU Signature


Criteria Check Type

Service report NOTE

Install temporary acoustic sensors and relevant tubing connection to data acquisition system.

W O - - - V -

Install exhaust gas analyzer probe and relevant measurement system. Perform analyzer calibration.

W O - - - D -

Verify the possibility to have fuel gas analisys during mapping execution. W O - - - V -

From the HMI interface, move the master selector on “AUTO” position. W O SOM5461051 - - V -



Run gas turbine on LEAN-LEAN mode for 2 hours (heat soak). W O SOM5461051 - - V -







GENERAL NOTES:

ITEM LINGUA/LANG.

A



Perform preliminary checks of DLN parameters. W O - - - V -

Load the unit to PREMIX mode with inlet bleed heating ON and IGV at various positions. W O - - - V -

Perform checks of DLN parameters. W O - - - V -

With the unit operating in steady conditions, a data file is recorded and submitted to GE Oil & Gas Project Management.

W O - - - D Reading form

From the HMI interface, give “STOP” command. W O SOM5461051 - - V -

Disable the inlet bleed heating control on MarkVIe controller and start again the turbine. W O SOM5461051 - - V -

Load the unit to LEAN-LEAN mode. W O SOM5461051 - - V -


Load the unit to PREMIX mode and IGV at various positions.

W O - - - V -


After mapping is completed all new schedules should be checked to ensure that the gas turbine can operate smoothly without high acoustics or blowouts.

W O - - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



3.8 FINAL VERIFICATIONS


CU Signature


Criteria Check Type

Service report NOTE

TURBINE FINAL VERIFICATIONS

From the HMI interface, move the master selector on “REMOTE” position. W O SOM5461051 - - V -



Load the unit at full load condition (temperature control) and verify that the unit parameters are as expected.

W O SOM5461051 SOM5461138 - - V -

Check that when the turbine exhaust temperature approaches the IGV control curve reference, the relevant control loop takes control of the exhaust temperature and keep it on the curve.

W O - - - V -

Check for turbine IGV servo control stability on the proper graphic screen on HMI interface. W O - - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



Check that when the turbine exhaust temperature approaches the base load temperature control curve reference, the relevant control loop takes control of the exhaust temperature and keep it on the curve.

W O - - - V -

Verify stability of control loops (VSR-1, VGC-1/2, IGV, speed). W O SOM5106410 - - V -

Check and record gas turbine, load gear and generator parameters (temperatures, pressures, vibrations, etc.)


GENERATOR FINAL VERIFICATIONS

Run the train for 4 hour at max load. Continuously monitor all running parameters of the train and ensure that they do not exceed alarm values. Record all instrument readings every 30 minutes.


At limited load (level to be agreed) perform a “load rejection test”, by manually opening the generator breaker and checking that the control system is able to prevent the over speed trip caused by the sudden load rejection.


Repeat the test from full load. W O - - - V -

The turbogenerator is ready for commercial operation (COD) W O - - - V -





GENERAL NOTES:

ITEM LINGUA/LANG.

A



ACCEPTANCE OF TURBOGROUP

Perform any performance/endurance test as per contract W O - - - D -

The turbogenerator is ready for commercial operation (COD) W O - - - V -

gtgb_start up_ric8955863 rev 0.1 (1)

Documents

journal thrust

general electric company

proper graphic screen

jacking oil pump

maintaining nominal voltage

local portable extinguishers

auxiliary turbine compartment

relative job project documentation