001 Gas Turbine Generator Commissioning Procedure

Procedure Title

Gas Turbine Generator Commissioning Procedure

TC2000PLUSSM Control System Commissioning Procedure Application: This Commissioning Procedure provides overall instruction for site testing of the customer‟s equipment listed in the following table. The Outline beginning on page 2 lists all of the commissioning tests that are required for this project. Customer Site ICS Project Number Customer Unit No. GT OEM. GT Model No. Fuel Type

Doc ID: TIS-CS-GT-G-01

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Procedure Title


DO NOT PROCEED WITHOUT THESE DOCUMENTS References: Obtain a copy of the as-built drawings. Document Number

Rev

Title Control Schematic

Turbine Controller

Technical Specification IO List

Voltage Regulator

Piping & Instrumentation

Other

NOTE: During commissioning there may be changes to the settings in the PLC. Each change should be noted, initialed and dated on this form.

This test procedure is to be used in conjunction with a Gas Turbine Operating Data sheet. Record the form number of the applicable data sheet here: Form Number

Rev.

FM-OD-GT-G-FR-001 FM-OD-GT-G-GG-001


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Procedure Title


Table of Contents

1.0. Safety Review ..................................................................................... 4 2.0. Panel Power-up Checks ....................................................................... 5 2.1. 2.2. 2.3. 2.4. 2.5.

Visual Inspection ........................................................................................................ 5 Control Panel Power-Up Checks................................................................................... 5 DC Power Circuits ....................................................................................................... 6 AC Power Circuits ....................................................................................................... 7 HMI Interface and Controller Checks ........................................................................... 7

3.0. I/O Checks........................................................................................... 9 3.1 Verify the Master Protective Circuits ............................................................................. 9 3.2. Discrete Input Checks ............................................................................................... 13 3.3. Thermocouple Inputs ............................................................................................... 14 3.4 RTD Inputs .............................................................................................................. 14 3.5 Analog Inputs .......................................................................................................... 15 3.6. Discrete Output Checks ............................................................................................ 16 3.7. Analog Output Checks .............................................................................................. 17 3.8. Vibration Protection System I/O Checks ..................................................................... 18 3.9. Motor Control Center Checks ..................................................................................... 18

4.0 System Checks .................................................................................... 20 4.1 4.2. 4.3. 4.4. 4.5.

Electro-hydraulic actuator Tests ............................................................................. 20 Off-line Running Checks .......................................................................................... 28 Synchronization Checks ........................................................................................... 41 Turbine On-Line / Load Checks ................................................................................ 48 Shutdown Checks .................................................................................................... 59

NOTES ....................................................................................................... 62


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Procedure Title


1.0. Safety Review Record data

Check Completed

Completed by / date

Identify customer representative responsible for site safety. Verify with Customer that all site specific safety practices and issues are identified Establish lock-out and tag-out procedure with Customer safety representative Identify subcontractor reps responsible for „crew‟ safety

Ensure that installation personnel are fully aware of site safety issues and of proposed testing. Completely inspect turbine for any work that may not have been finished and may impact safety. Completely inspect generator for any work that may not have been finished and may impact safety. Completely inspect area for any work that may not have been finished and may impact safety. Before proceeding with the following checks ensure that a device not controlled by the ICS system isolates the fuel supply(s). Ensure that the starting device is locked out.


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Procedure Title


2.0. Panel Power-up Checks 2.1. Visual Inspection Record data

Check Completed

Completed by / date

Visually check that the control panel has not been physically damaged during transit to site. Ensure that the relays and other auxiliary equipment have not been disturbed and that the internal wiring is secured. Check that all removable modules are correctly aligned and fully inserted. Inspect field wiring. Check for loose connections, frayed wires.

2.2. Control Panel Power-Up Checks Consult the Turbine Controller drawing for panel power distribution circuit wiring details. Record data

Check Completed

Completed by / date

Verify TCP (Turbine Control Panel) main ground connection is terminated and connected to plant ground grid. Ground conductor should be same size (or larger) as biggest power feed conductor. Verify that turbine systems are tagged-out and isolated including ac and dc oil pumps, turning gear, starting motor, etc. Ensure that all panel circuit breakers are off and all fuse holders are open. Verify that the power supply for each control rack is OFF.


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Procedure Title


2.3. DC Power Circuits Main DC Power Circuits Refer to the DC Panel Power Distribution of the Turbine Controller drawing. Record data

Check Completed

Completed by / date

Verify polarity of DC source input power at the main fuse. Verify that DC input power is not grounded. If so determine its source and correct. Record DC voltage. Check that there are no grounds on the positive and negative legs on the panel side of main DC fuse. Check that no short-circuit exists between the positive and negative legs. Record insulation resistance. Insert the main DC fuse and apply DC power to the panel. Successively power-up each control rack, verifying rack initialization. Successively power-up any Remote I/O (RIO) modules, verifying initialization.


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Procedure Title


DC Power Sub-Circuits (24Vdc) Refer to the DC Panel Power Distribution sheets of the Turbine Controller drawing. Check Completed

Record data

Completed by / date

Energize all control panel 24Vdc circuits. Do not install fuses for field circuits. Record panel 24Vdc power supply Voltage.

2.4. AC Power Circuits Refer to the AC Panel Power Distribution sheets of the Turbine Controller drawing. Check Completed

Record data

Completed by / date

Verify all AC power circuit breakers are open. Verify value of AC source input power at the isolating circuit breaker. Record the AC voltage. Turn AC power on. Successively close the other ac circuit breakers in the panel and verify all circuits are energized.

2.5. HMI Interface and Controller Checks Load Software to HMI Record data

Check Completed

Completed by / date

Ping the PLC If the request times out, check the IP and subnet addresses again and also verify that the link LED is solid green at both the system and the hub end. Transfer of necessary files to the HMI PC at site The latest PLC folder should be transferred from the service laptop to HMI PC under E:\???\Unlocked\Current\ Doc ID: TIS-CS-GT-G-01

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Procedure Title

Gas Turbine Generator Commissioning Procedure Record data

Check Completed

Completed by / date

The latest HMI folder should be transferred from the laptop to the HMI PC under E:\WW Projects\Current\ The latest LTI application should be downloaded to the HMI PC under E:\???\Current\ Establish Ethernet Communication to PLC from HMI Record data

Check Completed

Completed by / date

Download the latest PLC logic and the reference tables to the CPU. Enable PLC Record data

Check Completed

Completed by / date

Open PLC Programming Software (RSLogix, Proficy, etc.) and confirm that the software is connected to the PLC CPU and that PLC status indications are correct. Confirm that each of the modules is healthy. Resolve any discrepancies. Review the Diagnostic Alarm display of the HMI and confirm that the system is healthy with the exception of I/O Faults.


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Procedure Title


3.0. I/O Checks 3.1 Verify the Master Protective Circuits The Master Protective Circuits provide a means of tripping the gas turbine by shutting off fuel flow. These circuits use relays in various combinations to cause the fuel stop valves to close in the event of an emergency. The Master Protective Circuits are shown in the Turbine Controller drawings. Energize the Field Master Protective Circuit Record data

Check Completed

Completed by / date

Record data

Check Completed

Completed by / date

Reference Turbine controller drawing. Verify that all the conditions required to energize the field Master protective relay are properly wired. Energize the Master Protective Circuit

Force the software master protect logic(s) to energize the software master protect relay(s). Verify that the Master Protective relays energize. Press the emergency stops pushbutton on the front of the ICS system and verify that the solenoid drops out. Reset the emergency stop pushbutton and verify the solenoid is energized. Drop out one part of the master protective circuit by removing the force on the software master protect logic and verify that the solenoid drops out. Pick up the master protective circuit by restoring the force on the software master protect logic and verify that the solenoid picks up. Drop out the other part of the master protective circuit by dropping out the field master protective relay and verify that the solenoid drops out.


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Procedure Title


Test the „Fail-Safe Solenoids‟ The term „fail-safe solenoid‟ describes any solenoid that is required to be independently deenergized in the event the unit is to be tripped. A fail-safe solenoid can be identified by the presence of master protective relay contacts in its circuit. Because these solenoids are hardwired to master protective relay normally open contacts it will ensure that the fail-safe solenoid will be de-energized when a trip signal is received. During normal unit operation, a fail-safe solenoid is normally energized and de-energized by an interposing relay that is operated by a PLC output.

Record data

Check Completed

Completed by / date

Reference the „Solenoid sheets‟ of the Turbine Controller drawing. Force the logic to energize the solenoids listed below. Verify the solenoid is energized. Complete chart below:


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Procedure Title

Gas Turbine Generator Commissioning Procedure Check Completed

Solenoid


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Procedure Title

Gas Turbine Generator Commissioning Procedure Check Completed

Solenoid


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3.2. Discrete Input Checks Discrete or Digital Inputs: Discrete inputs are listed in the IO list. The preferred method to check the integrity of discrete inputs is to simulate the process condition operating the field device, for example, by applying process pressure to a pressure switch. Toggling the actual device is the next best method. Jumpering or removing wires is also acceptable where simulation or toggling is not possible. When jumpering, always jumper at the field device. Each input should be verified to the PLC, HMI screen and/or alarm per the IO list. Verify that the field device is in its proper state per the IO list. If not, set device to proper state and correct the software, I/O list or drawing as required. Verify description is correct.

Record data

Check Completed

Completed by / date

Verify that all discrete inputs are connected at the panel per the Turbine Controller drawing. Check for grounds on field wiring. If a ground is found, isolate field circuits to locate ground. Apply power to the discrete input circuits by closing the appropriate circuit breaker or inserting the required fuse (refer to Turbine Controller drawing).

NOTE ANY DEVICE STATE CHANGES:


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3.3. Thermocouple Inputs Use the following procedure as a guide and verify each thermocouple listed in the IO list. Lift individual thermocouple wire at the field device and verify that the Thermocouple Fault diagnostic alarm occurs. Verify type of thermocouple. Note wire colors or any markings in the IO list. At the HMI, verify the signal failure for the particular thermocouple. The failed thermocouple temperature should be shown in red. Reconnect the wire at the field end. Reset the diagnostic alarm from the Diagnostic Alarm display and verify the alarm reset. For thermocouples that are accessible heat each thermocouple and verify the change in temperature on the Temperature Summary screen. Otherwise verify thermocouple is reading ambient. Record data

Check Completed

Completed by / date

Verify that all thermocouple inputs are connected at the panel per the Turbine Controller drawing.

NOTE ANY T/C TYPE CHANGES:

3.4 RTD Inputs Use the following procedure as a guide and verify each RTD input to the IO list. Record data

Check Completed

Completed by / date

Lift all wires on one side of RTD element at the field device junction box and verify the RTD Fault diagnostic alarm occurs. At the HMI Temperature Summary screen, verify the signal failure for the particular RTD. The failed RTD temperature should be shown in red. Reconnect the wire at the field end. Reset the diagnostic alarm from the Diagnostic Alarm display and verify the alarm reset. Verify RTD is reading ambient. Doc ID: TIS-CS-GT-G-01

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Procedure Title


3.5 Analog Inputs Use the following procedures as a guide and verify each current analog input in the IO list. Record data

Check Completed

Completed by / date

Reset the PLC Fault Tables. Reset diagnostic alarms from the Diagnostic Alarm display. Disconnect the device wire at the field end and verify the „signal fail‟ diagnostic alarm for the device. Verify signal failure for the device on the applicable HMI screen. The failed signal should be displayed in red. Reconnect the wire at the field end. Reset the diagnostic alarm from the Diagnostic Alarm display and verify the alarm reset. Verify that with the field device connected, the displayed value for the device corresponds to the value of the signal, +/- 5.0% of span. For instance, a 420mA signal which is expected to display a value of 0 200 psig, must be within 10 psi of expected value (200 x .05 = 10). Verify sections in the IO list. If not correct, make revision to software, I/O list and drawing as required.


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Procedure Title


3.6. Discrete Output Checks Verify that all discrete outputs and any field devices driven by these outputs are connected at the control panel per the Turbine Controller drawing. Contacts being driven by discrete outputs may be „wet‟ with power supplied by the ICS system or may be „dry‟ with power being supplied from another source. Refer to the Turbine Controller drawing. Some discrete outputs may drive Motor Control Center devices. Verify that all Motor Control Center circuits are locked out or safe to operate. MCC function checks are done in section 3.9. Use the following procedures as a guide and verify each discrete output in the IO list. Record data

Check Completed

Completed by / date

Using the IO list and the Turbine Controller drawing as a guide, toggle each PLC discrete output. Verify that the field device controlled by the relay changes state as the PLC output is toggled. For certain solenoids, the Master Protective Circuit must be energized; see the Master Protective Circuit checks. If it is not possible to verify a change in the field device, use a multimeter at the field device interface point to verify a change in the circuit. Verify that the relay contacts are in the proper deenergized state, e.g., the NC contacts are closed when the relay is de-energized.


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Procedure Title


3.7. Analog Output Checks Use the following procedures as a guide and verify each procedure to the IO list for each analog output. Cross check the IO list against the Turbine Controller drawings. Record data

Check Completed

Completed by / date

Disconnect the device wire at the field end. Connect a multimeter to the circuit to monitor current or voltage as applicable. Clear the PLC Fault Table. (FOR GE FANUC ONLY) From the appropriate analog output test screen on the HMI enable the analog output test. Simulate values for the entire range of the variable and verify the output of the multimeter. Disable the analog output test. Disconnect the multimeter and reconnect the device in the circuit; verify at the display. Clear the PLC Fault Table. (FOR GE FANUC ONLY)


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Procedure Title


3.8. Vibration Protection System I/O Checks All the vibration signals have been configured and the circuits checked at ICS. Voltages were injected to the connection points for the various transducers and the alarm and trip functionality for each of those channels verified. Record data

Check Complete

Completed by / date

Record data

Check Completed

Completed by / date

After the transducers have been wired in the field, use the IO list to verify that each is correctly connected to the proper channel by “stimulating” the transducer in the field verifying a change in the display. *NOTE: Record method of “stimulating” transducer:

3.9. Motor Control Center Checks

Confirm that it is safe to operate all of the Motor Control Center devices. Verify that all oil and other fluid lines are connected. Use the following procedures as a guide and verify each procedure to the IO list for each MCC device. Record data

Check Completed

Completed by / date

Verify that the device runs when Manual mode is selected at the MCC. Select Auto.


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Procedure Title


Record data

Check Completed

Completed by / date

Verify that the device runs when Automatic mode is selected at the MCC and its driving logic is true. a. For any devices requiring an additional permissive from a hardware device, e.g., pressure switch, toggle the hardware device and logic to verify correct operation of the device. b. For any group of devices using a lead/lag arrangement, e.g., dual lube oil pumps, verify the lead/lag configuration functions correctly, as well as any hardware device permissives. c. For any devices triggering another MCC device to start, e.g., lube oil heater triggering a lube oil pump, verify the complete sequence. Verify that the dc motor driven lube oil pump starts if the PLC is stopped or turned off. Be sure to remove all logic forces/overrides at the completion of the checks.


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Procedure Title


4.0 System Checks 4.1 Electro-hydraulic actuator Tests Application: This section provides instructions for calibration of an electro-hydraulic actuator with servo valve and LVDT/RVDT position feedback. (Check box if this section is not applicable for this commissioning) Feedback Calibration For each device listed on the Electro-hydraulic Actuator Calibration Table below, perform the following steps: 

Position feedback (LVDT/RVDT) calibration



Actuator Stroke Test

Ensure that the fuel supply is mechanically isolated from the turbine fuel system by something other than the gas turbine controller. A Signal conditioner is used to convert the LVDT feedback from the actuator to a 4-20 mA signal for the turbine controller. The purpose of these checks is to calibrate the signal conditioner so that the LVDT feedback accurately represents actuator position. This requires driving the actuator against its „closed end‟ mechanical stop and adjusting the signal conditioner, then driving the actuator against its „open end‟ mechanical stop and adjusting the signal conditioner and repeating the procedure until fully closed and fully open consistently yields values as close to 20 and 4 mA as possible. This procedure requires an HMI access level of maintenance or higher.


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Procedure Title


Actuator LVDT/RVDT Calibration Record data

Check Completed by Completed / date

Reference the relevant sheet of the controller drawing. Install an ammeter in series between the actuator LVDT signal conditioner and the controller analog input card. Install a mechanical indication device (dial indicator, protractor, etc) to show the actual mechanical travel of the actuator. Ensure that hydraulic oil pressure is available. If required, the hydraulic trip circuit will be enabled when the test is enabled. From the Maintenance Menu of the HMI, access the relevant Test display for the valve / actuator; this requires at least a maintenance level password. Enable the actuator Servo Test. Select „Enter Output To actuator Servo Coils‟ and enter a value (+ or – Vdc) that will move the actuator to the open position. With the actuator fully open, adjust the „zero‟ on the signal conditioner to yield a 4.00 mA feedback output signal to the turbine controller. Select „Toggle Voltage Sign‟. This should change the output to the servo coil move the actuator to the closed end stop. With the actuator fully closed, adjust the „span‟ on the signal conditioner to yield a 20.00 mA feedback output signal to the turbine controller. Continue back and forth from fully closed to fully open, adjusting the span and zero to get as close to 20.00 mA and 4.00 mA as possible. Record the data in the LVDT calibration section of the table below. Doc ID: TIS-CS-GT-G-01

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Procedure Title


Check Completed by Completed / date

Leave the ammeter and mechanical feedback measurement in place and disable the Servo Test.

Actuator Stroke Test This test will verify that the actuator follows the position reference. Record data

Check Completed

Completed by / date

Enable the actuator Position Test. Select „Enter actuator Position Reference‟ and enter values from 0% to 100.00% per the table below. Record the data in the table below. Disable the actuator Test Review the position data for linearity. Position errors of greater than +/- 2% are to be resolved. Contact ICS Engineering Dept. if this accuracy cannot be obtained over the full actuator range. Remove ammeter and mechanical position sensor. NOTE: Data tables for electronic valves follow these for electro hydraulic actuators


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Procedure Title


ACTUATOR NAME: DEVICE TAG

Position Reference

Position Feedback on HMI

Mechanical Position

Meter mA

Servo Volts Vdc

LVDT Primary Volts

LVDT Scdy. Volts

Vrms

Vrms

LVDT Primary Volts

LVDT Scdy. Volts

Vrms

Vrms

Position feedback (LVDT/RVDT) calibration CLOSED OPEN ACTUATOR STROKE TEST 100% 75% 50% 25% 0%

ACTUATOR NAME : DEVICE TAG

Position Reference


Mechanical Position

Meter mA

Servo Volts Vdc



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Procedure Title



Position Reference


Mechanical Position

Meter mA

Servo Volts Vdc

LVDT Primary Volts

LVDT Scdy. Volts

Vrms

Vrms

LVDT Primary Volts

LVDT Scdy. Volts

Vrms

Vrms



Position Reference


Mechanical Position

Meter mA

Servo Volts Vdc



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Procedure Title



Position Reference


Mechanical Position

Meter mA

Servo Volts Vdc

LVDT Primary Volts

LVDT Scdy. Volts

Vrms

Vrms



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Procedure Title


For use with electric valves VALVE NAME: DEVICE TAG

Position Reference


Mechanical Position

LIMIT SWITCH TEST CLOSED OPEN STROKE TEST 100% 75% 50% 25% 0% VALVE NAME: DEVICE TAG

Position Reference


Mechanical Position

LIMIT SWITCH TEST CLOSED OPEN STROKE TEST 100% 75% 50% 25% 0%


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Procedure Title


VALVE NAME: DEVICE TAG

Position Reference


Mechanical Position


VALVE NAME: DEVICE TAG

Position Reference


Mechanical Position



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Procedure Title


4.2. Off-line Running Checks Full Speed No Load Operation HD & AD Application: This section provides instructions for commissioning a Heavy Duty Gas Turbine or a Multi Shaft (Aero Derivative) Gas Turbine to Full Speed No Load. Check Completed

Record data

Completed by / date

Verify turning gear operation Turbine Crank / Spin Checks These checks are to verify the integrity of the gas turbine and the speed signals from the gas turbine. Record data

Check Completed

Completed by / date

Verify starting motor operation Verify that all MCC starters are On and in Auto. Verify that all panel board DC and AC breakers are On Verify that all DC and AC fuses are installed. Disable the ignition system by removing the ignition relay(s). Disable generator breaker closing. Verify Ready To Start condition. If not ready to start, check the start permissives and trips to obtain a ready to start. Select Spin or Crank mode on the Turbine Control Panel display of the HMI. This mode will engage starter, but not allow fuel into combustors. Issue START. The unit start sequence should commence. After unit has reached ignition speed, observe that the individual speed sensors read properly in the PLC and on the HMI. Verify (using DVM) that speed frequency as measured at the panel terminal blocks compares with speed rpm in PLC and on HMI.


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Procedure Title


Check Completed

Completed by / date

No. 1 Magnetic Pickup Speed (Hz): No. 1 Magnetic Pickup Voltage (Vac): No. 2 Magnetic Pickup Speed (Hz): No. 2 Magnetic Pickup Voltage (Vac): No. 3 Magnetic Pickup Speed (Hz): No. 3 Magnetic Pickup Voltage (Vac): No. 4 Magnetic Pickup Speed (Hz): No. 4 Magnetic Pickup Voltage (Vac): No. 5 Magnetic Pickup Voltage (Hz): No. 5 Magnetic Pickup Voltage (Vac): No. 6 Magnetic Pickup Voltage (Hz): No. 6 Magnetic Pickup Voltage (Vac):

Shaft

HMI Speed (%):

Shaft

HMI Speed (Rpm):

Shaft

HMI Speed (%):

Shaft

HMI Speed (Rpm):

Shaft

HMI Speed (%):

Shaft

HMI Speed (Rpm):

Stop unit using the Emergency Stop push button on the panel. Record unit coast down time. Shaft Shaft Shaft Confirm that all Hz to % scaling are correct


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Procedure Title


(Check box if this section is not applicable for this commissioning)

COMPLETE TABLE BELOW ONLY FOR “B” ENGINE OF A P&W TWINPAC UNIT Record data

Check Completed Completed by / date

No. 1 Magnetic Pickup Speed (Hz): No. 1 Magnetic Pickup Voltage (Vac): No. 2 Magnetic Pickup Speed (Hz): No. 2 Magnetic Pickup Voltage (Vac): No. 3 Magnetic Pickup Speed (Hz): No. 3 Magnetic Pickup Voltage (Vac): No. 4 Magnetic Pickup Speed (Hz): No. 4 Magnetic Pickup Voltage (Vac): No. 5 Magnetic Pickup Voltage (Hz): No. 5 Magnetic Pickup Voltage (Vac): No. 6 Magnetic Pickup Voltage (Hz): No. 6 Magnetic Pickup Voltage (Vac):

Shaft

HMI Speed (%):

Shaft

HMI Speed (Rpm):

Shaft

HMI Speed (%):

Shaft

HMI Speed (Rpm):

Shaft

HMI Speed (%):

Shaft

HMI Speed (Rpm):

Stop unit using the Emergency Stop push button on the panel. Record unit coast down time. Shaft Shaft Shaft Confirm that all Hz to % scaling are correct Doc ID: TIS-CS-GT-G-01

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Procedure Title


GAS FUEL CHECKS Fuel System - No Ignition Check The purpose of these checks is to verify that the gas fuel flow during the ignition phase of startup is at the right level. Gas manifold pressure must be independently checked with a pressure gage; the measured pressure may be compared to the pressure recorded on the HMI. Record data

Check Completed

Completed by / date

Verify that the unit is Ready To Start. Disable the ignition system by removing the ignition relay(s). At the Turbine Control Panel display of the HMI, select FIRE (IDLE, or other mode indicating OK to start fuel), and then START. Verify that all gas valve positions match the command setpoint from control system. Monitor gas pressures at the unit gauge panel during the start attempt. Check fuel flow stability (no oscillation in fuel flow). When the ignition timer has timed out – verify the “Failure to Fire” / “No Flame After Ignition” alarm. Using the Historical Trend, verify correct system operation. Record applicable data in the table below. Printout the HMI trend.


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Procedure Title


GAS FUEL IGNITION CHECKS Record data

Check Completed

Completed by / date

Main Line Gas Fuel Supply Pressure (If regulator or upstream pressure control is installed). Gas Pressure to GT Gas Fuel System: Pressure downstream of stop valve (Inter-valve Pressure on GE units): Pressure upstream of control valve Gas Fuel Manifold Pressure: Ignition Gas Pressure: Gas Control Valve Position SRV position (GE units only) Pressure Regulating Valve Position Turbine Speed _____________ Temperature (hot gas) _____________ Temperature (hot gas)

The purpose of these checks is to verify that the amount of light-off fuel is correct. independent means of verifying flow is used then record this:


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If any

Procedure Title


Gas Fuel Firing Test (Check box if this section is not applicable for this commissioning) Do not continue with firing checks if fuel flow exceeds the requirements in the previous No Ignition check. This test will admit fuel to the combustion chambers and then ignite it. Expected Gas Manifold Pressure

Unit Type GE Frame type

5 to 10 Psig

Pratt & Whitney FT4

Record data

Check Completed

Completed by / date

Reinstall the ignition relay(s). Verify that the unit is Ready To Start. Select FIRE as the operating mode and start the unit. With the unit firing, check that fuel control valve position matches control valve reference. Unit should indicate flame detection within 15 seconds of applying fuel to the combustors. Once flame has been detected, verify the start-up fuel flow reference decreases to the warm-up value. Record the warm-up FCR. If flame is detected normally then STOP the unit and use the Historical Trend of the HMI to review the data and verify correct system operation. Record applicable data in the table below. Printout the HMI trend.


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Procedure Title


GAS FUEL FIRING CHECKS Record data

Check Completed

Completed by / date

Main Line Gas Fuel Supply Pressure (If regulator or upstream pressure control is installed). Gas Pressure to GT Gas Fuel System: Pressure downstream of stop valve (Inter-valve Pressure on GE units): Pressure upstream of control valve Gas Fuel Manifold Pressure: Ignition Gas Pressure: Gas Control Valve Position SRV position (GE units only) Pressure Regulating Valve Position Turbine Speed _____________ Temperature (hot gas) _____________ Temperature (hot gas)


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Procedure Title


FULL SPEED NO LOAD CHECKS This test will bring the unit to full speed and is used to verify the start-up, acceleration and turbine speed control loops. This may be done as a continuation of the Ignition Test above or the unit may be started from zero speed in the AUTO mode with the synchronizer OFF. Record data

Check Completed

Completed by / date

Verify that the unit is Ready To Start. Select AUTO as the operating mode and start the unit. Verify that at 100% speed, the unit is on „Speed/Load Governor‟ control. Verify that all system (lube oil, cooling water, etc.) pressure and temperatures are as expected. Verify the HMI display with any gauge readings. Record FSNL data in the appropriate Unit Data Sheet. Use the Historical Trend of the HMI to review speed, fuel flow, and temperature curves from the startup. Turbine speed should smoothly come to the full speed setpoint without overshooting and stay there without „hunting‟. Print out the „start-up curve‟ and attach to this report At the Turbine Control Panel display of the HMI enter a Speed Setpoint Target of 102%. Verify that the Speed Setpoint ramps to the Setpoint Target at the normal loading rate and that turbine speed tracks the setpoint and settles at 102%. At the Turbine Control Panel display of the HMI enter a Speed Setpoint Target of 105%. Verify that the Speed Setpoint ramps to the Setpoint Target and that turbine speed tracks the setpoint and settles at 105%. At the Turbine Control Panel display of the HMI enter a Speed Setpoint Target of 100%. Verify that the Speed Setpoint ramps to the Setpoint Target and that turbine speed tracks the setpoint and settles at 100%.


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Procedure Title


Check Completed

Completed by / date

Use the Historical Trend of the HMI to review Speed Setpoint Target, Speed Setpoint and turbine speed from the previous checks. Verify the speed control regulation and adjust the integral and lead gains if necessary. NOTE: Contact ICS Engineering Dept. before making any adjustments If overspeed testing is required then allow the unit to run at full speed no load for sufficient time in advance of testing. Record this FSNL “warm-up‟ time.


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Page 36 of 62

Procedure Title


Metering Valve Liquid Fuel Check (Check box if this section is not applicable for this commissioning) Liquid Fuel No Ignition Check The purpose of these checks is to verify the amount of fuel used to „fire‟ the unit. This may be done by checking the fuel flow with a separate metering device. The measured fuel flow may be compared to the fuel flow recorded on the HMI (if any).

Record data

Check Completed

Completed by / date

Verify that the turbine is Ready To Start. Disable the ignition system by removing the ignition relay(s) and fuses. At the Turbine Control Panel select a Control Mode that will admit fuel to the turbine, and then START. Verify the fuel metering valve moves to the firing position and that fuel control valve position matches the control valve reference. See table below for Required „firing‟ fuel flow. Verify that the actual fuel flow matches the desired fuel flow with the control valve at the firing position. Do not continue with firing checks if actual fuel flow does not match the required fuel flow. Check fuel flow stability (no oscillation in fuel flow) and adjust associated gains accordingly. When the ignition timer has timed out the sequence should shut the fuel stop valve. Allow the unit to coast down to zero speed.


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Procedure Title


Liquid Fuel Fire Check Do not continue with firing checks if fuel flow exceeds the requirements in the previous No Ignition check. This test will admit fuel to the combustion chambers and then ignite it. This is used to examine various operating parameters to verify the starting fuel flow. Check Completed

Record data

Completed by / date

Ensure that the unit is Ready to Start. Reinstall the ignition relay(s). At the Turbine Control Panel display of the HMI, select FIRE, and then START. With the unit firing, check that fuel control valve position matches control valve reference. Unit should indicate flame detection within 45 seconds of applying liquid fuel to the combustors. Once flame has been detected, verify the fuel flow follows expected governor schedule.

Fuel Flow Reference Table Start-up Fuel Manufacturer

Gas

Model

Nozzle Pressure

Flow GE

Frame 5

GE

Frame 7


Liquid Flow

Nozzle Pressure

2.5 gpm

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Page 38 of 62

Procedure Title


Turbine Overspeed Trip Checks Once the unit is at full speed no load, allow the unit to run for 20 - 30 minutes before performing the overspeed trip checks.

Electronic (Software) Overspeed Trip Test Record data

Check Completed

Completed by / date

Start the unit and bring it to full speed no load. Do not enable the overspeed test. Change the value of the electronic overspeed control constant to a value higher than the running speed. Record value: Raise the speed of the unit until it trips on „Electronic Overspeed Trip‟ and record the speed at which the unit trips: Change the value of the electronic overspeed control constant back to its original value.


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Procedure Title


Mechanical Overspeed Trip Test Record data

Check Completed

Completed by / date

From the Maintenance Menu, select Overspeed Test. Enable the overspeed test. This will raise the electronic (software) overspeed trip setting above the mechanical setting. Enter in a speed setpoint approximately 1% above the mechanical trip setpoint. Record Speed setpoint entered: Observe operation and record the speed at which the unit trips:

% Rpm

When the unit goes into the cooldown cycle, reset the mechanical overspeed trip mechanism and clear the overspeed trip.


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Page 40 of 62

Procedure Title


4.3. Synchronization Checks Application: This document provides instructions for performing Manual Synchronization, and applies units regardless of the Exciter/Voltage Regulator applied. PHASE ROTATION CHECKS Required Tools: Voltmeter rated for generator terminal voltage, high voltage gloves, face shield and ground mat. A full voltage test with “hot sticks” across like phases is highly recommended. A full voltage rotation test consists of utilizing a voltmeter rated for the voltage of the generator. The following is a short procedure that should be carried out by qualified personnel only. Ensure that the breaker is racked out and in the test position before performing checks. Locate a high voltage test stick for checking the voltage difference (hence phase angle) between the Bus and Generator Phase A, then B and then C. Only persons with proper training should attempt this procedure. Record data

Check Completed

Completed by / date

Verify that field wiring between the generator control panel and the switchgear is complete and correct. Turn the voltage regulator off. Tape off area for testing personnel only. Rack out generator breaker and expose bus bars. Verify the breaker close circuit is disabled and that synchronizing is OFF. Verify bus voltage and frequency readings on control panel meters. Record readings. Start the unit and bring it to synchronous speed. Start the voltage regulator. At the generator control panel, verify that the synchronizing lights and the synchroscope are functioning.


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Procedure Title


Check Completed

Completed by / date

At the generator control panel, verify that Voltage Raise and Lower Switch is working. Verify that the raise and lower voltage buttons are working on the HMI. At the generator control panel, verify that Governor Raise and Lower Switch is working. Verify that the raise and lower speed/load buttons are working on the HMI. Adjust generator voltage and speed until the generator and bus voltage and frequency as indicated on the meters are the same, with the synchroscope is rotating slowly in the fast direction. When the sync lights are extinguished and the sync needle at 12 o‟clock position, verify that Phase A Generator-to-Bus voltage difference is zero using the high voltage test sticks. At 6 o‟clock verify that Phase A Generator-to-Bus voltage difference is at the maximum voltage. This proves that the synch scope indicates inphase when the buses are actually in phase. When the sync lights are extinguished and the sync needle at 12 o‟clock position, verify that Phase B Generator-to-Bus voltage difference is zero using the high voltage test sticks. At 6 o‟clock verify that Phase B Generator-to-Bus voltage difference is at the maximum voltage. This proves that the synch scope indicates inphase when the buses are actually in phase.


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Procedure Title


Check Completed

Completed by / date

When the sync lights are extinguished and the sync needle at 12 o‟clock position, verify that Phase C Generator-to-Bus voltage difference is zero using the high voltage test sticks. At 6 o‟clock verify that Phase C Generator-to-Bus voltage difference is at the maximum voltage. This proves that the synch scope indicates inphase when the buses are actually in phase. Remove the high voltage test sticks.


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Page 43 of 62

Procedure Title


Manual Synchronizing Circuit Before performing this check, ensure the phase rotation is correct. Perform any required off-line checks for the voltage regulator. Record data

Check Completed

Completed by / date

Verify that the generator breaker is in the test position. If the breaker does not have a test position, rack the breaker out, remove the wire to the breaker-close coil and monitor voltage to the coil with a voltmeter. Set synchronizing to MANUAL. Bring the unit to synchronous speed and meet the conditions required for manual breaker closing (e.g., frequency, voltage, etc.). Watch the synchroscope, synchronizing lights and indications on the synch-check relay. Verify the synch-check relay gives a breaker close permissive when the synchroscope is at 12 o‟clock and the synch lights are out. Give a manual breaker close command when the synchroscope is at 12 o‟clock. Verify that the breaker closes in the test position or that voltage is indicated at the breaker close coil. If the breaker closes in the test position, verify proper indication of breaker close signal back to the controller. Trip the generator breaker open. Give a manual breaker close command when the synchroscope is at 6 o‟clock. Verify the breaker does not close or that voltage is not indicated at the breaker close coil. Consult the turbine controller drawings and repeat the above steps for any variations on manual breaker closing, e.g., local, remote, etc.


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Procedure Title


Generator Breaker Trip Circuit Checks These checks are to verify the integrity of the applicable generator breaker trip commands. If possible, these checks should be done with the breaker racked out and in the test position. If the breaker does not have a test position, rack the breaker out, remove the wire to the breaker-trip coil and monitor voltage to the coil with a voltmeter. Record data

Check Completed

Completed by / date

With the unit still running and the breaker in the test position, close the breaker manually. Consult the turbine controller drawings and test all possible combinations of the breaker trip circuit.


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Procedure Title


Automatic Synchronizing Circuit Before performing this check, ensure the phase rotation is correct and complete the manual synch checks. Record data

Check Completed

Completed by / date

Verify that the generator breaker is in the test position. If the breaker does not have a test position, rack the breaker out, remove the wire to the breaker-close coil and monitor voltage to the coil with a voltmeter. Set synchronizing to MANUAL. Bring the unit to synchronous speed and meet the conditions required for manual breaker closing (e.g., frequency, voltage, etc.). Watch the synchroscope, synchronizing lights and indications on the synch-check relay. Verify the synch-check relay gives a breaker close permissive when the synchroscope is at 12 o‟clock and the synch lights are out. Set synchronizing to AUTO. Verify the auto synchronizer gives a breaker close command and the synch-check relay gives a breaker close permissive when the synchroscope is at 12 o‟clock and the synch lights are out. Trip the generator breaker open. Set synchronizing to OFF. Manually lower the generator terminal voltage to 95% of rated. Manually lower generator speed to 99.5% of rated. Set synchronizing to AUTO. Give the unit a start signal to reset the auto-synch permissive. Verify autosynchronizer speed matching and voltage matching.


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Page 46 of 62

Procedure Title


Check Completed

Completed by / date

Trip the generator breaker by utilizing logic in the turbine controller. Verify the breaker opens and speed setpoint goes to 100%. The breaker should not re-close. Set generator synchronizing selector switch to OFF. Consult the turbine controller drawings and repeat the above steps for any variations on automatic breaker closing, e.g., local, remote, etc.


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Procedure Title


4.4. Turbine On-Line / Load Checks Turbine Online Commissioning Procedure Application: This section provides instructions for commissioning a Gas Turbine Generator up to Full Load. Use appropriate corresponding operating data sheet to record data in this section: Unit Type GE Frame type Pratt & Whitney FT4

Form Number FM-OD-GT-G-FR-001 FM-OD-GT-G-GG-001

Check Completed

Completed by / date

Check Completed

Completed by / date

Synchronize the generator to the electric grid

Meter Display Checks Record data Verify that all customer-supplied and ICS-supplied meters, HMI, LTI, panel-mounted meters and any other displays the correct values. Turbine Speed Generator Frequency Generator Phase Currents Generator Phase Voltages Generator MW/kW Generator MVar/kvar Generator Power Factor Generator Field Voltage / Current


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Procedure Title


Load Control and Base Load Checks Check Completed

Completed by / date

At the Turbine Control Panel display of the HMI, enable Speed/Load Control and the Normal load rate. At the Turbine Control Panel display of the HMI, enter a speed setpoint target of 101.0%. Verify that the load increases at the set ramp rate value. Verify that all systems (lube oil, cooling water, etc.) pressure and temperatures are as expected. Record Operating Data in the appropriate Unit Data Sheet. At the Turbine Control Panel display of the HMI, enter a speed setpoint target of 102.0%. Verify that the load increases at the set ramp rate value. Verify that all systems (lube oil, cooling water, etc.) pressure and temperatures are as expected. Record Operating Data in the appropriate Unit Data Sheet. At the Turbine Control Panel display of the HMI, enter a speed setpoint target of 103.0%. Verify that the load increases at the set ramp rate value. Verify that all systems (lube oil, cooling water, etc.) pressure and temperatures are as expected. Record Operating Data in the appropriate Unit Data Sheet. At the Turbine Control Panel display of the HMI, select BASE load. Verify the machine goes on temperature control. Verify that all systems (lube oil, cooling water, etc.) pressure and temperatures are as expected. Record Operating Data in the appropriate Unit Data Sheet.


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Procedure Title


Peak Load Operation These checks are to verify the peak load function of the controller. Record and investigate any alarms that occur during testing. Unit should be running with the generator breaker closed. Record data

Check Completed

Completed by / date

At the Turbine Control Panel display of the HMI, select Peak Load. Verify that the speed setpoint target goes to 107.0% and the setpoint ramps to that value. Verify the unit goes on exhaust temperature control at a higher exhaust temperature than the base load value. Verify that all systems (lube oil, cooling water, etc.) pressure and temperatures are as expected. Record Operating Data in the appropriate Unit Data Sheet.


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Procedure Title


Load Rejection Test (optional) With the unit on-line select a load level to test the load rejection capability and proceed with the test. Record data

Check Completed

Completed by / date

With the unit on-line, select a load at which the test is to be done. Record below.

Open the generator breaker and verify the speed setpoint goes to 100.0%, the speed governor takes over and the unit does not trip on overspeed. Record turbine max speed after breaker open.


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Page 51 of 62

Procedure Title


Megawatt Control Checks (Check box if this section is not applicable for this commissioning) These checks are to verify the megawatt control function of the controller. investigate any alarms that occur during testing.

Record and

Unit should be running with the generator breaker closed. Record data

Check Completed

Completed by / date

At the Turbine Control Panel display of the HMI, select MEGAWATT CONTROL ENABLE. The megawatt setpoint target and setpoint should be equal to the present megawatt value. Enter a megawatt setpoint target equal to 25% of rated load. Verify the megawatt setpoint tracks to the setpoint target at the normal rate and that the unit output follows the setpoint. Record Megawatt Setpoint here. Record MW output here. Enter a megawatt setpoint target equal to 75% of rated load. Verify the megawatt setpoint tracks to the setpoint target at the normal rate and that the unit output follows the setpoint. Record Megawatt Setpoint here. Record MW output here.


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Procedure Title


VAR Control Checks (Check box if this section is not applicable for this commissioning) These checks are to verify the VAR control function of the controller. Record and investigate any alarms that occur during testing. Unit should be running with the generator breaker closed. Record data

Check Completed

Completed by / date

At the Generator Control Panel display of the HMI, select VAR CONTROL ENABLE. The VAR setpoint target and setpoint should be equal to the present VAR value. Enter a VAR setpoint target. Verify the VAR setpoint tracks to the setpoint target at the normal rate and that the unit output follows the setpoint. When the generated VARs, the VAR setpoint target and the VAR setpoint are all equal, change the megawatt load on the unit. Verify the VARs do not change as the megawatts change.


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Procedure Title


Power Factor Control Checks (Check box if this section is not applicable for this commissioning) These checks are to verify the power factor control function of the controller. investigate any alarms that occur during testing.

Record and

Unit should be running with the generator breaker closed. Record data

Check Completed

Completed by / date

At the Generator Control Panel display of the HMI, select PF CONTROL ENABLE. The power factor setpoint target and setpoint should be equal to the present power factor. Enter a PF setpoint target of 0.80. Verify the PF setpoint tracks to the setpoint target at the normal rate as the control system automatically adjusts the Reactive power of the generator. NOTE: Generator MW should NOT change With Power factor control enabled, change the megawatt load on the unit. Verify the power factor does not change as the megawatts change.


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Procedure Title


Automatic Synchronizing to Base Load These checks are to verify the automatic synchronizing and loading functions of the controller. Record and investigate any alarms that occur during testing. Unit may be running, or shutdown, generator breaker should be open. Record data

Check Completed

Completed by / date

At the Turbine Control Panel display of the HMI, select Base Load. At the Generator Control Panel display of the HMI, select automatic synchronizing. If the unit is not running, give a START command to start the unit. If unit is running, give a START command to initiate the auto synch mode. Verify that the breaker closes, the speed setpoint target goes to 107.0% and the setpoint ramps to that value. Record Exhaust Temperature Setpoint here. Record Time from breaker close to base load Record Megawatts Verify the unit goes on exhaust temperature control; record Exhaust Temperature here. In the applicable OPERATING DATA FORM record the key turbine data.


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Page 55 of 62

Procedure Title


Fast Load Control Checks These checks are to verify the fast loading functions of the controller. Record and investigate any alarms that occur during testing. Unit may be running or shutdown, generator breaker should be open. Record data

Check Completed

Completed by / date

At the Turbine Control Panel display of the HMI, select Base Load and Fast Load. At the Generator Control Panel display of the HMI, select automatic synchronizing. If the unit is not running, give a START command to start the unit. If unit is running, give a START command to initiate the auto synch mode. Verify that the breaker closes, the speed setpoint target goes to 107.0% and the setpoint ramps to that value. Verify the unit loads at the fast rate and goes on exhaust temperature control; record Time from breaker close to base load here.


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Procedure Title


Emergency Load Control Checks (Check box if this section is not applicable for this commissioning) These checks are to verify the emergency loading functions of the controller. investigate any alarms that occur during testing.

Record and

Unit may be running or shutdown, generator breaker should be open. Record data

Check Completed

Completed by / date

At the Turbine Control Panel display of the HMI, select Base Load and Fast Load. At the Generator Control Panel display of the HMI, select automatic synchronizing. If the unit is not running, give a START command to start the unit. If unit is running, give a START command to initiate the auto synch mode. Verify that the breaker closes, the speed setpoint target goes to 107.0% and the setpoint ramps to that value. Verify the unit loads at the emergency rate and goes on exhaust temperature control; record the Time from breaker close to base load here.


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5

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Page 57 of 62

Procedure Title


Isochronous Operation Checks Isochronous Testing typically involves different configurations based on each customer application. If isochronous testing is performed, describe below the preparation for the testing, test results.


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Procedure Title


4.5. Shutdown Checks These checks are to verify the shutdown sequencing of the controller. Record and investigate any alarms that occur during testing. Automatic Shutdown Record data

Check Completed

Completed by / date

Record data

Check Completed Completed by / date

At the Turbine Control Panel display of the HMI, select MEGAWATT CONTROL ENABLE. Enter a megawatt setpoint equivalent to 75% of machine‟s capability. At the Turbine Control Panel display of the HMI, select STOP. Verify the unit unloads at the normal rate. Record the megawatt level when the generator breaker trips. Verify that when the rotor reaches zero speed, the rotor cooldown mechanism starts. Verify that the rotor cooldown mechanism runs for the correct amount of time.

Scheduled Unit Cooldown

Adjust the scheduled cooldown time to start shortly. Verify that the rotor cooldown mechanism starts and runs for the scheduled amount of time.


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Procedure Title


Final Operating Data Obtain a copy of the Historical Log for this run to archive the operating conditions.


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Procedure Title


Software Backup and Handover Record data

Check Completed

Completed by / date

Configurations and Reference Tables of all units must be backed up to the specific unit configuration files. (Number of files = Number of units at site). Back up Locked and Unlocked PLC folders. Back up latest HMI application. Export latest LTI software to the PRJ file under E:\TCP\ and backup. Ensure that all the software is stored in the appropriate folders on the E drive of the HMI PC The following is a list of software that must be returned from the site by the Start up engineer at the completion of the project: 1.

Current Locked copy of PLC folder

2.

Current Unlocked copy of the PLC folder

3.

Current copy of the HMI folder

4.

Current copy of individual unit configuration / Reference tables

5.

Current LTI Application

6.

Current Basler / Decs software if applicable

7.

Current Ultraware software if applicable

8.

Current IO configuration - for panel/field devices


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Procedure Title


NOTES Use this space to record any notes on this procedure. Be sure to indicate the paragraph reference number before each comment.


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001 Gas Turbine Generator Commissioning Procedure

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