As Built
D
04 Apr. 2012
RB
LL
EH
RE-IFC
C
02 Feb. 2012
VS
MW
EH
IFC
B
23 Aug. 2011
VS
MW
EH
IDC
A
22 July 2011
VS
MW
EH
REASON FOR ISSUE
REVISION
REV. DATE
PREP. BY
CHECKED
APPROVED
Document Family:
No. Of pages
ANST PROJECT: FPU for Terang Sirasun Batur Field Company: BW Offshore Project: 4059 Vessel: BW Joko Tole IMO No.: 8802911 COMPANY LOGO:
16
Document Title:
DEAD-SHIP START-UP AND BLACK-OUT RE-START PROCEDURES Doc. type:
FD – Design Criteria and Philosophy Discipline:
E - Electrical BWO Doc. No.:
Rev.
4059-KA-00289231 Supplier Doc. No:
Z0 Rev.
1182090
D
Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures
Doc. No: 1182090 Rev. D
TABLE OF CONTENT About this document ......................................................................................................... 3 Document history................................................................................................................. 3 1.
INTRODUCTION...................................................................................................... 4
1.1
DEFINITIONS .......................................................................................................... 4
1.2
ABBREVIATIONS .................................................................................................... 5
1.3
ASSUMPTIONS ....................................................................................................... 5
1.4
SAFETY PRECAUTIONS ........................................................................................ 6
2.
SCOPE .................................................................................................................... 6
3.
GENERAL ............................................................................................................... 6
4.
STARTING METHODS AND AUXILIARIES REQUIRED FOR GENERATORS ...... 7
4.1
EMERGENCY GENERATOR (84-EG-5001) ............................................................ 7
4.2
ESSENTIAL DIESEL GENERATORS (82-EG-5501A and 82-EG-5501B) ................ 8
4.3
STEAM TURBINE GENERATORS (80-EG-9000 and 80-EG-9100) ......................... 9
5.
DEAD-SHIP START-UP SEQUENCE OPERATION ................................................ 9
5.1
START EMERGENCY DIESEL GENERATOR 84-EG-5001 (Manual Start) AND POWER-UP EMERGENCY LOADS......................................................................... 9
5.2
START ESSENTIAL DIESEL GENERATORS 82-EG-5501A and 82-EG-5501B (Manual/Local Start) AND POWER-UP ESSENTIAL LOADS ................................. 10
5.3
ENERGIZING THE NORMAL SWITCHBOARD FROM THE NEW ESSENTIAL SWITCHBOARD, IF REQUIRED FOR OPERATIONAL REASONS BEFORE MAIN POWER IS AVAILABLE FROM THE STGs............................................................ 12
5.4
START STEAM TURBINE GENERATORS 80-EG-9000 and 80-EG-9100 (ManualStart) AND POWER-UP PROCESS LOADS .......................................................... 12
6.
BLACK-OUT RE-START SEQUENCE OPERATION ............................................ 14
6.1
START EMERGENCY DIESEL GENERATOR 84-EG-5001 (Auto-Start) AND POWER-UP EMERGENCY LOADS....................................................................... 14
6.2
START ESSENTIAL DIESEL GENERATORS 82-EG-5501A and 82-EG-5501B (Auto-Start) AND POWER-UP ESSENTIAL LOADS .............................................. 14
6.3
START STEAM TURBINE GENERATORS 80-EG-9000 and 80-EG-9100 (AutoStart) AND POWER-UP PROCESS LOADS .......................................................... 14
7.
OTHER STARTING PROCEDURES ..................................................................... 15
7.1
BASIC PROCEDURE FOR STARTING THE BOILER SYSTEM ............................ 15
7.2
ENERGIZATION OF 80-ET-4001A/B and 82-EN-4001A/B NORMAL SWITCHBOARDS .................................................................................................. 15
8.
SPECIAL RECOMMENDATIONS ......................................................................... 16
8.1
Standby Personnel ................................................................................................. 16
8.2
Purge Sequence for running Fuel Gas Compressors ............................................. 16
8.3
Black-out /Dead-ship Restart with only one DG available ....................................... 16
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Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures
Doc. No: 1182090 Rev. D
About this document Document history Revision
Description of Change
A
First issue for IDC.
B
Review comments incorporated. Page 3: Added document history page. Page 4: Deleted extra information. Page 5: Added abbreviations and arrange list in alphabetical order. Pages 6~10: Statements modified as per comment.
C
Review B comments incorporated. Pages 2, 3: Update TOC. Pages 7, 8, 9, 10, 11, 12, 13, 14: Write-up modified as per comments.
D
As Built
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Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures
1.
Doc. No: 1182090 Rev. D
INTRODUCTION
This document covers the requirements for the detailed procedure of the electrical start-up / re-starts for the FPU BW Joko Tole. 1.1
DEFINITIONS
For purposes of this document, the following definitions apply: Dead-ship or Black-out A Dead-ship or Black-out refers to the total power outage in the facility. Cause for total power outage can be attributed to failure of any component such as protection relay trip, activation of ESD 1 or ESD 2 , etc. (Black-out) or activation of AVS or ESD 0 (Dead-ship) in the facility. The main difference between Black-out and Dead-ship is that during Black-out the UPS System is still available while it is not during a Dead-ship.
Dead-ship Start-up When AVS or ESD 0 is initiated, the facility will be in total power outage including the UPS System. Re-instating the electrical system shall follow a dedicated procedure termed as Dead-ship Start-up to allow the safe re-start of electrical supply. All start-up procedures shall be manually initiated. Black-out Re-start In case of the power outage other than AVS or ESD 0, the electrical UPS System is still available for the immediate resumption of electrical supply. Start-up operation shall be generally initiated automatically through the PMS, assisted by Operation personnel in case auto function fails.
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Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures 1.2
ABBREVIATIONS ACB AVS CCR DG EDG ESD ESB FPU F&G ICSS LO LSM LSU LV MCC MDO MV NESB PMS STG STG LCP UPS VCB VFD [OP-XX]
1.3
Doc. No: 1182090 Rev. D
Air Circuit Breaker Abandon Ship Shutdown Central Control Room Essential Diesel Generator Emergency Diesel Generator Emergency Shutdown Emergency Switchboard Floating Production Unit Fire and Gas Integrated Control and Safety System Lube Oil Load Sharing Module Load Sharing Unit Low Voltage Motor Control Center Marine Diesel Oil Medium Voltage New Essential Switchboard Power Management System Steam Turbine Generator Steam Turbine Generator Local Control Panel Uninterruptible Power Supply Vacuum Circuit Breaker Variable Frequency Drive Denotes the Operational Procedure tag reference of the Circuit Breakers
ASSUMPTIONS
It is assumed that 1.3.1
All the FPU utility systems are commissioned and ready for operation, and complete safety requirements have been complied with, together with other relevant operational procedures.
1.3.2
The basic design philosophy of all electrical loads is fail – safe. Feeders from MV and LV switchgear including MCC shall be tripped to OPEN position.
1.3.3
All normal Operator Equipment pre-start checks are carried out prior to the implementation of this procedure.
1.3.4
No unsafe condition exists.
1.3.5
All alarms are in their normal state.
1.3.6
Sufficient competent personnel are available.
1.3.7
Radio Communications (handy-talkie) are established.
1.3.8
All process valves are in their normal position (de-energised, fail-safe)
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Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures
1.4
2.
Doc. No: 1182090 Rev. D
SAFETY PRECAUTIONS
1.4.1
Permission to be obtained / information to be passed on to the concerned prior to every major activity for example switching ON Breaker / Starting of Equipment / Loads.
1.4.2
The operator involved will exercise caution and safety measures during the operations.
1.4.3
The entire sequence shall be a coordinated operation.
SCOPE
The procedure will cover starting of the Power Generation, Power Distribution and bringing the plant operation back in Normal Mode in a safe and logical manner, following a vessel wide power outage. The steps and sequences cover but not limited to the following activities:
3.
Manual/Auto start of the Emergency Power Generation and Distribution System
Manual/Auto start of the Essential Power Generation and Distribution System.
Manual start of the Steam Turbine Generators
Transfer of load from EDG to DG and DG to STG
GENERAL
In general terms, the Power Generation and Distribution systems of FPU BW Joko Tole shall be restarted by use of the following diesel-driven generators:
84-EG-5001 82-EG-5501A 82-EG-5501B
-250kW/312kVA 440V, 3-ph, 60Hz Emergency Diesel Generator (EDG) -910kW/1138kVA 440V, 3-ph, 60Hz Essential Diesel Generator No. 1 (DG-1) -910kW/1138kVA 440V, 3-ph, 60Hz Essential Diesel Generator No. 2 (DG-2)
The pre-requisites detailed in Section 1.3 are taken into account prior to re-start in order to fulfil the requirements of this procedure. Essentially, a Black-out Re-start shall use the ship ’s stand-by diesel generators (EDG and DGs) to provide power to emergency and essential consumers sufficient to maintain the normal requirements for safe habitation on board the FPU and to allow the Boiler and STG auxiliary equipment to be made available in order to re-start one of the Main Steam Turbine Generators. Upon restoration of ‘Normal mode of supply’ (MV system), the stand-by diesel generators will be returned to ‘auto / stand-by mode’. Operation, control and switching of the MV/LV electrical distri bution network, including the Essential Diesel Generators will be carried out through the PMS. The operation, control and switching of the Emergency Switchboard and Emergency Diesel Generator will be carried out by the stand alone control system within the Emergency Switchboard, however, transfer of load from the Emergency Generator back to normal supply is a manual operation.
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Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures 4.
Doc. No: 1182090 Rev. D
STARTING METHODS AND AUXILIARIES REQUIRED FOR GENERATORS
Dead-Ship Start Up: During initial start-up (Dead-Ship or after AVS/ESD 0), Emergency and both Essential (x2) Diesel Generators will be started manually from their respective local control p anels and manually closed onto their respective Switchboards in ‘Island Mode’. Ultima tely, this shall lead to the firing of a Steam Boiler and the starting of a Steam Turbine Generator, in order to bring the facility up to the normal operating condition. Once all stand-by Diesel Generators (DGs and EDG) have been shutdown, they must be returned to ‘Auto Stand-by Mode’. Black-Out Restart: For a Black-out restart, all stand-by Diesel Generators will start automatically and supply their respective Switchboards in ‘Island Mode’. Ultimately, this shall lead to the firing of a Steam Boilers and the starting of a Steam Turbine Generator, in order to bring the facility up to the normal operating condition. Emergency Generator: Upon detection of Undervoltage on the Emergency Switchboard (ESB) via the proprietary Undervoltage relay, the EDG will automatically start and connect to the ESB upon ‘Dead-Bus’ condition and stabilize the power supply to 440 V / 60 Hz. Essential Generators: The Black-out restart sequence for the Essential Diesel Generators (DGs) will be initiated through the PMS, where upon detection of Undervoltage and Underfrequency on the New Essential Switchboard (NESB), both DGs will be started sequentially, by the PMS. When selected for ‘Auto-Synchronize’ the closing of the resp ective DG Circuit Breaker will be initiated via each Automatic Synchronizer relay. The DGs shall be connected to the NESB and stabilize the power supply to 440 V / 60 Hz. In both starting methods (‘Dead-Ship’ and ‘Black-Out restart’ the stand-by diesel generators will be operated in ‘island mode’ where the Emergency Generator supply shall be limited to the ESB and the Essential Generators supply shall be limited to the NESB. The two switchboards (ESB and NESB) shall be operating in ‘Island Mode’ until such time that the EDG has been synchronized with th e NESB. Upon successful load transfer from the EDG to the DGs, the EDG circuit breaker must be opened immediately. If the EDG circuit breaker has not been opened after a successful load transfer to the NESB, it will automatically open after 30 seconds to avoid the EDG and DGs from running in parallel for prolonged periods, as per Class requirements. The next sequence will be starting the auxiliaries, required for the firing of a Steam Boiler. When normal steam pressure and temperature are stable, one Steam Turbine Generator (STG) will be started and ‘Dead Bus’ closed onto the 6.6 kV Main Switchboard at rated voltage and frequency. After successful energization of the 6.6 kV Main SWBD, the DGs will be synchronized through the secondary breaker of Essential Transformer (80-ET-5501) for transfer of loads. The PMS shall inhibit the other STG from coming on-line during this load transfer operation. A successful transfer of load to the operating STG from the operating DGs shall initiate proper disconnection and shutdown of the running DGs by the PMS. 4.1
EMERGENCY GENERATOR (84-EG-5001)
The Emergency Diesel Generator (EDG) is equipped with a dedicated local control panel (84-EC5001) for monitoring and auto-start functions. A synchroscope (CSQ-3) is provided at the ESB for paralleling the EDG to New Essential SWBD during load transfer as well as during regular maintenance routines and testing. Paralleling is done manually at the ESB and for a short time only. For starting reliability, the EDG is provided with 2x24Vdc Battery Banks charged by two (2) dedicated Battery Chargers which are also located in the Emergency Generator Room. As per Classification requirement, under normal operating conditions, the Emergency Generator will auto start on detection of ‘No Voltage’ at ESB Bus 84-EN-5001, provided that the EDG is in Auto mode and AVS/ESD 0 has not been activated. If the EDG auto-start fails, it will be started manually and controlled from its local control panel.
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Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures
Doc. No: 1182090 Rev. D
The minimum requirements for starting the EDG are given below. 1. 2. 3. 4.
Sufficient fuel in the Emergency Generator Day Tank. Sufficient Lube oil and Coolant level. Battery banks fully charged. Supply air damper to Emergency Generator Room must be open.
For detailed procedure for the safe starting of the EDG, refer to vendor’s operating manual. After ESB is powered, it is the duty of the operator to ensure that UPS -A and UPS-B are in normal operating mode and to ensure that the ICSS and all critical / emergency systems are powered up and operational. 4.2
ESSENTIAL DIESEL GENERATORS (82-EG-5501A and 82-EG-5501B)
The DG is electronically controlled and monitored by an electronic monitoring system A4 ECM. A fully redundant 24Vdc supply is provided for the DGs control and monitoring system which consist of a 24Vdc Battery Bank/Battery Charger and an internal 24Vdc supplied by a 220Vac UPS. Each DG is provided with an air starting motor for starting the diesel engine. A synchronizer relay is provided at the New Essential SWBD (NESB) for each es sential generator for auto-synchronizing the unit to the bus voltage of the New Essential SWBD 82-EN-5501. When selected to Manual-Local/Remote, synchronizing is carried out by a Check Synchronizing Relay (CSQ-3) within the Generator Synchronizing Panel. A load sharing module (Woodward LSM) is also provided for each DG for automatic load sharing parallel ed together in ‘Island Mode’. The DGs are started by compressed air, which is supplied from main air reservoir No 1, 63-VL-0001. Main air reservoir No 2 is interconnected with Main air reservoir No. 1. Four (4) main air compressors 63-KB-0001 A, B & 63-KC-0500A, B charge the Main Air Reservoirs. Main air reservoirs are fully charged at 30barg. A dedicated Emergency Air Reservoir 63-VL-0004 is also provided in case facility compressed air is not available. If necessary, the emergency air reservoir is can be charged by a diesel-engine driven emergency air compressor 63-KB-0002 to 30barg before starting the DGs. For detailed procedure for the safe starting of the DGs, refer to vendor’s operating manual. The pre-requisites for starting the DGs are given below. 1. 2. 3. 4. 5. 6. 7.
Sufficient fuel in the Essential Generator Diesel Oil Service Tank. Sufficient Charge in the No.1 Main Air Reservoir 63-VL-0001, to start 1 of 2 Essential Diesel Generators (DGs) or in the Emergency Air Reservoir 63-VL-0004. One Fire Water Jockey Pump (71-PA-0501A, B, or C) is running. One Diesel Oil Supply Pump is available (62-PE-0005A or 62-PE-0005B ) Lube Oil Priming Pump is available. Control Supply to all DG panels available. Emergency Diesel Generator (EDG) is running supplying power to the Emergency SWBD 84EN-5001.
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Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures 4.3
Doc. No: 1182090 Rev. D
STEAM TURBINE GENERATORS (80-EG-9000 and 80-EG-9100)
The synchronous brushless generator is rated at 5500kW, 6600V, 602A, 4-pole, 1800 rpm, 3-phase, 60 Hz, 0.8 pf. The Steam Turbine Generators (STGs) are started by a turning motor when saturated steam at 16barg is available. The STG Local Control Panels require 220Vac supply from UPS, 440Vac from the New Essential Switchboard, and 440Vac supply from the Emergency Switchboard. Engine Room ventilation fans (97-GK-0002, 0003, 0004, and 0005) located at B-Deck must be available and running before initiating STG start-up sequence. Instrument Air Compressor(s) are operational and sufficient air reserve is available, it may be necessary to override the PMS inhibit command. All equipment auxiliaries for the STG to be started must be available and running including lube and control oil systems. The start-up sequence for the STG is as per PMS screen. For detailed procedure for the safe starting of the STG, refer to vendor’s operating manual. Prerequisites for STG start are: 1. 2. 3. 4. 5. 6. 7. 8. 9.
5.
Power supply for STG LCPs 80-EC-9000 or 80-EC-9100. Pre/post lube oil pump motor (supplied via 80-EC-9000/9100). Ventilation system motors –1 (97-GK-0002, 0003). Ventilation system motors –2 (97-GK-0004, 0005). Space heater of generator, motors and enclosures. Battery chargers. Instrument Air Supply. Cooling water supply. Steam at rated pressure and temperature from Boiler.
DEAD-SHIP START-UP SEQUENCE OPERATION Prerequisites: 1. Ensure vessel is gas free and safe to start-up. 2. Check UPS batteries: If the batteries are OK, reset/start the UPS on battery power and provide power to the F&G / ESD systems.
5.1
START EMERGENCY DIESEL GENERATOR 84-EG-5001 (Manual Start) AND POWER-UP EMERGENCY LOADS 1. 2. 3. 4. 5.
6.
7.
8.
Verify the minimum requirements in Section 4.1 have been established. Ensure that all the incoming and outgoing feeder breakers on the ESB are open. If ESD has been activated and not reset at ICSS, select ESD key switch (2ESD) to ‘OVERRIDE’ position at the ESB. Open louver intake and exhaust of emergency generator room manually. At the EDG local control panel turn the Start Engine S elector Switch to ‘REMOTE’ position and the EDG control selector switch (2S2) on the ESB to ‘MAN’ (Manual) position. On Emergency diesel generator, Switch to OPEN position air intake manifold switch (84-XV-0757). START engine from engine local control panel (84-EC-5001) : - Select START selector switch to LOCAL - Release Emergency Stop button. - START Engine by pushing START Button. Confirm engine ‘Ready to Start’ pilot lamp (2H7) ON and start the emergency generator diesel engine by switching the engine control switch (2S7) at the ESB to ‘START’ and allow the engine to stabilize. If necessary adjust EDG speed via a speed control potentiometer (R21) and the Generator voltage via a voltage trimmer potentiometer (R20) at the ESB. Once the EDG is operating at the rated speed, voltage and frequency, close EDG Breaker [OP-01] onto ESB (closing on dead bus) by switching CB Control Selector Switch (2S1) to ‘CLOSE’. If the breaker cannot be closed from this switch, manually charge the spring and Page 9 of 16
Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures
9. 10. 11. 12. 13. 14.
15.
16. 17. 18. 19.
Doc. No: 1182090 Rev. D
close by pressing breaker ’s close push button. The ESB is now energized by power from EDG. Once stabilized, switch ON the feeders to the UPS (Un-interruptible Power Supply) 85-ER5001A and 85-ER-5001B [OP-02 and OP-03]. Reset all initiated active ESD signals on ICSS/CCR. Switch ON the feeder to the Emergency Transformer 84-ET-5001 [OP-04]. Switch ON the MCCB of Fire Water Jockey Pump A, 71-PA-0501A [OP-05]. Start the pump for the cooling water requirement of the EDG. Switch ON the MCCB of No. 1 Steering Gear, 58-XY-0001A [OP-06]. Ensure its availability when needed (applicable for sailing scenario only). At the UPS Room located at A-Deck, AFT/ Portside, confirm that both UPS (85-ER-5001A and 85-ER-5001B) are in normal operating mode. Reset any standing ESD trip signals to the Battery CBs by selecting ‘BYPASS’ on the ESD Bypass Switch and verify that the respective Battery Banks in the Battery Room adjacent to the UPS Room have returned to their normal charging cycle. Confirm that all emergency transformer loads are energized. (Engine Room Emergency DB 84-EL-5003A [OP-07], E-House Emergency DB 84-EL-4001 [OP- 08], Accommodation Emergency DB 84-EL-5002 [OP-09], and Decks Emergency DB 84-EL-5002A [OP-10]). The ICSS shall now be started in accordance with the standard ICSS starting procedure. All ESD signals that still exist shall be reset and ESD key switch returned to NORMAL position at the ESB. The rest of the emergency loads can now be started as required. The EDG shall be put on AUTO MODE after the successful Dead-ship Start-up so that it will start automatically when Black-out Re-start is initiated by the PMS.
The priority emergency loads at start-up are listed below: STARTING SEQUENCE
SWBD LOCATION
TAG NUMBER
DESCRIPTION
1
84-EN-5501-S3-4
85-ER-5001A
220V UPS Unit A
2
84-EN-5501-S3-5
85-ER-5001B
220V UPS Unit B
3
84-EN-5501-S5-5
84-ET-5501
Emergency Lighting Transformer
4
84-EN-5001-S3-1/S3-2/S3-3
71-PA-0501A/BC
Fire Water Jockey Pump A/B/C.
5
84-EN-5001-S3-9
58-YX-0001A
No.1 Steering Gear (Sailing Only)
5.2
START ESSENTIAL DIESEL GENERATORS 82-EG-5501A and 82-EG-5501B (Manual/Local Start) AND POWER-UP ESSENTIAL LOADS 1. 2.
Verify the minimum requirements in Section 4.2 have been established. At the local control panels of each DG, set the LOCAL/REMOTE start selector switch to ‘REMOTE’ while at the New Essential SWBD Synchronizing Panel set the AUTO/MAN control selector switch (16S01) to ‘MAN’ (Manual) and the LOCAL/REMOTE control switch (16S9) to LOC (Local). Switch DG Priority Selection Switch (16S02) to DG-1 at the New Essential Switchboard (NESB).
S/Switch Engine Control L/R NESB Auto/Man (16S01) NESB LOC/REM (16S9/18S9) DG Man Start Select (16S02)
LOC
82-EG-5501A REM M
A
LOC
X
82-EG-5501B REM M
A
X X
X
X
X
X
X Page 10 of 16
Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures
3.
4.
5. 6. 7.
8. 9.
Doc. No: 1182090 Rev. D
With ‘Engine Ready to Start’ pilot lamp (16H E1) ON, start DG-1 locally at the NESB by switching START/STOP control switch (19S7) to ‘START’. Verify that Generator starts and runs up to rated speed and voltage by monitoring the panel mounted meters. If necessary adjust generator speed by switching speed adjuster selector switch (16S8) to either ‘INCREASE’ or ‘DECREASE’ at the New Essential SWBD until a stable speed is achieved. (THIS FUNCTION ONLY APPLIES TO ‘AUTO SYNCH’ MODE VIA 16PP AUTO SYNCHRONIZER. WHEN IN ‘MAN/LOCAL’ ONLY 16KSYN SYNCHROSCOPE WILL ENABLE CB TO CLOSE). Confirm the Dual Voltage and Frequency meters are displaying correctly and that Synchroscope (16KSYN) is acti vated. On a ‘Dead-Bus’ condition the Synchroscope will be in the ‘12 o’clock’ position. Close the DG-1 Incomer CB by switching the corresponding CB control switch (16S1) to ‘CLOSE’. The New Essential Switchboard (NESB) is now powered by DG-1. Restart the E/R Main seawater cooling pumps after NESB energized by DG1/DG2. Repeat step 3 for DG-2. (THIS FUNCTION ONLY APPLIES TO ‘AUTO SYNCH’ MODE VIA 16PP AUTO SYNCHRONIZER. WHEN IN ‘AN/LOCAL’ONLY 16KSYN SYNCHROSCOPE WILL ENABLE CB TO CLOSE). Confirm the Dual Voltage and Frequency meters are displaying correctly and that Synchroscope (16KSYN) is activated. Monitor the Synchroscope and make necessary adjustments to DG-2 speed in order to match the system frequency. Initiate a Close of the DG-2 Incomer CB by switching the corresponding control switch (18S1) to ‘CLOSE’ upon reaching synchronism (when the Synchroscope reaches the 12 o’clock position). The New Essential SWBD is now powered by both DG-1 and DG-2. Confirm operation status as indicated by the corresponding pilot lamps on the SWBD. The following priority essential loads can now be started as required: Marine & Safety Systems Equipment
STARTING SEQUENCE
SWBD LOCATION
TAG NUMBERS
DESCRIPTION
1
82-EN-5501-S2-1
97-GK-0002
No.1 E/R Ventilation Fan
2
82-EN-5501-S2-2
97-GK-0003
No.2 E/R Ventilation Fan
3
82-EN-5501-S13-1
51-PA-0500A-DE
Main Sea Water Cooling Pump A
4
82-EN-5501-S6-10
53-PA-0001-DE
No.1 Main Fresh Water Cooling Pump
5
82-EN-5501-S7-1
82-ET-5501
General Lighting Transformer
6
82-EN-5501-S12-1
63-KC-0500A
Air Compressor A
7
82-EN-5501-S8-8
97-EC-0900
Chiller Units & CHW Pumps
8
82-EN-5501-S7-6
97-EC-0907
NSR CHW AHU
9
82-EN-5501-S7-7
97-EC-0908
ECR CHW AHU
10
82-EN-5501-S7-3
97-GK-0905
Vent. Fan Group Panel
11
82-EN-5501-S7-2
97-EC-0906
Group CHW AHU & DX A/C Panel
12
82-EN-5501-S7-10
97-EC-0903
E-Deck CHW AHU & DX A/C Panel
13
82-EN-5501-S7-5
97-EC-0904
B-Deck Mess Room CHW AHU
14
82-EN-5501-S7-8
97-EC-0901
Refrigeration Provision Panel
15
82-EN-5501-S2-3
97-GK-0004
No.3 E/R Ventilation Fan
16
82-EN-5501-S2-4
97-GK-0005
No.4 E/R Ventilation Fan
17
82-EN-5501-S2-5
97-GK-0006
Purifier Space Exhaust Fan
18
82-EN-5501-S2-6
97-GK-0001
Pump Room Exhaust Fan
19
82-EN-5501-S13-3
51-PA-0500B-DE
Main Sea Water Cooling Pump B
20
82-EN-5501-S6-6
53-XK-0500
Fresh Water Generator Page 11 of 16
Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures
Doc. No: 1182090 Rev. D
21
82-EN-5501-S6-5
66-XF-0500
Sewage Treatment
22
82-EN-5501-S6-3
98-EU-0500A
ICCP AFT
Boiler & STG Auxiliary Equipment (A System) STARTING SEQUENCE
SWBD LOCATION
TAG NUMBERS
DESCRIPTION
1
82-EN-5501-S11-10
80-EC-9001
STG-A Turbine Control Panel
2
82-EN-5501-S10-1
62-PA-8001
Boiler Feed Water Pump A
3
82-EN-5501-S11-4
62-PG-8001
Boiler MDO Pump A
4
82-EN-5501-S9-3
55-KE-9000
Gland Condensate Fan A
5
82-EN-5501-S8-1
55-PA-9001
No.1 STG-A Condensate Pump
6
82-EN-5501-S11-1
67-KE-8101
Combustion Air Fan A
7
82-EN-5501-S11-9
55-XQ-8101
Boiler A Chemical Dosing Pump
10. After the successful Dead-Ship start-up, the DGs shall be shutdown normally and their controls be returned to ‘Auto Standby Mode’. 5.3
ENERGIZING THE NORMAL SWITCHBOARD FROM THE NEW ESSENTIAL SWITCHBOARD, IF REQUIRED FOR OPERATIONAL REASONS BEFORE MAIN POWER IS AVAILABLE FROM THE STGs 1.
2. 3. 4.
5.
5.4
The incomer CB from the NESB at the Normal Switchboard B can be close only on the following conditions: a) The outgoing CB at the NESB to the Normal Switchboard B is closed. b) Both the incoming CBs from transformers 80-ET-4001A and 80-ET-4001B are open respectively. c) PMS permissive command to close the tie breaker is enabled. Verify that all CBs at the Normal Switchboards A and B are open. With a permissive command from the PMS is enabled, close the incoming tie breaker at the Normal Switchboard. Closed the CBs permitted by the PMS (such as feeders for Mid-ship Crane and Normal Lightings Transformers, and Subsea lightings) as may be required by the Operation. The rest of the loads shall be inhibited by the PMS. The incoming tie breaker at the Normal Switchboard will be open before synchronising the DGs to the STG. START STEAM TURBINE GENERATORS 80-EG-9000 and 80-EG-9100 (Manual-Start) AND POWER-UP PROCESS LOADS
Prior to starting the Steam Turbine Generator confirm all preparations on the 6.6kV Main Switchboard are complete sufficient to receive voltage/power (i.e. initially racking-in VCB into ‘SERVICE’ position - STG-A (80EG-9000) at 80-EH-5001A, Cubicle 9.). This decreases the risk of a potential ‘flash-over’ by minimizing the amount of ‘intrusive’ activities on a potentially li ve system and thus ensures increased safety for personnel. The Turbine Generators onboard the FPU shall be started following manufacturers design/recommended starting procedure. The following procedure (assuming STG-A shall be started) shall be i mplemented in accordance with the manufacturer’s operating manual:
1. 2. 3.
4.
Verify the minimum requirements in Section 4.3 have been established. Confirm that all alarms, if any, have been investigated, cleared and reset. Check steam turbine generator lube oil reservoir level ensuring it is free of contaminants i.e. water or other foreign bodies. Replenish the lube oil system if level is less than normal operation. Start the lube oil priming pump from the local station (COS -PR set to ‘START’ position) and check the lube oil pressure. Page 12 of 16
Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures
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5.
Confirm that the STG oil system has available lube oil pressure of 1.0 ~ 1.5 barg and control oil pressure of 7.0 ~ 9.0 barg. Change the priming oil pump to ‘Auto Mode’ (COS -PR set to ‘AUTO’). 6. Switch Emergency Oil Pump change-over switch (COS-EQP) to AUTO so that it will automatically starts when oil pressure drops below 0.2barg. 7. If required, the Turning Gear Motor can be manually started when lube oil pressure is above 0.5barg by activating the push-button PB-TM. This will initiate ‘barring over’ of the STG at speed specified by the manufacturer (refer to manufacturer’s operating manual) while the start-up operation is in-progress. 8. Confirm vacuum condenser (55-HE-9001) condensate to be at normal level (refer to manufacturer’s operating manual). Start STG- A Condensate Pump Motor No. 1 (55-PA9001A). Switch the pump to ‘Auto Mode’ to ensure that the level is maintained all the time. 9. Start Engine Room Main SW Cooling Pump Motor A (51-PA-0500A-DE). Confirm that cooling water to the condenser is available at the required pressure ( refer to manufacturer’s operating manual). Confirm the sea water valves for vacuum pump cooler, T/G lube oil cooler and gland condenser are opened. 10. Confirm Gland Condenser (55-HE-9000) condensate to be at normal level (refer to manufacturer’s operating manual). Start the Gland Condenser Fan (55-KE-9000) and bring up the vacuum in the Gland Condenser to normal pressure (refer to manufacturer’s operating manual). 11. Confirm that turbine casing drains and drains on the steam line going to the turbine are all open. This is to drain any condensed water from the steam line to avoid excessive hammering and vibration while starting the steam turbine generator. 12. Fully open the main steam inlet valve for the steam turbine generator. 13. Adjust the gland steam pressure to normal level (refer to manufacturer’s operating manual) . 14. Confirm that the condensate vacuum, gland steam pressure, steam inlet pressure, and lube oil pressure are normal. 15. Start the steam turbine generator from the local station and close the drain in the steam lines. 16. Check steam pressure. 17. Check condenser vacuum and water level. 18. Check lube oil pressure and vibration levels. 19. Check turbo generator speed, voltage, frequency, vacuum, condenser level and other parameters. 20. Transfer control from local control panel (STG- A TCP) to remote station MV Switchboard (80EH-5001A). 21. Confirm all other parameters by checking the panel -mounted meters. 22. At the MV SWBD Busbar Metering Panel-A (80-EH-5001A, Cubicle 8) set AUTO/OFF/MANUAL selector switch SMA to ‘MANUAL’. 23. Set LOCAL/REMOTE (S41, Cubicle 9) selector switch to ‘LOCAL’. 24. With the STG running at stable voltage and frequency, close the generator vacuum breaker on dead bus by switching the CB Control TRIP/N/CLOSE switch (CS1) to ‘CLOSE’ at 80 -EH5001A , Cubicle 9. The MV SWBD 80-EH-5001A is now powered from the STG-A (80-EG9000). This will also energize MV SWBD 80-EH-5001B since the MV Bus Coupler (80-EH5001A/B is normally open. 25. Switch ON feeder to Distribution Transformer (80-ET-5501) to New Essential SWBD and confirm its secondary voltage at 440Vac at the New Switchroom (NSR). 26. At the New Switchroom (NSR) switch the LOCAL/REMOTE selector switch (19S01) at panel S-19 (Incomer from Transformer 80-ET-5501) to ‘LOCAL’. 27. Synchronized 80-ET-5501 secondary voltage to New Essential Switchboard (82-EN-5501) voltage by switching TRIP/CLOSE CB Control switch to ‘CLOSE’ when the paralleling relay (HAS-111DG) SYNC lamp turns green. 28. Transfer loads from the Essential Generators (DG-1 and DG-2) to STG-A (80-EG-9000). 29. Once load transfer is completed, open the DG CBs and stop the engines normally. 30. Energize the distribution transformers (refer to Section 7.2) and proceed in normalizing process loads manually or through the PMS.
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Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures 6.
Doc. No: 1182090 Rev. D
BLACK-OUT RE-START SEQUENCE OPERATION
6.1
START EMERGENCY DIESEL GENERATOR 84-EG-5001 (Auto-Start) AND POWER-UP EMERGENCY LOADS 1. 2. 3.
4. 5.
6. 6.2
The EDG shall be in AUTO MODE to perform auto-start during a black-out re-start. When the minimum requirements in Section 4.1 have been established, a ‘start permissive’ signal will start the EDG automatically. Once rated speed, voltage & frequency are establish and the interlocking parameters on incoming tie-breaker from essential switchboard are satisfied as pre-loaded in PMS, a permissive signal will close the EDG’s breaker. The ESB is now powered by EDG. If auto function fails, operator shall perform the necessary sequence manually. After a successful start-up of the EDG, a ‘start permissive’ signal will be available to the DGs to commence auto-start sequence as programmed in the PMS. The required emergency loads connected to the ESB can now be switched ON as permitted by the PMS. START ESSENTIAL DIESEL GENERATORS 82-EG-5501A and 82-EG-5501B (Auto-Start) AND POWER-UP ESSENTIAL LOADS
1. 2. 3.
4. 5. 6.
7.
8. 6.3
The DGs shall be in AUTO MODE to perform auto-start during a black-out re-start. When the minimum requirements in Section 5.2 have been established and a ‘start permissive’ signal is available the pre-selected DG will start automatically. Once rated speed, voltage & frequency are establish and the interlocking parameters on incoming breaker from MV switchboard and the pre-selected DG are satisfied as pre-loaded in PMS, a permissive signal will close the DG breaker. The NESB is now powered by DG-1 or DG-2 whichever is selected. The second DG will auto start after 10 seconds depending on load requirement as determined by PMS Restart the E/R Main seawater cooling pumps after NESB energized by DG1/DG2. If auto function fails, operator shall perform the necessary sequence manually. After a successful start-up of the DGs, the outgoing ESB Feeder CB at the NESB shall be closed manually, then the EDG will be manually synchronized to the DG supply by closing the incomer No. 2 CB at the ESB. By default both DGs when in ‘Island Mode’ (single/parallel) will be operating in isochronous mode and automatically share load between them. The operation mode can be switched to droop mode through the PMS. Item 8 in Section 5.2 will be performed manually or as permitted by the PMS. START STEAM TURBINE GENERATORS 80-EG-9000 and 80-EG-9100 (Auto-Start) AND POWER-UP PROCESS LOADS
One STG is sufficient for normal plus off-loading operation. The standby STG shall be started only if PMS finds it necessary due to start-up of large motors, operational activities which require additional power, etc. When both the STGs are running, their digital excitation controls shall be set for parallel operation by opening the unit/parallel contact at terminal A35-A36. The steam turbine is started only manually (refer to Section 6.3, items 1~20), but the main vacuum breaker can be closed manually at local (refer to Section 6.3, items 21~23) or remotely at the MV SWBD automatically as described below. The procedure below refers to STG-A which is also applicable to STG-B. 1. 2. 3.
4. 5.
With steam turbine in normal operation turn selector switch SMA at the MV SWBD-A (Cubicle 8) to ‘AUTO’. (At cubicle 13 for STG-B). Select ‘REMOTE’ for the LOCAL/REMOTE selector switch S41 at the MV SWBD -A (Cubicle 9). (At cubicle 12 for STG-B). The STG-A (80-EG-9000) main circuit breaker will close automatically with a ‘close’ order from the generator protection relay SEPAM G87 via PMS directly on ‘dead bus’ (or through a synchronizer on ‘live bus’). This will power up 80-EH-5001A including 80-EH-5001B through a normally close MV bus coupler 80-EH-5001A/B. Switch ON feeder to Distribution Transformer (80-ET-5501) to New Essential SWBD and confirm its secondary voltage of 440Vac at the New Switchroom (NSR). At the New Switchroom (NSR) the LOCAL/REMOTE selector switch (19S01) at panel S-19 (Incomer from Transformer 80-ET-5501) shall be in ‘REMOTE’ position for auto-closing of the transformer secondary breaker. Page 14 of 16
Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures
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6.
Upon issuance of close command from PMS, the NESB Transformer (80-ET-5501) Incomer CB will close automatically on ‘dead bus’ (via DG incoming CBs interlock – 16KDG or ‘dead bus’ functionality of paralleling relay HAS -111DG). On ‘live bus” it will close through a paralleling relay (HAS-111DG) on synchronism. 7. Transfer of loads from the Essential Generators (DG-1 and DG-2) to STG-A (80EG-9000) will be executed automatically upon initiation of the ‘AUTO LOAD TRANSFER’ sequence from the PMS. 8. Once auto load transfer of the DGs is completed, the PMS opens the DG air circuit breakers and put the DGs off-line. Once off-line, the control of the DGs must be manually returned into AUTO STANDBY condition. 9. The network is now configured in Normal Operating mode of supply. 10. Process loads (Normal Consumers) can now be put on line manually or through the PMS (refer to section 8.2 below).
7.
OTHER STARTING PROCEDURES
7.1
BASIC PROCEDURE FOR STARTING THE BOILER SYSTEM
The following are basic steps that must be followed in accordance with the manufacturer’s recommended procedures (MB902923-800 / 4059-FD-00206699) for starting with reference to STARBOARD Boiler, 55-FB-8101 (Applicable also for PORT Boiler, 55-FB-8201): 1. 2. 3.
4.
5.
6.
7.
8. 9. 10. 11. 12.
7.2
Ensure that the vent valve on the boiler (55-FB-8101) is open and check there is no pressure in the boiler. Check that the steam stop valve (55-GB-8134) is closed. Check that all the valves for fuel are open and let the fuel circulate through the system (refer to doc. nos. 4059-XB-00191528.001/00191648.001) until it comes to the required temperature (MDO: ambient / Fuel Gas: 30~40°C). Check and open the feed water valves (55-GB-8131 & 55-GB-8132) to the boiler and fill the water inside the boiler drum to just above the low water level. This is done because it is not possible to start the boiler below the low water level due to safety feature which prevent boiler from starting. Also, the level is not filled much because if filled too much, the water inside the boiler might expand and over pressurize the boiler. Start the boiler in automatic mode. The Combustion Air Fan (67-KE-8201) will start the purging cycle which will remove any gases present in the furnace by forcing it out through the funnel. After the pre-set purge time (not less than 5 minutes) the pilot burner (55-IG-8101) will ignite. The pilot burner consists of two electrodes, through which a large current is passed, via a high-voltage step-up transformer, producing the spark between the electrodes. The pilot burner will ignite on a pre-selected fuel (either MDO or Fuel Gas or both). The main burner which is supplied by a pre-selected fuel catches fire with the help of pilot burner after which the Boiler will operate automatically according to the selected mode of operation. Check the combustion chamber from the sight glass (as well as in the Boiler Control System screen) to ensure the burner has lit and the flame is satisfactory. Keep a close eye on the water level (55-LT-8101/8102) as the pressure increases and open the feed water when the level of water inside the gauge glass is stable. Close the vent valve after the steam starts coming outside. Open the steam stop valve (55-GB-8134). Once the working steam pressure is reached, blow down the gauge glass and float chambers to check for the alarms.
ENERGIZATION OF 80-ET-4001A/B and 82-EN-4001A/B NORMAL SWITCHBOARDS
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Project: FPU for Terang Sirasun Batur Field Dead-ship Start-up and Black-out Restart Procedures 1. 2.
3.
4. 5.
Doc. No: 1182090 Rev. D
At 82-EN-4001A/B 440 V Normal Switchboard, confirm all ACB’s are in the ‘OPEN’ position (including the Bus-tie and the Tie Feeder Breaker to the New Essential SWBD). Close 80-EH-5001A-cub.7 – Out-going Feeder to Transformer 80-ET-4001A. Confirm energization of the Transformer by monitoring correct secondary bus voltage on the PMS graphic. Close 80-EH-5001B-cub.14 – Out-going Feeder to Transformer 80-ET-4001B. Confirm energization of the Transformer by monitoring correct secondary bus voltage on the PMS graphic. Close 82-EN-4001A-S7-1 via the PMS, Confirm INC.1 closes by verifying the change in state on the PMS graphic and monitoring the bus-volts. Close 82-EN-4001B-S9-1 via the PMS, Confirm INC.2 closes by verifying the change in state on the PMS graphic and monitoring the bus-volts.
The 440Vac Normal Switchboards 82-EN-4001A/B are now independently available. Normal consumers for the Process Systems can be started.
8.
8.1
SPECIAL RECOMMENDATIONS
Standby Personnel In the event of a power system outage and where intervention from the ICSS is not immediately available, it is recommended that Operations EIT personnel shall be on stand-by to provide additional support in order prevent prolonged delays to the re-starting of equipment.
8.2
Purge Sequence for running Fuel Gas Compressors The Solar Turbine Fuel Gas Compressors are equipped with a ‘Thermal Lock -out’ protection scheme which when activated will prevent the machines from being re-started for 4-hours unless the Purge sequence is initiated. If not available within the ICSS, this function shall be manually activated.
8.3
Black-out /Dead-ship Restart with only one DG available This scenario is foreseen when one of the two DGs is under maintenance. The largest motor to be started during the restart is the 150kW Boiler Combustion Air Fan. The starting of this motor was simulated with all possible non-essential loads shedded but the voltage dip (22%) during starting exceeds the Class requirement of 20% or less. To make this scenario possible, soft-starter was provided for each of the two Boiler Combustion Air Fans (67-KE-8101 and 67-KE-8201). With soft-starter, simulation shows that voltage dip during starting was less than 18%. The simulation was done using ETAP Electrical Engineering Software version 7.5.0C.
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