001 gas turbine generator commissioning procedure

Procedure

Title Gas Turbine Generator Commissioning Procedure

Doc ID: TIS-CS-GT-G-01 REV: 5 Date 18 JUN 08 of 62

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

Procedure



DO NOT PROCEED WITHOUT THESE DOCUMENTS

References: Obtain a copy of the as-built drawings.

Document Number Rev Title

Turbine Controller

Control Schematic

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

Procedure



Table of Contents 1.0. Safety Review ..................................................................................... 4

2.0. Panel Power-up Checks ....................................................................... 5

2.1. Visual Inspection ........................................................................................................ 5

2.2. Control Panel Power-Up Checks ................................................................................... 5

2.3. DC Power Circuits ....................................................................................................... 6

2.4. AC Power Circuits ....................................................................................................... 7

2.5. 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 Electro-hydraulic actuator Tests ............................................................................. 20

4.2. Off-line Running Checks .......................................................................................... 28

4.3. Synchronization Checks ........................................................................................... 41

4.4. Turbine On-Line / Load Checks ................................................................................ 48

4.5. Shutdown Checks .................................................................................................... 59

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

Procedure



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.

Procedure



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.

Procedure



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.

Procedure



DC Power Sub-Circuits (24Vdc)

Refer to the DC Panel Power Distribution sheets of the Turbine Controller drawing.

Record data

Check Completed

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.

Record data

Check Completed

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\

Procedure



Record data Check


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.

Procedure



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


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

Record data

Check Completed

Completed by / date

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.

Procedure



Test the „Fail-Safe Solenoids‟

The term „fail-safe solenoid‟ describes any solenoid that is required to be independently de-energized 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:

Procedure



Solenoid Check Completed

Completed by / date

Procedure



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


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:

Procedure



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


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


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.


Verify RTD is reading ambient.

Procedure



3.5 Analog Inputs

Use the following procedures as a guide and verify each current analog input in the IO list.

Record data Check


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.


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 4-20mA 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.

Procedure



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


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 de-energized state, e.g., the NC contacts are closed when the relay is de-energized.

Procedure



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


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)

Procedure



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

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

Record data Check


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


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

Select Auto.

Procedure



Record data Check


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.

Procedure



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.

Procedure



Actuator LVDT/RVDT Calibration

Record data Check

Completed Completed by

/ 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.

Procedure



Record data Check

Completed Completed by

/ 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


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

Procedure



ACTUATOR NAME:

DEVICE

TAG

Position Reference

Position Feedback on HMI

Mechanical Position

Meter mA Servo Volts

Vdc

LVDT Primary

Volts

Vrms

LVDT Scdy. Volts

Vrms


CLOSED

OPEN

ACTUATOR STROKE TEST

100%

75%

50%

25%

0%

ACTUATOR NAME :

DEVICE

TAG

Position Reference


Mechanical Position


Vdc

LVDT Primary

Volts

Vrms

LVDT Scdy. Volts

Vrms


CLOSED

OPEN


100%

75%

50%

25%

0%

Procedure



ACTUATOR NAME:

DEVICE

TAG

Position Reference


Mechanical Position


Vdc

LVDT Primary

Volts

Vrms

LVDT Scdy. Volts

Vrms


CLOSED

OPEN


100%

75%

50%

25%

0%

ACTUATOR NAME:

DEVICE

TAG

Position Reference


Mechanical Position


Vdc

LVDT Primary

Volts

Vrms

LVDT Scdy. Volts

Vrms


CLOSED

OPEN


100%

75%

50%

25%

0%

Procedure



ACTUATOR NAME:

DEVICE

TAG

Position Reference


Mechanical Position


Vdc

LVDT Primary

Volts

Vrms

LVDT Scdy. Volts

Vrms


CLOSED

OPEN


100%

75%

50%

25%

0%

Procedure



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%

Procedure



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%

Procedure



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.

Record data

Check Completed

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.

Procedure



Record data

Check Completed

Completed by / date

No. 1 Magnetic Pickup Speed (Hz):

No. 1 Magnetic Pickup Voltage (Vac):







No. 5 Magnetic Pickup Voltage (Hz):




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

Procedure




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

Record data Check




















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

Procedure



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 start-up 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.

Procedure



GAS FUEL IGNITION CHECKS

Record data Check


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)


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

Procedure



Gas Fuel Firing Test


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.

Unit Type Expected Gas Manifold

Pressure

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.

Procedure



GAS FUEL FIRING CHECKS

Record data Check


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



Procedure



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


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%.

Procedure



Record data Check


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.

Procedure



Metering Valve Liquid Fuel Check


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.

Procedure



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.

Record data Check


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

Manufacturer Model

Start-up Fuel

Gas Liquid

Flow Nozzle

Pressure Flow

Nozzle Pressure

GE Frame 5 2.5 gpm

GE Frame 7

Procedure



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.

Procedure



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.

Procedure



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


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.

Procedure



Record data Check


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 in-phase 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 in-phase when the buses are actually in phase.

Procedure



Record data Check


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 in-phase when the buses are actually in phase.

Remove the high voltage test sticks.

Procedure



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


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.

Procedure



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


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.

Procedure



Automatic Synchronizing Circuit

Before performing this check, ensure the phase rotation is correct and complete the manual synch checks.

Record data Check


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.

Procedure



Record data Check


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.

Procedure



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 Form Number

GE Frame type FM-OD-GT-G-FR-001

Pratt & Whitney FT4 FM-OD-GT-G-GG-001

Check Completed

Completed by / date

Synchronize the generator to the electric grid

Meter Display Checks

Record data

Check Completed

Completed by / date

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

Procedure



Load Control and Base Load Checks

Check


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.


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.


At the Turbine Control Panel display of the HMI, select BASE load. Verify the machine goes on temperature control.


Procedure



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.


Procedure



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.

Procedure



Megawatt Control Checks


These checks are to verify the megawatt control function of the controller. Record and investigate any alarms that occur during testing.


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.

Procedure



VAR Control Checks


These checks are to verify the VAR control function of the controller. Record and investigate any alarms that occur during testing.


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.

Procedure



Power Factor Control Checks


These checks are to verify the power factor control function of the controller. Record and investigate any alarms that occur during testing.


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.

Procedure



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.

Procedure



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.



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.

Procedure



Emergency Load Control Checks


These checks are to verify the emergency 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.



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.

Procedure



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.

Procedure



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

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

Record data

Check Completed

Completed by / date

Adjust the scheduled cooldown time to start shortly.

Verify that the rotor cooldown mechanism starts and runs for the scheduled amount of time.

Procedure



Final Operating Data

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

Procedure



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

Procedure



NOTES

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

001 gas turbine generator commissioning procedure

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