Commissioning of Combined

Cycle Power Plants Part 1

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This is the first in a series of four articles on the commissioning of combined cycle
plants. This article covers the preparatory work, normally conducted in the office of
the architect/engineering firm, before the startup team goes to the job site. 1
Introduction
Phases of a New Plant The creation of a new power plant moves through the
following phases:

 Contract negotiation
 Design
  Procurement
 Construction
 Startup/commissioning
 Operation

The startup phase is a crucial and final quality check of the previous phases. Any
previous mistakes or omissions which have been overlooked will be uncovered.
Problems which are brought to light during commissioning can be very expensive to
correct. The procurement and delivery of new equipment during the startup phase
can be costly. To commission a plant, experienced startup personnel are necessary,
since they have acquired the skills to implement the various programs that are
discussed in this article. Types of Plants to Discuss
A typical combined cycle power plant has two dual-fuel combustion turbine
generators, two heat recovery steam generators (HRSG’s), and one steam turbine,
with a hydrogen-cooled generator. Duct burners may be specified to compensate for
megawatt production shortfall during non-isometric conditions. The total output of a
typical combined cycle plant is approximately 500 MW. In this article, the term
“combustion turbine” will be used, rather than “gas turbine,” because many facilities
do not use fuel gas, but rather a liquid fuel. Many simple cycle combustion turbine
generators are also being commissioned at the present time. In addition, various
chemical plants, refineries, and process plants are adding combined cycle power
plant additions to their facilities. 2 Work in the Office
Assignments
The nucleus of the commissioning crew should be brought onto the project in the
early design stage. The startup manager and the lead discipline engineers should be
drafted to work in the office of the architect/engineering firm. They can assist in
design review, and, while in the office, they can prepare the startup deliverables.
Contract Review
The startup manager will review the project contract to identify the project
deliverables in his scope of responsibility. The schedule dates for the milestone
activities should be ascertained. Deliverables
The following are examples of typical contract deliverables that may be included in
the commissioning scope:

 Commissioning schedule
 System turnover packages
 Commissioning organization chart
 Manpower schedule
 Commissioning procedures
 Lockout and tag out program
 List of chemicals
 List of lubricants
 Startup consumables list
 Operating procedures
 Training program for operators and maintenance personnel
 Emission guarantee procedures (air permit)
 Heat balance guarantee procedures
 Plant acceptance testing procedures

(Note: On some projects, the last three items are prepared by the
architect/engineering firm.) Budget
The startup manager will review the budget for the commissioning effort, and will
prepare the estimate that keeps the commissioning effort within the budget and still
meets the contractual obligations. Some of the costs that will be considered are the
manpower, vendor representatives, and equipment. The scope of subcontracts can
be adjusted by self-performing some of the activities, to keep the budget costs
lower. The cost structure for field personnel should be developed, as well as the
various expenses (transportation to and from the jobsite, per diem, R&R breaks, and
living accommodations at the field location). Project Review
While in the office, the commissioning personnel can utilize their unique perspective
to review the design of the project. They can critique the piping and instrumentation
diagrams (P&ID’s), electrical one-line diagrams, vendor manuals, and other related
documents. They can interact with the design personnel, and develop relationships
which will promote problem solving during the difficult startup phase ahead. They
can review project drawings and documents for commissioning feasibility, system
operability, and maintainability. The architect/engineering firm will also produce
lists, such as equipment lists, valve lists, instrument lists, and line (piping) lists,
which should be collected by the commissioning crew for later use. Commissioning
Manual
The commissioning program is detailed in the Commissioning Manual, which should
be distributed to all project organizations. Cleaning Procedures
The cleaning of systems should be conducted in accordance with approved
procedures. The equipment and pipes must be cleaned to the level required for their
service. The procedures are included in the Commissioning Manual, and become
part of the respective system turnover package when the procedure is completed.
Commissioning Procedures
Each individual system should have a commissioning procedure which demonstrates
that the system has been placed into operation within design parameters. The
procedures are included in the Commissioning Manual, and become part of the
respective system turnover package when the procedure is completed. Schedule
The startup manager reviews the project schedule to identify activities and
milestone dates. The milestone schedule activities that are evaluated by the startup
manager are:

 Back feed power, or temporary power for startup testing

 HRSG chemical cleaning
 Air blow or steam blow of the steam piping
 DCS loop checks
 First fire of the combustion turbines
 Initial roll of the steam turbine
 Synchronization of the generators
 Full load testing
 Commercial operation date

Each system turnover package is integrated into the project schedule. The
commissioning schedule logic is tied to the construction schedule logic through the
turnover packages. When construction completes a system, the turnover package is
issued and the commissioning work begins. The commissioning portion of the
project schedule has the same outline as the commissioning work: the individual
components are inspected and tested, then the system is tested by itself, then the
combustion turbine is started, and finally the entire plant is operated and tested.
Most projects use scheduling software to track the project schedule. Commissioning
personnel can nowadays easily build and modify their own startup schedules that
can be linked to the construction schedule. The predecessor and successor
relationships, total float, constraints, and resources are some of the schedule
parameters that should be analyzed. Matrix of Responsibilities
The startup manager must identify the specific responsibilities of each party in the
project (the design organization, the construction team, the commissioning team,
the plant owner, the operators, etc.). The project management should approve and
implement the division of responsibilities. The matrix of responsibilities is included
in the commissioning manual. The plant owner is normally responsible for reviewing
and approving the commissioning data and results. The startup manager must
identify the process for the review and approval. Vendor Representatives
Some equipment may require the assistance of vendor representatives during the
commissioning phase, to bring their expertise and also to protect product
warranties. The startup manager will review the vendor representative requirements
and make arrangements for the vendors to arrive at the job at the correct time. The
representatives for the following equipment may be required:

 Heat recovery steam generators

 Duct burners
 Soot blowers
 Stack dampers
 Auxiliary boiler
 Emergency or black start diesel generator(s)
 Fire pumps
 Fire detection and suppression systems
 Water treatment equipment
 Chemical feed systems
 Feed water pumps
 Gas compressors
 Steam and combustion turbine generator sets
 Continuous emissions monitoring (CEM)
 Distributed controls system (DCS)
 Programmable logic controllers
 Power transformers
 High voltage oil-filled cables
 Switchgear
 Switchyard equipment

Some projects may have special equipment requirements, which necessitate a

vendor representative, but other projects do not need the vendor. Experienced
startup personnel can commission many pieces of equipment without the vendor
assistance. Additional Items to Review
Some additional programs or activities which the startup manager should review
while in the office:

 Commissioning water program (based on the source of water, destination of

waste water, recycling water during commissioning, waste water limitations,
and water permits.)
 Fuel specifications
  Fuel consumption (at some plants, the client needs to know the anticipated
consumption during commissioning, to make bids for fuel)
 Craft support requirements
 Maintenance program, in accordance with the vendors’ literature
 Interface-points between the new plant, outside utilities, or an existing plant
 Government or insurance company inspectors required for testing safety
valves, fire detection/protection systems, etc.

Equipment to Purchase or Rent

Before going to the job site, the startup manager should make the following
requisitions or rentals (per the contract requirements):

 Chemicals
 Lubricants
 Test equipment
 Chemical analysis equipment
 Tools (mechanic’s tool set, electrician’s tool set, packing removal tools,
rigging gear, air conditioning tool set, valve wrenches of all sizes)
 Storage container for tools
 Storage container for equipment which has been temporarily removed from
the plant
 Temporary pumps, hoses, plastic tubing, and fittings
 Spare parts (mechanical seals for pumps, DCS cards)
 Consumables (gaskets, packing, light bulbs, fuses, panel lenses, etc.)
 Solvents to dissolve grease or remove rust
 Truck(s) for hauling equipment and personnel on jobsite
 Office space, office equipment, furniture, supplies, telephones, fax machine
 Computers, printers, and software for the commissioning office
 Radios (and frequencies), antennas, base stations, and repeaters for onsite
communication
 Transportation requirements for personnel (automobiles, vans, and drivers for
international locations)

The startup manager needs to determine who is responsible for supplying the
various chemicals and lubricants. On some projects, the commissioning team is
responsible for supplying the first load of chemicals and/or lubricants, and the plant
owner is responsible after that. If the architect/engineering firm does not produce
their own lubrication list, the startup manager may be able to have one of the well-
known oil companies produce a lubrication list for the project, as part of their scope
of supply. It is more cost effective to rent the more unusual test equipment for a
limited time, and to purchase the normal, everyday type of test equipment. The
schedule for the full-blown commissioning effort occurs at a time when the
construction team is winding down their manpower and equipment, so you cannot
always rely on them for support in areas like tools and consumables. The startup
manager should therefore plan on purchasing or renting a full repertoire of tools.
Some tools, like welding machines, rigging equipment, and scaffolding, may be
supplied by the construction team, at least for the beginning of the commissioning
effort. On some projects, there has been considerable time lost because the right
gasket was not available, or maybe the pipefitters needed a 2 1/8” slugging wrench,
or no more fuses were left for the DCS input circuits. The commissioning team that
prepares all the necessary consumables and tools will not have those costly delays.
Some seemingly insignificant tools can be very important during a startup. A fin
comb, for example, can straighten out the fins on an air conditioning condenser
before a walk down, and therefore avoid unnecessary punch list records. Safety
Safety equipment, such as eye wash stations, safety showers, breathing apparatus,
respirators, etc. should be ready for use during the system commissioning, as
conditions warrant. If the permanent safety equipment is not yet available,
temporary equipment can be purchased or rented. Safety signs and warning
beacons must be in place, and the workers in the area should be trained in the
identification of safety hazards and the remedial actions in case of an incident or
accident. Permits should be used for confined space entry, in order to have the
proper equipment for monitoring the safety of the atmosphere in the vessel, and to
have the required standby personnel to monitor those in the vessel. Material Safety
and Data Sheets must be available onsite for all the hazardous chemicals used
during the startup. Work permits are used to allow construction personnel to work
within the boundaries of a system that has been turned over to startup. Special
attention should be placed on “hot work permits,” where any welding, cutting, or
grinding will occur. The safety tagging program (lock out and tag out) is the
principle means of preventing injury to personnel or equipment when the systems
have been energized. Figure 1

Commissioning of Combined
Cycle Power Plants Part 2

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This is the second in a series of four articles on the commissioning of combined

cycle plants. This article covers the beginning of the field work for the startup team,
from the point of the system turnovers from construction to the component testing.
1 System Turnover (from Construction to Commissioning)
Turnover Packages
The construction team builds the power plant by area (for example, the Fuel Storage
Area).

Figure 1
The construction equipment, such as a welding machine, is most efficiently used by
completing one area at a time and concentrating on the bulk work. As work
progresses, the construction team should change their focus to the completion of
systems (for example, the Fuel Oil Heating System, the Fuel Oil Unloading System,
and the Fuel Oil Forwarding System). When system construction is complete, the
construction team prepares a turnover package for each system. Early in the
project, the startup manager provides marked-up engineering drawings, P&ID’s, and
electrical one-line diagrams, which depict the boundaries of each system and the
equipment included. These drawings are the “system scoping drawings.” The
drawings identify all the equipment, pipes, cables, and instruments that are in each
system. On some projects, where computerized databases of equipment are
available, the lists can be coded for the respective systems and may be included in
the turnover package. The system scoping drawings and completed test documents
are assembled into a turnover package. The startup manager also provides a
schedule that specifies the target date for each system turnover. When the
construction team is satisfied that a system is ready for turnover, the system
turnover package is submitted to the startup manager for review. Any incomplete
construction items are noted in the package documentation. Those work items are
completed later, under the commissioning work permit program. System
Walkdown
After the startup manager reviews the turnover package, a joint construction and
commissioning walkdown of the system is scheduled. The walkdown verifies that all
work within the boundaries is complete. Any incomplete work is noted in the punch
list. Punch List
The punch list contains individual records for each deficiency noted. It lists the
respective system, the component tag number and description, a definition of the
discrepancy, the work group responsible for fixing the deficiency, the dates that the
item was generated and closed, etc. The punch list is sorted by the system
designator, using the same designators as the turnover packages. On some
projects, there is a tendency for each organization to keep their own punch list, but
those projects that combine the punch lists into one integrated list seem to
complete the work faster. A single project punchlist allows for better scheduling of
equipment and manpower, which allows for the work to be completed faster or in a
way that better supports the overall schedule. The punchlist should be kept in a
database program. On many projects, the punchlist is kept in a word processor file
or a spreadsheet file. But those applications do not have the sorting and report
capability of a database program. It definitely takes more effort to establish a
database format, but it allows much more flexibility. With the database, you can
quickly present to a work group a customized list of only those items that they are
responsible for fixing. You can also print customized lists of items belonging to one
system, for inclusion in system turnover packages. Although it seems tedious, it is
not a good idea to put multiple items within one record, because it is difficult
sometimes to determine which ones are closed. 2 Component Testing
Responsibilities
On some projects, the construction team performs some or all of the component
testing, and on other projects, the commissioning team performs some or all of
them.
Nameplate Data
Before testing any component, the nameplate data on the equipment should be
verified against the design documentation. Test Specifications
Equipment should be tested to the applicable specifications of the project. The
architect/engineering firm usually lists the technical specifications for equipment
and systems. In some cases, the project contract requires that equipment be tested
to various standards, such as the American National Standards Institute (ANSI),
American Petroleum Institute (API), National Electrical Manufacturers Association
(NEMA), or other programs. In other cases, the vendor’s specifications are the
testing criteria. Lubrication
Equipment must be properly lubricated before it can be commissioned. The field
personnel follow the manufacturer's instructions in the vendor manual. Equipment is
sometimes received with a factory-installed lubricant, which protects the equipment
during shipping and storage. The field personnel must replace this lubricant with a
charge of the normal lubricant. While the rotating equipment is in the warehouse, it
is a good idea to follow the recommendation of the various vendors, and rotate the
equipment by hand periodically. This ensures the shafts don’t become bowed, and
keeps lubricants in the bearings. All lubrication documents are inserted into the
turnover package. Flushing
Flushing is conducted on the following systems:

 Lubricating oil (using oil as the flushing medium)

 Fuel oil (using fuel oil as the flushing medium)
 Hydraulic oil (using hydraulic oil as the flushing medium)
 Cooling water (using water as the flushing medium, or at some projects the
system is chemically cleaned)
 Raw water and service water (using water as the flushing medium)
 Fire protection (using water as the flushing medium)
 Feed water and condensate (sometimes chemically cleaned)

When flushing a piping system, the startup engineer must be vigilant to spot
potential flushing problems early. If possible, the pipes should be inspected prior to
fit up, to guarantee there are no foreign objects in the pipe. Water and oil piping
systems are usually flushed using the installed pumps. In some cases, temporary
pumps of high volume are used during the flushing. Over the past few years, high-
pressure water has been used, with special lances and nozzles, to blast debris and
rust from pipe interiors. This technique has been successfully employed as a
prelude to steam blows or air blows on steam piping. Depending on the nature of
the debris, flush water may be considered a hazardous waste. At some facilities,
where there is a shortage of water, the flushing water has been recycled by
temporary filtration and ion exchange. Some modifications may be required to
prepare the system for flushing. Temporary piping jumpers are installed to avoid
pumping debris into heat exchangers or control valves, and to avoid putting flushing
oil into bearings. Before flushing, all orifice plates, control valves, or other
restrictions must be removed. Sometimes, a check valve needs to have its disc or
plug removed to allow flow in the opposite direction. All modifications should be
recorded, so that the corresponding restoration can be verified. The restorations
following the flushing should be recorded. A “bag and tag” procedure can also be
implemented so that all equipment, which has been removed, gets installed again.
When installing orifice plates, verify the correct tag number, dimensions, type, and
orientation. Make sure control valves are re-installed in the proper orientation. As
the system is restored following the flushing, verify the proper type and size of
gaskets are installed at each location. Valves
Valves should be inspected prior to system flushing, and should be monitored
during the period of initial operation. The manual valves must be inspected, in
addition to the air, motor, or hydraulically operated valves. Packing glands should
be adjusted, but tightened only as necessary to preclude leakage. Every check
valve must be inspected to insure the flow is in the correct direction. Some globe or
plug valves also have a flow orientation, which must be observed. Look for the
arrow or marking that indicates the direction of flow. Pumps
The correct direction of rotation of the pump and the driver should be verified.
Usually there is an arrow on the equipment, but sometimes you need to check the
vendor drawing. Review the vendor manual for any special operating characteristics
or additional hardware requirements. Make sure that the associated support
equipment is installed properly before starting the pump (cooling water, seal water,
seal leak-off, vents, coupling area drain pipes, etc.). Run the pump on the minimum
flow recirculation line, if there is one, with the minimum flow valve open, or spool
through the minimum flow valve with a temporary spool piece, if the minimum flow
valve is an automatic control valve. After the minimum flow recirculation line is
flushed, the line can be placed in service. Run the pump as necessary to flush the
system. During the flushing, after some time of regular operation is achieved, the
pump performance and vibration data can be collected. Pumps should be tested in
accordance with a standard test program (such as ASME Performance Test Code 7.1
or 8.2, or the Hydraulic Institute Standards). For centrifugal pumps, the capacity
versus the head is compared to the pump curve, which was developed during the
factory shop test. Verify the pump meets or exceeds the design point. Positive
displacement pumps should be tested for the capacity measurement by volume rate
of flow. Lubricating Oil Flushing
The site personnel may flush the combustion turbine and steam turbine lubricating
oil systems. The area around the turbine should be free of dirt and construction
debris (especially the reservoir and bearing areas). Temporary power and lighting
must be available. Several strategically located emergency lubricating oil pump
shutoff switches should be installed. Fire protection equipment must be available.
Although it seems like it would be very unusual to have a fire during a lubricating oil
flush, it has indeed happened in the past. Also, make provisions for dealing with oil
spills and leaks (have sufficient adsorbent compound, rags, plastic bags, squeegees,
and barrels on hand). Personnel should be trained to handle oil spills. At some
plants, a subcontractor, using temporary flush skids with pumps, filters, and heat
exchangers, performs the lubricating oil flushing. Some bigger pumps, like feed
water pumps, have an integral lubricating oil system. These systems are generally
cleaned in a manner similar to that used on the turbines. Heat Exchangers
When flushing the system, it is preferable to bypass any heat exchanger, to prevent
debris from entering the exchanger. Because the flow rate drops in the heat
exchanger, the debris might not ever come out, and it can affect the heat transfer
of the heat exchanger. One end of the heat exchanger is bolted down, and the other
end is free to travel, for thermal expansion. Check the hold-down bolts during the
initial inspection. This check must be performed even for huge heat exchangers, like
air-cooled condensers. Chemical Cleaning
Chemical cleaning of the HRSG’s takes place after hydrostatic testing. The boiler
waterside surfaces, condensate, and feed water piping will normally be chemically
degreased. At some plants, the additional step of acid cleaning is also employed. A
chemical cleaning subcontractor, who will supply the necessary chemicals,
equipment, and manpower, customarily performs the chemical cleaning of the boiler
and related piping. Equipment typically supplied are the circulating pumps, portable
boiler, heat exchangers, duplex filters, chemical mixing tanks, water and chemical
storage tanks (sized to store several hundred thousand gallons), and temporary
piping for fabricating flush path jumpers. Water and chemicals are introduced into
the boiler and related piping, heated in the temporary heat exchanger, and then
circulated by means of temporary jumper piping and the temporary pump. The
chemistry of the cleaning solution is closely monitored to ensure the proper
chemical reactivity. The safe and economical disposal of chemical cleaning effluent
is an important consideration in planning this activity. The waste water amounts to
several hundred thousand gallons, including the rinse water. Air Blow vs. Steam
Blow
Steam and gas piping systems are cleaned using the normal medium (steam or gas)
or by using a substitute medium (for example, compressed air). In order to properly
clean such piping, it is essential to develop a momentum that exceeds the
momentum encountered during normal operation. The measurement of this
cleaning is referred to as the Cleaning Force Ratio (CFR), or the Disturbance Factor

(DF),
where:
Wb = Mass flow rate during the blow,
Wn = Normal mass flow rate,
Vb = Specific volume during the blow,
Vn = Normal specific volume.
Calculations determine the “start” and “stop” pressure for each blow. Pressure
readings taken during the blows ensure that the momentum will meet or exceed the
CFR goals. Cleanness may be confirmed by placing a target in the outlet of the
piping, and evaluating any impacts, or “hits.” The target is made from polished mild
steel or copper. The steam turbine vendor specifies the number and size of
allowable impacts. Air blow and steam blow are generally considered equally
effective in removing pipeline debris and mill scale (although there still seems to be
some debate over the issue). The pro’s and con’s of the two processes are:
Air blows (pro):
Air blows can take place immediately after the HRSG and steam piping is
hydrostatically tested. This takes the air blow off the critical path of the schedule.
Air blows (pro):
Air blows do not use any water. Air blows (con):
Air blows require expensive compressor rentals and extra manpower. Steam blows
(pro):
Steam blows do not require extra equipment rental. (Both air blows and steam
blows require temporary piping, silencers, and valves.) Steam blows (con):
Steam blows can be done only after first fire, and only after the steam and
condensate cycle is operational. This puts the steam blow squarely on the critical
path of the schedule. The steam blows also require piping insulation to be installed.
Steam blows (con):
Steam blows use very large quantities of water. Where permanent demineralizer
water production is not sufficient to sustain the steam blow, expensive portable
demineralizer rentals are required. Temperature Cycling
This is the core of the debate on air blow vs. steam blow. The steam blow
proponents argue that it is only by flexing the pipe, through repeated heating and
cooling, that the mill scale is removed. Air blow proponents argue that a proper
disturbance factor ensures the mill scale will be scoured. As indicated previously,
high-pressure water has been used, with special lances and nozzles, to blast mill
scale, debris, and rust from pipe interiors. This technique has been successfully
employed as a prelude to steam line cleaning. On one project that had two identical
units side-by-side, one plant was cleaned by air blow and the other by steam blow.
The cleanness results were identical. On both air blow and steam blow, the
respective techniques must be performed accurately for good results. Depending on
the plant configuration, it may be beneficial when conducting air blows to connect
unrelated systems together to form a larger reservoir of air. This produces longer air
blows. For example, at one very large chemical plant, the product line was
combined with the main steam header to produce a reservoir of much larger size.
Motors
The internal heaters on large motors, generators, and motor-operated-valves should
be energized with temporary power. On projects which have a long duration, the
heaters may be energized in the warehouse or laydown area. Large motors and
generators are megger-tested during the construction period to verify insulation
integrity. A megger test instrument introduces a moderately high voltage into the
motor windings. Any winding insulation breakdown that permits winding-to-winding
shorts, or winding-to-ground shorts is detected by the megger instrument. Electric
motors should be tested uncoupled from the driven component to verify proper
motor rotation and operation. Cables, Switchgear, and Motor Control Centers
All cables and switchgear/MCC buses are tested prior to energization. Cables are
tested for continuity and insulation resistance. The megger test instrument
introduces a moderately high voltage (500 or 1,000 Volts) to detect any shorts to
ground that may be caused by an insulation breakdown. For switchgear and MCC’s,
hi-pot testing (using very high voltage) to test high voltage feeders and
switchgear/buses requires special test equipment. The design engineer typically
provides hi-pot test acceptance criteria. Breakers and switches should be tested in
accordance with the vendor instructions. Transformers and Switchyards
Transformer and switchyard tests are performed according to the manufacturer’s
instructions. Transformers, bushings, circuit breakers, and disconnect switches are
commonly inspected and tested by a subcontractor. Oil-filled transformers, HV
bushings, and circuit breakers may require conditioning of the insulating oil to
remove vapors and water. Special equipment is required for this conditioning and
testing process, and normally a subcontractor is hired to process the oil. Electrical
Meters and Relays
Power transformers, switchyard equipment, generators, switchgear, and load
centers are protected by sophisticated relay systems. If the protective relays detect
faults, they will re-route or trip the circuits in order to protect personnel and
equipment. Meter and relay testing must be coordinated with the local utility, for
those circuits that interact with the utility grid. Plant power output and utility-
supplied power input are metered for performance and billing data. Special
equipment and expertise is required for setting the meters and relays. The design
engineer specifies the relay settings, testing requirements, and acceptance criteria
by means of a relay coordination study. A subcontractor often tests the circuits.
Instrumentation
The field instrumentation devices must be calibrated and installed prior to
commissioning. Instrumentation devices are initially inspected and calibrated in the
shop, but final calibration often takes place in the field, in the installed
configuration. Calibration set points are provided by the design engineer, or by the
vendor. Calibration stickers are affixed to the instrument after the field calibration is
successfully completed. Loop Checks
A sensing instrument is tested by simulating a specific parameter, which is then
converted to an electrical signal and displayed on the control system graphics.

Figure 2
The displayed parameter, scaling, and engineering units are confirmed at the panel
display. The transmitter is then tested through a range of settings and certified as
accurately tuned. Many input signals to the plant control system are used to control
various system processes. For example, the input signal above may be used as an
output signal to control a valve. The architecture of this input and output (I/O) signal
configuration is known as a loop. There may be thousands of loops in a combined
cycle plant, with the total number dependent upon the design philosophy and
degree of automation. Alarm, runback, and trip signals are all functionally tested
during commissioning
Commissioning of Combined
Cycle Power Plants Part 3

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This is the third in a series of four articles on the commissioning of combined cycle
plants. This article covers the continuation of the field work for the startup team,
with the system commissioning, which energizes each system in the plant.
1 System Commissioning
DC Power and UPS System
The first electrical system to be energized during commissioning is the direct
current (DC) power system. Sometimes the project contract or specifications require
the DC system to be load tested. The commissioning team rents load banks for this
testing. The DC power system provides power to the switchgear circuit breakers,
equipment protective relays, and emergency pumps (such as the steam turbine
emergency lubricating oil and seal oil pumps). DC voltage also powers an
uninterruptible power supply (UPS), which supports the plant control system. During
commissioning, the DC system battery chargers are temporarily powered using
construction power. The battery room must be ventilated to exhaust hydrogen gas
developed during the charging process. An eyewash station must be available for
personnel safety. The battery room floors are coated with an acid-resistant sealer.
When the DC system distribution system is energized, testing of the AC switchgear
and associated relays may begin. Initial Plant Energization
The initial energization of switchgear is an important commissioning milestone.
Energization of large, high voltage equipment such as the switchyard or the
generator step-up transformer requires coordinated planning between the plant and
the public utility. A detailed procedure should be prepared, reviewed, and approved.
At some plants, due to the project schedule, back feed power cannot be achieved in
time to support the commissioning effort. Large diesel generators and transformers
can be rented to provide temporary power. Distributed Control System

Figure 1
Typical steps in the checkout of the distributed control system (DCS):

 Inspect and inventory the hardware

 Check the ground connection
 Clear any grounds
 Energize, but with no terminations made
 Energize each processor and check status
 Load software
 Setup the human machine interface (HMI)
 Perform component and functional checks
 Verify data historian hardware and software
 Establish communications between the DCS and the other control systems,
such as the combustion turbine controls, the steam turbine controls, the
CEMS, etc.
 As entire systems are placed in service, and the plant becomes operational,
the DCS personnel will perform “loop tuning,” where the control parameters
(proportional, integral, and derivative gains, or PID) are adjusted to achieve
optimum control. Schedule time should be allotted for this loop tuning.

Instrument Air
The first mechanical system to be started during commissioning is the instrument
air system. For complex air compressor configurations, the vendor should be
present to assist in the startup. The controls for the compressor should be verified
against the design. Moisture traps on the discharge of the air compressor should be
inspected very closely to make sure they are installed correctly. Review the vendor
literature. The air dryers, if they are self-regenerating, may take some time to
produce dry air. The system humidity indicator should be closely monitored for
proper indication during the initial operation. During the blowing of the system ’s
distribution piping, the air dryers should be monitored to prevent excessive flow
rates. The piping system must be blown out with dry air, and the drops to each
instrument should be cleaned vigorously. At add-on units where the existing unit
will provide the instrument air, the new plant undergoing commissioning may draw
more air than normal, because of the commissioning activities. This can jeopardize
the operation of the existing facility. In these cases, rented compressors and driers
may be necessary. Water Treatment
Normally, the second mechanical system to start is the water treatment system.
Modern water treatment systems can be very large, with complicated control
systems. The vendor representative should be expected to work with the
commissioning team until the system is running reliably in the automatic mode. The
chemical analysis equipment needed to monitor the systems should be made
available, and a suitable “laboratory” should be fabricated. At some projects, a
rented cargo container suffices for a temporary chemistry laboratory, with the
various utilities connected. The following items should be completed prior to adding
the resin to a demineralizer vessel:

 The interior portions of demineralizers should be inspected.

 The regeneration control sequence (valve stroking, pumps starts and stops)
should be thoroughly tested.
 The rinse water flow rates and chemical dilution flow rates should be
adjusted.
 An eductor should be purchased, since most vendors require that an eductor
be used to sluice the resin into the vessels.

Waste Water Treatment

When the water treatment system is started, there is a corresponding need to get
rid of waste water. Demineralizers and reverse osmosis units generate predictable
quantities of waste water. So the waste water treatment system is very important,
and should receive a high priority in the commissioning planning. At some projects,
waste water and solid waste export must be subcontracted. At some facilities, the
waste water treatment system can be quite complex, such as at a “zero discharge”
plant. This consists of multiple trains of reverse osmosis units, filtration systems,
evaporators, concentrators, and filter presses. Sometimes the influent water to the
plant is a “gray water” effluent from a nearby sewage treatment facility. Then there
are additional backwash filters, clarifiers, and filter presses. It is vital that the
manpower required to commission and maintain big systems like these not be
underestimated. Most plants incorporate some type of oily water separation. The
separating device should be tested early in the startup sequence, since invariably
there will be some oil to process. Fire Detection and Protection
The installation subcontractor normally tests the fire detection system, but the
commissioning personnel must monitor the testing closely, in order to become
familiar with the system. Fire protection systems, such as sprinklers, deluge valves,
and gas discharge systems may be tested by a subcontractor, or by the
commissioning team. Depending on the job location, a government inspector or an
insurance company inspector may need to witness the testing. Fire pumps should
be one of the first pumps to be placed in service, after the water supply system
makes water available. (At some plants, the fire protection water supply comes from
well water or raw water, while at other plants, the source may be a water treatment
system.) Monitor the jockey pump for frequent cycling, which may be an indication
that there is a leak in the fire main, perhaps underground. The motor-driven or
diesel-driven fire pump should be placed in the automatic mode as soon as possible.
If the cooling tower is fabricated from wood, the associated fire protection deluge
valves should be placed in service as soon as possible. Make sure that post indicator
valves have their indicators “calibrated” to show the correct position. Cooling Water
Circulating water systems that use seawater need special care during the
commissioning phase, due to the corrosive nature of seawater and the marine life
and debris associated with seawater. The rakes, traveling screens, tube cleaning
systems, and pump intake screens require meticulous care during the
commissioning phase, to prevent the introduction of debris into the condenser.
Large circulating water pumps must be aligned carefully and accurately. Depending
on the system design, the pumps may have a special valve that vents the air from
the discharge column. Seal water for lubrication of the pump packing may have to
be provided by a backup system. The pump discharge valve is normally motor-
operated, and its operation should be verified prior to starting the pump. The
condenser water boxes may have vent valves which must be opened and closed
manually when starting the system. If there is a water box priming system, it should
be commissioned and placed in service at the beginning of the program. If not, air
pockets will build up in the water boxes, and some tubes may not be filled with
seawater. Some plants require throttling of the outlet valves on the water boxes, to
setup the proper flow or pressure parameters. The water boxes may have sacrificial
zinc anodes. These anodes must be checked after the initial operation of the
system. The commissioning personnel must research these features prior to starting
the system. During the walkdown of the condenser, all the fittings should be
inspected closely, to make sure there are no materials installed that are non-
compatible with seawater. Cooling towers require special monitoring prior to use.
The spray nozzles, distribution headers, and fill should be inspected before starting
the system, and also sometime after the first use, to make sure there are no
problems created by the force of the water. Cooling tower fans should be checked
for vibration, and their gearboxes should be monitored for proper lubrication. If the
cooling tower has a place to mount corrosion coupons, the coupons should be
installed prior to introducing water. A wooden cooling tower should have its fire
protection system in service as soon as possible. Once a wooden cooling tower is
put in service, it should remain wet as much as practicable, so that it does not dry
out and become a fire hazard. Steam, Feed Water, and Condensate
After these systems are cleaned, as discussed above, they are prepared for service.
The condensate pumps are tested, along with their various control valves. Special
care is taken with the pump seal or packing. Some pumps require an external
source of seal water; the pump technical manual should be reviewed for this
feature. If possible, some spare seals or packing should be on the list of spare parts.
The condenser air removal system may consist of steam jet air ejectors, vacuum
pumps, or a combination of the two. The startup engineer must monitor the various
steam traps very closely, making sure they have free drainage to their destination.
Some traps on air ejector packages require a vent line back to the after condenser.
Some plants have a vacuum breaker valve, which requires seal water to prevent air
in-leakage. Make sure the seal water is installed. The condenser (or steam turbine)
rupture disc should be inspected closely prior to vacuum operations. Some discs
have to be installed in one particular direction. The area around the disc should not
be accessible for personnel. The deaerator should be inspected before use, to make
sure the trays are installed in the proper orientation, and that they are secure. The
spray nozzles should be left out, if not yet installed, or removed, if they have been
installed. The deaerator should be inspected after the initial round of flushing, to
remove any debris that settled in the storage vessel, and to install the spray
nozzles. The deaerator should receive a final inspection after the period of initial
operation, to check the spray nozzles and trays. The various types of feed water
pumps need customized care to ensure smooth operation. The pump suction
strainer is very likely to plug when first running the pump. The minimum flow valve
and any minimum flow orifice should be inspected to make sure they don’t cause
too much flow restriction for the pump. If the pump has an automatic recirculation
valve in the discharge, the valve should either be removed for the initial operation,
or (in some cases) a special “startup trim” installed for initial operation. Heat
Recovery Steam Generator (HRSG)
A few plants, which burn crude oil or some other heavy oil, have soot blowers. The
alignment of the soot blower is critical to their smooth operation. Also important is
proper lubrication. Some plants can run the combustion turbine solo, by means of a
stack damper and a simple cycle stack, then later put the exhaust through the
HRSG and out the main stack. The stack damper must be tested to ensure it
operates in simple cycle mode without allowing any leakage into the HRSG. HRSG’s
with horizontal tube bundles have recirculation pumps. Because they must operate
at all times, it is important to the commissioning team that the pump suction
strainers be easy to clean. The designers should avoid any in-line spool piece
strainers, since they require a longer time to clean. Sample Panels
Modern plants have sample panels, where sample lines are routed to centrally
located panels for analysis. The sample panels may measure conductivity, cation
conductivity, degassed cation conductivity, pH, sodium, hydrazine, dissolved
oxygen, silica, and other parameters. Too often, there is a push to put the sample
panels in service as soon as possible. But the steam and condensate systems can
be heavy with rust or debris during the initial startup, and the sample panel
equipment, with its tight tolerances, will get plugged with debris. At some plants,
temporary sample coolers have been installed, by running sample tubing through
55-gallon drums and using cooling water from a service water hose station, in order
to delay the use of the sample panels. Another helpful feature is a sediment pot
installed on the inlet of each sample connection. The pot’s large diameter in relation
to the sample tubing allows debris to settle to the bottom, where it can be blown
down. Sediment pots can be added to the sample panel design with minimal cost.
The maintenance of sample panels can be easily underestimated. They require
constant monitoring, chemicals, and calibrations. Fuel Gas
The introduction of fuel gas necessitates safety precautions, such as testing the gas
fuel piping flanges for leaks. This is done by wrapping each piping flange or joint
with masking tape, punching a small hole in the tape, and then positioning a hand-
held gas detector near the hole. (This leak testing is often preceded by leak testing
with air pressure, before the fuel gas comes into the battery limits.) The installed
gas monitor should be functionally tested using a calibrated gas. Gas fuel
temperature should be verified to be above the dew point temperature. If there is a
pressure letdown station, and there are liquid constituents in the gas, the expansion
of the gas causes the temperature to plummet precipitously, and freezing can
occur. Liquid Fuel
At some plants, a liquid fuel, such as distillate, is used as a backup fuel for the
combustion turbine, the auxiliary boiler, and the duct burners. The liquid fuel
system must be cleaned well, to prevent plugging of equipment with close
tolerances. Some liquid fuel tanks have floating suction devices. This hardware
should be inspected prior to filling the tank. Any special coatings in the tank interior
should also be checked. Siphon breakers on the tank should be disassembled, to
make sure there are no shipping stops in the valves. The liquid fuel unloading
station should be checked for proper spill containment and fire safety. Air
Conditioning and Ventilation
At many plants, the air conditioning and ventilation systems are seemingly
abandoned after their initial start, because they are “someone else’s” responsibility.
Therefore, a good commissioning team will monitor these systems, even if they are
in fact some other organization’s responsibility, because degradation of these
systems can have an adverse impact on plant performance. Replace air filters
regularly during startup. Use good quality pleated air filters, rather than the cheap
fiberglass types. The pleated air filters can take more abuse, and they keep your
system cleaner. Due to the dust and dirt at construction sites, air conditioning
condenser coils may need frequent cleaning. Condensate drains need to be directed
to a suitable location. Most units have a “p trap” on the condensate, to allow the
water to drain, but not allow un-filtered air to be drawn into the unit. If there are
troubles with the trap, it may cause water to back up in the unit. System Checkout
The remaining systems needed for running the combustion turbine and HRSG are
tested on a system basis. The equipment is energized, and the process fluid is put
into the system. The various control circuits are checked, to verify controls and
interlocks work as designed. Where possible, the system parameters are adjusted to
produce the various set points which cause the controls and interlocks to function.
For example, tank levels are raised and lowered to trigger alarms or trips, or system
valves are throttled to cause low flow or low pressure conditions. If a system has
heat tracing installed on its pipes or instrument lines, and the weather predictions
are for freezing temperatures, make sure the heating supply is ready and the
insulation is installed. The heat may be applied from steam or an electrical supply.
Combustion Turbine
In most plants, the commissioning of the combustion turbine itself is the
responsibility of the turbine vendor. They provide specialists in the various systems
of the turbine: the controls, the electrical systems, and the mechanical systems.
The lubricating oil flush is customarily one of the first activities, and has
traditionally been a milestone benchmark. Temporary power is used to power the
lubricating oil pumps for the flush. The oil should be purified before filling the
reservoir, since brand new oil shipments have been received with debris in the oil.
The turbine control systems also receive a temporary power supply, in order to
checkout the circuits early in the commissioning program. The aim of the system
commissioning period is to get the combustion turbine shaft rotating and ready for
firing. Steam Turbine
The steam turbine is also commissioned by the vendor’s personnel, who are
specialists in their area of responsibility. The steam turbine commissioning occurs
later in the schedule, so permanent power is usually available for the steam turbine
equipment. The lubricating oil flush of the steam turbine is conducted in a manner
similar to that of the combustion turbine. The goal of the system commissioning
period is to have the turbine shaft on turning gear, with gland sealing steam applied
and vacuum on the condenser. The steam turbine is then ready to admit steam.
Thermal Expansion
Before the initial heat up of the plant, the steam headers and other hot pipes will be
inspected. The spring hangers, supports, guides, will be adjusted according to their
design. During the initial heat up, the pipes and support devices must be inspected
very closely, to verify the proper direction and amount of thermal growth. (Example:
100 feet of schedule 80 carbon steel pipe, when heated up 300°F, will grow 2.5
inches!)
Commissioning of Combined
Cycle Power Plants Part 4
1 Operational Testing
First Fire
The combustion turbine is ready for first fire after successfully completing control
sequence checks, cranking checks, emergency shutdown checks, false-fire checks,
and has been on turning gear for twenty four hours. Once the combustion turbine is
fired, the hot exhaust gas will generate steam in the HRSG. The steam can be
vented from the HRSG drums and superheater vents during the initial first fire
operation. But after reaching a sustained full speed/no load condition (FSNL), these
vents will not be adequate for removing the steam and the HRSG pressure will rise.
If the air blow process was used to clean the steam pipes, the steam can be routed
to an atmospheric dump valve or to the steam turbine bypass. If the steam piping
will undergo steam blows, a temporary valve and silencer arrangement will take the
steam out of the system, until the necessary cleanness is achieved. When the
combustion turbine is fired and the HRSG heated up for the first time, blow down
the HRSG to remove any magnetite that has loosened from the tube walls. Steam
Turbine Bypass
The steam turbine bypass system dumps steam to the condenser through pressure-
reducing control valves that also have an associated attemperating water spray.
The initial operation of the steam turbine bypass must be monitored closely. The
steam temperature should not be too high in the superheated region, as this may
overheat the condenser structure. Also, the steam should not enter the saturated
range, as this heavier steam may cause condenser tube aerodynamic problems
(rattling and eventual cracking of the tubes, or damage to the bypass valve itself).
Steam is dumped to the condenser until steam purity is achieved (clean enough to
be admitted to the steam turbine). This can often take several days, or a week, of

continuous dumping. Figure 1

Generator Synchronization
After a combustion turbine or steam turbine starts, its generator is connected to the
utility grid to export power. The generator breaker is closed to the grid after
synchronizing the voltage and frequency of the generator to the system's voltage
and frequency. The generator's field excitation and speed are adjusted until the
voltage and frequencies of both systems are closely matched. The generator
breaker is then closed, and the power output of the generator is increased by
raising the combustion turbine firing (or by raising the steam turbine steam
admission rate). Failure to accurately synchronize the generator to the grid before
closing the circuit breaker may damage the generator. Protective relays detect any
out-of-phase conditions and will not permit breaker closure. Water Use
During chemical cleaning and first fire operation, demineralized water demands can
exceed the water production rate and storage capacity. Chemical cleaning requires
large quantities of demineralized water for preparing the cleaning solutions and the
subsequent filling, flushing, and rinsing of the piping and HRSG's. At the time of
combustion turbine first fire, frequent blowing down of the HRSG is required to
remove loose magnetite and achieve the steam purity necessary for steam
admission to the steam turbine. During commissioning, the water treatment system
will become increasingly reliable and will attain the throughput guarantees and
chemical purity specifications. It may be necessary on a temporary basis to
augment the water production by mobile demineralizers. Normal BOP Systems
Operation
After a balance of plant (BOP) system checkout is complete, the system is placed in
normal operation in a step-by-step fashion. This activity may take several days, and
may require frequent stops in order to perform inspections, make equipment
adjustments, or review data. The following example of the condensate and feed
water initial startup demonstrates this process.

 Step #1: The condensate storage tank is filled with demineralized water.
Tank level indicator signals are verified at the DCS.
 Step #2: The condensate make-up pump is started and placed in recirculation
operation from the DCS. Pump suction pressure, discharge pressure, and
suction strainer differential pressure are monitored.
 Step #3: The condenser hotwell is filled using the condensate make-up pump.
Hotwell level indicator signals are verified at the DCS. The control valve
operation is checked, and then the controls can be placed in the automatic

mode.
Figure 2
 Step #4: The condensate piping and the HRSG drums, economizers, and
evaporators are filled via the condensate make-up pump cold fill line.
 Step #5: The condensate pump is started and placed in recirculation
operation from the DCS. Pump motor amperage, thermal rise, and vibration
are monitored. Pump suction pressure, discharge pressure, and suction
strainer differential pressure are also monitored.
 Step #6: The condenser hotwell level controls are verified in both manual and
automatic operation.
 Step #7: Condensate flows to the HRSG LP economizer and is recirculated to
the condenser via the economizer recirculation line (if such a recirculation line
is included).
 Step #8: Condensate flows through the LP economizer 3-way valve bypass
and into the LP drum. The condensate is then redirected via the 3-way valve
into the economizer and into the LP drum. 3-way bypass control is verified at
the DCS. Thermocouple indications in the LP economizer are verified at the
DCS.
 Step #9: A feed water pump is started and placed in recirculation operation.
LP drum level indicator signals are monitored at the DCS. Level control valve
operation is verified. Feed water pump lubricating oil distribution, temperature
and pressure is verified locally and at the DCS. Cooling water flow and
temperature is monitored locally and at the DCS. Pump motor amperage,
thermal rise, and vibration are checked. Pump suction pressure, discharge
pressure, and suction strainer differential pressures are monitored.

If the condenser has excessive leakage while under vacuum, and all the normal
leakage sites have been checked by site personnel, it is beneficial to subcontract a
specialist in condenser air in-leakage testing. These companies use helium
detectors, installed at the air discharge of the condense air removal system, and
they spray helium around the joints, man ways, and flanges of the condenser and
steam turbine. The helium detector can even be "calibrated" to estimate the
amount of leakage. The subcontractor can spot the source of the leakage in a
matter of hours. Shift Work
When the combustion turbines are fired for the first time, the commissioning team
moves into shift work, with two or three shifts assigned for round-the-clock
coverage. On some projects, the most experienced personnel are assigned to the
night shift. Since there are fewer workers on night shift to coordinate, and fewer
distractions, the night shift can initiate new tests much easier than can be done on
day shift. Test Data
In preparing for testing, the startup manager prepares test log sheets and may also
use DCS software logs that capture operational data. Software logs can be
formatted to depict operating data graphically, displaying the dynamics of the
system operation. Steam Traps
Steam traps are deceptively simple components, which can cause big problems if
they are not specified properly, or if they are installed incorrectly. The
commissioning team should check the design features of the traps, to make sure
they are installed with the correct range of pressures, temperatures, and back-
pressures. They should also check the various piping runs, and verify that traps are
installed at all the necessary points in the systems. During the system walkdown,
the commissioning team should make sure the traps are installed in the proper
orientation, and that the associated piping is routed correctly. After some period of
operation, the traps which have internal strainers should be disassembled and
cleaned. Plant Outages
During the operation of the plant, there will be a collection of punch list items which
require the plant to be shutdown in order to perform the work. Also, the startup
schedule will include some known outage activities, like removing the strainers from
the steam turbine inlet valves, or pulling the strainers from the combustion turbine
fuel lines. The work should be scheduled just like a regular plant outage, with work
permits arranged in advance, materials staged in the warehouse, and personnel
assigned to the tasks. When the predetermined time arrives for the outage, the
work can then proceed smoothly. There should also be an ongoing list of punch list
items that can be done during a short outage, so that if the plant is shutdown or
trips without notice, some of those short work items can be accomplished. Special
Situations
Emergency leak repair is sometimes warranted if there is a bad leak but you don't
want to shutdown the plant to fix the leak. A leak repair subcontractor can be called
to the site. They will make a temporary fitting which can be applied around the leak,
and then they will pump a system-friendly compound into the fitting to stop the
leak. These leak repairs have been successfully employed on high pressure steam
systems, circulating water systems, glycol cooling systems, and elsewhere. Another
technique for making repairs on the run is to use a "freeze seal" to isolate an
otherwise un-isolable section of a system and allow a repair to be made. Kits are
available for "do it yourself" freeze seals, or subcontractors can be employed for the
more difficult cases. Repairs on flanges or valves can often be performed by an "in
place machining" subcontractor. Housekeeping
It is a well-known fact that plants that have good housekeeping are easier to start.
When the commissioning team is not encumbered by construction dirt and debris,
the equipment stays clean and more trouble-free. The startup manager should insist
on good housekeeping from all the organizations on the project. Performance
Testing
The heat rate test is based on the engineered heat balances supplied by the plant
designer. The net plant heat rate typically supercedes any individual combustion
turbine and steam turbine guarantees and is calculated as BTU/kWh.
Heat rate testing should be performed when the plant is in a new and clean
condition with less than 300 hours of operation. When this is not possible, the plant
designer will supply heat rate degradation correction curves for calculating the
adjusted heat rate. Additional correction curves are supplied to adjust the heat rate
calculation to the guaranteed combustion turbine compressor inlet temperature,
humidity, and barometric pressure (commonly cited as 59 o F, 60% relative humidity,
14.66 psia barometric pressure). The specified fuel gas heating value (BTU/lb) and
chemical composition (per cent methane, ethane, propane, etc.) is verified by
drawing samples during the test for subsequent analysis. Stable operating
conditions within the emission limit guarantees are required during the test period
(usually four hours at base load). Other operating conditions and limitations may
include:

 HRSG blowdown = 0%
 Generator power factor = 0.85 lagging
 Generator frequency = 60 Hz
 Electrical output = as measured on the high-voltage side of the step-up
transformer(s).

Combined cycle heat rates of approximately 6,000 BTU/kWh, LHV are now common.
The heat rate test procedure will typically identify the temporary test instruments
and permanent plant instruments that will be used to collect data. These
instruments require calibration certificates to validate their accuracy and
tolerances. Of special importance are the electrical power output meter, the
auxiliary electrical load meter, and the fuel gas flow meter. Whenever possible, the
data should be read on the actual plant revenue or billing meters, since these
meters will be used to pay fuel costs and to calculate the plant's electrical sales
revenues. Emissions Testing
HRSG stack emissions testing validates the emission limit guarantees. In many
plants, the combustion turbine exhaust gas nitrous oxide (NOx) reduction
equipment will not satisfy the local environmental permit requirements, and it is
therefore necessary to supplement the combustion turbine NOx reduction
equipment with an HRSG selective catalytic reduction (SCR) unit. The combustion
turbine exhaust enters the HRSG and passes through SCR modules located behind
the high pressure evaporator modules. Ammonia is injected into the flue gas, and it
reduces the NOx while on the catalyst surface. The ammonia decomposes NOx into

harmless N 2 and H2O, according to the reactions:

The stack NOx is tested as NO 2 and measured in parts per million (PPM) by volume
on a dry gas basis, corrected to 15% oxygen. HRSG stack emissions testing may
also include tests for:

 Ammonia (excess ammonia admitted to the SCR)

 Carbon monoxide
 Particulate (sized in microns)
 Volatile organic compounds (e.g. methane)
 Sulfur
HRSG stack emissions testing is typically performed after the installed CEM has
been certified. However, if the permanent plant CEM is not certified at the time of
emissions testing, a rented, portable CEM is used. The HRSG stack emission testing
may be performed in conjunction with the heat rate testing. However, the emissions
test may be conducted at several different load points (50%, 75%, 100% for
example, with and without duct burners) on a one-hour average basis, while the
heat rate testing may be performed at only one load point. Combustion turbine
exhaust gas NOX emission guarantees of 9.0 ppmvd (@15% O2) are now common.
Combined cycle plant HRSG stack emission guarantees (with an SCR) can be as low
as 3.5 ppmvd (@ 15% O2). Contract Testing
The following tests may be required by the contract:
Steam Turbine and Combustion Turbine Overspeed Tests Modern overspeed controls
are now redundant electronic circuits (replacing the spring-loaded mechanical bolt-
type overspeed device). At least two overspeed tests are performed (one on each
circuit), and then repeated if necessary. CO2 Concentration Tests
After the combustion turbine CO2 piping is cleaned and pressure tested with air,
and the fire control and alarm system is fully tested, the CO2 storage tank may be
filled. The system is dynamically tested by initiating a fire alarm (via any of the heat
detection sensors). The CO2 concentration is measured. The concentration test
requires special equipment and is typically performed by the fire system vendor.
Electrical Full-Load Rejection Test
A full-load rejection test demonstrates the ability of each combustion turbine and
the steam turbine to instantly shed their full-load, without tripping on overspeed,
and then run down to full-speed-no-load. Combustion turbine full-load rejection tests
are conducted individually, one combustion turbine at a time. In order to achieve
full-load on the steam turbine both combustion turbines must be in base load
operation. When the steam turbine generator breaker is opened, the combustion
turbines must runback to a preset lower load and begin dumping steam to the
condenser via the steam turbine bypass. Control of this runback and bypass
operation is a function of the DCS control logic. A station trip test simulates a
switchyard failure, wherein the combustion turbine generators and steam turbine
generator are separated from the grid. In this case, the steam turbine is tripped and
the combustion turbines run back to full-speed-no-load. In stations where there is no
backup power, one of the combustion turbine generators may be configured to
runback and later implement a safe shutdown. Duct Burner Testing
Duct burners may be functionally tested to full-fire capability only after the
combustion turbine is at base load. For this reason, the duct burners are frequently
the last system to be fully commissioned, and are on the critical path to
performance testing and emissions testing. Partial Load Stability Test
A partial load stability test seeks to determine the plant's lowest megawatt output
operating point. At this point the megawatt output remains stable, and the stack
emissions remain in compliance with the air permit. Reliability Test
A reliability test may take the form of a continuous operations test, where the plant
operates continuously, with no emergency trips, for a period of perhaps 7 to 30
days. Other variations of this test include performing repeated startup and
shutdown operations, performing hot and cold re-starts with fast loading, unit
maneuvering (for example, steam turbine extraction steam tests), and peaking
operation tests. 2 System Turnover (from Commissioning to the Owner)
The turnover from commissioning to the plant owner follows the same principles as
the turnover from construction to commissioning. Turnover Packages
The commissioning team maintains the system turnover packages during the
commissioning phase, and the various records collected for each system are added
to the packages during the commissioning. Sometimes an entire train of one
combustion turbine generator and associated HRSG are turned over to the owner as
one package. This type of turnover includes multiple system turnover packages
being turned over simultaneously. System Walkdown
The system walkdown is conducted in the same manner as the construction
turnover walkdown. The walkdown verifies the work within the boundaries is
complete. Any incomplete work is noted on the punchlist. Those work items are
completed later, under the owner's work permit program. "Wish List"
The owner's personnel are not always conversant with the contract for designing
and building the plant, and sometimes they write into the punch list items which are
beyond the scope of the contract (therefore known as "wish list" items). The startup
manager will differentiate between in-scope deficiencies and out-of-scope requests.
The plant owner may need to establish a separate contract to add these
enhancements at a later time, after the plant startup is completed. 3 Conclusions
Due to the popularity of the combined cycle power plant, many startups have
occurred in the past few years, and a system of commissioning has evolved. That
system is based on the historical groundwork of the electrical utility fossil and
nuclear plant startups, and has been modified to match the needs of the modern
combined cycle power plant. Experienced startup personnel have been trained and
are ready to meet the technical demands and challenges of their industry.

The punch list is an old tool used by construction and startup personnel. Here is how
to modernize the punch list for your project. Using the punch list
Before the construction of a new plant or refinery, the startup team breaks the plant
down into systems, and they identify the “scope” of each system. On a big plant,
with many auxiliary components, there may be 50 to 100 systems (for instance, the
main transformer, the 4160 V distribution, the circulating water system, the
demineralized water system, etc.). All of the electrical, instrumentation, mechanical,
and piping systems must be included. The various buildings, structures, and areas
should also receive “system” designators, in order to track architectural or
infrastructure punch list items (examples: turbine building, cooling water intake
structure, ammonia storage area, etc.). The scope of each system is detailed on
drawings, lists, or descriptions. Each system receives an abbreviated system
designator, which is used to classify each component in the plant. (For example, the
feed water system may be called “FW.”) A particular system may have within its
boundaries some piping, some electrical breakers and wiring, some pressure
gauges, and some pumps. The construction and startup groups send
representatives on a “walk down,” which is a hand-over-hand inspection of the
particular portion of the plant. The walk down typically covers the piping, the
electrical devices, the instrumentation, and any associated work documentation or
inspection records. The punch list is the tool used to document and track the
completion of any outstanding work or deficiencies, as witnessed on the walk down.
Any incomplete administrative issues should also be listed on the punch list, such as
weld records, instruction manuals, etc. The scope drawings, lists of equipment,
inspection and test reports, and punch lists are gathered together for each system
into the “turnover package.” The turnover package is assembled by the construction
organization, and reviewed and accepted by the startup organization, to signify the
care/custody/control of the system. During the system walk down, some people
bring several craft workers with them, so that, if any minor deficiencies are spotted,
they can be corrected immediately. This method cuts down on extra punch list
items, paperwork, and inspections. Before embarking on your punch list program,
check the project contracts. The contracts often have directions on the punch list
methodology and details on which entities are responsible. Entering records on
the punch list
As mentioned above, the primary input for the punch list is the system turnover
package walk down. After the system turnover, if any additional work items arise,
they can be added through an input form, either on paper or directly into the
computer database. Each new entry should be screened to ensure it is a valid work
item. At some plants, for instance, personnel may not be conversant with the
various contracts, and they may want to add an item that is outside the scope of the
contract. In these cases, we keep a separate list for out-of-scope work, or we give
those items a special priority code to flag them. Throughout the industry, this list
has become known as “plant betterment items” or the “wish list.” A procedure for
punch listing should be reviewed and approved by the appropriate parties, so that
everyone knows the ground rules. A good procedure can prevent some of these
possibly contentious issues. The old-fashioned way of punch listing
In the old days, before computers, we used a piece of paper and a clipboard, and
hand wrote each punch list item. The new-fangled way of punch listing
Now there are punch list applications for hand-held or palm computers. You can
carry your computer with you to the plant, and poke your punch list items directly
into the computer, then upload the records into your desktop computer back in the
office trailer. Or you can download punch list items to your hand-held computer for
a walk down, edit the items with your findings, and then upload the results to your
desktop computer. You can even include a picture field, and upload an image of the
discrepancy from your digital camera into the punch list record. Reports can be
printed, or automatically transmitted by e-mail or fax. The punch list may be
available on a network or company intranet. The right application
The punchlist should be kept in a relational database application. On many projects,
the punchlist is kept in a word processor file or a spreadsheet file. But those
applications do not have the sorting and report capability of a database program. It
definitely takes more effort to establish a database format, but it allows much more
flexibility. With a database, you can quickly give a work group a customized list of
only those items that they are responsible for fixing. You can also print customized
lists of items belonging to one system, for inclusion in system turnover packages.
Or, you can print out a list of all the items needed for a particular milestone activity.
For bilingual projects, you can have a computer screen in one language, and a
corresponding page in another language. For better control of the list, only one
individual (such as the startup manager) should be allowed to authorize punch list
alterations, the closing of items, or the removal of items from the list. All of the
techniques associated with good computing are also important in making a good
punch list. The files should contain error checking on input. Dates should be entered
automatically for new entries. Daily backups of the files are vital. Your computer is
guaranteed to crash and lose your precious data if you do not make backups
(Murphy’s Computer Law #1). Design your input forms in the same layout as your
input screen, to speed up your data entry. Make your reports “printer friendly” and
able to be printed on different types of printers without having to re-design them.
The basic punch list fields
The punch list contains individual records for each outstanding work item or
deficiency noted. Each record has fields for the system designator, the component
tag number and description, the problem (a discrepancy or work item), the action
group or work organization responsible for fixing the deficiency, the dates that the
item was generated and closed, the reference drawing or specification, and the
name of the person reporting the punch item. Each punch list record receives a
unique, sequential identification number. A comment field is useful, to list
requirements or tracking information. The discrepancy and comment fields can be
“memo” fields, which allow a large amount of text to be added, as required. A
priority field is very important. On a large project, there can be thousands of punch
list records. In order to prepare the plant for a particular milestone event, such as
the first fire of a gas turbine, every punch list item is coded with a priority field,
which can be queried for just those work items, across all systems, which must be
completed prior to the milestone event. Usually the priority field is a numeric field.
For example, 10 = Initial Back Feed, 30 = HRSG Hydrostatic Test, 50 = First Fire
Gas Turbine, 140 = Steam Blow, and 280 = Performance Test. The action group
field should encompass the entire project, with coded records for the various
construction disciplines (civil, electrical, instruments, mechanical, piping,
purchasing), engineering, startup, subcontractors, vendors, and the plant owner. A
shorthand designator for each action group makes it easy to edit the field (CC =
Construction Civil, EN = Engineering, SU = Startup). The action group field contents
will change as the work item gets completed. Maybe a part is required, so
purchasing is responsible. Then, when the part is received, the electrical group is
responsible to install it. Finally, the startup group is responsible for testing the
component. The relational database can be further refined, as necessary, adding
such fields as room number or area. Some plants use a “subsystem” designator to
break down the larger turnover systems into smaller packages. Maybe you will want
to add a “due date” for each open item. Printing the punch list report
Today, with the ubiquitous laser printers and copy machines, the standard paper is
letter or A4 size. Design your punch list report accordingly. Use the field “word
wrap” function to see all the information in each field. It is a good idea, with all the
top-secret codes that you used to designate the systems, the work organizations,
and the priorities, that you print a “decoder ring” page, which succinctly translates
the codes. You can include a decoder ring with each pile of paper that you generate
for a work organization. Soon, everybody will have the codes memorized. The punch
list report can be sorted by the system designator, using the same designators as
the turnover packages. This list is used to assess the readiness of a particular
system, such as for a turnover package meeting. The punch list report can be sorted
first by action group, then by system, so that each work organization can receive
the list of only those work items for which they are responsible. This list is good to
review in punch list meetings. The punch list report can be sorted by priority, and
then by system, so that all of the work items associated with an important
milestone can be identified and tracked. Another good reason for using a database
application is that customized status reports are easy to create. “Bean count”
reports, which list each action group and how many open/closed items they have, or
a percentage of completion, are very informative. The reports can be in a tabular
format or a crosstab. “Sign off forms” can be built. They print the details for a
particular work item and provide spaces for completion signatures and comments.
Everyone’s favorite: the punch list meeting
These meetings can be very tedious, as you discuss the details of every seemingly
insignificant work item, but, after a few sessions, the personnel usually find a
methodology which speeds up the process. Any project which thinks that it is not
important to review every punch list item is doomed to failure. A single missed work
item can stop an important milestone from occurring, maybe because the person
who was responsible was not made aware of the ramifications of the work. Or, in the
most dire cases, the work item does not get assigned to the action group with
enough time to finish, or it is assigned to the wrong organization, and never gets
done. There are several ways to conduct a punch list meeting. One of the most
efficient ways is to call each work organization, one at a time, and discuss with
them the status of their work items. The construction civil group can start at 9:00
AM, the construction electrical group at 9:20 AM, and so on. In this way, you do not
waste everybody’s time listening to all the other work organizations; however,
sometimes there is a debate as to who is really responsible for a particular item,
and the group that is not in the meeting can be tasked without their acquiescence,
and sometimes they are wrongly accused. Good management practices are
necessary to keep everybody informed. While in the meeting, markup the list with
the status and comments gleaned from the attendees. Then make your changes
later on the database. When reporting that a work item is complete, it has become
customary to follow Ronald Reagan’s proverb: “Trust, but verify.” Under the strictest
type of procedure, the work item cannot be closed until a signed quality control
inspection report is issued. On most projects, obtaining on a copy of the punch list
the signature of the startup engineer is sufficient to close the record item. On
several projects, we have learned that it is best to show a closed item as “closed on
such-and-such a date,” but not purged from the reports until another seven days
have passed. This allows a “sincerity test,” so that everyone agrees that it is really
completed. Sometimes, we have a punch list item that was closed, only to walk out
and see that it wasn’t really finished, or it was completed incorrectly. Closed items
should migrate over to an archived file, so that they are purged from the system,
but can be retrieved for historical purposes. Multiple punch lists: a no-no
On some projects, there is a tendency for each organization to keep their own
punch list, but those projects that combine the punch lists into one integrated list
seem to complete the work faster. A single project punchlist allows for better
scheduling of equipment and manpower, which allows for the work to be completed
faster or in a way that better supports the overall schedule. One at a time
Although it seems tedious, it is not a good idea to put multiple items within one
record, because it is difficult sometimes to determine which ones are closed.
Imagine a record with a list of twenty cables to pull and terminate. Six cables are
pulled this week, two the next week, and then later somebody asks, “Wait, which
ones are still not done?” Better to be excruciating, and make twenty records. Better
yet, wait for construction to actually finish building the system before the walk
down, so that all the cables are complete, and you don’t have any punch list to
worry about. Conclusion
The modern punch list may not look anything like the old clipboard report, but its
functions and usage haven’t changed. You still need to find out what remaining work
is out there, and keep track of it. Example relational database structure
Punch list table (main file):
Table fields:
Record identification number (primary key)
Component tag number
Component description
System designator (link #1)
Action group designator (link #2)
Priority designator (link #3)
Problem field (discrepancy or work item)
Date the item was generated
Date the item was closed
Reference drawing or specification
Name of the person reporting the punch item
Comments
Picture field for images
Forms:
Record form (look at one record)
Worksheet view (look at multiple records)
Input form for new items
Sign-off sheet
Reports:
Sorted by system
Sorted by action group
Sorted by priority
Status reports (action groups vs. open/closed item count)
Form letters to action groups
Queries:
All open items
All open items for a particular system
All open and closed items for a particular system
All open items for a particular priority
All open items for a particular action group
Search for a word or phrase
System table:
Table fields:
System designator (link #1)
System description
Date of system turnover from construction
Date of system turnover to the client
Reports:
List of systems (part of the “decoder ring”)
List of system turnover dates
Action group table:
Table fields:
Action group designator (link #2)
Action group description
Action group contact person
Reports:
List of action groups (part of the “decoder ring”)
Priority table:
Table fields:
Priority designator (link #3)
Priority description
Priority scheduled date
Reports:
List of priorities (part of the “decoder ring”)
System functions:
Archive the closed items
Backup
Data import and export
Password maintenance