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NOTE: THE IBH LINE MUST BE BLOWN JUST AT THE END OF FIRST STARTUP, REGARDLESS TO THE TYPE OF FUEL. IN CASE THE FIRST STARTUP IS PERFORMED WITH LDO INSTEAD THAN
NATURAL GAS, THE IBH CLEANING MUST BE PERFORMED, IN ANY CASE, DURING THAT PHASE.
ANY OTHER TYPE OF ADMISSIBLE FUEL WILL BE TESTED CHANGING OVER FROM NATURAL GAS OR LDO, ABOVE A MINIMUM LOAD LEVEL DEFINED ACCORDING TO CURRENT DESIGN. THE PROPOSED
SEQUENCE FOR TESTING THE DIFFERENT TYPES OF FUEL IS:
VARIOUS TYPES OF CO-FIRING (GT RUNNING ON A MIX OF DIFFERENT FUELS) WILL ALSO BE TESTED.
THE DLN TUNING WILL BE PERFORMED FOR EACH FUEL
FOR ALL PARTIES INVOLVED IN SITE ACTIVITIES, DIFFERENT LEVELS OF ATTENDANCE MAY BE SPECIFIED IN THE SPACE PROVIDED FOR THIS PURPOSE IN THE DOCUMENT.
THE FOLLOWING ACTIVITIES ARE POSSIBLE:
-W (WITNESSED): THIS IS A BINDING REQUEST TO WITNESS A INSTALLATION OR TESTING PHASE
-O (OBSERVED): THIS IS A REQUEST FOR OPTIONAL WITNESSING OF AN INSTALLATION OR TESTING PHASE
-R (REVIEWED): INSPECTOR WILL PERFORM A DOCUMENTATION REVIEW OF THE INSPECTION OR TEST.
NOTE: BHGE INSPECTOR ATTENDANCE IS REGULATED BY CONTRACTUAL TERMS AND CONDITIONS. ADVANCE NOTIFICATION IS DEFINIED ACCORDANCE WITH MOBILIZATION REQUIREMENTS.
1.3 CERTIFICATION
THE CERTIFICATION ISSUED FOR THE TESTS PERFORMED IS LISTED IN THIS DOCUMENT IN THE APPROPRIATE SPACE PROVIDED FOR THIS PURPOSE.
NOTE: IN CASE SR IS NOT REQUIRED, THE SIGNATURE OF THE OPERATOR/CONTROLLER CERTIFIES THE TEST EXECUTION. IN CASE OF CUSTOMER REQUEST, THE DOCUMENT SIC00283
CAN BE USED AS BLANK SERVICE REPORT TO BE FILLED ON SITE.
THE ACCEPTANCE CRITERIA DRAWN FROM THE SINGLE PROCEDURES VALID ON ISSUING THIS DOCUMENT ARE AN INTEGRAL PART OF SAID DOCUMENT AND ARE ENCLOSED FOR REFERENCE.
THE AFOREMENTIONED ACCEPTANCE CRITERIA, TO BE CHECKED PRIOR TO CARRY OUT THE SINGLE TEST, WITH REFERENCE TO THE ORIGINAL DOCUMENTS, WHICH COULD HAVE BEEN REVISED
AFTER ISSUE OF THIS DOCUMENT.
THE DOCUMENTS (SPECIFICATIONS OR DRAWINGS) MENTIONED IN THIS DOCUMENT CAN BE CONSULTED, ON REQUEST, AT BHGE SITE MANAGEMENT TEAM OFFICE AND ARE THE OFFICIAL
REFERENCES FOR ALL INTENTS AND PURPOSES.
NOTE: DRAWINGS MARKED WITH ** ARE CONFIDENTIAL DOCUMENTS, IT WILL BE AVAILABLE AT SITE TO BHGE FSE.
WARNING: BEFORE BEGINNING THE START-UP TEST, IT’S NECESSARY TO VERIFY THAT THE ABOVE LISTED DOCUMENTATION HAS NO OTHER REVISIONS SUCCESSIVE TO THOSE SPECIFIED. IF
SOME OF THESE DOCUMENTS HAVE BEEN REVISED, THE RELATIVE MODIFICATIONS MUST BE CONSIDERED.
NOTE: DRAWINGS MARKED WITH ** ARE CONFIDENTIAL DOCUMENTS, THEY WILL BE AVAILABLE AT SITE TO BHGE FSE.
WARNING: BEFORE BEGINNING THE START-UP TEST, IT’S NECESSARY TO VERIFY THAT THE ABOVE LISTED DOCUMENTATION HAS NO OTHER REVISIONS SUCCESSIVE TO THOSE SPECIFIED. IF
SOME OF THESE DOCUMENTS HAVE BEEN REVISED, THE RELATIVE MODIFICATIONS MUST BE CONSIDERED.
THE ACTIVITIES ARE IN EACH CLAUSE BELOW ARE WRITTEN IN THE PREFERRED CHRONOLOGICAL ORDER. HOWEVER, THE ORDER MAY BE ALTERED, IF DEEMED NECESSARY BY THE
APPROPRIATE QUALIFIED START-UP ENGINEER.
IF IT’S NECESSARY TO SUSPEND THE START-UP PHASE, WHEN IT STARTS AGAIN PAY ATTENTION TO BACK IN THE CONDITION OF THE LAST STEP THAT HAS BEEN EXECUTED.
NOTES:
THE INSTRUMENT SETTING VALUES SHOWN IN THIS DOCUMENT ARE ONLY FOR REFERENCE.
FOR OFFICIAL VALUES REFER TO THE RELEVANT DOCUMENTS (PIPING & INSTRUMENT DIAGRAM, INSTRUMENT LIST, ETC.).
THIS DOCUMENT RECALLS SEVERAL SEQUENCE, ALARM & TRIP TESTS; IN MANY CASES, IN ORDER TO ENABLE THE PORTION OF THE CONTROL SOFTWARE UNDER TEST, ONE OR MORE TURBINE
AND/OR PROCESS PARAMETER SHALL BE FORCED/SIMULATED. THE DETAILED DESCRIPTION OF THIS TECHNIQUE, GENERICALLY CALLED LOGIC FORCING, IS NOT INCLUDED IN THE SCOPE OF THIS
DOCUMENT.
NOTE: THIS CHECK LIST INCLUDES SEVERAL TESTING STEPS THAT, ONCE SUCCESSFULLY EXECUTED, WILL NOT BE EXPLICITLY PERFORMED AGAIN. THE COMPLETE TESTING PLAN, HOWEVER,
REQUIRES SEVERAL STARTUP AND RUNNING CYCLES, EVERY TIME PASSING THROUGH ALREADY TESTED STEPS BEFORE NEW ONES CAN BE TESTED, IN GENERAL, TO AVOID REDUNDANCY,
SOME DETAILS OF REPEATED STEPS WILL BE OMITTED, GROUPING THEM IN A SINGLE COMMAND (SUCH AS “STARTUP TO MINIMUM LOAD”) WHEN NO MORE DETAILS ARE NECESSARY. THE
STARTUP ENGINEER, HOWEVER, MUST BE AWARE OF SUCH DETAILS, BEING RESPONSIBLE, IN ANY CASE, TO DETECT ANY DEVIATION FROM THE CORRECT SEQUENCING, POSSIBLY CAUSED BY
SOME MALFUNCTION OF THE ALREADY TESTED PORTION OF THE PLANT <1>.
Warning: always remove the logic forcing after each start-up test.
Warning:
An off-line water wash is required before first
firing in order to remove axial compressor
internal preservation treatments, preventing
that the combustion of the preservation
product may damage the internal parts of the
turbine. In general, an actual Water Wash
should have been performed as one of the last
steps of commissioning. Note that after an off
7.5.
line water wash the gas turbine MUST be
started on FIRE within few hours for drying,
otherwise oxidation of internal parts might
occur. Correct planning of the water wash just
when ready for startup must be implemented.
<1>
Refer to the Commissioning SQCL for
instructions relevant to the execution of the
Water Wash. <1>
Prior to execute first start-up ensure that red
flag review 3rd milestone (tg3 – green light) Green light on
RFR
7.6. have been successfully executed. W O RFR control list NA relevant RFR V
control list
review meeting
8.1 Start-Up in Crank, step to FIRE mode (FAIL TO IGNITE TEST) with Natural Gas <1>
SOM6775546
8.1.9. From HMI select the Fuel Gas W O NA NA V NA
Sh.11
SOM6775546
When GT speed is above zero speed (L14HR=0),
Sh.11
8.1.24. verify ratchet System 88HR-1 (PM-05A) W O NA NA V NA
SOM6770884
is stopped.
Sh.20
SOM6775546
When GT speed >8% (L14QP=1), verify
Sh.11
8.1.25. Jacking oil pumps 88QS-1/2 (PM-07A/08A) are W O
SOM6770884
NA NA V NA
stopped.
Sh.30
When ready for Fail To Ignite test, from HMI
interface move master selector on “FIRE”
position. SOM6775546
8.1.26. W O NA NA V NA
NOTE: this will cause un-combusted fuel gas to Sh.13
reach the gas turbine and the exhaust stack
<1>
SOM6775546
8.1.27. Verify aux ready to fire (L3ARF=1). W O NA NA V NA
Sh.13
Verify that the ignition sequence is activated:
- Fuel Gas control valve on primary line is
partially opened
FV-1323 (VGC-1);
- Speed ratio control valve is opened SOM6775546
FV-1318 (SRV-1); Sh.13
8.1.28. W O NA NA V NA
- Fuel Gas Vent valve is closed XY-1322 SOM6770884
(20VG-1); Sh.12,13
- Ignition transformer command (no actual
sparking will occur because of the de-activation
of the igniters).
<1>
Fail To Ignite.
After the end of the firing timer (L2F=1), verify:
- activation of “Fail to ignite alarm”
- fuel gas control valves are closed
FV-1323 (VGC-1), FV-1327 (VGC-2) & FV-1331
SOM6775546
8.1.29. (VGC-3) W O NA NA V NA
Sh.13
- disabling of ignition transformer
- Intervalve vent valve is opened
XY-1322 (20VG-1)
- verify that unit remains in “Crank” mode
automatically.
Leave the unit at Crank speed for a sufficient
time allowing complete purging of the exhaust
SOM6775546
8.1.30. stack, then from HMI interface give “STOP” W O NA NA V NA
Sh.18
command to stop the unit.
<1>
Confirm Jacking Oil system is re-activated when
SOM6775546
8.1.31. the GT shaft speed is below 200 rpm. W O NA NA V NA
Sh.30
<1>
Analyze logged and trend data.
Focus on:
- Stability of FG pressure.
- Fuel Gas temperature correctly heated at 56
DegC <1>
- Stability and position of Servo and regulating
8.1.32. W O NA NA NA V NA
valve
- Correct Excessive Fuel Gas Flow protection
system reading.
Note: the following steps are required to the identify gas and air leakages from flanged connections inside the GT enclosure. It is recommended that this verification is performed soon after a startup
8.3.24. from cold machine conditions, before the temperature inside the enclosure becomes excessive.
Note: The following prescriptions are always applicable, regardless to the presence of BHGE personnel during start up activities. BHGE recommends to observe the limitations for inspections inside the
8.3.25. enclosure while the unit is running, as described by the NIC14.30 (included in the Operation & Maintenance Manual) <1>
- In order to minimize risk, the machine must be placed in minimum speed condition consistent with the activities and inspections to be performed.
- The ventilation system must be operating without anomalies. De-activation of the ventilation system is strictly forbidden.
- The gas detection system must be active and correctly maintained with no anomalies detected.
- The oxygen content and presence of fuel gas must be checked to verify that they are in the acceptable range. If necessary, depending on the type of fuel, the CO and/or H2S level must also be
checked by means of portable gas detectors.
- If there is an extinguishing device, the system must be mechanically disabled, closing and locking the block valves; a Lock Out Tag Out (LOTO) procedure must be applied.
- Portable fire extinguishers must be easily accessible and ready to use.
- The fire and gas detection and signaling system must be kept on. In the event of a detection signal, personnel must leave the turbine enclosure immediately even if fire is not apparent
- After entering the GT enclosure, the door must be closed to ensure proper operation of the gas detection system. The door must be provided with a system for the opening of ventilation doors by
8.3.26. ventilation loads. Access to the GT enclosure under running conditions with the door closed is prohibited unless access routes are provided for routine maintenance activities and adequate methods
of escape exist. An individual should be present outside the enclosure to monitor activities and take emergency action if a hazardous situation arises. This external person must be in contact with
personnel in the control room.
When the enclosure door is closed, the external person should monitor activities from a position close to the door with line of sight to the activity being undertaken. The external person must
have mechanisms and means for monitoring personnel within the enclosure. Where line of sight cannot be achieved, other methods must be used to enable an alarm to be raised if an incident occurs.
- The external person must be equipped with a portable fire-extinguisher.
- Before entering the enclosure, verify that the turbine is running normally and that no abnormal operation or transient conditions are expected.
- Access to any area, which is accessible with difficulty or is without easy egress, is prohibited.
- Avoid contact with hot parts and wear thermal insulating gloves.
- The procedure must also guarantee that after the activities have been completed and the personnel have exited the enclosure, the fire protection system will be reactivated
When ready, verify no gas alarm within the
enclosure is detected from Gas Monitoring
8.3.27. System. In case of alarm, abort the startup and W O NA NA NA V NA
investigate for improper flanges tightening,
missing plugs, etc. with the machine stopped.
While inside the enclosure, the operator must
verify there are no gas leaks around the fuel
nozzles, gas manifold and associated piping.
Verify no air leaks from flanged connections,
machine casings, etc.
8.3.28. W O NA NA NA V NA
NOTE 1: Minimize the time required for this
verification (max 5’).
NOTE 2: In presence of fuel gas leaks it is
necessary to stop the turbine, remove the
cause, and then restart the unit and recheck.
Normal Stop
SOM6775546
8.3.34. Stop the turbine using NORMAL STOP button W O NA NA V NA
Sh.18
from HMI.
Verify normal stop signal (L94X=1) is in SOM6775546
8.3.35. progress <1> W O NA NA V NA
Sh.19
Normal Stop
During deceleration, when GT speed is below the
M.O.S. (4850 rpm), verify:
- Mineral Lube Oil auxiliary pump 88QA-1 (PM-
01A) is started;
- Hydraulic Oil auxiliary pump 88HQ-1 (PM-04A is
started;
- Exhaust Frame Fan motor 88TK-1/2 (EM- SOM6775546
02A/3A) is stopped; Sh.19
8.3.36. W O NA NA V NA
- excitation contactor is disabled XS-1878 (41FX) SOM6770884
(no action on GCPP that is still disabled in this Sh.12,13
phase) <1>;
- Bleed valves open command XY-1307 (20CB) is
enabled;
- Fuel gas valve in safe position FV-1323 (VGC-
1), FV-1327 (VGC-2) & FV-1331 (VGC-3);
- Speed Ratio Valve in safe position FV-1318
(SRV-1).
Normal Stop
After flameout, during coast down, verify:
- HP speed <300 rpm (slow roll run out): radial
8.3.37. W O SOM6775546 NA NA V NA
vibration readings must be maximum 25% of
vibration trip set point or 12 microns pk-pk
unfiltered, whichever is lower.
Normal Stop
Verify that after the flameout, the following
system are de-energized/stopped:
- Hydraulic oil Aux. pump;
- Fuel Gas Shut-off valve XV-1314 (FG-1) SOM6775546
8.3.38. W O NA NA V NA
(closed); Sh.19,20
- Fuel Gas Ventilation valve XV-1315 (VG-6)
(open);
- Interstage Fuel Gas Vent valve XY-1322
(20VG-1) (open).
Normal Stop
SOM6775546
8.3.39. Confirm Jacking Oil pumps 88QS-1/2 (PM-07/8) W O NA NA V NA
Sh.21
are started when GT speed is below 200 rpm.
Normal Stop
After the gas turbine has come down to zero
speed, verify:
SOM6775546
8.3.40. - start of auxiliaries inherent the cool-down W O NA NA V NA
Sh.20,21
sequence.
- start the activation of the hydraulic ratchet
system (88HR-1).
Make sure that the main enclosure ventilation
fan is stopped 120 minutes after the flame out SOM6775546
8.3.41. W O NA NA V NA
is detected in turbine combustion chambers. Sh.47
<1>
Normal Stop
When the cool-down timer is elapsed verify the
de-activation of the following auxiliaries system:
SOM6775546
8.3.42. - Mineral Lube Oil System W O NA NA V NA
Sh.21
- Hydraulic Ratchet
- Oil Vapour Separator
- Jacking oil pumps
8.10.30. Shut down and cool down the unit W O SOM6775986 SOM6775986 SOM6775986 V SOM6775986
SOM6775546
9.1.8. From HMI select the Liquid Fuel. W O NA NA V NA
Sh.11
Trending.
Using trend recorder function on proper graphic
screen on HMI interface configure and start a
trend with the main system parameters relevant
to the Gas turbine and its auxiliaries. Focus on
LIQUID Fuel System variables.
The output file shall always be saved for
9.1.12. analysis, at test completion. W O NA NA NA V NA
HP Speed;
- L4;
- Flowrate and opening percentage of shutoff
valves and liquid regulation valve
- Command / feedback shutoff valve
- Spark plug command
SOM6775546
9.1.13. From the HMI interface, give “START” command. W O NA NA V NA
Sh.10
SOM6775546
9.1.22. Verify auxiliary ready to fire. W O NA NA V NA
Sh.13
SOM6775546
9.1.23. Verify Core Engine ready to fire. W O NA NA V NA
Sh.13
SOM6775546
9.1.25. Verify the firing timer is initiated. W O NA NA V NA
Sh.13
SOM6775546
9.2.11. Verify excitation enabled XS-1878 (41FX). W O NA NA V NA
Sh.14
Verify that all auxiliaries are correctly
SOM6775546
9.2.12. functioning and that turbine start sequence W O NA NA V NA
Sh.14
(L3=1) is ended and turbine is running.
Check that no liquid fuel is coming out from
the tell-tale connection BL254A/B (drain of
the liquid fuel purge manifold).
WARNING: any leakage would be a sign of SOM6770884
9.2.13. W O NA NA V NA
faulty purge check valves, allowing liquid to Sh.15
pass in reverse direction. In case this
happens, the turbine shall be stopped for
investigation.
SOM6775546
10.2.9. Stop the water injection from HMI W O NA NA V NA
SOM6770884
SIC00264
Perform any performance/endurance test as SIC00266
12.15. W O NA SIC00140 NA V/D
per contract. SIC00294
COM45-2
Formally Hand-Over to customer part#1:
According to SOM6766322, perform the
verifications and activities required to ensure
correct handover of the Unit Control System to
Customer. At the end, the deliverables will be:
12.16. W O SOM6766322 NA NA V COM45-3
a) Contractually due Software Passwords
b) Contractually due Complete Software Back-
ups
c) Contractually due Applications installation
Cd’s and licenses forms/Keys.
Formally Hand-Over to customer part#2:
a) As built (Mark-up) drawings according
12.17. to VDR. W O NA NA NA V COM45-3
b) Copy of all reading forms.
c) Copy of all SQCL.
The turbogroup is ready for commercial COM45-3
12.18. W O NA NA NA V
operation (COD) Punch List
Prepare Formal Hand-Over to Headquarter
(Technical Debriefing):
a) All Software Passwords
b) Complete Software Back-ups Field
12.19. c) As built (Mark-up) drawings. W O NA NA NA V Service
d) Copy of all reading forms. Report
e) Copy of all SQCL.
f) Hand-Over Certificates
COM45-1/2/3