Air Distribution System. Functional Test Procedure

Page: 1
SID-10-QFB_-MNP-IDM-001
Of: 12
CLIENT: ELECTRICITY GENERATION COMPANY OF BANGLADESH LTD.
PROJECT: SIDDHIRGANJ 335 MW COMBINED CYCLE POWER PLANT
AIR DISTRIBUTION SYSTEM. FUNCTIONAL TEST PROCEDURE
4 10/12/2015 FOR CONSTRUCTION (OC) EAA EAA ACM

0A 29/10/2015 FOR APPROVAL (OC) EAA EAA ACM
Page: 2 Of: 16
SID-11-MBE-MMO-IDM-001
Rev.: 4
GT COOLING SYSTEM. OPERATION MANUAL

REV DATE DESCRIPTION AUTHOR REVISED APPROVED
Page: 3 Of: 12
Rev.: 4
TABLE OF CONTENTS
1. PURPOSE.........................................................................................................3
2. SCOPE.............................................................................................................4
3. INITIAL REQUIREMENTS.........................................................................5
3.1. TEST Nº1 - Start and Changeover of the instrument running
compressor 10QFB05/10AN001 (Automatically)..................................5
3.1.1. Initial Requirements.......................................................................................5
3.1.2. Test Performance..........................................................................................6
3.2. TEST Nº2 - Start and Changeover of the service air running
compressor 10QFB15/20AN001 (Automatically)..................................6
3.3. TEST Nº3 – Lead and standby instrument air compressor operation
10QFB05/10AN001................................................................................7
3.4. TEST Nº4 – Lead and standby instrument air compressor operation
10QFB15/20AN001................................................................................8
4. ACCEPTANCE CRITERIA..........................................................................9
5. RELATED DOCUMENTS..........................................................................11
5.1. Piping and instrumentation diagrams....................................................11
5.2. Mechanicals...........................................................................................11
5.3. Instrumentation and control...................................................................11
5.4. Suppliers documentation.......................................................................11
 Annex 1: Test protocols and acceptance criteria.

 Annex 2: Equipment not available for test.
 Annex 3: Measurements record sheet
Page: 4 Of: 12
Rev.: 4
1. PURPOSE
The aim of this document is to describe the functional test procedure of the Air Distribution
System for the 335 MW Combined Cycle Power Plant that ISOLUX is going to build in
Siddhirganj, Bangladesh.
This document provides the information required for the performance of the functional tests
of the system, as well as the acceptance criteria for these.
Page: 5 Of: 12
Rev.: 4
2. SCOPE
This document is applicable to all the components and equipment included in the Air
Distribution System.
The main function of this system is to provide air compressed to the different equipment and
systems. This system will be able to provide air for instruments and air for services to the
different discharge points around the plant.
The system general and functional description is made in document SID-10-QFB_-MRS-IDM-

001.
The system is graphically described in P&ID SID-10-QFB_-MDD-IDM-001.
The system settings are defined in the Control Settings and Alarm List SID-10-YYD-YLI-IDM-
003.
Page: 6 Of: 12
Rev.: 4
3. INITIAL REQUIREMENTS
Herein are identified the tests to be performed to test the performance and integrity of the
functional system.
The actuation and checking of the tested equipment and performance values will be done
from the DCS, always if possible. When this is not possible or when an additional check is
needed, it will be shown specifically in the correspondent paragraph of the present
document.
The system has been filled and commissioned following the instructions of the document
SID-10-QFB_-MNP-IDM-002 (Air Distribution System. Commissioning Procedure).
The following tests will be performed.
Test nº1 - Start and Changeover of the instrument air running compressor
10QFB05/10AN001 (automatically).
Test nº2 - Start and Changeover of the service air running compressor
10QFB15/20AN001 (automatically).
Test nº3 - Lead and standby instrument air compressor operation 10QFB05/10AN001.
Test nº4 - Lead and standby service air compressor operation 10QFB15/20AN001.
3.1. TEST Nº1 - Start and Changeover of the instrument running compressor
10QFB05/10AN001 (Automatically)
Please see document Compressor factory acceptance test procedure SID-00-QFB-
QNP-CMP-001
3.1.1. Initial Requirements
Here it is indicated the starting conditions and the configuration of the system that has to be
done after starting the test;
- The system must be completely drained.
- The power plant shall be in operation at nominal load.

Page: 7 Of: 12
Rev.: 4

- Instrument air compressors (10QFB05/10AN001) shall be in operation and in
automatically mode.
3.1.2. Test Performance
This test will be done following the below indicated steps:
- Verify that the compressor selected in operation is working properly

- Verify that the functional group is in automatically mode
- Force, the trip in the operating compressor.
- Verify that the compressor on standby mode starts automatically and keeps the pressure
in the system in a stable way.
This procedure will be repeated changing the role of the compressors.
3.2. TEST Nº2 - Start and Changeover of the service air running compressor
10QFB15/20AN001 (Automatically)
QNP-CMP-001
- Service air compressors (10QFB15/20AN001) shall be in operation and in

automatically mode.
- Verify that the compressor selected in operation is working properly

- Force the trip in the operating compressor
Page: 8 Of: 12
Rev.: 4

- Verify that the compressor on standby mode starts automatically and keeps the pressure
in the system in a stable way.
3.3. TEST Nº3 – Lead and standby instrument air compressor operation 10QFB05/10AN001
QNP-CMP-001
- Instrument air compressors (10QFB05/10AN001) shall be in operation and in

automatically mode.
- Verify that the compressor selected as lead starts when the pressure drop below the
setpoint of 7 barg, according to document SID-10-QFB-MRS-IDM-001_Compressed
Air System Functional Description.
- Verify that the compressor selected as standby starts automatically when the
pressure drop 1 bar below the setpoint, according to document SID-10-QFB-YDY-
IDM-001 Compressed Air System. Logic Diagrams.

Page: 9 Of: 12
Rev.: 4

3.4. TEST Nº4 – Lead and standby service air compressor operation 10QFB15/20AN001
QNP-CMP-001
- Service air compressors (10QFB15/20AN001) shall be in operation and in

automatically mode.
- Verify that the compressor selected as lead starts when the pressure drop below the
setpoint of 7 barg, according to document SID-10-QFB-MRS-IDM-001_Compressed
Air System Functional Description.
- Verify that the compressor selected as standby starts automatically when the
pressure drop 1 bar below the setpoint, according to document SID-10-QFB-YDY-
IDM-001 Compressed Air System. Logic Diagrams.

Page: 10 Of: 12
Rev.: 4
4. ACCEPTANCE CRITERIA
The functionality of the system will be considered correct and accepted as result of the test
when it is checked that the following values has been obtained;
- Test nº1:
o Verify that the compressor on standby mode starts automatically and keeps
the pressure in the system in a stable way.
Please see the operating values to be accomplished on the document Control

Settings and Alarm List SID-10-YYD-YLI-IDM-003.
- Test nº2:
o Verify that the compressor on standby mode starts automatically and keeps
the pressure in the system in a stable way.
Please see the operating values to be accomplished on the document Control

Settings and Alarm List SID-10-YYD-YLI-IDM-003.
- Test nº3:
o Verify that the lead compressor starts automatically if the pressure drops
4
below 7 barg
o Verify that the standby compressor starts automatically if the pressure drops
below 6 barg
Please see the operating values to be accomplished on the document SID-10-QFB-

MRS-IDM-001_Compressed Air System Functional Description and SID-10-QFB-
YDY-IDM-001 Compressed Air System. Logic Diagrams.
Page: 11 Of: 12
Rev.: 4

- Test nº4:
o Verify that the lead compressor starts automatically if the pressure drops
4 below 7 barg
o Verify that the standby compressor starts automatically if the pressure drops
below 6 barg
Please see the operating values to be accomplished on the document SID-10-QFB-

MRS-IDM-001_Compressed Air System Functional Description and SID-10-QFB-
YDY-IDM-001 Compressed Air System. Logic Diagrams.
Page: 12 Of: 12
Rev.: 4
5. RELATED DOCUMENTS
5.1. Piping and instrumentation diagrams
- SID-10-QFB_-MDD-IDM-001 Air Distribution System. P&ID
5.2. Mechanicals
- SID-10-QFB_-MCD-IDM-001 Air Distribution System. Calculation Note
- SID-10-QFB_-MRS-IDM-001 Air Distribution System. General &

Functional Description
- SID-10-QFB_-MNP-IDM-002 Air Distribution System. Commissioning

Procedure
5.3. Instrumentation and control
- SID-10-YYD-YLI-IDM-003 Events and set point list
- SID-10-QFB_-YDY-IDM-001 Air Distribution System. Logic Diagrams.
- SID-10-QFB_-YDG-IDM-001 Air Distribution System. Graphics DCS
5.4. Suppliers documentation
- SID-00-QFB-QNP-CMP-001 Compressor Factory Acceptance Test

Procedure
- SID-10-QFB-ELK-CMP-001 Cabling list
- SID-10-QFB-ELQ-CMP-001 Electrical Consumption List
- SID-10-QFB-ESK-CMP-001 Wiring diagrams with terminal blocks to

DCS
Page: 13 Of: 12
Rev.: 4

- SID-10-QFB-GLJ-CMP-001 Spare parts list
- SID-10-QFB-GMO-CMP-001 Operation & Maintenance manual
- SID-10-QFB-MDA-CMP-001 General arrangement drawing
- SID-10-QFB-MDD-CMP-001 P&ID
- SID-10-QFB-MDD-CMP-002 P&ID of the equipments
- SID-10-QFB-MDP-CMP-001 Drawings of components
- SID-10-QFB-MHP-CMP-001 Valves Data Sheet
- SID-10-QFB-MLV-CMP-001 Valves list
- SID-10-QFB-YDZ-CMP-001 Control architecture
- SID-10-QFB-YLA-CMP-001 Hardwared signal with DCS and alarms

list
- SID-10-QFB-YLI-CMP-001 Communications signal list with DCS
- SID-10-QFB-YLP-CMP-001 Instrument list & Instrument data
- SID-10-QFB-YMO-CMP-001 Functional description

Page:
Rev.: 4
Annex 1
Test protocols and acceptance criteria

Page:
Rev.: 4
Annex 2
Equipment not available for test

Page:
Rev.: 4
Annex 3
Measurements record sheet

Air Distribution System. Functional Test Procedure

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PROJECT: SIDDHIRGANJ 335 MW COMBINED CYCLE POWER PLANT