Professional Documents
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for Stamp: IP/OE
RETURN CODE
A
Revision History
Rev. Revision Issued by Checked by Released by Brief Description
Date
Description current Revision
Owner
Owner’s Engineer: Contractor:
Project:
TAMBAK LOROK COMBINED CYCLE
POWER PLANT BLOCK 3 PROJECT
WITH NET DEPENDABLE CAPACITY OF 600 – 850 MW.
SEMARANG – CENTRAL JAVA
Subject: Commissioning ITPL - Steam Bypass System
Issue Purpose: Responsible Dept:
PE-ACE
Originator:
TBL/31/E/153b---001/SP/008 0 0 / 15
Issue date: 2022-03-18
Revision History
Rev. Revision Issued by Checked by Released by Brief Description
Date
A 05-12-2019 N. MEKALA S. SUGUMARAN B. Baskaran
B 05-08-2021 P. Annegowda S. SUGUMARAN B. Baskaran Customer comments
incorporated
Owner
Project:
TAMBAK LOROK COMBINED CYCLE
POWER PLANT BLOCK 3 PROJECT
WITH NET DEPENDABLE CAPACITY OF 600 – 850 MW.
SEMARANG – CENTRAL JAVA
Subject: Commissioning ITPL - Steam Bypass System
Originator:
TBL/31/E/153b---001/SP/008 1/12
Issue date:
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
Released
The first two pages of this document are only needed for the correct handling of this template file inside the PPDM.
To use it on site please take the word file (.docx) attached to this document (or inside PPDM tool).
Remove the first two pages by highlighting (selecting) the content starting from the title on the first page until the last
word of this second page and press the delete button. The current page 3 will then become the front page of the
relevant ITPL.
Before printing the file ensure the front page is correctly filled and that the GE Document Code (already prepared in
the footer) is adjusted with the three-digit project mnemonic and if needed the unit numbering and the last three-digit
continuous numbering (for more details about GE document code refer to GAS/00/E/02a----002/IS/013).
Ensure that all headers and footers on each page are complete and contain the correct page numbers, date and
document codes.
The attachment (if used) contains a list of all sub-item KKS’ belonging to the scope of this ITPL. For multi-unit plants
the list contains all KKS’ across all units. When issuing a unit specific ITPL the other units KKS’s shall be deleted from
the list.
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
System Name: Steam Bypass System
Name of the System / Item covered by this ITPL
Use this space for the contractual document designation if needed. Otherwise keep empty and delete this text.
The inspection and test plan does not release the subcontractor / manufacturer from his obligation to take all steps necessary to ensure that
the requirements stipulated in drawings and specifications are fulfilled for the product concerned.
GE POWER GE Document Code Rev. Date Lang. Sheet
Gas Power Systems TBL/31/E/153b---001/SP/008 0 en 3/15
© COPYRIGHT 2022 General Electric Company Non-Public
All rights reserved. The information herein is Proprietary and Technically Exclusive content of the General Electric Company and/or its legitimate
affiliates.
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
TABLE OF CONTENTS:
SAFETY SYMBOLS ........................................................................................................................................................ 5
GENERAL ......................................................................................................................................................................... 6
PLANT CONDITIONS ...................................................................................................................................................... 7
PRECOMMISSIONING TEST FOR MEASURMENT CIRCUIT................................................................................... 7
PRECOMMISSIONING AND START-UP TESTS FOR APPARATUS (PIPE SYSTEMS, TANKS AND
HEAT EXCHANGERS) .................................................................................................................................................... 8
PRECOMMISSIONING AND START-UP TESTS FOR EQUIPMENT (AGGREGATES)......................................... 8
VISUAL INSPECTION ..................................................................................................................................................... 9
COLD COMMISSIONING OF FUNCTION GROUP / SEQUENCER CONTROL ...................................................... 9
PROTECTION TEST ........................................................................................................................................................ 9
INITIAL START OF SYSTEM ......................................................................................................................................... 9
OPTIMIZATION AND FINAL TESTS ............................................................................................................................. 9
AFTER COMMISSIONING ............................................................................................................................................ 10
ATTACHMENT ............................................................................................................................................................... 11
The inspection and test plan does not release the subcontractor / manufacturer from his obligation to take all steps necessary to ensure that
the requirements stipulated in drawings and specifications are fulfilled for the product concerned.
GE POWER GE Document Code Rev. Date Lang. Sheet
Gas Power Systems TBL/31/E/153b---001/SP/008 0 en 4/15
© COPYRIGHT 2022 General Electric Company Non-Public
All rights reserved. The information herein is Proprietary and Technically Exclusive content of the General Electric Company and/or its legitimate
affiliates.
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
SAFETY SYMBOLS
The User must understand the following symbols used within this document:
DANGER
WARNING
Warning indicates a potentially hazardous situation that if not avoided,
could result in death or serious injury.
CAUTION
Note
Note indicates an important instruction or the best practices
It may also be used to alert against mechanical damage to the equipment
The inspection and test plan does not release the subcontractor / manufacturer from his obligation to take all steps necessary to ensure that
the requirements stipulated in drawings and specifications are fulfilled for the product concerned.
GE POWER GE Document Code Rev. Date Lang. Sheet
Gas Power Systems TBL/31/E/153b---001/SP/008 0 en 5/15
© COPYRIGHT 2022 General Electric Company Non-Public
All rights reserved. The information herein is Proprietary and Technically Exclusive content of the General Electric Company and/or its legitimate
affiliates.
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
1) Performed by B = GE or GE’s representative unit H = Hold point (observe notification period) Q = Q record to K
K = Customer or his representative
2) Acceptance by L = Erection Contractor M = Witness point (observe notification period) R = Internal Record
S = Official acceptance authority
3) Q – Record U = Material supplier, supplier ext. products and ext. processes Y = Internal test C = Record in Com. Record Set
System Name
Inspection and Test Plan Steam Bypass System
Q Activities Step Completed
No. Description Procedure Record Remarks
1) 2) 3) Date / Signature
1
GENERAL
1.1 Make sure the general and project specific environmental aspects are known - -
and observed. Y
1.2 Make sure that all tests are carried out in accordance with the specified - -
regulations and requirements. Y
1.3 Make sure that the safety requirements are observed as mentioned in the TBL/00/P/CSR-------/CM/001 -
project specific commissioning safety rules. If other regional requirements have B Y
to be considered follow the more strict one.
1.4 Ensure that commissioning permit to work rules are known and followed. TBL/00/P/PTW--------/CM/001 -
B K*
1.5 Check that system is turned over from erection to commissioning, that TBL/00/P/TP-- ------/CM/001 -
“Notification of Change Certificate” (NOCC) is issued and that “Energisation B Y
Clearence Protocol” (ECP) is filled out before first energisation.
1.6 Check system readiness and that preceding activities are completed and that - -
relevant open items from turn over are closed. B K*
1.8 Verify the completeness of the documentation as mentioned in the ITPL, collect - -
all relevant drawings and documents at the latest revision. B K*
1.9 Verify the needs of special tools. Make sure they are ordered / organised and - -
verify if the calibration of entire test equipment is certified and valid. B Y
1.10 Verify the needs of equipment original supplier or official authority. Ensure the - -
arrangement in time. Y
*Note: Activities marked with “K&M” in Q- Activities column 2 will be coordinated/informed during the daily site commissioning planning meeting only
The inspection and test plan does not release the subcontractor / manufacturer from his GE POWER GE Document Code Rev. Date Lang. Sheet
obligation to take all steps necessary to ensure that the requirements stipulated in TBL/31/E/153b---001/SP/008 0 en 6/15
drawings and specifications are fulfilled for the product concerned. Gas Power Systems
© COPYRIGHT 2022 General Electric Company Non-Public
All rights reserved. The information herein is Proprietary and Technically Exclusive content of the General Electric Company and/or its legitimate affiliates.
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
1) Performed by B = GE or GE’s representative unit H = Hold point (observe notification period) Q = Q record to K
K = Customer or his representative
2) Acceptance by L = Erection Contractor M = Witness point (observe notification period) R = Internal Record
S = Official acceptance authority
3) Q – Record U = Material supplier, supplier ext. products and ext. processes Y = Internal test C = Record in Com. Record Set
System Name
Inspection and Test Plan Steam Bypass System
Q Activities Step Completed
No. Description Procedure Record Remarks
1) 2) 3) Date / Signature
2
PLANT CONDITIONS
2.1 Low voltage power supply available - - Y
2.2 Control voltage available - - Y
2.3 Control system ready: - -
• The control cubicles are energized
• The measuring circuits are installed, connected and checked out (wiring check
resp. Loop check done)
B Y
• The control circuits and the signal processing is completed
• Control room equipment is ready (Hmi, alarm recorder, communication)
• Check of communication interface between field equipment / local control
system and DCS
2.4 Instrument air system operational - - B K*
2.5 Hydraulic control oil system operational - - B K*
2.6 Main condensate system operational - - B K*
2.7 Steam system depressurized and cold, turbine tripped - - B K*
2.8 Gt off / steam isolation valves closed - - B K*
3
PRECOMMISSIONING TEST FOR MEASURMENT CIRCUIT
3.1 Precommissioning tests for temperature transmitter GAS/00/E/153B---001/TP/203 GAS/00/E/153B---001/TQ/200 Signals listed in
B K* Q attachment
3.2 Precommissioning tests for pressure transmitter GAS/00/E/153B---001/TP/201 GAS/00/E/153B---001/TQ/200 Signals listed in
B K* Q attachment
3.3 Precommissioning tests for steam flow meter GAS/00/E/153B---001/TP/207 GAS/00/E/153B---001/TQ/214 Signals listed in
B K* Q attachment
3.4 Precommissioning tests for level switch GAS/00/E/153B---001/TP/202 GAS/00/E/153B---001/TQ/201 Signals listed in
B K* Q attachment
*Note: Activities marked with “K&M” in Q- Activities column 2 will be coordinated/informed during the daily site commissioning planning meeting only
The inspection and test plan does not release the subcontractor / manufacturer from his GE POWER GE Document Code Rev. Date Lang. Sheet
obligation to take all steps necessary to ensure that the requirements stipulated in TBL/31/E/153b---001/SP/008 0 en 7/15
drawings and specifications are fulfilled for the product concerned. Gas Power Systems
© COPYRIGHT 2022 General Electric Company Non-Public
All rights reserved. The information herein is Proprietary and Technically Exclusive content of the General Electric Company and/or its legitimate affiliates.
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
1) Performed by B = GE or GE’s representative unit H = Hold point (observe notification period) Q = Q record to K
K = Customer or his representative
2) Acceptance by L = Erection Contractor M = Witness point (observe notification period) R = Internal Record
S = Official acceptance authority
3) Q – Record U = Material supplier, supplier ext. products and ext. processes Y = Internal test C = Record in Com. Record Set
System Name
Inspection and Test Plan Steam Bypass System
Q Activities Step Completed
No. Description Procedure Record Remarks
1) 2) 3) Date / Signature
4
PRECOMMISSIONING AND START-UP TESTS FOR
APPARATUS (PIPE SYSTEMS, TANKS AND HEAT
EXCHANGERS)
4.1 Visually inspect the piping system and verify: P&ID -
• Completeness according to P&ID TBL/31/E/LBF-----EN/FD/001
• Arrangement of the pipes: e.g. location, pipe slope, pipe diameter and TBL/31/E/MAN40---EN/FD/001
possibility to drain and vent the pipe line TBL/31/E/MAN20---EN/FD/001
• Hangers and supports operational: check the possibility to accommodate B Y
thermal expansion of the system
• Flow direction of installed devices (valves, flow meters, orifices)
• Thermal insulation or touch protection is sufficient for initial operation
• Access to all equipment used for operation
4.2 Verify earthing equipment is connected - -
B Y
4.3 Verify operation configuration of the system: - -
• Apparatus, devices and instrumentation (sampling probe on stack nozzle) are B Y
installed as required for initial start of system
4.4 Verify the correctness of orifices (by measuring the orifice hole diameter) - GAS/00/E/153B---001/TQ/206 Equipment listed in
B Y Q
attachment
5
PRECOMMISSIONING AND START-UP TESTS FOR
EQUIPMENT (AGGREGATES)
5.1 Precommissioning checks for hydraulic operated control valve. Check for proper GAS/00/E/153B---001/TP/214 GAS/00/E/153B---001/TQ/218 Equipment listed in
function, adjust the limit / torque switch (close/open) and verify correct indication B Y Q attachment
5.2 Precommissioning checks for hydraulic or pneumatic operated shut-off valve. GAS/00/E/153B---001/TP/212 GAS/00/E/153B---001/TQ/208 Equipment listed in
Check for proper function, adjust the limit / torque switch (close/open) and verify B Y Q attachment
correct indication
5.3 Precommissioning checks for motorized valve (incl motor space heater). Check GAS/00/E/153B---001/TP/216 GAS/00/E/153B---001/TQ/205 Equipment listed in
for proper function, adjust the limit / torque switch (close/open) and verify correct attachment
B Y Q
indication.
The inspection and test plan does not release the subcontractor / manufacturer from his GE POWER GE Document Code Rev. Date Lang. Sheet
obligation to take all steps necessary to ensure that the requirements stipulated in TBL/31/E/153b---001/SP/008 0 en 8/15
drawings and specifications are fulfilled for the product concerned. Gas Power Systems
© COPYRIGHT 2022 General Electric Company Non-Public
All rights reserved. The information herein is Proprietary and Technically Exclusive content of the General Electric Company and/or its legitimate affiliates.
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
1) Performed by B = GE or GE’s representative unit H = Hold point (observe notification period) Q = Q record to K
K = Customer or his representative
2) Acceptance by L = Erection Contractor M = Witness point (observe notification period) R = Internal Record
S = Official acceptance authority
3) Q – Record U = Material supplier, supplier ext. products and ext. processes Y = Internal test C = Record in Com. Record Set
System Name
Inspection and Test Plan Steam Bypass System
Q Activities Step Completed
No. Description Procedure Record Remarks
1) 2) 3) Date / Signature
6
VISUAL INSPECTION
6.1 Inspect and verify all manually operated equipment (valve, local instruments - -
etc.) is lubricated, clean and functional B K*
7
COLD COMMISSIONING OF FUNCTION GROUP /
SEQUENCER CONTROL
7.1 Check implementation of functional requirements logic and control TBL/31/E/LBF-----EN/LO/001 - Mark discrepancies
TBL/31/E/MAN20---EN/LO/001 as red correx and
B K*
TBL/31/E/MAN40---EN/LO/001 inform mechanical
systems engineering
8
PROTECTION TEST
8.1 Check of steam bypass trip signals TBL/31/E/003b---001/DO/001 - B K*
9
INITIAL START OF SYSTEM
9.1 Exclusion zone during start up: - -
During initial start up activities, an appropriate exclusion zone with limited
access shall be foreseen. Special attention must be paid during the first start Y
ups of the system until the system has seen stable operating condition
9.2 Prepare system for cleaning (Validation blow) according procedure TBL/31/E/150b---001/CL/212 - B Y
9.3 Perform system cleaning according procedure TBL/31/E/150b---001/CL/212 GAS/00/E/153b---001/TQ/302 B K* Q
9.4 Check systems after cleaning. Verify all cleaning provisional’s are removed and TBL/31/E/150b---001/CL/212 -
B K*
systems are reinstated for start up and normal operation
10
OPTIMIZATION AND FINAL TESTS
10.1 Verify system behavior during plant nominal load operation TBL/31/E/LBF-----EN/DM/001 -
TBL/31/E/MAN20---EN/DM/001 B K*
TBL/31/E/MAN40---EN/DM/001
*Note: Activities marked with “K&M” in Q- Activities column 2 will be coordinated/informed during the daily site commissioning planning meeting only
The inspection and test plan does not release the subcontractor / manufacturer from his GE POWER GE Document Code Rev. Date Lang. Sheet
obligation to take all steps necessary to ensure that the requirements stipulated in TBL/31/E/153b---001/SP/008 0 en 9/15
drawings and specifications are fulfilled for the product concerned. Gas Power Systems
© COPYRIGHT 2022 General Electric Company Non-Public
All rights reserved. The information herein is Proprietary and Technically Exclusive content of the General Electric Company and/or its legitimate affiliates.
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
1) Performed by B = GE or GE’s representative unit H = Hold point (observe notification period) Q = Q record to K
K = Customer or his representative
2) Acceptance by L = Erection Contractor M = Witness point (observe notification period) R = Internal Record
S = Official acceptance authority
3) Q – Record U = Material supplier, supplier ext. products and ext. processes Y = Internal test C = Record in Com. Record Set
System Name
Inspection and Test Plan Steam Bypass System
Q Activities Step Completed
No. Description Procedure Record Remarks
1) 2) 3) Date / Signature
11
AFTER COMMISSIONING
11.1 Check the completeness of Q.A. documentation - - B Y
11.2 Finalize red correx - - B K* C
11.3 "Make sure this I & T plan as well as the test certificates and red correx - -
belonging to it are signed by the commissioning manager.
Name: _______________________________ B Y
*Note: Activities marked with “K&M” in Q- Activities column 2 will be coordinated/informed during the daily site commissioning planning meeting only
The inspection and test plan does not release the subcontractor / manufacturer from his GE POWER GE Document Code Rev. Date Lang. Sheet
obligation to take all steps necessary to ensure that the requirements stipulated in TBL/31/E/153b---001/SP/008 0 en 10/15
drawings and specifications are fulfilled for the product concerned. Gas Power Systems
© COPYRIGHT 2022 General Electric Company Non-Public
All rights reserved. The information herein is Proprietary and Technically Exclusive content of the General Electric Company and/or its legitimate affiliates.
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
System Name
Inspection and Test Plan AutoField for: Item or System Name
KKS Function Designation Component Step Test certificate Checked Remarks
ATTACHMENT
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
System Name
Inspection and Test Plan AutoField for: Item or System Name
KKS Function Designation Component Step Test certificate Checked Remarks
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
System Name
Inspection and Test Plan AutoField for: Item or System Name
KKS Function Designation Component Step Test certificate Checked Remarks
31MAN40CP001A PIS PRESSURE AFTER IP BYPASS STEAM CONTROL VALVE TRANSMITTER 3.2 GAS/00/E/153B---001/TQ/200
31MAN40CP001B PIS PRESSURE AFTER IP BYPASS STEAM CONTROL VALVE TRANSMITTER 3.2 GAS/00/E/153B---001/TQ/200
31MAN20CP001A PIS PRESSURE AFTER LP BYPASS STEAM CONTROL VALVE TRANSMITTER 3.2 GAS/00/E/153B---001/TQ/200
31MAN20CP001B PIS PRESSURE AFTER LP BYPASS STEAM CONTROL VALVE TRANSMITTER 3.2 GAS/00/E/153B---001/TQ/200
31MAN20CL201 LSA LEVEL DRAIN LP BYPASS STEAM CONTROL VALVE SWITCH 3.4 GAS/00/E/153B---001/TQ/201
31LBH40BP201 ORIFICE DRAIN IP BYPASS STEAM SHUTOFF VALVE ORIFICE 4.4 GAS/00/E/153B---001/TQ/206
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
System Name
Inspection and Test Plan AutoField for: Item or System Name
KKS Function Designation Component Step Test certificate Checked Remarks
31MAN40BP201 ORIFICE DRAIN IP BYPASS STEAM CONTROL VALVE ORIFICE 4.4 GAS/00/E/153B---001/TQ/206
31MAN20BP201 ORIFICE DRAIN LP BYPASS STEAM CONTROL VALVE ORIFICE 4.4 GAS/00/E/153B---001/TQ/206
31MAN20BP211 ORIFICE DRAIN LP BYPASS STEAM CONTROL VALVE ORIFICE 4.4 GAS/00/E/153B---001/TQ/206
HYDRAULIC
31LBF50AA001 HP BYPASS STEAM CONTROL VALVE CONTROL 5.1 GAS/00/E/153B---001/TQ/218
VALVE
HYDRAULIC
31LBF51AA002 HP BYPASS WATER INJECTION CONTROL VALVE CONTROL 5.1 GAS/00/E/153B---001/TQ/218
VALVE
P&ID:
HYDRAULIC
TBL/31/E/LBF-----EN/FD/001
31MAN40AA002 IP BYPASS STEAM CONTROL VALVE CONTROL 5.1 GAS/00/E/153B---001/TQ/218
TBL/31/E/MAN40---EN/FD/001
VALVE
TBL/31/E/MAN20---EN/FD/001
HYDRAULIC
31MAN41AA001 IP BYPASS WATER INJECTION CONTROL VALVE CONTROL 5.1 GAS/00/E/153B---001/TQ/218
VALVE
HYDRAULIC
31MAN20AA002 LP BYPASS STEAM CONTROL VALVE CONTROL 5.1 GAS/00/E/153B---001/TQ/218
VALVE
HYDRAULIC
31MAN21AA001 LP BYPASS WATER INJECTION CONTROL VALVE CONTROL 5.1 GAS/00/E/153B---001/TQ/218
VALVE
HYDRAULIC
31LBF51AA001 HP BYPASS WATER INJECTION SHUTOFF VALVE SHUTOFF 5.2 GAS/00/E/153B---001/TQ/208
VALVE
HYDRAULIC
31MAN40AA001 IP BYPASS STEAM SHUTOFF VALVE SHUTOFF 5.2 GAS/00/E/153B---001/TQ/208
VALVE
HYDRAULIC
31MAN41AA002 IP BYPASS WATER INJECTION SHUTOFF VALVE SHUTOFF 5.2 GAS/00/E/153B---001/TQ/208
VALVE
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22
System Name
Inspection and Test Plan AutoField for: Item or System Name
KKS Function Designation Component Step Test certificate Checked Remarks
HYDRAULIC
31MAN20AA001 LP BYPASS STEAM SHUTOFF VALVE SHUTOFF 5.2 GAS/00/E/153B---001/TQ/208
VALVE
HYDRAULIC
31MAN21AA002 LP BYPASS WATER INJECTION SHUTOFF VALVE SHUTOFF 5.2 GAS/00/E/153B---001/TQ/208
VALVE
DRAIN VALVE HP STEAM BEFORE BYPASS CONTROL
31LBA55AA201 MOV 5.3 GAS/00/E/153B---001/TQ/205
VALVE
31LBH40AA202 DRAIN VALVE IP BYPASS STEAM SHUTOFF VALVE MOV 5.3 GAS/00/E/153B---001/TQ/205
31MAN20AA202 DRAIN VALVE LP BYPASS STEAM CONTROL VALVE MOV 5.3 GAS/00/E/153B---001/TQ/205
ReleasedforConstruction-setbyS.SUGUMARANon21-Mar-22