Commissioning & Start Up Manual

TECHNICAL PACKAGE FOR COMMISSIONING (TPC)
Commissioning & Start-Up Manual

Customer Dangote Oil Refining Company LTD.
Location NIGERIA
Plant Dangote Refinery and Petrochemicals
Project
Unit Gas Turbine MS6001B DLN Dual Fuel +
Load Gear + Electric Generator
JOB 1606600÷07
© 2018 Nuovo Pignone Tecnologie S.r.l., a Baker Hughes, a GE Company, LLC (“BHGE”) company: the information contained in this document is company confidential and
proprietary property of BHGE or its affiliates. It is to be used only for the benefit of BHGE and may not be distributed, transmitted, reproduced, altered or used for any
purpose without the express written consent of BHGE.
Nuovo Pignone
Commissioning & Start up Manual
CUSTOMER
Dangote Oil Refining Company LTD.
PLANT LOCATION
NIGERIA
PLANT
Dangote Refinery and Petrochemicals Project
BHGE / NP JOB
1606600÷07
TRAIN COMPOSITION
MS6001B DLN Dual Fuel + E.G.
BHGE job # ITEM # Driver Serials #
1606600 MS6001B + ELECTRIC GENERATOR G09115
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© 2018 Nuovo Pignone Tecnologie S.r.l., a Baker Hughes, a GE Company, LLC (“BHGE”) company: the information contained in this document is company confidential and pro-
prietary property of BHGE or its affiliates. It is to be used only for the benefit of BHGE and may not be distributed, transmitted, reproduced, altered or used for any purpose with-
out the express written consent of BHGE.
Nuovo Pignone
COMMISSIONING & START-UP MANUAL
Status and description of the revisions
Stato di revisione Data Eseguito Controllato Approvato Descrizione della revisione

Revision Status Date Prepared Checked Approved Description of the revisions
00 04-17 G.D.S. Panufnik M. Lascialfari G. ISSUE
01 11-18 G.D.S. Lascialfari G. Arcioni M. UPDATE DOCUMENTS
© 2018 Nuovo Pignone Tecnologie S.r.l., tutti i diritti riservati

NUOVO PIGNONE TECNOLOGIE PROPRIETARY INFORMATION
QUESTO DOCUMENTO CONTIENE INFORMAZIONI RISERVATE DI PROPRIETA DI NUOVO PIGNONE TECNOLOGIE S.r.l. CHE NON DEVONO
ESSERE UTILIZZATE O DIFFUSE A TERZI, AD ECCEZIONE DI AUTORIZZAZIONE SCRITTA DI NUOVO PIGNONE TECNOLOGIE S.r.l. INEDITO
©2018. TUTTI I DIRITTI SONO RISERVATI A NUOVO PIGNONE TECNOLOGIE S.r.l.
© 2018 Nuovo Pignone Tecnologie S.r.l., all rights reserved

NUOVO PIGNONE TECNOLOGIE PROPRIETARY INFORMATION
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF NUOVO PIGNONE TECNOLOGIE S.r.l WHICH
SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE WRITTEN PERMISSION OF NUOVO PIGNONE TECNOLOGIE S.r.l .
UNPUBLISHED WORK ©2018 NUOVO PIGNONE TECNOLOGIE S.r.l. ALL RIGHTS RESERVED.
11-18-E 1606600÷07 P. 1-1

© 20187 Nuovo Pignone Tecnologie S.r.l., a Baker Hughes, a GE Company, LLC (“BHGE”) company: the information contained in this document is company
confidential and proprietary property of BHGE or its affiliates. It is to be used only for the benefit of BHGE and may not be distributed, transmitted, reproduced,
altered or used for any purpose without the express written consent of BHGE.
Nuovo Pignone
BHGE Technical Communication
Technical Bulletins (NIC/TIL and TEC) represent the official documents issued for Customers by BHGE to
communicate product improvements and technical recommendations for the resolution of fleet issues.
An application referred to as the “Technical Enhancements & Notifications (TEN) platform” is the online
repository for all Technical Bulletins and Enhancements published by BHGE.
Using this platform, Customers can monitor and update the implementation status of the documents
applicable to their fleet, and search and download all the technical communications relevant to their
equipment.
The TEN platform is available on the official BHGE website at the link:
www.geoilandgas.com/technicalupdates
After registering, Customers can log in any time to easily access and download all bulletins relating to their
specific BHGE equipment. Queries can be made by the following categories: technology type, equipment
serial number, bulletin number, title/keyword, issue date, compliance category and others.
Customers registered for the TEN platform are automatically notified by email of newly issued bulletins
relevant to their equipment. Instructions for obtaining access to the TEN platform along with additional
information relevant to the application are available within the TEN website.
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© 2018 Nuovo Pignone Tecnologie S.r.l., a Baker Hughes, a GE Company, LLC (“BHGE”) company: the information contained in this document is company confidential and proprietary
property of BHGE or its affiliates. It is to be used only for the benefit of BHGE and may not be distributed, transmitted, reproduced, altered or used for any purpose without the express
written consent of BHGE.
Nuovo Pignone
Customer Service Center

Customers can call our CSC 7x24 or find the appropriate Expert for an issue on Support Central – CCM – in
the Technical Assistance Community. The Expert will take ownership of the case ID until a solution is found.
The CSC Team collects Customer’s issues, and records and tracks them using Customer Claim Management
– or supports the Customer in doing so – thus streamlining the process.
CSC- Technical Assistance Form

The following information is needed by the Customer Service Center at the time that a technical assistance
request is submitted. Missing information can delay the process. The Customer Service Center is available
24/7 to receive the form and to help you with a rapid response.
− Serial number of the unit (For auxiliaries and associated equipment always include the machine serial
#.)
− Machine fired hours
− Number of starts
− Current machine status
− Last intervention type and date
− Alarm and trip log
− Is machine covered by remote monitoring & diagnostics (Y/N)
− Description of the event
− Is the event recurrent (Y/N)
If Applicable
− Vibration and axial displacement values with respective BHGE tag number
− Bearing temperature values with respective BHGE tag number
Phone: +39-055-427 2500

Fax: +39-055-423 2800
e-mail: customer.service.center@ge.com
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Advisory Monitoring & Diagnostics (AM&D)

Machinery and peripheral equipment for oil and gas applications must operate within specified parameters in
order to achieve the desired performance, production targets and operating costs.
Traditional monitoring methods require on-site personnel and analysis, with periodic OSM engineering
support. BHGE’s AM&D service offers the superior alternative of continuous monitoring by expert engineers
with significantly enhanced response times – and without additional on-site staffing costs or logistics.
How it works
Our standard monitoring instruments (for temperature, pressure, vibration, etc.) are supplemented with a Site
Connectivity Kit so that operating data can be securely transferred from the site to the BHGE AM&D Center.
The M&D system is linked to our headquarters in Florence, Houston and Kuala Lumpur, where a dedicated
team of diagnostic engineers evaluates the actual and target parameters as well as correlations between
components to continuously monitor the performance and health status of components. They then work with
your staff to support onsite activities – ranging from detailed optimization plans to immediate emergency
procedures.
The diagram below shows the overall architecture of the AM&D system:
The system is used to enhance machine protection as well as performance and for this purpose, a set of
diagnostic thresholds are implemented in the central system. In addition, the system facilitates technical
assistance activities and Customer support.
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PURPOSE OF THE COMMISSIONING & START-UP MANUAL
This Commissioning & Start-Up Manual is being delivered for general guidance purposes, in
order to provide Customer with technical background information needed for carrying out the
Commissioning & Start-Up of the Products.
Commissioning & Start-Up of the Products entails the use of complex technical Products that
requires using special tools and expert know-how.
Only technically qualified personnel should commissioning & start up the Products.
Responsibilities for products Commissioning & Start-Up are defined by contractual terms and
conditions applicable to the project.
In case the responsibilities of the product Commissioning & Start-Up are owned by the cus-
tomer or by any other party / contractor reporting to him, in no event shall BHGE-NP be liable
whether in contract, warranty, tort (including negligence whether active, passive or imputed),
product liability or strict liability or other theory), for cover or for any indirect, incidental, special
or consequential damages (including without limitation any loss of profits or data, business in-
terruption, computer failure or other pecuniary loss) arising out of the use or inability to use
this manual.
This Commissioning & Start-Up Manual and any and all information set forth therein are pro-
prietary to NP; therefore, Customer agrees not to assert any proprietary rights therein, or to
represent this Commissioning & Start-Up Manual and/or any information set forth therein to
anyone other than as a document and/or information which is exclusively proprietary to NP.
This manual contains and has been developed using a set of documents and drawings that
are current as at the date of publication of this manual. Later revisions to such documents
and drawings may be contained in the Vendor Document Register as defined by the applica-
ble contractual terms and conditions. In the event of a conflict between the manual and the
Vendor Document Register, the latter shall prevail.
BHGE reserves any right to revise this manual as it deems appropriate without any notifica-
tions.
SUGGESTED ACROBAT READER SETTINGS FOR EASIER NAVIGATION
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Commissioning & Start up Manual
INDEX
Description Section
FOREWORD ................................................................................................................................1
SAFETY PRESCRIPTIONS ...........................................................................................................2
MAIN ACTIVITIES .......................................................................................................................3
REFERENCE DRAWINGS ...........................................................................................................4
STANDARD PRACTICES .............................................................................................................5
QUALITY PROCESSES AT SITE ..................................................................................................6
COMMISSIONING .......................................................................................................................7
START-UP ....................................................................................................................................8
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Commissioning & Start-up Foreword Section 1
INDEX
Contents Page
1 FOREWORD ................................................................................................................................................... 1
1.1 SCOPE ...................................................................................................................................................................................... 1
1.2 DEFINITIONS ......................................................................................................................................................................... 2
1.3 ORIGINAL EQUIPMENT MANUFACTURERS MANUAL ......................................................................................... 5
1.4 HOW TO READ BHGE TPI&C MANUALS <1> .......................................................................................................... 6
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Nuovo Pignone
1 FOREWORD
1.1 SCOPE
The purpose of this document is to define the general guidelines governing the commissioning and
start-up activities to be executed for the machineries included in the BHGE scope of supply and it is
intended that it shall be merged by Customer into an overall plan of Commissioning and start-up
which necessarily involves not only the machineries being part of BHGE scope of supply, but also all
inferred systems as they might be linked by function, by sequence, by process and/or by contiguity to
the plant where the machineries shall be installed.
This Commissioning and start-up manual is being delivered for general guidance purpose, in order to
provide Customer with technical background information needed for carrying out the Commissioning
and Star-up activities of the machineries.
The Commissioning and Start-up activities refer to a TURBOGROUP composed mainly with:
- MS 6001B;
- Load Gear;
- Electric generator
Every work shall be carried out according to the BHGE and/or to the Customer standards and specifi-
cations either for the general prescription or for specific manufacturing standards, norms, special
norms of commissioning, execution, checking, etc..
These instructions, that do not purport to cover all details not to provide for every possible con-
tingency, are intended to supplement the experience and ability of qualified personnel who is as-
sumed to be familiar with the machineries in general (like but not limited to Gas Turbines, Cen-
trifugal Compressors, Steam Turbines, Power generator) and with the use of tools and commonly
used elements, materials and methods.
Good judgment and proper safe practices to avoid personal injury and property damage shall be ex-
ercised by the personnel who shall not consider the instructions as relieving him from the responsibil-
ity of ensuring a competent care of the equipment.
The personnel entrusted with the installation of BHGE products shall have the neces-
sary technical characteristics and suitable technical training for the task it has to ac-
complish.
In case the installation, commissioning and startup of BHGE equipment is performed

by third parties, BHGE shall have no responsibility for loss or damages caused by im-
proper installation, commissioning and startup, unless such third parties have been
certified and trained by BHGE.
Any damage, even partial, ascribable to failure to comply with aforesaid essential
characteristics shall be attributable to the purchaser and BHGE will be discharged of
any liability and indemnification thereof.
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1.2 DEFINITIONS
As general rules and for guidance only, the following terms and definitions are normally used in the activities
of Precommissioning, Commissioning and Start-up of machineries.
However, the definitions indicated in the contractual documents shall prevail to those listed hereinafter.
a) Customer. Is the party that initiates the project and ultimately pays for its design and constructions. The
Customer shall generally specify the technical requirements.
b) BHGE. Is the party that carries out all or part of the design, engineering, procurement, construction,
commissioning (when requested) of the machineries included in his scope of supply.
c) EPC Contractor. Is the party that carries out all or part of the design, engineering, procurement, con-
struction of a plant/facility where the machineries will be installed.
d) Erection Contractor: is the party that carries out the activities related to the installation & pre-
commissioning of the plant. It can also be providing support for the execution of the Commissioning.
e) Supplier. Is the party that manufactures or supplies equipment and services to perform the duty speci-
fied by the Customer
f) Operator. Is the party nominated by the Customer for the normal operation of the Unit.
g) Unit. Generic word referred to machineries, equipment, piping, vessels and all support facilities (as in-
strumentation,/control, electrical, civil/structural) within defined Unit limits, included in BHGE scope of
supply, required to carry out a specific process
h) System. Portion of the Unit dedicated to perform a specific function. It is composed of mechanical com-
ponents and instrumentation, and includes a portion of the control system dedicated to manage the sys-
tem functionality, without or with limited interactions with other portions:
i) Pre-commissioning. This phase comprises those non-operational check and test activities carried out to
prove that equipment and facilities within a Unit have been properly installed. It include installation
checks, flushing of piping, chemical cleaning, motor bump test, alignment of rotating equipment, etc.
NOTE: the precommissioning is included in TPI, Technical Package for Installation.
j) Ready for Commissioning (RFC). For each system, this status is achieved when all precommissioning
activities have been completed, all category A agreed punch list items have been corrected and all facili-
ties are available to support safe commissioning activities.
k) Mechanical completion. This status is achieved when all systems of the Unit has reached the RFC sta-
tus. This means also that the Unit has been erected in accordance with the drawings, specifications, ap-
plicable codes and supplier instructions to the extend necessary to permit the commence of commis-
sioning activities.
l) Commissioning. For each system, this phase comprise those activities carried out subsequent to RFC
and before RFSU, which are necessary to prepare the Unit for the first introduction of feed.
m) Ready for Start-up (RFSU). This status is achieved when all commissioning activities have been com-
pleted and all agreed punch list items have been corrected and all facilities are available to support safe
start-up activities. This status can be managed at System level or at complete scope of supply level, as
required by Customer Quality Control System.
n) Introduction of feed. This operation refers to the opening of valve admitting the process fluid (as hydro-
carbons, steam) and it require the Customer written authorization
o) Start-up. This phase commence when the Unit has achieved the status of RFSU and is initiated the in-
troduction of the feed into Unit.
p) Punch item. It is a deviation from applicable drawings and specifications, standard workmanship, a
hazardous installation or incomplete QA/QC documentation. They are categorized A, B, C and D accord-
ing to the erection, commissioning and startup phase.
q) Performance test. The test is carried out in agreement with contractual terms and conditions once
when the Unit has achieved the production and product specification, at design throughput.
r) Provisional unit acceptance. Usually the same as COD, specific contracts may place certain provisions
on acceptance for payment purposes. It also may identify the hand-off of responsibilities of machine’s
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operation from BHGE to Customer’s Operators while clearing Master Punch List, or prior to execute the
Performance test (if required by the contract)
s) Final acceptance. Usually the same as COD, it may identify the complete closure of all Master Punch List
items and the fulfillment of all contractual obligations from BHGE.
t) Commercial Operation Date (COD). It defines events in order that machine is ready to operate. All test-
ing and tuning is complete and the machine can operate. Generally begins warranty period
u) Lock Out Tag Out (LOTO) is a safety procedure dedicated to prevent that an operator may get in con-
tact, during site activities, with dangerous sources of energy, such as mechanical (moving parts), pres-
sure, electricity, etc. It is based on the use a of physical locking mean to be applied on the device control-
ling the source of energy, preventing it to be inadvertently operated and letting the energy to pass and
reach some unprotected portion of the plant where the operator may be performing some activity. The
procedure also includes the management of the insertion and removal of the locking device, that shall
be done involving the operator potentially in contact with the energy. See also the work instruction EHS-
WI.005 at section 2.1.
This operation refers to the opening of valve admitting the process fluid (as hydrocarbons, steam) and it re-
quire the Customer written authorization
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Installation & Commissioning Control

•COM45/1: Mechanical completion certificate
Installation Schedule - Certificates
•COM45/2: 72h reliability running test certificate
•COM45/3: COD certificate
Construction and Commissioning, Contractual Performance Punchlist items closed
Pre-Commissioning complete System Tuning and Tests complete, machine and machine accepted
Site Skids on the & Ready for Commissioning Startup completed is ready to operate by owner
Mobilization Foundations
Positioning of Com 45/1 Com 45/2

Com 45/3 Punch List
skids on the foun- Mechanical comple- 72h running test
COD Closed
dations tion completed
Commercial
Erection & Pre-commissioning Commissioning & Startup Contractual tests Operation
COD = Commercial Operation Date. It defines events in order that machine is ready to operate. All testing and tuning is complete and the
machine can operate. Generally begins warranty period
Provisional Acceptance = Usually the same as COD, specific contracts may place certain provisions on acceptance for payment purposes
Mechanical Completion = Construction work is complete. Include Pre-commissioning activities.
Pre-Commissioning = All checks required prior to system being energized
Commissioning = All checks required to be completed after each system has been energized, to prepare the system to operate
Start up = All tuning that is done on the machine after first starting and required for contractual performance test
Warranty period = Typically starts at COD and runs for a period defined in the Prime Contract
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© 2018 Nuovo Pignone Tecnologie S.r.l., a Baker Hughes, a GE Company, LLC (“BHGE”) company: the information contained in this document is company confidential and proprietary property of BHGE or its affiliates. It is to be used only for the benefit of BHGE and may not be
distributed, transmitted, reproduced, altered or used for any purpose without the express written consent of BHGE.
Nuovo Pignone
1.3 ORIGINAL EQUIPMENT MANUFACTURERS MANUAL
The TPC contains the information to commission all the equipment in BHGE-NP scope of
supply, some equipment are not manufactured by BHGE-NP. In this case TPC’s infor-
mation are completed by Original Equipment Manufacturer (OEM) manuals.
OEM manuals (also called “supplier manuals”) are available in BHGE-NP “Operation &
Maintenance Manual” (OMM).
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© 2018 Nuovo Pignone Tecnologie S.r.l., a Baker Hughes, a GE Company, LLC (“BHGE”) company: the information contained in this document is company confidential and proprie-
tary property of BHGE or its affiliates. It is to be used only for the benefit of BHGE and may not be distributed, transmitted, reproduced, altered or used for any purpose without the
express written consent of BHGE.
Nuovo Pignone
1.4 HOW TO READ BHGE TPI&C MANUALS <1>
Technical Packages for Installation and Commissioning are designed to provide instruc-
tions and quality requirements to reach a flawless Start-up of the equipment supplied by
BHGE.
TPI&C define the key activities to be performed, applicable documentation and records &
overall responsibilities.
I&C activities entail the use of complex techniques that require special tools and expert
know-how.
Only technically qualified personnel should install the products.
Some equipment’s are not manufactured by BHGE, in this case TPI&C’s information are
completed by Original Equipment Manufacturer (OEM) manuals; OEM manuals (called
“supplier manuals”) are available within the BHGE “Operation & Maintenance Manual”
(OMM).
Before beginning any activity, the operator shall take about safety prescriptions included
in the relevant section of the TPI&C and OEM manuals.
Manuals shall be read in conjunction with project specific documentation, I&C stand-
ard procedures, Site Quality Check list and Operation and Maintenance manuals.
All needed documentation is listed under the section “REFERENCE DRAWINGS” and within
the Site Quality Check List (SQCL) the operator can find the applicable docu-
ment/acceptance criteria/certification etc.… at Installation and Commissioning activities.
Every document is reached by means of hyperlinks.
For easier navigation, the manuals contain also a useful excel file “Document Table”
which provides the list of Job documents, Standard Procedures applicable to specific op-
erations, Standards and Quality Documentation, broken down by installa-
tion/commissioning sequences.
Site Quality Check List summarize the standard installation and testing stages for the
major components supplied. Site operators shall follow SQCL content to assure an effec-
tive quality check of the installation activities and their certification in agreement with all
the parties involved.
Here attached an example on how to proceed prior to start an activity.
NOTE: all the references showed in below figure are given only for reference. Please
refer to job TPI index.
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Oil Flushing
a) Check relevant section in the TPI manual and select hyperlink “see attached marked
up P&ID for system to be flushed”:
b) Check relevant section in the SQCL:

This section explains the list of activity, checks and certification to carryout for Oil
Flushing
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c) Collect needed documentation according to the “REFERENCE DRAWINGS” section

(or “Document Table” file) and SQCL.
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And reference procedures in same Table:
d) Start to operate according Job documentation, SQCL step description, applicable

Standard procedures and OEM manuals (when referred). The supplier manuals have
to be extracted from OMM.
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Commissioning & Start-up Safety Prescription Section 2
INDEX
Contents Page
2 SAFETY PRESCRIPTION
2.1 STANDARD SAFETY INSTRUCTIONS .................................................................................................................. 1
2.2 FIELD ACTIVITIES EHS POLICY .............................................................................................................................. 2
2.3 JOB SAFETY ANALYSIS DESCRIPTION ................................................................................................................ 5
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proprietary property of BHGE or its affiliates. It is to be used only for the benefit of BHGE and may not be distributed, transmitted, reproduced, altered or used for any pur-
pose without the express written consent of BHGE.
Nuovo Pignone
2.1 STANDARD SAFETY INSTRUCTIONS
Safety instructions for all Machines supplied by Nuovo Pignone are available in SOM6755584.
It is important that all the instructions, directions, warnings and rules relative to accident prevention
are fully respected.
The document SOM6755584 is intended for skilled operators and skilled personnel and provides in-
structions about procedures and operations aimed at ensuring correct and functional use of the plant
concerned.
For the purpose of favoring immediate consultation of this document, it is recommended make it easi-
ly accessible, as well as known, to all of the users involved.
In compliance with the provisions of the directives applicable to the supplied product, indicated in the
Declaration of Conformity issued by Nuovo Pignone, this documentation contains important infor-
mation, whose knowledge is fundamental both for operators and for maintenance technicians, in or-
der to be able to work in safety conditions.
Every operation described herein must be performed by the operator considered most suitable for the
tasks to be carried out.
Personnel operating on the plant must have sufficient knowledge of the functioning of the plant itself
and must have read this document carefully, and must then apply the provisions given in it and follow
the instructions received from the manufacturer. Moreover, the operator and for the authorized to the
maintenance must have acquired sufficient training for the activity he is to carry out. For this reason,
the operators must have received proper training, also through an initial training period, provided by
the BHGE Nuovo Pignone Training Center.
For all situations not described in this document and in any case where specifi-
cally indicated, it will be necessary to contact the Nuovo Pignone assistance ser-
vice.
Updated lists of contacts can be found also at the Customer Service Center site.
(http://www.geoilandgas.com/pipeline-storage/gas-processing-compression/rotating-equipment-service-support)
Before beginning any activity the operator must also take note of the particular safety pre-
scriptions issued by the manufacturers of the individual devices. These prescriptions are found
in the Manuals for the auxiliary equipment and the instrumentation. The safety prescriptions
contained in this document are to be utilized in the operating procedures for running the plant.
The machinery and its auxiliaries have been designed and constructed in such a way as to re-
duce to a minimum any risk to the operator. The residual risks and relevant precautions are re-
ported both in this section (for those of general nature) and in the various sections pertinent to
the relevant activities and the ensuing possible damage to things or persons.
Failure to observe safety regulations and/or the removal or modification of safeguards

will nullify the manufacturer’s guarantee and make the user fully liable.
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2.2 FIELD ACTIVITIES EHS POLICY
BHGE Site Team has to comply with BHGE EHS Policy and instructions when performing field
activities, together with any other site specific EHS prescriptions and safety plan established by
Customer or by Local Authorities. In case of discrepancies between different policies, BHGE Site
Team has to comply with the more stringent one.
The following EHS procedures are given to Customers for information and reference only.
The Hazard Controls / Preventative Measures contained in the Safety Risks Assessment Forms
(explained later) take also into consideration the application of the EHS prescriptions (e.g.: EHS-
WI.005 Lockout / Tagout program).
NOTE: ALL SAFETY WARNING AND HAZARD CONTROLS / PREVENTATIVE MEASURES CONTAINED
IN THE PRESENT MANUAL, AND/OR IN THE SAFETY RISKS ASSESSMENT FORMS ANNEXED TO IT,
ARE GIVEN AS AN INPUT TO ANY PARTY FORMALLY RESPONSIBLE FOR THE PREPARATION OF
THE SITE EHS OPERATIONAL PLAN. THESE EHS RELATED INFO, THEREFORE, SHALL NOT BE IN-
TENDED AS DIRECT INSTRUCTIONS FOR THE OPERATORS EXECUTING SITE ACTIVITIES.
Here below is reported the link to BHGE Global Services EHS Documents website, where it is
possible to find the latest Environment, Health and Safety prescriptions for field activities:
BHGE Oil and Gas Global Services EHS Documents

(http://libraries.ge.com/LibrariesWiki/2833480101/GE Oil and Gas Global Services EHS Documents)
NOTE: THE ABOVE LINK IS ACTIVE ONLY FOR BHGE PERSONNEL, THAT IS RESPONSIBLE TO
DOWNLOAD THE PROCEDURES FROM THE REPOSITORY LINKED ABOVE, TO ENSURE THAT THAT
NO NEWER REVISIONS HAVE BEEN ISSUED. THE PROCEDURES LINKED TO FOLLOWING TABLE OF
CONTENTS ARE TO BE CONSIDERED AS “NON CONTROLLED COPIES.
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• EHS Policy
EHS policy is also available at the website mentioned in previous page, where all the contents
listed below can be downloaded by personnel with a valid SSO:
EHS Manual and Management Procedures
• EHS-MAN - EHS Manual

• EHS-PG.001 - Documental Management and Coding
• EHS-PG. 001.Saf01 - Documents List
• EHS-PG.002 - Training
• EHS-PG.003 - PPE Management
• EHS-PG.004 - Controls, Monitoring, Measurement Management
• EHS-PG.005 - Accident Reporting, Investigations and Follow up
• TMS-GO-EHS-06 - EHS Plan Management and Annexes - Outage Safety Plan
• EHS-PG.007 - Motor Vehicle Safety
• EHS-PG.008 - Site Activities Management
• EHS-PG.009 - Emergency Management
• EHS-PG.010 - Risk Assessment
• EHS-PG.011 - Workers Involvement
• EHS-PG.013 - Industrial Hygiene
• EHS-PG.014 - Medical Surveillance
• EHS-PG.015 - Waste and Environmental Emergency Management
Operative Procedures & Work Instructions
• EHS-WI.001 Confined Space Entry

• EHS-WI.002 Fall Protection
• EHS-WI.004 Permit to Work System
• EHS-WI.005 Lockout / Tagout program
• EHS-WI.007 Lifting and Rigging
• EHS-WI.008 Offshore Safety
• EHS-WI.009 H2S - Hydrogen Sulfide
• EHS-WI.010 STOP Work Authority
• EHS-WI.015 Short Service Employee Program
• EHS-WI.016 – Pre-travel Procedure
• EHS-PO.008 Manual Material Handling
• EHS-P13.000 Portable and mobile tools
• EHS-P16.000 Compressed gas
• EHS-P17.000 Commissioning
• EHS-P18.000 Radio Protection
11-18-E 1606600÷07 P. 3 of 9
Nuovo Pignone
BHGE employees duties and responsibilities concerning Environment, Health & Safety
Each worker, according to laws in force and to the BHGE’s EHS manual, takes care about
safety of himself and of other persons present in the work site, on which his actions and
omissions can fall upon, compliant to his training, his instructions and devices supplied by
the employer.
Obligations are:
• to observe dispositions and instructions given by the employer, managers and Site;
Manager, concerning collective and personal protection;
• to use in a proper way machinery, equipment, tools, hazardous substances and
preparations, means of transport and other work equipment, as well as safety de-
vices;
• to use in a correct way protection devices placed at their disposal;
• to report immediately to the employer, manager or Site Manager, safety device defi-
ciencies, as well as any other hazard conditions that they become aware of, acting
directly in case of emergency, within their competence and ability, to eliminate or
reduce those deficiencies or hazards, informing the representative for workers safe-
ty;
• to neither remove nor modify, without authorization, safety, signaling or control de-
vices;
• not to carry out on his own initiative operations, maneuvers that do not fall in his;
competence or that can compromise his or other persons’ safety;
• to undergo sanitary checks foreseen for them;
• to contribute, together with the employer, managers, and Site Manager, to carry out
all obligations imposed by competent authority, or however necessary for protect-
ing workers safety and health during work.
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2.3 JOB SAFETY ANALYSIS DESCRIPTION

The Job Safety Analysis (JSA) forms provided in this manual have been developed according to the following procedure:
BASIC JOB STEPS

The JSA is an method of risk analysis, aimed at identifying hazards associated with each
step of the job or task to be executed. In the JSAs, the actions are detailed, that will elimi- Each job or operation consist of a set of steps or tasks. Divide a Job in a set of Steps or Tasks
nate, nullify, or prevent such hazards. enable to discover potential hazards employees may encounter.
In this part of the JSAs form the steps that must be performed for the execution of the spe-
The JSAs do not take into account the risks associated to the working environment (i.e., cific Job are defined.
noise of the workplace, explosion hazard due to nearby operating plants, holes in the
ground, suspended leads that are not connected to the tasks that are going to be per- POTENTIAL HAZARDS
formed), and they are intended as a part of a more in depth risk assessment process.
Risk assessment is applied principally on Operational Risk Assessment: for the evaluation of
It must be clearly understood that the risk analysis of the JSAs do not exempt manage- the operational risk, the task carried out by a person directly on the plant and the associated
ment from its duty to provide a safe workplace. risk are considered.
The JSAs have to be issued, verified, and approved by relevant functions. If applicable, also After identifying all the steps that compose a specific job, each step is analyzed to identify all
the Customer and the EHS representative at site shall approve the JSAs. In the first page of hazards associated with it.
the JSAs, the Specific PPE and the general safety requirements are detailed, as well as the In this part of the JSAs form the potential hazards that are associated with each job steps
Emergency measures. are defined.
The implementation of the JSA method has significant benefits such as:
• Establishing job performance standards and standard operating procedure HAZARD CONTROLS/PREVENTIVE & PROTECTIVE MEASURES
• Eliminating or minimizes hazards
After the risk assessment, compensation and mitigation measures are assessed and ap-
• Creating a job training tool plied.
– New employee(s) Above-mentioned measures can be classified into:
– Pre-job instructions, irregular jobs
• Preventive Measure – reduce the risk diminishing the Probability that the unfavourable
• Creating a tool for job observation, for incident investigations, and for possible im- event occurs;
provements in job methods
• Protective Measures – reduce the risk diminishing the seriousness of Damag-
• Making safety and health a part of the production process, not an add-on to es/Consequences that come from an accident or from the exposure to a Risk factor for
– Encourage teamwork (especially with new employees) health.
– Involve everyone performing the job in the process The safeguard measures can be divided into:
– To improve awareness
• Engineering safeguard
The JSAs execution process is carried out in three main steps: Breaking the job down into
• Organizational/Managerial (including (E/T/I – Education/Training/Information)
steps, identifying hazards in each step, identifying actions to be taken to eliminate or min-
• PPEs
imize the hazards.
In this part of the JSAs form all the measures identified to reduce the relevant risk are de-
fined.
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Example and description of JSA [First Page]

Number and title of job or task to
be executed.
List of responsible functions for

issuing, verification and approval
of JSA’s.
Note:
“EHS representative at site” is
BHGE Site Manager or the BHGE
NP EHS manager when required
List of PPE & General Safety Re-

quirements.
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Example and description of JSA [Analysis of steps of activities]

Basic Job steps:
Steps that must be performed for
the execution of the specific job.
Potential Hazard:
Potential Hazards that are associ-
ated with each job steps.
Hazard Controls/Preventive & Pro-

tective Measures:
All Measures identified to reduce
the relevant risks.
Owners:
Responsible of the execution of
Hazard Controls / preventive &
protective measures.
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Example and description of JSA [Last Page]
List of Specific PPE & Safety Re-

quirements for the execution of
the analysed job.
Part of JSA dedicated at signs of

workers.
11-18-E 1606600÷07 P. 8 of 9
Nuovo Pignone
The zones surrounding the plant are considered dangerous and for each one there should be signs that show the residual risks. In general, for
each zone, there should be indicated the Personal Protective Equipment (PPE) prescribed to operate in that zone. The following table contains the
Minimum List of Site Signs which could be displayed.
PRESCRIPTION
Safety helmet must be worn Protective footwear must Wear ear protectors when Protective clothes must be Eye protection must be
Hand protection must be worn Wear safety harness
at all times be worn operating the machines worn worn
Located in entry yard zone,

Located in proximity of noisy
Located in entry yard zone Located in entry yard zone Located in entry yard zone Located in entry yard zone in proximity of working at Located in entry yard zone
work areas
heights areas not protected
PROHIBITION WARNING EMERGENCY
NO ENTRY to unauthorized No passing and parking

Generic Warning Electrical hazard Overhead loads First Aid Box First Aid
persons within range of lifting
Located on electrical sub- Located in proximity of ac-
Outside the areas where it Located outside infirmary
Located in entry yard zone Located in entry yard zone As needed stations, switchboards, high cess in overheads loads and
is located the first aid box room
voltage devices handling areas
FIRE FIGHTING BOUNDARY AREA FALL HAZARD SIZE SIGNAL
Fire Estinguisher Hydrant Contractors shall install EHS signs related to their machinery/equipment.
Fire estinguisher Each obstacle, each slope or hole in the round shall be signaled using yellow-black or white-
Hydrant identification red tape.
identification
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Commissioning & Start-up Main Activities Section 3
INDEX
Contents Page
3 MAIN ACTIVITIES ........................................................................................................................... 1

3.1 GENERAL ............................................................................................................................................................. 1
3.2 PRECOMMISSIONING .................................................................................................................................... 1
3.3 COMMISSIONING ............................................................................................................................................ 2
3.4 START UP ............................................................................................................................................................ 2
3.5 SUMMARY OF MAIN ACTIVITIES ................................................................................................................ 3
11-18-E 1606600÷07 3-Index

Nuovo Pignone
3 MAIN ACTIVITIES
3.1 GENERAL
After the construction activities and before to put the unit into operation a series of verifications
and tests shall be carried out in order to ensure, as thoroughly as practicable, that every machinery
will operate as per design conditions.
These operations are also the last review of the design before start-up. The ultimate goals of these
verifications are to render the Unit in as safe and trouble free as possible and the period necessary
to test the Unit before entering into routine production status, the shortest possible.
These completion activities are separated into the two phases of Precommissioning and Commis-
sioning; this split roughly corresponding to static and dynamic tests phases respectively.
The following paragraphs describe the main activities related to Precommissioning, Commissioning
and Start-up phases.
3.2 PRECOMMISSIONING
Precommissioning activities will be described in details in the TPI, Technical Package for Installa-
tion.; main Precommissioning activities are described in this manual for convenience in order to
well identify the relationship occurring between the various phases before the Unit start up.
Precommissioning includes four main types of field activities:
a. Systematic conformity checks, carried out on each item of Unit, such as any type of in-
stalled instrumentation, electric motors, valves, breakers, electrical and instrumentation
cables, etc to verify visually the conditions of the equipment, the quality of the installa-
tion, the compliance with project drawings and specifications, Supplier’s instructions,
safety rules, codes , standards and good construction practices.
b. To carry out on selected equipment static/de-energized tests, to ensure the quality of a

number o critical components. These “cold” testing concerns all disciplines, e.g. calibra-
tion of instruments, machinery alignments, setting of safety valves, pressure testing of
piping, cable continuity check, etc.
c. Piping and vessels air and/or water flushing and cleaning.
d. In addition to the above ones, BHGE includes in the pre-commissioning also some other
activities
• electrical and control panels energization
• electric motor direction of rotation
Each of the above tests shall be certified by filling proper forms/certificates signed by all involved
parties.
11-18-E 1606600÷07 P. 1 of 3
Nuovo Pignone
The completion of the above pre-commissioning activities marks the end of the construction of the
Unit and the achievement of the status of “Mechanical completion” or “Ready for commissioning”.
3.3 COMMISSIONING
Commissioning phase essentially includes the following tasks categories.
a. Dynamic verifications that each elementary electrical and instrumental function that
the Unit equipment is designed to achieve, performs properly. Typical examples of such
tests are electric motor uncouple run, instrument loops tests, electrical breakers opera-
tion. Complete energization of electrical distribution networks, initiated during pre-
commissioning, is part of this activity.
b. Mechanical preparation and running and on-line tests for a significant period of the util-
ities of the Unit.
c. A number of activities related to the feed-in preparation, such as piping drying out, leak
test and inerting, and ,when required, loading of various chemicals (such as glycol, wa-
ter softening)
Once all these commissioning activities are complete, the Unit will reach the “Ready for start up”
status.
3.4 START UP
Since the start up of the Unit is considered a commissioning operation, the real start up phase be-
gins with the introduction of feed into the Unit.
The main start up activities are therefore:
a. Feed-in
b. Bringing the Unit into operation
c. Functional Test (72-hr) to prove machine’s reliability
d. Performance tests to prove the Unit satisfy design specifications (if required by the Contract)
e. Punch list clearance
Technical milestone corresponding to final start up phase is the “COD - Commercial Operation
Date”.
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3.5 SUMMARY OF MAIN ACTIVITIES
Phase Activities Milestone Certificate

Precommissioning • Conformity checks Ready for commis-
• Static tests sioning (by systems) COM45-5
• Flushing and cleaning
• Panels energization Mechanical comple-
tion when all systems
COM45-1
are “Ready for Com-
missioning”
Commissioning • Energization, dynamic Ready for start up
tested
COM45-6
• Equipment running in
• Prestart up activities
Start up • Introduction of Feed Unit in operation
• Bringing the Unit on
line COM45-2
• 72 hrs reliability test
• Performance tests (if COD - Commercial

required by the con- Operation Date
COM45-3
tract)
• Punch list clearance
Job Safety Analysis (JSA)

Evaluation of specific risks, typical for duties carried out by personnel during Commissioning &
start-up activities, is contained in the JSA attachments provided at the beginning of each sec-
tion. Such attachment contains indications for prevention and protection operative measures
and modes, PPE to be used, references to the EHS Manual. (see section 2).
See following table for the list of JSA applicable to this job:
LIST OF JSA APPLICABLE TO TE JOB
Section Applic. JSA
Commissioning JSA044
START-UP_OPERATION JSA045
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Commissioning & Start-up Reference Drawings Section 4
INDEX
Contents Page
4 REFERENCE DRAWINGS .............................................................................................................. 1

4.1 HOW TO USE DOCUMENT TABLES ......................................................................................................... 1
4.2 REFERENCE DOCUMENTS ........................................................................................................................... 2
4.3 REFERENCE PROCEDURES.......................................................................................................................... 4
4.4 STANDARD PRACTICE ................................................................................................................................... 7
4.5 QUALITY MANAGEMENT AT SITE ............................................................................................................. 8
11-18-E 1606600÷07 4-Index

proprietary property of BHGE or its affiliates. It is to be used only for the benefit of BHGE and may not be distributed, transmitted, reproduced, altered or used for any purpose
without the express written consent of BHGE.
Nuovo Pignone
4 REFERENCE DRAWINGS
In the following tables there are collected the drawings mentioned in this Commissioning &
Start-up manual.
In the last columns of the tables it is explained to which section(s) of this manual the document
is referred.
As for the data contained in the unit construction drawings, please apply to the
BHGE Nuovo Pignone technical department.
This manual contains and has been developed using a set of documents and draw-
ings that are current as at the date of publication of this manual. Later revisions to
such documents and drawings may be contained in the Vendor Document Register
as defined by the applicable contractual terms and conditions. In the event of a con-
flict between the manual and the Vendor Document Register, the latter shall prevail.
NOTE: for information relevant to auxiliary equipment, refer also to OEM Manuals
4.1 HOW TO USE DOCUMENT TABLES

Quick link to open the
document from EDM (Enterprise Doc-
ument Management) system.
Drawing Quick link to open
NOTE: only available to BHGE
description the document
BHGE Drawing employee with proper EDM account
directly from CD
Number (internet connection required
Ope Ope Applicable to TPC

Document Customer n n section(s)
Description Rev
code doc. code from from
CD EDM 4 5 6 7
Piping and Instruments Diagram xxxxxxxxxx xxxxxxxxxx x open open x x x
Field Instrument List xxxxxxxxxx xxxxxxxxxx x open open x x
Interconnecting Wiring Diagram xxxxxxxxxx xxxxxxxxxx x open open x
Field Wiring Diagram xxxxxxxxxx xxxxxxxxxx x open open x
Functional Description xxxxxxxxxx xxxxxxxxxx x open open x
Etc... Etc... Etc... x open open x
Customer Drawing Drawing Revision

Number Number “where used” table
(if any)
NOTE: for easier navigation, an Excel version of the following tables can be opened by clicking on this link
11-18-E 1606600÷07 P. 1 of 8
prietary property of BHGE or its affiliates. It is to be used only for the benefit of BHGE and may not be distributed, transmitted, reproduced, altered or used for any purpose
Nuovo Pignone
4.2 REFERENCE DOCUMENTS

Applicable to
BHGE VDR Open Open TPC
Customer
Description DWG Rev doc. from from section(s)
Doc. No.
Number (Y/N) CD EDM
5 6 7 8
CONTROL NARRATIVE FOR PROPANE
NON40660 1 - Y open open - - X -
TREATMENT SKID
CONTROL NARRATIVE FOR NATURAL
NON40670 2 - Y open open - - X -
GAS TREATMENT SKID
STEP-UP TRANSFORMER TERMINAL
SOK0942633 0 - N open open - - X -
STRIP OUTLINE AND WIRING
STEP-UP TRANSFORMER TEST
SOK0942637 0 - N open open - - X -
PROCEDURE
DIESEL GENERATOR SET GENERAL
SOK2260132 3 - Y open open - - X -
ARRANGEMENT
GCPP OUTLINE DRAWING SOK2313514 3 - Y open open - - X -
GCPP WIRING DIAGRAM SOK2313515 3 - Y open open - - X X
GCPP WIRING DIAGRAM SOK2313516 2 - N open open - - X -
GENERATOR & TRANSFORMER PRO-
SOK2313517 1 - Y open open - - X -
TECTION SETTING STUDY
GEP OUTLINE DRAWING SOK4413773 3 - Y open open - - X -
GEP WIRING DIAGRAM SOK4413774 3 - Y open open - - X -
GENERATOR WIRING DIAGRAM SOK4413777 1 - Y open open - - X -
DC PANEL OUTLINE DWG SOK6824272 2 - Y open open - - X -
DC PANEL SINGLE LINE DIAGRAM SOK6824273 2 - N open open - - X -
DC PANEL WIRING DIAGRAM SOK6824274 2 - Y open open - - X -
PMCC OUTLINE DWG SOK7265215 3 - Y open open - - X -
PMCC SINGLE LINE DIAGRAM SOK7265216 3 - N open open - - X -
PMCC ELEMERNTARY SOK7265217 3 - Y open open - - X -
PMCC PROTECTION SETTING LIST SOK7265218 n.a. - N n.a. open - - X -
SINGLE LINE DIAGRAM SOK7350217 4 - Y open open - - X X
LOCAL CONTROL CABIN GENERAL
SOK9950845 2 - Y open open - - X -
ARRANGEMENT
PIPING & INSTRUMENT DIAGRAMS SOM6770884 7 - Y open open - - X X
NATURAL GAS TREATMENT SKID
SOM6770934 5 - Y open open - - X -
P&ID
PROPANE GAS TREATMENT SKID
SOM6770935 3 - Y open open - - X -
P&ID
ELECTRICAL LOAD LIST SOM6774670 7 - Y open open - - X -
UTILITY CONSUMPTION LIST SOM6774671 1 - Y open open - - X X
CONTROL SYSTEM SCHEMATIC SOM6775541 8 - Y open open - - X -
CONTROL SYSTEM POWER SCHEMA-
SOM6775542 2 - Y open open - - X -
TIC
UNIT CONTROL PANEL LAYOUT &
SOM6775543 4 - Y open open - - X -
MAIN EQUIPMENT LIST
UNIT CONTROL SYSTEM I/O LIST SOM6775545 7 - Y open open - - X -
CONTROL SYSTEM FUNCTIONAL
SOM6775546 n.a. - Y n.a. open - - X X
DESCRIPTION
CAUSE AND EFFECT DIAGRAM SOM6775547 2 - Y open open - - X -
11-18-E 1606600÷07 P. 2 of 8
Nuovo Pignone
Applicable to
Customer
Doc. No.
Number (Y/N) CD EDM
5 6 7 8
FIRE FIGHTING LOGIC DIAGRAM SOM6775549 2 - Y open open - - X -
UNIT CONTROL SYSTEM WIRING DI-
SOM6775551 5 - Y open open - - X -
AGRAM
FIRE FIGHTING MONITOR WIRING DI-
SOM6775552 3. - N open open - - X -
AGRAM
UNIT CONTROL SYSTEM INTERCON-
SOM6775554 n.a. - Y n.a. open - - X -
NECTING WIRING DIAGRAM
FIELD INSTRUMENT LIST SOM6775748 5 - Y open open - - X X
FIELD ELECTRICAL WIRING DIAGRAM SOM6775749 6 - Y open open - - X -
INSTRUMENTS PRIMARY AND PNEU-
SOM6775779 3 - N open open - - X -
MATIC HOOK-UP
FIRE FIGHTING MONITOR CONSTRUC-
SOM6800280 4 - N open open - - X -
TION DRAWING
REMOTE CABINET WIRING AND CON-
SOM6800282 1 - N open open - - X -
STR. DRAWING
OIL PURIFIER TROLLEY OUTLINE
SOM6801087 1 - N open open - - X -
DRAWING
NOTE: all codes marked DT-C are BHGE internal documents containing proprietary in-formation protected by IP
law. They are not included in this manual but can be accessed by authorized BHGE personnel through the EDM
“open” link. EDM (Enterprise Document Management system) is the BHGE engineering documents repository,
whose access is regulated by BHGE internal policies.
VDR Doc (Y/N): Y= document included into VDR Vendor Document Register; N= document available by BHGE
personnel (for consultation only, not subject to comments by the customer).
n.a.: not available
11-18-E 1606600÷07 P. 3 of 8
Nuovo Pignone
4.3 REFERENCE PROCEDURES

Applicable to
Customer
Doc. No.
Number (Y/N) CD EDM
5 6 7 8
ASSEMBLY AND CHECK PROCEDURE
OF FUEL GAS FLANGES ON HEAVY
RIC8990422 2 - N open open - - X -
DUTY GT MAINTENANCE ACTIVI-
TIES
GENERIC TEST CERTIFICATE / RE-
RIC8990423 2 - N open open - - X -
PORT FOR FLANGE MANAGEMENT
GENERAL NOTES FOR LUBE OIL
SIC00006 8 - N open open - - X -
SYSTEM FLUSHING
GENERATOR ELECTRICAL TESTS -
PROCEDURE FOR SHORT CIRCUIT,
SIC00036 3 - N open open - - - X
OPEN VOLTAGE TESTS AND SYN-
CHRONIZATION
SETTING OF AXIAL DISPLACE-
MENT,RADIAL & KEYPHASOR NO SIC00042 4 - N open open - - X -
CONTACT PROBES
GENERATOR ELECTRICAL SYSTEM
STD PRECOMMISSIONING & COM- SIC00052 0 - N open open - - X -
MISSIONING PROCEDURE
GENERAL PROCEDURE FOR INSTAL-
LATION OF MARK VI & MARK VIe SIC00053 1 - N open open - - X -
- UCP PANELS
JACKING OIL SYSTEM VERIFICA-
TION/CALIBRATION PROCEDURE
OSM FUNCTIONAL CHECKLIST SIC00066 2 - N open open - - X -
GAS TURBINE INLET SYSTEM IN-
STALLATION GENERAL GUIDELINE
UCS CONTROL SYSTEMS (MKVI,
MKVIE AND SAFETY/PROTECTION SIC00105 2 - N open open - - - X
PLC) REDUNDANCY TEST
VALVES FUNCTIONAL TEST
PROCEDURE
HYDRAULIC OIL SYSTEM SET UP
FOR HEAVY DUTY GAS TURBINES
PIPING/TUBING ERECTION & CON-
STRUCTION PROCEDURE
GENERAL NOTES FOR CLARIFI-
ER/PURIFIER INSTALLATION AND SIC00118 0 - N open open - - X -
COMMISSIONING
72 HOURS RUNNING TEST STAND-
ARD PROCEDURE
CO2 FIREFIGHTING SYSTEMS TEST
PROCEDURE SUPPLIER SANCO
LOOP CHECK PROCEDURE SIC00146 2 - N open open - - X -
LOOP CHECK EXECUTION GUIDE-
SIC00147 0 - N DT-C open - - X -
LINES
EXCESSIVE FUEL PROTECTION EM-
ERSON ELITE CORIOLIS FLOW- SIC00148 3 - N DT-C open - - X X
TRANSMITTER
INSTALLATION & COMMISSIONING
PROCEDURE CDM COMPOSED BY
PCB PROBE, PCB CHARGE AMPLI- SIC00155 1 - N open open - - X -
FIER AND PAMC ACQUISITION SYS-
TEM
11-18-E 1606600÷07 P. 4 of 8
Nuovo Pignone
Applicable to
Customer
Doc. No.
Number (Y/N) CD EDM
5 6 7 8
PNEUMATIC LEAKS TESTING GEN-
SIC00157 n.a. - N n.a. n.a. - - X -
ERAL GUIDELINES
GENERAL GUIDELINES FOR IN-
SPECTING GAS TURBINES WHILE IN SIC00161 1 - N DT-C open - - - X
OPERATION INSIDE AN ENCLOSURE
GENERAL NOTES FOR TURBINE EN-
CLOSURE - COMPLETION & VERIFI-
CATION OF CORRECT INSTALLA-
TION AT SITE
VERIFICATION OF THE CORRECT IN-
STALLATION, PRECOMMISSIONING
AND COMMISSIONING OF LV MO-
TORS AT SITE
MINERAL OIL SYSTEM COMMISSION-
ING & SETTING - SITE PROCEDURE
FOR MAIN + AUX + EMERGENCY
PUMPS CONFIGURATION
OVERSPEED TESTING PROCEDURE
FOR SINGLE SHAFT HD GAS TUR-
BINES: MS5001, MS6001, MS7001,
SIC00209 1 - N DT-C open - - X X
MS9001
OF EXPLOSIVE GAS DETECTION SIC00233 0 - N open open - - X -
SYSTEM
FIRE & GAS DETECTION SYSTEM.
SITE INSTALLATION & TEST SIC00234 0 - N open open - - X -
STANDARD PROCEDURE
GENERAL NOTES FOR CO2 FIRE
FIGHTING SKID INSTALLATION & SIC00236 0 - N open open - - X -
COMMISSIONING
GENERAL NOTES FOR OIL VAPOUR
SEPARATOR INSTALLATION
INLET BLEED HEATING CLEANING
SIC00256 0 - N open open - - X X
PROCEDURE
ALIGNMENT AND INSTALLATION
PROCEDURE SSS CLUTCH 64T SIC00258 0 - N open open - - X -
TYPE
PROCEDURE TO VERIFY INSERTION
DEEP OF SPARK PLUG .
STANDARD COMMISSIONING PROCE-
DURE - ACOUSTIC ENCLOSURE SIC00261 0 - N open open - - X -
(LEAK / SMOKE TEST)
HEAVY DUTY GAS TURBINE READ-
INGS FORMS
GEARBOX READINGS FORMS SIC00266 0 - N open open - - - X
PROCEDURE FOR DC PANELS AT SIC00277 0 - N open open - - X -
SITE
PROCEDURE FOR LOW VOLTAGE SIC00278 1 - N open open - - X -
MOTOR CONTROL CENTRE
GENERIC TEST CERTIFICATE / RE-
PORT
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Nuovo Pignone
Applicable to
Customer
Doc. No.
Number (Y/N) CD EDM
5 6 7 8
ELECTRIC GENERATOR (WATER
COOLING SYSTEM) READINGS SIC00294 0 - N open open - - - X
FORMS
STANDARD MKVI AND MKVI-E GCV
SIC00299 0 - N DT-C open - - X -
SRV CALIBRATION PROCEDURE
MS6001 DUAL FUEL DLAN LIQUID
FUEL SYSTEM AND PURGING TU- SIC00315 0 - N open open - - - X
NING
n.a.: not available
11-18-E 1606600÷07 P. 6 of 8
Nuovo Pignone
4.4 STANDARD PRACTICE

Applicable to
Customer
Doc. No.
Number (Y/N) CD EDM
5 6 7 8
DESIGN GUIDLINE FOR FIRE
FIGHTING SYSTEMS FOR GAS
TURBINE PACKAGES-TOTAL ITM65300 3 - N open open - - X -
FLOODING CARBON DI OXIDE (CO2)
SYSTEM
PNEUMATIC SEAL TESTING
ITN07022 14 - N open open - - X -
PROCEDURE
GENERAL SPECIFICATION OF FAB-
ITN07881 3 - N open open - - X -
RICATED CONTROL CABIN
CDM CUSTOMER OPERATOR MA-
SOM5082719 0 - N open open - - X -
NUAL
PROCEDURE FOR INSTALLATION,
INSTRUMENT AND SOFTWARE
SOM5458856 1 - N DT-C open - - X X
SETTINGS FOR EMERSON CORIOLIS
FLOWMETER
BACK UP CONTROL SOFTWARE
SOM6614234 9 - N open open - - X -
ARCHIVE PROCEDURE
CONTROL SYSTEM ELECTRICAL
GROUNDING GUIDELINE - PART2 -
SOM6614380 2 - N open open - - X -
SAFETY INSTRUCTION SITE
PREPARATION
CONTROL SYSTEM ELECTRICAL
GROUNDING GUIDELINE- PART3 –
SOM6614381 2 - N open open - - X -
SITE GROUNDING MINIMUM RE-
QUIREMENTS
HMI USB MEMORY STICK CYBER
SOM6650987 1 - N open open - - X X
SECURITY POLICY
OPERATION AND MAINTENANCE
RECOMMENDATIONS FOR GAS SOM6664411 3 - N open open - - X -
TURBINE INLET SYSTEMS
FR6 DLN-1 COMBUSTION SYSTEM
COMMISSIONING: REQUIREMENTS SOM6667380 0 - N open open - - - X
AND GUIDELINES
UCP CUSTOMER HANDOVER SOM6766322 2 - N open open - - - X
UCP COMMISSIONING/SUPPORT PC
SOM6769279 1 - N open open - - X X
CONNECTION POLICY
MS6001B DLN1 DF WI MAPPING
SOM6775986 n.a. - N DT-C open - - - X
PROCEDURE
n.a.: not available
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4.5 QUALITY MANAGEMENT AT SITE
Cus- Applicable to
tomer
Doc.
Number (Y/N) CD EDM
No. 5 6 7 8
MECHANICAL COMPLETION CERTIFI-
COM45-1 - - N open - - X - X
CATE
START-UP CERTIFICATE COM45-2 - - N open - - X - X
COD CERTIFICATE COM45-3 - - N open - - X - X
READY FOR COMMISSIONING CERTI-
COM45-5 - - N open - - X - X
FICATE
READY FOR START UP CERTIFICATE COM45-6 - - N open - - X - X
SITE QUALITY COMMISSIONING
SOI0002894 1 - N open open - X X -
CHECK LIST
SITE QUALITY START-UP CHECK
SOI0002895 1 - N open open - X - X
LIST
SITE QUALITY LOOP CHECK LIST SOI0002896 0 - N open open - X X -
n.a.: not available
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Commissioning & Start-up Standard Practices Section 5
INDEX
Contents Page
5 STANDARD PRACTICES ................................................................................................................ 1

5.1 INSTRUCTIONS FOR MANAGEMENT OF ORDERING SPARE PARTS DURING
COMMISSIONING ...................................................................................................................................................... 1
5.2 STORAGE OF SPARE PARTS ........................................................................................................................ 1
5.3 PIPING FLANGES TIGHTENING.................................................................................................................. 2
5.3.1 Flanges Tightening Torque .................................................................................................... 2
5.3.2 Checks To Be Carried Out Before Tightening ................................................................ 2
5.3.3 Tightening Procedure ............................................................................................................... 3
5.3.4 Checks To Be Carried Out After Tightening ................................................................... 3
5.4 TIGHTENING TORQUE FOR BOLTS (GENERAL APPLICATIONS) ................................................... 4
5.4.1 Torque Procedure ....................................................................................................................... 5
5.5 HOUSEKEEPING ............................................................................................................................................... 6
11-18-E 1606600÷07 5-Index

Nuovo Pignone
5 STANDARD PRACTICES
This paragraph contains a series of standard instructions relevant to the equipment treatment.
5.1 INSTRUCTIONS FOR MANAGEMENT OF ORDERING SPARE PARTS DURING COMMISSIONING
Use of parts, other than as manufactured or authorized for use by BHGE, or re-
pairs or modifications performed by others not authorized by BHGE to be so per-
formed, will void any warranty on BHGE equipment and will relieve BHGE of any
liability for injury or damages resulting there from.
When ordering spare parts for machines manufactured by BHGE Nuovo Pignone provide the fol-
lowing information:
 BHGE Nuovo Pignone job number. This will be a seven-digit number

 Model and serial number of the machine as given on the nameplate
 Parts list number and assembly drawing number to refer to
 Part number as shown in the parts list and name of part
 Quantity required
 Complete address to which shipment of parts is to be made.
When ordering parts for accessory equipment give manufacturer name, type and serial number
of equipment as given on the nameplate.
If no parts list is available a brief description of the part and its function must be clearly specified
in the order.
5.2 STORAGE OF SPARE PARTS
As a general rule, here is highlighted the need to use high care in keeping spare parts in good
condition in the store.
Upon receipt, spare parts should be visually inspected for sign of corrosion, damage or other
problems, which might require correction.
Following inspection, and if necessary, completion of corrective actions, the parts shall be stored
indoors in a clean and dry place.
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5.3 PIPING FLANGES TIGHTENING
For detailed information on piping flange bolts tightening see ITN31012.
5.3.1 Flanges Tightening Torque
The following table, extract from ITN31012, defines the minimum tightening torques of the bolts
for piping flanges, the applicability is limited to the cases of missing information on job drawings:
NOTE: 1 N m = 0.73 lb ft
1 N m = 0.10 kg m
5.3.2 Checks To Be Carried Out Before Tightening
a) Check the status of the flange sealing surfaces: they shall be without excessive scratches
and shall be cleaned.
b) the bolts shall be cleaned and without excessive oxidation, the threads shall be in perfect
conditions and the tie rods shall be straight.
c) the gaskets shall be in good conditions and clean.
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5.3.3 Tightening Procedure
The tie rods shall be tightened following the sequence shown below. The tightening shall be car-
ried out in two phases. The first tightening shall be carried out at 60% of the expected torque.
The final tightening shall be made following the provided torque and the same sequence of the
first one. At the end of the tightening the torque applied shall be within the allowed values of
±5% than that provided.
5.3.4 Checks To Be Carried Out After Tightening
a) The flanges check is necessary in order to avoid oil, air or fuel leaks, which may cause var-
ious dangers to the operator.
b) Check coupling flanges bolts and nuts, making sure that they have been tightened at the
torque indicated on the relevant drawings.
c) A visual check must be performed for piping coupling flanges in which fluids (oil, water or
liquid fuel) run.
d) To avoid being hit by a possible leak, remain parallel with axis; do not remain by the cou-
pling.
e) At this point gradually pressurize and visually check for leaks.
f) A check by means of leak detectors (foam, detergent, etc.) is performed for the piping
coupling flanges in which gas or air flow.
g) To avoid being hit by a possible leak, remain parallel with axis; do not remain by the cou-
pling.
h) Cover the external coupling surface with these detectors, gradually pressurize and visual-
ly check for leaks.
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5.4 TIGHTENING TORQUE FOR BOLTS (GENERAL APPLICATIONS)

Torque tightening is the application of correct preload to a fastener by the turning of the fasten-
er's nut. The amount of preload created when torqueing is applied, is largely dependent on the
effects of friction. The torque value is normally indicated in assembly drawing.
For carpentry and general applications, and only in case of missing information on job drawings,
it can be useful the table below:
BOLTS TIGHTENING TORQUE (Nm)

diameter BOLTS MATERIAL
(mm) 8.8 10.9 12.9
M6 11 14 16
M8 26 33 39
M10 52 65 78
M12 91 113 136
M14 145 181 217
M16 225 281 337
M18 310 388 466
M20 439 548 658
M22 598 748 897
M24 758 948 1137
M27 1111 1389 1667
M30 1507 1884 2260
M33 2051 2563 3076
M36 2634 3293 3952
M39 3410 4262 5114
M42 4218 5273 6327
M48 6336 7919 9503
M52 8190 10237 12285
M56 10186 12732 15278
M60 12698 15872 19047
M64 15345 19181 23017
NOTE: 1 N m = 0.73 lb ft
1 N m = 0.10 kg m
For flanges tightening check see section 5.3.
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The table above is valid only for:
 Not lubricated bolting: in case of lubrication (for example applied on Stainless steel hard-
ware in order to avoid seizure) designer shall clearly indicate what kind of lubricant has to
be used, with relevant torque reduction coefficient that depends from the friction reduc-
tion properties of the lubricant itself. Using Molycote 1000 (one of the most commonly
used lubricant), the values on the table shall be reduced by 40%. In case of doubts contact
HQ.
Moreover it is not valid for:
 High resistance bolts, marked “HV” or “HR” according to EN14399 (used on support struc-
tures for example): correct torque is directly shown on hardware box and assembly draw-
ings (see SIC00116 for reference).
5.4.1 Torque Procedure

It is recommended to use the appropriate cross-pattern tightening sequence. As guideline for
the correct sequence, see the sketch below:
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5.5 HOUSEKEEPING
In addition to the specific Installation e Commissioning procedures which follow, it is recom-
mended to perform general “housekeeping” for the unit and annexed equipment, accessory
compartments, etc., dedicated to keep them clean and tidy.
This will be beneficial to the safety and reliability of machine plant operation, facilitating “nor-
mal” maintenance tasks, preventing the accumulation of problems over time, allowing the easy
identification of new problems when they occur.
The following checklist will give the operator a start toward establishing his own routine for
maintaining the unit and annexed equipment, accessory compartments, etc., in a clean, well-
functioning condition:
General
a. Check door seals for deterioration. Schedule replacement as required.
b. All parts shall be inspected for cleanliness and wear before being installed.
c. Gaskets and preformed packings shall be free from dirt, lint, and/or grit.
d. Mating flanges, tube flanges, and couplings shall be wiped clean to make sure that a
good seal will be obtained.
e. Hands and gloves must be clean when handling machined surfaces.
f. After performing any maintenance, the work area shall be thoroughly inspected for loose
parts, rags, tools, and other materials. The area shall be cleaned to remove grit, dust,
chips, safety wire, and other small objects.
g. Use P&I diagram to identify all piping connections of the line.
h. In case of spills duly clean ALL parts to remove all the oil or any other chemicals.
i. Maintain strong housekeeping standards and encourage others to do the same
Control cab – if applicable
WARNING: OBSERVE ALL SAFETY NOTICES AND PRECAUTIONS WHEN OCCUPYING

THE UNIT CONTROL CAB.
a. Check the condition of control panel and motor control center lamps.
NOTE: REPLACEMENT OF BULBS WHILE UNIT IS OPERATING COULD RESULT IN

INADVERTENT UNIT SHUTDOWN.
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b. Observe that all instruments are functional and readable; clean glass faces when dirty,
and replace broken glasses.
c. Periodically check the filter element in the compartment air conditioner; clean it as neces-
sary.
d. Inspect for evidence of loose or chafing wires, and schedule corrective action, if required.
e. Clean the floor.
f. Note battery charger output level.
Unit
WARNING: OBSERVE ALL SAFETY NOTICES WHEN OCCUPYING THE UNIT COM-
PARTMENT.
a. Observe both AC and DC lighting systems. Replace burned out bulbs.

b. Inspect items for leakage of air, gas, lube oil, fuel or water.
c. Inspect the compartment for cleanliness. Remove any dirt, rags, or other debris, wipe up
oil, fuel and water spills.
d. Note any loose or vibrating fittings, piping or accessory components, and schedule cor-
rective action if required.
e. Check the torque of all flanged connections.
Accessory
a. Observe AC and DC lighting systems. Replace burned out bulbs.
b. Inspect items for leakage of air, gas, lube oil, fuel or water.
c. Note the condition of the gauge panel (if any); clean dirty instruments, schedule repair of
damaged gauges, check calibration if gauges do not show reasonable values for shut-
down.
d. Clean the floor of dirt, water, oil and other debris. Locate source of spills.
e. Note loose or vibrating piping conduit, or other fittings, and schedule repairs if necessary.
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f. Check faces of clutch (if any) for cleanliness or possible damage. Clean or schedule
maintenance as appropriate.
g. Inspect for evidence of overheating of accessory components (such as paint discolora-
tion), and schedule maintenance inspection or test of suspect components.
h. Check the torque of all flanged connections.
Off-base systems – if applicable

a. Note loose or vibrating piping, conduit, or fittings. Schedule maintenance action if re-
quired.
Clean the floors of dirt, water, fuel, or lubricating oil spills. Dispose of rags and other debris.
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Commissioning & Start-up Quality Processes at Site Section 6
INDEX
Contents Page
6 QUALITY PROCESSES AT SITE ..................................................................................................... 1

6.1 RED FLAG REVIEW...........................................................................................................................................1
6.1.1 Red Flag Review Process .........................................................................................................1
6.1.2 Introduction ...................................................................................................................................1
6.1.3 Background / Purpose ..............................................................................................................1
6.1.4 Red Flag Review Team .............................................................................................................2
6.1.5 Red Flag Review Milestones...................................................................................................3
6.1.6 Red Flag Review Control List .................................................................................................6
6.1.7 Red Flag Review Community ................................................................................................6
6.2 INTEGRATION PARTLY COMPLETED MACHINE / FINAL COMPLEX MACHINE.......................6
6.3 SITE QUALITY LOOP, COMMISSIONING & START-UP CHECK LIST .............................................6
6.4 NC Standard dispositions* .........................................................................................................................7
6.5 INSTALLATION CERTIFICATES ....................................................................................................................8
6.6 SITE ORGANIZATION ......................................................................................................................................8
6.7 PUNCH LIST ........................................................................................................................................................9
11-18-E 1606600÷07 6-Index

© 2018 Nuovo Pignone Tecnologie S.r.l., a Baker Hughes, a GE Company, LLC (“BHGE”) company: the information contained in this document is company confidential and propri-
etary property of BHGE or its affiliates. It is to be used only for the benefit of BHGE and may not be distributed, transmitted, reproduced, altered or used for any purpose without
the express written consent of BHGE.
Nuovo Pignone
6 QUALITY PROCESSES AT SITE

Good execution of commissioning and start-up of the plant is ensured by proper application of
Quality Control Processes, implying that a number of tasks and sub-tasks are checked and ap-
proved by the parties involved in these activities by means of a set of Quality Management Docu-
ments and Check Lists to be filled in on site during following phases:
• commissioning and start-up
• contractual tests
6.1 RED FLAG REVIEW
6.1.1 Red Flag Review Process
The following notes have been extracted from the "Red Flag Review Process" presentation issued
by the GFS ENG Commissioning CoE Team. The content has been slightly modified in order to be
adapted to the present Manual.
6.1.2 Introduction
The Red Flag Review (RFR) is an Oil & Gas internal mandatory process that has the purpose to
prevent issues during installation & commissioning activities at site. Its implementation will be tak-
ing place for all new units under installation where a Service Job is opened, involving Site Team
(Site Manager, Mechanical Engineer, Control Specialist, etc.) and HQ Teams (RFR team, Tech. Ex-
pert and Installation Manager). Critical issues related to First Fire are discussed and resolved
"online", if possible, and receipt of all required documentation (i.e. site Audit, Commissioning Pro-
cedures, etc.) is verified and documented. The Red Flag Review also initiates communication be-
tween the site and the Product service Installation Engineer who will "own" the site from factory
shipment to COD. Customers may participate to the process, however this is owned by BHGE.
6.1.3 Background / Purpose
The 1998 F-Rotor Task Force developed a plan intended to "contain" a progression of undesirable
issues involving F-Class units. As a result of their recommendations, GE Power systems began
conducting a series of Red Flag Reviews prior to the First Fire of any F-class unit. BHGE has adopt-
ed the same method, applying it to all its products and installations at site.
A "Red Flag Review" process is intends to “contain” a progression of undesirable issues
Involving units under installation & commissioning activities. As a result of their recommenda-
tions, GE Oil & Gas GSSA and shall conduct a series of controls prior to the first start up.
This process foresees three Milestone Meetings to verify the compliance to RFR Control List. It is
critical for the quality and benefits of process for Site Team and Customer, that Control list status
is reviewed at all 3 milestones, along with site activities progress.
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6.1.4 Red Flag Review Team
This Team coordinates each call trough RFR form into Support Central and select specific skilled
Technical Supporter to assist Milestone Meeting. This Team will be the only interface for Installa-
tion Manager and will also issue the Control List that Site team will fill prior each Milestone Meet-
ing. Each person inside RFR Team has different responsibilities. The Green Light is given by this
team.
Here below are reported the main duties of the RFR team:
- To provide customized RFR Control List
- To coordinate Technical Experts
- To manage RFR Community and RFR Cases
- To interface with IM
- To arrange Meetings and to provide Action Items
- To provide Green Light for Start Up when all Action Items are closed.
Here below are listed the main components of the team and relevant duties:
COE Commissioning Leader
- The COE Commissioning Leader is responsible for the correct implementation of the
process and for the consistency of the relevant outputs.
Red Flag Review Team (RFR Team).

- Issue and upload Control List into Support Central.
- Select specific skilled Technical Experts to attend to the Milestone Meetings.
- Coordinate and chair each Milestone Meeting (generally executed via conference call
and/or Site visit) checking the RFR Control List, TA, SB, open NCM (SR) and asking for
checks and information as deemed necessary to detect possible technical or EHS risks.
- Issue review MoM
- Give final Green Light granting final release to start-up.
- Advise/Involve EHS Specialist in case of Non-green light due to EHS issues.
Installation Manager (IM).

- Be responsible that RFR process is duly implemented for his/her installations
- Timely Ask RFR Team to arrange for Milestone Meetings, as required by process, depend-
ing on current status of BHGE activities, on site.
- Participate to review meetings, as required by RFR process.
- Stay up to date with RFR Minute of Meetings and Pending Action Items, ensuring follow
up by Turbomachinery or Technology Services, as applicable, and by site team
- Establish communication between the site FSE's, to address any technical issues detect-
ed during installation and commissioning of the unit, having a clear situation of the SRs
still open for a specific Job.
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Technical Experts.
- Attend Milestone(s) Meeting(s) when requested by RFR team, according to his/her specific
skills.
- Interview the Site Team to understand the status of the project and, if necessary, ask for
checks or procedures to be adopted to detect technical ar EHS risks and assign action
items to eliminate or mitigate these detected risks.
- Provide technical support to Site Team and RFR Team, if necessary, to support closure of
action items
Site Manager (SM)

- Inform Client and IM about Milestone(s) Meeting(s) approach date.
- Have the CL regularly filled in by Site Team
- Ensure hand off of updated RFR CL at each FSE turnover
- In case of Site Manager turn over the leaving Site manager shall provide to the new one
the RFR status and the updated CL.
- Be aware about status of the project and advise Installation Manager when milestone is
approaching, as per process above.
Project Manager (PM).

- Advise IM about problems/issues discovered during Factory Test (if any).
- Advise IM about possible NPI content or specific topics out of standard, included in the
scope of supply.
- Notify to the Customer by Official Communications the reason why a Green Light condi-
tions has not been achieved.
6.1.5 Red Flag Review Milestones
There will be three (3) Red Flag Review meeting; scheduled via conference call by the Red Flag Re-
view Team according to the following schedule (all dates are approximate):
 Flushing Milestone (requested at least from 7 days before Oil Flushing Start)
 Loop Check Milestone (requested at least 7 days before Loop Check Start)
 Start Up Milestone (requested at least 7 before first Engine rotation)
NOTE: Red Flag Review's milestones sequence shown above is the standard for all New
Units. Applicable milestones can be different basing on BHGE scope of work/supply on the
specific project. Moreover some exceptions are included into RFR process, such as Recov-
ery Plan. Further explanation is into RFR process.
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© 2018 Nuovo Pignone Tecnologie S.r.l., a Baker Hughes, a GE Company, LLC (“BHGE”) company: the information contained in this document is company confidential and proprietary property of BHGE or its affiliates. It is to be used only for the benefit of BHGE and may not
be distributed, transmitted, reproduced, altered or used for any purpose without the express written consent of BHGE.
Nuovo Pignone
11-18-E 1606600÷07 P. 5 of 11
© 2018 Nuovo Pignone Tecnologie S.r.l., a Baker Hughes, a GE Company, LLC (“BHGE”) company: the information contained in this document is company confidential and proprietary property of BHGE or its affiliates. It is to be used only for the benefit of BHGE and may not
be distributed, transmitted, reproduced, altered or used for any purpose without the express written consent of BHGE.
Nuovo Pignone
6.1.6 Red Flag Review Control List
A RFR Control List is a Specific Check List customized per job. It is updated before and discussed
during each Milestones Meeting. Site team will provide it within 10 days before flushing or start
up meeting; 3 days before loop check meeting.
6.1.7 Red Flag Review Community
On RFR Community it is possible to find useful information, for example Training Material and
RFR Experts support.
Link: http://supportcentral.ge.com/products/sup_products.asp?prod_id=43713
6.2 INTEGRATION PARTLY COMPLETED MACHINE / FINAL COMPLEX MACHINE
The final machine assembler will have to carry out the various mechanical and electrical tests
and inspections during assembly and final testing of the machine, to ensure the compliance of
the resulting complex machine with the applicable local requirements and laws and directives
in relation to the partly completed machinery supplied by BHGE Nuovo Pignone.
6.3 SITE QUALITY LOOP, COMMISSIONING & START-UP CHECK LIST

These check list are documents where are reported the main steps of activity needed to pro-
ceed with the completion of unit installation and commissioning.
The purpose of the document is not intended to provide a complete list of activities nether an
installation detailed instruction, but it is a useful tool for the installation activity completion
check and for their certification in agreement with all the parties involved.
The standard codes present in “applicable document” field, are references for BHGE Service in-
ternal procedures used by BHGE personnel only.
This signature means that lube oil

Example:
console foundation have been cor-
rectly accomplished and checked
Applicable JOB Applicable procedures
Activity according to the relative job/project
documents for check execution
description documentation
Visual, dimensional or
Parties involved in site
penetrant test check
activities
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SOI0002894 Site Quality Commissioning Check List

SOI0002895 Site Quality Start-up Check List
SOI0002896 Site Quality Loop Check List
NOTE: all documents are listed and can be opened at section 4 (click to follow link)
6.4 NC Standard dispositions*

The purpose of a standard disposition is to establish guidelines for on-site modifications to the
original design to solve site non conformities (NC) during assembly activities.
Typically, a standard disposition is applicable to:
a. Resolution of NCs due to wrong or damaged material.
b. Resolution of NCs due to interferences, assembly issues, etc.
c. Modifications to solve other NCs or according to Customer requirements.
Each standard disposition defines the requirements to be satisfied in order to keep the original
design functionality and specifications and it defines the scope and applicability of the disposi-
tion itself. *Standard dispositions are available for BHGE employees at this link:
http://libraries.ge.com/download?fileid=247945955101&entity_id=21555216101&sid=101
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6.5 INSTALLATION CERTIFICATES

On the next page a typical installation schedule is provided along with a definition of the main
activities and indication of when installation certificates have to be filled in.
The installation certificates are:

COM45-1: Mechanical Completion Certificate
COM45-5: Ready for commissioning certificate
COM45-6: Ready for start up certificate
COM45-2: Start-up Certificate
COM45-3: COD Certificate
6.6 SITE ORGANIZATION

A special care shall be observed by all personnel involved in the commissioning phase to comply with
EHS requirements, with local and applicable regulations for safety in any commissioning step, and to
implement all actions and precautions as might be necessary to ensure a high level of safety during
execution of the activities.
In this regards the Customer will take the responsibility of issuing the work permits and to establish the
safe procedures for initialization of the commissioning activities for the machineries and for any step
involved.
The introduction of any feed inside the Unit will constitute an operational phase and
shall be executed under the responsibility of the Commissioning manager, by proper
work permit.
In no instance any feed (as process fluid, hydrocarbons, flammable fluid) and any
dangerous substance can be introduced in the Unit circuit and can be operated prior
to the commissioning and before attaining readiness to operation of adequate fire
and gas detection systems and fire extinguishing systems.
To manage all the activities, the Site organization should be arranged creating the following main
roles:
• Commissioning Manager
• EHS Manager
• Technical advisors and supervisors
• EPC specialists
• Erection Contractor specialists
• Plant Operation representatives
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Depending on the type of contract, the above roles may be covered by BHGE specialists or by other
parties.
The following list describes the recommended BHGE site team composition.
• Site Manager
• Startup manager
• Field Service control & mechanical Engineer(s)
• Other specialists depending on the scope of supply (DLE/DLN mappers, Supplier specialists,
etc)
In general, roles & responsibilities shall be defined well in advance, preferably at Pre-Installation Meet-
ing.
6.7 PUNCH LIST

Starting from pre-commissioning phase, all discrepancies, (as but not limited to deviation between in-
stallation and project documentation, damaged or missing equipment, malfunctioning, missing doc-
umentation, etc.) are recorded in the Master Punch lists, if the discrepancy are not corrected immedi-
ately.
These lists shall be kept updated during the Precommissioning activities, so as to have a precise status
of each system at the Ready for commissioning stage (by which time there should be very few punch
list items yet to be cleared, and of minor importance). Mandatory pre-condition to commence the
commissioning of a system is the absence of type A punch items (as defined below) for that system.
At Commissioning stage, those new items discovered by the Commissioning team during their cross-
checking of the machineries shall be incorporated in the Master punch list. Mandatory pre-condition
to declare the Ready for Startup condition is the absence of type B punch items (as defined below).
The Master Punch List shall be kept updated also during Startup Phase, adding type C punch items
that shall be cleared before COD.
When all conditions allowing the achievement of COD milestone are met, but for a few punch items
that may not be cleared for any reason (for instance when the machine’s operation does not allow the
resolution activity), all parties may agree to change them to Type D punch items, to be cleared at a
later stage, before warranty period expiry date.
Punch lists shall be arranged by system for each machinery (or equipment belonging to the machin-
ery), specifying the discipline (Mechanical, Electrical, Instrumentation and Control).
Each Punch list shall be categorized as follows:
• A: discrepancy to be rectified before commencing the commissioning (before the mechanical
Completion)
• B: discrepancy to be rectified before the start-up (before the Ready for Start-up)
• C: discrepancy to be rectified before COD
• D: discrepancy to be rectified within warranty period.
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Each Punch list shall contain the following information:

Item N° : progressive number assigned to punched point
Description : description of the revealed discrepancy
Discipline : engineering discipline (mechanical, electrical, instrumentation) where the dis-
crepancy occurred
System code : code assigned to each system
Service request # : ref. number from Maximo (BHGE non-conformity management system)
Category : within when the discrepancy will be cleared
Identifier : kind of work of the discrepancy
Date entered : when the discrepancy has been revealed
Entered by : the party that revealed the discrepancy
Date cleared : when the discrepancy has been cleared
Cleared by : the party that clear the discrepancy
An Excel spreadsheet having the following typical format can be used
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DOCUMENT CODE
MASTER PUNCH LIST
Customer :
Project : JOB:
Machineries :
Service Date
Item Disci- System Cate- Date Cleared
Description Request Identifier Entered by cleared
N° pline Code gory entered by
#
1= Outstanding work A= To be rectified before Mechanical completion

2= Rectification work B= To be rectified before Start up
Identifier Category
3= Variation work C= To be rectified before COD
D= To be rectified within warranty period
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Commissioning & Start-up Commissioning Section 7
7 COMMISSIONING .......................................................................................................................................... 6
7.1 PRESCRIPTIONS....................................................................................................................................................................6
7.2 GENERAL .................................................................................................................................................................................6
7.3 SYSTEM POWER UP & CONTROL LOOPS CHECK-UP ...........................................................................................7
7.4 PANEL POWER-UP ..............................................................................................................................................................9
7.4.1 Control Cabin Verification ....................................................................................................................................9
7.4.1.1 Reference Documents: ..........................................................................................................................................9
7.4.2 PMCC Verification ..................................................................................................................................................10
7.4.2.1 Reference Documents: .......................................................................................................................................10
7.4.3 D.C.P. Verification ..................................................................................................................................................11
7.4.4 U.C.P. Verification and power-up ................................................................................................................... 12
7.4.5 OSM panel power-up...........................................................................................................................................13
7.4.6 FFP Verification and power-up ....................................................................................................................... 14
7.4.7 Diesel Engine panel verification and power up ..................................................................................... 15
7.4.8 GCPP Verification and Power up .................................................................................................................... 16
7.4.9 GEP Verification and Power up ....................................................................................................................... 17
7.4.10 Water Washing panel verification ................................................................................................................ 18
7.4.10.1 Reference Documents:..................................................................................................................................18
7.4.11 Oil Purifier panel verification ............................................................................................................................ 19
7.4.11.1 Reference Documents:..................................................................................................................................19
7.4.12 Functional Check of 4÷20mA Pressure Transmitters (Including Differential PT)..................... 20
7.4.13 Functional Check of Temperature Loops: 4÷20mA Transmitters, Thermocouples and
RTD’s 21
7.4.14 Functional Check of 4÷20 mA Flow Meter Transmitters .................................................................... 22
7.4.15 Functional Check of 4÷20 mA Level Transmitters ................................................................................. 23
7.4.16 Functional Check Accelerometer/Velocimeter Seismic Probe ........................................................ 24
7.4.17 Functional Check of Digital Input .................................................................................................................. 26
7.4.18 Functional Check of Analog Output ............................................................................................................. 27
7.4.19 Functional Check of Digital Output............................................................................................................... 28
7.5 SYSTEMS FUNCTIONAL TESTING / COMMISSIONING ...................................................................................... 30
7.5.1 COMMISSIONING OF CONTROL CABIN ........................................................................................................ 31
7.5.1.1 Purpose ......................................................................................................................................................................31
7.5.1.2 System description ...............................................................................................................................................31
7.5.1.3 Tooling Requirements: ........................................................................................................................................31
7.5.1.4 Guidelines: ................................................................................................................................................................31
7.5.1.5 Reference Documents and Procedures ..................................................................................................... 31
7.5.2 COMMISSIONING OF STEP-UP ELECTRICAL TRANSFORMER ............................................................. 32
7.5.2.1 Purpose ......................................................................................................................................................................32
7.5.2.2 Safety and Precautions ......................................................................................................................................32
7.5.2.3 Tooling Requirements .........................................................................................................................................32
7.5.2.4 Guidelines: ................................................................................................................................................................32
7.5.3 COMMISSIONING OF CO2 FIRE FIGHTING SYSTEM ............................................................................... 34
7.5.3.1 Purpose ......................................................................................................................................................................34
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7.5.3.4 Safety and precautions: .....................................................................................................................................34
7.5.3.5 Guidelines: ................................................................................................................................................................34
7.5.4 INSTRUMENT AIR SYSTEM ..................................................................................................................................36
7.5.4.1 Purpose ......................................................................................................................................................................36
7.5.4.4 Guidelines: ................................................................................................................................................................36
7.5.5 COMMISSIONING OF MINERAL OIL SYSTEM .............................................................................................. 37
7.5.5.1 Purpose ......................................................................................................................................................................37
7.5.5.4 Guidelines: ................................................................................................................................................................37
7.5.6 COMMISSIONING OF MINERAL OIL VAPOUR SEPARATOR .................................................................. 39
7.5.6.1 Purpose ......................................................................................................................................................................39
7.5.6.4 Guidelines: ................................................................................................................................................................39
7.5.7 COMMISSIONING OF ATOMIZING & PURGE AIR SYSTEM.................................................................... 40
7.5.7.1 Purpose ......................................................................................................................................................................40
7.5.8 COMMISSIONING OF OIL PURIFIER TROLLEY ............................................................................................ 41
7.5.8.1 Purpose ......................................................................................................................................................................41
7.5.8.4 Guidelines: ................................................................................................................................................................42
7.5.9 COMMISSIONING OF HYDRAULIC OIL SYSTEM ........................................................................................ 43
7.5.9.1 Purpose ......................................................................................................................................................................43
7.5.9.4 Guidelines: ................................................................................................................................................................43
7.5.10 COMMISSIONING OF RATCHET SYSTEM ...................................................................................................... 45
7.5.10.1 Purpose.................................................................................................................................................................45
7.5.10.2 Tooling Requirements:...................................................................................................................................45
7.5.10.3 Guidelines: ...........................................................................................................................................................45
7.5.10.4 Reference Documents and Procedures ................................................................................................ 45
7.5.11 COMMISSIONING OF TURBINE FILTER HOUSE SYSTEM ....................................................................... 46
7.5.11.1 Purpose.................................................................................................................................................................46
7.5.11.2 System description .........................................................................................................................................46
7.5.11.4 Guidelines: ...........................................................................................................................................................47
7.5.12 COMMISSIONING OF GT VENTILATION SYSTEM ...................................................................................... 48
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7.5.12.1 Purpose.................................................................................................................................................................48
7.5.12.3 Tooling Requirements....................................................................................................................................48
7.5.12.4 Guidelines: ...........................................................................................................................................................48
7.5.13 COMMISSIONING OF EXHAUST FRAME COOLING AIR BLOWER ...................................................... 50
7.5.13.1 Purpose.................................................................................................................................................................50
7.5.13.4 Guidelines: ...........................................................................................................................................................50
7.5.14 COMMISSIONING OF GAS DETECTION SYSTEM ....................................................................................... 51
7.5.14.1 Purpose.................................................................................................................................................................51
7.5.14.4 Guidelines: ...........................................................................................................................................................52
7.5.15 COMMISSIONING OF TURBINE CONTROL DEVICES SYSTEM .............................................................. 53
7.5.15.1 Purpose.................................................................................................................................................................53
7.5.15.3 Safety and Precautions.................................................................................................................................53
7.5.15.4 Guidelines: ...........................................................................................................................................................53
7.5.16 COMMISSIONING OF FUEL GAS TREATMENT SYSTEM FOR NATURAL & LGP GAS ................... 56
7.5.16.1 Purpose.................................................................................................................................................................56
7.5.16.5 Guidelines: ...........................................................................................................................................................57
7.5.17 GENERATOR CONTROL DEVICES SYSTEM COMMISSIONING ............................................................. 59
7.5.17.1 Purpose.................................................................................................................................................................59
7.5.17.3 Guidelines: ...........................................................................................................................................................59
7.5.18 COMMISSIONING OF ELECTRIC GENERATOR WATER COOLING SYSTEM ..................................... 60
7.5.18.1 Purpose.................................................................................................................................................................60
7.5.18.4 Guidelines: ...........................................................................................................................................................60
7.5.19 GENERATOR ELECTRICAL SYSTEM COMMISSIONING ............................................................................ 61
7.5.19.1 Purpose.................................................................................................................................................................61
7.5.19.5 Guidelines: ...........................................................................................................................................................62
7.5.20 DIVERTER SYSTEM .................................................................................................................................................63
7.5.20.1 Purpose.................................................................................................................................................................63
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7.5.20.4 Guidelines: ...........................................................................................................................................................63

7.5.21 COMMISSIONING OF STARTING MEANS SYSTEM .................................................................................... 64
7.5.21.1 Purpose.................................................................................................................................................................64
7.5.21.4 Guidelines: ...........................................................................................................................................................64
7.5.22 COMMISSIONING OF FUEL GAS SYSTEM ..................................................................................................... 66
7.5.22.1 Purpose.................................................................................................................................................................66
7.5.22.4 Guidelines: ...........................................................................................................................................................66
7.5.23 LIQUID FUEL SELECTION & FILTER SKID SYSTEM .................................................................................... 68
7.5.23.1 Purpose.................................................................................................................................................................68
7.5.23.4 Guidelines: ...........................................................................................................................................................68
7.5.24 COMMISSIONING OF LIQUID FUEL SYSTEM ............................................................................................... 69
7.5.24.1 Purpose.................................................................................................................................................................69
7.5.25 COMMISSIONING OF LIQUID DRAIN TANK SYSTEM .............................................................................. 70
7.5.25.1 Purpose.................................................................................................................................................................70
7.5.26 PURGE AIR SYSTEM ...............................................................................................................................................71
7.5.26.1 Purpose.................................................................................................................................................................71
7.5.26.4 Guidelines: ...........................................................................................................................................................71
7.5.27 WATER INJCTION SYSTEM .................................................................................................................................72
7.5.27.1 Purpose.................................................................................................................................................................72
7.5.27.4 Guidelines: ...........................................................................................................................................................72
7.5.28 COMMISSIONING OF GAS CHROMATOGRAH METERING SYSTEM................................................... 73
7.5.28.1 Purpose.................................................................................................................................................................73
7.5.28.4 Guidelines: ...........................................................................................................................................................75
7.5.29 COMMISSIONING OF WATER WASHING SYSTEM .................................................................................... 76
7.5.29.1 Purpose.................................................................................................................................................................76
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7.5.29.4 Guidelines: ...........................................................................................................................................................76

7.5.30 COMMISSIONING OF INLET GUIDE VANES (IGV) SYSTEM..................................................................... 78
7.5.30.1 Purpose.................................................................................................................................................................78
7.5.30.4 Guidelines: ...........................................................................................................................................................78
7.5.31 COMMISSIONING OF START ON CRANK MODE........................................................................................ 80
7.5.31.1 Purpose.................................................................................................................................................................80
7.5.31.2 Guidelines: ...........................................................................................................................................................80
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7 COMMISSIONING
Prior to begin the loop checks ensure that Red Flag Review 2nd milestone (TG2)
have been successfully executed.
7.1 PRESCRIPTIONS
For evaluation of specific risks, typical for duties carried out by personnel during Commissioning
activity, indications for prevention and protection operative measures and modes, PPE to be
used, refer to BHGE’s EHS Manual and to Job Safety Analysis (JSA).
Refer to section 2 (Safety Prescription) of this manual for detailed instructions about Job Safety
Analysis (JSA).
Warning: Before starting the operations described in this section (7) refer
to the relevant “Job Safety Analysis” (JSA): JSA044
7.2 GENERAL
For each system, Commissioning can only proceed after the issue of RFC certificate and, when re-
quired, function testing on inert (i.e check of set points of level transmitters/switches with water) has
been executed and each component (valve, instrument, etc.) has been duly tagged and it is in the cor-
rect position to start commissioning operations. The water used for function testing on inert shall be
clear and filtered water, having less than 500ppm chlorides when used for items in carbon steel ma-
terial or less than 50ppm chlorides when used for items in stainless steel material.
Prior the introduction of feed, the Unit that will receive Hydrocarbons or flammable fluids shall be
purged with Nitrogen to ensure it is oxygen free.
The commissioning phase essentially includes, but not limited to, the following main activities:
• Control loop check up as described by Site Quality Loop Check List (see section 4)
• Functional Test of Systems, as described by Site Quality Commissioning Check List
(see section 4)
Once all these commissioning activities are complete, the Unit will reach the “RFSU - Ready for start
up” status
Here below are described the commissioning activities to be carried out on the equipment in-
cluded in BHGE scope of supply
The main reference documents for start-up and operating of gas turbine are the following:
• Piping & Instruments Diagram
• Field Instrument List
• Control System Functional Description
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Do not attempt to operate the unit until personnel has acquired a thorough
knowledge of safety devices and emergency operation procedures and the pre-
operation safety and the control features has been checked and verified.
Prior to start commissioning, verify plant conformity with last P&Id revision. Pay
attention that all the unity instruments and valves are in ready to start condi-
tion and, if not, modify them accordingly
7.3 SYSTEM POWER UP & CONTROL LOOPS CHECK-UP
Description
This paragraph aims to provide general directions for the functional loop test of the instru-
ments/devices installed on GE/NP equipments and the relevant control system(s). The control
loop checks are performed to verify the integrity of electrical and instruments interconnection
made at the site, to verify the calibration (three points calibration: zero, midpoint, full scale) of all
indicators transmitters and regulators (level, pressure, temperature, humidity, flow) and to verify
the set point of all the instruments listed in the “Instrumentation List”, for which a set point is in-
dicated.
It is very important to remember that the set points must be checked simulating the operation
status: a set point for “high” value must be checked starting from a lower value and increasing
the value up to the set point value; a set point “low” value must be checked in the opposite way.
Typically, a loop is composed by the following components:
 Instrument, transducer that converts a physical process variable into an electrical
analog signal (4-20 mA), or digital (open/closed contact). This may also be an out-
put device, such as an actuator, a solenoid, etc converting an electric signal into a
physical process variable.
 Electrical connection, that may include several terminal boards.
 Electronic data acquisition and control system, generally microprocessor based.
 Control software.
 Animated display system (HMI).
These loops shall be checked including, as much as possible, all the above components, mean-
ing that the preferred test method implies to simulate the physical process variable, verifying
the reading on the animated display and the actions caused by the control software, such as
alarms, trips, sequencing, etc.
Sometime, the entire loop may not be tested due to limited or impossible access to some por-
tion of the loop itself, for instance when an instrument is installed inside a sealed or assembled
part of machinery. In this case, only the portion that is available can be checked, injecting an
electrical signal, equivalent to the instrument output, at the first terminal board, closest to the
instrument. The inaccessible portion of the loop must has been checked and certified in the fac-
tory, at assembly. The correct functionality can also be confirmed at site comparing the output
of the instrument with the process variable measured elsewhere, using a verified loop.
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The simulation of the instrument output can be also recommended when the process physical
variable cannot be changed or simulated or measured, or when this is unrealistic at site.
Loops including “Smart” instruments can be checked using an “Hart communicator”, when the
physical variable cannot be simulated.
Tooling Requirements
Suitable tools and equipments to verify the interconnections, the calibration and the set points.
Common tools (mm/inch)
Multimeter
Resistance box
Signal generator (i.e. microcal)
Pressure simulator (pneumatic / hydraulic hand pump)
Calibrated pressure gauges
Thermostatic oven
Reference thermometers
Hart communicator
Guidelines:
A. Perform the interconnections loop checks:

 Verify that each terminal switch is in “open” position.
 Check with a voltmeter across each terminals switch.
 Verify that the continuity and insulation test of interconnecting wiring between gas
turbine skid and panels has be performed, or provide.
 Verify that the connections between gas turbine skid and panels comply with inter-
connecting drawings.
 Verify the tightening of terminals.
 Make sure that all junction box covers are mounted and locked.
 Verify that all plates (data plates, nameplates etc.) are correct and duly fixed.
 Make sure that all equipments (electrical motors, panels, ducts etc.) are properly
earth connected.
 Check direction of motors rotation.
 Check setting of thermal overload protection.
 Measure terminal voltage.
 Measure starting current during motor starting.
 Measure full load current and terminal voltage at full load.
 Measure the vibrations on the cap of auxiliaries motors on two points at 90 degree
by portable vibration analyzer (max. value allowed = 76 micron pk-pk)
 Make r.p.m. check (if possible).
B. Perform the instruments calibration checks.
C. Perform the operating set-points checks as per “Field Instrument List” indications.
D. Perform the software control-points check.
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The following sections contain summarized descriptions of the Loops Checking recommended
methods relevant to a wide set of loop types. For tracking and certification purpose, the dedicat-
ed Site Quality Check List can be used.
See “Site Quality Loop Check List”
7.4 PANEL POWER-UP
7.4.1 Control Cabin Verification
Description:
Check the operation of control cabin
Tooling Requirements:
Appropriate tools for voltage and instrument check.
Guidelines:
The commissioning of control cabin shall be executed following ITN07881. In summary:
a) Visual inspection of control cabin and the correct positioning in their final location
b) Verify the correct cables laying inside control cabin.
c) Verify that the grounding connections are tested and fastened
d) Check correct phase sequencing and voltage of A.C. power supplier for control
cabin distribution and lighting.
e) Verify the functioning of the normal, emergency and external lighting.
f) For detail refer to “Site Quality Loop Check List”.
7.4.1.1 Reference Documents:
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7.4.2 PMCC Verification
Description
Check the operation of PMCC
Guidelines:
The commissioning of PMCC requires the following steps:
1. Visual inspection of cubicles and drawers.
2. The PMCC panel shall be vacuum cleaned.
3. It will be verified functionality of cubicles and devices.
4. It will be verified the correct installation of power and control cables in the
PMCC drawer.
5. It will be verified the setting of protection relays.
6. The PMCC shall be already commissioned and operative.
7. For details refer to “Site Quality Loop Check List”.
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7.4.3 D.C.P. Verification
Description:
Check the operation of D.C.P.
Guidelines:
The commissioning of D.C.P. shall be executed following SIC00277. In summary:
1. Visual inspection of internal components.

2. The D.C.P. panel shall be vacuum cleaned.
3. It will be verified that all cables are clean and properly fastened
4. It will be verified that each power connection corresponds to the right power
supply.
5. It will be verified that each battery cell is installed correctly and is connected with
correct polarity.
6. As soon as possible, the batteries shall be fully charged, in case of NiCd batteries,
they shall also be fully discharged and recharged again, following manufacturer’s
prescriptions. At each step, individual cell’s voltage and total battery voltage shall
be recorded.
7. It will be verified the availability of D.C.P. Ready for operation.
8. For detail refer to “Site Quality Loop Check List”.
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7.4.4 U.C.P. Verification and power-up
Description
Check the operation of U.C.P.
Guidelines:
The commissioning of U.C.P. requires the following steps:
1. It will be checked the U.C.P. cabinet installation and relevant cable entry proper
clamping/sealing.
2. The U.C.P. panel shall be vacuum cleaned.
3. It will be verified that knifes of the terminals are opened and all barrier field
connectors are disconnected.
4. It will be verified that all U.C.P. power supply isolators and breakers are switched
off.
5. It will be checked the correct input voltage and polarity.
6. It will be checked the U.C.P. cabinets heater and cooling fan operation and relevant
thermo-switches setting.
7. It will be verified the U.C.P. maintenance doors limit switches set, energizing &
operation.
8. It will be checked the correct installation of communication networks.
9. For detail refer to “Site quality loop check list”.
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7.4.5 OSM panel power-up
Description
The primary On-Site Monitor functions are to acquire and buffer data for subsequent transmis-
sion to a remote centralized location. The OSM consists of server grade PC, running under Win-
dows Operating system, using CIMPLICITY as SCADA software.
Appropriate tools.
Guidelines:
For details refer to the OSM functional checklist SIC00066. The commissioning of OSM
System requires the following steps:
1) Verify if the OSM is present into the UCP rack

2) Verify if the WorkstationST is running and if it’s collecting data
3) Verify if Cimplicity project is running and if it is acquiring data
4) Verify if data are correctly stored into the database
5) Verify if the WebView feature is working properly
6) Verify if NTP synchronization is working properly
7) Verify if System Display is properly installed
8) External Internet Connection (if applicable)
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7.4.6 FFP Verification and power-up
Description
Check the operation of FFP
Guidelines:
The commissioning of FFP requires the following steps:
1. It will be checked the FFP cabinet installation and relevant cable entry proper
clamping/sealing.
2. The FFP panel shall be vacuum cleaned.
3. It will be verified that knifes of the terminals are opened and all barrier field
connectors are disconnected.
4. It will be verified that all FFP power supply isolators and breakers are switched off.
6. It will be verified the FFP maintenance doors limit switches set, energizing &
operation.
7. It will be checked the correct installation of communication networks.
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7.4.7 Diesel Engine panel verification and power up
Description:
Check the operation of Diesel Engine panel.
Guidelines:
In summary:
1. Visual inspection of internal components.

2. The Diesel Engine panel shall be vacuum cleaned.
3. It will be verified that all cables are clean and properly fastened
4. It will be verified the availability of Diesel Engine panel ready for operation.
5. For detail refer to “Site Quality Loop Check List”.
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7.4.8 GCPP Verification and Power up
Description
Check the operation of GCPP
Guidelines:
The commissioning of GCPP requires the following steps:
1. The GCPP panel shall be vacuum cleaned.
2. It will be checked earthing and power supply of GCPP, then power up the panel.
3. It will be verified correct functioning of GCPP panel auxiliaries (lighting,
cooling fans, sockets, annunciator, indicators, lamps, etc).
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7.4.9 GEP Verification and Power up
Description
Check the operation of GEP
Guidelines:
The commissioning of GEP requires the following steps:
1. The GEP panel shall be vacuum cleaned.
2. It will be checked earthing and power supply of GEP, then power up the panel.
3. It will be verified correct functioning of GEP panel auxiliaries (lighting, cool-
ing fans, sockets, annunciator, indicators, lamps, etc).
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7.4.10 Water Washing panel verification
Description
Check the operation of Water Washing panel.
Guidelines:
The commissioning of Water Washing panel requires the following steps:
1. The Water Washing panel shall be vacuum cleaned.
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7.4.11 Oil Purifier panel verification
Description
Check the operation of oil purifier panel.
Guidelines:
The commissioning of oil purifier panel requires the following steps:
1. The Oil Purifier panel shall be vacuum cleaned.
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7.4.12 Functional Check of 4÷20mA Pressure Transmitters (Including Differential PT)

All pressure transmitters shall be test bench calibrated and certified. The certificate shall be
available.
The loop check shall be done by increasing the pressure sensed by the transmitter, connecting
it temporarily to a portable pressure generator. Alternatively, if the instrument is not included in
a protection control loops, it may be acceptable to simulate the instrument output using a Hart
communicator (Smart instruments) or a 10 kΩ potentiometer.
 Preliminary check
1) Open UCP terminal board knives / fuses (if existing) or disconnect wiring.
2) Continuity/ground check from UCP terminal board to device.
3) Disconnect the device from TB, close UCP knives / fuses (if existing) or re-connect wiring.
4) Check correct voltage and polarity at TB, then reconnect the transmitter.
5) Disconnect the primary tubing from the sensing connection of the instrument, and connect
a portable pressure simulator (hydraulic or pneumatic manual pump, depending on the pres-
sure range).
6) Measure the pressure using a calibrated and certified gauge (the calibration certificate shall
be available).
7) Keep the pressure test gauge as much at the same height as possible with the pressure
transmitter to be calibrated, in order not to introduce an error in the pressure measurement,
due to the oil head in the interconnecting tubing / hose.
If the instrument is not included in a protection control loop, the previous steps 5 to 7 may be
omitted.
8) Connect the wires in the transmitter, inserting an Hart communicator in the loop if the in-
strument is a Smart type. Otherwise, connect in parallel a 10 kΩ potentiometer in the TB, leav-
ing the instrument disconnected.
 Loop check
1) Set a pressure value equal to 0%, 25%, 50%, 75%, 100% of the instrument span. For each
value measure the instrument output signal and the corresponding readings displayed on the
monitoring system. If the instrument is not included in a protection control loop, the previous
step 1 may be omitted.
2) Simulate the transmitter output using a Hart communicator (Smart instrument) or change
the potentiometer resistance to have 4, 8, 12, 16 and 20 mA. For each value verify the corre-
sponding readings displayed on the monitoring system.
3) Visual check for HMI Video pages, verify the correct visualization of analog values, correct
visualization of event type (alarm, trip) and video animations.
 Acceptance criteria
The loop check is successfully completed when it is confirmed that the process variable and
the value acquired by the control system are aligned within the level of accuracy of the “worse”
component of the loop (refer to the component ordering sheet).
Typical +/- 0.25%.
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7.4.13 Functional Check of Temperature Loops: 4÷20mA Transmitters, Thermocouples and RTD’s
Temperature transducers that can be reasonably disassembled, should be checked using a
thermostatic oven in the field to simulate full range of temperature. Otherwise, it will be possi-
ble to simulate the transmitter / instrument output. If the transmitter / instrument is not includ-
ed in a protection control loop, this is the recommended method. For high temperatures (above
200 DegC) the thermostatic oven method is unrealistic at site.
1) Continuity/ground check from UCP terminal board to field instrument.
2) Check the fault by disconnecting the wire from the sensor.
3) If the max temperature range is not defined in the job instrument list, it shall be indicatively
set at 25% higher than the max expected process temperature while in operation.
4) Disconnect the temperature sensing element and insert it in a thermostatic oven.
If the instrument is not included in a protection control loops, the previous step 4 may be omit-
ted.
5) Disconnect the wires in the transmitter / instrument and connect the Hart communicator
(Smart transmitters) or a mA generator, or a microcal / mV generator (thermocouples) or a re-
sistance box (RTD’s).
 Loop check
1) Set a oven temperature at 0%, 25%, 50%, 75%, 100% of the max temperature range. For
each value measure the instrument output signal and the corresponding readings displayed
on the monitoring system.
If the instrument is not included in a protection control loop, the previous step 1 may be omit-
ted.
2) Simulate the transmitter output using a Hart communicator (Smart instrument) or a mA
generator. Set 4, 8, 12, 16 and 20 mA, for each value verify the corresponding readings dis-
played on the monitoring system.
3) With thermocouples, set the mV values corresponding to 0%, 25%, 50%, 75%, 100% of the
instrument span, compensated at cold joint temperature.
4) With RTD’s, set the box resistance at a value corresponding to 0%, 25%, 50%, 75%, 100% of
the instrument span, using the correct RTD temperature / resistance conversion table.
Typical +/- 0.25%.
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7.4.14 Functional Check of 4÷20 mA Flow Meter Transmitters
It is considered generally not possible to simulate an actual flow at site, therefore the only test
method proposed is to simulate the flow transmitter output. The instrument calibration certifi-
cate shall be available from the supplier.
NOTE: flow transmitters should be always configured as DP – Linear reading (not SQR reading)
4) Check correct voltage and polarity at TB.
strument is a Smart type. Otherwise, connect a 10 kΩ potentiometer in the TB, leaving the in-
strument disconnected.
 Loop check
2) Set 4, 8, 12, 16 and 20 mA on signal generator and make sure that the readings displayed
on the monitoring system are correct.
3) Verify that the instrument power supply at 20 mA is at least 16 Vdc (it may change, refer to
instrument manufacturer manual).
component of the loop (refer to the component ordering sheet). The typical accuracy of a flow
meter is +/- 1,5%, however the mA output shall be converted by the control system acquisition
system within +/- 0,25%.
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7.4.15 Functional Check of 4÷20 mA Level Transmitters
It is considered generally not possible to simulate an actual flow at site, therefore the only test
method proposed is to simulate the flow transmitter output. The instrument calibration certifi-
cate shall be available from the supplier.
4) Check correct voltage and polarity at TB.
strument is a Smart type. Otherwise, connect a 10 kΩ potentiometer in the TB, leaving the in-
strument disconnected.
 Loop check
2) Set 4, 8, 12, 16 and 20 mA on signal generator and make sure that the readings displayed
on the monitoring system are correct.
3) Verify that the instrument power supply at 20 mA is at least 16 Vdc (it may change, refer to
instrument manufacturer manual).
component of the loop (refer to the component ordering sheet). The typical accuracy of a flow
meter is +/- 1,5%, however the mA output shall be converted by the control system acquisition
system within +/- 0,25%.
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7.4.16 Functional Check Accelerometer/Velocimeter Seismic Probe
Seismic vibration loops may be tested using a “vibrating plate”, such as the following one (also
available for hire by BHGE)
DESCRIPTION GE CODE
Vibrating Plate SMO1456991
• Variable FRE-
QUENCY (25 to
10.000 Hz)
• Adjustable vibra-
tion amplitude
The seismic probe (either a velocimeter or accelerometer) shall be removed from its support on
the machine and placed on the vibrating plate, positioned in the field close to the measuring
point. The probe shall be connected to measuring chain using job extension cables as for nor-
mal operation. The cable shall be properly supported in order not to affect probe operation.
Warning: the vibrating plate is not Atex certified therefore the test shall be exe-
cuted excluding the possibility of explosive gas presence
1) Check that each wire is secured in its terminal board (by applying a moderated traction on
the wire)
5) Check correct polarity at TB, then re-connect the device.
 Loop check
2) Re-connect the cable and verify the functionality of sensor shaking it.
3) Visual check for HMI Video pages, verify the correct visualization of analog values.
4) Energize the vibrating plate, set frequency at 100 Hz and the amplitude at the values corre-
sponding to 0%, 25%, 50%, 75% and 100% of the vibration trip setpoint
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7.4.17 Functional Check of Digital Input
Digital inputs are referred to devices able to discriminate between two discrete physical states
/ conditions of a process variable, by closing / opening an electric contact. The loop check, as
much as possible, should be done changing the process variable physical state / condition. If
this is not safely feasible prior to operate the equipments, in pre-start condition, the loop check
shall be done by opening / jumper the switch in the field, as close as possible to the sensing
device (i.e. limit switch, pressure / temperature / level switch, push button, relay contact, etc.).
NOTE: The contact may be electrically N.O. or N.C., meaning that the control system will see an
open circuit when the switch is not actuated, and a closed circuit in the reverse condition.
Generally, a closed circuit means a safe state, while an open circuit initiates an alarm or a trip
sequence.
Field wiring diagrams always have the indication of the N.O./N.C. contact to be connected, re-
ferring to a standard definition for the steady state of the instrument when not in operation,
that is when no energy of any type is applied to it. For instance:
 Pressure switches at 0 BarA
 Thermo switches at –273 DegC
 Level switches at zero level
 Push buttons / limit switches released
 Etc.
It is a common bad practice to identify an N.O./N.C. contact by measuring its resistance with a
Multimeter. This may be dangerous if it is not well understood the switch action and its current
state. For instance, the switch could has been actuated even when the equipment is not in op-
eration, as it is the case, for instance, with a temperature switch calibrated at a setpoint below
ambient temperature.
Some confusion may arise when referring to limit switches detecting a mechanism movement.
Depending on how they are mounted, the switch and the mechanism might have reverse ac-
tions, meaning that the mechanism in released state (no external energy applied) may cause
the switch to be actuated. An example is the closure limit switch installed on a normally closed
valve.
To prevent this dangerous misunderstanding, it shall be always necessary to understand the
meaning of the two physical states / conditions of the process variable, its current state at the
moment of the test, and the action of the contact in the control system (refer to Cause & Effect
diagram).
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4) Check correct sensing voltage at TB, then re-connect the device.
 Loop check
1) Activate / deactivate the mechanism where the switch is installed.
2) If the mechanism cannot be safely actuated during loop check phase, jumper or open the
wires at field instrument terminals.
3) Visual check for HMI Video pages, verify the correct visualization of status, correct visualiza-
tion of event type (alarm, trip) and video animations.
This is a Go / No go check.
7.4.18 Functional Check of Analog Output
The analog outputs treated here are control system (UCP) current outputs in 4-20 mA range.
They can be used to drive an actuator, modulating an external energy source able to cause a
process variation (open/close a valve, move a mechanism, etc.). As much as possible, the loop
check should be done by changing the output and verifying the corresponding process varia-
tion, or at least the actuator response. If this is not reasonably feasible in a safe way in pre-
start up phase, the test can be limited to the current measurement in the field, as close as pos-
sible to the actuator.
Analog outputs can also be used to send to external control systems (DCS, etc) the replication
of internal UCP variables. In such case, the loop check shall be done including the receiving
control system, in order to verify the correct signal scaling.
WARNING: Prior to start any check, consider the consequences of the actuation of the device
in the field. Source of energy might be driven in dangerous way, if not controlled. Apply safety
procedures such as LOTO.
4) Check correct polarity at TB, then re-connect the device.
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 Loop check
1) Check the fault by connecting and disconnecting the wires from the device.
2) Force the analog output signal to 0, 25, 50, 75 and 100% of full range from the UCP inter-
face.
3) Visual check for HMI Video pages and device, verify the correct visualization of analog val-
ue, correct visualization of stroke device (i.e. valve) or process variable, if feasible, and video an-
imations.
4) Check in the field local indicator for current received from the actuator (if existing) and/or
actuator output (if applicable).
5) For signals sent to external control system (DCS, etc.) check correct visualization / scaling of
the received signal.
The loop check is successfully completed when it is confirmed that the actuator / field device
follows the forced signal within a deviation that is function of the actuator accuracy (refer to
purchase spec).
7.4.19 Functional Check of Digital Output
The digital outputs treated here are relay’s contacts driven by the control system (UCP). These
contacts may be either internally powered or voltage free. In the first case the output is a DC
voltage that is used to drive solenoids, external relays, on-off actuators etc, causing an effect
on a process variable. In the second case, they are powered / sensed by an external system
(DCS, MCC, etc) that “reacts” to the open / closed state of the contact and initiates an action as
a consequence of the combination between the UCP control software and the receiving sys-
tem internal logic. The loop check for internally powered outputs shall be as much as possible
done by verifying the action caused by the driven device (change of a process variable, open-
ing / closing of a valve, movement of a mechanism, etc). If this is not reasonably feasible in a
safe way in pre-start up phase, the test can be limited to the voltage measurement in the field,
as close as possible to the device / actuator. Voltage free contacts may be tested by measur-
ing the open / closed circuit from the external system terminal board, not powered. Alterna-
tively, the test may be combined with the external system loop check, verifying that the open /
closed contact is correctly sensed.
WARNING: Prior to start any check, consider the consequences of the actuation of the device
in the field. Source of energy might be driven in dangerous way, if not controlled. Apply safety
procedures such as LOTO.
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 Preliminary check (internally powered outputs)

 Loop check (internally powered outputs)

1) Force the digital output signal from the UCP interface.
2) Verify at device TB the correct voltage. Unforce the output, verify that no voltage is present
in the field.
3) Re-connect the device in the TB.
4) Force output on and off, visual check for HMI Video pages and device, verify the correct vis-
ualization of status, correct visualization of device (i.e. solenoid valve, motor) and video anima-
tions.
5) Check in the field that the device is actuated, either by observing the process variable
change, or at least verifying some physical change at device level (an audible noise, a vibra-
tion, etc.).
 Preliminary check (free voltage contacts)

1) Open terminal board knives / fuses (if existing) or disconnect wiring at both sides, UCP and
external system.
2) Continuity / ground check from external system TB to UCP TB.
3) Enable the external system to feed the UCP contact by closing knives / fuses (if existing) or
connecting the wiring at external system side.
4) Verify at UCP TB the presence of the power supply coming from the external system.
5) Close UCP knives / fuses (if existing) or re-connect wiring.
 Loop check (free voltage contacts)

1) Force the digital output signal from the UCP interface.
2) Verify at external system side that the closed loop is correctly sensed.
3) Repeat the check unforcing the output.
4) Force output on and off, visual check for HMI Video pages, verify the correct visualization of
status and video animations.
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This is a Go / No go check
7.5 SYSTEMS FUNCTIONAL TESTING / COMMISSIONING

Prior to startup the equipment, each system composing the scope of supply, including also the
relevant control functions implemented in the Unit Control System, has to be functionally test-
ed / commissioned to confirm that its behavior and performances are in accordance with the
design.
Usually, the tests start on individual system’s components, performing (or verifying the relevant
certification issued during installation / pre-commissioning) any preliminary activity necessary
to set the component in operational status (e.g: motor bearings greasing, shafts alignment,
etc.), then testing it in stand-alone conditions and assessing its running parameters (e.g: motor
bearings vibration, etc).
When all components are confirmed to be functional and, if required/applicable, their opera-
tional parameters have been measured and adjusted according to design, the entire system is
tested as a whole, at operating conditions that should be as close as possible to real operation,
minimizing any kind of simulation, logic forcing, etc..
During this phase, the tests main objectives are:
• Verification of automatic sequencing, that is the ability of the control system to start, stop,
monitor and regulate the system.
• Verification of the system parameters at various modes of operation, including “expected”
failure modes.
Most systems usually interact with several others and/or with Customer process to perform
their functions. The commissioning schedule should consider these interactions, anticipating
systems whose functionality is an enabler for other systems testing. If necessary, for testing
purpose some of these interactions with external systems can be replaced by some sort of
simulation (logic or analog forcing).
The following sections contain summarized descriptions of the systems functional tests. The
activities are defined in a step-by-step format in the dedicated Site Quality Check List
See “Site Quality Commissioning Check List”
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7.5.1 COMMISSIONING OF CONTROL CABIN
7.5.1.1 Purpose
Main purpose of commissioning of control cabin system is to verify:
-the correct operation of system
7.5.1.2 System description
The control cabin is equipped by the following main item:

- Equipment and personnel access doors;
- battery room:
- Normal lighting system;
- Emergency lighting system;
- Fire detection system and fire alarms;
- HVAC conditioning system (100% Redundant system).
7.5.1.3 Tooling Requirements:
Hand tools.
Amp meter (clamp type) to measure current absorption.
Portable vibration analyzer to measure motor vibrations.
7.5.1.4 Guidelines:
The commissioning of HVAC system requires the following steps:

1. The electric motors shall be started up and tested, measuring current absorption
and radial vibrations.
2. It will be verified the instrumentation proper functioning.
3. Check alarm & trip functions performed by instruments and UCP
For additional prescriptions, refer to supplier manual and SQCL Commisisoning SOI0002894
7.5.1.5 Reference Documents and Procedures
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7.5.2 COMMISSIONING OF STEP-UP ELECTRICAL TRANSFORMER

7.5.2.1 Purpose
Main purpose of commissioning of the step-up down electrical transformer is to verify:
-correct termination and wiring of power cables
-correct insulation
-correct filling of the insulating oil, including the verification of its dielectric properties
-correct functioning of instrumentation, including secondary injection of VT’s.
7.5.2.2 Safety and Precautions
NOTE: transformer commissioning is normally executed under OEM Vendor supervision, according to Ven-
dor’s best practices and procedures. The prescriptions given here shall be used as reference and guide-
line.
Warning: Live high voltage may be present during most of the tests. Ensure that a safety plan
is in place, understood and observed at all time.
7.5.2.3 Tooling Requirements
Hand tools.
Proper tools for instruments calibration.
Megger 100 V, 500 V and 5KV
Current/voltage injection box
7.5.2.4 Guidelines:
The commissioning of step-up down electrical transformer system requires the following steps:
1. Verify the quality of the electrical connections.
2. Verify the windings resistance
3. Check the Transformer protection loops towards control system (pressure relief device,
winding temperatures, Bucholtz alarm & fault, etc.)
4. Check the insulating oil sub-system: level, leakage absence, dielectric property (Vacuum
treatment could be required), etc..
5. Perform insulation resistance test
6. Verification relevant to all VT’s:
a. Record plate data and check vs design (ratio, accuracy & precision class)
b. P1-P2: check connections vs schematic diagram (visual check)
c. S1-S2: check connections vs schematic diagram (point to point check)
d. Primary fuse check
7. Verification of VT signals acquisition through secondary injection.
8. Transformer power-up at no load conditions, verifying correct acquisition of
parameters, instruments, etc.
9. Check alarm & trip functions performed by instruments and PCS
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7.5.3 COMMISSIONING OF CO2 FIRE FIGHTING SYSTEM

7.5.3.1 Purpose
Simulate the CO2 fire fighting system operation checking mainly:

-the activation of fire fighting system on fire detection;
-the activation of audible alarm horns;
-the CO2 initial and the extended discharges,
-the closure of fire dampers;
-the cut-out of compartments ventilation.
The carbon dioxide fire protection system used for the gas turbine unit extinguishes fires by re-
ducing the oxygen content of the air in the gas turbine compartments. To reduce the oxygen
content, a quantity of carbon dioxide (CO2 ) delivered from a cylinders bank is discharged into
2
the compartments in one minute and, due to the reignition potential of combustibles exposed to
high temperature metal, an extended discharge is provided to maintain an extinguishing con-
centration for a prolonged period to minimize potential reignition. Two separate distribution sys-
tems are used: initial discharge and extended discharge systems. Within a few seconds after ac-
tuation, sufficient CO2 flows from the initial discharge system into the gas turbine compartments
2
to rapidly build up an extinguishing concentration. A CO2 concentration is then maintained by 2
the gradual addition of more CO2 from the extended discharge system to compensate for com-
2
partment leakage.
7.5.3.4 Safety and precautions:
The simulation of the fire fighting system must be performed with discharge of the extinguishing
CO2 inhibited.
7.5.3.5 Guidelines:
Notes:
As per NFPA12 requirements, each CO2 system will be tested with full discharge, in order to make
sure that the project characteristics are observed, causing the intervention of the systems with
the distribution of the extinguishing agent in the considered area. System certification as in-
stalled, is under Customer responsibility.
1. It will be tested the CO2 initial and extended discharge lines.
2. It will be verified the fire fighting system functionality.
4. Leave the fire fighting system in ready to start condition.
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Do not enter into the enclosure if the discharge system is active. The electric dis-
charge inhibit selector key on Fire Fighting monitor front is never to be consid-
ered as LOTO accomplishment. Only CO2 discharge line isolation valves closure
prevent accidental discharge events.
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7.5.4 INSTRUMENT AIR SYSTEM
7.5.4.1 Purpose
- The instrument air system is composed by the main items:
- Compressor driven by electric motor;
- Process air cooler;
- Intake filter-silencer;
- Air Tank (Dry Air Receiver);
- Air Dryer ;
- Local control panel;

The air, to be compressed, is filtered (dry filter) into an intake filter before passing into the com-
pressor. Compressor shall be able to elaborate a flow of 40 Nm^3/h with a pressure of 8 barg at
35 °C. The filtered air is compressed by a single or plus compressor stages at 8 barg max. deliv-
ery pressure. The skid shall be placed outdoor under sun shelter. The air to be compressed shall
be taken in from outside of the shelter. The compressed air shall be cooled by an after cooler and
then discharged in a wet air buffer vessel. Compressed wet air is sent to a full-capacity pre-filters
to protect the air dryer. The pre-filters shall be suitable for wet service . Downwards the pre-
filters, two dual air dryer shall dry all compressed air to a dew point not higher than -20 °C at 10
barg.
No tools required.
7.5.4.4 Guidelines:
The commissioning of instrument air system requires the following steps:

1. A.C. power must be available for the air compressor electric motor (88SC)
2. It will be checked the power supply and current absorption of the anticondensation
space heater (23SC).
3. It will be checked the local control panel power supply and the main devices proper
functioning.
4. The electric motor shall be started up and tested, measuring current absorption and
radial vibrations. See SIC00202 for reference.
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7.5.5 COMMISSIONING OF MINERAL OIL SYSTEM
7.5.5.1 Purpose
Main purpose of commissioning of mineral oil system is to verify:
-the oil tank heater to heat the oil to the minimum requested temperature to safely start the oil
system;
-the correctness of oil temperature regulation downstream the oil coolers
-the correctness of oil pressure to the users;
-the start/stop of auxiliary pump in case of low/high oil pressure to the users;
-machinery trip on low low oil pressure to users
The lubrication system, which includes an oil tank, pumps, heat exchangers (oil coolers), filters,
valves and miscellaneous devices to assure control and protection to the system, is designed
to provide a supply of filtered lubricants at the proper temperatures and pressures for opera-
tion of the turbine and its associated equipment. Oil for the hydraulic supply system, the con-
trol oil system, and the starting means system is also taken from this system.
The mineral oil system is a closed-loop, forced feed system. Lube oil is drawn from the oil tank
by the pumps and is forced under pressure through the heat exchangers to cool the oil flow to
the requested temperature, oil filters and the bearing header manifold to the bearing.
Multiple oil pumps are provided to ensure redundant oil sources: an AC electric motor driven
pump is used during startup, cooldown and in case of failure of the main mechanical pump,
driven by the accessory gearbox, that is the “normal” oil source while in operation. A DC elec-
tric motor driven pump provides emergency lubrication during rotors coast down, following a
unit trip, and during cooldown.
Protection devices are incorporated into those systems, where required, to protect the equip-
ment against low lubricant supply, low lubricant pressure and high lubricant temperature.
Hand tools.
7.5.5.4 Guidelines:
Note: Before proceeding with the lube oil system commissioning the compressor seal system
activities have to be successfully executed.
Note: Before starting the mineral oil system must be verified the proper execution of flushing
activities and the correct cleaning of the entire piping system.
A. Prepare mineral oil system to start-up.

1. Be sure that the oil reservoir is filled with the recommended grade of oil.
2. A.C. power must be available for the auxiliary lube oil pump motor (88QA-1) and
lube oil tank heater (23QT-1).
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3. D.C. power must be available for the emergency lube oil pump motor (88QE-1),
checking the charge of the accumulator batteries in the D.C. power centre.
4. It will be checked the power supply and current absorption of the auxiliary and
emergency pump motor anticondensation space heaters (23QA-1, 23QE-1).
5. A.C. power must be available for the trolley control panel.
and radial vibrations. See SIC00202 for reference
B. Start-up mineral oil system. Check mineral oil system operation.

1. The system will be tested on auxiliary pump (PL-2) and on emergency pump (PL-3).
2. It will be verified the lube oil filters functionality (FL-1A/B).
3. It will be verified the thermostatic valve functionality (if feasible)
4. It will be verified the ability of the D.C. system (batteries & DCP) to sustain the entire
duration of emergency cooldown
5. It will be verified the relevant instruments reading with turbine control system inter-
face (HMI).
6. It will be verified that all bearings are properly lubricated by watching oil flow at
each sight glasses at oil drains.
7. It will be tested the trolley local panel.
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7.5.6 COMMISSIONING OF MINERAL OIL VAPOUR SEPARATOR
7.5.6.1 Purpose
Main purpose of commissioning of mineral oil vapor separator is to verify:
-the correct operation of oil vapors extraction motor and fan;
-the pressure drop across vapor separator;
-free oil drainage from goose-necks to lube oil tank

The system eliminates the traces of oil from oil vapor flow drawn up by the oil vent pipe. On the
oil vent pipe there is a vapor separator separating the oil droplets from vapor vent flow; a fan
creates a slightly depression to facilitate the passage of the vapor vent flow through the oil va-
por separator. Separated oil is collected to lube oil tank. In case of failure, the separator is by-
passed by a check valve and the vapors are temporarily vented to the atmosphere without
tripping the unit, unless excessive positive pressure of Lube Oil tank is detected.

Hand tools.
7.5.6.4 Guidelines:
The commissioning of mineral oil separator requires the following steps:
1. A.C. power must be available for the fan extractor motor (88QV-1/2)
2. It will be checked the power supply and current absorption of the main/auxiliary anti-
condensation space heaters (23QV1/2).
3. A.C. power must be available for the motor of the lube oil pump (88QA-1).
4. The lube oil system shall be already commissioned and operative.
5. The electric motor shall be started up and tested, measuring current absorption and
radial vibrations. See SIC00202 for reference.
6. The oil vapour separator manual by-pass valve will be pre-adjusted to regulate oil
tank de-pressurization. The final adjustment shall be repeated with turbine running at
load.
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7.5.7 COMMISSIONING OF ATOMIZING & PURGE AIR SYSTEM
7.5.7.1 Purpose
Main purpose of commissioning of atomizing air system is to verify:
-the correct operation of atomizing & purge air system
The Atomizing Air Cooler system is equipped with two fans (MAIN &STAND-BY), each designed to
provide 100% of rated airflow. The heat from the atomizing air is removed by a direct air-to-air
heat exchanger. Main/Stand-by selection can be done through a dedicated HMI pushbutton,
normally when both fans are stopped. Selection can be changed, even if main fan is running. At
change over, the new selected main fan starts immediately and the stand-by will be stopped
with a delay time. This change over sequence doesn't activate stand-by fan running alarm. Each
fan is equipped with a vibration switch installed on its own shaft. Each vibration switch is
equipped with its own reset coil.
Hand tools.
The commissioning of atomizing air system requires the following steps:

1. It will be checked the atomizing air filters (FA1-1 & FA2-1) correct installation and
cleanness condition.
2. A.C. power must be available for the motors of atomizing air cooler fans (88QFC-
1/2) and their space heaters (23QFC-1/2).
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7.5.8 COMMISSIONING OF OIL PURIFIER TROLLEY
7.5.8.1 Purpose
Main purpose of oil purifier trolley is to verify:
-correct installation of disks pack and gravity disk suitable for the actual type of oil and service
-correct operation of trolley local control panel
-correct operation and ability of the trolley to perform the desired function
• Clarification (removal of solid particles)
• Purification (removal of water)
The purpose of oil purifier equipment is to remove water, oily deposit and solid particles from
mineral lubrication oil, restoring its viscosity and flashpoint: the presence of free water, in mineral
oil can contribute to machinery reliability reduction, accelerated wear, corrosion and sludge for-
mation. With reference to P&ID mineral lube oil system, clarifier sucks oil from oil tank, purifies it
and gets it back to tank.
The operation of the trolley is based on centrifugal separation between the mineral oil and water
due to difference in specific density: it is performed in a separator bowl, rotating at high speed
(approx 8600rpm), installed inside the collecting cover. The bowl is driven by a motor through a
gear. The trolley includes a gear pump for untreated oil inlet and clean oil discharge. On the
frame top part are located the connections for water inlet and outlet.
Regarding separation process, pump feeds oil in the bowl. By action of centrifugal forces, heavy
phases (water and solid particles) are forced to the periphery of the bowl: solid parts, if any, settle
on the walls while separated water moves along the upper side of top disc towards the outer
outlet, that is defined and fixed by the gravity disc.
The light phase (oil) is directed to the center of the bowl, flows along the discs and goes out
through the hole in the neck of top disk (it’s the inner outlet).
Before each start-up, oil clarifier shall be filled with water to create a seal between the bowl hood
and the top disk in order to prevent that oil leaves the bowl through the external outlet: is re-
quired about 1.5 liter for each starting and is recommended to supply water until flows out
trough the system outlet.
Before the start-up it is also mandatory to install the gravity disc: it is fundamental to set the in-
terface between the oil and the water phase and guarantee the purification inside the clarifier.
Without gravity disc the only purpose of the equipment is to remove solid particles but any sepa-
ration between oil and water is performed.
In fact, the gravity disc is mounted on the top of bowl externally to outer edge of top disc (and di-
rectly defines the dimensions of outlet way for heavier phase (outlet way of light one is fixed): this
point is very critical because on basis of oil density a larger or smaller disc diameter will cause a
different separation efficiency causing oil to flow through external way instead of internal one.
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Hand tools.
7.5.8.4 Guidelines:
The commissioning of oil purifier trolley shall be done following supplier manual. In summary,
the main steps are:
1. It will be checked the power supply and current absorption of the oil purifier trolley
local panel.
3. Check/install proper gravity disk according to lube oil characteristics (density, tem-
perature, etc.)
4. Check for lube oil (inlet & outlet) & water piping leak during operation.
5. Check the proper functioning of the oil-water separation.
6. After the commissioning activities completion, restore the trolley and set in opera-
tional condition, paying attention on the complete opened position of the inlet and
outlet lube oil valves.
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7.5.9 COMMISSIONING OF HYDRAULIC OIL SYSTEM
7.5.9.1 Purpose
Main purpose of commissioning of hydraulic oil system is to verify:
-the pressure charge with Nitrogen of Hydraulic Oil accumulators;
-The correct installation and cleanliness of Hydraulic Oil filters
-the oil pressure value on auxiliary oil pump discharge;
-the differential pressure across the oil filter;
-the change-over of oil filter to check the continuity of oil flow
Regulated, filtered oil from the Lube Oil system of the gas turbine is used as the high pressure flu-
id to meet the hydraulic system requirements. A volumetric type pump, driven by a shaft of the
accessory gear, is the primary pump for this high pressure oil; a motor-driven volumetric type
pump provides the necessary auxiliary backup. Hydraulic oil, pressurized by the main hydraulic
pump, is controlled by pressure compensator VPR3-1, built into the pump. The action of the com-
pensator varies the stroke of the pump to maintain a set pressure at the pump delivery.
Hand tools.
Oil accumulators charging kit.
7.5.9.4 Guidelines:
The commissioning of hydraulic oil system requires the following steps:

1. Check and correct nitrogen pressure of hydraulic oil accumulators.
2. Check and clean hydraulic oil filter body, confirming correct cartridge installation
3. A.C. power must be available for the auxiliary lube oil pump driver (88QA-1).
4. A.C. power must be available for the auxiliary hydraulic oil pump driver (88HQ-1).
5. It will be checked the power supply and current absorption of the hydraulic anti-
condensation electric space heater (23HQ-1).
6. The electric motor shall be started up and tested, measuring current absorption
7. The hydraulic oil pressure regulator installed on the auxiliary section of the system
will be adjusted to obtain hydraulic oil pressure as per design.
8. It will be verified the hydraulic oil filters (FH2-1/2) functionality.
9. It will be verified the instrumentation functionality and calibration.
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10. Any oil leakages will be identified and eliminated

11. It will be verified the instrumentation functionality and calibration.
NOTE: the hydraulic oil pressure adjustment relevant to the main mechanical pump
shall be done during Crank tests
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7.5.10 COMMISSIONING OF RATCHET SYSTEM
7.5.10.1 Purpose
Main purpose of commissioning of ratchet system is to verify:
-the correct operation of ratchet motor
-the control system correct sequencing
-the correct operation of self sequencing control valve
-the actual shaft rotation;
-the engagement of self synchronizing starting clutch
-the ratcheting sequence during turbine cooldown
No tools required.
7.5.10.3 Guidelines:
During these tests the GT shaft and any other shaft connected to it will actually
rotate at very low speed. This requires that any exposed shaft parts, flanges, etc.
shall be protected to prevent any contact of personnel with moving parts. Shafts
uncontrolled rotation might also cause damages to the equipment, for instance
if shipping locking devices have not been removed
Note: Before proceeding with the ratchet system commissioning the lube oil system activities
have to be successfully executed.
The commissioning of ratchet oil system requires the following steps:
1. D.C. power must be available for the ratchet pump motor (88HR-1).
3. Verification of auxiliary side shafts and clutch alignment
4. Adjustment of starting clutch position micro switch
5. Verification of ratchet pump motor start/stop
6. Verification of self-sequencing ratchet control valve correct operation, together
with control system correct sequencing.
7. Verification of shafts actual rotation.
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7.5.11 COMMISSIONING OF TURBINE FILTER HOUSE SYSTEM
7.5.11.1 Purpose
NOTE: the general guidelines for commissioning gas turbines inlet systems are described by the
document SOM6664411 - OPERATION AND MAINTENANCE RECOMMENDATIONS FOR GAS TUR-
BINE INLET SYSTEMS.
Main purpose of commissioning of turbine filter house system is to verify:

-absence of any gap in any part of the clean side of the filter house and inlet duct allowing the
air to be sucked bypassing the filter cartridges.
-correct installation of filter cartridges
-cleanliness of filter house and inlet duct downstream of the filter cartridges (“clean side”)
-Instruments correct operation
At the end, the filter house shall be left clean and all access doors shall be closed and locked.

The entire purpose of cleaning the combustion air of a gas turbine is to prevent damaging con-
taminants and performance inhibiting materials from reaching the component parts of the gas
turbine. Poor air quality may lead to compressor fouling or compressor erosion as well as corro-
sion and cooling passages blockage in the hot parts of the gas turbine
The type of Air Filtration System described here is:
• High Velocity Systems for Off-shore installations
High Velocity Filtration Systems suitable for the removal of liquid salt from the incoming air
stream typically consist of a three (or four) stages.
The first stage is a demister vane separator that separates entrained droplets imposing several
direction changes to the incoming air. Droplets, due to their greater mass, impinge upon of the
sides of the vanes. The effectiveness of such a system is proportional to the velocity of the air
stream and thus the momentum of the droplets.
A coalescer/high efficiency element is installed downstream the demister stage. The coales-
cer/high efficiency stage captures smaller droplets that were not removed in the first stage of
the separator. After capture these droplets may either drain down to the catch through below
or agglomerate with other droplets to form larger droplets which become re-entrained in the air
stream. These agglomerate droplets are captured by the last stage of vanes, which is typically
identical to the first stage.
Dust elimination is performed by two stages of filtration. The first stage consists of low cost pre-
filters (generally bag filters to increase Dust Holding Capacity at a lower pressure drop) that are
used for the removal of larger contaminants and as mist eliminators as well. The pre-filters pro-
tect and extend the life of the more expensive high efficiency filters.
The high efficiency filters are placed downstream of the pre-filters and remove finer particles.
High Efficiency static filter elements are generally panel (rectangular) shaped with mini pleated
media (to increase media surface). Panel shaped filters are mounted side by side in a framing
system in the air inlet compartment.
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Static filter media is typically depth-loading media (micro glass fiber for high efficiency ele-
ments). The particles are trapped within the body of the media. This media has a billowy texture,
which allows the particle to penetrate and deposit. With extended use, static filter media will
become laden with particulates from the surrounding ambient. Once the static filter media be-
comes loaded with particulates, it should be replaced with new similar filter media type, as dirty
media will inherently have higher pressure drop which reduces turbine efficiency. The specific
replacement timing will depend upon surrounding environmental conditions, and gas turbine
operational practices. Replacement timing is usually a compromise between machine efficien-
cy, maintenance cost, and required availability (outages).
The commissioning of filter house system requires the following steps:
2. Inspect the “clean” side of the filter house and inlet duct and perform a “light test”,
as described by SOM6664411, to identify and eliminate any openings allowing the
air to bypass the filter
3. Perform air inlet system final cleaning before starting the turbine.
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7.5.12 COMMISSIONING OF GT VENTILATION SYSTEM
7.5.12.1 Purpose
Main purpose of commissioning of ventilation system is to verify:
-the correct operation of ventilation fans
-the gravity dampers open/close positions when the ventilation fans operate/shut-down
-the enclosure sealing with one-two ventilation fans in operation
-the enclosure pressurization with one-two ventilation fans in operation
-the ventilation fans trip and fire dampers closure when a fire alarm is detected
Clean and cool air is circulated inside GT enclosure in order to remove the heat produced by
the running turbine. The air is extracted by ventilation fans from the clean side of the filter
house and, through several sections of ventilation ducts, it is sent to the enclosure different
zones. The hot air from the enclosure is then discharged to the atmosphere through ventilation
exhaust ducts, whose number and position is calculated to have an optimized air circulation
inside the enclosure.
The ventilation system of the gas turbine enclosure is always in operation when the unit is
working, and it’s stopped a few hours after unit stop. Gas turbine enclosure purging is per-
formed by starting the ventilation fan at the beginning of the starting sequence.
The system is composed with two redundant (selectable main/stand-by) ventilation fans, in-
let/outlet duct dampers and instruments as necessary.
Hand tools.
7.5.12.4Guidelines:
The commissioning of ventilation system requires the following steps:

1. A.C. power must be available for the ventilation fan motors (88BA-1/2).
2. Check the operation and current absorption of the ventilation fan motors
anticondensation space heaters (23BA-1/2).
3. Check the operation of the ventilation fan motors (88BA-1/2). The electric motor
shall be started up and tested, measuring current absorption and radial
vibrations. See SIC00202 for reference
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4. Check and adjust gravity dampers on the ventilation fan outlet

5. Measure enclosure pressurization with one or two ventilators on, verifying no
over/under pressurization.
6. Check ventilation fans sequencing and cut-out/interlocks
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7.5.13 COMMISSIONING OF EXHAUST FRAME COOLING AIR BLOWER
7.5.13.1 Purpose
Main purpose of commissioning of cooling and sealing air system is to verify:
-the correct operation of Gas Turbine exhaust frame cooling air blowers
Air blowers are used to provide cool air used for exhaust frame cooling. The blower suction is
taken from clean side of Filter House.
Hand tools.
The commissioning of cooling and sealing air system requires the following steps:
and radial vibrations.
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7.5.14 COMMISSIONING OF GAS DETECTION SYSTEM
7.5.14.1 Purpose
Main purpose of commissioning of gas detection system is to verify:
-correct calibration of gas detection sensors
-correct orientation of sampling system (Pitot tube) on ventilation exhaust
-correct installation and alignment for IR sensors inside filter house
-correct activation of alarms, trips and interlocks
The presence of a combustible gas can be very dangerous if the concentration

reaches explosive limit. For this reason, this system has to be considered of ex-
treme importance and shall be commissioned and operational prior to introduce
hydrocarbons inside the equipment.
The gas detector checks the presence of a selected gas (noxious or dangerous) in atmosphere.
There are three main categories of gas sensor used on BHGE typical installation: Catalytic, Elec-
trochemical and Infrared.
Catalytic and electrochemical sensors are used to detect localized gas leakages, and are mostly
installed inside enclosures and/or close to valves, flanges, fittings, etc. that could be subject to re-
lease the dangerous gas in case of failure. This type of sensor is composed by a sensing head
coupled with a conditioning unit, providing an output signal (usually 4-20 mA) proportional to the
gas concentration. In other (older) versions the sensing head is directly connected to an electron-
ic monitoring unit/rack installed in the Unit Control Panel. In both cases, it is possible to calibrate
the system to measure the gas concentration in a range from 0 to 100% LEL (Lower Explosive
Limit), that is defined as the minimum concentration of a particular combustible gas necessary to
support its combustion in air. This value is, for instance, 5% in case of methane. The system acti-
vates alarm and trip signals when the gas concentration is above a fraction of the explosive limit,
also activating additional actions, such as starting stand-by ventilator.
The above sensors are also used to monitor an entire volume by measuring the gas concentra-
tion in a sample of air extracted from that volume. The sampling can be done:
- using the air velocity with a Pitot tube properly oriented in the air flow (typical for Duct
Mounting sensors),
- The infrared (IR) method of gas detection relies on the IR absorption characteristics of gases
to determine their presence and concentration. IR gas detectors consist of an IR light source
(transmitter) and light detector (receiver) to measure the intensity both at the absorption
wavelength and a non-absorbed wavelength. If gas is present in the optical path, it will affect
the intensity of light transmitted between the light source and the detector. This change in
intensity provides the data for determining that a specific gas, or type of gas is present. This
method works only for gases that can absorb infrared radiation.
- Combustible IR gas detection can take one of two forms: either the point detector or the
open path detector. The first one is used to monitor fixed areas of space, having limited size,
in a similar way as to the catalytic or electrochemical sensors. The open path detector usual-
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ly consists of a separate transmitter and receiver, which monitor much larger areas of space.
Transmitter and receiver have to be optically aligned to see each other in order to work
properly. The typical application of this type of sensor is to monitor the presence of combus-
tible gas in a gas turbine filter house, that has to be monitored to prevent that the turbine in-
gests combustible gas.

Gas sensors calibration kit (typical for each type of sensors)
Optical IR sensors alignment kit
The commissioning of gas detection system requires the following steps:

1. Gas detectors ZERO and SPAN adjustment, using the sample gas bottle included in
the calibration kit
2. Duct Mounting sensors with Pitot tube:
a) verify the correct installation and orientation of the Pitot tube on the
exhaust ventilation duct
3. IR optical system: perform alignment of transmitter and receiver following supplier
manual.
4. Check sequence and interlocks with ventilation system, according to the Functional
Description
For reference see the standard procedure SIC00233.
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7.5.15 COMMISSIONING OF TURBINE CONTROL DEVICES SYSTEM
7.5.15.1 Purpose
Most of protection and control instruments installed on the gas turbine are tested during loop
checks, and for them refer to section 7.3.
This section describes the functional test of a few more complex instruments / devices that has
to be managed during commissioning. These are:
-axial compressor antisurge valve
-flame detectors and spark plug on combustion chambers
-automatic drain (false start) pneumatic valves
-the shafts axial displacement probes
Generic tools for instruments calibration.

UV torch for flame detectors test
Fixture for shaft axial displacement test (see SIC00042); dial gage and magnetic bases.
Before testing spark plug proper functioning, it’s necessary to verify the absence of explosive
gas.
Testing flame detector with an open flame may be dangerous in case of presence of explosive
gas.
1. It will be verified the functionality of flame detectors, simulating the flame with an
UV torch and confirming correct acquisition of the signal on the HMI.
2. It will be verified the functionality of spark plug and relevant ignition transformer,
removing it from combustion chamber, exciting ignition transformer and verifying
the spark. After the test, the spark plug must be reinstalled, paying attention to
guarantee its correct installing depth, according to the applicable procedure of the
BHGE manual. For reference see also SIC00298.
3. The axial compressor antisurge valve has to be functionally tested using instrument
air temporarily connected to the solenoid valve 20CB. Energizing the solenoid valve,
the antisurge valves shall close as detected by the relevant microswitches, that
may need to be fine-tuned to detect cracked open position.
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4. The automatic drain (false start) pneumatic valves are directly operated by the axial
compressor discharge pressure, that at the end of startup increases up to a value
that causes the pneumatic valves to close. During commissioning it is required to
test these valves with instrument air to confirm correct operation.
5. The shaft axial displacement probes and the relevant monitoring system have to be
tested and, if necessary, adjusted. This shall be done as follows:
a. Move axially the shaft within the entire range allowed by the thrust bearing
b. Measure the travel and set the shaft at mid position
c. Set the monitor reading to zero
d. Repeat step a verifying the correspondence between shaft axial displacement
and monitor reading.
For details refer to the procedure SIC00042
6. Simulated overspeed test (applicable to MK6/MK6e) to be repeated for each
shaft of the gas turbine
a. Connect a frequency generator in parallel to the speed magnetic pick-up
terminals in the field. The signal generator shall be connected to all three speed
probes included in the protection loops (VPRO/PPRO/PPRA). No need to connect
the three probes on control loops.
b. Isolate the fuel gas supply to the gas turbine skid, applying Lock Out Tag Out
(LOTO) procedure
c. Perform logic forcing as required for fuel valves calibration, in order to energize
dump/shutoff valves.
d. Increase signal generator frequency in order to simulate increasing speed (1 Hz
= 1RPM). Signal amplitude can be any value between 1 and 15 Vrms, the
waveform should be sinusoidal (refer to MK6-MK6e manual for speed input
more accurate specification).
e. Verify that dump/shutoff valves are de-energized at trip speed as specified by
job TDCSS
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7.5.16 COMMISSIONING OF FUEL GAS TREATMENT SYSTEM FOR NATURAL & LGP GAS
7.5.16.1 Purpose
Main purpose of commissioning of the fuel gas treatment system for natural & lgp gas is to per-
form:
-final verification of correct installation, calibration and functionality of instruments and devices.
-Leak test
-Verification of control, alarms and trip functions
-First filling of scrubber liquid sump (option: see below)
Fuel gas reaching gas turbine manifold system has to be free from solid and liquid contami-
nants within the limits defined by job specifications (UTILITY CONSUMPTION LIST). For this pur-
pose, the fuel gas has to be treated passing through the Fuel Gas treatment skid for natural &
lgp gas.
The skids, for natural & lgp gas, are composed by two Fuel gas Scrubber filter/separator, each
with a separator portion and a coalescing filter portion. Each filter/separator allows for mainte-
nance without removing gas turbine from service. Separation of solid and liquid contaminates
from the fuel gas is accomplished by inertial separation and filtration.
The lower separation section (first stage) consists of a cyclone bundle where a large percentage
of the incoming liquids and solids are mechanically removed. The intent of this criterion is to en-
sure that the vessel removes as much of the incoming moisture/particles as possible to prevent
clogging of the coalescing filters
The upper separation section (second section) of the filter consists of micro-fiber synthetic ma-
terial coalescing elements, mounted vertically in parallel on support tubes. This arrangement
will ensure that the elements remain above liquid level.
When the fuel gas enters the lower separator portion, large liquid and solid particles are re-
moved by first stage and are collected in a lower sump. The gas then flows through a coalesc-
ing filter element, which filters solid particles and entrained liquids. Liquid droplets pass through
the filter elements, coalescing into larger particles.
The liquid removed by the cartridges is drained to an upper sump.
A high level alarm informs the operator of a high liquid level in the sump.
A manual Ball Valve drains lower sumps with operator action.
A drainage point from upper chamber is present provided with a manual ball valve in case of
high level in the coalescing section
At the bottom of the vessel is also present a manual drain valve 2” for a complete discharge of
the bottom chamber.
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Ensure that the type of drain system connected to the scrubber is suitable for
receiving flammable gas and condensates.
If the above is not confirmed, it might be necessary to pre-fill the scrubber sump
with liquid (such as water) in order to introduce a hydraulic guard preventing di-
rect discharge to an open drain. In case of doubt contact BHGE Headquarter.
NOTE: the quality of the gas reaching the scrubber/filter determines the life of the filter cartridg-
es and the intervals between their replacements. Some preliminary treatment system by Cus-
tomer, upstream of the one supplied by BHGE, is therefore recommended.
Fuel gas scrubber system includes valves, local and transmitters instruments and miscellane-
ous devices.
Generic hand tools and calibration instruments
Prior to perform first pressurization, it shall be confirmed that the mechanical erection of the in-
volved portions of the plant and equipment have been completed, all relevant certification have
been issued, checked and signed by the responsible parties, and are available on request. Spe-
cial attention has to be given to the piping Non Destructive Testing (NDT) certificates and to the
mechanical completion certificates for piping system, assessing proper installation and tighten-
ing of all flanged connections, using the right type of gaskets, etc.
Before pressurizing the system, the involved personnel shall be inducted about the EHS plan in
place, in order to have full knowledge of the activities being performed, the related risks and rel-
evant mitigation / prevention measures.
The rate at which the pressure will be increased / decreased shall be controlled and limited in or-
der not to cause dangerous stress to the piping and to any other system components.
The maximum pressure reached during the test shall never exceed the rating of the system.
It is very important that gas turbine operators always check for fuel gas leaks. At commission-
ing, the entire system shall be pressure tested with nitrogen to identify and eliminates any leak-
ages.
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Elimination of fuel gas leaks is of extreme importance as a fire and/or explosion

danger preventive measure.
Prior to pressurize the system, ensure that all certificates are available, confirm-
ing the skid conformity to all prescriptions for pressurized vessels (such as PED,
CE marking, etc.)
The commissioning of the fuel gas scrubber/filter system requires the following steps:
a) Installation of blind flanges at skid battery limits.
NOTE: this test can also be performed while leak testing fuel gas piping. In such case,
the above step shall be adapted moving the blind flanges at the end of the involved
piping.
b) Prepare all flanged connections for leakage test, wrapping them with adhesive
tape to be perforated in one point. The hole on the tape can be used later to
identify more easily the flange leakages, that will be concentrated on that point.
c) Pressurization with nitrogen of the skid, verifying leakages through the valves
and from the flanges.
d) Verification of proper operation of the change-over three way valve
e) Check alarm & trip functions performed by instruments and UCP
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7.5.17 GENERATOR CONTROL DEVICES SYSTEM COMMISSIONING

7.5.17.1 Purpose
Main purposes of the generator control devices system commissioning are:

• Verification of the generator space heaters
• Verification of the vibration and temperature protection system
• Verification of the jacking oil system
Generic tools for instruments testing

Dial indicator and magnetic support
1. Check the operation and current absorption of the generator space heaters. Verify
that the generator RTDs are showing actual heating of the generator internals.
2. Perform functional test of jacking oil system, confirming actual shaft lifting by
measurement with a dial indicator. Check and adjust, if required, the pressure
regulator for each bearing. Refer to SIC00054 for additional prescriptions.
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7.5.18 COMMISSIONING OF ELECTRIC GENERATOR WATER COOLING SYSTEM
7.5.18.1 Purpose
Main purpose of commissioning of the electric generator water cooling system is to verify:
- correct water circulation
The excess heat produced by the electric generator, while in operation, has to be removed in
order to keep the generator temperature below dangerous limits. This is achieved by forced cir-
culation of cooling water, ensured by electric motor driven pumps (not treated here).
Hand tools.
The commissioning of electric generator water cooling system requires the following steps:
1. Suggested: perform pneumatic test of motor heat exchanger(s) to identify
possible internal leaks prior to start water circulation.
2. Start water circulation and verify no leaks are visible.
3. While cooling water is circulating, vent any air from the top vent valve (or tap
point).
4. Confirm that the water is actually circulating
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7.5.19 GENERATOR ELECTRICAL SYSTEM COMMISSIONING
7.5.19.1 Purpose
Main purposes of the generator electrical system commissioning are:

• Verification of generator insulation & polarization index
• Generator Control & Protection Panel (GCPP) and Generat energization, setup and func-
tional testing or Excitation Panel (GEP)
• Verification of protection relays, current and voltage transformers (CT and VT) through
secondary injections
Generic tools for instruments testing

Megger 100 V, 500 V and 5KV
Phase sequence meter
Current/voltage injection box (with the possibility to change phase angle)
NOTE: Generator, Generator Control Protection Panel and Generator Excitation Panel precom-
missioning & commissioning are normally executed under OEM Vendor supervision, according to
Vendor’s best practices and procedures. The prescriptions given here shall be used as reference
and guideline.
Warning: Live high voltage may be present during most of the tests. Ensure that a
safety plan is in place, understood and observed at all time.

The generator electrical system is mainly composed by the generator itself (brushless type), vari-
ous protection and monitoring instruments mounted on the generator and/or its auxiliaries, cur-
rent and voltage transformers (CTs and VTs), Generator Control Protection Panel and Generator
Excitation Panel.
Without entering into a detailed description of the generator and other components (for which it
is possible to refer to the job Operation & Maintenance Manual), this system allows the manage-
ment of one power generator installed in an electrical power primary plant. The main functions
performed are:
- Generator Excitation control, allowing automatic or manual regulation of the generated
power parameters (voltage, active and reactive power).
- Generator control: automatic or manual synchronizing with line, main circuit breaker closure,
monitoring and display of electrical parameters.
- Generator protection against faults and malfunctioning, management of main circuit break-
er trips (fully automatic).
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The generator protection unit (protection relays) combines in various way the generator electrical
parameters (current, voltage, phase angle, frequency) detected by a number of CTs and VTs in-
stalled on the power bars, on the generator and on the line side, calculating derived parameters
and protecting the generator against various failure modes, as described by the job specification
“PROTECTION SETTING STUDY”.
The heart of the GEP is the Automatic Voltage Regulator (AVR), whose function is to regulate the
generator excitation current. The AVR is fed by an AC current generated by a small auxiliary al-
ternator (PNG) mounted on the main generator shaft. The AVR output is a regulated DC current,
feeding the stator coils of the exciter, that is another auxiliary alternator mounted on the main
generator. The exciter rotating armature coils generate an AC current that, after rectification by
a rotating diodes assembly, feeds the main generator field coils, generating power in the stator
windings.
The GCPP and GEP allows the operator to monitor the status of the controlled generator with the
aid of the measuring instruments, the indicating lamps, the signaling and text display, the dis-
plays of protection devices, which are all mounted on the panel front together with switches and
pushbuttons allowing the operator to control and set the generator parameters.
The panel provides interfacing with turbine and auxiliary control systems, plant and electrical
system supervisors.
1. Verification of generator insulation & polarization index
2. Generator Control & Protection Panel (GCPP) and Generator Excitation Panel (GEP)
energization, setup verification and internal functional checks
3. Generator instruments Loop checks and Functional tests
4. Current & Voltage transformers (CT & VT) Loop check
5. CT’s & VT’s acquisition verification through secondary injections
6. Verification of protection relays through secondary injections
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7.5.20 DIVERTER SYSTEM

7.5.20.1 Purpose
Main purpose of commissioning of diverter system is to verify:
-the start/stop of Main & Auxiliary seal air fan motor;
-the start/stop of guillotine damper actuator motor;
-the start/stop of diverter motor.
The basic function of the system is to send the exhaust gas from turbine to WHRU system or to
by-pass stack. This operation is executed moving a diverter according the position demanded
by the sequence. A sealing system is also provided to guarantee a correct isolation between
the volume purged and the diverter isolated one: in fact, when the diverter is in one of the two
“closed” position (BY-PASS STACK or WHRU) a set of limit switches inform the UCS (SIS part)
about the diverter position and the dedicated sealing system will be activated.
Hand tools.
The commissioning of diverter system requires the following steps:

1. A.C. power must be available for the main/auxiliary seal air fan motor (88PF-7A/B).
2. A.C. power must be available for the guillotine damper actuator motor (88DD-2).
3. A.C. power must be available for the diverter motor (88EP-2).
4. It will be checked the power supply and current absorption of the diverter motor
anticondensation space heater (23EP-2).
6. Check seal air blowers sequencing and cut-out/interlocks.
7. Perform test on linked inlet and by-pass diverter damper.
8. Check by-pass and inlet damper blade seal adjustment.
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7.5.21 COMMISSIONING OF STARTING MEANS SYSTEM
7.5.21.1 Purpose
Main purpose of commissioning of starting means system is to perform:

-No load test of the starting motor (test performed at no actual rotation of turbine)
-starting clutch alignment and setup

A gas turbine has to be accelerated to ignition speed by an external starting system. This oper-
ation is made by a diesel engine. This is cranked for starting by an electric motor PM-12 (88DS-
1), which is installed as an integral part of the engine. As a first step for the starting sequence,
the PM-12 (88DS-1) is energized as well as the 88HR-1 and the XY-1364 (20HR-1) which are
part of the ratcheting system that is used as assistance to the starting diesel engine. 88HR-1
motor and solenoid valve XY-1364 (20HR-1) are de-energized as soon as the shaft moves. After
the 88DS-1 has been started through command XS-1211C (4DS) sent to DCP, 88KM-1 diesel
engine cooler is started as well. The engine idles through the warm-up cycle (1 minute) and the
starting clutch engages, detected by limit switch ZSL-1361 (33CS-2).
After this cycle the XY-1359 (20DA-1) is energized in order accelerate the engine till the turbine
crank speed. The Torque Converter is used to adapt the torque supplied by the diesel engine
and the one absorbed by the gas turbine during the various phases of acceleration.
The clutch allows the diesel engine and the torque converter to be stopped and disconnected
from the rotating gas turbine at the end of startup. The self-synchronizing type clutch engages
when the driving torque is higher than the resistant one (when the diesel engine is started and
the turbine shaft is standstill), and disengages automatically when the torque is reversed (dur-
ing acceleration, when the gas turbine reaches self-sustaining speed). A position feedback mi-
croswitch detects the engagement/disengagement of the clutch: the status of this switch is
used by the Unit Control System to stop the starting motor at the end of startup.
The auxiliary gearbox, in addition to the main task of providing power to several gas turbine
auxiliaries (lube oil and hydraulic oil pumps, etc.), is also used to adapt the different rotational
speed of the starting system and the gas turbine shaft.
Amp meter (clamp type) to measure current absorption. Portable vibration analyzer to meas-
ure motor vibrations.
Dial indicators and magnetic bases to verify clutch alignment
The commissioning of starting system requires the following steps:
1. A.C. power must be available for the diesel engine local panel;
2. A.C. power must be available for cooling fan motor (88KM-1);
3. A.C. power must be available for the starter motor (88DS-1).
4. The tank must be filled with diesel fuel.
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5. b) It will be checked the power supply and current absorption of the cooling fan
motor anticondensation space heater (23KM-1).
6. Verification of starting clutch alignment and calibration of its position feedback mi-
croswitch – see SIC00258 for reference.
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7.5.22 COMMISSIONING OF FUEL GAS SYSTEM
7.5.22.1 Purpose
Main purpose of commissioning of fuel gas system is to verify:
-no leakages from piping flanges
-no leakages through isolation, shutoff, control and vent valves
-the correct operation of fuel gas valves (isolation and vent)
-the control valves position against command
-the SRV complete closure when a control oil dump valve opens
-the VGC complete closure when a control oil dump valve opens
The fuel gas system is designed to deliver fuel gas to the turbine combustion chambers at the
proper pressure and flow rate to meet all the starting, acceleration and load requirements for
gas turbine operation.
The clean fuel gas arriving from fuel gas treatment system (scrubbers, filters, etc.) enters the GT
skid passing through a strainer (“last chance filter”) prior to flowing through the gas valves and
into the gas manifold piping. Upstream of the strainer, an isolation valve and a vent valve is posi-
tioned in order to isolate and completely depressurize the GT enclosure while it’s not running.
Downstream of the strainer, another vent valve is present to be used at start-up to purge cold
fuel gas trapped inside the line (fuel warm-up vent valve). The system includes also a flow meas-
urement device used mainly to detect excessive fuel flow at ignition.
The gas fuel is metered and controlled by the gas valves (Speed Ratio Valve - SRV and Gas Con-
trol Valves –VGC1-2-3) to supply the required flow to the gas turbine combustion system.
It is very important that gas turbine operators always check for fuel gas leaks. At commissioning,
the entire system, up to the last flanges connecting fuel nozzles, shall be pressure tested with ni-
trogen to identify and eliminates any leakages. The fuel nozzles connections will be leak tested in
operation at very low load, during first.
Elimination of fuel gas leaks is of extreme importance as a fire and/or explosion

danger preventive measure.
The commissioning of fuel gas system requires the following steps:

1. Confirmation, through cleaning certificate, of proper line blowing up to GT skid limit.
2. Functional test of each automatic valve, verifying and setting position feedback
microswitches.
4. Installation of blind flanges at strainer and fuel nozzles flanges.
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5. Pressurization with nitrogen of fuel gas system, operating each valve in sequence,
from upstream to downstream, in order to include in different steps all sections of
the system, verifying each time leakages through valves and from flanges.
6. Calibration and functional testing of SRV and VGC.
a. A.C. power must be available for the auxiliary lube oil pump driver (88QA-1).
b. A.C. power must be available for the auxiliary hydraulic oil pump driver (88HQ).
c. LVDT calibration at SRV and VGC1-2-3 full closed position.
d. Servo control loops calibration (actuators stroking)
e. Verification that the valves actual strokes are as per design.
f. Verification of Control Oil ability to drive SRV and VGC1-2-3 to full closed
position in case of trip
7. At the end of test, remove blind flanges and restore all piping connections as per
P&I, then remove the logic forcing at all signals involved during checks and leave
the fuel gas system in ready to start condition.
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7.5.23 LIQUID FUEL SELECTION & FILTER SKID SYSTEM
7.5.23.1 Purpose
Main purpose of commissioning of liquid fuel selection & filter skid system is to verify:
-the correct operation of valves according to the liquid fuel selected;
The purpose of the skid is to provide liquid fuel to the GT executing a selection between LCO or
diesel by an HMI command.
Hand tools.
1. During the commissioning of liquid fuel selection & filter skid system will be
executed the check on liquid fuel valves.
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7.5.24 COMMISSIONING OF LIQUID FUEL SYSTEM
7.5.24.1 Purpose
Main purpose of commissioning of liquid fuel system is to verify:
-flushing/cleaning of liquid fuel system
-the correct operation of liquid fuel valves
The liquid fuel system is mainly composed by:

-Liquid clutch on accessory gear box
-LF system permissive to start
-LF system control valve regulator
-LF filters
-LF system speed sensor
-Shut-off valves
Liquid Fuel Shut-Off valve
This shut off valve is a fail to close valve, controlled by MKVIeS, to cut off the LF in case of trip and
shutdown (according to shutdown sequence). This valve energizes to open when firing permis-
sive is true.

The commissioning of liquid fuel system requires the following steps:

1. It will be verified the correct functionality of each valves.
2. It will be verified that casings for liquid fuel filters are clean and filters are installed.
3. Functional test of each valves, verifying and setting position feedback
microswitches.
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7.5.25 COMMISSIONING OF LIQUID DRAIN TANK SYSTEM
7.5.25.1 Purpose
Main purpose of commissioning of liquid drain tank system is to verify:
-the correct operation of motors;
The purpose of the liquid drain tank is to collect in storage vessel waste fuel oils (LCO and Distil-
late2) coming from Gas Turbine utilizers (filters drains, false start drains, liquid fuel piping, LCO
purge). Drains from gas turbine are sent, by means of funnel connections, to fuel oil header
and subsequently to Liquid Fuel Drain Tank. The Liquid Fuel Drain Tank is equipped with
2x100% pumps (MAIN / AUXILIARY) to discharge wastes to slop oil header.
Hand tools.
The commissioning of liquid drain tank requires the following steps:

1. A.C. power must be available for the pump motor (88PLP-/1&2).
2. It will be checked the power supply and current absorption of the main/auxiliary
anticondensation space heaters (23PLP/1&2).
3. It will be verified that casings for liquid fuel filters are clean and filters are installed.
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7.5.26 PURGE AIR SYSTEM
7.5.26.1 Purpose
Main purpose of commissioning of purge air system is to verify:
-the correct operation of motor;
The scope of the system is to provide air for the auxiliary systems of the turbine.
Hand tools.
7.5.26.4Guidelines:
The commissioning of purge air system requires the following steps:

1. A.C. power must be available for compressor local panel;
2. A.C. power must be available for the air compressor motor (88SC).
3. Check the operation and current absorption of the air compressor motor anticon-
densation space heater (23SC).
4. Check the operation of the air compressor motor (88SC). The electric motor shall be
started up and tested, measuring current absorption and radial vibrations. See
SIC00202 for reference.
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7.5.27 WATER INJCTION SYSTEM
7.5.27.1 Purpose
Main purpose of commissioning of water injection system is to verify:
-the correct operation of motor;
The water injection system is used to control NOx emissions during operation with liquid fuel
(LCO and Distillate2). The allowable NOx ratio at the turbine exhaust is achieved by the injec-
tion of a certain amount of water flow in the combustion chamber, depending on ambient
temperature, relative humidity and fuel flow.
Water injection system receives water from Customer’s demineralized water supply header
and, after pumping and filtration stages, delivers water at the required pressure and flow rate
to the combustion chamber nozzles. No operation is foreseen with fuel gas nor during fuel
transfers involving gas.
Hand tools.
7.5.27.4Guidelines:
The commissioning of water injection system requires the following steps:

1. A.C. power must be available for the water injection motor (88WN-1).
2. Check the operation and current absorption of the water injection motor anticon-
densation space heater (23WN-1).
3. Check the operation of the water injection motor (88WN-1). The electric motor shall
be started up and tested, measuring current absorption and radial vibrations. See
SIC00202 for reference.
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7.5.28 COMMISSIONING OF GAS CHROMATOGRAH METERING SYSTEM
7.5.28.1 Purpose
Main purpose of commissioning of a chromatograph metering system is to verify:
-initial system setup
-calibration/validation of the measurement system
-communication with Unit Control System
-instrumentation (gauges, transmitters) and valves functionality.
The following description is an abstract from supplier manual.
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Pressure safety valves prevent overpressure on item working at pressure lower than that existing
upstream the pressure control valves.
Gas chromatograph metering system includes valves, local and transmitters instruments and
miscellaneous devices.
Generic tools for instruments calibration.

Sample bottles for calibration
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This equipment shall be powered up and commissioned according to supplier manual (it is sug-
gested to have the system commissioned by a supplier representative). The steps below are de-
scribed for reference only.
1. Sample line, carrier and calibration lines pressurization and leak check
2. Carrier and calibration lines purging
3. System power up and setup verification
4. Calibration using reference gas bottles
5. Communication link setup and testing
6. Operational check of fuel gas sampling and analysis
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7.5.29 COMMISSIONING OF WATER WASHING SYSTEM
7.5.29.1 Purpose
Main purpose of commissioning of water washing system is to verify:
-the washing solution heater cut out for excessive temperature
-the pump delivery pressure for both on-line/off –line conditions
-the functionality of on-line/off-line regulating valves
-the cleanliness of the piping/tubing lines
-the correct operation of water nozzles on GT inlet bellmouth.
The water washing skid is permanently connected to the gas turbine water wash OFF line or
ON line connection and is controlled through a control station depending on which one has to
be performed. The on-line /off-line washing system is substantially composed of washing tank,
washing pump and electric heater. The heated cleaning solution is delivered, through piping /
flexible hoses, to a number of nozzles installed on the GT inlet bellmouth. Water flow is con-
trolled by two solenoid valves driven by the Unit Control Panel (UCP). During water wash se-
quence, the water and detergent solution is sprayed inside the inlet of the GT axial compresor,
that is rotating at crank speed in case of the off-line wash, or at full operational speed in case
of on-line wash. Water Wash execution is described in Operation & Maintenance manual.
The commissioning of Water Washing system requires the following steps:

1. A.C. power must be available for the water washing skid local panel.
2. Check setting and operation of thermo switches and level switches.
3. The electric motor shall be started up and tested, measuring current absorption
5. Functional check of washing water system.
a. Water pump start/stop test
b. Flushing of water wash lines from WW skid to GT entry flanges, using WW skid
pump
c. At GT zero speed, with GT inlet bellmouth protected with a tarpaulin in order to
prevent water ingress, select off-line wash and start pump. Set water pressure
in order to have required water flow for off-line wash
d. Repeat above test selecting on-line wash
e. Restore system and clean GT inlet plenum
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NOTE: as best practice, it is suggested to perform an off-line water wash before starting-up the
turbine. This will ensure best performances while in operation by removing dust, dirt, oily films
etc. that may have been deposited on the axial compressor during extended non-operational
periods.
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7.5.30 COMMISSIONING OF INLET GUIDE VANES (IGV) SYSTEM
7.5.30.1 Purpose
Main purpose of commissioning of Inlet Guide Vanes (IGV) system is to verify:

-the IGV actuator travel as per design
-the calibration of the actuator servo control loop
This model of gas turbine is equipped with variable Inlet Guide Vanes (IGV), placed in front of the
axial compressor. These vanes can be moved, all together, to more open or closed positions
changing the axial compressor air flow, optimizing it for all operating conditions of the gas tur-
bine. Particularly, the IGV are kept at max closing position during the initial phase of startup, un-
loading the axial compressor and preventing surge phenomena, then they are driven to partially
open position during acceleration and up to full speed no load, reaching full open position and
full axial compressor air flow at max load conditions.
Each variable vane has a toothed wheel that is engaged with a toothed ring, whose rotation,
driven by a hydraulic cylinder, determines the position of all vanes. The initial setup of the system,
done in the factory, includes the adjustment of the angle position of each vane, the full open and
full closed positions stops of the toothed ring and the verification that the hydraulic cylinder can
drive the ring and, therefore, the vanes within the expected travel. A mechanical indicator is also
calibrated in order to show the IGV angle position.
The position of the hydraulic piston is controlled by a servo control loop composed by a servo-
valve and two LVDTs. The servovalve is a device that directs the hydraulic oil to the cylinder ac-
cording to an electric signal, while the LVDTs are position feedback devices, whose output elec-
tric signal is proportional to the stroke of the cylinder and, therefore, to the angular position of
the IGV.
The algorithms implemented in the UCS software calculate the required position (setpoint) of the
IGV, generating an electrical signal that is sent to the servovalve, changing the actuator position
until the feedback from the LVDT is equal to the setpoint.
The commissioning of this system requires the following steps:

1. A.C. power must be available for the auxiliary lube oil pump driver).
2. A.C. power must be available for the auxiliary hydraulic oil pump driver.
3. LVDT calibration at IGV full closed position.
4. Servo control loop calibration (actuator stroking)
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5. Verification that the IGV angle position is as per design when fully open / fully
closed, using IGV external dial indicator as reference.
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7.5.31 COMMISSIONING OF START ON CRANK MODE
7.5.31.1 Purpose
The Crank tests are performed as the final step of commissioning of the Gas Turbine, setting as
much as possible all auxiliaries as for normal operation, usually just before proceeding to the
test in FIRE mode.
The main objectives of these tests are:
- Verification of the automatic startup sequence, observing control system ability to

check Ready to Start conditions, energizing all auxiliaries involved in this phase,
managing all relevant interlocks, alarms, etc.
- Final verification of the starting system, including actual Gas Turbine shaft rotation
- First assessment of the behaviour of the Gas Turbine and its auxiliaries while
running at Crank speed
- Adjustment of Hydraulic Oil pressure regulator
Prior to execute the following steps with an operational Gas Turbine, confirm
that all EHS risks connected with this phase have been evaluated and proper-
ly addressed by an EHS plan, that shall be known and strictly observed by all
parties involved in these operations.
Prior to execute first start-up ensure that Red Flag Review 3rd milestone
(TG3 –Green Light) have been successfully executed.
During all tests never exceeds max running time of the starting system, par-
ticularly at acceleration speed (refer to supplier manual).
1. Set Gas Turbine auxiliaries in operational conditions, removing LOTO as per appli-
cable EHS procedure
2. Check Ready to Start conditions, performing any troubleshooting required
3. Start the Gas Turbine and stop it at a few hundreds RPM. During coast down, lis-
ten for rubbing noises in the turbine compartment. In case, do not proceed to fur-
ther startup prior to having understood the cause of the abnormal noise.
4. At Crank speed verify Gas Turbine shaft parameters.

Focus on
Bearings metal temperatures
Bearings vibrations.
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5. At Crank speed, after Hydraulic Oil pressure adjustment, perform servo calibra-
tion (see relevant sections)
6. Check alarm & trip functions performed by instruments and UCP.
7. Perform turbine Water Wash system .
NOTE: in case a water wash is actually performed, this shall be planned in order to be followed
by a fired start in no longer than 24 hours. This is required to properly dry the Gas Turbine.
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Commissioning & Start-up Start-Up Operations Section 8
8 START-UP OPERATION ................................................................................................................................. 2

8.1 FOREWORD ........................................................................................................................................................................... 2
8.2 PRELIMINARY SAFETY CHECK ....................................................................................................................................... 3
8.3 MACHINE’S OPERATIONAL PARAMETERS AND LIMITS ...................................................................................... 3
8.3.1 Temperature Limits .................................................................................................................................................4
8.3.2 Pressure Limits ..........................................................................................................................................................5
8.3.3 Turbine Vibration Limits ........................................................................................................................................5
8.3.4 Load Limit ....................................................................................................................................................................6
8.4 Combustion System Operating Precautions ........................................................................................................ 6
8.5 Cooldown/Shutdown Precautions ............................................................................................................................ 7
8.6 CHECKS PRIOR TO OPERATION .................................................................................................................................... 8
8.6.1 STANDBY POWER REQUIREMENTS ...................................................................................................................8
8.6.2 PRELIMINARY CHECKS ............................................................................................................................................8
8.7 UNIT START-UP PROCEDURE - NORMAL LOAD OPERATION ........................................................................ 9
8.7.1 START-UP ON CRANK, STEP TO FIRE MODE (liquid fuel) ..........................................................................9
8.7.2 START-UP ON CRANK, STEP TO FIRE MODE (fuel gas)..............................................................................9
8.7.3 IBH CLEANING RUN ..............................................................................................................................................10
8.7.4 MANUAL OPERATION ...........................................................................................................................................10
8.7.5 GENERATOR ELECTRICAL TESTS ..................................................................................................................... 10
8.7.6 PRIMARY/SECONDARY FUEL GAS STRAINER CLEANING RUN ........................................................... 10
8.7.7 DLN TUNING MAPPING .......................................................................................................................................11
8.7.8 DUAL GAS - TRANSFER TESTS .......................................................................................................................... 11
8.7.9 DUEL LIQUID - TRANSFER TESTS ................................................................................................................... 11
8.7.10 LOADING AND UNLOADING ............................................................................................................................. 11
8.7.11 NORMAL STOP SEQUENCE VERIFICATION.................................................................................................. 11
8.7.12 START-UP ON REMOTE AND REMOTE OPERATION................................................................................. 11
8.7.13 UNIT FINAL VERIFICATIONS...............................................................................................................................11
8.8 ROUTINE CHECKS DURING NORMAL OPERATION ............................................................................................12
8.8.1 Gas Turbine ..............................................................................................................................................................12
8.9 Reference Documents and Procedures................................................................................................................12
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8 START-UP OPERATION
Prior to execute first start-up ensure that Red Flag Review 3rd milestone (TG3 –
Green Light) have been successfully executed.
8.1 FOREWORD
For evaluation of specific risks, typical for duties carried out by personnel during Start-Up activity,
indications for prevention and protection operative measures and modes, PPE to be used, refer to
BHGE’s EHS Manual and to Job Safety Analysis (JSA).
Refer to section 2 (Safety Prescription) of this manual for detailed instructions about Job Safety
Analysis (JSA).
Warning: Before starting the operations described in this section (8) refer
to the relevant “Job Safety Analysis” (JSA): JSA045
The personnel entrusted with the operation of BHGE products shall have the nec-
essary technical characteristics and suitable technical training for the task it has
to accomplish. Any damage, even partial, ascribable to failure to comply with
aforesaid essential characteristics shall be attributable to the purchaser and
BHGE will be discharged of any liability and indemnification thereof.
These instructions describe the procedure for the operation of the machine.
These activities are described on Site Quality Start-up Check List:
SOI0002895 Site Quality Start-up Check List
The instructions are supplied as a guide and do not necessarily include the required elements for
every possible condition variation that could take place during operation. Therefore, slightly dif-
ferent procedures may be used to deal with particular conditions.
Regardless of the procedure used only qualified and experienced personnel shall be entrusted
with this task.
Any injury or damage resulting from off design or improper operation, negligent
procedure and maintenance deficiency or effect of corrosion, erosion, deposit of
scale and wear and tear are excluded from BHGE warranty.
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8.2 PRELIMINARY SAFETY CHECK
Before performing any operation, a general check of safety conditions must be carried out; such
inspection must follow instructions given herein after.
Any actual or potential risk must be removed, before any operation.
Preliminary inspection must be carried out as follows:
 Learn all special emergency procedures concerning each system.

 Note the location and learn the operation of any other emergency or protection appliance.
 Note dangerous areas for possible escape of gases, acid gases, condense collection, drain-
age line, high voltage, high pressure and other predictable risks.
 Ensure the appliance and the adjacent area are in good conditions and without obstacles
and ensure that vent lines are not obstructed.
 Ensure the fuel gas filters and associated piping and equipment have been correctly purged
and the filters internals are in place.
 Check if other personnel is operating in the area and if their work is so dangerous to pre-
clude the operation of the unit.
8.3 MACHINE’S OPERATIONAL PARAMETERS AND LIMITS
Before starting the equipment it is necessary to be familiar with its operational limits. This means
to be aware of the maximum / minimum acceptable values for all the physical parameters that
are measured by the instruments installed on the equipment.
In general, the Unit Control System monitors these parameters and provides automatic protec-
tion in case of abnormal behavior, preventing any damage of the equipment. In most cases, the
effectiveness of the protection functions has been confirmed during commissioning, making first
Startup a relatively safe operation. However, some of these protection functions cannot be effec-
tively and fully tested during commissioning, without actually running the equipment. For this
reasons the Startup team has to be aware of the operational limits, and shall continuously moni-
tor the equipment’s parameters in order to be able to abort the tests in case some of them ap-
proaches dangerous conditions.
In normal conditions, the equipment parameters should remain all time below the alarm level de-
fined by job design documents (mainly by Instruments List). However, during first startups and
first periods of operation, particularly during transients, some parameter may reach and stay
above alarm level for a limited period of time, decreasing below alarm level after stabilization.
These phenomena are usually caused by the long period of inactivity of the equipment after
manufacturing and testing (e.g: rotor bowing due to horizontal storage may cause high vibra-
tions). In some other cases, some operational conditions might need to be adjusted/optimized, for
instance changing process settings, tuning control systems constants, stabilizing control loops,
etc.
It is not acceptable to operate the equipment with parameters above trip levels,
whose values shall never be changed unless this is authorized by BHGE.
For reference, the following sections describe some of the main operational parameters to be
monitored.
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8.3.1 Temperature Limits
Refer to the TURBINE DATA FOR CONTROL SYSTEM SETTING for actual exhaust temperature
control settings.
It is important to define a “base line value” for the exhaust temperature spread for future data
comparison. This base line data is established during steady-state operation in each of the fol-
lowing situations:
a. Following initial unit start up
b. Before and after a planned shutdown
c. Before and after planned maintenance.
Note that is not necessarily the magnitude of the spread that is important for evaluating ex-
haust temperature spreads, but the change in spread over a period of time. Accurate daily re-
cording and plotting of exhaust temperatures can give early warning of a developing problem.
The absolute maximum value of Turbine wheelspace temperatures permissible during opera-
tion.
The thermocouples, together with their nomenclatures, are shown on the Field Instrument List.
The wheelspace temperature readings should be the average for at least two thermocouples lo-
cated nearly diametrically opposite each other in the wheelspace. If there is a good reason to
doubt the reading, it should be rejected. A reading from another thermocouple should be taken
(if more than two thermocouples are installed). The faulty thermocouple should be replaced as
soon as possible.
When the average temperature in any wheelspace is higher than the temperature limit defined
above, it indicates a problem. High wheelspace temperature may be caused by any of the fol-
lowing faults:
a. Restriction in cooling air lines

b. Worn turbine seals
c. Excessive distortion of the turbine stator
d. Poor positioning of thermocouples
e. Malfunctioning combustion system
f. Leakage in external piping
g. Excessive distortion of exhaust inner diffuser.
Check wheelspace temperatures very carefully at initial start up. If they are consistently high,
and a check of the external cooling air circuits reveals no problems, it is permissible to slightly
increase the size of the cooling air orifices. Consult BHGE Headquarter and obtain its recom-
mendations regarding the increase in the size of an orifice.
Following a turbine overhaul, all orifices should be restored to their original size, ensuring that all
the turbine clearances are returned to normal and all leakage paths are corrected.
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NOTE
The first stage turbine forward wheelspace is cooled by compressor discharge air which leaks
past the compressor high pressure air seal.
This air is channeled internally to the wheelspace through the annular cavity formed by the in-
ner barrel of the discharge casing and the turbine rotor distance piece. There are no orifices to
control the air flow.
8.3.2 Pressure Limits
Refer to the Schematic Piping Diagram and Field Instruments List for actual pressure transmit-
ters settings.
Lube oil pressure in the bearing feed header has a nominal value of 1.75 kg/cm2 G. The turbine
will trip at 0.82 kg/cm2 G.
Pressure variations between these values will result from particulate matter entrapped within
the lube oil filtering system.
8.3.3 Turbine Vibration Limits

The maximum overall vibration velocity of the gas turbine should never exceed 1.0 inch (25.4
mm) per second (trip set point) in either the vertical or horizontal direction.
Corrective action should be initiated when the vibration levels exceed 0.5 inch (12.7 mm) per
second (alarm set point) as shown on the UCP panel HMI.
In case of doubts regarding the accuracy of the HMI reading or if more accurate and specific vi-
bration readings are desired, it is recommended to carry out a vibration check using vibration
test equipment. A meaningful Vibration Analysis should be able to find the velocity component
of the readings taken at a given speed (or frequency).
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8.3.4 Load Limit
Gas Turbine overload - Facts and Policy.

It is BHGE practice to design and build margins of safety into gas turbines to comply with con-
tract requirements and to ensure long life and trouble-free operation.
In order to ensure maximum trouble-free operation, BHGE designs these machines with more
than ample margins on turbine bucket thermal and dynamic stress, compressor and turbine
wheel stress, coolers, etc. As a result, these machines are designed somewhat better than strict-
ly necessary, but BHGE believes that such design margins are required, considering the great
importance of reliability of these turbines to its customers and to the industry.
The exhaust temperature control system detects the turbine exhaust temperatures and intro-
duces proper bias to limit the fuel flow so that neither the maximum allowable turbine inlet tem-
perature nor the maximum allowable turbine exhaust temperature is exceeded.
8.4 Combustion System Operating Precautions
During Operation, Exhaust temperatures are monitored by the turbine control system. The tem-
perature spread is compared to allowable spreads with alarms resulting if the allowable spread
limits are exceeded.
NOTE: Sudden emission of black smoke from gas turbine units may indicate serious combustion
difficulties. If black smoke develops. The unit should be immediately removed from op-
eration, and a combustion inspection performed.
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8.5 Cooldown/Shutdown Precautions
In the event of an emergency shutdown in which internal damage of any rotating

equipment is suspected, do not turn the rotor after shutdown. Maintain lube oil
pump in operation, since lack of circulating lube oil following a hot shutdown will
result in rising bearing temperatures, which can result in damaged bearing sur-
faces.
If the malfunction that caused the shutdown can be quickly repaired, or if a
check reveals no internal damage affecting the rotating parts, reinstate the
cooldown cycle.
If there is an emergency shutdown and the turbine is not turned with the ratchet, the following
factors could be noted:
a. Within maximum 20 minutes following turbine shutdown, the gas turbine

may be started. Use the normal starting procedure.
b. Between the twenty-minute period mentioned above and a total of two

hours after shutdown, rotor bowing will result in high vibration levels and
rubbing that will prohibit startup of the turbine. Do not attempt any restart
unless rotation has been performed for one to two hours minimum, so as to
reduce rotor bowing.
c. If the unit has been shut down and not turned at all, it must be shut down
for approximately 24 hours before it can be restarted without danger of
shaft bow.
If the cooldown operation hasn’t been performed after shutdown and a restart is
attempted, the operator should maintain a constant check on vibration velocity
as the unit is brought up to its rated speed.
If the vibration velocity exceeds 25,4 mm per second at any speed, the unit
should be shut down and turned with the ratchet for at least one hour before a
second starting attempt is made. If seizure occurs during the ratchet operation
of the gas turbine, the turbine should be shut down and remain idle for at least
30 hours, or until the rotor is free. The turbine may be turned at any time during
the 30-hour period if it is free; however, audible checks should be made for rubs.
NOTE: The vibration velocity must be measured at points near the gas turbine bearing caps.
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8.6 CHECKS PRIOR TO OPERATION

These preparations are described in more detail in the following paragraphs.
8.6.1 STANDBY POWER REQUIREMENTS
Standby AC power is required to ensure the immediate start up capability of particular turbine
equipment and related control systems, when the start signal is given. Functions identified by an
asterisk are also necessary for unit protection and should not be turned off except in the case of
maintenance work on that particular function:
a. In case of low ambient temperatures, heat up and circulate turbine lube oil, in order to main-
tain proper oil viscosity.
8.6.2 PRELIMINARY CHECKS

The following checks must be made before attempting to operate a new turbine or an overhauled
turbine. It is assumed that the turbine has been assembled correctly, is in alignment and that cal-
ibration of the Unit Control System (UCS) has been performed in line with the BHGE Control Speci-
fications. A standby inspection of the turbine should be performed with the auxiliary lube oil
pump operating, with emphasis on the following areas:
a. Check that all piping and turbine connections are securely fastened and that all blinds have
been removed. Most tube fittings incorporate a stop collar which ensures proper torqueing of the
fittings at initial fitting installation and at reassembly. These collars fit between the body of the fit-
ting and the nut, ensuring contact is maintained when tightening the fitting. The stop collar is
similar to a washer and can be rotated freely on unassembled fittings. During initial assembly of a
fitting with stop collar, tighten the nut until the collar cannot be rotated by hand. This is the check
for a proper fitting, the nut should be tightened until the collar cannot be rotated.
b. Inlet and exhaust plenums and associated ducts are clean and free of any foreign objects. All
access doors are secured.
c. Where fuel, air or lube oil filters have been replaced, check that all covers are intact and tight.
d. Verify that the lube oil tank is within the operating level and if the tank has been drained that it
has been refilled with the recommended quality and quantity of lube oil. If lube oil flushing has
been carried out verify that all filters have been replaced and any blinds used have been re-
moved.
e. Check the operation of auxiliary and emergency equipment, such as lube oil pumps, water
pumps, etc. Check for signs of leakage, abnormal vibration, noise or overheating.
f. Check the lube oil piping for signs of leakage. Using the oil flow sights provided, check visually
that the oil is flowing from the bearing drains. The turbine should not be started unless flow is vis-
ible at each flow sight.
g. Check the condition of all thermocouples on the HMI. Readings should be at approximately
ambient temperature.
h. Check spark plugs for proper arcing.
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WARNING
DO NOT TEST SPARK PLUGS WHERE EXPLOSIVE ATMOSPHERE IS PRESENT.
If the arc occurs anywhere other than directly across the gap at the tips of the electrodes or if, by
blowing on the arc, it can be moved from this point, the plug should be cleaned and the tip clear-
ance adjusted or if necessary, replaced.
i. Devices requiring manual lubrication must be properly serviced.
j. Check that the cooling system has been properly flushed and filled with the recommended
coolant. Any fine powdery rust, which may form in the piping during short time exposure to the
atmosphere, can be tolerated. If there is evidence of scaly rust, the cooling system should be
power flushed until all scale is removed.
If the use of a chemical cleaner is required, most car cooling system cleaners are acceptable and
will not damage the carbon and rubber parts of the pump mechanical seals or rubber parts in the
piping.
k. At this point any grounding faults found should be cleared. It is advisable not to operate the
units when a grounding fault is indicated. Immediate action should be taken to locate all grounds
and correct the problems.
8.7 UNIT START-UP PROCEDURE - NORMAL LOAD OPERATION
The entire train will be started and operated in Normal Load arrangement, exploring various pro-
duction conditions; all equipment, machines and auxiliaries shall be functional and in service; in
case some limited portion of the scope of supply cannot be operated, or some running condition
cannot be explored, the relevant tests shall be completed prior to final Hand Over.
Impact to/from Customer Process/Plant shall be managed as a coordinated effort.
NOTE: Unit Integration and impact on/from Customer process have to be evalu-
ated at site. Integrated test plan shall be agreed with customer prior to startup.
8.7.1 START-UP ON CRANK, STEP TO FIRE MODE (liquid fuel)

During this phase, the test main objectives will be:
• Verification of auxiliaries automatic startup
• Liquid Fuel system purge, flushing and flow test
• Failure to ignite test (startup with ignition system disabled)
• Ignition test
• Overspeed Protection test @ reduced setpoint
8.7.2 START-UP ON CRANK, STEP TO FIRE MODE (fuel gas)

• Verification of auxiliaries automatic startup
• Fuel gas system purge,
• Failure to ignite test (startup with ignition system disabled)
• Ignition test
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• Overspeed Protection test @ reduced setpoint
8.7.3 IBH CLEANING RUN

• Cleaning of the Inlet Bleed Heating piping.
WARNING
This cleaning run requires a preparation prior to first startup
The IBH line must always be cleaned before the Gas Turbine is operated, in order to avoid that
any debris present in the line after fabrication at site may enter into the gas turbine suction and
damage the axial compressor. Also, the VA20-1 control valve may be damaged if the dirt is not
removed before it is put in operation.
The cleaning is executed by removing the VA20-1 valve and installing a spool with an orifice at its
place. Downstream of the IBH line, upstream of the IBH manifold of the filter house, a strainer has
to be installed to block the dirt. The cleaning is executed during gas turbine first fired start-up,
running for 5 minutes at FSNL, allowing the axial compressor air to blow the IBH line through the
spool/orifice and the strainer. The cleanliness acceptability condition is achieved when no dirt is
visible on the strainer at the end of the cleaning.
The size of the spool/orifice and the strainer are function of the gas turbine model/size.
For reference see RIC8954760
8.7.4 MANUAL OPERATION

• Verification of auxiliaries sequencing during Start Up and after End of Sequence
• Flanges leakages test
• Verification and calibration of Lube Oil system at operational speed
• Verification and calibration of train auxiliaries
• Verification and tuning of control loops
• Testing of protection function (ESD)
• Data acquisition and analysis of equipment parameters, without loading the train.
8.7.5 GENERATOR ELECTRICAL TESTS

• Short Circuit Tests
• Open Voltage Tests
• Voltage, Phase sequence and Synchronization Tests
For reference see also SIC00036
8.7.6 PRIMARY/SECONDARY FUEL GAS STRAINER CLEANING RUN

• Cleaning of DLN fuel gas piping
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8.7.7 DLN TUNING MAPPING

• Optimization of combustion parameters
8.7.8 DUAL GAS - TRANSFER TESTS

• Verification of smooth transition during fuel changeover
• Verification of combustion stability with any fuel
8.7.9 DUEL LIQUID - TRANSFER TESTS

• Verification of smooth transition during fuel changeover
• Verification of combustion stability with any fuel
8.7.10 LOADING AND UNLOADING

• Verification of smooth loading, in steps from min to max load conditions
• Verification and tuning of control loops at increased load
• Verification of smooth unloading, in steps from max to min load conditions
• Data acquisition and analysis of equipment parameters
8.7.11 NORMAL STOP SEQUENCE VERIFICATION

• Verification of automatic unloading
• Verification of auxiliaries sequencing during Normal Stop
• Verification and tuning of fuel schedule for correct fired shutdown sequence
• Verification of Cool Down activation
8.7.12 START-UP ON REMOTE AND REMOTE OPERATION

• Start Up from Remote
• Loading and Unloading from Remote
• Stop from Remote
8.7.13 UNIT FINAL VERIFICATIONS

• Completion of any contractual testing requirement
• Completion of data acquisition
• Troubleshooting all alarms and abnormalities
• Execution of any performance/endurance test as per contract.
• Preparation for Handover of equipment to Customer (As Built, Software backups, pass-
words, etc.)
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8.8 ROUTINE CHECKS DURING NORMAL OPERATION
8.8.1 Gas Turbine
To be performed on a regular basis on the running machine, where available.
 Temperature in the gas turbine journal and thrust bearings.

 Radial vibration in the gas turbine journal bearing.
 Axial displacements in the gas turbine thrust bearing.
 Oil flow in the discharge from gas turbine bearings through flow sight glasses.
 Unusual rotor noise or rubbings.
8.9 Reference Documents and Procedures
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Commissioning & Start Up Manual

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TECHNICAL PACKAGE FOR COMMISSIONING (TPC)

Commissioning & Start-Up Manual

Dangote Oil Refining Company LTD.

Dangote Refinery and Petrochemicals Project

MS6001B DLN Dual Fuel + E.G.

BHGE job # ITEM # Driver Serials #

1606600 MS6001B + ELECTRIC GENERATOR G09115

1606601 MS6001B + ELECTRIC GENERATOR G09116

1606602 MS6001B + ELECTRIC GENERATOR G09117

1606603 MS6001B + ELECTRIC GENERATOR G09121

1606604 MS6001B + ELECTRIC GENERATOR G09123

1606605 MS6001B + ELECTRIC GENERATOR G09120

1606606 MS6001B + ELECTRIC GENERATOR G09119

1606607 MS6001B + ELECTRIC GENERATOR G09118

COMMISSIONING & START-UP MANUAL

Status and description of the revisions

Stato di revisione Data Eseguito Controllato Approvato Descrizione della revisione

00 04-17 G.D.S. Panufnik M. Lascialfari G. ISSUE

01 11-18 G.D.S. Lascialfari G. Arcioni M. UPDATE DOCUMENTS

© 2018 Nuovo Pignone Tecnologie S.r.l., tutti i diritti riservati

© 2018 Nuovo Pignone Tecnologie S.r.l., all rights reserved

11-18-E 1606600÷07 P. 1-1

BHGE Technical Communication

Customer Service Center

CSC- Technical Assistance Form

Phone: +39-055-427 2500

Advisory Monitoring & Diagnostics (AM&D)

PURPOSE OF THE COMMISSIONING & START-UP MANUAL

SUGGESTED ACROBAT READER SETTINGS FOR EASIER NAVIGATION

SAFETY PRESCRIPTIONS ...........................................................................................................2

MAIN ACTIVITIES .......................................................................................................................3

REFERENCE DRAWINGS ...........................................................................................................4

STANDARD PRACTICES .............................................................................................................5

QUALITY PROCESSES AT SITE ..................................................................................................6

11-18-E 1606600÷07 1-Index

In case the installation, commissioning and startup of BHGE equipment is performed

Installation & Commissioning Control

Positioning of Com 45/1 Com 45/2

1.3 ORIGINAL EQUIPMENT MANUFACTURERS MANUAL

1.4 HOW TO READ BHGE TPI&C MANUALS <1>

b) Check relevant section in the SQCL:

c) Collect needed documentation according to the “REFERENCE DRAWINGS” section

And reference procedures in same Table:

d) Start to operate according Job documentation, SQCL step description, applicable

2.1 STANDARD SAFETY INSTRUCTIONS .................................................................................................................. 1

2.2 FIELD ACTIVITIES EHS POLICY .............................................................................................................................. 2

2.3 JOB SAFETY ANALYSIS DESCRIPTION ................................................................................................................ 5

11-18-E 1606600÷07 2-Index

2.1 STANDARD SAFETY INSTRUCTIONS

Failure to observe safety regulations and/or the removal or modification of safeguards

2.2 FIELD ACTIVITIES EHS POLICY

BHGE Oil and Gas Global Services EHS Documents

EHS Manual and Management Procedures

• EHS-MAN - EHS Manual

Operative Procedures & Work Instructions

• EHS-WI.001 Confined Space Entry

2.3 JOB SAFETY ANALYSIS DESCRIPTION

BASIC JOB STEPS

Example and description of JSA [First Page]

List of responsible functions for

List of PPE & General Safety Re-

Example and description of JSA [Analysis of steps of activities]

Hazard Controls/Preventive & Pro-