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I. ON-BASE SYSTEMS
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START-UP PROCEDURES
Turbine Consultancy & Oil Services
SAT-GTOBS-18-70-7161/3201151
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START-UP PROCEDURES
Turbine Consultancy & Oil Services
SAT-GTOBS-18-70-7161/3201151
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TABLE OF CONTENTS
DESCRIPTION SECTIONS
PART I.
LUBE OIL SYSTEM ........................................................................................................................1
TRIP OIL SYSTEM .........................................................................................................................2
HYDRAULIC OIL SYSTEM ............................................................................................................3
INLET GUIDE VANE SYSTEM.......................................................................................................4
COOLING AND SEALING AIR SYSTEM ......................................................................................5
HEATING AND VENTILATION SYSTEM ......................................................................................6
CONTROL DEVICES......................................................................................................................7
DIESEL ENGINE STARTING DEVICE ..........................................................................................8
FUEL GAS SYSTEM ......................................................................................................................9
LIQUID FUEL SYSTEM ................................................................................................................10
ATOMIZING AIR SYSTEM ...........................................................................................................11
PURGE SYSTEM ..........................................................................................................................12
FIRE PROTECTION SYSTEM......................................................................................................13
COOLING WATER SYSTEM .......................................................................................................14
PART II.
CONTROL SYSTEM I/O CHECKS ................................................................................................1
SIMULATED CHECKS ...................................................................................................................2
RATCHET CHECKS ......................................................................................................................3
CRANKING CHECKS.....................................................................................................................4
FIRING CHECKS ............................................................................................................................5
FSNL CHECKS ...............................................................................................................................6
LOAD CHECKS ..............................................................................................................................7
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PROCEDURE SIGN/DATE
2. Check all sight glasses are clean and correctly positioned for easy viewing.
3. Check calibration of temperature switches 26QT, 26QA, 26QN, 26QL (MCC only) and
26QM (MCC only). Complete FETS D1.
5. Complete FETS A1 for each of following temperature elements f33 (IT_LGBD1), and
f34 (IT_LGBD2).
6. Check calibration of pressure switches 63QA, 63QL (MCC only), and 63QT. Complete
FETS D1 for each.
7. Check the operation of lube oil tank level switches 71QL and 71QH. These
switches are wired in series, open to alarm on a low or high level. Complete FETS
D1.
START UP PROCEDURE
1. Ensure AC and DC pump motors 88QC and 88QE rotate freely and in the correct
direction. Check for acceptable running currents and motor speed.
2. Simulate speed and low-pressure conditions to ensure correct sequencing of 88QE,
and 88QC.
3. With the system operational, check that all pressure gauges are reading correct
pressure in accordance with system design. Record values in table below.
zero speed Pressure Gauge Header Temperature
measurements OL-3 OL-2 63QT OL
88QC
88QE
4. Check correct operation of pressure control valve VPR2.
5. Verify correct operation of 23QT via operation of 26QL and 26QM.
COMMENTS:
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START-UP PROCEDURES
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Note: Refer to the following Drawing(s): H2181 A001 EL, H2187 A003 EL
PROCEDURE SIGN/DATE
COMMENTS:
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PROCEDURE SIGN/DATE
COMMENTS:
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START-UP PROCEDURES
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PROCEDURE SIGN/DATE
COMMENTS:
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START-UP PROCEDURES
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PROCEDURE SIGN/DATE
COMMENTS:
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PROCEDURE SIGN/DATE
COMMENTS:
Original AEG PID Drawing H2192 A002 EL does not show turbine compartment temperature switch, 26BT or turbine
package filter house pressure switches, 63BA-1 and 63BA-2. These devices are shown on revised AEG MCC
drawing, 521.02 2051.033 SH 39.
Original AEG PID Drawing H2192 A002 EL does not show load gear compartment temperature switches, 26BL-1
and 26BLT or load gear filter house pressure switches, 63BL-1 and 63BL-2. These devices are shown on revised
AEG MCC drawing, 521.02 2051.033 SH 36.
Original AEG PID Drawing H2192 A002 EL does not show package pressure switches, 63PL-1, 63PL-2, 63PH-1
and 63PH-2. These devices are shown on revised AEG MCC drawings, 521.02 2051.033 SH 37 and 38.
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7. CONTROL DEVICES
PROCEDURE SIGN/DATE
COMMENTS:
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START-UP PROCEDURES
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Note: This procedure should be read in conjunction with manufacturer's service manual, with particular attention
to engine coolant, fuel and lubricating oil requirements.
PROCEDURE SIGN/DATE
1. Check that the engine has been installed and wired correctly in accordance with the
above drawings.
2. Check the engine's acceleration and shutdown solenoid valves, 20DA, 20DT, and
20DV, for the following:
a) Acceptable insulation resistance
b) Wiring continuity
c) Security of terminations
d) Check for acceptable coil resistance and record values in table below. Complete
FETS D1 for each.
Solenoid Ohms
20DA
20DT
20DV
3. Check calibration of pressure switches 63QD and 63DM, complete FETS D1.
4. Ensure that control switch 43DE operates correctly and complete FETS D1.
Ensure magnetic pick-up 77S is installed correctly and measure coil resistance.
speed pickup Gap Coil Ω
77DS
NOTE: The diesel engine governor has been factory set for shutdown idle and full
throttle operation. However, should it be necessary to re-adjust, the setting
procedure given in the manufacturers maintenance manuals should be followed.
COMMENTS:
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PROCEDURE SIGN/DATE
COMMENTS:
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PROCEDURE SIGN/DATE
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9. Make any final adjustments to servo proportional gain during running checks and
record as-built null-bias offset and proportional gains below.
Potentiometer Initial% Final%
Proportional P1 19
Signal Offset (Null Bias) P7 21
COMMENTS:
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PROCEDURE SIGN/DATE
COMMENTS:
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START-UP PROCEDURES
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PROCEDURE SIGN/DATE
COMMENTS:
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Note: Refer to the following Drawing (s): H2187 A003 EL, 521.02 2015.033 SH.50
PROCEDURE SIGN/DATE
COMMENTS:
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PROCEDURE SIGN/DATE
COMMENTS:
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PROCEDURES SIGN/DATE
1. Perform cold wire checks and verify that all the I/O signals are correctly connected.
Reference all wirings schematic diagrams, including but not limited to: MCC, field
junction boxes, generator control/protection panel, and turbine control panel.
2. Verify the control panel has been properly grounded to the plant ground grid.
3. Ensure that all wiring is complete and proceed to power up panel. Refer to panel power
up procedure SAT-TCP-PEPS-18-70-7161.
4. Verify correct sensing of Digital Inputs and ensure that logic signals are correctly
changed when the Digital Input signals change contact sense. This should be observed
in the PLC address and on the Human Machine Interface (HMI) system and I/O screens.
Complete FETS D1.
5. Verify correct sensing of Digital Outputs and ensure that logic signals are correctly
changed when the Digital Output signals change contact sense. This should be
observed in the PLC address and on the Human Machine Interface (HMI) system and
I/O screens. Complete FETS D2.
6. Verify correct operation of Analog Input signals. Inject at primary input source, where
possible. Complete FETS A1.
COMMENTS:
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2. SIMULATED CHECKS
PROCEDURE SIGN/DATE
COMMENTS:
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START-UP PROCEDURES
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3. RATCHET CHECKS
PROCEDURE SIGN/DATE
1. Ensure that the gas turbine and auxiliary systems are complete and in a safe state for
rotation.
2. Clear machine of all debris and inform all personal that running checks are to take
place.
3. Run lube oil pump and ensure that no lube oil leaks are evident and that oil flow is
observed at each bearing drain sight glass.
4. Just prior to ratcheting, make a final check of the inlet and exhaust plenums and
ensure there are no obstructions that may affect rotor movement.
7. Put the unit into normal ratchet operation (select start from off position) and check that:
COMMENTS:
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START-UP PROCEDURES
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4. CRANKING CHECKS
PROCEDURE SIGN/DATE
1. Prior to cranking the unit for the first time, inspect and thoroughly clean the inlet and
exhaust ducts. Ensure all hatch covers are securely fitted. Inspect the filter house to
ensure it is clean and filters are securely and correctly installed. Close and lock filter
house access doors.
2. Check the inlet guide vanes and first row of compressor blades for any sign of
damage.
3. From the exhaust end, check the trailing edge of the second stage buckets for any sign
of damage.
6. Run lube oil pump and check oil is flowing in all the drain sight glasses.
7. Station personnel in all compartments, then start unit on ratchet and ensure there are
no abnormal noises from any areas.
8. WARNING: Prior to running the unit at crank, all personnel involved with testing
must ensure that adequate warning notices are posted around the unit and that
all personnel not involved with testing are in a safe area away from the unit.
Select crank and start the unit cranking to a speed of approximately 200 rpm as
indicated on the HMI, and initiate a stop signal. During run-up and rundown, ensure
that:
c) The rotor gradually coasts down to zero speed and does not stop too quickly.
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START-UP PROCEDURES
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9. Restart the unit and run to approximately 1000 rpm, initiate a normal stop command,
and repeat above checks a, b, c.
10. Restart the unit and run at continuous crank and ensure that:
12. Unit should now be made ready for “FALSE FIRE CHECKS”.
COMMENTS:
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START-UP PROCEDURES
Turbine Consultancy & Oil Services
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5. FIRING CHECKS
PROCEDURE SIGN/DATE
1. Prior to firing, the Lead Commissioning Engineer must ensure himself and all other
parties that the safety of plant and personnel has been taken into consideration before
attempting to fire the unit. The logic sequence and constants from the control system
must have been reviewed.
2. Ensure that the appropriate fuel is available at the inlet of the machine.
3. Select fire mode of operation on the HMI and initiate a start command.
4. At the end of the purge period, ensure that the Fuel Flow Demand (FFD) steps to its
firing value (see Control Specification) and once flame is established, reduce to warm-
up value.
5. Once unit has established steady state warm-up conditions, ensure that:
a) All combustion cans have flame.
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START-UP PROCEDURES
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7. Check around the unit to ensure there are no leaks of air, fuel or exhaust fume.
9. Stop the unit and ensure that the rundown is satisfactory and the ratchet system
operates when the unit reaches zero speed.
10. Unit should now be made ready for ‘FULL SPEED NO LOAD (FSNL) CHECKS”.
COMMENTS:
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START-UP PROCEDURES
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6. FSNL CHECKS
PROCEDURE SIGN/DATE
1. Prior to firing, the Lead Commissioning Engineer must ensure himself and all other
parties that the safety of plant and personnel has been taken into consideration before
attempting to fire the unit. The logic sequence and constants from the control system
must have been reviewed.
2. Personnel should be located at all compartments to witness running. Select the auto
mode and start the unit. Any abnormalities reported must be rectified and/or explained
before committing the unit to full speed.
e) Bleed valves and inlet guide vanes are in their correct position.
5. Make any necessary adjustments to the lube oil system, in order to trim pressure and
temperature values to meet their specified ranges.
6. Refer to the control specification systems adjustments and perform all running
adjustments.
7. Simulate low lube oil pressure using isolation/dump valves at the accessory gauge
lube oil panel (63QA) and ensure that the lube oil pump 88QC starts up.
8. Simulate low lube oil pressure using isolation/dump valves at the accessory gauge
lube oil panel (63QL) and ensure that the lube oil pump 88QE starts up. Return both
pumps to normal operating condition.
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START-UP PROCEDURES
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9. Record steady state values in tables below. Append a printout of the trend for each
fuel with the associated tags from the table data.
FSNL Check (Gas Fuel) Running Value Units
Unit Speed at 33CS dropout rpm
Unit Speed at FSNL rpm
Exhaust Temperature deg C
28FD-7 %
28FD-8 %
P2 Pressure bar
SRV Position %
GCV Position %
Lube Oil Header Pressure bar
Lube Oil Header Temperature deg C
Maximum Vibration inch/sec
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START-UP PROCEDURES
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10. The following trips must be demonstrated with the unit running in order to prove
reliability trips: (Note: Unit trips to be agreed upon with Customer beforehand.)
c) Overspeed (Electronic/Independent/Mechanical)
Setpoint Tripped At
Mechanical Overspeed
Electronic Overspeed
Independent Overspeed
11. Append a printout of a historical trend with unit speed and the associated trip for each of
the overspeed tests conducted.
COMMENTS:
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START-UP PROCEDURES
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7. LOAD CHECKS
Note: Prior to load checks, generator control/protection panel checks should be conducted. At a minimum, the
following offline tests should be conducted prior to online load checks: breaker close, breaker trip, phase rotation
checks, and synchronization checks. Consult generator control/protection panel schematics and commissioning
manual.
PROCEDURE SIGN/DATE
2. Personnel should be located at all compartments to witness running. Select the auto
mode and start the unit. Any abnormalities reported must be rectified and/or explained
before committing the unit to on-load conditions.
e) Bleed valves and inlet guide vanes are in their correct position.
5. Conduct fuel transfers above minimum load and verify correct operation.
6. Unit should now be handed over for operation and Take Over Certificates signed and
issued.
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
SIGN-OFF SHEET
Page 1 of 40
FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
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FETS A1
ANALOG INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
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FETS A1
ANALOG INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS A1
ANALOG INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS A2
ANALOG OUTPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS D1 (sheet 1 of 2)
DIGITAL INPUTS
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS D1 (sheet 2 of 2)
DIGITAL INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS D1 (sheet 1 of 2)
DIGITAL INPUTS
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
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FETS D1 (sheet 2 of 2)
DIGITAL INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS D1 (sheet 1 of 2)
DIGITAL INPUTS
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
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FETS D1 (sheet 2 of 2)
DIGITAL INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS D1 (sheet 1 of 2)
DIGITAL INPUTS
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS D1 (sheet 2 of 2)
DIGITAL INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS D1 (sheet 1 of 2)
DIGITAL INPUTS
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS D1 (sheet 2 of 2)
DIGITAL INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS D2 (sheet 1 of 2)
DIGITAL OUTPUTS
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
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FETS D2 (sheet 2 of 2)
DIGITAL OUTPUTS
PLC HMI
Tag name Channel
Open Closed
OM_4QE_1 16
OM_4QE_2 17
OM_4QE_3 18
OM_4HR 19
OM_4DS 20
SPARE_N2S2_CH21 21
SPARE_N2S2_CH22 22
SPARE_N2S2_CH23 23
SPARE_N2S2_CH24 24
OT_2TVX 25
OG_52GTX 26
OM_4FA 27
OM_4QC_1 28
OM_4QC_2 29
OM_4FD 30
OM_4BA_BL 31
COMMENTS:
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FIELD ENGINEERING TEST SHEET
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FETS-18-70-7161/3201151
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FETS D2 (sheet 1 of 2)
DIGITAL OUTPUTS
PLC HMI
Tag name Channel
Open Closed
OP_4PLC 0
OF_SC1_RES 1
OF_SC1_SD 2
OF_SC2_RES 3
OF_SC2_SD 4
SPARE_N3S2_CH05 5
SPARE_N3S2_CH06 6
SPARE_N3S2_CH07 7
SPARE_N3S2_CH08 8
SPARE_N3S2_CH09 9
SPARE_N3S2_CH10 10
SPARE_N3S2_CH11 11
SPARE_N3S2_CH12 12
SPARE_N3S2_CH13 13
OM_D151 14
OM_4HQ 15
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FIELD ENGINEERING TEST SHEET
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FETS D2 (sheet 2 of 2)
DIGITAL OUTPUTS
PLC HMI
Tag name Channel
Open Closed
OM_4DL 16
OG_52LC 17
OG_52LO 18
OG_52SX 19
OG_41CS_ON 20
OG_U3_RESET 21
OG_AVR_RESET 22
OG_90R4L 23
OG_90R4R 24
SPARE_N3S2_CH25 25
OM_4CF_51 26
OM_4CF_52 27
OM_4CF_53 28
OM_4CF_54 29
OM_4CF_55 30
OM_4CF_56 31
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS S1
SPEED INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
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Revision: 0
FETS S1
SPEED INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
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FETS-18-70-7161/3201151
Revision: 0
FETS V1
VIBRATION INPUTS
Node: 5 Slot: 0
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
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Revision: 0
FETS T1
THERMOCOUPLE INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS T1
THERMOCOUPLE INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS T1
THERMOCOUPLE INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS T1
THERMOCOUPLE INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
FETS-18-70-7161/3201151
Revision: 0
FETS T1
THERMOCOUPLE INPUTS
COMMENTS:
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FIELD ENGINEERING TEST SHEET
RASCO SAT-TCP-
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FETS R1
RTD INPUTS
COMMENTS:
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ALARMS
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FETS-18-70-7161/3201151
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FIELD ENGINEERING TEST SHEET
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FIELD ENGINEERING TEST SHEET
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FIELD ENGINEERING TEST SHEET
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UNLOADS
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FIELD ENGINEERING TEST SHEET
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TRIPS
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FIELD ENGINEERING TEST SHEET
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Turbo Control Solution Inc.
Turbine Consultancy & Oil Services
For
RASCO Gas Turbine System Upgrade
Project No.: 3201151
SIGN-OFF SHEET
Page 2 of 12
SITE ACCEPTANCE TEST
RASCO
SAT-TCP-PEPS-18-70-7161/3201151
Revision: 0
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SITE ACCEPTANCE TEST
RASCO
SAT-TCP-PEPS-18-70-7161/3201151
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Check polarity to ground from the A - side of X100(1-16), should be approximately +63VDC
(dependent upon battery charger float voltage).
Measured positive to ground voltage _.
Check polarity to ground from the B - side of X100(17-20), should be approximately -63VDC
(dependent upon battery charger float voltage)
Measured negative to ground voltage .
Verify that there is 125VDC between X100(1) and X100(17). X100(1) will be positive
polarity and X100(17) will be negative polarity.
Confirm that 125VDC is available between K1(14), X100(17).
Confirm that 125VDC is available between K2(14), X100(18).
Confirm that 125VDC is available between K3(14), X100(26).
Page 4 of 12
SITE ACCEPTANCE TEST
RASCO
SAT-TCP-PEPS-18-70-7161/3201151
Revision: 0
COMMENTS:
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SITE ACCEPTANCE TEST
RASCO
SAT-TCP-PEPS-18-70-7161/3201151
Revision: 0
For each of the AC circuits in the TCP perform the following checks:
Close circuit breaker CB-AC2 to energize the AC distribution. Close the fuse to
energize the associated equipment. Verify that the proper voltage is transported
to all the places it is required according to the drawings.
• X7(1) & X7(6): Control Panel Light
• X7(2) & X7(7): 26TCP
• X7(3) & X7(8): Spare
• X7(4) & X7(9): Spare
• X7(5) & X7(10): Outlet
Check resistance to ground from CB-AC1(1) and CB-AC1(3). Verify both terminals are open
to ground and open to each other.
Close CB-DC9 (Inverter supply) and verify proper potential and polarity at CB-AC1
terminals 1 and 3 in the control panel.
Measured supply voltage _.
Verify that CB-AC1(2) and CB-AC1(4) are open to ground and open to each other.
Close CB-AC1 in the control panel and verify that power is now available at X100(79) and
X100(81) for inverter fed ignition transformer power.
Make sure NO voltage appears on any unrelated circuits in the same manner as with the
125VDC checks.
COMMENTS:
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COMMENTS:
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For each of the Digital DC circuits in the TCP perform the following checks:
Before closing circuit breakers CB-DIG1 through CB-DIG9 check the following:
Resistance to ground
Resistance between circuits (e.g. CB-DIG1 (2) and (4))
Close circuit breaker to energize associated equipment.
CB-DIG1: Node 1A, 1B, 2, and 3 Power Supplies (Ensure that the node power
supplies are in the off position)
CB-DIG2: Digital Input I/O Power (Verify that the fuses are open on X200A,
X200B, X201, X202, X203, and X204)
CB-DIG3: Digital Output I/O Power
CB-DIG4: Master Protective Circuit
CB-DIG5: 64D Ground Bus Monitor (Already closed in previous step)
CB-DIG6: PanelView Power
CB-DIG7: Spare
CB-DIG8: Spare
CB-DIG9: Spare
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COMMENTS:
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2. I/O POWER
Test Equipment Required: Digital Multimeter
Drawing(s) Referenced: GTC-5003, GTC-5203 Sh.1 & 2, GTC-5204 Sh.1 & 2, GTC-5205
Sh.1 & 2
Ensure that all the fuse blocks on X200A, X200B, X201, X202, X203, and X204 are open.
Check resistance to ground and voltage to ground of X200A(3) on the fuse side, it should
be open and +12VDC.
Check resistance to ground and voltage to ground of X200A(33). Should be -12VDC.
Verify that there is 24VDC between X200B(3) and X200B(33)
Verify that there is 24VDC between X201(3) and X201(65)
Verify that there is 24VDC between X202(3) and X202(65)
Verify that there is 24VDC between X203(3) and X203(65)
Verify that there is 24VDC between X204(3) and X204(33)
Fuse blocks for field devices can be closed after cold wire loop checks have been
completed and confirmed that no grounds or shorts exist on field wires.
COMMENTS:
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COMMENTS:
COMMENTS:
Page 12 of 12
Turbo Control Solution Inc.
Turbine Consultancy & Oil Services
For
RASCO Gas Turbine System Upgrade
Project No.: 3201151
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Verify that the SPC is supplying excitation voltage to the LVDTs by measuring the voltage on the outgoing
terminals. Verify that the LVDT feedback with the SRV and GCV feedback is 0.7 VAC RMS with the valves
fully closed. Record the values in the table below.
Connect to the appropriate servo positioned controller (SPC) for the intended calibration. A serial cable
should be used to connect your PC to the SPC. The configuration software can be found in All Programs –
Woodward – SPC Service Tool.
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To perform a calibration, the SPC must be shutdown. The bottom banner of the SPC Service Tool shows
your connection status, operating mode, alarm and shutdown status. The SPC will be running until a
shutdown command is given by the control system. Go online with the controller in Studio5000. Open
controller tags. In the filter, type “_SC” without the quotation marks. This will display the SPC shutdown
and reset tags. OF_SC1_SD is the shutdown output for the SRV. OF_SC2_SD is for the GCV. These outputs
are wired normally closed; a value of 1 is the equivalent of Run. Figure 2 shows the tags after applying the
filter.
Enable I/O Forcing and force the appropriate SPC shutdown output to a value of 0 using the Force Mask.
The shutdown status will change and can be seen within the SPC Service Tool. Refer to Figure 3 below.
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Once you have shut down the SPC select Action and Calibrate. If you did not shutdown the SPC prior to
selecting Calibrate, you will receive a warning indicating that the SPC is running and cannot be calibrated.
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Selecting Calibrate will automatically bring up the calibration window seen below in Figure 5. The
calibration will not begin until the Next button is selected. It is recommended that a True RMS electrical
multimeter such as a Fluke 87 be used to monitor the LVDT feedback voltage while performing a
calibration. Refer to the appropriate TTS SPC drawings for the terminals on the SPC to monitor the voltage.
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Isolate gas supply upstream of the SRV. Ensure that all personnel are clear of valve stem as the following
steps will move the valve. Adjust the null current offset to -8.00 mA and hit enter. The actuator current
should change, and the valve will attempt to drive further closed. Should the valve move towards open,
the servo polarity is incorrect.
Select the Next button. You will now see the Maximum Position Adjustment screen. Set the null current
offset to +8 mA and hit enter. The actuator current should change, and the valve will stroke to full open.
Typical LVDT values at 100% are 3.0 VAC RMS for the SRV and 3.5 VAC RMS for the GCV. Should the valves
not move/LVDT feedback voltage not change, check the polarity of the servo coil wiring.
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After verifying the valve opened and the LVDT feedback is close to the expected value, select next. The
Calibration Verification screen will appear.
Use the two Demand % setpoints to move the valve open/closed. Verify that the feedback %
corresponds to the active setpoint. Verify that the valve position feedback to the turbine control
system corresponds to the position % shown in the SPC calibration window. Move the valve to 50%
and note the actuator current.
Change the Actuator Null Current value to the value recorded in table 4 and then select next. Save the
settings and then exit the calibration. Once the calibration process has been completed within the SPC,
the shutdown force needs to be removed from within RSLogix5000. Remove the force and within the
SPC Service Tool select Action – Run.
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• Inject the corresponding LVDT feedback voltage for 0, 50, and 100%. Verify SPC output to PLC and
record in the table below.
• Modify the PLC output to the SPC and verify from within the SPC the demand signal for both
analog (4-20mA) and DeviceNet is the same. Record values in table below.
• Record the actuator current for each position demand and position feedback in the table below.
* When demand and feedback are nearly equal, the actuator current varies as a result of the position
error. Make small adjustments to position demand and verify actuator current changes in direction
according to error.
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Note that without a LVDT connected the SPC will see an out of range position alarm, and feedback to the
PLC will be less than 4mA.
Page 10 of 10
Turbo Control Solution Inc.
Turbine Consultancy & Oil Services
For
RASCO Gas Turbine System Upgrade
Project No.: 3201151
E Field Calibration
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Note: Ultra Slimpak modules have been calibrated and tested during FAT testing 10/5/18. Section
A can be skipped unless a new module has been installed.
2. Isolate Power
3. Configure dip switches per drawing above.
a. Switch 1: 2, and 3 turned on are for a 0 to 10V output
b. Switch 2: 1 on for low sensitivity, 150mVp to 1Vp (50Vrms max)
4. Verify device has been powered on for at least an hour for temperature acclimation
5. Verify and record power supply and record value in table below.
6. Connect injection source to frequency input terminals (reference drawing above).
7. Connect multimeter to signal output terminals and set measurement to VDC.
8. Input Calibration
a. Maximum Frequency
i. Set Freq. Calibrator to Max Freq. Input (3600Hz with 5V amplitude) and hold the
calibrate button for 4 seconds. Red and Yellow Lights will turn on.
ii. Push the calibrate button, the Green and Yellow lights will turn on
iii. Increase the frequency to 3600Hz (Voltage reading should increase as input is
increased)
iv. Push the calibrate button again to save the max frequency input
v. Yellow Light should be on
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b. Minimum Frequency
i. Input Min. Freq. Range by injecting a frequency signal of 0 Hz.
ii. Adjust the input to the minimum frequency
iii. Press the calibrate button
iv. Green and Red Lights should be on
9. Output Calibration
a. Maximum Voltage
i. Adjust the frequency until 10VDC is output to multimeter
ii. Press the calibrate button
iii. The Red Light should be on
b. Minimum voltage.
i. Adjust the frequency until 2VDC is the output to the multimeter
ii. Push calibrate button
iii. Green and Yellow and Red Lights should be on
12. Repeat the above steps for 96FDX-2 and record the calibration results in the table below.
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Note: Young & Franklin Servo Controller has been calibrated and tested during FAT testing 10/5/18.
Section B can be skipped unless a new module has been installed. Record final proportional and null
bias gains in SAT-GTOBS-18-70-7161.
4. Configure gain settings per the above drawing and record values below:
Proportional (P1) :
Null Bias (P7):
Note that null bias will need to be fine-tuned during commissioning for stability at fire and
FSNL on liquid fuel.
5. Energize SC-3, verify and record power supply VDC.
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Note: Young & Franklin Servo Controller has been calibrated and tested during FAT testing 10/5/18.
Section C can be skipped unless a new module has been installed. Record final proportional and null
bias gains in SAT-GTOBS-18-70-7161.
1. Identify the adjustment potentiometers for each of the feedback channels, located just above
the terminal blocks on the Y & F Card. See figure below.
2. Connect a frequency calibrator to the field terminals allocated for the respective speed pickups.
You may also connect directly to the input of the SlimPack.
3. Select channel being calibrated using the switch below the LCD display
4. Inject 0 Hz
5. Using the ZERO Course and Fine Tune potentiometers, adjust until the value reads 0.00
6. Inject 3600 Hz (or upper-end value required)
7. Using the SPAN Course and Fine Tune potentiometers, adjust until the value reads 100.0
8. Inject 1800 Hz (or mid-scale value required). Verify the display reads 50.0.
9. With respective frequency value injected, adjust the ZERO and SPAN potentiometers several
times or as necessary until the Low-End Value reads 0.00, the Mid-Scale Value reads 50.0, and
the Full-Scale Value reads 100.0
10. Repeat procedure for Channel B.
11. Record calibration results in the tables below.
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Servo
Valve Coil #1 (ohms) Coil #2 (ohms)
Fuel Bypass Valve
4. Complete the following table by injecting frequency, driving demand signal through logic and
recording the servo current as measured by IF_65FA.
5. Calculate the gains and null bias (offset average) and record below.
Gain Calculated mA/Hz
Offset Average mA
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6. Graph the results in Table D.1. in Excel and compare to Figure D.1. shown below. Print a copy
of the trend and append to this document. Should the results not closely match Figure D.1.,
there is a problem with the servo or the servo wiring.
15.000
10.000
5.000
Servo Current (mA)
0.000
0 1000 2000 3000 40 00
-5.000
-10.000
-15.000
Demand (Hz)
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E. FIELD CALIBRATION
The Young and Franklin PID Controller, 8605D202, is used to control the liquid fuel bypass valve,
65FP-1. The TMS-1000 sends a flow demand signal (4-20mA =0-3600Hz) to the Y&F PID Controller.
The Y&F Pid Controller closes the loop using two of the flow divider speed pickups, 77FD-1 and 77FD-
2. The frequency signal from the speed pickups is converted to voltage by two frequency input signal
conditioners, Action Instruments Ultra Slimpak II WV478-200. The Slimpaks are calibrated 0-3600Hz
= 2-10VDC.
The Y&F PID Controller has been configured for proportional gain only. This procedure covers tuning
the proportional and null bias gain. For complete controller configuration details, refer to Y&F
Document No. FSM8605D200.
Figure 1 shows the front of the Y&F PID Controller. There are two boxes highlighting the
potentiometers P1 and P7 used to set the proportional and null bias gains. P1 is highlighted in
GREEN and is used to set the proportional gain. P7 is highlighted in RED and is used to set the null
bias gain (offset).
In order to tune the gains, the liquid fuel system must be in operation. The initial tuning is done
while conducting false fires. There will be an initial flow “spike” once the stop valve opens. The flow
will drop out until there is adequate pressure to open the check valves. Open the appropriate
RSLogix5000 project and go online with the controller. Navigate to the trends in the Controller
Organizer Pane and open the trend Liq_Fuel. Select Run to start the trend. The three important tags
to monitor during tuning is the servo current, IF_65FP_A, flow frequency demand, CV.LCV_HZ_DEM,
and flow frequency feedback, CV.LCV_HZ. Flow frequency feedback is the high select of the two
flow divider speed pickups.
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Figure 2 shows the liquid fuel trend of a false fire with a bad servo installed. The servo current is in
red, the flow demand is in yellow, and the flow feedback is in blue. The initial proportional gain was
too high. During this run the gain was gradually decreased until the flow started to settle. After the
proportional gain was adjusted, the null bias (offset) was increased to reduce the difference
between demand and actual. The trend shows that the actual flow, while trending upwards, does
not reach the demand. At this point the null bias was maxed out. This is an indication of a failed
servo.
Figure E.2. Liquid Fuel Trend in RSLogix5000 – False Fire with Failed Servo
Figure 3 shows a trend after the gains have been adjusted closer to the final settings. The flow
settles within one cycle to the demand. The trend shows that the unit established flame and the
flow demand cut back from its’ fire to warmup value. There is a small offset of 25Hz that is
maintained through the start. Adjusting the proportional gain to a smaller value will decrease the
overshoot. Adjusting the null bias higher will decrease the offset; however the running values at
FSNL should be monitored before making further adjustments. At FSNL monitor the difference
between flow demand and actual. Make any necessary adjustments to the null bias offset. If there
were significant oscillation in flow as the unit approached FSNL, make a small incremental change
in the proportional gain. Shut the unit down and conduct an additional false fire test to ensure that
the changes made at FSNL do not compromise the control a fire.
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Figure E.3. Liquid Fuel Trend in RSLogix5000 – Auto Start After False Fire Gain Tuning
It is important to note that after several false fires, the unit should be allowed to ignite to burn the
unspent fuel.
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