Plant operation - Operation manual

1. START, STOP AND

OPERATION

General
This chapter describes the actions to Operation method
take in the order they should be per-
The operation of the genset is carried
formed when operating the power plant.
out from the control room. Auxiliary
These instructions gives general view of
equipment is controlled from local con-
the daily routines and step-by-step in-
trol panels mounted close to the equip-
structions when starting or shutting
ment.
down the power plant.

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1. START, STOP AND OPERATION
Start-up sequence
General Start-up sequence
LO system
It is assumed that all units are shut
down but that power is available from
the main grid. It is also assumed that all
units are in operational condition.
Some of the actions to take depend on
the length of time the plant has been
shut down and may not be required if
the plant has been shut down for a brief
period only. In such cases the decision of
what to exclude must be left to the dis-
cretion of the operating personnel.
Occasionally during stoppage covers are
removed for measurements and checks.
Before start it should be made sure that
all covers and protective shields are
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mounted properly.
NOTE :
If a unit is found to be faulty it
should be repaired or replaced be-
fore continuing the start-up proce-
dure.
10 hours before start of the
genset
Compressed air system
1 Drain the condensate out of the sys-
tem.
2 Set the compressor unit in automatic
operation.
3 Ensure that the backup compressor,
if installed, are in operational condi-
tion.
Fuel system
4 Ventilate the engine hall properly.
5 Prepare the pressure reduction, gas
measuring unit and gas regulating
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unit for start of the engine.
NOTE :
Do not open the gas circuit main
valve at this point.
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Hitz; F1-Project, WPP10185
6 Check the oil level in the engine
sump. Add oil if necessary.
7 Check the centrifugal filter. Clean if
necessary.
8 Purge the sludge out of the safety fil-
ter chambers. Replace the filter car-
tridges if the engine has been shut
down for a prolonged period.
Cooling water system
9 Check the water level of the expan-
sion vessels. Fill up and vent the sec-
tions if necessary.
10 Check that the automatic preheating
unit is activated.
Generator
11 Clean the generator from moisture,
dust and dirt.
12 Check that the generator is ready for
start.
13 Check that the anticondensation
heater is in AUTO position.
1 hour before start of the
genset
LO system
1 Set the prelubricating pump in auto-
matic operation.
2 Check the prelubrication.
! Cut-off valves open.
! All chambers in the fine filter are
in use. Vent the filter if necessary.
30 minutes before start of the
genset
Charge air and exhaust gas system
1 Check the air intake for obstructions.
Clear if necessary.
2 Drain out any accumulated liquid
from the silencers.
3 Check that the drain pipe of the
charge air cooler casing is open.
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Start-up sequence
4 Check that the exhaust gas ventila-
tion unit is in automatic operation.
Starting air system
5 Open the starting air valve on the air
bottle.
Gas fuel system
If the power plant has been shut-down
for a prolonged period and the gas inlet
valves are closed:
6 Open the valves slowly to avoid a
blast.
7 Check that all manual operated
valves are in correct position.
Cooling system
8 Set the cooling system in to opera-
tion.
Before start
Before starting the engine check that:
+ Starting air pressure exceeds 15 bar.
+ Control air pressure exceeds 7 bar.
+ The gas fuel system is in running or-
der:
! Correct gas inlet pressure.
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Plant operation - Operation manual
! Safety shut-off valves are open.
+ The cooling system is in running or-
der:
! Correct preheating and pressure.
! Sufficient precirculation to heat
the engine.
+ LO pressure exceeds 0.5 bar.
+ Turning gear is not engaged.
+ Engine is in the “STOP” condition.
+ Exhaust gas system is properly
vented.
Start of the genset
1 Start the genset from the central
control panel or operators station.
2 Check that the pressure and temper-
ature readings are normal.
3 Check for alarms.
Connecting the genset to the
grid
1 Synchronize the genset to the busbar
and grid.
! When connecting to a live busbar,
the connection must be synchro-
nized.
! When connecting to a dead busbar,
no synchronizing is needed.
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1. START, STOP AND OPERATION
Normal operation, daily checklist
General + Test checklist
Normal operation, daily
lighting system.
There is no automatic supervision or
control arrangement that can replace an
experienced engineer’s observations. Genset
On the daily inspection tours the opera-
tor should take readings, perform mea-
surements and other inspection routines.
It is of great importance that all actions
are scrupulously and well recorded in
the power plant logbook. Note the devi-
ating values and give the possible source
of the cause. Read appropriate sections
in the corresponding binder series for in-
formation on maintenance routines. To
utilise trend information a continuous
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record is essential.
NOTE :
Although some readings can be
read straight from the terminal of
the control room, the readings
should be checked from the local
gauges and indicators, if installed.
At the same time it is good opportu-
nity to check the unit visually and
ensure that the sensors and trans-
mitters are functioning properly.
There will be occasions when the shift
operator will find it more important to
attend a situation rather than collect log
data. If the readings are not taken, the
operator should mark the vacant log
spaces “Reading not taken because…”
and make a concise notation of the in-
terfering event in the remarks column.
Under no circumstances should the log
be falsified by inserting reading that
were not actually observed.
Miscellaneous
+ Check the ambient temperature and
humidity.
+ Read the preceding day’s log sheets.
+ Check that the crane, its hook, ma-
noeuvring chains, and control box are
in safe positions.
+ Inspect the fire extinguisher seals.
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Hitz; F1-Project, WPP10185
the functioning of the emergency
Gas engine
+ Check the operating hours.
+ Read all thermometers and pressure
gauges.
! Read the load at the same time.
+ Check the ventilation of the engine
cooling water system.
+ Check that the crankcase breather is
functioning properly.
+
Check the speed of the engine.
+ Check the main bearing temperatures.
+ Check the speed of the turbocharger.
+ Clean the compressor of the turbo-
charger (every second day).
Generator
+ Check the power of the generator.
+ Check the phase current of the gener-
ator.
+ Check the power factor of the genera-
tor.
+ Check the excitation current of the
generator.
+ Check the generator winding tempera-
tures.
+ Check the generator bearing tempera-
tures.
+ Check the temperature of the genera-
tor cooling air.
+ Check the generator frequency.
Electrical system
+ Check the DC voltage.
+ Check the DC current.
+ Check the battery level, clean termi-
nals and add electrolyte if needed.
Fuel system
+ Inspect the system for leaks.
+ Check the pressure and temperature
from the engine.
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Normal operation, daily checklist
+ Check the pressure drop over the gas
regulating filter.
Lubricating oil system
+ Inspect the system for leaks.
+ Check the pressure and temperature
from the engine.
+ Check the oil level in the sump.
+ Ensure that there are sufficient quan-
tities of lubricating oil in stock.
Filters
+ Check the operation of LO filters.
LO cooler
+ Check the cooling efficiency (inlet and
outlet temperatures).
+ Check the inlet and outlet pressure.
+ Check that the telltale holes are open.
Compressed air system
+ Inspect the system for leaks.
+ Check the pressure from the engine.
+ Drain the system.
Starting air bottle
+ Drain the bottle.
+ Check the air pressure.
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Plant operation - Operation manual
Compressor units
+ Check the running hours of the com-
pressors.
+ Drain the water separator.
+ Check the air pressure.
+ Check the oil level.
Cooling water system
+ Inspect the system for leaks.
+ Check the pressure and temperature
readings at the inlet and outlet of the
engine.
Heat exchangers
+ Check the pressure and temperature
readings at the inlet and outlet of all
heat exchangers.
+ Check that the telltale holes are open.
Cooling pumps
+ Check that the leakage from the tell-
tale hole of the pump is normal.
Charge air & exhaust gas sys-
tem
+ Check the charge air pressure and
temperature from the engine.
+ Check the exhaust gas temperature
from the engine.
+ Check that the drain pipe of the
charge air cooler is open.
+ View the exhaust outlets for smoke,
colour and sparks.
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1. START, STOP AND OPERATION
Shut-down sequence
Normal stop Shut-down sequence
Tripping
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1 Stop the engine.
NOTE :
In manual mode the genset has to
be manually unloaded and the gen-
erator breaker opened before stop-
ping the engine.
The auxiliary systems shall always be in
operation circulating, cleaning and heat-
ing the fluids, thus ensuring the best
performance and trouble free operation
of the genset. It also reduces start-up
time and enables the operator to start
and load the engines very quickly.
Switch off the units only if prolonged
stoppage is planned or for maintenance
purposes.
If necessary, shut down auxiliary units
according to instructions in the following
chapters.
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Hitz; F1-Project, WPP10185
and blocking circuits
Tripping
The breaker trip circuit opens the genset
breaker and disconnects the excitation of
the generator. After the breaker has
been opened and excitation disconnected
the genset runs unloaded for a preset
time before it stops.
The breaker trip circuit is self holding
over an auxiliary contact and will re-
main on until it is reset by the tripping
reset push button.
Before restart the cause for tripping
must be investigated and remedied.
Blocking
The blocking circuit opens the genset
breaker, disconnects the excitation and
stops the engine immediately without
any recooling time.
The blocking circuit is self holding over
an auxiliary contact and will remain on
until the blocking reset button is
pressed. The genset cannot be started if
the shut-down circuit is activated.
Before restart the cause for blocking
must be investigated and remedied.
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