PT.

ADHI KARYA (PERSERO), TBK DIVISI EPC

COMMISSIONING PROCEDURE

Rev. 00
Document No. 505
Page Number
PARAMETER SETTING
PSG-7-PR-T&C-I/C-???
Page 1 of ?

PT.PLN (PERSERO) PUSAT SERTIFIKASI

PUSERTIF

OWNER : PT. PLN (PERSERO)

PROJECT NAME : PLTU SINTANG 3X7 MW

JOB NUMBER : 2011000057

LOCATION : SINTANG, WEST KALIMANTAN, INDONESIA

Rev Date Description Prepared Verified Checked Approved

01 09-10-2017

Issued for Approval

1
COMMISSIONING PROCEDURE
FOR
505 PARAMETER SETTING
 TABLE OF CONTENT

NO PURPOSE PAGE
1 REFERENCE DOCUMENT
2 TEST EQUIPMENT
3 SAFETY PRECAUTIONS
4 PRE-REQUISITE
5 COMMISSIONING PROCEDURE
1. Purpose

To confirm that Woodward 505 system working correctly.

2. Reference Document

1. Woodward 505 Installation and Operation Manual

2. 505 Wiring Diagram (PSG-104-DW-IC-0002-01)

3. TSI Panel Wiring Diagram (PSG-104-DW-IC-0001)

3. Test Equipment

1. Multitester (mA, OHM, V).

2. Tool kit (Containing screwdrivers, pliers, wrenches and special tools).

4. Safety Precautions

1. Ensuring for all of authorized personal has been provided for “Personal protective
equipment” (electrician safety hand gloves for cable technicians).

2. Ensuring labeling / Marking for all inspected electrical equipment, tools or appliances that
era safe for use before issuing them workers.

3. All construction machinery, mechanical equipment and electrical appliances shall by

inspection and tested safe for use by competent person for non-statutory equipment. And
by an approved person for statutory equipment. In addition all construction equipment must
be checked by competent / authorized personal before commencement of work at site.

4. Provide “Warning line” erected around all sides of work area for the purpose of preventing
disturbing form unauthorized personal during calibration and inspection.

5. No one shall change, alter or modify any electrical equipment, tools or instrument except
authorized electrician / technician.

5. Pre-requisite
1. Check name plate, cleanness, and labeling.

2. Check wiring according schematic diagram / approved drawing.

3. Check all equipment has been installed completely.

4. BAPPK has been issued by construction team that system is ready for commissioning
6. Commissioning Procedure
6.1 Visual Inspection

1. Check cable termination on the TSI panel especially 505.

2. Check core cable marking on the terminal.
3. Check shield cable grounding.
4. Check 505 components have been installed correctly.
5. Record all data to test form sheet.

6.2 Methode of 505 First Energize

1. Ensure 24 VDC is ready at the input terminal of K Circuit Breaker (Open Position), use
Multitester to do voltage testing.
2. Ensure K1 Circuit Breaker is in Open Position.
3. Close K Circuit Breaker and test 24 VDC has ready at the output of K Circuit Breaker
and at the input of K1 Circuit Breaker.
4. Close K1 Circuit Breaker and test 24 VDC has ready at the output of K1 Circuit Breaker.
5. The 505 is energized, Woodward 505 display will appears.
6. The 505 will do self test and Checking Configuration Automatically.
6.3 Entering Programing Mode

Fig 1. The 505 Front View

 1. After Checking Configuration finished, the “Push Run or Program” message will shown at
the bottom of 505 display.
2. Push PRGM Push button locate at the top left side of The 505 buttons.
3. The Password Popup will appears, fill in 1113 value and Press ENTER button locate at
bottom right side of the 505 buttons.
4. The SHUTDOWN CONTROL Y/N messages will appears. Push Yes by pressing number 1
button.
5. The 505 will entering Programming Mode, The Programming Mode has 13 Programming
Header Blocks
6. Use Left  and Right  arrow pushbuttons to move accross those 13 Programming
Header Blocks
Fig 2 show flowchart procedure entering Programming Mode of the 505

Fig 2. Entering Programming Mode Flowchart

6.4 Entering TURBINE START Programming Block
Setting the blocks using ↓ and ↑ arrow pushbuttons and ENTER button. The Block
Sequences and PLTU Sintang Turbine Start Blocks Setting is shown bellows.
Blocks Sequence Blocks Settings

Manual Start NO
Automatic Start YES
Semi Auto Start NO
Rate To Min 2500 rpm/s
Vlv Limiter 1 %/sec
Use Idle/Rated NO
Use Autostart Seq YES
Cold Start 10 HRS
Hot Start 4 HRS
Low Idle SP 600 rpm
Low Idle Delay (Cold) 25 min
Low Idle Delay (Hot) 10 min
Rate To Hi Iddle (Cold) 2 rpm/sec
Rate To Hi Iddle (Hot) 4 rpm/sec
High Idle SP 1200 rpm
High Idle Delay (Cold) 60 min
High Idle Delay (Hot) 10 min
Rate to Rated (Cold) 2 rpm/sec
Rate to Rated (Cold) 4 rpm/sec
Rated SP 3000 rpm
Auto Halt at Idle SP NO
Ext Trips in Trip Relay YES
Reset Clears Trip Otpt NO

Table 1. Turbine Start Blocks Setting

6.5 Entering SPEED CONTROL Programming Block
Setting the blocks using ↓ and ↑ arrow pushbuttons and ENTER button. The Block
Sequences and PLTU Sintang Speed Control Blocks Setting is shown bellows.

Blocks Sequence Blocks Settings

Teeth Seen By MPU 60

Gear Ratio 1
Failed Speed Level 200 rpm
Use Speed Input #2 YES
Failed Speed Level 200 rpm
Off line Prop Gain 5%
Off line Int Gain 0.312 rps
Off line Deriv Ratio 5%
On line Prop Gain 5%
On line Int Gain 0.374
On line Deriv Ratio 5%

Table 2. Speed Control Blocks Setting

6.6 Entering SPEED SETPOINT VALUE Programming Block

Setting the blocks using ↓ and ↑ arrow pushbuttons and ENTER button. The Block
Sequences and PLTU Sintang Speed Setpoint Value Blocks Setting is shown bellows.
Blocks Sequence Blocks Settings

Overspeed Test Limit 3260 rpm

Overspeed Trip 3250 rpm
Max Governor Speed 3180 rpm
Min Governor Speed 2820 rpm
Stpt Slow Rate 2 rpm/s
Use Remote Speed Setpt YES
Rmt Spd Stpt Max Rate 3 rpm/s
Use Critical Speeds YES
Critical Speed Rate 10 rpm/s
Critical Speed 1 Max 2300 rpm
Critical Speed 1 Min 1300 rpm
Use Critical Band 2 NO

Table 3. Speed Setpoint Values Blocks Setting

6.7 Entering OPERATING PARAMETERS Programming Block
Setting the blocks using ↓ and ↑ arrow pushbuttons and ENTER button. The Block
Sequences and PLTU Sintang Operating Parameters Blocks Setting is shown bellows.
Blocks Sequence Blocks Sintang Settings

Generator Application YES

Use Gen Bkr Open Trip NO
Use Tie Brkr Open Trip NO
Use KW Droop NO
KW Max Load 10000 KW
Droop 5%
Rated Spd Setpoint 3000 rppm
Use Freq Arm/Disarm NO
Use Local/Remote NO

Table 4. Operating Parameters Blocks Setting

6.8 Entering DRIVER CONFIGURATION Programming Block

Setting the blocks using ↓ and ↑ arrow pushbuttons and ENTER button. The Block
Sequences and PLTU Sintang Driver Configuration Blocks Setting is shown bellows.
Blocks Sequence Blocks Sintang Settings

Act #1 is 4-20 mA YES

Invert Driver Outputs NO
Use Act 1 Flt Shutdown YES
Act #1 Dither 0%
Use Actuator #2 NO

Table 5. Driver Configuration Blocks Setting

6.9 Entering ANALOG INPUTS Programming Block
Setting the blocks using ↓ and ↑ arrow pushbuttons and ENTER button. The Block
Sequences and PLTU Sintang Analog Inputs Blocks Setting is shown bellows.
Blocks Sequence Blocks Sintang Settings

Analog Input #1 Function Remote Speed Setpoint

Input 1 4mA Value 2880
Input 1 20mA Value 3150
Analog Input #6 Function KW/Unit Load Input
Input 6 4mA Value 0 KW
Input 6 20mA Value 10000 KW

Table 6. Analog Inputs Blocks Setting

6.10 Entering CONTACT INPUTS Programming Block
Setting the blocks using ↓ and ↑ arrow pushbuttons and ENTER button. The Block
Sequences and PLTU Sintang Contact Inputs Blocks Setting is shown bellows.
Blocks Sequence Blocks Sintang Settings

Contact Input 2 Function Gen Breaker

Contact Input 3 Function Utility Tie Breaker
Contact Input 4 Function Start Permisive
Contact Input 5 Function Remote Aux Setpoint Enable

Table 7. Contact Inputs Blocks Setting

7. Appendix
7.1 505 Program Mode Worksheet
 505 Digital Governor Manual 85017V1

Appendix.
505 Program Mode Worksheets

Governor Serial Number ______________________

Application ________________________________ Date ___________

For details on individual settings, refer to Chapter 4.

TURBINE START SPEED SETPOINT VALUES

Manual Start YES _____ NO _____ Overspeed Test Lmt (rpm) rpm
Automatic Start YES _____ NO _____ Overspeed Trip (rpm) rpm
Semiautomatic Start YES _____ NO _____ Max Governor Speed (rpm) rpm
Rate to Min (rpm/Sec) rpm/sec Min Governor Speed (rpm) rpm
Valve Lmtr Rate (%/Sec) %/sec Setpt Slow Rate(rpm/sec) rpm/sec
Use Idle/Rated? YES _____ NO _____ Use Remote Speed Setpt ? YES ____NO _____
Idle Setpt (rpm) rpm Rmt Spd Setpt Max Rate rpm/sec
Rated Setpt (rpm) rpm Use Critical Speeds? YES _____ NO _____
Idle/Rtd Rate (rpm/sec) rpm/sec Critical Speed Rate rpm/sec
Use Auto Start Sequence YES _____ NO _____ Critical Speed 1 Max rpm
Cold Start = ( > xx Hrs) HRS Critical Speed 1 Min rpm
Hot Start = ( < xx Hrs) HRS Use Critical Band 2 ? YES _____NO _____
Low Idle Setpt (rpm) rpm Critical Speed 2 Max rpm
Low Idle Delay (Cold) MIN Critical Speed 2 Min rpm
Low Idle Delay (Hot) MIN
Rate to Hi Idle (Cold) rpm/sec OPERATING PARAMETERS
Rate to Hi Idle (Hot) rpm/sec Generator Application? YES _____NO _____
High Idle Setpt (rpm) rpm Use Gen Brkr Open Trip ? YES _____NO _____
High Idle Delay (Cold) MIN Use Tie Brkr Open Trip ? YES _____NO _____
High Idle Delay (Hot) MIN Use KW Droop? YES _____NO _____
Rate to Rated (Cold) rpm/sec KW Max Load __________KW
Rate to Rated (Hot) rpm/sec Droop (%) %
Rated Setpt (rpm) rpm Rated Spd Setpt rpm
Auto Halt at Idle Setpts YES ____NO ____ Use Freq Arm/Disarm ? YES _____ NO _____
Ext Trips in Trip Relay YES ____NO ____ Use Local/Remote YES _____ NO _____
Reset Clears Trip Output YES ____NO ____
DRIVER CONFIGURATION
SPEED CONTROL Act #1 is 4–20 mA? YES _____NO _____
Teeth Seen by MPU Invert Driver Outputs ? YES _____NO _____
Gear Ratio 1 : Use Act 1 Flt Shutdown YES _____NO _____
Failed Speed Level(rpm) rpm Act #1 Dither %
Use Speed Input #2? YES ____NO _____ Use Actuator #2? YES _____NO _____
Failed Speed Level(rpm) rpm Act #2 is 4–20 mA? YES _____NO _____
Off-Line Prop Gain % Act #2 Offset (%) %
Off-Line Int Gain rps Use Act 2 Flt Shutdown YES _____NO _____
Off-Line Deriv Ratio % Act #2 Dither (%) %
On-Line Prop Gain % Use Act #2 as Readout? YES _____NO _____
On-Line Int Gain rps Act #2 Readout is: %
On-Line Deriv Ratio % Readout 4 mA Value Units
Readout 20 mA Value Units

164 Woodward
 Manual 85017V1 505 Digital Governor

ANALOG INPUTS CASCADE CONTROL

Analog Input # 1 Function Use Cascade Control? YES _____NO _____
Input 1 4 mA Value Units Invert Cascade ? YES _____NO _____
Input 1 20 mA Value Units Min Cascade Setpt Units
Analog Input # 2 Function Max Cascade Setpt Units
Input 2 4 mA Value Units Casc Setpt Rate (/sec) Units/sec
Input 2 20 mA Value Units Use Setpoint Tracking ? YES _____NO _____
Analog Input # 3 Function Setpt Initial Value Units
Input 3 4 mA Value Units Speed Setpt Lower Limit rpm
Input 3 20 mA Value Units Speed Setpt Upper Limit rpm
Analog Input # 4 Function Max Speed Rate(rpm/sec) rpm/Sec
Input 4 4 mA Value Units Cascade Droop %
Input 4 20 mA Value Units Casc PID Prop Gain %
Analog Input # 5 Function Casc PID Integral Gain rps
Input 5 4 mA Value Units Casc Derivative Ratio %
Input 5 20 mA Value Units Use Remote Casc Setting YES _____NO _____
Analog Input # 6 Function Remote Casc Max Rate Units/sec
Input 6 4 mA Value Units Casc Units of Measure
Input 6 20 mA Value Units
READOUTS
CONTACT INPUTS Analog Readout 1 Is
Contact Input 1 Function Readout 1 4 mA Value Units
Contact Input 2 Function Readout 1 20 mA Value Units
Contact Input 3 Function Analog Readout 2 Is
Contact Input 4 Function Readout 2 4 mA Value Units
Contact Input 5 Function Readout 2 20 mA Value Units
Contact Input 6 Function Analog Readout 3 Is
Contact Input 7 Function Readout 3 4 mA Value Units
Contact Input 8 Function Readout 3 20 mA Value Units
Contact Input 9 Function Analog Readout 4 Is
Contact Input 10 Fctn Readout 4 4 mA Value Units
Contact Input 11 Fctn Readout 4 20 mA Value Units
Contact Input 12 Fctn Analog Readout 5 Is
Readout 5 4 mA Value Units
FUNCTION KEYS Readout 5 20 mA Value Units
F3 Key Performs Analog Readout 6 Is
Blink when not Active? YES _____NO _____ Readout 6 4 mA Value Units
F4 Key Performs Readout 6 20 mA Value Units
Blink when not Active? YES _____NO _____

AUXILIARY CONTROL
Use Auxiliary Control ? YES _____ NO _____
Lost Aux Input Shutdown? YES_ ____ NO _____
Use KW Input ? YES _____ NO _____
Invert Aux ? YES _____ NO _____
Min Aux Setpt Units
Max Aux Setpt Units
Aux Setpt Rate units/sec Units/sec
Use Aux Enable? YES _____ NO _____
Setpt Initial Value Units
Aux Droop %
Aux PID Prop Gain %
Aux PID Integral Gain rps
Aux Derivative Ratio %
Tiebrkr Open Aux Disable YES ____NO _____
Genbrkr Open Aux Disable YES ____NO _____
Use Remote Aux Setting YES _____ NO ____
Remote Aux Max Rate Units/sec
Aux Units of Measure

Woodward 165
 505 Digital Governor Manual 85017V1

RELAYS COMMUNICATIONS
Use Relay #1? YES ____NO _____ Use Communications ? YES _____ NO _____
Relay # 1 is Level Switch? YES ____NO _____ Use Modbus Port 1? YES _____ NO _____
Relay 1 Is Level Sw For Mode Ascii=1 Rtu=2
Relay 1 ON Level Units Modbus Device #
Relay 1 OFF Level Units Port #1 Driver
Relay 1 Energizes On Port #1 Baud Rate
Use Relay # 2? YES _____NO _____ Port #1 Stop Bits
Relay # 2 is Level Switch? YES ____NO _____ Port #1 Parity
Relay 2 Is Level Sw For Use Modbus Port 2? YES _____NO _____
Relay 2 On Level Units Mode Ascii=1 Rtu=2
Relay 2 Off Level Units Modbus Device #
Relay 2 Energizes On Port #2 Driver
Use Relay # 3? YES _____NO _____ Port #2 Baud Rate
Relay # 3 is Level Switch? YES ____NO _____ Port #2 Stop Bits
Rly 3 Is Level Sw For Port #2Parity
Relay 3 On Level Units
Relay 3 Off Level Units
Relay 3 Energizes On
Use Relay # 4? YES _____NO _____
Relay # 4 is Level Switch? YES ____NO _____
Rly 4 Is Level Sw For
Relay 4 On Level Units
Relay 4 Off Level Units
Relay 4 Energizes On
Use Relay # 5? YES _____NO _____
Relay # 5 is Level Switch? YES ____NO _____
Rly 5 Is Level Sw For
Relay 5 On Level Units
Relay 5 Off Level Units
Relay 5 Energizes On
Use Relay # 6? YES _____NO _____
Relay # 6 is Level Switch? YES ____NO______
Rly 6 Is Level Sw For
Relay 6 On Level Units
Relay 6 Off Level Units
Relay 6 Energizes On

166 Woodward