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Supervision During Commissioning Procedure for Commercial Operation of 32

MW Turbogas Power Plants

Conference Paper · January 2008

DOI: 10.1115/POWER2008-60025

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Norberto Pérez Rodríguez Erik Rosado

Instituto Nacional de Electridad y Energías Limpias Instituto Nacional de Electricidad y Energías Limpias
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 Draft
Proceedings of PWR2008
ASME Power 2008
July 22-24, 2008, Orlando, FL, USA

POWER2008-60025
SUPERVISION DURING COMMISSIONING PROCEDURE FOR COMMERCIAL OPERATION OF
32 MW TURBOGAS POWER PLANTS

Norberto Pérez Rodríguez Erik Rosado Tamariz

Instituto de Investigaciones Eléctricas Instituto de Investigaciones Eléctricas
Av. Reforma 113, Col. Palmira, 62490 Cuernavaca Av. Reforma 113, Col. Palmira, 62490 Cuernavaca
Morelos, México Morelos, México
Tel: 52 777-3623811, Fax: 52 777-3623834 Tel: 777- 52 3623811, Fax: 52 777-3623834
E-mail: [email protected] E-mail: [email protected]

Rafael García Illescas

Instituto de Investigaciones Eléctricas
Av. Reforma 113, Col. Palmira, 62490 Cuernavaca Morelos, México
Tel: 777- 52 3623811, Fax: 52 777-3623834
E-mail: [email protected]

ABSTRACT integrated approach to assessing the quality of the product

This article presents the supervision and testifying process were accomplished. Finally, it was verified if each unit meets
during the start of commercial operations of several turbogas the technical requirements established in terms of thermal
plants generating electricity rate of 32 MW each fueled by capacity of the machine, noise levels and emissions. As a
natural gas. Supervision and testifying process were conducted result of this supervision and testifying process, it is
at the request of the customer to confirm and observe that the guaranteed to the client that the power plants and all their
evidence of commissioning, testing and operation of equipment, comply with the requirements, conditions and
acceptance tests were carried out as specified by international specifications in agreement with the provider, concerning test
regulations, calling the outcome of each tests agree the applied of putting into service, operational and acceptance test.
rules. The work was done in collaboration with the supplier
and manufacturer of equipment, the client and the institution KEYWORDS
responsible for certification and approval of the plant. All this Commissioning test, Operational test, Acceptance tests,
according to a logical and chronological order for the Supervision, Turbogas Power Plants.
sequence of tests commissioning, operation and acceptance.
Tests for putting into service are carried out on-site at normal INTRODUCTION
operating conditions, according to the design and operation The growing demand of power in the world, as well as the
needs of the plant. Once implemented in full and in a pressing need for generating plants technologically modern,
satisfactory manner, test operation of each plant was carried efficient, which will be developed in harmony with the
out considering that they must operate automatically, reliable, environment and promote energy saving; entails the design,
stable and secure, fulfilling at least, one hundred hours of installation and marketing of new power plants.
operation at full load. After completed operation tests are
conducted, acceptance testing on the power plant and The Mexican electricity industry, in order to comply with

1 Copyright © 2008 by ASME

the energy needs of the country, is currently constructing
several plants like nuclear, wind, hydroelectrical, geothermal,
coal, thermal and independent productions type
thermoelectric. In average, thermoelectric plants represent
about 65% of the total production of electricity in Mexico,
thus the importance of the installation of such turbogas plants.

Figure 1 shows a comparison of fuel consumption for

electric power generation by means of the use of
thermoelectric plants in Mexico between the years 2003 (red
columns) and expected in the year 2013 (blue columns)
according to projections.

70

60 55.7
Fuel Consumption (%)

2003
50 Figure 2. Turbogas plant of 32 MW.
2013 42.1
40 37

30 For the correct and optimal development of testing, the

19.2 20.2 equipment supplier must ensure the implementation and
20 14 execution of the work safely, both for the personnel involved
10 and for the equipment and facilities of the plant.
1.6 0.3
0
Diesel Coal Fuel Oil Natural Gas
Fuel Client

Figure 1. Fuel consumption in the electricity industry in

Mexico.
Supplier Certifier Organization
(Commissioning (Supervision Woks)
The reduction in the consumption of fuel oil is due to the Works)
process of its replacing by natural gas. This is due to Project Manager General
environmental reasons and techniques to increase the installed
capacity from central turbogas and combined cycles based on
natural gas. Site Manager Plant Resident Plant Supervisor

In this paper, the monitoring and testifying process of Startup Site Supervisors
putting into service, operation and acceptance testing of Manager (Engineers)
turbogas plants, is presented.
Lead Startup
However, depending on the type and plant conditions, Engineer Mechanic Electrical Control
different tests can be applied for entry into operation. The
important goal is to test equipment and systems for entry into
Figure 3. Organizational Structure of the Project.
service, operation and acceptance after the completion of their
installation.
It is worth mentioning that the three companies involved
in the process of putting into commercial operation of the
PROJECT DESCRIPTION
generating plant and its activities have clearly defined
To ensure the entry into commercial operation in a
responsibilities.
reliable and secure way, every turbogas plant (figure 2), a
consistent methodology was established. This process was
The client, at the beginning of tests, assigns personnel to
developed in agreement with the equipment supplier, customer
supervise them, whose role will be the monitoring, liaison
and the institution responsible for the certification. The latter
with all areas of the company and testifying compliance with
is also responsible of checking calendar with a logical and
the procedures and protocols tests. For that purpose there will
chronological order of activities and of recovering evidences
be good agreement and connection between the involved
of the entire putting-into-service process, including
companies, delimiting their participation and responsibilities.
operational and acceptance tests. Figure 3 shows the overall
organizational structure of the project.
The supplier of equipment must guarantee the proper
equipment and systems installation according with the
requirements of the design and functionality of the systems in

2 Copyright © 2008 by ASME

each unit, in such a way that the provider must leave the units Tests of putting into service
in reliable, stable and safe operation.
These are functional tests conducted in various integrated
The tests should be conducted by the supplier with its test systems of the plant, and they also include the development of
equipment and its personnel, with testifying staff of the models for operating in accordance with the requirements of
accrediting institution. the design and operation of the unit. It is applied to various
systems to verify them and in case of failures, to correct
The test equipment must be new and have a calibration functionality of the different devices, minimizing the problems
certificate issued by an accredited laboratory either national or that arise often during acceptance tests for reliable plant
international, but by an official institution. operation (see Figure 5).

The institution responsible for certification and approval

must prove that the entire generating plants and their
supplementary areas, comply with all requirements, conditions
and specifications agreed between the equipment supplier and
the customer, as well as tests for entry into service. Operating
and acceptance tests, should take place in accordance with the
protocols and specific procedures for testing and b)
a)
commissioning. All results had to be verified by the supplier
and the accrediting institution, both in quantity and content,
including the acceptance criteria, before starting tests.

DESCRIPTION OF PROCESS
During the process of commercial operation of the power
plants, the efficient functioning of the methodology developed c) d)
for sequence of tests is vital to ensure optimum operation of
the equipment and systems, and thus for the plant. In Figure 4,
a general diagram of the methodology of putting into Figure 5. Tests putting into service in a 32 MW turbogas plant.
operation of commercial plants is shown. A) Fire-protection system for the main transformer, b)
Vibrations measurement in the gas compressor, c)
Turbogenerator, d) power cables).
Commercial Operation
Because of the large number of devices and systems used
in the power plant, is practically impossible to describe each
of them and their corresponding tests for putting into service,
Construction Installation therefore it is described, in a general way this procedure in
(Civil Works) (equipment and Systems) order to show the main characteristics of each area. It is also
shown a list of some equipments and systems subjected to
their respective tests:
Tests

Electric Area:
Commissioning Operation Acceptance The functional testing of all electrical equipment and systems
inherent in the plant is accomplished. These tests are related to
Mechanical 100 hours Emissions the proper operation, through the assessment of some general
conditions of operation, for example:
Electrical Noise a) Verify that any electrostatic loads have appropriate
dissipation in order to avoid risks such as that generate
Control Full Load sparks or fire, discharges on the staff, or discharges on
machinery or equipment.
CTU b) Identify points with high resistance in conductors or parts
uses for conducting electricity, which are a source of
problems in electrical circuits, as they can originate
Figure 4. Methodology for putting into operation of voltage drops, heat and power losses.
commercial power plants Turbogas (32MW). c) Identify some of the characteristic changes of isolation,
caused by aging and pollution, as a result of time and
operating conditions of the equipment and produced by
the crown effect.

3 Copyright © 2008 by ASME

d) Verify that the auxiliary equipment for the supply of
Critical speeds of rotating machines
potential equipment and specific systems of the plant in
Stresses
case of failures, disturbs or contingencies, work properly.
Oxidation and corrosion

Allowed noise
The major equipment and electrical systems which were
Heat treatments
tested for entry into service are listed below:
Metallographic analysis

Dimensional control

Battery modules
Purity Oil

Power cables
Water quality

Synchronization schemes

Electric generators The list of main equipment and mechanical systems tested

Power switches for entry into service is shown here:

Voltage regulators

AC uninterruptible systems
Air conditioning

Unit substations
Pumps behavior

Armored (shielded) circuit boards
Behavior of rotating machinery

Overvoltage board
Supervisory vibration systems

Instrument transformers
Level meters

Power transformers
Pressure meters

Temperature measurement

System fire
Control Area:
Washing system for the turbine
All functional testing concerning all devices and systems
Air intake system
instrumentation and control inherent in the plant were
Turbogenerator
accomplished. These tests are related to the proper operation
Safety valves
of the equipment, so they can be able to meet the objectives
Flushing system (hydraulic oil, fuel oil, cooling
for which they were designed, for example: water)

a) Integrate mechanical, electrical, electronic and fluid

systems with programmable automation and control to Tests for functional and safe operation
operate at different scenarios of functioning. Once completely satisfied and successful testing of entry
b) Conducting effective management of the automatic into service, operation test of each power plant must be
controls during the start-up process, stop operation and conducted, which will have duration of seven (7) days. During
trips of the machines. this period, each unit should operate automatically, reliable,
c) Measure variables parameters of every equipment and stable and secure, fulfilling at least one hundred (100) hours at
instruments involved in the process correctly. one hundred percent (100%) of cargo. The operation test will
be carried out without any temporary facility, without any
The list of the major equipment and control systems tested simulation, and with all control systems at automatic settings.
for putting into service is shown below:

Control circuits To evaluate the previous features, there will be a monitor

Intercommunication system system for surveillance and taking readings (see figure 5). This

Control valves should be done as often as the responsible representatives of

Solenoid valves the three entities involved (supplier, customer and accrediting

Pneumatic controls. institution) have in agreement. The following parameters are

Control loops and control parameters recorded:

Data acquisition system

Calibration instruments

Control automatism
Output power of the power generator

Power factor

Generator voltage
Mechanical Area:
Fuel flow
Functional testing of all mechanical equipment and
Turbine temperatures, cooling water system
systems inherent in the plant, related to their proper operation temperature, and lubrication system temperature.
was done. All tests are designed to evaluate the mechanical
Contaminant emissions
integrity of each component by measuring, monitoring and
Any other parameter that is representative of the
assessing some general variables, in example: operation.

Vibrations of rotating and moving equipment

Temperatures

Pressures

4 Copyright © 2008 by ASME

 loads with all its controls in automatic mode.

The principal objective of the tests is to verify if all devices

of the open cycle turbogenerator comply with the requirements
established before such as the following:

Guaranteed Net Capacity and Net Unit Heat

Consumption.
The performance test measures power thermal net
consumption of the turbo unit related to net capacity
guaranteed for Generating Plant type turbogas of 32 MW. This
was carried out in conditions of operation under base load with
the air cooling system at the entrance to the turbine (chiller)
running. Moreover, it is also done at partial load capacity of a
net power output of 21 MW (nominal). Three series of tests,
Figure 6. Modules for taking readings during the operation under these operating conditions, of 30 minutes each were
test. carried out.

The test measurements were developed with a combination

During the operation test, the turbogas plant must operate of high precision instruments installed isolated and
in a stable way concerning its main parameters and without independent of the whole system. The measuring system
fluctuations within the range allowed by the control system, implemented in the plant itself was also done. The
checking that all values set by the manufacturers, as well as measurements with high precision instruments were developed
applicable standards and codes are met during either, the with instruments installed specifically for the performance
normal base load operation and during load changes. test. Measurements of the plant are those made with
permanent instrumentation of the plant, including
measurements made by the flow meters from the gas station.
Operability Test Records
Date: Time
A Data Acquisition System (DAS) for temporary monitor
Description Units 00:00 hours 01:00 hours 02:00 hours environmental conditions was used. Measurements on the
MW station system were conducted manually.
Generator MVAR
kV The data recorded automatically (through the DAS
Gen DMM MWH
installed for the test) were recorded at intervals of 30 seconds.
DMM-A MWH
DMM-B MWH The recorded data were recorded manually at intervals of five
Fuel Flow Lbs/hr (5) minutes.
Ambient Temp. °F
O2 The measurements used for the parameters of the test are
CEMS NOX as follows:
DAHS NOX Corr.
CO
Notes: The net capacity was measured on the high side of the
transformer primary with "wattmeter" (in kilowatt/hour units)
For Client: For Supplier: For Certifier Org.: installed (DMM-B in the line of departure called 52B). The
readings were recorded energy of manually from the screen
Figure 7. Format for data collection during the test operation meter. The readings of energy (kWh) and the precise
of a generating plant. schedules (time) were used to calculate the average net
capacity for the execution of the test by using the following
formula:
ACCEPTANCE TESTS
Acceptance tests are basically functional testing on the
whole system, in which the aim is to prove in practice that the
power comply with all required features in the technical Power (kW ) =
(End (kWh )) − (Start (kWh ))
specifications, both regarding the general characteristics and ∆Time (hours )
regarding every equipment and systems involved.
The flow meter of the gas station was used to measure the
These tests are made on the final individual devices of the natural gas consumed by the unit. The gas flow into
plant and integrate approaches to assessing the quality of the circulation was measured directly with the meter installed at
product: This is done in order to verify agreement between the the gas station. The total flow readings were taken directly
guaranties and collected data on their performance under from the respective instrument. The flow velocity became the
normal conditions of operation of the turbo unit, in different conditions of online real values through standard conditions of

5 Copyright © 2008 by ASME

fluid temperature and pressure with certain instruments performance test.
installed at the plant. A computational fluid routine based on All test results for the specific heat consumption are based
the Flow Measurement Engineering Handbook and the ASME on the analysis of gas fuel samples taken during the test.
/ ISO standards was used to calculate flows to performance
tests. The uncertainty was based on the applicable standards Guaranteed Noise levels .
AGA / ASME. The measurement of pressure gas flow was The noise emission test takes just when the machine is
based on the 2088 Rosemount pressure transmitter located operating at capacity and consumption net thermal unit for the
near the flow meter of the gas station. The pressure was purpose of countering the results of the test with the maximum
recorded manually on the screen of the meter pressure permissible noise emission generated by the operation of
transmitter. stationary sources to the environment.

The measurement of the gas flow temperature was based Test measurements were performed using the following
on the temperature sensor of the gas station located near the equipment for measuring noise level:
gas flow meter. Temperature readings were recorded manually
from the computer screen flow meter (Mercury).
Sonometer precision.

Calibrator or piezoelectric pistófono specific
The gas properties were calculated with a composition sonometer employee.
analysis of the fuel samples which were taken during the test.
Printer graph paper or a tape recorder.
The heat power (calorific value) was calculated according to
Extension wire microphone, with a minimum length
ASTM D3588 and PTC 22 – 2005 standards. A gas sample of 1 m.
was taken at the beginning and another was taken at the end of
Tripod to place the microphone or receiving
each test session thirty minutes. A total of eight gas samples equipment.
for three test sessions were taken. All fuel samples were sealed
protector against wind on the microphone.
and labeled individually. However only one of the two (2) gas
samples collected in each period of sampling using a portable
gas chromatograph on the site was used. The second sample For proof of noise emission is developed correctly took
was retained as a control element to the review and approval measurements near field and far-field.
of samples.
For far-field measurements of the area and was elected
The barometric pressure was measured using a barometer critical time where the stationary source produces the
(1) Rosemount 3051 calibrated and located in the center line maximum levels of emission. During the period of maximum
of the gas turbine. emission was selected a period of 30 to 90 minutes for the
measurement. In the area of emission maximum is located
The dry-bulb temperature in the duct entrance of the gas randomly 5 critical points of measuring and adjusting the
turbine was measured using temperature sensors calibrated sound level meter with a selector scale.
and installed for testing in eight different points before the
entrance to the chiller and were localized to obtain a valid It puts the SLM or microphone sound level meter at each
average value of the air entry temperature. measurement point pointing to the source and made at each
point no fewer than 35 readings, seeking
The relative humidity of the air was calculated by Do every 5 seconds to get the maximum value observed.
measuring dry bulb temperature, wet bulb temperature and Before and after measurements in each critical area must
barometric pressure. The wet bulb temperature was measured register signal calibration.
using a calibrated temperature sensor installed to test and
install a psicometer aspired mechanically. The dry-bulb The location of the measurement points were located as
temperature for calculating the moisture was measured using a close as possible to the elements (at a distance of 0.30 m)
calibrated temperature sensor installed to test installed in a outside the premises and at an altitude of the floor of not less
psicometer aspired mechanically without water. The than 1.20 m.
temperature instruments were located at floor level near the air
inlet duct of the gas turbine. The DTR used to measure the To make the measurement of emission of noise near field
temperature of dry bulb for calculating moisture was found took place the same procedure developed in the measurement
slightly above of the allowed limit deviation from the standard of far field with the difference that are selected 5 points within
during the post-calibration. Therefore, before using these the source to 2 m away from the building block or source
values in the calculations, extreme data points were removed broadcast, directing the microphone or sound level meter to
and the average temperature was corrected using the resulting generate noise.
value of the given deviation for post-calibration process.
Finally, we compared the results with maximum
After the carried out tests, some analyses were used to permissible noise emission for stationary sources of Oficial
estimate the uncertainty of the average net capacity corrected Mexican Norm NOM 081-ECOL [23], which are shown
and heat consumption corrected average net unit of the unit, below.
for the approval of the performance test. All this reflects the
precision errors and precision instrumentation for real Time Maximum Limit

6 Copyright © 2008 by ASME

 06:00 to 22:00 hours 68 dB of the areas as: Electrical, Mechanical, transmission.
22:00 to 06:00 hours 65 dB Distribution, instrumentation, control and electronics. During
the monitoring protocols were followed evidence provided by
the manufacturer and reference standards.
Guaranteed Contaminant Emissions.
Measurements were performed by using a team of The tests were conducted in accordance with the
continuous emission monitoring (CEMS) installed on the site. procedures provided by the client and the specific procedures
The team monitoring emissions must be calibrated before and provided companies subcontracted for tests Monitoring
after the test, with an allowable deviation of 3% of the values activities are reported weekly to the customer through reports
of the reference gas. delivered to link technical plants.

Measurements are recorded manually from an interface The work was done in collaboration with the supplier of
(PC) monitor emissions. The emission levels are recorded at equipment, the client and the institution responsible for the
intervals of 5 minutes, during the entire trial period of 110 certification and approval of the generating plant, following a
minutes. logical and chronological order for the chain of evidence for
putting into service, operation and acceptance.

Performance Test Records (Emissions) It called for the overall coordination of project oversight of
Date: Name: Signature: the operational tests, putting into service and acceptance in
Start Time Start Time Start Time
Description 00:00 hours 00:05 hours 00:10 hours generating plants which included the following activities: a)
Participation in the weekly meetings of PPR of the installation
O2 and testing generating plants, which involves the customer, the
manufacturer and supervisory personnel. B) Participation in
NOX
meetings with staff from GE for coordination of the testing
NOX_CORR programmed. C) Participation in meetings with the operational
staff of LFC for coordination of monitoring and reviewing
CO pending.
Notes Remarks:
By monitoring and testifying done, it was monitored and
found that the evidence put into service, testing and operation
Figure 8. Format for data collection pollutant emissions during of acceptance tests were conducted according to the technical
the test performance of a generating plant specification provided by the client, and the outcome of each
of the tests were described as According to the applicable
rules.
The tests are conducted during emission net capacity and
unit heat Consumption. Las runs emission testing were The evidence of entry into service took place at the site to
conducted while operating the machine to a base load (100% normal operating conditions, according to the needs of the
load), while operating nominally 75% of the capacity Neta design and operation of the plant. Once satisfied in full and in
Guaranteed (21 MW net). a satisfactory manner, was conducted test operation of each
generating plant, namely that the plant operated automatically,
reliable, stable and secure, fulfilling at least one hundred (100)
Emissions Test Summary hours one hundred percent (100%) of load.
Guaranteed Test
Description Value Average Subsequently completed testing operation took place
100% load Test 25 14.6
NOX concentration at 15% O2, ppmV
acceptance testing on the finished product and integrated
approach to assessing the quality of the product. Finally, it is
75% load Test N/A 9.3 checked whether the unit complied with the requirements laid
NOX concentration at 15% O2, ppmV down in terms of thermal capacity of the machine, noise levels
and emissions. As a result of the work of supervision and
Figure 9. Summary of the results obtained during the emission testifying was assured the customer that generating plants and
performance test of a generating plant property belonging to comply with the requirements,
conditions and specifications committed to the supplier, as
tests for entry into service, testing operation and acceptance
SUMMARY AND CONCLUSIONS testing.

During the work of supervision and testifying to

accomplished during putting into operation of commercial
plants generating power of 32 MW type Turbogas fuelled by REFERENCES
natural gas, it was concluded that:
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7 Copyright © 2008 by ASME

[2] SCP903- Commissioning Manual. “Uninterrupted AC [25] NMX-AA-01 Determinación de la densidad aparente
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8 Copyright © 2008 by ASME

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