KPP 000 Xa96 702 A

KIMANIS POWER SDN BHD (842208-H)
(A joint venture company between PETRONAS Gas Berhad and NRG Consortium (Sabah) Sdn
Bhd)
KIMANIS POWER PROJECT

ENGINEERING, PROCUREMENT, CONSTRUCTION AND COMMISSIONING (EPCC)
FOR
300MW COMBINED CYCLE POWER PLANT
PROJECT
MANAGEMENT
CONSULTANT:
CONTRACTOR: CTCI Corporation, CTCI Overseas Corporation Limited,
CTCI Malaysia Sdn Bhd, Synerlitz (Malaysia) Sdn Bhd,
SCHB Engineering Services Sdn Bhd CONSORTIUM
CONTRACT NO.: PGB/HO/18/2008/0139
DOCUMENT NO.: KPP-000-XA96-702 REV. A
TITLE:
GAS TURBINE UNIT TEST PROCEDURE
STATUS: FOR APPROVAL
Contractor Doc. No.: XA96-00000-701
Proj. No.: 10K0523B
PROJECT CERTIFIED
Mgr. Rick Wu Date
A ISSUE FOR APPROVAL M.S. Chen K.H. Kuo Jeff Chou Rick Wu 26/10/2012 Client Anuar Date
Rev. Description By Chk. App. Proj. App. Date Page No. 1 of 3
THIS DOCUMENT CONTAINS CTCI CORPORATION CONFIDENTIAL INFORMATION OF A PROPRIETARY NATURE. THIS INFORMATION MUST NOT BE COPIED OR DISCLOSED IN WHOLE OR IN PART TO
OUTSIDE PARTIES NOR USED FOR OTHER THAN THE PURPOSE FOR WHICH PROVIDED WITHOUT PERMISSION OF MANAGEMENT.
( )
THIS DOCUMENT CON TAINS CTCI CORPORATI ON CON FIDENTIAL INF OR MATION OF A PROPRIETARY NATURE. THIS INFORMATION MUST NOT BE COPIED OR DISCLOSED IN WHOLE OR I
CONTENTS
PART TO O UTSIDE PARTIES NOR USED F OR O THER THAN THE PURPOSE FOR WHICH PR OVIDED WITHOU T PERMISSION OF MANAGEMENT.
PAGE
1.0 SCOPE ..................................................................................................... 3
2.0 PROCEDURE........................................................................................... 3
3.0 GAS TURBINE UNIT TEST PROCEDURE............................................... 3
10K0523B
XA96-00000-702
GAS TURBINE UNIT TEST DATE
84.10
PROCEDURE 26/10/2012
2 OF 3
REV. A
GN-504
THIS DOCUMENT CON TAINS CTCI CORPORATI ON CON FIDENTIAL INF OR MATION OF A PROPRIETARY NATURE. THIS INFORMATION MUST NOT BE COPIED OR DISCLOSED IN WHOLE OR I
1.0 SCOPE
The commissioning procedure covers the general requirement of Gas Turbine Unit Test
Procedure.
2.0 PROCEDURES
PART TO O UTSIDE PARTIES NOR USED F OR O THER THAN THE PURPOSE FOR WHICH PR OVIDED WITHOU T PERMISSION OF MANAGEMENT.
See Attachment for Gas Turbine Unit Test Procedure.
3.0 GAS TURBINE UNIT TEST PROCEDURE. (See Attachment)
10K0523B
XA96-00000-702
GAS TURBINE UNIT TEST DATE
84.10
PROCEDURE 26/10/2012
3 OF 3
REV. A
GN-504
Customer :
CTCI Overseas Corp. Ltd
9)
02
Project :
1
(E
KIMANIS POWER PROJECT, 300MW COMBINED CYCLE POWER PLANT
IS
AN
27-Sep-2012-14:50
M
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REFERENCE NUMBER : E1029 --- --- SM 003 REVISION : A
EX
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ECH / SCALE DATE 19/09/2012 24/09/2012 25/09/2012
None
R
NOM / NAME MURAT JEAN-MICHEL CAINERO CHRISTOPHE LASNE DOMINIQUE

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FORMAT / SIZE VISA MURAT JEAN-MICHEL CAINERO CHRISTOPHE LASNE DOMINIQUE

A4 REDIGE / MADE VERIFIE / CHECKED APPROUVE / APPROVED
O
TITRE / TITLE VALIDE

GENERAL DOCUMENTATION-COMMISSIONING BOOK
E
UTP 875081 337X682

G
CHENUT BRIGITTE
Ce document, propriété exclusive de REVISION

GE Energy Products France SNC
est strictement confidentiel. Il ne peut
être communiqué, copié ou reproduit
sans son autorisation écrite préalable
GE Energy A
INSTRUCTION DE
MODIFICATION
This document, exclusive property of

GE Energy Products France SNC N° 403A8936 Section Doc.
is strictly confidential. It must not be
communicated, copied or reproduced
without our previous written consent.
DT-7C GRD X
SHEET. N°
Unit Test Procedure GPO / GFO / CTQ
403A8936
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Page : 1 / 35
1 UNIT TEST PROCEDURE:
Achievement GEEPE Customer

Date Visa Visa
Unit Test Procedure
Based on 6FA+E_UTP_EN_A
Observations :
This document, sole property of our company, is Ce document, propriété exclusive de notre Este documento, proprietad exclusiva de nuestra
strictly confidential. It must not be Société, est strictement confidentiel. Il ne peut Compania, es estricamente confidential. No puede
communicated, copied or reproduced without our être communiqué, copié ou reproduit sans notre ser communicado, copiado o reproducido sin su
written consent. autorisation écrite. autorizacion escrita.
DT-7C
403A8936
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1.1 Summary:
1 Unit Test Procedure: .................................................................................................................................... 1

1.1 Summary:............................................................................................................................................. 2
1.2 Revision status: ................................................................................................................................... 3
2 General information: .................................................................................................................................... 4
2.1 Safety policy:........................................................................................................................................ 4
2.2 Tests purpose: ..................................................................................................................................... 4
2.3 Standard planning proposal: ................................................................................................................ 5
3 Standard Tests: ........................................................................................................................................... 7
3.1 Prior to start up .................................................................................................................................... 9
3.2 TURNING GEAR (SLOW COOLDOWN sequence with 88TG) ........................................................ 11
3.3 First cranking: .................................................................................................................................... 11
3.4 First fire / Loss of flame trip test:........................................................................................................ 12
3.5 First FSNL / Overspeed trip test: ....................................................................................................... 13
3.6 Generator and Electrical tests: .......................................................................................................... 15
3.7 First synchronization: ......................................................................................................................... 15
3.8 First loading: ...................................................................................................................................... 18
3.9 Steady load data collection: ............................................................................................................... 18
4 Specific Tests: ........................................................................................................................................... 29
4.1 On-line water wash: ........................................................................................................................... 29
4.2 Load control tests: ............................................................................................................................. 30
4.3 Load rejection / Island mode test: ...................................................................................................... 32
4.4 Black-start / Dead bus bar synchronization test (optional): ............................................................... 33
5 Reliability Run: ........................................................................................................................................... 34
6 Final Conditions: ........................................................................................................................................ 35
6.1 Fuel lines:........................................................................................................................................... 35
6.2 Unit ready for performance tests and commercial operation:............................................................ 35
Observations :
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1.2 Revision status:
REV. DATE DOCUMENT OBJET
A 24/09/2012 UTP_6FA+E First issue-JMM
Observations :
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2 GENERAL INFORMATION:
2.1 Safety policy:

All EHS (Environment, Hygiene and Safety) rules and recommendations, recorded in the “EHS Construction
Plan” must be applied, particularly wearing required PPE (Personal Protective Equipment).
No job can be started if people or equipment safety is compromised. This is a GE Global Policy requirement
and nothing can lead to ignore these safety rules.
Commissioning activity generates mainly 2 types of risk:

 Electrical hazards: all needed precautions have to be taken to avoid contact with electrical parts
under voltage. Be conscious that on generator, residual voltage is present even if machine is at
standstill and not excited ;
 Mechanical hazards: all needed precautions have to be taken to prevent contact with rotating parts
(shaft line, motor, pumps, etc.).
Before any rotating test on the shaft line, ensure that:

 No one is working on the shaft line or in the compartments
 All accesses to the unit and its direct auxiliaries are free and can be used easily
 Access to transformers area are closed and signalization is in place
 Fire detection is fully functional in automatic mode
 CO2 is available in manual release mode (and secured on this mode only for till synchronization)
 Firefighting means (at least temporary) are available near hazardous zones
 Needed precautions have been taken with generator commissioning engineer to prevent accidental
closure of the 52G breaker
 When applicable, needed precautions have been taken with cogeneration and/or combined cycle
commissioning engineer to prevent interferences between their respective activities.
2.2 Tests purpose:

The purpose of all these tests is to verify the global functioning of the Gas Turbine & Generator and its direct
auxiliaries. Once all these tests have been validated, the GTG can be used safely for power production
according to OMM.
Observations :
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2.3 Standard planning proposal:

This is a standard planning to be used as a guide. It has to be confirmed on site by the GE commissioning
engineer or the GE technical advisor in charge of the unit.
 Crank tests
 Gas fuel false fire
 Gas fuel first fire
 Loss of flame trip
 Compressor washing (if coated compressor)

 Gas fuel first FSNL
 Motors change over
 Speed limitations
 Overspeed trip
 Generator electric tests

 Synchronization
 Gas fuel load tests
2.3.1 Day 1 – Cranking and first fire:

A. 0 to 300 rpm
B. 0 to 900 rpm
C. HP oil check, lube oil test trip and turning gear test
D. False fire test
E. First Fire and Trip Test by Loss of Flame
F. Turning gear over the night with operator monitoring
A B C D E F
Observations :
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2.3.2 Day 2 – Washing and first FSNL:

A. Washing: see 403A8934 GTU09_TEP03 §6.3.2. pre-wash
B. Washing: see 403A8934 GTU09_TEP03 §6.3.2.3. wash, 6.3.2.4 & 6.3.2.5 rinse
C. Washing: see 403A8934 GTU09_TEP03 §6.3.2.5 turning gear
D. Washing: see 403A8934 GTU09_TEP03 §6.3.2.6. drying
E. Washing: see 403A8934 GTU09_TEP03 §6.3.2.7. end of washing
F. cranking
G. Fire for first FSNL
H. Speed Limitations (95%/107%) after 90 minutes stabilization only
I. Trip by Overspeed
J. Turning gear over the night with operator monitoring
90 minutes
minimum
AB C D E F G H I J
2.3.3 Day 3 – FSNL for Electrical Tests:

A. Fire for FSNL
B. Short circuit test
C. Open circuit test
D. Normal shut down
E. Turning gear over the night with operator monitoring
A B C D E
Observations :
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3 STANDARD TESTS:
The following steps must be completed prior to first rotation of the shaft!
Air inlet Inspection

 Check that light-test (using at least 500 W sources for confined space) has been performed by
mechanical team to ensure complete sealing between “clean side” and “dirty side” of the filter
 Check flange sealing between the different parts of the air inlet (air filter, transition pieces, elbow and
bell-mouth).
 Check that all screw/nut inside the filter housing is welded
 Check that all filtering elements are in place (sealing with the frame must be correct)
 Check that the “clean side” of the air filter house is totally clean, including transition piece and
compressor inlet, if any fragments are found, ask for a new cleaning and recheck after cleaning
 Check that all manholes or doors are closed and locked after final inspection
Air inlet final inspection date: …………………………
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The following steps must be completed prior to first rotation of the

shaft!
Load Compartment Inspection
 Check that space under load compartment is clean without any scrap (wood, oil, fuel, etc.)
 Check that load compartment is clean
Load compartment final inspection date: …………………………
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Exhaust Frame Inspection
 Check that exhaust frame and exhaust stack are clean without any scrap
 Check that expansion joints are clean of any scrap (fire risk!)
 Check that all screw/nut inside the exhaust frame housing is welded
 Check that exhaust siphon is filled with water
 Check that all manholes or doors are closed and locked after final inspection for gas turbine and boiler
if present
Exhaust frame final inspection date: …………………………
CDM Inspection
 CDM installed and configured (if applicable), if CDM is not a customer
chosen option a DLN tuning kit must be ordered and installed
 If a CDM is installed, installation & configuration reports* written by CDM
installation and configuration team MUST be collected and it is
COMPULSORY to insert a paper copy of this file as an appendix of this
chapter of this commissioning book
*At least RDLNT EQUIPMENT RECORDS & FINAL INSTALLATION REPORT
Commissioning Leader Visa
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3.1 Prior to start up
Please note that during all runs a complete set of data (trends) must be collected to ensure proper
analysis of any problem that may be detected during the runs.
In any case, the following sets of data have to be collected and sent to PacCase on “*.csv” files for
storage and future reference:
 Normal Start
 Normal Stop
 Fast Load Start (if available)
 Load rejection
 Steady data collection at FSNL, 25%, 50%, 75%, Base load.
 Ensure you get the data for :
o Mode 1,2,3
o Mode 6
o Mode 6Q (if applicable)
o Liquid fuel mode (if applicable)
The data collection in the appendix has also to be completed; any relevant data can be added.
The collected trends are for internal use and are not given to the client on numerical media.
Observations :
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3.1.1 Before first cranking check:

 Check that previous GTU tests have been carried out to allow a first crank
 Check that the protection checks have been successfully accomplished in previous GTU:
Emergency trip pushbuttons: local and distance
Customer tripping order
Generator tripping order
Lube oil pressure and temperature
Lube oil pump changeover
Overspeed protection setting
Flame detection setting
Fire detection & protection
Gas leak detection when applicable
 Check that the generator is ready for short circuit test and available for first rotation.
 Check that the installation is safe to run the unit and access is free.
 Check that the exhaust hot gas path inspection is complete and that safety clearance is declared (by
others).
 Acknowledge that the final Red Flag Review has declared the unit “READY FOR FIRST FIRING”.
 Attach a print out of the timer/counter screens at the end of this Section and/or record the following
counters:
 Total starts counter : .....................

 Fired starts counter : .....................
 Emergency trips counter : .....................
 Total fired hours : .....................
 Fuel gas fired hours : .....................
 Customer trip counter : .....................
Observations :
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3.2 TURNING GEAR (SLOW COOLDOWN sequence with 88TG)

 Proceed to turning gear sequence test.
 During barring, check for abnormal noise friction in turbine and generator and the free rotation of the
shaft.
 Leave the shaft at barring speed for 20 minutes.
 Do the Lube oil low pressure AC lube oil pumps back-up & Emergency lube oil pump backup
verification according to 403A8934 GTU03_TEP03
 Record the load current of the turning gear motor and fill up the corresponding test sheet.
 GT barring speed (rpm): .....................
3.3 First cranking:
For 0-300 and 0-900 rpm tests, if time between 0-100 rpm is less than 120 seconds,
open an emergency PacCase with records and wait for additional information!
3.3.1 0-300 rpm:

 Check that the installation is safe to run the unit and access is free.
 Machine must be on barring before any attempt to start and previous pumps changeover test done.
 Using normal start-up sequence, crank the turbine up to 300 rpm and depress the local emergency
pushbutton.
 Measure the shut down time from 300 rpm to 14 HR zero speed
 Measured time (300 rpm – 0 rpm): .....................
100 to 0 RPM shut down time*:
 During run down check for abnormal noise, rubs, friction in turbine, load gear and generator. Check
for free rotation of the shaft.
 Check that the barring system operates when the turbine is at standstill.
3.3.2 0-900 rpm:

 Give a second start order and crank the turbine up to about 20% of its nominal speed.
 Check that the Static Frequency Converter operates properly.
 Give a stop order and record the shut down time
 Measured time (900 rpm - 0 rpm): .....................
100 to 0 RPM shut down time*:
 During run down, check for abnormal noise and free rotation of the shaft.
Observations :
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3.3.3 Crank speed, Oil tests:

 Using normal sequence, crank the turbine up to crank speed.
 Do the Hydraulic oil pressure verification according 403A8934 GTU3_TEP03.
 Do the Lube oil low pressure trip verification according to 403A8934 GTU03_TEP03.
 Once the trip occurs, check for normal down conditions .
 Check the proper restart of the turning gear motor.
 Record the following data:
o Shaft line stabilized speed during turning gear: (=12 RPM) …………………………
o Lube oil temperature in header (LTTH): …………………………
First cranking date: …………………………
Commissioning Leader Visa Client Visa
3.4 First fire / Loss of flame trip test:

Please note that if your unit is coated for corrosion protection,
you must not reach more than 20% speed for first fire.
You must complete a compressor wash prior to reach FSNL.
 Check that the gas fuel system is ready for operation.

 Make sure that the spark plugs have been tested and make sure that they WILL NOT operate for the
first test: remove the fuses or switch the breaker off.
 Check that the firefighting system is available: detection should operate in automatic mode and CO2
discharge in manual mode.
 Make sure that the generator excitation will switch on during the acceleration phase (14 HS speed
level).
 Proximitor Vibration Measurement (Bently Nevada) system is operational.
 Inlet Bleed Heating system is ready.
Technical Support :
 OSM system ready.
 Qualified DLN Technical Adviser is on site with tuning kit installed. (DLN 2.x combustion systems
only).
 Data acquisition files are configured for start-up.
 Red Flag Review Team has given the Green Light to proceed with First Firing Test.
GAZ fuel: For first fire and loss of flame trip test, please refer to 403A8934 GTU06_TEP03.
Observations :
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Liquid fuel (when applicable): For first fire and loss of flame trip test, please refer to 403A8934
GTU04_TEP03.
First fire / Loss of flame trip test date: …………………………
3.5 First FSNL / Overspeed trip test:

Please note that if your unit is coated for corrosion protection,
you must complete a compressor wash prior to reach FSNL.
Please refer to 403A8934 GTU09 if needed.
For first FSNL on gas fuel, please refer to 403A8934 GTU06_TEP03.
If unit can be safely kept at Full Speed No Load, proceed to following tests:
3.5.1 Motors change over:

 Proceed to change over motor as per corresponding GTUs:
o 88TK see 403A8934 GTU01_TEP03
o 88BN see 403A8934 GTU01_TEP03
o 88BT see 403A8934 GTU02_TEP03
o 88FV see 403A8934 GTU02_TEP03
o 88JS see 403A8934 GTU02_TEP03
o 88VG see 403A8934 GTU02_TEP03
o 88VL see 403A8934 GTU02_TEP03
o 88BL see 403A8934 GTU02_TEP03
o 88HQ see 403A8934 GTU03_TEP03
o 88QA see 403A8934 GTU03_TEP03
o 88QV see 403A8934 GTU03_TEP03
Motors change over test completed date: …………………………
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3.5.2 Speed limitations:

 Proceed to speed limitations test (TNH) from 100,2% to 95% and from 95% to 107%
Speed limitations test date: …………………………
3.5.3 Overspeed Trip:

Speedtronic has two independent overspeed protection channels.
PPRO cores and PTUR cores are respectively in charge of one the two channels.
Speed feedback is monitored and compared with a preset value.
Overspeed protection test must be carried out as per the following instructions:
Prepare an acquisition file to catch the overspeed actual tripping value.
Start trend file with the following signal names:
CSGV, TNH, CSBHX, CQBH, AFPAP, CPR, TTXM, CTD, CTIM, TNR, TNHCOR, TNHA, CSRGV,
TTXSP1FSGPM1, FSGPM2, FSGPM3, FPG2, FPG3, FTG, AFQ, L4, L33CB10 l33cb1o, l33cb2o, l33cb3o,
l33cb4o, L4T, BBMAX, L4TG, L28FDX,fsgr.
Verify machine parameters are stabilized as per TIL 1354.

Verify and set VIGV setting as per TIL 1345.
It is critical to adjust constant in 1 deg steps in order to prevent inducing a large step change IGV’s
Stabilize at this setting as per TIL1345.

If all the above conditions are met GE commissioning engineer or GE technical advisor can decide to proceed
to Overspeed Trip Test.
Perform overspeed test as per TIL 1345.
Slowly raise set point and check the speed at which unit trips (once increasing do not leave unit at steady
state high speed setting or interrupt sequence).
Monitor vibrations and data record.
GE commissioning engineer or GE technical advisor record the following parameters:

 Channel selected: …………………………
 Theoretical Overspeed setting: …………………………
 Actual speed at trip command: …………………………
 Time from 100% TNH to turning gear start: …………………………
 Insert a printout of the relevant part of the trip log display.
 Insert a plot showing the GT speed and vibration level during the test.
 Check compliance of the overspeed actual value versus specification.
Overspeed trip test date: …………………………
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3.6 Generator and Electrical tests:
3.7 First synchronization:

The aim of this test phase is to synchronize and to load safely the unit, then to check the operation features at
steady load steps and carry out load operational tests.
For cogeneration and combined cycle units without bypass stack, as gas turbine hot gases are exhausted
directly through the boiler, load tests shall be undertaken in strict co-ordination with the plant partners and
managers
 The mechanical tests of the gas turbine unit and the electrical tests of the generator (pre
synchronizing tests) should be completed.
 The software audit must be complete prior to firing the unit. The latest Design Standard should be
incorporated in the site code. Certain site-by-site variances may necessitate different sequencing. The
responsible Controls Requisition Engineer must approve all changes to the code.
Notes for cogeneration and combined cycle applications:
 Progress of the Heat Recovery Steam Generator (boiler) erection and commissioning should be
sufficient to allow a safe start up.
 When applicable, HRSG, damper, steam process commissioning clearance and insurance should be
given to prevent from excessive external trips sent to the gas turbine control.
 ‘Purge time’ (Amount of air blown at cranking speed through exhaust path) should be agreed with the
exhaust and boiler responsible people so that no flammable gas pocket exists at the firing time
(explosion hazard).
 Electrical power supplies: Medium/High Voltage – AC Low Voltage – DC supply (typically 125 VDC).
Fluid supplies: fuels with nominal conditions (flow, pressure, temperature) – cooling water –
compressed air (if necessary).
Note: The power evacuation shall be ready for load tests (i.e. HV line ready including grid connection or load
consumers and relevant protection devices commissioned)
 Prior to perform load test make sure the firefighting protection is available in fully automatic sequence.
 Before any new load step, obtain the co-ordination clearance about others activities.
 CDM installed and configured (if applicable), if CDM is not a customer chosen option a DLN
tuning kit must be ordered and installed
 If a CDM is installed, installation & configuration reports* written by CDM installation and
configuration team MUST be collected and it is COMPULSORY to insert a paper copy of this
file as an appendix of this chapter of this commissioning book
 *At least RDLNT equipment records & final installation report
 Devices, instrumentation & DLN TA necessary for tuning operation ready
 It is recommended that a short-term trend file and real time plot be set up and enabled prior to firing
unit. If not use for specific operational analysis, real time plot should monitor the following signals :
 TTRF1, DWATT, FSGPM1, FSGPM2, FSGPM3 and FSGQ
 Dynamics Monitoring:
 A DLN tuning Kit or equivalent must be in place and functional checkout complete before firing the
unit.
 Check all wave guides and probes for proper installation.
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 Emissions Monitoring:
 Emissions measurements from Continuous Emissions Monitoring System (CEMS) or equivalent are
required for loading the turbine.
 Make certain the CEMS is checkout, calibrated, and fully operational.
 Turbine Monitoring:
 It is critical to have at least two <HMI> for proper monitoring and operation of the unit while
commissioning.
 After generator and electrical protection tests, the Gas Turbine Commissioning Engineer participates
in the synchronizing sequence check:
 Ensure breakers position are working properly (L52GX, L52LX)

 Ensure generator breaker will not close (closing loop open to be checked with generator
commissioning engineer)
 Check with generator commissioning engineer voltage and phase errors between generator and grid
(DV, SVL, SSDIFF1)
 Check with generator commissioning engineer that voltage and frequency matching is required for
synchronization
 Do blank tests by monitoring voltage and phase with oscilloscope if possible
First synchronization is achieved manually: …………………………
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3.7.1 Manual synchronization:

 Set the shaft line speed just above grid frequency and adjust the generator voltage
 Have the Grid clearance for first synchronization
 At zero phase error, close the circuit breaker from HM
 Once synchronized, proceed to the reverse power protection checking
First manual synchronization date: …………………………
3.7.2 Automatic synchronization:

 Ensure generator breaker will not close (closing loop open to be checked with generator
commissioning engineer)
 Check with generator commissioning engineer that voltage and frequency matching are OK when
automatic closing order is sent from HMI (monitor voltage and phase with oscilloscope if possible)
 Normalize situation
 Proceed to first automatic synchronization and check the unit goes to "spinning reserve"
First automatic synchronization: …………………………
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3.8 First loading:

Refer to 403A8934 GTU06_TEP03 for loading on gas fuel.
 On both fuels, Check that at Base Load: TTXM = TTRXP = TTRX
Base load on Gas Fuel date: …………………………
3.9 Steady load data collection:
3.9.1 Gas:
Keep the unit at least two hours at the different TNR: 101, 102, 103% and Base load and fill in the data sheets
in the appendix.
Observations :
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TURBINE DATA RECORD

OPERATION WITH FUEL GAS
OPERATING DATA UNIT FSNL END OF END OF END OF BEG. BASE

MODE 1 MODE 2 MODE 3 OF MODE 6
MODE 6
DATE
TIME
OPERATION DATA
DWATT MW
DVAR MVAR
FSR %
CSGV DGA
CPR Prs_R
TNR %
TNH %
CTIM °C
TTXM °C
TTRF1 °C
TTRX °C
TTRXB °C
TTRXS °C
TTRXP °C
TTXSPL °C
TTXSP1 °C
TTXSP2 °C
TTXSP3 °C
COUNTERS
TOTAL STARTS
FIRED STARTS
FIRED HOURS
GAS FUEL HOURS
TOTAL TRIPS
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MODE 6
AIR INLET
CTBD1 °C
CSRIHOUT %
CSBHX %
CPBH1 BAR
CPBH2 BAR
ITDP °C
CMHUM KG/KG
ATID °C
AFPAP1A MMHG
AFPAP1B MMHG
AFPAP1C MMHG
TR96TF2 MMH2O
TR96TF3 MMH2O
AFPCS MMH2O
AFPBD MMH2O
CTIF1A °C
CTIF1B °C
CTIF2A °C
CSRGV DGA
CSGV DGA
CSRGVOUT DGA
CAGV %
CPD BAR
CTDA1 °C
CTDA2 °C
CTDA3 °C
CTIFR °C
AFQ KG/S
AFPCS MMH2O
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APCS MMH2O

MODE 6
VIBRATIONS
BBMAX MM/S
BB1 MM/S
BB2 MM/S
BB4 MM/S
BB5 MM/S
BB7 MM/S
BB8 MM/S
BB9 MM/S
BB10 MM/S
BB11 MM/S
BB12 MM/S
WHEELSPACES
TTWS1FI1 °C
TTWS1FI2 °C
TTWS1AO1 °C
TTWS1AO2 °C
TTWS2AO1 °C
TTWS2AO2 °C
TTWS3AO1 °C
TTWS3AO2 °C
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MODE 6
OIL
LTTH °C
LTG1D °C
LTG2D °C
LTRG1D °C
TRG2D °C
LTB1D1 °C
LTB2D1 °C
LTOT1 °C
LTOT2 °C
TR96QL1X MM
TR96HQ1 BAR
TR96QH1 BAR
TR96QA2 BAR
COMPARTMENTS
ATDLN1 °C
ATLO1 °C
ATTC1 °C
ATTC2 °C
TR95BT11
TR95BT12
TR95BT13
TR95BT14
TR95BT15
TR95BT16
TR95VL11
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TR95VL12
TR95VL13

MODE 6
BEARINGS
BTTI1_4 °C
BTTI1_8 °C
°C
BTTA1_6 °C
BTTA1_12 °C
BTJ1_1 °C
BTJ1_2 °C
BTJ2_1 °C
BTJ2_2 °C
BTGJ1_1 °C
BTGJ1_2 °C
BTGJ2_1 °C
BTGJ2_2 °C
BTRGB1_1 °C
BTRGB1_2 °C
BTRGB2_1 °C
BTRGB2_2 °C
BTRGP1_1 °C
BTRGP1_2 °C
BTRGP2_1 °C
BTRGP2_2 °C
EMISSION
O2 %
CO PPM
NOX PPM
Observations :
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MODE 6
FUEL GAS
FTG1 °C
FTG2 °C
FTG3 °C
FPG1 BAR
FQGUV Kg/S
FSGR1 %
FSGR2 %
FPG2A BAR
FPG2B BAR
FPG2C BAR
FAGR %
FSR2 %
%
FSG1 %
FSG2 %
FAG1 %
FSG3 %
FSG4 %
FAG2 %
FSG5 %
FSG6 %
FAG3 %
FSG6 %
FAG3 %
FSG7 %
FSG8 %
FAG4 %
Observations :
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MODE 6
EXHAUST
TTXD1_1 °C
TTXD1_2 °C
TTXD1_3 °C
TTXD1_4 °C
TTXD1_5 °C
TTXD1_6 °C
TTXD1_7 °C
TTXD1_8 °C
TTXD1_9 °C
TTXD1_10 °C
TTXD1_11 °C
TTXD1_12 °C
TTXD1_13 C°
TTXD1_14 °C
TTXD1_15 °C
TTXD1_16 °C
TTXD1_17 °C
TTXD1_18 °C
TTXD1_19 °C
TTXD1_20 °C
TTXD1_21 °C
TTIB1 °C
TTIB2 °C
TTIB3 °C
EXHMASSOUT
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MODE 6
MISCELLANEOUS
FGN04 BAR
FGN05 BAR
FGN06 BAR
FGN07 BAR
FLAME
FD_INTENS_1
FD_INTENS_2
FD_INTENS_3
FD_INTENS_4
COOLING WATER
LOTROUT %
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MODE 6
GENERATOR
DWATT MW
DVAR MVAR
DPF
DF HZ
DVX KV
SVLX KV
IST1 AMP
IST2 AMP
IST3 AMP
UST12 KV
UST31 KV
UST23 KV
IEX AMP
UEX VOLT
DTGSF1 °C
DTGSF2 °C
DTGSF3 °C
DTGSA4 °C
DTGSA5 C°
DTGSA6 °C
DTGGC10 °C
DTGGC11 °C
DTGGH18 °C
DTGGH19 °C
Observations :
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4 SPECIFIC TESTS:
4.1 On-line water wash:

Refer to 403A8934 GTU09_TEP03 for On-line water wash test.
On-Line water wash date: …………………………
4.2 GFC water wash use during an under frequency event:

Refer to 403A8934 GTU09_TEP03 for GFC water wash test.
GFC water wash date: …………………………
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4.3 Load control tests:
4.3.1 Auto Loading / Unloading:

Auto Loading / Unloading tests show the ability of the unit to respond to demand according specification.
4.3.1.1 Test description for auto loading:

 Check with client test manager that national grid is ready to dissipate generated power
 Unit running at full speed no load,
o Select base load
o Select normal loading (if there is no fast loading option, you do not have any target to select
the normal loading)
o Initiate auto synchronization sequence
4.3.1.2 Test acceptance criteria and records for auto loading:

 Record loading time: …………………………
 Unit takes load up to base load according specified ramp
 Mode change is achieved at the requested temperature
4.3.1.3 Test description for auto unloading:

 Check with client test manager that national grid is ready to compensate power decrease
 Unit running at base load,
o Select preselect load for 10 MW under base load and wait for unit to reach it
o Select normal loading (if there is no fast loading option, you do not have any target to select
the normal loading)
o Select 10 MW
4.3.1.4 Test acceptance criteria and records for auto unloading:

 Record unloading time: …………………………
 Unit go back to 10MW according specified ramp
 Mode change is achieved at the requested temperature
Loading / unloading control test date: …………………………
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4.3.2 Fast loading (optional)
4.3.2.1 Test description:

Fast loading test shows the ability of the unit to respond to high demand for quick power generation.
 Check with client test manager that national grid is ready to dissipate quickly generated power
 Unit running at full speed no load,
o Select base load
o Select fast loading
o Initiate auto synchronization sequence
4.3.2.2 Test acceptance criteria and records:

 Record fast loading time: …………………………
 Unit take load up to base load according specified ramp
Fast loading test date: …………………………
4.3.3 Remote control (optional):

This paragraph concerns both Remote Interface (HMI) and DCS controls (check with A4108 – Network
topology)
All the commands and monitoring signals must have been validated during precommissioning.
The remote control functions are validated via a start and full control on load from the remote control
HMIS/DCS Console.
Remote control test date: …………………………
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4.4 Load rejection / Island mode test:
4.4.1 Load rejection test:

Load rejection test shows the ability of the GTG unit to sustain an opening of the generator breaker while
providing power to the grid (synchronized and loaded).
Load rejection test is performed with primary fuel (Gas).
 Check with client test manager that national grid is ready to sustain the load rejection of the unit
 Trip the generator breaker (52G)

 Unit does not trip and go back to full speed no load
 Induced temporary overspeed does not reach tripping limit
 Generator excitation does not trip and generator voltage remains at nominal level
Load rejection test date: …………………………
4.4.2 Island mode test (optional):

Island mode test shows the ability of the GTG unit to sustain an opening of the line breaker while providing
power to the grid (synchronized and loaded) and to continue to power its direct auxiliaries.
Island mode test is performed with primary fuel (Gas).
 Check with client test manager that national grid is ready to sustain the load rejection of the unit
 Trip the line breaker (52L)

 Unit does not trip and go back to full speed no load
 Induced temporary overspeed does not reach tripping limit
 Generator excitation does not trip and generator voltage remains at nominal level and continue so
power the unit direct auxiliaries
Island mode test date: …………………………
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4.5 Black-start / Dead bus bar synchronization test (optional):
4.5.1 Black-Start test (optional):

Black start test shows the ability of the unit to start in case of national black-out.
 Unit on turning gear, switch power from grid to plant MV generator set
 Reset all alarms
 Start the unit

 Unit reach full speed no load and is ready for synchronization
Black-Start test date: …………………………
4.5.2 Dead bus bar synchronization test (optional):

Dead bus bar synchronization test shows the ability of the unit to participate to rebuild the national grid after a
black out.
The power output side must be isolated from the grid and
the client test manager must certify that there is no load
(no transformer nor long distance line) on the line used for the test.
 Check with client test manager that national grid is ready and there is no voltage on chosen line
 With unit at FSNL, confirm the no voltage situation
 Select or manually execute the dead bus bar synchronization sequence
 Check the breaker closure at nominal voltage and nominal seed

 Unit is available for loading on demand
Dead bus bar synchronization date: …………………………
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5 RELIABILITY RUN:
When all standard tests are completed, unit is ready for trial run.
If possible, all strainers have to be removed prior to trial run. If not, they will have to be removed before
performance tests.
Trial run observations:

……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………….
Trial run performed from ………………………… to …………………………
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6 FINAL CONDITIONS:
6.1 Fuel lines:

All temporary strainers must be removed prior to Performance Test.
Gas fuel strainers removal date: …………………………
6.2 Unit ready for performance tests and commercial operation:

When all previous tests have been performed, unit is ready for performance tests and commercial operation.
--- End of Document ---
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KIMANIS POWER SDN BHD (842208-H)

KIMANIS POWER PROJECT

Contractor Doc. No.: XA96-00000-701

Proj. No.: 10K0523B

Mgr. Rick Wu Date

Rev. Description By Chk. App. Proj. App. Date Page No. 1 of 3

1.0 SCOPE ..................................................................................................... 3

3.0 GAS TURBINE UNIT TEST PROCEDURE............................................... 3

See Attachment for Gas Turbine Unit Test Procedure.

3.0 GAS TURBINE UNIT TEST PROCEDURE. (See Attachment)

CTCI Overseas Corp. Ltd

NOM / NAME MURAT JEAN-MICHEL CAINERO CHRISTOPHE LASNE DOMINIQUE

FORMAT / SIZE VISA MURAT JEAN-MICHEL CAINERO CHRISTOPHE LASNE DOMINIQUE

TITRE / TITLE VALIDE

UTP 875081 337X682

Ce document, propriété exclusive de REVISION

This document, exclusive property of

1 UNIT TEST PROCEDURE:

Achievement GEEPE Customer

Unit Test Procedure

1 Unit Test Procedure: .................................................................................................................................... 1

1.2 Revision status:

REV. DATE DOCUMENT OBJET

A 24/09/2012 UTP_6FA+E First issue-JMM

2.1 Safety policy:

Commissioning activity generates mainly 2 types of risk:

Before any rotating test on the shaft line, ensure that:

2.2 Tests purpose:

2.3 Standard planning proposal:

 Compressor washing (if coated compressor)

 Generator electric tests

 Gas fuel load tests

2.3.1 Day 1 – Cranking and first fire:

2.3.2 Day 2 – Washing and first FSNL:

2.3.3 Day 3 – FSNL for Electrical Tests:

Air inlet Inspection

Air inlet final inspection date: …………………………

Site Quality Specialist Visa Commissioning Leader Visa Client Visa

The following steps must be completed prior to first rotation of the

Load Compartment Inspection

Load compartment final inspection date: …………………………

Site Quality Specialist Visa Commissioning Leader Visa Client Visa

Exhaust Frame Inspection

Exhaust frame final inspection date: …………………………

Site Quality Specialist Visa Commissioning Leader Visa Client Visa

Commissioning Leader Visa

3.1 Prior to start up

3.1.1 Before first cranking check:

 Total starts counter : .....................

3.2 TURNING GEAR (SLOW COOLDOWN sequence with 88TG)

3.3 First cranking:

3.3.1 0-300 rpm:

3.3.2 0-900 rpm:

3.3.3 Crank speed, Oil tests:

Commissioning Leader Visa Client Visa

3.4 First fire / Loss of flame trip test:

 Check that the gas fuel system is ready for operation.

Commissioning Leader Visa Client Visa

3.5 First FSNL / Overspeed trip test: