Commissioning Manual (Rev 4, 10-6-06) Tp60

(1)

TWINPAC™ and SWIFTPAC™

Commissioning Manual

United Technologies Corporation

Pratt & Whitney Power Systems

80 Lamberton Road

(2)

PROPRIETARY INFORMATION WARNING

This document is the property of United Technologies Corporation (UTC). You may not possess, use, copy, or disclose this document or any other information in it, for any purpose including without limitation to design, manufacture, or repair parts, or to obtain FAA or other government approval to do so, without UTC’s express written permission. Neither receipt nor possession of this document alone, from any source, constitutes such permission. Possession, use, copying, or disclosure by anyone without UTC’s express written permission is not authorized and may result in criminal and/or civil liability.

(3)

FT8™ COMMISSIONING MANUAL REVISION RECORD

Revision Number

Date of Issue Issued

By

Initial Issue K. Nagy

Rev 1 September 12, 2001 J. Picard

Rev 2 March 1, 2002 M. Cowan

Rev. 3 December 15, 2002 M. Cowan

(4)

FT8

TM

COMMISSIONING MANUAL TEMPORARY REVISION RECORD

TEMPORARY

REVISION NUMBER DATE OF ISSUE AFFECTED SECTION(S)

INCORPORATED INTO MANUAL

07-01 3/15/07

11.4 – Rack Software Configuration Check &

Setting (Bently 3.85)

3/15/07

07-01-Figures 3/15/07 Procedure 11 – Vibration

Monitor Checkout Procedure 3/15/07

07-02 3/28/07

Procedure 29 – Initial Light-Off, Power Turbine Start-up

and Break-in 3/28/07 07-03 3/28/07 Procedure 36 – Water Injection System, Tables 36-1 and 36-2 3/28/07 07-04 3/30/07 Procedure 35 – Breaker Closure and On-Line

AVR Tests

3/30/07

07-04-TPM375 3/30/07

Supplement to Procedure 35 – Breaker Closure and

On-Line AVR Tests (outlines procedure for Protective Relay 27TN and 59D

functions)

3/30/07

08-01 12/17/08

Procedure 32 – Protective Relay Calibration and

Testing 12/18/08 08-03 12/17/08 Procedure 17 – Fire Protection System 12/18/08 09-01 7/30/09 Procedure 18 – Hydraulic Start System 7/30/09 10-01 8/10/10 Procedure 04 – Piping Systems 8/10/10 10-02 10/22/10 Procedure 11 – Vibration Monitoring System Checkout

Procedure

(5)

Pratt and Whitney Power Systems, Inc.

Commissioning Manual

TEMPORARY REVISION NO. 10-02

Please insert these Temporary Revision pages in the Commissioning Manual as

follows:

TR NO. 10-02

Replace Procedure 11, formerly named, “Vibration Monitor

Checkout Procedure,” in its entirety.

(6)

FT8 COMMISSIONING MANUAL AND SIGN-OFF SHEETS TABLE OF

INTRODUCTION TO THE FT8™ COMMISSIONING MANUAL

1.0 Checkout and Start-Up Duties and Responsibilities

The checkout and start-up of the FT8 is the sole responsibility of the Customer.

PWPS being very protective of the FT8 reputation and performance supports this activity by providing an experienced site Checkout and Start-up Technical Advisor (C&STA) and furnishing the Customer copies of the FT8 Commissioning Manual and the FT8 Commissioning Manual Sign-Off sheets.

The PWPS Project Manager, prior to the commencement of the scheduled checkout activities, sends the C&STA to the site. While on site, C&STA activities are directed by the PWPS Site Manager. His primary area of responsibility is to work with the Customer and the EPC contractor to ensure that all systems are checked and started in accordance with current FT8 procedures. The C&STA does not schedule the checkout activities nor does he supervise the contractor’s laborers.

1.1 C&STA Work Scope

C&STA work scope consists of the following duties and responsibilities: • Reports to the PWPS Site Manager.

• Provides advice and suggestions to the Customer and EPC Contractor regarding checkout and start-up of the FT8.

• Works closely with the electrical and mechanical subcontractors to ensure adherence to the checkout procedures.

NOTE

The PWPS site manager, on the advice of the C&STA, will stop checkout activities if procedures are not being followed.

• Assists the Contractor in loading the control system software and adjusting the software tunables.

• Coordinates the site activities of the Brush electrical generator and fire protection system representatives and any other FT8 vendor representatives sent to the site. • Ensures that the system checkout sheets are signed off and placed in the PWPS Site

(9)

NOTE

The C&STA will check the commissioning book on a daily basis. If the sheets are not filled out in a timely fashion after the checks have been completed, The PWPS site manager, on the advice of the C&STA, will stop checkout activities until the data in the commissioning books catches up to the checks being done. • Does not supervise laborers

• Does not use tools.

• Does not assist in fixing, adjusting or setting instruments, controls, relays or other devises.

• Is not responsible for primary troubleshooting of the systems. Does provide troubleshooting technical assistance to the Customer and/or EPC Contractor on an “as required” basis.

• Is not responsible for scheduling checkout and start-up activities.

1.2 Customer and/or EPC Contractor Work Scope

The Customer and/or EPC Contractor work scope consists of the following duties and responsibilities:

• Has overall responsibility for both FT8 and Balance of Plant (BOP) checkout and start-up.

• Is responsible for providing electrical, mechanical and controls labor to complete these tasks.

• Is responsible for supervision of the above labor and work scope.

• Is responsible, under the direction of the C&STA, for loading the control system software and adjusting the software tunables. This might be accomplished using a dial-in phone connection in the control house a PWPS controls representative on site, by the Customer/EPC Contractor PWPS or by the C&STA through mutual consent. • Is responsible for scheduling and monitoring the checkout and start-up activities to

meet the contractual dates.

• Is responsible for providing the appropriate and necessary tooling, instruments and equipment to complete checkout of each procedure provided in the FT8 Commissioning Manual. Test equipment shall have current, valid calibration stickers. • Is responsible for primary troubleshooting of the systems. The C&STA will provide

troubleshooting technical assistance on an “as required” basis.

• Will utilize the PWPS provided FT8 Commissioning Manual and sign off sheets to complete the checkout of the FT8 scope.

(10)

• Is responsible for checking and setting, as required, all instruments, gauges, protective relays, meters and controls provided in the FT8 scope. This includes recording all information required by the checkout procedures.

• Is responsible for ensuring that each FT8 procedure has been completed as described and that the person doing the work or the foreman has signed the corresponding sign off sheet.

• Will ensure that the signed procedure sign off sheets have been copied and the originals are placed in the master-commissioning book. This master-commissioning book shall have a record of all the latest checkout data prior to first fire and initial synchronization.

• Will provide the PWPS site manager with the completed master-commissioning book and a complete set of as-built documentation for any changes or modifications made during the installation and/or checkout phase. These documents will be used by PWPS to generate the customer required as-built drawings

2.0 Safety

Because of its importance, site safety information is a prominent part of this manual. In order to insure safety at PWPS gas turbine installations, the following rules must be adhered to:

1. The only time personnel are allowed in the gas turbine enclosure when the unit is operating is when the unit is at gas generator idle and/or synchronous idle.

2. No personnel are allowed in the gas turbine enclosure during a start cycle. The start cycle is defined from initial rotation on the starter until the gas generator reaches idle operating conditions. For dual engine configurations, this includes no personnel being allowed in the enclosure on the opposite side not starting, even for de-coupled gas turbines.

3. No personnel are allowed in the gas turbine enclosure when the gas turbine is above idle speed (any time after breaker closure).

4. If one side of a dual engine configuration is operating, after the start cycle is completed, it is acceptable to be in the opposite side's enclosure if the gas turbine is windmilling or de-coupled.

5. It is acceptable to enter the gas turbine enclosure when the gas generator is rotated on the starter only start-cycle not initiated, or during coast down after the gas turbine has been shutdown (fuel shutoff).

6. All personnel must be at least 20 feet away from the gas turbine enclosure during start cycles. Start cycle is defined as from when the start horn activates and until the gas turbine, including both sides of a dual engine configuration if both gas turbines are to be started, reach GG idle and / or sync idle.

7. It is recommended that suitable high visibility tape or lines on ground be used to define the 20 feet boundary.

(11)

3.0 Change Recommendations

Recommended changes to this manual or any other Pratt and Whitney Power Systems manual may be submitted by anyone using a copy of the PWPS Manual Change Recommendation form included at the end of this chapter. The completed form can be submitted via email, standard ground mail or facsimile transmission. If submitting the form via email, please transmit the completed form to: [email protected]

If submitting the completed form via standard mail, please address to: Pratt and Whitney Power Systems

80 Lamberton Road Windsor, CT 06095

Attn: Customer Technical Services

Publications Supervisor

If submitting the manual change recommendation via facsimile transmission please forward to: (860) 565-8500. Address the facsimile cover sheet to the attention of the Publications Supervisor, PWPS Customer Technical Services.

4.0 Change Symbols

The FT8 Installation Manual is subject to amplification and revision as additional information becomes available. Revised text is indicated by a black vertical line in either margin of the page, adjacent to the affected text, like the one printed next to this paragraph. The change symbol identifies the addition of new information, a changed procedure, the correction of an error, or a rephrasing of the previous material.

5.0 Warnings, Cautions and Notes

The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this manual.

WARNING

A procedure, practice or condition, etc. which may result in injury or death if not carefully observed or followed.

CAUTION

A procedure, practice, or condition, etc. which may result in damage to equipment if not carefully observed or followed.

NOTE

A procedure or condition, etc. which is essential to emphasize or expand upon.

(12)

6.0 Use of Tools and Instrumentation Used On PWPS Equipment

All subcontractor tools and/or instrumentation used for the installation and maintenance of PWPS equipment shall be calibrated and/or certified in accordance with the specific tool or instrument manufacturer’s recommended calibration cycle.

All subcontractor tools and/or instrumentation shall be used or operated in accordance with the specific tool or instrument manufacturers recommended operating procedures

(13)

PWPS MANUAL CHANGE RECOMMENDATION FORM

Date:

From: Company:

To: Technical Publications Supervisor PWPS Customer Technical Support 80 Lamberton Road Windsor, CT 06095

Complete Name of Manual: Revision Number and Date: Chapter:

Page: Paragraph:

Recommendation (Be Specific)

Justification (Be Specific):

(14)

PROCEDURE 01 – SITE SPECIFIC DATA

1.0 Site Specific Data

Record the required information in Procedure 01 of the FT8 Commissioning Manual Sign-Off Sheets Manual. The first column should include the component serial number or specific data, such as site name or unit number. The unit configuration should also be defined by indicating which options, such as evaporative cooler, are included. The second column should contain the manufacturer of the component, noted data and any applicable remarks pertaining to the device.

Some sites may have more than one remote control point either on or off site. Ensure that data is recorded for all FT8 associated equipment. Enter data into the space provided at the end of the Sign-Off Sheet section. Also add any PWPS supplied equipment which is not listed in the tabulation.

Current Transformers (CTs) and Potential Transformers (PTs) should be listed by CT and PT part numbers and the serial number of the device located on each phase. The tabulation does not include blank spaces for this information since this may vary with site. Include the specific data in the space provided after the tabulation.

NOTE

It should not be necessary to disassemble any equipment to obtain the required data. Installed control house component data should be available from the control house fabricator. Contact the PWPS Project Manager, as required.

(15)

PROCEDURE 02 - AIR CONDITIONING CHECKOUT PROCEDURES

2.0 Control House Air Conditioner Checkout and Start-Up Procedure

NOTE

The condenser motor is phase rotation sensitive. If the unit is run and cooling output is inadequate or current draw is abnormal, the phase rotation may be incorrect. Check phase sequence and see vendor manual. Newer models have a module to monitor phase sequence. If the unit does not run and the module in the control panel shows a red indicator light, the phase sequence is wrong. Correct as necessary. See vendor manual.

There are several different control and cooling unit combinations depending on control house configuration.

1. Before turning the circuit breaker on for the air-conditioner, verify that the 380-VAC, 50-Hz or 480-VAC, 60-Hz selection switch, if equipped, is in the correct position. Verify that the thermostat is set at mid-position and that the run switch is in the OFF position.

2. Verify that the air filters are in place.

3. Verify that condensate drain trap assemblies are installed. Pipe to local drain, as required. 4. Set thermostatic controls as below:

A. Unit 1 Cool - 70° F B. Unit 1 Heat - 62° F C. Unit 2 Cool - 71° F D. Unit 2 Heat - 61° F

5. Manually turn the condenser fan and verify that it rotates freely without rubbing the fan shroud. Adjust for unhindered operation, if required.

6. Close the local disconnect switch.

7. Turn ON the power supply circuit in ACD 2 and verify that it is 380-VAC, 3-Phase, 50-Hz or 480-VAC, 3-Phase,60-Hz, depending on the site.

8. Turn the System Switch to ON.

9. The blower in the unit should start after a time delay; adjust the supply grille(s) to obtain an even air distribution through the control house. Check blower current and confirm it to the nameplate rating.

(16)

NOTE

Thermostat configurations may vary with different control house configurations. There may be one thermostat controlling both units, or a single thermostat for each unit. Follow Paragraph 2.0, Steps 10 and 11 for single thermostat units and Paragraph 2.1, Steps 12 and 13 for individual thermostat units.

10. To ensure that the refrigeration system is functional, adjust the thermostat to a setting below room temperature (SLIDE BAR UP, if fitted with this type of thermostat). The compressor and condenser fan in unit #1 will start. Continuing to move slide bar upward will start unit #2 compressor/condenser fan.

After 10-minutes of operation, read operating voltage and total amperage draw and compare to the ratings in Table 2-1. A qualified Airconditioning Service Technician should further check abnormally low or high amperage readings. Return the thermostat slide bar back to MIDPOINT. 11. To ensure that the heating system is functional adjust the thermostat slide bar to a setting above

room temperature (slide bar down). The electric heater on Unit 1 will energize. Continuing to move slide bar downward will energize Unit 2. Measure the heater circuit operating voltage and total amperage draw and compare these readings to the ratings in Table 2-1. Return the thermostat slide bar back to mid-position.

Operating Voltage 480-VAC, 3Ph, 60Hz or 380-VAC, 3Ph, 50Hz

Compressor Data Welded Hermetic FLA 8.4

Evaporator Motor Data 1/3 HP, 1075 RPM, Open Drip Proof FLA 1.5 Condenser Motor Data 1/5 HP, 1075 RPM, Open Drip Proof 1 FLA 1.3 Heater Data 9KW, One Stage Open, Coil Type FLA 10.8 Cooling Amperage Draw Approximately 11.2 Amps

Heating Amperage Draw Approximately 12.3 Amps

Table 2-1 Control House Airconditioner Data 2.1 Operating Instructions, Single Thermostat For Two (2) Units

Normally, the unit will continuously run and adjustments are not necessary.

If a change in control house temperature is desired the temperature sensors in the thermostat should be adjusted. Allow at least one (1) hour to elapse after the setting has been changed to permit temperature stabilization before changing the setting again.

If any of the safety devices in the unit trips, the cause of trip must be addressed before re-starting the unit.

(17)

NOTE

With individual thermostats, each airconditioning/heating unit operates independently from the other. Commissioning for each unit is similar.

12. To ensure that the refrigeration system is functional, adjust the thermostat to a setting below room temperature. The circulating fan, compressor and condenser fan in the unit will start. After 10-minutes of operation, read the total amperage draw. A qualified A/C service technician should further check abnormally low or high amperage readings.

13. To ensure that the heating system is functional, adjust the thermostat to a setting above room temperature. The circulating fan and the electric heater on the unit will energize. Take heater circuit total amperage draw.

2.2 Operating Instructions, Single Thermostat for Each Unit

The units will cycle ON and OFF as the cooling/heating load demands.

If a change in control house temperature is desired the temperature sensors in the thermostat should be adjusted. Allow at least one (1) hour to elapse after adjusting the setting to permit temperature stabilization before changing the setting again.

If any of the safety devices in the unit trips, the cause of trip must be addressed before re-starting the unit.

14. Record results, current readings and thermostat settings in the Procedure 02 Section of the Sign-Off Sheets Manual.

NOTE

To obtain long and satisfactory equipment operational life, the Maintenance Schedule should be closely followed. Inspect return air filter elements regularly, change or a monthly basis or sooner if conditions warrant.

(18)

PROCEDURE 03 – BATTERY BANKS AND CHARGERS

3.0 Battery Banks, Battery Chargers and Inverter Checkout Procedures

CAUTION

DC circuits can produce high energy levels which may be dangerous and can cause serious injury. Batteries and battery chargers should be serviced and maintained by trained and qualified personnel only.

NOTE

Complete operating instructions and adjustment procedures may be obtained from vendors' manuals.

3.1 Installation Inspection

NOTE

The following steps should be completed at the control house manufacturer’s site during factory checks.

1. Ensure that the cell interconnecting straps are properly installed and battery terminals have been properly tightened to 100-in.lb. and greased with STL8 or equivalent.

2. Ensure that all wiring terminations are secure and tight. 3. Verify that AC-phase rotation to the chargers is correct. 4. Verify correct polarity of charger output wiring.

5. Perform applicable sections of Procedure 10 to energize power circuits.

Because of the possibility of internal damage during shipping, verify the ammeter operation measuring the millivolt drop across the shunt using an external meter, and convert milli-volts to amps by the formula:

Output amps = MEASURE MILLIVOLTS

x

IS 50

(IS = the current rating stamped on the shunt)

If the unit does not operate correctly, check the fuses. AC fuses (or breakers) are rated at 1.4 times the AC current nameplate rating. DC fuses (or breakers) are rated at 1.5 times the DC current nameplate rating. If fuses are good and the unit does not operate, refer to the vendor manual section for troubleshooting procedures.

(19)

3.2 General Operating Procedure

The main control on standard units is the float/equalize switch, located on the front panel. This control allows the operator to select either the float or equalize output voltage mode. Float and equalize modes are two different output voltage settings, with the equalize voltage being slightly greater than the float voltage. The equalized mode is used to eliminate charge level differences between individual cells and charge the battery at a faster rate than does the float mode.

The output of the charger may vary considerably when first turned on, depending upon the charge state of the battery. If the battery is almost fully discharged, the charger will supply its maximum rated current and will be in the current limit mode. As the battery charge is restored and the current demand decreases, the charger will automatically switch from the current limit mode to the float or equalize voltage mode, depending on the position of the float/equalize switch. Once the float or equalize mode is reached, the charger output current will gradually decrease, while the float or equalize voltage is maintained. If the battery is at or near full charge when first turned on, the charger will assume the float or equalize voltage and the output current may be less than the current limit value. As noted, the output of the charger will be different depending upon the charge state of the battery.

After the charger has been working for 24-hours, general operation can be checked by switching between the float and equalize modes. When switched from float to equalize, the output (voltage and current) will increase as necessary to achieve the equalize voltage, and then the current will decrease slowly, to maintain the equalize voltage. When switched back to float, the output current will go to zero (0) for a period of time as the battery voltage decreases to the float level, at which time the current will slowly increase as necessary to maintain the float voltage across the battery. In the float mode, the battery is maintained in a fully charged condition.

The control module, through information supplied by the shunt, limits the output current of the unit. If the output current reaches the limit or set value before the output voltage reaches its set value, the unit will be in the current limit mode with the ammeter showing the set current value. In the current limit mode, changes in load requirements result in the output voltage changing, while the output current remains steady. A direct short across the output terminals of the battery charger will put the charger in the current limiting mode.

WARNING

Do not short the output with the battery connected.

If less than the current limit value is required to achieve the set value of output voltage, the battery charger will be operating in the voltage limit control mode.

Normally, the current drawn by the load or battery is less than the set current limit value, so the battery charger operates in the voltage limit mode. In this mode, the output current varies per load requirements while the output voltage remains steady. The voltage limit modes include the float and equalize modes.

3.3 Adjustment of Float, Equalize and Current Limit Controls

1. Turn OFF the charger DC output circuit breaker.

2. Set the float voltage to the value listed in Paragraph 3.9, Battery Charger Data, using the float adjust potentiometer located on the front panel.

(20)

4. Current limit is set at the factory and should not require adjustment. If an adjustment is required, refer to the vendor manual for adjustment instructions

NOTE

The current limit light may be on if there is no load on the battery bank, breakers in DCD1 and DCD2 are not energized.

3.4 Alarms

1. There is a 10-second time delay on all alarms.

2. Alarms are non-latching and will clear when parameters return to normal.

3. All alarms are sent to the monitoring system, recorded and annunciated via the HMI.

4. All alarms, except 125-VDC low voltage, are annunciated only and the control system issues no action.

5. A 125-VDC low voltage alarm will result in a unit emergency trip, which is initiated by the control system.

6. Verify all alarms back to the control and complete the FT8 Commissioning Manual Sign-Off Sheets, as required.

Alarm _{Operating Point}24-VDC _{Operating Point}125-VDC Result of Alarm

Batter Charger Voltage Low 23-VDC Falling 115-VDC Falling Annunciation Batter Charger Voltage High 29.5-VDC Rising 145-VDC Rising Annunciation Battery Charger AC Supply

Failure No AC Input No AC Input Annunciation Battery Charger Failure Battery Charger Failure or Loss

of AC Input

Battery Charger Failure or Loss

of AC Input

Annunciation Battery Ground _GroundedEither leg _GroundedEither leg 24-VDC – Annunciation 125-VDC – Unit

Emergency Shutdown

Table 3-1 24-VDC and 125-VDC Battery Charger Alarms 3.5 AC Power Failure Alarm

The AC power failure alarm is activated when power is disrupted by any of the following conditions: 1. The AC input fails.

(21)

No adjustments are normally required on the power failure alarm circuit.

3.6 Low DC Voltage Alarm

The battery charger DC output voltage is monitored and low DC voltage alarm is activated if the voltage drops below a preset level. See Table 3-1 for the operating points.

The following steps are recommended to check the low DC voltage alarm: 1. Disconnect the battery from the charger.

2. Energize the charger in float mode and record the value of float voltage.

3. Slowly misadjust the float voltage potentiometer to obtain desired low voltage alarm.

NOTE

Remember there is a 10-second alarm delay. 4. Adjust the float voltage back to the value in the table.

3.7 High DC Voltage Alarm

The battery charger DC output voltage is monitored and the high DC voltage alarm is activated if the voltage increases above the preset level. See the Table 3-1 above for the operating points.

To check the high DC voltage alarm, the following steps are recommended: 1. Disconnect the battery from the charger.

2. Energize the charger in equalize mode and record the value of equalize voltage.

3. Slowly misadjust the equalize voltage potentiometer to obtain desired high voltage alarm.

NOTE

Remember there is a 10-second alarm delay. 4. Adjust the equalize voltage back to the value in the table.

3.8 Low Charge Current

The low charge current lamp may illuminate when there is no load on the battery bank as when all breakers in DCD1 and DCD 2 are OFF. If a lamp remains illuminated after the normal circuits are energized, adjust the low charge current alarm by rotating P5 in the clockwise (CW) direction until the alarm clears.

(22)

3.9 Battery Charger Data

Battery chargers should be factory set as follows:

125-VDC Charger (CPI Model BCF3-6-60-[380 or 480])

Batteries: 60 (GnB Model 6-90A07, 265AH cell voltage of 2.23 to 2.27VDC) Float voltage: 135-VDC

Equalize voltage: 138-VDC

Low voltage alarm: 118-VDC (Falling) High voltage alarm: 145-VDC (Rising) Low current alarm: 3A

Max current limiter: 66A (110%)

24-VDC Charger (CPI Model BCF3-12-150-[380 or 480])

Batteries: 12 (GnB Model 6-90A07, 265AH cell voltage of 2.23 to 2.27VDC) Float voltage: 27-VDC

Equalize voltage: 27.6-VDC Low voltage alarm: 23-VDC (Falling) High Voltage alarm: 29.5-VDC (Rising) Low current alarm: 3A

Max current limiter: 165A (110%)

3.10 Inverter

The inverters are installed, powered and tested at the factory. They are powered in the field in accordance with the following procedure:

3.10.1 Inverter Start

1. Turn OFF all switches and breakers.

2. Apply AC and DC power to the inverter from ACD1 and DCD1. 3. Turn ON CB2 AC input.

4. Turn ON CB1 AC output.

CAUTION

Output to load will be energized. 5. Turn ON DC input switch

6. To start inverter, turn ON soft start switch

7. After about 10-seconds, the load will transfer to inverter

(23)

2. Turn OFF soft start switch 3. Turn OFF DC input switch

4. Remove DC power to inverter at DCD1

CAUTION

The following steps will secure power to the load. 5. Turn OFF CB2 AC input and CB1 AC output breakers.

6. Turn OFF AC power to the inverter at ACD1

After following the Inverter Start procedure outlined in Paragraph 3.10.1, all green LEDs should be illuminated. Ensure that the inverter is left operating on DC input rather than the AC input. If operating on AC power the bottom green LED will be OFF and the red LED will be ON.

This function may be tested by turning the ACD1 breaker OFF. The green LED will go OFF and the red LED will go ON.

After restoring the AC power the inverter should switch back to the DC input. If it does not, it may be manually switched by pressing the red push button for SWITCH TO INVERTER POWER.

3.11 Recorded Data

Record the individual cell voltages and the battery charger serial numbers on the forms provided in Procedure 03 of the Commissioning Manual Sign-Off Sheets after the banks have been fully charged.

(24)

Pratt and Whitney Power Systems, Inc.

Commissioning Manual – Revision 4

TEMPORARY REVISION NO. 10-01

PROCEDURE 04 - PIPING SYSTEMS

4.0 Introduction

After installation of Pratt & Whitney Power Systems (PWPS) supplied hardware and its associated field piping, it is necessary to inspect, pressure test, and prepare each piping system for operation. These systems could include the following depending on the scope of supply for a specific project:

1. Liquid Fuel System 2. Gas Fuel System 3. Water Injection System

4. Gas Turbine Lubricating Oil System 5. Electric Generator Lubricating Oil System 6. Hydraulic Control Oil System

7. Hydraulic Start System 8. Engine Bleed System 9. Engine Heat System 10. Buffer Air System 11. Water Wash System 12. Vent and Drain System 13. Fire Protection System 14. Inlet Fogging System

The piping for these systems are all shop fabricated and cleaned, however it is prudent to assume that the piping could have been contaminated in shipping and handling at site. Both shop and field fabricated piping is subject to contamination from weld slag, chips, sand, dirt and miscellaneous particulate contamination. Contamination in any of the fluid or pneumatic systems can cause serious damage and deterioration of system performance if not eliminated. Proper piping system commissioning will reduce this risk to a minimum.

CAUTIONS

Personal Protective Equipment (PPE), not limited to eye protection, hearing protection, hard hat, gloves and protective clothing should be used as applicable while performing cleaning, pressure testing, accumulator charging, and filter changes.

Hot oil can cause burns. Be careful during flushing not to come in contact with hot piping, hoses or fluids.

Pressure testing, in general, should be done with liquids. Pressure testing using gasses can cause injury to personnel with the release of stored energy of the gas.

Follow all applicable federal, state, local, customer and company safety standards and regulations while performing piping commissioning procedures.

(25)

Follow all applicable federal, state, local, customer and company environmental standards and regulations while performing piping commissioning procedures.

Prior to operating any system for testing or commissioning, verify proper valve line-up in accordance with the P&ID and applicable commissioning procedure.

4.1 Standards and Specifications

The standards and/or specifications listed in Table 4-1 apply to the piping systems inspection, testing, cleaning and fluid fill.

ITEM SPECIFICATION

Liquid Fuel PWPS Specification FR-1

Gas Fuel PWPS Specification FR-2

Demineralized Water PWPS Specification TPM-AR-1

Potable Water PWPS Specification TPM-AR-2

Flushing ISO 4406

Power Piping (fuel, oil, water, air) ANSI B31.1

Fire Protection System Piping NFPA 12

Table 4-1 Standards and Specifications 4.2 Systems Inspections

All components shall be inspected for correct installation and proper mounting, using the system piping and instrumentation diagrams (P&ID) listed in Table 4-2, as well as the applicable field assembly drawings. Tubing and piping connections are to be secure and leak free. Piping shall be supported to cause minimal external load to be applied to the equipment.

Electrical and operational checks of the listed devices will be undertaken in a separate section of the Commissioning Manual.

Record inspection results and comments on the Procedure 04 Sign-Off Sheets of the FT8 Commissioning Manual.

(26)

4.3 Temporary Start-Up Strainers

Foreign object damage (FOD) to gas turbine engines can be costly. Even with system cleaning of plant piping leading up to the GTG package, it is often possible to have contamination present in piping systems. Therefore, PWPS supplies “last chance” filters on the liquid fuel, gas fuel and water injection skids. It is therefore not necessary to install temporary filters or strainers for commissioning. Prior to systems operation, verify that filter elements have been installed per the Procedure 04 Sign-Off Sheets of the FT8 Commissioning Manual.

Table 4-2 PWPS Drawing or Vendor Documentation

4.4 Filling Oil Tanks and Other Lubricants 4.4.1 Gas Turbine Lube Oil Tanks

Prior to filling the gas turbine lube oil tanks, remove the access cover and inspect the tank for cleanliness.

SYSTEM PWPS DRAWING OR VENDOR

DOCUMENTATION

Gas Turbine Instrumentation XXXX -181-M100D

Liquid Fuel System XXXX-181-M201D

Gas Fuel System XXXX-181-M202D

Water Injection System XXXX - 181 - M203D

Hydraulic System XXXX-181-M401D

GT Lube Oil System XXXX-181 -M402D

Hydraulic Start System XXXX - 181 -M403D

Bleed Air System XXXX - 181 - M404D

Engine Heat System XXXX-181-M405D

Fire Protection System XXXX-181-M501D

Buffer Air System XXXX-181-M502D

Water Wash System XXXX-181-M506D

Vent and Drain System XXXX-181-M507D

Combustion and Ventilation Air System XXXX-181-M509D

Inlet Fogging System See Vendor Drawing

(27)

Insure drain plugs are in place and that valves to system piping are closed. Always connect the supply hose to the fill line filter. Locate the wiring to the low-level (LSL601) and low low-level (LSLL601) switches. Using an ohmmeter verify that the level switches change state as oil is being added. Mark the level where the switches change state on the sight glass case. Use only approved oils from the PWPS Lubricants List, Appendix A, this manual. (for example: Mobil Jet Oil 254, CT116675)

4.4.2 Electric Generator Lube Oil Tank

Prior to filling the electric generator lube oil tank, remove the access cover and inspect the tank for cleanliness. Wipe out any particulate with dust free rags. Insure drain plugs are in place and that valves to system piping are closed. Locate the wiring to the low level (LSL3001) and low-low level (LSLL3001) switches. Using an ohmmeter verify that the level switches change state as oil is being added. Mark the level where the switches change state on the sight glass case. The low-low level switch should alarm at approximately 155 gallons and the low level switch should alarm at approximately 284 gallons. Use only approved oils from the PWPS Lubricants List, Appendix A, this manual. (for example: Mobil DTE Light Oil ISO VG 32, CT116676)

4.4.3 Hydraulic Starter System Supply Tank

Any oil left in the hydraulic system supply tank must be drained. Remove the plug from the round cover on the side of oil tank and drain any residual oil. Remove the tank access plate and hand clean the remaining oil using lint free media. This is important because the system manufacturer may use lightweight oil for testing. Replace the cover and plug.

Always connect the supply hose to the fill line filter. Locate the wiring to the low-level (LSL101) and low low-level (LSLL102) switches. Using an ohmmeter verify that the level switches change state as oil is being added. When the tank access cover is opened for cleaning of residual oil, operate the float switches manually and verify electrical operation of the switches. Note that the level switches will change state below the visible sight glass case. Use only approved oils from the PWPS Lubricants List, Appendix B, of this manual. (For example: Mobil DTE-13M, CT116677)

4.4.4 Other Lubricants

4.4.4.1 Water Injection Pump Gearbox

Drain the oil from the water injection pump gearbox. Refill with the same oil that is used in the generator lube oil system. (For example: Mobil DTE Light Oil ISO VG 32, CT116676)

4.4.4.2 Motor Bearings

CAUTION

Do not over lubricate motor bearings.

Using a grease gun, add one (1) shot of bearing grease to all motors with zirc-type grease fittings. Survey all motors and record if grease was added. Use only approved greases from the PWPS lubricants list,

(28)

The following motors may be equipped with grease fittings: 1. Hydraulic Starter Pump Motor

2. Secondary Air Fan Motors 3. Buffer Air Fan Motors

4. Gas Turbine Lube Oil Pump Motors 5. GT Lube Oil Cooler Fan Motors 6. EG Lube Oil Pump Motors 7. EG Lube Oil Cooler Fan Motors 8. Water Injection Pump Motors

4.5 Pressure Test and Cleaning of Balance of Plant Piping

Balance of plant (BOP) piping delivering fuel, water and air to the gas turbine package piping systems should be pressure tested and cleaned by the Customer in accordance with all applicable codes, laws, ordinances, regulations and standards. BOP pipe cleaning procedures should be reviewed with PWPS commissioning personnel to insure that the procedures follow generally accepted industry practices and will result in the delivery of fluid that meets PWPS requirements for cleanliness. Targets, screens, testing, etc., as applicable, should be used to confirm system cleanliness. However, it remains the Customer’s sole responsibility to meet the fluid quality requirements outlined in the applicable PWPS specifications for the fuel, water and air systems.

BOP systems should be cleaned up to the point of connection with the gas turbine package prior to allowing the flow of any fluids through the package piping.

4.6 Cleaning Gas Fuel Piping 4.6.1 Introduction

This section provides a general discussion of the cleaning of gas fuel piping that is to be installed to support the operation of new aero-derivative gas turbine generator units.

During transport, storage, installation and welding of pipelines, foreign matter inevitably finds its way into the piping system in spite of all care taken. In addition, there is typically contamination associated with the manufacturing processes (i.e., mill scale) and corrosion. This matter must be removed to the extent practical to help protect equipment connected downstream.

The balance of plant (BOP) gas fuel piping up to the new gas turbine generator unit interface flanges must be cleaned to mutually agreed upon acceptance criteria. It is important that the acceptance criteria be agreed upon prior to the commencement of any cleaning procedures. The customer, plant engineer,

(29)

gas turbine generator (GTG) equipment supplier, and the construction contractor should all review the criteria.

A detailed gas fuel system cleaning procedure including the design of any temporary piping should be completed and submitted by the construction contractor to the customer and plant engineer for review and approval.

4.6.1 Methods

There are several standard industry practices to remove foreign matter and contamination from gas fuel piping, these include:

• Mechanical Cleaning, Hand Tools • Mechanical Cleaning, Pigging • Hydro-Blasting

• Chemical Cleaning

• Compressed Air/Nitrogen Gas Blowing • Froth Flushing

Mechanical cleaning with the use of hand tools is an acceptable and effective way to clean small sections of gas fuel piping that can be easily accessed and visually inspected following cleaning. This method is typically used for short piping spool pieces that are connected to GTG package interface flanges and for field piping provided with each GTG package.

Pipeline "pigging" is loosely defined as the propelling of a projectile (the pig) through a pipeline to push the contents out. Pigging is utilized to flush out debris and build-up, scrape and clean the interior pipe walls. It is performed during new construction and pipeline repair or modification. Typically the industry uses four basic types of pigs: polyurethane foam pigs, mandrel or mechanical pigs, solid cast urethane pigs, and high tech "smart pigs". The most common of them is the versatile "poly pig" which is thrust through the pipeline by hydraulic or pneumatic pressure to clean the interior walls, remove debris and flush liquids from the pipeline.

Hydro-blast cleaning can be used to assist in cleaning small sections of pipe that can be visually inspected. This is typically an alternative or supplement to cleaning with hand tools.

Products of oxidation and corrosion, as well as welding residues, can be dissolved by chemically treating the inner surfaces of the piping and then they can be removed with a flush. Chemical residues from this type of cleaning are unavoidable and might not be removed adequately with flushing alone. Therefore, following acid cleaning and flushing, the piping should be blown down with clean and dry compressed air or nitrogen gas prior to operation of attached equipment. Chemical cleaning procedures are typically performed by specialized contractors and can be somewhat expensive for the gas fuel pipeline application.

(30)

“Blowing” of piping systems can be performed with compressed air or nitrogen gas to clean the piping. The quantity of air or nitrogen required to achieve acceptable velocities and blow durations can be significant. Typically, larger receivers are needed to supply a sufficient quantity of air or nitrogen. .

It should be noted that it has been a standard industrial practice for some time to use natural gas to clean BOP gas fuel piping. This is commonly referred to as conducting “gas blows” during plant commissioning. However, this practice has been determined to be inherently dangerous by the US Chemical Safety and Hazard Investigation Board (CSB). Since there are safer methods available, PWPS strongly discourages the use of natural gas to clean plant piping in accordance with the Urgent Recommendations of the CSB dated 28 June 2010. It should also be noted that even though there are safer methods, there are still dangers and hazards involved with the alternate cleaning methods. It is important that no matter what method is utilized by the Customer and contractors to clean piping, proper safety precautions must be taken and detailed procedures should be prepared, reviewed, approved and followed.

WARNING:

PWPS STRONGLY DISCOURAGES THE USE OF NATURAL GAS TO CLEAN GAS FUEL PIPING.

4.6.2 Environmental, Health and Safety Notes

The customer and contractor performing the pipe cleaning procedures shall be responsible for following all site, federal, state and local environmental, health & safety rules and regulations, as well as the following guidelines:

1. The construction contractor shall take care in the installation of the piping to minimize the amount of contamination and corrosion to limit the discharge of debris during the cleaning process. 2. Non-destructive testing in accordance with AMSE/ANSI B31.1, Power Piping Code or equivalent

shall be completed prior to the commencement of cleaning procedures.

3. All permanent and temporary piping that is part of the cleaning procedure shall be properly restrained prior to the commencement of the procedure.

4. The outlet of temporary piping that is to be blown with compressed air or nitrogen shall be pointed in a safe direction or contained to avoid causing damage or injury from the discharge of high velocity debris and liquids. Debris is typically small but could include larger miscellaneous objects such as wrenches, welding rods, cans, rocks, etc. Liquids such as oil, water and glycol can also be present in the piping.

5. Representative from the gas utilities shall be properly informed of all commissioning activities that could impact their piping or interface connection.

6. Neighbors of the plant and local authorities shall be informed of any procedures that may cause public alarm, such as from loud noise emissions or significant discharges of odorized natural gas. Temporary silencers may be required to limit the noise emissions during the cleaning process. 7. Compressed air or nitrogen blows should only be performed when activity in the area is at a

minimum. Restrict access to the vicinity of the temporary outlet pipe to eliminate the possibility of personnel injury caused by high-velocity debris.

(31)

9. Hand held gas analyzers shall be available to check concentrations of natural gas during filling and purging procedures.

10. Gas fuel piping should be purged with nitrogen following completion of the cleaning procedure to prevent corrosion of the piping system prior to gas turbine commissioning activities.

4.6.3 Preparation

Components in the piping system that could be damaged or would restrict flow during the cleaning process should be removed in preparation for the start of the process. These components could include:

• Flow measuring elements • Thermo-wells

• Strainer elements • Filter elements • Control valves

• Auxiliary skids that were verified to be clean

The main gas fuel supply header should be cleaned prior to the branch lines that connect to each gas turbine unit. Temporary piping and equipment to support cleaning should be fabricated and connected to the end of the main header by the Construction Contractor.

If piping is to be cleaned with compressed air or nitrogen it is important to achieve gas velocities between 160 and 180 percent of maximum normal operating velocities. This can be achieved with reduced mass flows by conducting compressed air or nitrogen blows at reduced pressures.

In order to prove system cleanliness, the construction contractor may prepare “targets” that can be fabricated from either painted plywood or polished metal. A target should not be installed until the initial series of blows are completed with no visible debris exiting the piping. The targets are only for use in conducting a final check of cleanliness.

If plywood targets are utilized, they should be painted gloss white. One target at a time should be positioned approximately 2 feet from the end of the temporary piping outlet. The target should be positioned at about a 45 degree angle to the pipe to allow debris exiting the pipe to impact the target without restricting the flow. Since there will be large forces on the target, the construction contractor will need to fabricate a rigid temporary structure to support the plywood.

If polished metal targets are to be utilized, the following figure provides a typical target assembly with supports and flanges for easy change out.

(32)

Figure 4-1 Typical Target Assembly

The branch gas fuel supply lines to each unit should be cleaned following the cleaning of the main header. Temporary piping and equipment to support cleaning should be fabricated and connected by the construction contractor.

Following installation of temporary piping and equipment, the Customer, plant engineer, PWPS Commissioning Manager, and construction contractor shall walk down the piping and ensure the system is ready to proceed with the any cleaning procedure.

4.6.4 Acceptance Criteria

Acceptance criteria for determining that the piping systems are clean must be agreed upon prior to proceeding with any cleaning procedures.

When using plywood targets, the compressed air or nitrogen gas blowing shall be conducted until the targets show no holes, pits or dings. This should be demonstrated with a minimum of two (2) consecutive target blows, otherwise, blowing must be continued until this criteria is met.

When using polished metal targets, blowing shall be conducted until the number of pits without raised edges does not exceed five (5) in the high velocity zone (center) and there are no pits in the target edge zones. This should be demonstrated with a minimum of two (2) consecutive target blows; otherwise, blowing must be continued until these criteria are met.

It should be noted that for the subject installation, there are “last-chance” particle filters provided in the GTG package piping to protect the gas turbines from contamination, however, the amount of debris in the new supply pipeline header must be minimized to prolong the life of the filter elements and protect the engines in the case of filter element failure.

(33)

Following successful completion of all phases of the cleaning procedure, the piping should be purged with nitrogen gas to remove air and moisture from the lines and provide protection from corrosion. This step may be avoided if temporary piping is to be immediately removed and permanent piping immediately purged and filled with natural gas.

4.6.6 Commissioning

The BOP Gas Fuel System components that were removed prior to pipeline cleaning shall be properly hand cleaned and inspected when installed in preparation for commissioning of the gas fuel system in support of GTG operations..

The customer and construction contractor shall be responsible for the cleanliness of the gas fuel field piping that is provided with each GTG unit. Under the supervision of the PWPS site representative, this piping shall be hand cleaned and blown out with compressed air before final inspection and assembly, as a minimum. This is most critical for the stainless steel piping installed downstream of the “last-chance” gas fuel filters and up to the gas turbine base assemblies inside each GT enclosure.

Following the final assembly of the Gas Fuel System, the piping shall be slowly pressurized to normal operating pressure with natural gas and purged to a safe area to fill the system. Perform a final check of system integrity during pressurization.

4.6.6.1 De-mineralized Water Piping

Customer furnished de-mineralized water piping should be pressure tested and flushed up to the GTG package interface connections. All supply and return line should be pressure tested and flushed.

4.6.6.2 Potable water Piping

Customer furnished potable water supply or de-mineralized water supply to both the water wash system and the evaporative coolers should be pressure tested and flushed.

4.6.6.3 Plant Air Supply Piping

Customer furnished plant air supply should be pressure tested and blown down at full system pressure with a full pipe diameter vent to atmosphere.

4.7 Proof Pressure Tests and System Flushing

All gas turbine systems piping must be leak free and deliver fluids free of contamination. All piping systems that are field-installed must be cleaned and leak checked. The following sections describe system Proof Pressure Testing, Leak Check, Flushing, Blow-down and System Cleaning requirements. See specifications outlined in paragraph 4.1. Fuel, oil and water samples will be collected for laboratory analysis, refer to Procedure 05.

4.7.1 Liquid Fuel System – Proof Test and Leak Check of PWPS Furnished Piping

After cleaning of the BOP liquid fuel piping has been completed and the GTG package piping has been cleaned and assembled, a leak check of the GTG package piping should be completed. A pressure test in accordance with ASEM B31.1 Power Piping Code is not required since it was completed in the factory. Do not pressurize the system with a pressure greater than 150 PSIG. The system may be pressurized

(34)

with compressed air or liquid fuel to check for leaks. All PWPS provided filter housings should be vented to remove air from the system when filling with fuel.

4.7.2 Gas Fuel System - Cleaning and Leak Checking of PWPS Furnished Piping

GTG package piping should be cleaned by hand and blown down with compressed air prior to final assembly. A pressure test of the gas fuel system in accordance with ASEM B31.1 Power Piping Code is not required, but a leak check must be made. This can be done with lower pressure compressed air or natural gas. Do not pressurize the system over 600 PSI.

CAUTION

Extreme caution should be observed while venting gas fuel. Site personnel must be advised and briefed on the time and procedure. The site or area should be blocked and marked with barriers and safety tape as required. Personnel should be evacuated from the area as required. Personal Protective Equipment (PPE) not limited to hard hat, safety glasses and hearing protection must be used, as applicable.

4.7.3 Hydraulic Start

4.7.3.1 Pressure Test and Leak Check of PWPS Furnished Piping

Field assembled piping must be flushed and leak tested. This piping was fabricated and pressure tested in the factory.

4.7.3.2 Flushing

This flushing procedure utilizes the hydraulic pump/motor to accomplish the cleaning of the pressure and return field piping only.

1. Ensure the availability of the following:

A. 3-Phase, 380/480-VAC power supply for MCC hydraulic start pump motor starter. B. 125-VDC for operation of solenoids.

C. 24-VDC for operation of shuttle valve.

2. Inspect the hydraulic skid for any damage resulting from shipment. If any damage is observed, report immediately to any PWPS personnel on site.

3. Remove the yellow shipping blocks and ensure that floor plugs are in place.

4. Check for correct phase rotation. Actively check rotation by electrically bumping the motor from the MCC panel. This is accomplished by putting the breaker in the ON position then turning the operation switch briefly to HAND.

(35)

5. In some cases, the reservoir (Hydraulic Lube Tank) is shipped to the site with some residual oil inside. This oil should be drained, discarded and the tank refilled. (See Paragraph 4.6.3)

6. Disconnect the pressure, return and drain hoses from the hydraulic start motor on the gas generator. Tie all three (3) lines together using the block from the hydraulic flushing kit, P/N TBD, supplied by PWPS.

7. Walk down the field piping and ensure that no abnormal condition exists. Confirm that the supply ball valve BV101 is open. From the MCC panel inside the control room turn ON the breaker for the hydraulic pump and allow the pressure to stabilize. From the discrete relay output block (2-2-C) install jumpers on terminals 67/68 to energize the engine select solenoid “A” and for engine “B” terminals 70/71. These outputs may be “forced” if the control system is operational.

8. The first part of the flush will be a supply/return flush which utilizes a blank at the case drain (D1 or D2) connection on the start-pac.

9. After completing the flush on that circuit, a blank is installed on the return pipe at the start-pac, the blank on the case drain is removed and a jumper hose is fitted from the case drain to the return connection on the start-pac. The return connection is used because there is no filter on the case drain return to the start-pac.

10. Hydraulic Start Flush:

A. Install the temporary circuit shown in Figure 4-2 below to energize the flow servo and start oil circulation.

B. Add temporary jumpers to operate servo to high flow.

(36)

CAUTION

Do not run pump dead headed (SOV 103 and SOV 104 closed) for extended periods. Do not start motor with jumpers in place.

1) Start motor in manual.

2) Energize SOV103 or SOV104 to fill piping on charge pump. Check for leaks.

3) Install jumpers (complete circuit) to energize high flow. 11. Run the system for a total of two (2) hours

12. Tap piping during flush with a rubber mallet.

13. Repeat the above for engine “B”. It will probably be necessary to shut down and add oil to the tank after the engine “B” piping is filled with oil.

14. Collect samples as outlined in Procedure 05.

15. Carefully observe the differential pressure on the return filters after the flush to determine if they are still usable. If there is a high differential pressure, replace the filter element(s) as required.

4.7.4 GT Lube Oil System

4.7.4.1 Pressure Test and Leak Check of GT Lube Oil System

The GT Lube Oil systems are factory assembled and tested. Field pressure testing is not required. Periodic leak checking during system test operation and during initial running is required.

The GT Lube Oil systems are factory flushed and do not require further field flushing. Include factory flushing test sheets in the Sign-off Sheets. Collect samples as outlined in Procedure 05.

4.7.4.3 Pump Alignment

Prior to operating lube oil pumps, motor to pump alignment must be checked and couplings installed per the tabulation in the Sign-Off Sheets

.

(37)

NOTE

Accumulator Charging Kit, CT112535-1 (PWPS supplied) is required.

There are one (1) or two (2) bladder type accumulators located in each gas turbine system depending on Customer configuration.

ACM501 is a one (1) gallon engine high-pressure hydraulic fluid accumulator for the IGV and VSV actuators and is mounted on the engine base. The accumulator is located downstream of the high-pressure gearbox driven pump and high-high-pressure filter. Refer to PWPS P&ID drawing XXXX – 181 – M401D. The nominal hydraulic pressure in this system is 750 PSIG. The nominal bladder charge pressure should be set accordingly:

400 PSIG for Ambient Temperatures –20°F to 20°F 440 PSIG for Ambient Temperatures >20°F But < 50°F 470 PSIG for Ambient Temperatures >/= 50°F

A601 is a one (1) gallon free turbine lube oil pump accumulator and it is mounted in the lube oil enclosure or under the inlet plenum with an enclosure mounted lube oil skid. The accumulator is located after the free turbine lube oil pump and filter. Refer to PI&D drawing XXXX – 181 – M402D, Sheet 2. The nominal free turbine supply pressure is 65 PSIG. The nominal bladder charge pressure for A601 should be 45 to 50 PSIG.

CAUTION

Use only dry nitrogen when charging accumulators.

4.7.5.1 Charging Accumulators ACM501 and A601

ACM501 and A601 can be charged directly from a regulated nitrogen bottle supply using the following procedures:

1. On the charging kit assembly, back the top T- handle fully out (CCW). 2. Screw the charge kit on the accumulator.

3. Connect the supplied hose from the nitrogen bottle regulator to the charge kit port.

4. On the charging kit assembly, turn the T-handle clockwise (CW) to open the valve stem in the accumulator.

5. Slowly open the valve on the nitrogen bottle and charge the accumulator to above charging specification.

6. Close the valve on the nitrogen bottle.

7. Wait a couple of minutes for the gas temperatures to stabilize.

(38)

9. On the charging kit assembly, back the top T-handle fully out (CCW) to disengage the accumulator valve stem.

10. Remove the charging hose and charging kit.

11. Record charge pressures and date in the area provided on the Sign-off sheets.

4.7.6 Electric Generator Lube Oil System

The electric generator lube oil system is pressure tested and flushed at the factory. It is only necessary to flush the field installed piping between the lube oil system and the bearing compartments.

4.7.6.1 Pressure Test and Leak Check

1. Perform leak check on initial system operation

CAUTION

Do not flush through the generator bearings as contamination may occur. In addition, inspect and clean pipes with lint free media before installation.

1. A jumper connection must be installed between the oil supply and return piping on each end of the generator so as not to contaminate the generator bearings.

2. Remove the generator filter element before flushing through the 100-mesh screen. Re-install the filter element when the screen is clear and perform one final flush.

3. Install 100-mesh "witch’s hat" filters after the piping return to the tank. 4. Turn on generator lube oil tank heater

5. Run AC Pump # 1 in manual mode for 2-hours 6. Run AC Pump # 2 in manual mode for 2-hours 7. Run DC pump in manual mode for 20-minutes

8. Check "witches hat" filter after each flush. Continue steps 4 thru 6, as required, until no contamination or particles are visible.

9. Ensure that piping system components are clean when reinstalling. 10. Collect samples as outlined in Procedure 05.

(39)

4.7.7 Bleed System

4.7.7.1 Pressure Test and Leak Check of PWPS Furnished Piping

Pressure test not required, leak check during initial engine operation.

CAUTION

All bleed piping is hot during operation and may cause serious burns and personal injury. Exercise proper precautions and use adequate PPE during inspections.

4.7.7.2 Thrust Balance Piping Flushing

4.7.7.3 Cold Air Buffer Piping Flushing

4.7.8 Water Injection System

4.7.8.1 Proof Test and Leak Check of PWPS Furnished Piping

Proof test not required. Perform a visual inspection when system is operating inside and outside of the enclosure.

Flush water through the water injection skid and through the piping to the engine base. Install temporary hose or pipe to the enclosure exterior and drain during flush. Restore piping with new gaskets after the flush. Assure that FM801 is filled during the flush. Inspect the system for leaks during operation.

4.7.9 Water Wash

4.7.9.1 Proof Test and Leak Check

Proof test not required. Perform visual inspection when system is operated.

4.7.9.2 Flushing, Blow-down and Purge

Blow-down and flush of the system is required prior to use if the water supply is piped from a potable water supply. If the water wash supply is tapped from the de-mineralized water supply to the water injection skid, only a flush to the spray nozzle is required.

1. Disconnect the 2-Inch hose at the nozzle connection (W3). 2. Connect a hose or pipe outside the enclosure.

(40)

4. Flow water for 10-minutes or until clear and free from debris. 5. Reconnect piping.

4.7.10 Engine Drying System

4.7.10.1 Proof Test, Leak Check and Flushing of PWPS Furnished Piping

Proof test not required. Wipe engine heat duct clean with lint free media at assembly. Prior to connecting engine heater supply hose to the engine, run the heater manually and blow out the hose. Ensure that the check valve is installed in the correct direction on the engine piping before connecting the hose.

4.7.11 Hydraulic System (IGV/VSV)

4.7.11.1 Proof Test, Leak Check and Flush of PWPS Furnished Piping

These systems are factory flushed and are NOT to be opened for field flush. A leak check of the high-pressure hydraulic system should be made during the initial run on the engine starter.

4.7.12 Engine Vent and Drain Systems

4.7.12.1 Proof Test, Leak Check and Flush of PWPS Furnished Piping

Proof test and flushing is not required. Perform visual inspection for system completeness.

4.7.12.2 Proof Test and Leak Check of Customer Piping

Proof test customer piping to the engine enclosures. If a muscle air compressor is supplied, test tubing form the generator enclosure to each engine enclosure. Perform leak check on initial system pressurization.

Blow out field installed piping with compressed air prior to connection to engine base piping

4.7.13 Evaporative Cooling System 4.7.13.1 Proof Test and Leak Check

Proof test customer piping to the engine enclosures. Perform leak check during initial system operation

.

1. Open the tray drain on the evaporative cooler. 2. Open the supply line to the evaporative cooler. 3. Flush until supply is clear.

Commissioning Manual (Rev 4, 10-6-06) Tp60

TWINPAC™ and SWIFTPAC™