Commissioning procedure for CCGT Power Plant

XXXX CCPP power plant 450MW
Surabaya, Indonesia
Technical and Administration Proposal - Volume I Preliminary commissioning and Test Guideline
Nov, 2014
Consortium of SEPCOIII – REKADAYA
Preliminary Test Guideline
1.General.
Upon completion of construction and throughout start-up and commissioning of GT, HRSG, Turbine and other auxiliaries, contractor will perform various tests to demonstrate that the equipment in the scope of contractor supplied, comply with this contract.
Herein is the general test guideline for Owner’s information and the final test procedure will be issued during the execution stage
1.1 Guideline and Test Procedures
The object of the tests is to demonstrate that the facility complies with requirement of the specifications, standards and codes. Test procedure will be submitted to the owner for approval prior to test, which include a summary defining the tests to be conducted, their durations, acceptance criteria, scheme for direction of test and test code, format for recording / calculation of test results, corrections to be applied and corresponding correction curves, sequence and general conditions. Test procedure will be developed to include test requirements to allow a complete understanding of how the testing will proceed, what the quality of the tests are expected to be and consequently what the quality of the test results will be.
1.2 Testing Sequence.
The Testing will be performed in following order:
1.2.1 Pre-commissioning
1.2.2 System commissioning
1.2.3 Start-up test
1.2.4 Performance test
1.2.5 Reliability run test
1.3 Test Coordinator.
Contractor will assign a test coordinator who has overall Contractor responsibility for implementation of each of the tests, and who will carry out the Test Procedures (the “Test Coordinator”). The Test Coordinator will supervise all of the test preparatio n,
implementation and computation of the results. The Test Coordinator will also serve as the interface between Owner’s operations and management personnel, plant engineers, the test crew, Owner’s representatives, and others as applicable.
1.4. Test Reports.
Contractor will prepare test reports for each of the tests (other than the pre-commissioning tests) and each test report which will be provided in the format of CCC files (CCC: commissioning clearance certificate), at a minimum, shall include:
1.4.1. An executive summary containing a summary of the tests;
1.4.
2. An introduction including general information about each test, diagrams of the test boundary(s), test personnel and organization, etc.;
1.4.3. An acceptance criteria section detailing the criteria required to successfully pass or achieve each test;
1.4.4. An outcome, calculations and results section, including tabulations of measured data, calculations of the results, verification that equipment was operating in its normal range, etc.;
1.4.5. An instrumentation section containing tabulations of instrumentation employed in the tests and description of data acquisition system, etc.
1.4.6. A conclusions section containing a detailed discussion of the test results and any issues;
1.4.7. An appendices section containing copies of the original data acquisition system print-outs and any other data sheets, alarms that annunciated during the relevant test, screen printouts during the Test, etc.
The hard copies of each test report will be delivered to Owner.
2.Pre-Commissioning
The objective of the pre-commissioning activities is to demonstrate that the construction phase of the works, system and equipment are complete and ready for turnover to the start-up / commissioning teams. The Contractor shall supervise the pre-commissioning activities. At a minimum, the following pre-commissioning activities will be completed:
2.1 Pressure testing of all required equipment and systems in accordance with the codes and standards referenced in the Design Specifications;
2.2 Cleaning of piping systems and vessels;
2.3 Alignment, coupling and equipment guarding of rotating equipment;
2.4 Rotational direction checks of all rotating equipment;
2.5 Balancing of all rotating equipment;
2.6 Switchgear functional testing;
2.7 Control system, PLC and data acquisition system check out;
2.8 Calibration of all instruments (including all meters); and
2.9 Loop check.
The Contractor will carry out all pre-commissioning tests.
3.System Commissioning
When the Mechanical Complete has have been obtained, the system shall be handed over from erection to commissioning. The purpose of commissioning tests is to demonstrate that the independent systems can run safety and steadily. The following test scope is provided for reference only.
3.1 GT System Commissioning Including,
3.1.1 Lube oil system
3.1.2 Air inlet and exhaust system
3.1.3 Cooling water system
3.1.4 Fuel supply system
3.1.5 Gas turbine system
3.1.6 Load Commutated Inverter system
3.1.7 Excitation system
3.1.8 Generator system
3.2 I&C System Commissioning Including,
3.2.1 DCS system
3.2.2 Continuous emission monitoring system
3.2.4 Logic protection and interlock
3.3 Electrical System Commissioning Including,
3.3.1 Auxiliary power system
3.3.2 Excitation system
3.3.3 Generator system
3.3.4 UPS system
3.3.5 Intercommunication system
3.3.6 DC system
3.4 BOP System Commissioning Including,
3.4.1 Water treatment system
3.4.2 Water distribution system
3.4.3 Fire detection& protection system
3.4.4 Compressed air system
4.Start-up Test
All necessary adjustments will be made during this period. The original operation enables the facilities to be made ready for performance test.
4.1 GT start up
4.2 Electrical test during startup
4.3 CCGT start up
4.4 Electrical test during CCGT start up
5.Performance Test of Power Plant
The purpose of the Performance Test is to prove that the Plant can achieve the Performance Guarantees values as described in the EPC Agreement under the reference site condition. All correction curves (including :ambient temperature, pressure, humidity, frequency, fuel composition, cooling water temperature, degradation etc. ) and the performance procedures will be submitted at least 90 days before the scheduled test date for Owner's approval. The results of the Performance Test will be compared to the Performance Guarantees.
The owner shall prepare enough design fuel and required test load for the test. The representatives of the Contractor, manufacturer and Owner shall be present and check unit test conditions jointly and sign on recording sheet before the commencement of the test to make it effective. The Contractor shall record the data, after the test and all representatives shall sign on the recording sheet for the test result to be effective. The samplings shall be sent for analysis by qualified and recognized assay organizations.
The following Performance Tests will be completed:
Gross Power Generation
Auxiliary Power Consumption
Plant Heat Rate
Net Plant Heat Rate
6.Reliability Run Test
Reliability Run test shall be undertaken jointly with the Owner after completion of Performance Tests.
The duration of the Reliability Run test of the GT shall be spread over a period of ninety six (96) hours at different load regimes or any other load as agreed by the Owner.
The duration of the Reliability Run test of the Block shall be spread over a period of thirty (30) days at different load regimes or any other load as agreed by the Owner.
The Reliability Run may be interrupted on a maximum of three (3) occasions, if such interruption lasts no more than four (4) hours between opening and closing of the generator breaker, as a result of equipment or operator failure, provided that the Owner is notified of the interruption in good time. The Reliability Run of the Block will be extended by the duration of any forced outage, due to defects attributable to the Bidder in the Block.
The Contractor shall carry out a reliability run on Gas for a period of one hundred and sixty eight (168) hours during which time the Facility shall operate continuously (without interruption) for seventy-two (72) continuous hours at the base load. The output during the remaining ninety six (96) hours of the test will be as requested by the Owner
This test shall have been satisfactorily completed if the reliability run on Gas continues without interruption (arising out of factors internal to the Facility) for not less than one hundred and sixty eight (168) hours. In the event that the reliability run is interrupted for reasons external to the Facility, the accumulated testing time prior to such interruption shall be deemed acceptable for testing purposes. The Contractor shall be required to carry out the reliability run only for such remaining period after such interruption ceases and the reliability runs carried out during the period prior to the interruption and the period after the interruption shall be deemed as one continuous period as if such interruption had not occurred.
7.Provisional Acceptance of the First GT and BOP System
Provisional Acceptance of the first GT or BOP system will be achieved upon the Contractor meeting to the Minimum Performance Guaranteed Values as described in the EPC Contract and Reliability Run Test for the GT respectively.
The PAC shall be considered issued by the Owner after completion of Performance Tests and Reliability Run.
8.Taking-Over of the Power Plant (each GT and Power Block)
Upon completion of Reliability Run test, as soon as practicable, the Taking-Over Certificate of the Power Plant shall be issued by the Owner.
9.Final Completion of the Power Plant
The Final Acceptance Certificate (FAC) will be given by the Owner after the expiration of the warranty period.。