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

TWINPAC™ and SWIFTPAC™ Commissioning Manual

United Technologies Corporation Pratt & Whitney Power Systems 80 Lamberton Road Windsor, CT 06095 Revision 4 October 6, 2006

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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.

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FT8™ COMMISSIONING MANUAL REVISION RECORD Revision Number

Date of Issue

Initial Issue

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Issued By K. Nagy

Rev 1

September 12, 2001

J. Picard

Rev 2

March 1, 2002

M. Cowan

Rev. 3

December 15, 2002

M. Cowan

Rev. 4

October 6, 2006

M. Cowan and K. Nagy

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FT8TM 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 LightOff, 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 OnLine 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

10/22/10

Oct 22/10 Rev -

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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.

TR-10-02 Instructions, Page 1 of 1

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FT8 COMMISSIONING MANUAL AND SIGN-OFF SHEETS TABLE OF CONTENTS PROCEDURE 01 02 03 04 05 06 07 08 09 09 09 09 09 09 09 09 09 09 10 11 12 13 14 15 16 16A 16B 16C 16D 16E 16F 16G 16H

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TITLE Table of Contents Site Specific Data Air Conditioner Battery Banks, Battery Chargers & Inverter Piping Systems Inspection, Testing, Cleaning and Fluid Fill Fuels, Water and Lube Oil Sampling Inspection of System Junction Boxes and Connectors Grounding Electrode System and Equipment Grounding Conductor Visual Inspection Inlet Filter, Inlet Plenum and Engine Inlet Inspection MCC and Motor Rotation Panel ACD 1 Panel ACD 1 (Mobile Pac) Panel ACD 2 Panel ACD1A Panel ACD 1B Panel ACD 1G Panel ACD 4 Panel DCD 1 Panel DCD 2 NL and NH Rotation Vibration Monitors Manual Transfer Switch Auto Transfer Switch Gas Turbine Engine Heat System Initial Software Loading Engine and Unit Control Discrete Inputs – Pressure, Temperature, Level and Position Switches Other Contact Closures T5.0 Thermocouples (Cr./Al, Type K) RTDs 100-Ohm Analog Inputs NL, NH and NP Speed Transducers Pressure Transducers Clutch, Igniters and Shut-off Valves (SOVs) Generator RTD Calibration

SOS PAGE 13 15 20 21 24 36 37 41 43 44 51 53 55 56 57 58 59 60 61 63 64 67 68 69 70 71 71 79 80 82 87 89 97 103

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16I 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

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IGV, VSV and Fuel Valve Resistance Check, Calibration and Driver Setup Fire Protection System Hydraulic Start System Chip Detectors Airpax Tach-Pak 3 Flow Meters Alignment Verification Lube Oil Functional Test Cold Air Buffer System Thrust Balance Evaporative Coolers Fuel Forwarding and Conditioning, Liquid and Gas Incomplete Sequence Starts Initial Light-Off, Power Turbine Start-up and Break-in Overspeed Test High Voltage Switchgear Protective Relay Calibration and Testing Short Circuit Test Phasing and Synchronization Checks Breaker Closure and On-Line AVR Tests Water Injection System Full Load Data Run Drop Load Test (Optional Procedure) Water Wash System Performance Testing Black Start Diesel

105 111 114 116 117 119 121 122 125 128 131 132 136 137 139 140 142 145 146 149 152 154 156 157 158

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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.

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•

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 Managers master-commissioning book.

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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:

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•

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.

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•

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.

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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.

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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

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PWPS MANUAL CHANGE RECOMMENDATION FORM Date: From: To: Technical Publications Supervisor

Company: 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):

Signature:

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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.

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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 480VAC, 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 480VAC, 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.

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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.

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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 SignOff 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.

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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.

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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.

3.

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

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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

24-VDC Operating Point

125-VDC Operating Point

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 or Loss of AC Input

Battery Charger Failure or Loss of AC Input

Annunciation

Either leg Grounded

Either leg Grounded

24-VDC – Annunciation 125-VDC – Unit Emergency Shutdown

Battery Charger Failure Battery Ground

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. 2. The AC breaker trips due to over current or high voltage shutdown. 3. The battery charger is manually shut-off.

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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.

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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: Float voltage: Equalize voltage: Low voltage alarm: High voltage alarm: Low current alarm: Max current limiter:

60 (GnB Model 6-90A07, 265AH cell voltage of 2.23 to 2.27VDC) 135-VDC 138-VDC 118-VDC (Falling) 145-VDC (Rising) 3A 66A (110%) 24-VDC Charger (CPI Model BCF3-12-150-[380 or 480])

Batteries: Float voltage: Equalize voltage: Low voltage alarm: High Voltage alarm: Low current alarm: Max current limiter:

12 (GnB Model 6-90A07, 265AH cell voltage of 2.23 to 2.27VDC) 27-VDC 27.6-VDC 23-VDC (Falling) 29.5-VDC (Rising) 3A 165A (110%)

3.10 Inverter The inverters are installed, powered and tested at the factory. accordance with the following procedure:

They are powered in the field in

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

3.10.2 Inverter Shutdown 1. Press transfer to bypass pushbutton.

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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.

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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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Liquid Fuel System Gas Fuel System Water Injection System Gas Turbine Lubricating Oil System Electric Generator Lubricating Oil System Hydraulic Control Oil System Hydraulic Start System Engine Bleed System Engine Heat System Buffer Air System Water Wash System Vent and Drain System Fire Protection System 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.

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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.

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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.

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

Electric Generator Lube Oil System

See Brush Generator 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. Wipe out any particulate with dust free rags.

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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, Appendix A this manual. (Shell Dolium R or Chevron SRI)

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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,

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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.

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“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. 8. Personnel involved in the cleaning procedure should use Personal Protection Equipment (PPE), including but not limited to hard hats, safety glasses and hearing protection, as applicable.

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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.

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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.

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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

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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.

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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 (2-2C) 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.

Figure 4-2 Hydraulic Start Flush Procedure Temporary Circuit

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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.

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

Include factory

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.

4.7.5 Accumulators

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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 highpressure gearbox driven pump and 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 440 PSIG for Ambient Temperatures 470 PSIG for Ambient Temperatures

–20°F to 20°F >20°F But < 50°F >/= 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. 8. Adjust the pressure, if necessary, such that it complies with specification.

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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

4.7.6.2 Flushing 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.

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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.

4.7.8.2 Flushing 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.

3.

Energize SOV701.

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Pratt and Whitney Power Systems, Inc.

Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 10-01

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 highpressure 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.

4.7.12.3 Flushing, Blow-down and Purge 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.

4.7.13.2 Flushing, Blow-down and Purge 1.

Open the tray drain on the evaporative cooler.

2.

Open the supply line to the evaporative cooler.

3.

Flush until supply is clear.

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Pratt and Whitney Power Systems, Inc.

Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 10-01

4.7.14 Inlet Fogger System 4.7.14.1 Proof Test and Leak Check Piping to the inlet fogger skid should be proof tested during test of customer piping to the water injection skids. Perform leak check during initial system operation.

4.7.14.2 Flushing, Blow-down and Purge Flush during water injection skid flush.

4.7.15 Fire Protection System Fire protection piping to be installed and tested to NFPA requirements. Refer to Procedure 17 in this manual. Prior to installing the discharge nozzles and the secondary air fan damper control pneumatic actuators, blow down the piping from the CO2 bottle rack to the nozzle(s) and actuators using clean, dry compressed air or nitrogen.

4.7.16 Vents and Drains System Each site is fitted with a unique drainage system to handle effluent from the various skids and enclosures. Experience has shown that improperly connected piping creating backpressure, lack of adequate venting and drain tank level indication malfunctions have lead to combustible fluids entering engine enclosures resulting in fires. While responsibility for the site drainage design is not generally within the PWPS scope, site personnel are encouraged to understand how the entire system functions in order to assure compliance with PWPS requirements and overall reliability, environmental compliance and safety. The following is a brief description of PWPS drainage systems. Additional information can be found on the P&ID’s (181 drawing series). PWPS enclosure drains are routed to the edge of the foundation where they typically tie into site drainage system. The engine enclosures also include a segregated venting system to avoid the possibility of gas fuel being introduced into the liquid drains. The engine enclosures operate at a positive pressure induced by the secondary air fans. This produces a positive pressure in the floor drains. The generator enclosure operates at a negative pressure induced by the generator rotor mounted cooling air fans. The drain systems between the enclosures must be isolated or equipped with traps to prevent flow from one enclosure to the next. The hydraulic start skid, fuel filtering and metering skids, duplex filter skid, fuel forwarding skid, gas scrubber skid and fuel heater skid are also equipped with vents and drains which may tie into a common drain system. Site personnel, including PWPS, Customer, Contractor and other Third Party personnel should review the drain/vent design and carefully inspect the installation to assure conformance with the design intent. Inspection attributes should include but not be limited to: •

Floor drains open and not covered or plugged

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Pratt and Whitney Power Systems, Inc.

Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 10-01

•

Vents for drain tanks installed and appear adequate

•

Piping vents appear adequate and are routed to safe elevations and areas

•

Drain tank level alarms functional

•

Flame arrestors (where specified) installed

•

Relief valves not hard piped to drain (could create backpressure on relief and drain)

•

No obvious drain path directly to the ground or places creating environmental issues

NOTE These attributes vary depending on site design. The intent is to highlight the importance of the drainage function and assure safe, reliable operation to the extent possible.

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PROCEDURE 05 - FUEL, WATER and LUBE OIL SAMPLING CHECKOUT PROCEDURES 5.0 Fuel, Water and Lube Oil Sampling and Analysis Checkout Procedures Lube oil sampling and analysis is to be accomplished in accordance with TPM Service Bulletin No. 6. All fuel, water and lube oil samples are to be sent to the laboratory specified by PWPS. Acceptable laboratory reports are to be received by the PWPS Site Manager before any liquid fuel, gas fuel or demineralized water is introduced into the engine. All analysis must conform to the requirements and limits of the following specifications that can be found in Appendix B of this manual: 1. PWPS Specification FR-1, Gas Turbine Liquid Distillate Fuel Requirements 2. PWPS Specification FR-2, Gas Turbine Natural Gas Fuel Requirements 3. PWPS Specification TPM-AR-1 Gas Turbine Injection Water Requirements 4. PWPS Specification TPM-AR-2 Potable Water Quality Inspection 5. Service Bulletin No.6, Approval of, and Sampling Procedure for, Oil and Lubricant, Synthetic Fuel and water samples are to be collected after the last chance filters before introduction into the engine. Temporary sampling ports may be installed for convenience. Sampling ports are to be removed and capped or plugged prior to full commercial operation. Install a temporary valve and tube arrangement at the hydraulic start pac charge pump discharge to collect an oil sample for analysis. Remove the tubing and replace the factory-supplied plug after flushing and sampling is completed. Required components are included in the SWIFTPAC™ field flushing kit, BOM Item 173. Include laboratory test results in the Sign-Off Sheets and complete the necessary data in the spaces provided.

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PROCEDURE 06 - INSPECTION OF SYSTEM JUNCTION BOXES AND CONNECTORS 6.0 Inspection of System Junction Boxes and Connectors 6.1 Power Island All power island junction boxes are listed on the Sign-Off Sheets. Not all junction boxes are applicable to all units since SWIFTPAC™ and MOBILPAC™ unit boxes are included. Open each of the listed junction boxes and complete a through inspection in accordance with the listed guidelines. 1. Check for loose, missing or non-terminated conductors. 2. Check terminal tightness with a screwdriver. Check terminal security by tugging on conductors. 3. Ensure that all junction box penetrations are sealed. 4. On SWIFTPAC™ and MOBILEPAC™ units ensure that the quick disconnect connectors on junction boxes are properly torqued as per the values listed in the Table 6-1 below. 5. On SWIFTPAC™ and MOBILEPAC™ units ensure that the quick disconnect connectors on the engine enclosures and the control house are properly torqued as per the values shown in Table 6-1 below. 6. Ensure that each junction box is properly connected to the earth grounding bus. 7. Ensure that doors are properly bonded to the box. 8. Verify that ring lugs are used on CT circuits in the neutral cubicle. 9. Check for secure mounting of components in the neutral cubicle. 10. Ensure that the flex links in the neutral cubicle are correctly installed, bolted and that bolts are torqued as per the values shown in Table 6-1 below. 11. Inspect flex links in the bus duct at the generator and at the control house. Ensure proper bolting, bolt torque and insulation. Bolt torque values are listed in Table 6-1 below and are posted in the bus duct. 12. Check bus duct joint torques by removing the inspection plates and boots. Replace the boots and inspection plates after verifying that torques are proper. Note any discrepancies in the SignOff Sheets. 13. All shutoff valves and relays are to be equipped with a surge suppression device. Back to back Zenier diodes IPB20541A (125-VDC) or IPB21077C (24-VDC)) are placed across the coils of valves. These are usually mounted on the terminal strip nearest to the valve. Ensure that all suppressors are in place in accordance with the Unit Control Schematic, PWPS drawing XXXX187-E101D, and as listed in Section 06 of the Sign-Off Sheets.

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6.2 Control House Panels 1.

Check for loose, missing or non-terminated conductors in control and switchgear panels.

2.

Check terminal tightness with a screwdriver. Check terminal security by tugging on conductors.

3.

A single diode (IPB-21702) is used for suppression on electromechanical relay coils. The single diode suppressors are polarity sensitive; verify that they are mounted correctly (cathode connected to the positive side (+).

4.

Verify that all connectors on equipment including Field Termination Modules (FTMs), Micronet, MAVR, etc. are secure.

Size

M10 M12 1 3⁄4-Inch 2 1⁄4-Inch 2 3⁄4-Inch 1⁄4-Inch 3/8-Inch 1⁄2-Inch 5/8-Inch

Torque

21 Ft-Lb (28NM) 33 Ft-Lb (45NM) 11 Ft-Lb 13.5 Ft-Lb 15.5 Ft-Lb 5-7 Ft-Lb; 0.7-0.97 KG-M 20-30 Ft-Lb; 2.8-4.2 KG-M 35-50 Ft-Lb; 4.8-6.9 KG-M 55-70 Ft-Lb; 7.6-9.7 KG-M

Remarks

Metric size in neutral cubicle Metric size in neutral cubicle Quick disconnect coupling nut shell size 12 Quick disconnect coupling nut shell size 16 Quick disconnect coupling nut shell size 20 HV Bus Duct HV Bus Duct HV Bus Duct HV Bus Duct

Table 6-1 Torque Table

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PROCEDURE 07 - GROUNDING ELECTRODE SYSTEM AND EQUIPMENT GROUNDING CONDUCTOR VISUAL INSPECTION 7.0 Grounding Electrode System and Equipment Grounding Conductor Visual Inspection CAUTION Rubber floor mats must be installed in the control house prior to energizing the MCC with temporary or permanent power.

NOTE Portions of this procedure pertaining to the control house, enclosures and skids to be partially assembled for factory testing must be completed prior to powering the control house or associated equipment. All equipment must be connected to an approved earth ground prior to energizing temporary power. Complete the inspections listed below in Steps 1 through 11 prior to energizing power. Perform pull test of bonding straps and conductors. Inspect connections to painted surfaces and ensure that a good metal-to-metal connection has been made. Perform continuity checks as applicable. 1. Inspect the equipment ground connection to the ground grid connections as listed on the Sign-Off Sheets for conformance to Assembly Grounding Field Electrical drawing XXXX-123-E300D, Sheet 1. Connections shall be physically secured to the terminal lug and ground strap. Cable shall be free of damage at the connection to the grid and connection points will be free of paint and corrosion. Thermal welds shall conform to the manufacturer’s requirements. 2. Verify adequate conductor size per article T250.60 of the National Electrical Code (NEC). 3. Verify that all specific grounding devices are UL and/or CE listed devices. 4.

Verify all junction boxes have ground wires securely connected to a grounding lug and to the grounding grid. Ensure that junction box doors to junction boxes containing greater than 100 volts potential are adequately bonded to the junction box.

5.

Verify that all cable trays are grounded and that bonding straps between sections or a continuous ground conductor are installed.

6.

Verify all Control Room interior ground straps are secured correctly. Verify that exterior doors, MCC doors, control panel doors, battery enclosure doors, battery charger doors, switchgear doors and other equipment doors are securely bonded.

7.

Ensure that all distribution panels are fitted with a neutral bus and grounding connections per the drawings. Ensure that panel doors are bonded.

8.

Ensure that the hydraulic start motor has a supplemental grounding strap from the motor to ground.

9.

Verify that all shields are correctly single-point grounded.

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10. Complete ground grid testing as per the customer's requirements, as necessary. 11. Complete Sign-Off sheets and note any discrepancies.

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PROCEDURE 08 - INLET FILTER, PLENUM, GENERATOR AND ENGINE INSPECTION PROCEDURES 8.0 Inlet Filter, Plenum, Generator and Engine Inspections 8.1 Engine Inspections It is essential that maximum personal attention be given to the overall cleanliness and structural integrity of inlet filters, plenums and inlet sound baffling and instrumentation. This is of such importance that the following items must receive the personal attention of the engineer in charge of each site: 1. Before installation, all inlet filters, baffles and sound packaging material should be inspected for shipping damage, defects in workmanship, and other signs of possible deterioration. Filters should be inspected for condensation or water damage, tears, and manufacturer defects. 2. It is extremely important that the sealed integrity of the clean air path be maintained. All seams, joints, welds and connections must be inspected. The inspector should enter the clean air path and inspect for light leaking into the clean air chamber. Any openings must be adequately closed by welding, bolting, and application of RTV silicone sealant or other PWPS approved method prior to running the engine. Special attention should be focused on the joints between the filter element frames. RTV should be applied to joints from the outside to prevent it from coming loose and entering the engine clean air path. 3. After all inlet baffles, inlet filters, and other sound packaging, including all flashings, have been installed, the filter area and the installed baffles should be given a clean sweep-down followed by a blow-down using compressed air. This may be accomplished with a broom, vacuum cleaner and/or other mechanical means. 4. The compressed air blow-down may be accomplished with a jet fashioned from a single piece of tubing or a wand with multiple holes, passed between the baffles over their entire length and height.

CAUTION PPE not limited to hardhat, eye and ear protection must be worn when performing blow-down. 5. Following the blow-down of the baffles, all small, inconspicuous areas, ledges, etc. should be given a hand inspection for the purpose of detecting and removing all pieces of slag, loose rivets and bolts, pieces of weld rod, etc. All bolts in the inlet plenum, regardless of their position, on hinges, inspection windows, ice detectors, temperature sensing probes, etc., must be either safety wired or tack welded or, in the case of bolts for which nuts need not be removed for maintenance, the bolts may be peened over.

NOTE Remove everything that can become FOD before entering inlet plenum. If possible, remove footwear to maintain level of cleanliness within plenum area. Inventory all items prior to and just before sealing the plenum. If there is an item missing from the inventory, the engine cannot be started until the issue has been resolved.

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6. Following the completion of all erection and checkout work in the filters area and plenum and, prior to motoring the gas turbine, a final inspection by the engineer is to be accomplished and the engine inlet shipping covers removed. 7. Inspect the engine nose cone area i.e., tab locks peened over properly and nose cone bolts checked for tightness. 8. Check Engine A inlet plenum. 9. Check Engine B inlet plenum. 10. Close and bolt the inlet plenum door

8.2 Generator Inspections 1. The generator is handed by the location of the oil service module on the right hand side (RHS). 2. The generator ends are referenced by the pilot exciter end (PEE) and main exciter (MEE). 3. The core compartments are counted 1 through 5 from the pilot exciter end (PEE) of the generator. 4. The inspection shall be performed in conjunction with the Generator Representative and in accordance with the Vendor’s "Generator Site Inspection Procedure" shown in Tables 8-1 and 82 below. Tables 8-1 and 8-2 are provided for reference only.

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LOCATION

CONTAMINATION

Generator Enclosure

Yes / No

Generator Air Inlet Filters

Yes / No

Generator and Exciter Air Inlet Screens

Yes / No

Exciter Air Outlet Screen

Yes / No

Pilot Exciter End Air Inlet Compartment Floor and Ledges Pilot Exciter End Winding Compartment Floor and Ledges Core Compartment 1 Floor and Ledges Core Compartment 2 Floor and Ledges Core Compartment 3 Floor and Ledges Core Compartment 4 Floor and Ledges Core Compartment 5 Floor and Ledges Main Exciter End Winding Compartment Floor and Ledges Main Exciter End Air Inlet Compartment Floor and Ledges All Accessible Areas of the Core Enclosed by the Exhaust Ductwork

LHS

Yes / No

RHS

Yes / No

LHS

Yes / No

RHS

Yes / No

LHS

Yes / No

RHS

Yes / No

LHS

Yes / No

RHS

Yes / No

LHS

Yes / No

RHS

Yes / No

LHS

Yes / No

RHS

Yes / No

LHS

Yes / No

RHS

Yes / No

LHS

Yes / No

RHS

Yes / No

LHS

Yes / No

RHS

Yes / No

DESCRIPTION OF CONTAMINANTS

Yes / No

Table 8-1 Generator Inspection Stage 1

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LOCATION

CONTAMINATION

Rectifier Assembly Rotor Fan Blades

Rotor End Cap

Rotor Fan Baffle

Borescope examination of rotor surface Borescope examination of rotor end windings Borescope examination of rotor sub slots

DESCRIPTION OF CONTAMINANTS

Yes / No MEE

Yes / No

PEE

Yes / No

MEE

Yes / No

PEE

Yes / No

MEE

Yes / No

PEE

Yes / No

MEE

Yes / No

PEE

Yes / No

MEE

Yes / No

PEE

Yes / No

MEE

Yes / No

PEE

Yes / No

Table 8-2 Generator Inspection Stage 2

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PROCEDURE 09 - MOTOR CONTROL CENTER AND MOTOR ROTATION CHECKOUT PROCEDURES 9.0 Motor Control Center and Motor Rotation Checkout Procedures CAUTION Follow the standard safety guidelines when working with power equipment. Obey all local tagging and lockout procedures. Use adequate Personal Protection Equipment (PPE).

9.1 Visual and Mechanical Inspection of Motor Control Center NOTE Switchgear not energized. These are normally factory checks performed and documented by the Control House Vendor. 1. Circuit breaker shall be checked for proper mounting, conductor size and feeder designation. 2. Operate the circuit breaker to ensure smooth operation. 3. Inspect the case for cracks or other defects. 4. Check tightness of connections with calibrated torque wrench. Refer to manufacturer's instruction. 5. Check internals on unsealed units. 6. Remove all blocking material used for shipment. 7. Check motor overload relays for proper current range, in accordance with the motor nameplate full load amperes. 8. Check the closing coils for proper operating voltage. 9. Check all auxiliary contacts for correct arrangement with coil de-energized, i.e., normally open or normally closed. 10. Check all fuses or air circuit breakers for proper rating. 11. Check secondary fuses, on motor starter control power transformer supply, for proper rating. 12. Check resistance of all wiring to ground and between phases. 13. Record required data on Check-Off Sheets.

NOTE MTS - Magnetic Trip Setting OVLD - Overload Size

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9.2 Meggering of Motor Control Center (MCC) Circuits CAUTION The 380/480-VAC circuits and field run wiring only may be meggered. Do not megger DC circuits or any low voltage circuits where devices or components may be subjected to test voltage. Do not megger the variable frequency drives (VFDs). Megger motor leads with wiring disconnected from the VFD. 1. Ensure that all MCC feeder breakers and switches are "OFF" and "OPEN" and “Tagged Out”. 2. Ensure that all function switches and selector switches are "OFF" or in "AUTOMATIC". 3. Ensure that alternative feed breaker or tie - breaker is "OPEN". 4. Check equipment ground to assure continuity of connections and check that there is no voltage on load side of breaker. 5. With meg-ohmmeter, test MCC bus at 500-VDC phase to phase and phase to ground with all breakers and disconnects open. Resolve any abnormal readings prior to proceeding. Record in Check-Off Sheets. 6. With meg-ohmmeter, test each motor and heater wiring at 500-VDC phase to ground from MCC buckets through the motor windings or resistive heating elements. Resolve any abnormal readings prior to proceeding. Record results in Check-Off Sheets.

9.3 Electric Motor Checks - Motor Winding and Rotation 1. Open and tag motor breaker. 2. Check motor leads and check bucket for loose connections. 3. Check equipment ground to assure continuity of connection. 4. Using an ohmmeter, measure the phase to phase resistances of each motor or heater. Record the results on the Sign-Off Sheets where indicated. 5. Liquid systems must have fluid over pump inlet (flooded suction) before rotation is checked. 6. Station someone at the motor to watch rotation. Clear the area of personnel for initial rotation check. 7. Observing all applicable site safety, tagging and lockout procedures energize the 3-phase 380/480-VAC power feed to the MCC. 8. Determine the correct motor rotation direction by markings on the driven device or other instructions. Remove the tag from the breaker and bump the motor observing rotation direction. Correct rotation if required.

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9. If rotation is found to be incorrect, clear and tag the breaker. Change any two (2) of the motor leads and check again. Note rotation check on the Sign-off Sheets. 10. After the system is operational, run the motor for at least ten (10) minutes to ensure equipment reliability. Measure running amps-per-phase and record on the Sign-Off Sheet. Motor running amps should be recorded under actual motor running conditions when the system is fully commissioned. Flushing amps for pumps used for flushing are not required, but may be noted for reference.

9.4 Fuel, Space and Equipment Heaters 1. The equipment should be inspected for secure mounting and proper installation. All piping connections should be tight and checked for leaks during system flushing. All conduit connections should be tight.

WARNING Do not energize immersion heaters unless the system has been filled with the correct operating fluid and heater elements are fully covered by fluid. Bleed air from heater casings as required. 2. Use an ohmmeter to check phase-to-phase resistance and record results on the appropriate Sign-Off Sheet. Check each heater system on the station drawings to determine point(s) of temperature control (station control, local thermostat, etc.). 3. After power is available and the appropriate control loop has been checked, set the operating temperature of each individual heater system. Post personnel caution notices as necessary.

NOTE Engine heat is a self-contained subsystem powered via the 3-Phase, 380/480-VAC distribution panel ACD2, circuits 5 (Engine A) and 6 (Engine B). Refer to Procedure 14 for checkout and startup of this unit.

9.5 Distribution Panels 1. The control house includes up to seven (7) distribution panels to supply 3-Phase, 380/480-VAC sub-systems, single-phase 220/110-VAC loads, single-phase 110-VAC loads, 125-VDC loads and 24-VDC loads. 2. New units (SP61 configurations) have fewer distribution panels in the control house, but have relocated one panel into each enclosure. 3. Each panel and its components are to be thoroughly inspected and cleaned before power is applied to the main breaker. 4. Check for proper installation and wiring per drawings and secure connections. 5. Check the ground bus for continuity to a known good ground. 6. Check each circuit breaker for proper operation.

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7. Prior to energizing any circuits, the load side of the breaker should be checked with a meter to assure that no shorts, grounds or feedback voltage exists.

NOTE One leg of the 110-VAC circuits is grounded. Some configurations may have a 110-VAC configuration with a center tap to ground yielding a 500-50-volt to ground system. 8.

Resolve all discrepancies prior to powering circuits.

9.

Prior to energizing any circuits, ensure that connected loads have been inspected and are ready for operation. Ensure that operating fluids have been installed as required.

CAUTION Follow and obey all applicable tagging, lockout and safety procedures. Use adequate Personal Protective Equipment (PPE). 10. Clear, check and energize circuits, as required, to support commissioning efforts and schedules. Record required data on the Sign-Off Sheets.

9.6 Low Voltage Motors The gas turbine lube oil tank mist eliminator motors and chip detector modules are powered from the 110/220-VAC single-phase, distribution panels. 1. Check winding resistance and grounds. 2. Record results on the sign off sheet.

9.7 MCC Input and Output (I/O) Checks Each motor controller bucket (except VFD and Soft Start) sends a RUN and OVERLOAD output to the station control system. Heater buckets send only a RUN signal. The Hydraulic Start Fan Motor bucket sends no I/O signal to the control. With the bucket main breaker OFF, operate the RUN contact and the OVERLOAD contact for each bucket and verify the correct indication on the Station Monitor. Complete Sign-Off Sheets as required.

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PROCEDURE 10 - LOW COMPRESSOR AND HIGH COMPRESSOR ROTATION CHECKOUT PROCEDURES 10.0 Low Compressor and High Compressor Rotation Checkout Procedures The low compressor (NL) and high compressor (NH) rotors must be checked for freedom of rotation before motoring and lighting off the engine.

WARNING While turning the NL and NH rotors manually, it is most important to eliminate any chance of an inadvertent start initiation or engine motoring by locking the unit out and removing the keys from the Start Lockout Switches 43-7A and 43-7B, and by locking out and tagging the hydraulic start motor. Follow local Lockout/Tag-Out procedures.

10.1 Low Compressor Rotor The low compressor (NL) rotor may be turned by reaching through the inlet guide vanes and manually turning the rotor. Take precautions not to contaminate the clean air path to the gas turbine inlet.

10.2 High Compressor Rotor Turn the Engine A and Engine B NH rotors manually as follows: 1. Tools required (Snap On or equivalent): A.

3

B.

3

/8 Inch drive ratchet – Do not use a breaker bar /8 Inch to 1/4 -Inch reducer

C. 24-Inch long, 1/4 -Inch drive extension 2. Remove the tachometer drive cover (P/N 1080435) by removing four (4) nuts and washers. 3. Insert the adapter (P/N PWA 77542) and secure in place with the four (4) nuts and washers removed in Step1 above. This adapter will mesh with the bevel drive gear shaft P/N 446734. 4. It will require approximately 230 In/lb. of torque to turn the NH rotor through the tachometer drive pad. Liquid fuel engines may require up to 600 In/lb. of torque. 5. The rotor turns in the opposite direction from the tachometer drive. Rotate the compressor slowly in the normal direction when running.

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Tool referenced in paragraph 3 will turn this gear, PWA 446734

Figure 10-1 Hydraulic Pump Drive

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Pratt and Whitney Power Systems, Inc. Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 10-02

PROCEDURE 11 - VIBRATION MONITORING SYSTEM CHECKOUT PROCEDURE 11.0 Vibration Monitoring System Checkout Procedure (Bently 3500) – Bently Nevada 3500 System NOTE This commissioning manual is for the Bently Nevada 3500 Vibration Monitoring System with Bently rack configuration software commissioning only for SWIFTPACTM and MOBILEPACTM and with 3500/22M for communication card starting from Project-1002 •

Follow the procedure step by step. Skipping a step may cause faulty results.

•

For the sites equipped with other Vibration Monitoring Systems, please reference the following: -

TWINPACTM, SWIFTPACTM, and POWERPACTM with Bently Nevada 3500 Vibration Monitoring System with Bently rack configuration but with 3500/22M Rim Rack Interface Module, reference early commissioning manual on the section of Vibration Monitor Bently Nevada 3500 v5

-

TWINPACTM, SWIFTPACTM, and POWERPACTM with Bently Nevada 3500 Vibration Monitoring System with Bently rack configuration revision 2.71 and 3.85, locate a previous copy of the PWPS FT8 Commissioning Manual

-

VibraMetrics system & Bently Nevada 3300 Vibration Monitoring System: and/or the Bently Nevada 3300 systems, locate a previous copy of the PWPS FT8 Commissioning Manual

-

Mechanical Drive and other configurations: request modified checkout procedures

11.1

Referenced Specifications, Drawings and Manuals

11.1.1

Referenced Specifications PWPS Specification CT117711 - Vibration System Bently Nevada (External Terminations)

11.1.2

Referenced Drawings PWPS Drawing - XXXX-187-E101D PWPS Drawing - XXXX-187-E203D

Oct 22/10 Temporary Revision 10-02

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Pratt and Whitney Power Systems, Inc. Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 10-02

11.1.3

Referenced Manuals Bently Nevada Manuals: 1. 3500 Monitoring System Rack Installation and Maintenance Manual (PN 129766-01) 2. 3500 Monitoring System Rack Configuration and Utilities Guide (PN 129777-01) 3. 3500 Monitoring System Computer Hardware and Software Manual (PN 128158-01) 4. 3500 Operation and Maintenance Manuals for specific monitors 5. 330750 High Temperature Velocity Transducer Operation and Maintenance (PN 13509001) 6. PWPS 3500 Rack Configuration Supplemental Maintenance Manual (PN 146425-01) Brush Operations and Maintenance Manual: 1. Proximitor and Keyphasor Installation Drawings

11.1.4

Recommended Tools and Equipment 1. Screwdrivers - Very small tipped standard screwdriver for connections on back of rack or on external termination block 2. Two (2) digital multi-meters (DMM) - Fluke Model 87V, 0-1000-VAC/VDC, 0-10 Meg-Ohm 3. Two frequency generators with DC offset - Sinusoidal signal; Frequency ranges 0.1- to 3.0 MHzMHz; DC offset. (Alternate procedure is provided to allow use of a generator without offset capability) 4. Sine wave generator or frequency source - For speed signal injection (Fluke 744) 5. Digital frequency meter (Not necessary if Fluke Model 83 is available) 6. Two 6-foot male BNC to clip lead 7. One male - female BNC T connector

11.2

Hardware Verifications The following steps assume a TWINPAC™ configuration. For a MOBILEPAC™, there will be no card in slot 6 and slot 5 channels 3 and 4 will be inactive. For other configurations, such as a mechanical drive application, see the system drawings for configuration details.

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NOTE Disconnect Bently rack wiring to control panels before performing this check procedure.

WARNING Power off while performing hardware checks

11.2.1

Sensor and Cable Mounting Inspect each Velomitor®, Proximitor® and their cable mounting • No sharp turns on cables • Cables should be away from heat sources; S and K flange sensors’ cable should have heat shields. • All cables should be mounted firmly by mounting devices. • Use isolation materials on flange mountings as required, and an isolator should be installed with S-flange sensor. • Safety wire inspection for Proximitor® and their cable mountings. • Reference Brush Generator Manual Drawings for details of assembly for Proximitor® probes and cables.

11.2.2

1 meg-ohm Resistors on Alignment and Water Injection Channel Wiring 1. 1 meg-ohm resistors should be installed across SIG/B to COM/A for all active Alignment and Water Injection channels per drawing XXXX-187-E203D Page-5. 2. Record the results on the Sign-Off Sheet. 3. Disconnect one leg of each resistor in the INSTRUMENT CABINET. (Ref. XXXX-187E203D Page-5).

NOTE These “end of line resistors” are to help detect an open wire. One leg of each resistor must be disconnected during loop checks to avoid false readings.

11.2.3

Common Wiring Set 1. A jumper wire should be installed per the drawings between Slot-2, bottom Keyphasor® Channel-1 COM and Slot-4, Channel-4, COM/A. (Ref. XXXX-187-E203D Page-2 and -4). 2. Record the results on the Sign-Off Sheet.

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11.2.4

Speed Sensor Wiring Continuity 1. Measure the resistance between KPH and COM for all active speed pickups and the resistance should be 150 to 300 ohms. (Ref. XXXX-187-E203D Page-2). 2. Record the results on the Sign-Off Sheet.

NOTE To avoid a false reading, use an ohmmeter with less than 0.7 VDC open circuit voltage.

11.2.5

Velomitor Wiring Continuity 1. Measure the resistance between SIG/B and COM/A for all pickups on drawing XXXX187-E203D Page-4 and –6. The resistance should be between 1.3 to 1.5 Meg-ohms. 2. Record the results on the Sign-Off Sheet.

NOTE To avoid a false reading, use an ohmmeter with less than 0.7 VDC open circuit voltage.

11.2.6

Proximitor Wiring Continuity 1. Measure the resistance between SIG/B and COM/A for all pickups on drawing XXXX187-E203D Page-3. The resistance should be 1.3 to 1.5 Meg-ohms. 2. Record the results on the Sign-Off Sheet.

NOTE To avoid a false reading, use an ohmmeter with less than 0.7 VDC open circuit voltage.

11.2.7

Grounding Wiring 1. Measure the resistance between SIG/B, COM/A, and PWR to SHID (Ground) for all channels on drawing XXXX-187-E203D Page-2, -3, -4, and –6. The resistance should be greater than 100 Meg-ohms. 2. Record the results on the Sign-Off Sheet.

11.2.8

Ground Switch Position on Bently 3500/15-Power Supply Module 1. Remove the Power Supply Module from the back of the monitor in upper card Slot-0.

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2. Make sure that the single point ground switch is in the HP Closed position. (Ref. XXXX187-E203D Page-1). 3. Remount the Power Supply Module back to the rack. 4. Record the results on the Sign-Off Sheet.

NOTE For redundant Power Supply configuration, repeat 1 to 4 for the lower card in Slot-0.

11.2.9

Pin Settings on Bently 3500/42M-Proximitor/Seismic Modules 1. Check the placement of the jumpers on the back of the 3500/42M Proximitor/Seismic modules per drawing XXXX-187-E203D Page-1. 2. Record the results on the Sign-Off Sheet.

11.2.10 Set the Relay Mode switches on Bently 3500/32-Relay Module 1. Set the Relay Mode switches to NE for four channels on slot-7 per drawing XXXX-187E203D Page-1 2. Record the results on the Sign-Off Sheet.

11.3

Rack Software Configuration Installation and Verifications NOTE Before performing the following procedures: • Connect all cables to Bently rack • Turn on the power for Bently rack 1. Check the Mod file 146227.mod is placed in F:/3500/Rackcfg/Mods. 2. Indicate the correct Bently Configuration Rak file to be used for the application per drawing XXXX-189-E203L. 3. Locate appropriate Rak file *.rak from folder 3500/Trains/Primcfg /Rack files for update for 1002 on 3.93 and load it into F:/ 3500/Trains/Primcfg. 4. Record the results on the Sign-Off Sheet. 5. Connect ICE monitor’s com-1 (lower port) or com-2 (upper port) in the back of the ICE monitor to Bently Rack Slot-1, 22M card, front panel using RS232 cable provided.

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6. Open the ICE monitor F drive and locate 3500/Rackcfg/cconfig.exe. 7. Double click on the cconfig.exe file to open the Bently Configuration Software. 8. Check the software version; It should be the new revision indicated per drawing XXXX189-E203L. If not, contact PWPS for the correct Bently Configuration Software version. 9. Drag cconfig.exe file in to the computer screen to create a shortcut. 10. Double click the shortcut icon on the screen or 3500/Rackcfg/cconfig.exe to open Bently Configuration Software. 11. When the Bently 3500 Configuration Software user interface opens, click on the Open icon to locate the configuration file, *.rak, in 3500/Trains/Primcfg folder and then open the *.rak file. 12. With Option selected, open slot-1 to check the following: • • • • •

DC Low Voltage is selected for top and No Power Supply is selected for bottom under Power Supply Option. 10/100 Base T should be selected under I/O Option and it should match on card type indicated on the back of the 22 card. Under Rack IP Address, 1.0.14.0 should be written. Under Rack Subnet Mask, 255.255.0.0 should be written. Under Getaway Address, 159.134.1.0 should be written.

13. Click on Slot-14 to open the Communication Getaway user interface. 14. Change Rack IP Address to the correct IP address, such as 172.17.U.111 (U= Unit Number as 1 for unit 1, 2 for unit 2 …), and • •

Turntables in Gap (Control Assistant WinPanel) for Bently should match. Subnet Mask should be 255.255.0.0.

15. Save the configuration file, *.rak back in to 3500/Trains/Primcfg folder. 16. Turn the key in front panel of Bently rack to “Program”. 17. Click the Connect button and choose Direct Connect to open the user interface opens, then Click Connect button to connect. (No password is needed) • • •

The Com number should match the Com port chosen from ICE monitor. As default, Baud is 38400, but 19200 or 9600 can be used too. Rack Address selected as 1.

18. Open Utilities/Software Switches. At Slot dropdown, choose 1: 22M TDI-Transient Data Int. With Module Switches checked, check the Configuration Mode.

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19. Click Download to rack button to open Download Configuration user interface. 20. Click on Select All button, and click OK button to download configurations to rack. (No password is needed) 21. Click OK for following three popup windows, and wait for no less than 20 seconds for the rack to reset.

NOTE When close the window, it should indicate change made is saved If no indication of the change made saved, or if a Token error or anther error appears during download rak file to Racks: • Wait for 5 minutes for 3500/22M reset the Token. • Or Disconnect to Rack and Reconnect to Rack, and then reset the Software Switches. 1. Synchronize the Bently rack clock to Citect clock from Utilities/ Date And Time; when the window is open, click Send button to send the updated time to rack. 2. Click the Connect button to disconnect to the rack. 3. Turn the key in front panel of Bently rack to “run”. 4. Close the Bently 3500 Rack Configuration Software user interface. Click YES and OK for popup windows. 5. Record the download completion on the Sign-Off Sheet.

11.4

Static Checks/Sensor Verifications WARNING Ensure on the back of the Rack, all jumpers were installed per drawing, if not, make correction before continuing the following procedure.

11.4.1

Velomitor® Transducer Sensors and Channels 1. Measure the VDC output from the front of the rack Slot-4 and/or Slot-6 BNC output for channel-1, -2 and -3. The value should be between −7 to −12 VDC with the Velomitor connected. If the voltage is not in this range, verify –24 VDC excitation voltage between SIG/B and COM/A per drawing XXXX-187-E203D Page-4 and -6. 2. Record the results on the Sign-Off Sheet. 3. Open Bently 3500 Rack Configuration Software user interface. 4. Click the Connect button to connect to the rack.

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5. From Utilities, open Verification window to be able to see slot-4 or slot-6 channel vibration response bar. 6. Gently tap the sensor using a plastic screwdriver handle on the correct flange to check if the channel is setup correctly and if the channel responds to the taps. 7. Ensure the probe responds to the correct channel on Bently Monitor Verification window. 8. Repeat the process for all channels. 9. Disconnect the Velomitor® wires from channels 1, 2 and 3 terminals of A, S, and K flange on slots 4 and 6 monitors. 10. Measure the resistance between SIG/B and COM/A for each channel. Resistance should be between 1.3 and 1.5 meg-ohms. Use an ohm meter with less that 0.7-VDC open circuit voltage or the sensors circuitry may cause a false reading. (See Reference 5). Ensure that the 1 Meg-Ohm resistors are removed from the circuit. 11. Measure the ground resistance of each leg. 12. Record the results on the Sign-Off Sheet.

11.4.2

Proximitors® and the Gaps 1. Open Bently 3500 Rack Configuration Software user interface. 2. Click the Connect button to connect to the rack. 3. From Utilities, open Verification window to be able to see the slot-3 channel vibration response bar. 4. Measure the VDC output from one of the front rack Slot-3 BNC outputs. 5. Loosen the lock nut on a proximity probe. 6. Screw the probe in or out until the Gap reading is between −9.5 to −10 VDC. 7. Tighten the lock nut on the probe. 8. From Bently Monitor Verification window, the gap voltages should be observed the same. 9. Ensure the probe gap responds to the correct channel on Bently Monitor Verification window. 10. Repeat the process for all four channels. 11. Record the results on the Sign-Off Sheet.

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11.5

Channel Test

11.5.1

A and S–flange Channel Tests 1. Setup instrumentation per Figure 11.5.1. 2. Set signal generator output per requirements on Table 11.5.1.1 and Table 11.5.1.2. 3. Repeat test for all channels in the Table 11.5.1.1 and Table 11.5.1.2. 4. Record the results on the Sign-Off Sheet.

NOTE A tool (IPD25243) can be ordered for this test.

11.5.2

K–flange Alarm Channel Tests 1. Setup instrumentation per Figure 11.5.1 and Figure 11.5.2. 2. Set signal generator outputs per requirements on Table 11.5.2. 3. Repeat test for all channels in the Table 11.5.2. 4. Record the results on the Sign-Off Sheet.

NOTE The Keyphasor input amplitude from a signal generator has to be higher than 2 Volt to be able to reach Hysteresis setting in Bently for 2 to 2.5 Volts, and less than 10 Volts.

11.5.3

Electric Generator Channel Tests 1. Setup instrumentation per Figure 11.5.3. 2. Set signal generator outputs per requirements on Table 11.5.3. 3. Repeat test for all channels in the Table 11.5.3. 4. Record the results on the Sign-Off Sheet.

11.6

Procedure Completion 1. After testing, restore all wiring per drawings. 2. Record the results on the Sign-Off Sheet.

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3. Verify relays per table. 4. Record the results on the Sign-Off Sheet for 11.6. 5. During the first run to synchronous speed, verify that the trip multiply is removed by the control system at 2910 (50Hz) or 3492 (60Hz) NP. 6. Record the results on the Sign-Off Sheet.

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Volt Meter Signal Generator

Monitor Channel Input (Typical: A, K, S, Water Inject & Align) PWR

+

-

-

+

COM/A SIG/B

C H X

SHLD PWR COM/A

2.74kΩ Resistor

SIG/B

C H Y

SHLD 10μƒ Capacitor Figure 11-1 Signal Injection Circuit

Signal Generator Keyphasor Channel Input +

-

CH 1 PWR / NC COM / SIG KPH / SIG+ SHLD

Figure 11-2 Keyphasor Injection Circuit

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PWPS PART NUMBER

BENTLY .RAK FILE NAME

CONFIGURATION

CT117492-17

17492-17

TWINPAC™ w/ Water Injection

CT117492-17-1

17492-1

TWINPAC™ w/o Water Injection

CT117492-18

17492-18

MOBILEPAC™ w/ Water Injection

CT117492-18-1

17492-23

MOBILEPAC™ w/o Water Injection

CT117492-19

17492-19

Licensee TWINPAC™ w/ Water Injection

CT117492-19-1

17492-24

Licensee TWINPAC™ w/o Water Injection

CT117492-20

17492-20

Licensee MOBILEPAC™ w/ Water Injection

CT117492-20-1

17492-25

Licensee MOBILEPAC™ w/o Water Injection

CT117492-21

17492-21

Licensee Mechanical Drive w/ Water Injection

CT117492-21-1

17492-26

Licensee Mechanical Drive w/o Water Injection

CT117711-1

17711-14

TWINPAC™ w/ Water Injection – External Terminations

CT117711-2

17711-15

MOBILEPAC™ w/ Water Injection – External Terminations

CT117711-3

17711-16

TWINPAC™ w/o Water Injection – External Terminations

CT117711-4

17711-17

MOBILEPAC™ w/o Water Injection – External Terminations

Table 11-3 Cross Reference of PWPS Plant Configurations and Bently .rak File Names

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Volt Meter Signal Generator

Monitor Channel Input (Typical: A, K, S, Water Inject & Align) PWR

+

-

-

+

COM/A SIG/B

C H X

SHLD 2.74kΩ Resistor 10μƒ Capacitor

PWR COM/A SIG/B

C H Y

SHLD

IPD25243 Note:  If the signal generator has the DC offset function, then no need for  capacitor/resistor set, the test kit

Figure 11.5.1 A and S–flange Channel Test Diagram

Signal Generator Keyphasor Channel Input +

-

CH 1 PWR / NC COM / SIG KPH / SIG+ SHLD

Figure 11.5.2 K–flange Channel Test Keyphasor Diagram

Volt Meter Signal Generator

Monitor Channel Input (Typical: A, K, S, Water Inject & Align) PWR

+

-

-

+

COM/A SIG/B

C H X

SHLD PWR COM/A SIG/B

C H Y

SHLD

Figure 11.5.3 Electric Generator Channel Test Diagram

PROCEDURE 12 - MANUAL TRANSFER SWITCH CHECKOUT PROCEDURES 12.0 Manual Transfer Switch Checkout Procedures The Manual Transfer Switch is located on Motor Control Center (MCC), MCC-5. This switch is rated at 600-Amps. Before energizing the MCC, use a phase rotation meter to verify that the phase sequence is the same for the emergency and normal supply. The PWPS standard for phase rotation at the MCC is A-B-C, L1-L2-L3, clockwise (CW) from left to right. Verify that the phase to phase voltage is 380/480-VAC. On four (4) wire systems, verify that the phase to neutral voltage is equal to the phase voltage divided by √3 (1.732). Verify that the key interlock system is operational and visually inspect all linkages for correct configuration. Assure that the key cannot be removed from the lock mechanism when either of the breakers is closed. Verify that both breakers cannot be closed at the same time. Refer to PWPS drawings XXXX-187-E303D, Sheet 2 and XXXX-187-E307D, Sheet 1.

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PROCEDURE 13 - AUTOMATIC TRANSFER SWITCH (ATS) 13.0 Auto Transfer Switch (ATS) Refer to PWPS drawings XXXX-185-E600D, XXXX-187-E101D and the ASCO 940 Operators Manual. Verify the settings on ATS dip switches.

13.1 Checking Phasing and Voltage Level Checks. To check phasing and voltage level on normal and emergency power:

1. Using a phase rotation meter, compare phase relationship between normal and emergency power, both should be A-B-C. 2. Verify that the voltage on both sources of power is 380/480-VAC phase to phase.

13.2 Checking Transfer Due to Loss of Power 1. Ensure that the ATS switch is in the normal position and that emergency power is available. 2. Before conducting the first transfer tests, power down all equipment that will be affected by the transfer of power, notably battery chargers and air conditioning units. 3. Open the normal feed breaker. After a time delay, the ATS will transfer to the emergency power. Verify that all three phases are available. 4. Restore normal power. After a time delay the ATS will transfer back to the normal supply. 5. Observe the ATS status on the ICE monitor. 6. Restore control house loads to normal.

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PROCEDURE 14 - GAS TURBINE ENGINE HEAT SYSTEM CHECKOUT PROCEDURES 14.0 Gas Turbine Engine Heat System Checkout Procedures 14. 1 System Operation The engine heater consists of an electric heater, blower and control system mounted on the engine enclosure roof, with flexible ducting into the gas generator. The engine heater system maintains the internal parts of the gas turbine at a temperature above the dew point of the ambient air during non-operating periods. Hot air forced into the compressor section and out through the exhaust and inlet ducts prevents condensation, which can cause corrosion. The engine heating system is automatically controlled by the unit control system. Thirty minutes after engine shutdown under the correct ambient temperature conditions, a signal from the controller energizes a relay which turns on the blower and the heater. The blower supplies 740 CFM of air to the heater and increases the temperature of this air approximately 40°F above ambient. The heated air is then passed through a flexible duct fitted with a check valve and enters the engine through a flanged connection mounted between case flanges G and F at the twelve o'clock position. The blower motor is protected by a normally closed, overload relay which will turn off both the blower and the heater when activated. The heater is protected from an over temperature condition by a primary and secondary system. The primary system automatically resets and is designed to de-energize the heater if insufficient airflow, air blockage or other problems, could cause overheating. The secondary system requires manual reset and is designed to operate at a higher temperature and de-energize the heater in the event of failure of the primary system or continued operation under unsafe conditions. To protect engine heater system against loss of airflow, the heater element is interlocked with the blower motor, so that the heater cannot operate unless the motor circuit is energized. When the engine start signal is initiated, the unit controller turns off the heater and blower. The heater element is monitored for a failed element by three current sensitive switches which will activate the common alarm if any phase of the heater element opens. For single engine operation, the engine heater on the windmilling engine is also shutdown. The engine heaters are powered via circuits 5 (Engine A) and 6 (Engine B) from ACD2. Refer to Procedure 09 prior to completing this section. Engine heat should be started as soon as the unit control and 380/480-VAC are available to keep condensation out of the engine.

14.2 Inspection 1. Check that the roof mount is secure and the gasket is in place. 2. Check that all shipping materials have been removed. 3. Check that the flex ducting to the engine is installed and properly clamped.

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4. Check that the valve is free to operate. 5. Check that the air inlet filter is clear and ready to operate. 6. Check that the engine heat box is clean and free of loose debris.

14.3 Checkout Procedures Refer to PWPS drawings XXXX – 181 – M405D and XXXX – 187 – E101D, Sheets 42, 43, 46 and 47.

NOTE The unit control must be operational. 1.

Perform resistance and megger checks on the motor and heater at the heater junction box. Record results on the data sheet.

CAUTION Do not operate the unit for long periods of time with top enclosure removed. 2.

Disconnect the hose to the engine for the first run so no foreign debris is blown into the engine. Let the heater run for at least 10-minutes prior to connecting the hose to ensure nothing gets blown into the engine. See Procedure 04, Paragraph 4.8.9.

3.

Check the rotation and running amperages of the motor and record the results. Check and record the running amperages of heater. Motor current draw shall not exceed 6.7 amperes. Heater current draw should be approximately 8 amperes per phase.

4.

Inspect ductwork for leaks with the unit running.

5.

Check the operation of the automatic start signal from unit control. Perform the checks shown in Table 14-1 using Watch Windows II or Micro-panel in Debug Mode:

ENGINE

TAG NAME

ACTION

OBSERVATION

A

HC1201A

Force 2-3-C-9 True

Engine heater "A" starts

A

HC1201A

Force 2-3-C-9 False

Engine heater "A" stops

B

HC1201B

Force 2-4-C-9 True

Engine heater "B" starts

B

HC1201B

Force 2-4-C-9 False

Engine heater "B" stops

Table 14-1 Operation of Automatic Start Signal From Unit Control Checks A. Observe that engine heaters stop during the unit start sequence while performing incomplete sequence tests (Procedure 30) and restart at the end of coast down. 6.

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Each engine heater is fitted with two (2) pressure switches, which monitor the pressure in the duct between the heater and the engine. If a pressure in excess of 0.85 PSI is detected, the engine will be shut down and “Engine Heat Duct Pressure High” will be annunciated. A shutdown will not be initiated if the engine is not running.

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Each switch is to be tested by applying a pressure in excess of 0.85 PSI to the duct pressure switches and observing the appropriate input to the control as indicated in Table 14-2 below. DEVICE TAG

INPUT ADDRESS

ENGINE

PSHH1201A

2-3-A-27

A

PSHH1202A

2-3-A-28

A

PSHH1201B

2-4-A-27

B

PSHH1202B

2-4-A-28

B

ACTION

INPUT STATE

Apply Pressure Remove Pressure Apply Pressure Remove Pressure Apply Pressure Remove Pressure Apply Pressure Remove Pressure

True False True False True False True False

Table 14-2 Engine Heat Duct Pressure Checks 7.

Check engine heater common alarm. With heater operating, install a jumper in the heater junction box at TS-2, Terminal 4 to TS-2, Terminal 5. The alarm should activate. If power to the heater is turned off, the alarm should activate. Input addresses to the control are shown for reference in Table 14-3.

DEVICE TAG

ENGINE

INPUT ADDRESS

XA1201A

A

2-3-A-26

Install jumper

Engine heater alarm "A" on alarm screen

A

2-3-A-26

Remove jumper

Alarm clears

A

2-3-A-26

Remove 480-VAC power

Engine heater alarm "A" on alarm screen

A

2-3-A-26

Remove 480-VAC power

Alarm clears

B

2-4-A-26

Install jumper

Engine heater alarm "B" on Alarm screen

B

2-4-A-26

Remove jumper

Alarm clears

B

2-4-A-26

Remove 480-VAC power

Engine heater alarm "B" on Alarm screen

B

2-4-A-26

Reconnect 480-VAC power

Alarm clears

XA1201B

Heater Current =

8.5 Amps/phase

Motor Current

5.6 Amps/phase

8.

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=

ACTION

OBSERVATION

Check the operation of the current activated switches COS-1, -2 and -3. The switches should operate to activate the common alarm when current flow is less than 2 amps.

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PROCEDURE 15 - INITIAL SOFTWARE LOADING 15.0 Initial Software Loading Procedures Each project will require software or settings to be loaded into the various components or systems.

15.1 Station Monitor. The station monitor software is developed by PWPS and is installed locally or remotely, if a dial-up connection is available, by controls personnel. Several versions may be installed during the course of the commissioning process. Record the date and software version number of the final installation on the Sign-Off Sheet.

15.2 Micronet Control. Micronet control software is developed by PWPS and is installed locally or remotely if a dial-up connection is available. Installation may be made by controls personnel or by qualified site personnel. Several versions of the software may be installed during the course of the commissioning process. Record the date and software version number of the final installation on the Sign-Off Sheet. 15.2.1 Using OPC ServeLink Server 1.5 Using OPC ServeLink Server 1.5 to connect to the MicroNet Plus allows Control Assistant and its internal program “WinPanel” to communicate with the controller. 15.2.1.1 Open OPC ServeLink Server 1.5 from the desktop icon and the already configured controller will show. If not, follow the below steps.

15.2.1.2 Select “Session” from the menu, then “New Session”. Type in the controller IP address in the “Primary TCP IP Address” window, and press the “Connect TCP” button.

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15.2.1.3 Connection information will show in the window, and the program will automatically try to connect to the Controller. It will take a few moments to complete the connection.

15.2.1.4 The Updated Status indication showing “Connected” is the end result.

15.2.1.5 Start and run Control Assistant to communicate with the Controller. 15.2.1.6 To close the OPC Server follow the below steps 15.2.1.7 – 15.2.1.9 to end the session. 15.2.1.7 Highlight the connected IP address 15.2.1.8 Select “Session” from Menu and choose “Disconnect”. The connection to the Controller will close. 15.2.1.9 Exit Servlink when finished.

15.2.2 Using Control Assistant 3.3

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Caution: Take all precautions for personal safety in or around the FT8, when changing software, testing I/O, forcing discrete I/O or placing the controller into I/O Lock. The software will automatically start the DC pumps after a controller re-start to protect the generator bearings if the controller is shutdown while the generator and power turbine shaft is still rotating. Turn off DC lubrication pumps prior to stopping the running application or placing the controller in to I/O Lock. Three breakers must be turned off for a TwinPac and two for a PowerPac, one for the generator and one for each engine. If this step is not complete the DC pumps will run when the controller is placed in I/O lock or when the control application is stopped. Use Control Assistant 3.3 or greater to receive/send tunables and place the controller into/out of IO Lock. This tool replaces the MicroPanel tool. 15.2.2.1 Open Control Assistant from the desktop icon, to receive or send tunables. 15.2.2.2 Click the

icon to receive and display the tunables stored in the controller. Be sure

to save the values in Control Assistant or select the Name this file “Date”_U#_VXXX.tc”.

“Save Values on Control” icon.

15.2.2.3 Verify the controller IP address is correct for the unit being worked on, 172.17.U.1, and the port is 5003, and select the “OK” button to continue.

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15.2.2.4 A status window will open showing the transfer process activity

15.2.2.5 Using Application Manager, load the new software into the controller, using the “Transfer Software to Current Control”

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icon on the right side menu. It will be

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necessary to log in to the MicroNet Plus as “ServiceUser” and password as “ServiceUser”. 15.2.2.6 Delete the oldest software from the controller hard drive by highlighting the oldest software and selecting the “Delete Files from the Current Controller” icon from the right side menu. Choose the “Type of File” pull down menu and select “Application Files (*.exe;*.rtss;*.out)” to see the *.out file on controller. (this is done to have only two software versions on the controller hard drive) “example: 0302VXXX.out” 15.2.2.7 Highlight the running application and select “Stop” running.

icon to stop the software from

15.2.2.8 Once the version is “Stopped”, highlight the new software version and select the “Start” icon from the right side menu to run the new application. 15.2.2.9 After the application is running, select the OPC Server tool and make sure the connection is reestablished or reconnect to the controller. (ref: Using OPC Serverlink1.5 instructions) 15.2.2.10 From Control Assistant, download a new tunable file from the new running software icon and elect to display a new view for the file. This tunable file will be using the named with the new version of the software. 15.2.2.11 Compare the new tunable list to the list created in step 2 to create a “Differences” file. 15.2.2.12 Set the properties for the “Differences” file to be the same as the file downloaded from the new application in step 10.

15.2.2.13 Select the “Lock” symbol window highlighted.

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to place the control into I/O lock with the “WinPanel”

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15.2.2.14 Select the “Yes” button to place the controller into I/O lock.

15.2.2.15 Using Control Assistant, highlight the difference file and select the “Tunable Upload” Icon 15.2.2.16 With the “WinPanel” window highlighted, select the “Reset” controller from I/O Lock.

icon to remove the

15.2.2.17 Select the check box to acknowledge the warnings, and then choose the “Save Values” button to store the tunables in to the controller’s memory.

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15.2.2.18 Select the “Reset” button to allow the controller to reset.

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15.2.2.19 Select the “Ok” button and go to Application Manager

15.2.2.20 Once in Application Manager notice the “Unlock I/O” note in the lower right status window, requesting the controller software to be restarted.

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15.2.2.21 Highlight the new software version and select the “Stop/Start” Icon and the software will restart to running status. 15.2.2.22 Select the “yes” button to restart the application and put the controller back into operation.

15.2.2.23 Reset all protective relays, reset Overspeed switch button to illuminate the green light and turn on the DC lubrication pumps breakers in the 125VDC cabinet which were previously turned off. 15.2.2.24 Reset all alarms and trips on the ICE monitor. 15.2.2.25 Generator and GT A & B Lubrication pumps will run for 30 minutes after the controller is back in operation. (Count down timers can be found on the Start or GT Lube Oil pages)

15.3 Vibration Monitor. The vibration monitor software is developed by the vendor, Bently

Nevada. The current version in use is Bently Nevada 3500 Configuration Software, Version 2.71 W/Mod # 146227-01, Revision C. This software is normally loaded on the station monitor computer on “F” drive and may be downloaded to the 3500 system via the control house network. See Procedure 11, Paragraph 11.3. Record the date and software version number on the SignOff Sheet.

15.4 Automatic Voltage Regulator (AVR). AVR software is developed by the generator manufacturer, Brush. It is normally loaded on the AVR from the factory, but may require revision in the field by the Brush representative. The AVR and generator are matched at the factory. Ensure that the AVR and generator pair is correct as soon as the equipment arrives at the site by sending the AVR and generator serial numbers to the PWPS Project Manager for verification. Record the date and software version number of the final installation on the Sign-Off Sheet.

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15.5 Fire Protection System (FPS).

FPS software is developed by the system manufacturer, AFP. It is normally loaded on the FPS from the factory, but may require revision in the field by the AFP representative. Record the date and software version number of the final installation on the Sign-Off Sheet.

15.6 Generator Protective Relay(s). Protective relay settings are developed by PWPS and are issued as a project specific document XXXX-189-E011L. Generator protection will consist of either a single Beckwith M3420 and a single Beckwith M3430 relay or one (1) or two (2) Beckwith M3425A relay(s). The protective relay settings are loaded either during factory checkout or in the field by Checkout/Startup personnel using a laptop and a serial cable with a null modem. Beckwith IPSCOM® and IPSUTIL® software are required for the relay setup. This software may be downloaded from the Beckwith web site at www.beckwithelectric.com. Record date and version number of the final installation on the Sign-off Sheet.

15.7 Station Watt-hour Meter (Jemstar). The settings are developed by PWPS and are entered at the factory during checkout or in the field by Checkout/Startup personnel using a laptop and a customized cable.

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PROCEDURE 16 − ENGINE AND UNIT CONTROL CHECKOUT PROCEDURES 16.0 Engine and Unit Control Checkout Procedures Refer to the below listed PWPS project specific drawings which are the governing documents for the checkout of the unit. If conflicts exist between items of documentation, the schematic diagrams take precedence over the other documents. Verify any and all discrepancies with the PWPS Project Manager. XXXX-187-Series XXXX-189-C005L XXXX-189-C003L

Wiring Schematics Alarm and Trip List I/O List

The following equipment is required for checkout: 1. Calibrated volt / ohm meter. 2. Calibrated pressure sources: A. 0 to 30 PSI B. 0 to 150 PSI C. 0 to 1000 PSI D. 0 to 5000 PSI E. Vacuum to 2 PSIA 3.

Type K thermocouple simulator - two (2) required

4.

100-Ohm RTD simulator

5.

4 to 20ma source

6.

Signal generator with − 12-VDC offset capability.

7.

Frequency generator

16.1 Wiring Checks CAUTION The plug connectors to the Micronet modules and the field termination modules must be inserted carefully to avoid bending the pins. The plug must be inserted square and straight. Inserting the plug at an angle from side to side or from top to bottom will damage the pins. Prior to powering the engine control and monitoring system, continuity and closed loop resistance checks are to be completed on all circuits to field devices. These checks are to be completed with the

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connector plug to the control and interface cards unplugged and the LinkNet module inputs disconnected. Checks are to be made using an ohmmeter at the device input terminal blocks to the control. Check for continuity through the device and between each leg of the device and ground. Ensure that shielded cables have only a single point ground located as shown on the schematics. Ensure that stray AC and or DC voltages are NOT present prior to plugging in the connector and powering the control system. All discrepancies are to be resolved prior to connecting to the control and applying power. Some circuits include contacts from other controlling devices and therefore must be conditioned to allow continuity checks to proceed. Refer to referenced drawings. There are several ways of keeping track of continuity and resistance measurements: 1. Record continuity and resistance measurements directly onto the Sign-Off sheets in Section 16 of the Commissioning Manual Sign-Off Sheets. 2. Record continuity and resistance measurements directly onto the master copy of the schematics and then transfer the readings to Section 16 of the Commissioning Manual Sign-Off Sheets at a later time.

16.2 Powering Up the Controls After the wiring checks have been cleared of any discrepancies, plug the connectors into the unit control and FTM cards and reconnect the Linknet modules. After reconnecting the Linknet modules, close breakers 10, 11 and 13 in DCD2 in that order.

16.3 Power ON Calibrations and Tests 16.3.1 Required Information and Documentation All inputs and outputs must be verified and calibrated, where required. All analog inputs require gain and offset calibration in the installed configuration. Digital inputs and outputs require verification at the device level. Analog outputs require verification of stable control. The following information and software must be available for use during the checkout process: 1. I/O List - (XXXX)-189-C003L A master I/O list should be referenced to insure all points are tested, calibrated and marked off on the Sign-Off Sheets when each point has been checked. The I/O list and Sign-Off Sheets provide the lower and higher calibration points to check the offsets and gains. 2.

Alarm and Trip List – (XXXX)-189-C105L The Alarm and Trip List provides a list of all the alarm and trip points within the control and monitoring system. It also provides the set points for all input functions. It will be necessary to become familiar with both lists and how to navigate through each category.

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3.

MicroPanel, Watch Windows II or Control Assistant 3.2 A working knowledge of MicroPanel and/or Watch Windows II is required to perform calibrations and checkout on the Micronet. Control Assistant 3.2 is required for the Micronet Plus. The monitor operator must have the ability to bring up these tools and to find and locate categories and specific block names within those categories.

4. Woodward Citect Control Software A working knowledge is required to navigate to the analog input and digital input and output screens as well as perform other controls and monitoring tasks on other screens. 5.

System schematics, XXXX-187-series drawings, must be available for reference

6.

Commissioning Manual and Commissioning Manual Sign-Off Sheets The Commissioning Manual and the Commissioning Manual Sign-Off Sheets (SOS) are provided as guidelines to the checkout process. The Sign-Off Sheets must be used to document the checkout process.

16.4 Input and Output Categories 1.

Inputs A. Discrete inputs (contact closures): Pressure, Temperature, Level and Position switches. (SOS section 16A)Control switch or relay contacts (SOS, Procedure 16B) B. Type K, Cr/Al TC analog inputs (SOS, Procedure 16C) C. RTD 100 ohm analog inputs (SOS, Procedures 16D and 16H) D. Speed (frequency) transducers (SOS, Procedure 16E) E. Pressure and miscellaneous transducers, 4 to 20-ma analog input (SOS, Procedure 16F)

2.

Outputs A. Discrete outputs: 1) Solenoid valves (SOS, Procedure 16G) 2) MCC contactor (See Procedure 09) 3) Other devices B. Analog outputs 1) IGV/VSV actuators and mod valve driver analog outputs (SOS, Procedure 16 I) 2) VSD 4 to 20-ma outputs

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16.5 Checkout Process

All devices on the I/O list must be verified or calibrated. The checkout process for each type of input and output is listed below. 16.5.1 Discrete Inputs - Pressure Switches Refer to PWPS drawing XXXX-187-E101D, Sheets 41, 42, 45, 46 and 49. There are pressure-actuated switches associated with each engine, which must be calibration checked and functionally tested. The switch may be calibrated prior to or as part of functional testing. If the switch is calibrated prior to functional test, it is not necessary to pressurize the switch for functional testing. Terminals may be lifted or jumpered at its junction box to simulate switch operation. Field devices send various discrete commands to the engine control. The status of these signals may be seen on the ICE monitor. Making the applicable field device change contact state (CLOSEDTRUE/OPEN-FALSE) and observing the correct indication on the ICE monitor checks signals. Manually operate the tabulated device or switch. Observe input and record the results on the Sign-Off Sheet. 1. Calibration A. Apply a calibrated pressure source to the inlet part of the switch. B. Observe switch operation at the applicable terminal strip using an ohmmeter or on the ICE monitor. If using an ohmmeter, lift at least one switch lead at the terminal strip to avoid the possibility of false readings. If applicable, verify each alarm set point and status change on the alarm page of the ICE Monitor. C. Adjust switch pressure setting as required. After adjustment, cycle the switch several times to prove repeatability. D. Restore piping and wiring to normal.

16.5.2 Discrete Inputs - Temperature Switches 1. It may not be practical to calibrate temperature switches when they are immersed in process piping. 2. If heat can safely and practically be applied to have the switch change state then it is permissible to activate the switch using this method. 3. If heating is not practical then lift and or jumper contacts to simulate the sensor changing state. 4. Observe the change of state of the point in MicroPanel. Open contacts show up as “False” closed contacts show up as “True” 5. Insure the status lights change on the appropriate Digital Status Page. 6. Where practical verify each alarm set point and status change on the alarm page

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16.5.3 Discrete Inputs - Level Switches 1. Level switches should be checked using an ohmmeter at a local terminal strip as the tank to be monitored is filled with the operating fluid. 2. Insure the status lights change on the appropriate Digital Status Page. 3. Where practical, mark the level near the tank sight gage where the low and low-low level switches operate.

16.5.4 Discrete Inputs – Position Switches 1.

Manually operate the switch to observe contacts change state on the ICE monitor.

2.

Verify that the text on the system schematic page or the digital in page matches the state of the device being monitored for position.

16.5.5 Other Contact Closures (Control Switches, Relays, Etc.) 1.

All contact closures, switch inputs, etc. should also be verified by cycling the device or if that is not possible jumper or lifting contacts at the device.

2.

Observe the change of state of the point in MicroPanel. Open contacts show up as “False” closed contacts show up as “True”

3.

Insure the status lights change on the appropriate Digital Status Page.

4.

Where practical verify each alarm set point and status change on the alarm page

16.5.6 T5.0 Thermocouples (Cr/Al, Type K) There are two (2) thermocouples in each probe, only one (1) of which is connected to the control. The second is a spare. On field terminated units, the spare TC is carried back to the control house and the spare TC wires are coiled in the MTB panel. On SWIFTPAC™ and MOBILEPAC™ units, the TC connection ends at the end of the engine mounted harness. 1.

Verify that the continuity and resistance checks for the thermocouples have been completed. There are nine (9) individual signals transmitted back to the engine control on all engines. See Sign-Off Sheet for tabulation and test points.

NOTE DLN ONLY There are thirty-two (32) thermocouples located in the DLN fuel nozzles that detect and protect against a flashback condition in the fuel nozzle. Refer to Figure 16-1. There are also four (4) combustion temperature thermocouples, two (2) of which are active and two (2) are spares. They should be checked and calibrated similar to the T5 thermocouples. See Table 16-1 (Engine A) and Table 16-2 (Engine B) for device numbers and input address. 2.

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Check for tightness of each T5 connector nut on the T5 probes. TC nuts have a “top” and a "bottom", replace correctly with the washer side down. Care must be exercised not to break the thermocouple terminals when replacing the leads. Torque the nuts on the smaller diameter terminal to 8 to 12 in-lb and the nuts on the larger diameter terminal to 10 to 15 in-lb.

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3.

Check continuity from the engine control connector plug through the T5 circuit and back with an ohmmeter. Record approximately 70 to 80 Ohms.

4.

Check resistance to ground of each T5 circuit and record. Resistance of probe to ground should be over 15K ohms. Each thermocouple input to the engine control must be calibrated.

NOTE FTM P/N 5437-525 - TE001A to TE008A and cold junction "A" are located on MTB2-1-8-A. TE009A is located on MTB2-1-8-B. TE001B to TE008B and cold junction "B" are located on MTB2-1-9-A. TE009B is located on MTB2-1-9-B. Both TE009 signals pass through a 4-20mA converter as shown on sheets 15 and 16 of drawing XXXX-187-E101D. FTM P/N 5503-282 – TE001A to TE009A are located on FTM 1-8-A and TE001B to TE009B are located on FTM 1-8-B. See drawing XXXX-187E101D, Sheets 15 and 16. For FTM P/N 5503-282, the thermocouples must be calibrated in pairs using two (2) TC simulators. The calibration pairs are 1-2, 3-4, 5-6, 7-8 and 9-10. Since there is no #10 thermocouple, fabricate a TC junction at the FTM using TC wire. Connect the second TC calibrator directly to the FTM while calibrating TE009. To calibrate the “A” engine, connect to 18-A channel 10, terminal 19, (-), red and terminal 59, (+), yellow. To calibrate the “B” engine, connect to 1-8-B channel 22, terminal 19, (-), red and terminal 59, (+), yellow. After calibration, leave the fabricated TC junction in place at the above terminals. 5.

Remove the leads at the individual thermocouple probe terminals on the engine.

6.

Using a thermocouple simulator connected to the leads, inject a signal to the engine control and calibrate each TC input. Adjust the “gain” and “offset” as necessary. Lower Calibration Value = 0°F Upper Calibration Value = +1700°F

7.

During calibration verify that the temperature values displayed on the analog input page agree with the values observed in MicroPanel, Watch Windows II Control Assistant 3.2.

DEVICE VALUE

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INPUT ADDRESS

TEST POINT

LOWER CAL

UPPER CAL

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VALUE

VALUE

TE021A

1-11-2-6-1

Nozzle 1

0°F

+2000°F

TE022A

1-11-2-6-2

Nozzle 2

0°F

+2000°F

TE023A

1-11-2-6-3

Nozzle 3

0°F

+2000°F

TE024A

1-11-2-6-4

Nozzle 4

0°F

+2000°F

TE025A

1-11-2-6-5

Nozzle 5

0°F

+2000°F

TE026A

1-11-2-6-6

Nozzle 6

0°F

+2000°F

TE027A

1-11-2-7-1

Nozzle 7

0°F

+2000°F

TE028A

1-11-2-7-2

Nozzle 8

0°F

+2000°F

TE029A

1-11-2-7-3

Nozzle 9

0°F

+2000°F

TE030A

1-11-2-7-4

Nozzle 10

0°F

+2000°F

TE031A

1-11-2-7-5

Nozzle 11

0°F

+2000°F

TE032A

1-11-2-7-6

Nozzle 12

0°F

+2000°F

TE033A

1-11-2-8-1

Nozzle 13

0°F

+2000°F

TE034A

1-11-2-8-2

Nozzle 14

0°F

+2000°F

TE035A

1-11-2-8-3

Nozzle 15

0°F

+2000°F

TE036A

1-11-2-8-4

Nozzle 16

0°F

+2000°F

TE041A

1-11-2-8-5

Nozzle 1

0°F

+2000°F

TE042A

1-11-2-8-6

Nozzle 2

0°F

+2000°F

TE043A

1-11-2-9-1

Nozzle 3

0°F

+2000°F

TE044A

1-11-2-9-2

Nozzle 4

0°F

+2000°F

TE045A

1-11-2-9-3

Nozzle 5

0°F

+2000°F

TE046A

1-11-2-9-4

Nozzle 6

0°F

+2000°F

TE047A

1-11-2-9-5

Nozzle 7

0°F

+2000°F

TE048A

1-11-2-9-6

Nozzle 8

0°F

+2000°F

TE049A

1-11-2-10-1

Nozzle 9

0°F

+2000°F

TE050A

1-11-2-10-2

Nozzle 10

0°F

+2000°F

TE051A

1-11-2-10-3

Nozzle 11

0°F

+2000°F

TE052A

1-11-2-10-4

Nozzle 12

0°F

+2000°F

TE053A

1-11-2-10-5

Nozzle 13

0°F

+2000°F

TE054A

1-11-2-10-6

Nozzle 14

0°F

+2000°F

TE055A

1-11-2-11-1

Nozzle 15

0°F

+2000°F

TE056A

1-11-2-11-2

Nozzle 16

0°F

+2000°F

TE011A

1-11-2-11-3

Engine A

0°F

+2000°F

TE012A

1-11-2-11-4

Engine A

0°F

+2000°F

Table 16-1 Engine A Devices (DLN Only)

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Nozzle 1

LOWER CAL VALUE 0°F

UPPER CAL VALUE +2000°F

1-11-3-6-2

Nozzle 2

0°F

+2000°F

TE023B

1-11-3-6-3

Nozzle 3

0°F

+2000°F

TE024B

1-11-3-6-4

Nozzle 4

0°F

+2000°F

TE025B

1-11-3-6-5

Nozzle 5

0°F

+2000°F

TE026B

1-11-3-6-6

Nozzle 6

0°F

+2000°F

TE027B

1-11-3-7-1

Nozzle 7

0°F

+2000°F

TE028B

1-11-3-7-2

Nozzle 8

0°F

+2000°F

TE029B

1-11-3-7-3

Nozzle 9

0°F

+2000°F

TE030B

1-11-3-7-4

Nozzle 10

0°F

+2000°F

TE031B

1-11-3-7-5

Nozzle 11

0°F

+2000°F

TE032B

1-11-3-7-6

Nozzle 12

0°F

+2000°F

TE033B

1-11-3-8-1

Nozzle 13

0°F

+2000°F

TE034B

1-11-3-8-2

Nozzle 14

0°F

+2000°F

TE035B

1-11-3-8-3

Nozzle 15

0°F

+2000°F

TE036B

1-11-3-8-4

Nozzle 16

0°F

+2000°F

TE041B

1-11-3-8-5

Nozzle 1

0°F

+2000°F

TE042B

1-11-3-8-6

Nozzle 2

0°F

+2000°F

TE043B

1-11-3-9-1

Nozzle 3

0°F

+2000°F

TE044B

1-11-3-9-2

Nozzle 4

0°F

+2000°F

TE045B

1-11-3-9-3

Nozzle 5

0°F

+2000°F

TE046B

1-11-3-9-4

Nozzle 6

0°F

+2000°F

TE047B

1-11-3-9-5

Nozzle 7

0°F

+2000°F

TE048B

1-11-3-9-6

Nozzle 8

0°F

+2000°F

TE049B

1-11-3-10-1

Nozzle 9

0°F

+2000°F

TE050B

1-11-3-10-2

Nozzle 10

0°F

+2000°F

TE051B

1-11-3-10-3

Nozzle 11

0°F

+2000°F

TE052B

1-11-3-10-4

Nozzle 12

0°F

+2000°F

TE053B

1-11-3-10-5

Nozzle 13

0°F

+2000°F

TE054B

1-11-3-10-6

Nozzle 14

0°F

+2000°F

TE055B

1-11-3-11-1

Nozzle 15

0°F

+2000°F

TE056B

1-11-3-11-2

Nozzle 16

0°F

+2000°F

TE011B

1-11-3-11-3

Engine B

0°F

+2000°F

TE012B

1-11-3-11-4

Engine B

0°F

+2000°F

DEVICE VALUE

INPUT ADDRESS

TEST POINT

TE021B

1-11-3-6-1

TE022B

Table 16-2 Engine B Devices (DLN Only)

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TE 036 TE 056

TE 021 TE 041

TE 035 TE 055

TE 022 TE 042

TE 034 TE 054

TE 023 TE 043

TE 033 TE 053

TE 024 TE 044

TE 032 TE 052

TE 025 TE 045

TE 031 TE 051

TE 026 TE046

TE 030 TE 050

TE 027 TE 047 TE 029 TE 049

TE 028 TE 048

Figure 16-1 Schematic, Viewed From Rear (DLN Only)

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16.5.7 RTDs 100-Ohm Analog Inputs Refer to PWPS drawing XXXX-187-E101D, Sheets 21, 22, 25, 26, 29 and 30. 1. A continuity check is required for the RTD (Resistance Temperature Device) input signals transmitted back to the control. See signoff sheets for tabulation and test points. Test points for RTD's are listed in the tabulation as shown in the example below: 1-11-1-3 -->

Rack # - Slot # - Plug # - Linknet Module #

5-6/4/7 ---> Positive Pole - Negative Pole of resistance element/sense lead common to positive pole/shield 2. Using an ohmmeter, check continuity through the resistance element and the two common leads to the RTD at the test points indicated in the tabulation. Record the resistance across the element and to ground. Resolve high resistance readings in the common leg. 3. After the above checks have been made and the control system has been energized, perform a closed loop check and calibrate the control input. A. Inject a signal at the RTD connection box using an RTD simulator or resistance decade box. Observe results on MicroPanel, Watch Windows II or Control Assistant 3.2. Adjust “gain” and “offset” as necessary. B. The upper and lower limit values will be found on the Sign-off Sheets or I/O list. C. During calibration verify that the temperature values displayed on the analog input page agrees with the values observed in MicroPanel or Watch Windows II

16.5.8 NL, NH, NP Speed Transducers Refer to PWPS drawing XXXX-187-E101D, Sheets 6 and 7. Two (2) NL, three (3) NH and three (3) NP speed transducers are located in the No. 1 bearing area, the GG gearbox and NP tunnel area respectively. These transducers and their related circuits must be checked for continuity and for the proper resistance as follows: 1.

Use PWPS Drawing XXXX-181-M100D to verify the location. They should be as shown on the schedule.

2.

Check resistance through the transducer and resistance to ground at the test points indicated on the Sign-Off Sheet. Resistance through the transducer and back to the terminal block should be between 150 and 200 Ohms. Record results on the Sign-Off Sheet.

3.

Using a variable frequency source, inject a speed signal to the unit control sensing circuits from the connector or terminal strip closest to the speed transducer. Verify the correct indication in WWII and on the station monitor. The two (2) NH transducers feeding the vibration monitor will indicate on the Bentley Nevada 3500 Monitor screen. Speed ranges and conversions from frequency to RPM are shown in Table 16-3 below:

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SPEED SIGNAL

SPEED RANGE (RPM)

CONVERSION (RPM/HZ)

NL

0 to 7,650

4.90198

NH

0 to 12,550

4.2863

NP

0 to 3,960

1.0

NL

270° ± 10° CCW rotation from FULL IN.

NH

270° ± 10° CCW rotation from FULL IN. Nominal gap settings are 0.027 to 0.047-Inch. Screw pitch is 18Threads per Inch.

NP

Table 16-3 Speed Ranges and Conversions from Frequency to RPM NOTE The information is shown for reference purposes only. Do not remove speed pickups for checkout. Just verify their gaps. Lock-nut torque = 95 to 105 lb-in. on all pickups

16.5.9 Pressure Transducers Refer to PWPS drawing XXXX-187-E101D, Sheets 9,10, 24 and 28. 1. Insure that the continuity and resistance checks have been completed and recorded. 2. After the above checks have been made and the control system has been energized, perform a closed loop check and calibrate the engine control input. A. Introduce a calibrated pressure into the transducer. Observe output on MicroPanel, Watch Windows II or Control Assistant 3.2, as applicable. B. Where introduction of a pressure is not feasible, inject a signal at a convenient junction box (or as near as possible to the pressure transducer) using a 4 to 20 ma simulator. Observe results as in Step A. C. Calibrate control input as outlined earlier in the calibration procedure. Adjust “gain” and “offset” as necessary until the process value agrees with the known signal.

NOTES A vacuum source will be required to obtain pressures less than approximately 14.7 PSIA. Derive absolute pressures lower than ambient by subtracting gage vacuum from ambient. Derive absolute pressures greater than ambient by adding gage pressures to ambient. Pressure and vacuum conversion tables are included for convenience. Example: Obtain calibration pressures of 4 PSIA and 30 PSIA.

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D. Determine ambient pressure using a calibrated barometer or absolute reading indicator. For this example an ambient of 30.36 inches of mercury ("Hg) will be assumed. E. Convert " Hg to PSIA 30.36 " Hg x 0.491 psi/1" Hg = 14.91 PSIA. F. Determine the difference between ambient pressure and target pressures. 30 to 14.91 = 15.09 14.91 to 4 = 10.91 G.

Calibrate device. Apply 15.09 PSIG to device to obtain a device output of 30 PSIA.

H.

Apply a vacuum of 10.91 PSIG to device to obtain a device output of 4 PSIA.

Measurement

kp/cm3

BAR

In.WG

In.HG

PSI

mm HG TORR

mm WS

1-kp/cm3

1

0.981

393.7

28.94

14.22

736

10,000

1-BAR

1.02

1

401.6

29.53

14.5

750

10,210

1-In.WG

.00254

.00249

1

.0736

.0361

1.87

25.4

1-In.Hg

.0345

.0339

13.6

1

.491

25.4

345.4

1-PSI

.0703

.0689

27.72

2.043

1

51.7

703.1

1-mm Hg TORR

.0014

.0013

.054

0.039

0.019

1

13.6

1-mm WS

.0001

.0001

.04

0.003

0.0015

.074

1

Table 16-4 Pressure and Vacuum Conversion Table 16.5.10 Igniters and SOVs Refer to PWPS drawings XXXX-187-E101D, Sheets 17,18,19,20 and 48 and XXXX-187-E303D, Sheets 25 and 28. The following checks are done through the ICE monitor system: 1. Ensure that the continuity and resistance checks have been completed and recorded. 2. Ensure that the back-to-back suppression devices have been installed on all solenoids per procedure 6. 3. After the above checks have been made and the control system has been energized, perform a closed loop check of the system. Station an observer near the device; operate the device by "forcing" the appropriate values in the control true or false. The observer should verify device operation visually or by listening for an audible "click" in the device. A. Force each discrete output from the appropriate Discrete Output Page. B. Observe that each MicoPanel output point toggles False / True.

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C. Observe that the relay output-board relay LED changes state. D. Observe that each driven device responds appropriately.

NOTE DC power must be supplied to the circuits in order to energize the device. All applicable tags must be cleared. The following circuits are required: ƒ ƒ ƒ ƒ ƒ

DCD1/11 DCD1/9 DCD1/13 DCD2/1 DCD2/17

Engine "A" base SOVs Igniters (both engines) Engine "B" base SOVs Engine "A" bleed and turbine cooling SOVs Engine "B" bleed and turbine cooling SOVs

4. When the engine control system is operating and the gas turbine is shutdown, the bleed valve solenoids will be energized. This can be checked electrically or manually. The solenoids will be hot to the touch when energized for an extended period. 5. It will be necessary to "condition" several circuits in order to power their device. Refer to system schematics.

CAUTION Circuits must be restored after the operation tests are completed. Turn off DC power to generator and power turbine DC lube oil pumps prior to placing valves in manual to avoid running DC pumps 6.

Engine control must be in shutdown (not reset) to complete this procedure.

NOTE The 86EA (ENGINE A) or 86EB (ENGINE B) relay can be tripped to put engine control in shutdown. This will allow the “Valves to Manual” icon to become active on the Ice Monitor start page. 7.

To actuate a device, set ‘Valves to Manual’ on the ICE Monitor. Access the desired output point by going to the I/O card on the monitor and double clicking on the I/O point of interest. The I/O point should light up red indicating output is true. The Inputs should also be monitored here as well. Red being True (energized) and not red being False (de-energized).

8.

Table 16-5 shows the lockout relay contacts to be closed for each test. Jumpers will be required to complete the circuit as indicated in Table 16-5 since the lockout relays will trip when valves are placed in manual.

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OUTPUT DEVICE

OUTPUT ADDRESSES

86E

86EA / 86EB

SOV1101-A

1-10-A-1

11-13

11-13

SOV1102-A

1-10-A-2

11-13

11-13

SOV1001-A

1-10-A-3

11-13

11-13

SOV1002-A

1-10-A-4

11-13

11-13

SOV1103-A (DLN Only)

1-10-A-3

11-13

11-13

SOV1104-A(DLN Only)

1-10-A-4

11-13

11-13

SOV1101-B

1-10-B-33

15-17

11-13

SOV1102-B

1-10-B-34

15-17

11-13

SOV1001-B

1-10-B-35

15-17

11-13

SOV1002-B

1-10-B-36

15-17

11-13

SOV1103-B (DLN Only)

1-10-B-35

15-17

11-13

SOV1104-B(DLN Only)

1-10-B-36

15-17

11-13

Table 16-5 Lockout Relay Contacts to be Closed for Each Test

9.

It may be difficult to hear the bleed valve and turbine cooling valves click. Forcing one output at a time should energize solenoids. After a few minutes, the energized solenoid(s) will be warm to the touch. Use of a magnetic solenoid checker will aid in checking for solenoid activation.

CAUTION Dangerous energy levels exist at the igniter plugs during operation. Do not touch; maintain safe distance. Post an observer familiar with igniter operation on each side of the engine being tested to enforce safety precautions.

NOTE Follow steps 1 thru 9 to operate solenoids and fuel pump clutch. Igniters are operated with the addition of steps 10 thru 15. DC power is fed from DCD1/9 to a set of fuses. Fuses MTB4/1 and 4/3 supply the engine "A" igniters and fuses MTB4/2 and 4/4 supply engine "B". The igniter power supply output voltage should be checked to insure that a minimum of 29-VDC is present at the exciter on the engine. The voltage can be adjusted via the adjustment potentiometer on the power supply. Do not exceed 30 VDC for the setting. Because of the longer cable lengths used on the SWIFTPAC™ (SP) design, power supply CT117718 must be utilized. Record the voltage setting for “A” and “B” engines on the Sign-Off Sheets. 10. Remove the igniters from the engine as follows:

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A. Loosen and completely remove cable-coupling nut from the igniter. B. Pull cable straight out of igniter. Do not twist. C. Remove igniter from the engine. D. Carefully re-insert the cable into the igniter. Tighten cable coupling nut hand tight. Do not allow the igniter to rotate. E. Allow the igniter to hang on the cable away from the engine. 11. Force the engine igniters on from the discrete output page. 12. Observe that the appropriate MicroPanel or Watch Windows II point changes state 13. Observe that the igniters fire. 14. Unforce the output to the igniters.

CAUTION Wait five (5) minutes after the test for the exciter to discharge. 15. Ground the igniter to the engine case. A. Loosen and remove the cable-coupling nut from the igniter. Do not allow the igniter to rotate. B. Remove the cable from the igniter. C. Install the igniter with gaskets and torque to 330 ± 30-Inch pounds. D. Inspect red rubber bushing on the cable ceramic for damage. Replace if necessary. E. Clean bushing and end of cable with PMC 9056 solvent and a lint free clean cloth. F. Insert cable end into igniter plug. Push in on cable and install and tighten cable nut. Tighten cable nut hand tight and turn up to 45-degrees more. Do not allow the cable to rotate while tightening.

16.5.11 MCC I/O Check Prior to proceeding with this section, ensure that the system including the motor or heater to be checked is completely ready for full operation. Unit control must be powered, software loaded and ready to operate. Complete sections A, B, C and D of this procedure before proceeding. Refer to systems schematics, XXXX-187-series drawings as an integral part of this procedure. Refer to PWPS drawings XXXX-187-E101D, Schematic, Unit Control, XXXX-187-E303D, Schematic, Power Distribution, Lighting and Motor Control Center and XXXX-189-C003L, I/O List.

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1.

Close breaker on MCC bucket to be tested. Ensure control switch is in "OFF" or "AUTO".

2.

Select "AUTO' operation as required.

3.

Force the output from the ICE monitor for the motor to be tested.

4.

Observe correct motor start, see a “Run” indication or the digital in status page and indicator lights on the MCC change from green to red.

5.

Manually operate the MCC bucket overload.

6.

Observe the contactor drop out, the motor stop, the proper overload alarm on the ICE Monitor and the alarm event. (This step not applicable to heater circuits.) (Motor will not stop on DC LO pumps.)

7.

Un-force the motor run command.

8.

De-energize MCC bucket by opening the circuit breaker. (Avoid cycling of motors.) DC pump motors are monitored to assure that DC power is available by a health circuit consisting of a relay connected across the incoming DC power. When the DC circuit breaker is switched off or if DC power is not available for other reasons, the relay drops out and causes an alarm on the ICE monitor and an alarm event. This alarm should be verified when this step is completed for DC motors.

9.

Reset the overload.

10. Observe alarm on ICE Monitor clear.

16.5.12 IGV/VSV Static Calibration (Sign-Off Sheets, Section 16I) 16.5.12.1 Introduction. This procedure defines the calibration requirements for the Woodward Governor Micronet final driver cards associated with the inlet guide vanes and the variable stator vanes. It must be performed whenever the valve hardware is changed. It also must be performed if the “calibration data”, resulting from a successful calibration is lost. This procedure also requires that the personnel performing this calibration have working knowledge of the FT8 Micronet engine control hardware and software, including: A. Knowledge of the ICE monitoring system B. The ability to display software blocks on the MicroPanel or Watch Windows II C. The ability to modify and store tunables

16.5.12.2 Definitions 1. FY001 - Identifies the IGV addresses. This prefix is used when calibrating the IGV’s 2. FY002 - Identifies the VSV addresses. This prefix is used when calibrating the VSV’s

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CAUTION Before attempting to perform this procedure, the engine must be shutdown.

NOTE The calibration procedure can be interrupted and restarted from the beginning.

16.5.12.3 Tools Required. A large adjustable wrench is required 16.5.12.4 Set-Up for Engine A IGV/VSV 1. Ensure the engine to be calibrated is in a “shutdown” state: A. Depress the emergency stop push-button. B. Turn off DC breakers for power turbine/generator lube oil pumps. 2. Switch the control to actuators in manual. Find the valves to manual icon on the ICE monitor start screen. Depress actuators to manual icon and ensure the control system has switched to manual by the “Stop Sign” indication on the actuators in manual Icon. 3. Launch MicroPanel or Watch Window II program.

NOTE This procedure is written for “A” engine. For “B” engine, replace nomenclature FY001A and FY002A with FY001B and FY002B FY001A and FY1002A are located in category A2_A08

4.

Set up a page in Watch Windows II to display the addresses shown in Table 16-6. These addresses should be maintained throughout calibration procedure for reference.

16.5.12.5 Performing the Calibration - IGV 1.

Enable the IGV actuator to allow for calibration by tuning the following addresses: A. FY001A.CAL_ENABL: tune the value from FALSE to TRUE. B. Ensure FY001A.CAL.STATUS changed from 0 to 1

2.

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Using the large adjustable wrench, manually move the IGV actuator piston to it’s fully retracted position (down) (closed).

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SYSTEM

TUNABLE

DEFAULT VALUE

IGV

FY001A.CAL._ENABLE

FALSE

IGV

FY001A.CAL_STATUS

FALSE

IGV

FY001A.AT_POS_0

FALSE

IGV

FY001A.AT_POS-100

FALSE

IGV

FY001A.POS_RDBK

000.000

VSV

FY002A.CAL._ENABLE

FALSE

VSV

FY002A.CAL_STATUS

FALSE

VSV

FY002A.AT_POS_0

FALSE

VSV

FY002A.AT_POS-100

FALSE

VSV

FY002A.POS_RDBK

000.000

Table 16-6 Watch Windows II Addresses 3.

Set the closed position tunable: A. FY001A.AT-POS_0 Tune the value from FALSE to TRUE. B. Ensure FY001A.CAL.STATUS changed from 1 to 2

4.

Using the large adjustable wrench, manually move the IGV actuator piston to it’s fully extended position (up) (open).

5.

Set the open position tunable: A. FY001A.AT-POS_100 tune the value from FALSE to TRUE. B. Ensure FY001A.CAL.STATUS changed from 2 to 3

16.5.12.5.1 Restore Control and Monitoring System 1. FY001A.CAL_ENABL: tune the value from TRUE to FALSE. 2. FY001A.AT POS_0 tune the value from TRUE to FALSE 3. FY001A.AT POS_100 tune the value from TRUE to FALSE 4. Ensure FY001A.CAL.STATUS changed from 3 to 0.

16.5.12.5.2 Verify IGV 0 to 100 Percent Calibration 1.

Stroke the IGV actuator slowly through the fully extended and fully retracted positions and ensure the 0% and 100% positions are accurate on the following addresses: A. FY001A.POS_RDBK

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B. ICE monitor analog screens

16.5.12.6 Performing the Calibration - VSV 1. Enable the VSV actuator to allow for calibration by tuning the following addresses: A. FY002A.CAL_ENABL: tune the value from FALSE to TRUE. B. Ensure FY002A.CAL.STATUS changed from 0 to 1 2. Using the large adjustable wrench, manually move the VSV actuator piston to its fully retracted position (down). 3. Set the Closed position tunable to 0 A. FY002A.AT-POS_0 tune the value from FALSE to TRUE. B. Ensure FY002A.CAL.STATUS changed from 1 to 2 4. Using the large adjustable wrench, manually move the VSV actuator piston to it’s fully extended position (up). 5. Set the open position tunable to 100 A. FY002A.AT-POS_100 tune the value from FALSE to TRUE. B. Ensure FY002A.CAL.STATUS changed from 2 to 3

16.5.12.6.1 Restore Control and Monitoring System 1. FY002A.CAL_ENABL: tune the value from TRUE to FALSE. 2. FY002.AT POS_0 tune the value from TRUE to FALSE 3. FY002.AT POS_100 tune the value from TRUE to FALSE 4. Ensure FY002.CAL.STATUS changed from 3 to 0.

16.5.11.6.2 Verify VSV 0 to 100 Percent Calibration 1.

Stroke the VSV actuator slowly through fully extended and fully retracted positions and ensure the 0% and 100% positions are accurate on the following addresses: A. FY002A.POS_RDBK B. ICE monitor analog screens

16.5.12.6.3 Returning to Normal Mode 1.

Find the actuators to manual icon on the ICE monitor start screen.

2.

Depress actuators to manual icon and ensure the control system has switched to normal mode.

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3.

The stop sign turns off.

4.

Reset the emergency stop switch and depress the software reset push-button located on the start screen of the ICE Monitor.

5.

Turn the power turbine/generator lube oil pump breakers back on.

This completes the calibration procedure for the IGV actuator. The calibrations should be accomplished one (1) at a time substituting IGV or VSV. Save the calibration (99 enter) before exiting MicroPanel. To save the calibrations in Watch Windows II or Control Assistant 3.2, right click on the I.P. Address then click Save Values then click yes to save.

16.5.13 Generator RTD Calibration (Sign-Off Sheets, Section 16H) Note that stator RTD’s are electrically isolated from the control. Resistance checks should be made at the RTD isolation module. Calibration of gain and offset are to be made at the RTD to 4-20ma device at the Generator Instrumentation junction box. Calibrate the Generator RTD’s per the following procedure: 1.

Remove the silver rectangular center cover on the 4-20ma transmitter.

2.

Set dipswitch #3 down and to the left, and all others up.

3.

Set the “SPAN” dial to “3”.

4.

Set “0” dial to “0”.

5.

Connect a Fluke or equivalent milli-ammeter on the output of the RTD module to measure milliamperes. With the RTD simulator connected to the input of the RTD module (with the generator RTD disconnected), adjust the fine “0” for 5.19ma at 0°F. With the fine “Range” adjustment on the module set the output for 20ma with a 500°F RTD input. Verify the readings are accurate at the ICE monitor. The Micronet offset should equal 0 and Micronet gain should equal 1.

16.5.14 Electric Valves (Sign-Off Sheets, Section 16I) There are two types of electric valves used in the FT8 and they require an electronic controller called the EM24 to drive them: 1. EM35MR/3103 (GAS FUEL) 2. LQ25 (LIQUID FUEL) Perform a static resistance check on the applicable valve using XXXX-187-E101D-XX, as reference. Record results as listed on the Sign-Off Sheets.

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CAUTION The valves do not require field calibration however the resolver offset, which is stamped on each gas valve, must be checked with the software to verify that it matches the valve offset. Each gas mod valve (FCV1101) is stamped on the Woodward Valve data plate with a “Resolver Offset Angle” which is installed in the Electronic Control as a tunable. This offset determines the minimum position of the mod valve for calibration. The gas mod valve is not to be installed if the Resolver Offset Angle on the gas mod valve data plate is not within 18 to 22 degrees. Any value outside this range is not to be used. If gas mod valve Resolver Offset Angle is between 19 and 21 degrees, insert this value into the control. If Resolver Offset Angle is between 18 and 19 degrees or 21 and 22 degrees, the value is to be verified through PWPS Projects with Woodward for that valve serial number.

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Pratt and Whitney Power Systems, Inc.

Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03 Please insert this Temporary Revision 08-03 in the Commissioning Manual Rev 4, to replace Procedure 17 in its entirety.

PROCEDURE 17 – FIRE PROTECTION SYSTEM 17.0

Fire Protection System Overview

In general, the fire system consists of four parts: Detection, Alarm, Control and Suppression. Detection, Alarm and local Control systems are provided as standard on all SP61 power plants in the Gas Turbine A & B enclosures, Generator enclosure and Power Control Room. The main Control system is also provided as standard and is located in the Power Control Room. Suppression is provided as standard for Gas Turbine Enclosures A & B, and as optional for the Generator enclosure and Power Control Room.

17.0.1 Gas Turbine A and B Enclosures 1.

Fire Detection: Thermal detectors are located inside the turbine compartment that sense heat given off by a fire, and they are divided into two circuits. Circuit 1 consists of TS201, TS203, TS205, TS209 and TS213. TS213 is located at the circuit’s end is equipped with a 3.9K end of line resistor to monitor circuit continuity. Circuit 2 consists of TS202, TS204 and TS206. TS206 is located at the circuit’s end has a 3.9K end of line resistor to monitor circuit continuity. The thermal detectors are rated for hazardous locations, and the contacts will close on either a rising temperature rate of 40 degrees F per minute or a temperature of 450 degrees F.

2.

Combustible Gas Detection: Two combustible gas detectors, GS201 and GS202, are provided (for gas or dual fuel units only) to monitor combustible gases within the turbine enclosure. The detectors are set for a HIGH alarm of 20 percent LEL combustible gas and for a HIGH-HIGH alarm of 60 percent LEL combustible gas or as dictated by the local Authority Having Jurisdiction (AHJ). Upon loss of power to GS201 or GS202, a fault will occur at FCC-201 and a signal will be sent to the engine controller. The gas detectors are calibrated using a 50 percent LEL concentration of methane gas. The detectors use catalytic bead sensor heads that are sensitive to combustible particles. The changes in gas level measured by the catalytic bead sensors communicate with the panel via a 4-20mA signal.

3.

Alarm: One strobe light is provided inside the turbine enclosure and two strobe lights are provided on the enclosure exterior mounted above the FP boxes to provide a visual alarm. These strobe lights will flash when an alarm condition exists on any of the turbine’s detection circuits.

4.

Alarm & Local Control: Fire Protection Panel Boxes will be FP3 style for domestic FM certified fire systems and FP4 style for ATEX certified fire systems. A.

FP3 Boxes: Outdoor fire protection panel boxes FP3-202 and FP3-203 are provided, with one located on each side of the turbine enclosure. These boxes are painted red for easy identification. Each box contains a hand switch pull station (described in paragraph 3 above), a weatherproof reverberating fire horn of 85dBA, a keyed NORMAL / INHIBIT selector switch, and a green indicating status light with a push-to-test switch. When the selector switch is in the NORMAL position the solenoids at the CO2 cylinders are in service and the green light burns to indicate that the CO2 system is armed. When the selector switch is in the INHIBIT position the CO2 system is disarmed from the thermal detectors but is still armed from the hand switch pull station circuit. This allows work to be performed within the turbine compartment without accidentally setting off a thermal detector but still keeps the CO2 suppression system active in case of a fire alarm from a hand station. The green indicating light is off in the INHIBIT position and can be pushed to test the bulb.

B.

FP4 Boxes: Outdoor fire protection panel boxes FP4-202 and FP4-203 are provided, with one located on each side of the turbine enclosure. These boxes are painted red for easy identification. A

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Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03 weatherproof reverberating horn and a hand switch pull station are mounted adjacent to each box and wired into the box. Each box contains a keyed AUTO/MANUAL selector switch, and a green indicating status light with a push-to-test switch. When the selector switch is in the AUTO position the solenoids at the CO2 cylinders are in service and the green light burns to indicate that the CO2 system is armed. When the selector switch is in the MANUAL position the CO2 system is disarmed from the thermal detectors but is still armed from the hand switch pull station circuit. This allows work to be performed within the turbine compartment without accidentally setting off a thermal detector but still keeps the CO2 suppression system active in case of a fire alarm from a hand station. The green indicating light is off in the MANUAL position and can be pushed to test the bulb. 5.

Local Control: The hand switch pull stations are on one circuit consisting of HS201, HS202, HS203 and HS204. HS201 is located at the end of the circuit and has a 3.9K end of line resistor to monitor circuit continuity.

6.

Suppression: The turbine enclosure is protected by a dual solenoid activated CO2 suppression system consisting of eight 100-pound cylinders. The two solenoids, SOV201 and SOV202, are energized when a discharge signal is activated by a thermal detector or a hand switch pull station within the turbine compartment protection zone. The CO2 suppression system can also be activated via mechanical hand wheel located atop both pilot CO2 cylinders. When the solenoids are activated they discharge the pilot cylinder they are attached to. Each pilot cylinder is connected to an initial discharge header with one slave cylinder. The pressure on the header will rupture the release disc on the slave cylinder, which will discharge into the initial release header. The initial CO2 discharge is vented to the turbine compartment via four nozzles X202, X203, X204 and X205. Motor operated dampers are commanded shut/closed by FCC-201. The extended discharge pipe header is connected to the initial discharge header through a check valve that allows flow from the pilot cylinders that discharges the other five slave cylinders. The extended discharge header vents to the enclosure through nozzle X201. The Control Panel is programmed to keep the solenoids energized for 10 minutes. The extended CO2 discharge will continue to discharge for 20 minutes. A CO2 discharge will activate pressure switches PS201 and PS202, which will alarm the main panel. A block valve with limit switches is provided on each CO2 header for isolating the cylinders. When a block valve is closed the CO2 system is automatically inhibited. When the valve is opened the system returns to normal.

7.

Suppression: Fuel shutoff valves are provided as standard on each liquid fuel metering skid and each gas fuel metering skid located outside of the enclosure. They aid in fire suppression by shutting off fuel flow into the enclosure. The fuel shutoff valves will automatically close in the event of a fire alarm and/or gas HIGH-HIGH alarm within the turbine fire protection zone. These are solenoid operated globe valves that are controlled by FCC-201. Each valve also has a lever for manual operation. A position switch connected to the engine controller monitors each valve. This position switch is not connected to FCC-201.

17.0.2 Power Control Room (PCR) 1.

Fire Detection: The control room is equipped with smoke detectors that are divided into two circuits. Circuit 1 consists of smoke detectors SM201 and SM202. Circuit 2 consists of smoke detectors SM203 and SM204. If any smoke detector on either circuit detects smoke, all audio and visual alarms in the PCR will activate. However, in order for the optional suppression system to activate and the HVAC dampers to shut, at least one smoke detector on circuit 1 and 2 must detect smoke.

2.

Alarm & Local Control: Fire Protection Panel Boxes will be FP3 style for domestic FM certified fire systems and FP4 style for ATEX certified fire systems. A.

FP3 Boxes: Outdoor fire protection panel boxes FP3-207 and FP3-212 are provided, with one located on each side of the PCR. These boxes are painted red for easy identification. Each box contains a hand switch pull station and a weatherproof reverberating fire horn of 85dBA. If optional FM200 suppression is supplied, then each box will also contain a keyed NORMAL / INHIBIT selector switch, and a green indicating status light with a push-to-test switch. When the selector switch is in the

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Procedure 17-2

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Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03 NORMAL position, the solenoid at the FM200 cylinder is in service and the green light burns to indicate that the system is armed. When the selector switch is in the INHIBIT position the FM200 system is disarmed from the thermal detectors but is still armed from the hand switch pull station circuit. This allows work to be performed within the turbine compartment without accidentally setting off a smoke detector but still keeps the FM200 suppression system active in case of a fire alarm from a hand station. The green indicating light is off in the INHIBIT position and can be pushed to test the bulb. B.

FP4 Boxes: Outdoor fire protection panel boxes FP4-207 and FP4-212 are provided, with one located on each side of the turbine enclosure. These boxes are painted red for easy identification. A weatherproof reverberating horn and a hand switch pull station are mounted adjacent to each box and wired into the box. If optional FM200 suppression is supplied, then each box will also contain a keyed AUTO/MANUAL selector switch, and a green indicating status light with a push-to-test switch. When the selector switch is in the AUTO position, the solenoid at the FM200 cylinder is in service and the green light burns to indicate that the system is armed. When the selector switch is in the MANUAL position the FM200 system is disarmed from the smoke detectors but is still armed from the hand switch pull station circuit. This allows work to be performed within the PCR without accidentally setting off a smoke detector but still keeps the suppression system active in case of a fire alarm from a hand station. The green indicating light is off in the MANUAL position and can be pushed to test the bulb.

3.

Main Control: The main fire control computer (FCC-201) is located in the PCR.

4.

Suppression: Two CO2 portable fire extinguishers are located inside the control room near each door.

5.

Suppression: The PCR is protected by an optional FM200 suppression system consisting of one 250-pound capacity solenoid activated gamma cylinder. The solenoid, SOV205, is energized when a discharge signal is activated by at least two smoke detectors on different circuits or a hand switch pull station within the PCR protection zone. The FM200 suppression system can also be activated via a mechanical hand lever located on the cylinder valve. When the solenoid is activated the cylinder will discharge to the piping header that is connected to nozzles X220 and X221. The HVAC system is commanded to shut down by FCC-201. If the FM200 is discharged via the hand lever, it will activate pressure switch PS205, which will alarm the main panel and shut down the HVAC system. A manual block valve, BAV205, with limit switch, ZS205, is provided on the header for isolating the cylinder if necessary. When the block valve is closed the FM200 system is automatically inhibited. When the valve is opened the system returns to normal. The position switch is monitored by the FCC201.

17.0.3 Generator Enclosure 1.

Fire Detection: Thermal detectors are located inside the generator compartment that sense heat given off by a fire, and are wired in series on one circuit. The circuit consists of TS207, TS208, TS210 and TS211. TS211 is located at the circuit’s end is equipped with a 3.9K end of line resistor to monitor circuit continuity. The thermal detectors are rated for hazardous locations, and the contacts will close on either a rising temperature rate of 40 degrees F per minute or a temperature of 450 degrees F.

2.

Alarm: One strobe light is provided outside the generator enclosure and one reverberating horn of 85dBA is provided inside the enclosure. The strobe light will flash and the horn will sound when an alarm condition exists for the generator enclosure.

3.

Alarm & Local Control: Fire Protection Panel Boxes will be FP3 style for domestic FM certified fire systems and FP4 style for ATEX certified fire systems. A.

FP3 Boxes: Outdoor fire protection panel box FP3-211 is provided on the exterior of the enclosure. The box is painted red for easy identification and contains a hand switch pull station and a weatherproof reverberating fire horn of 85dBA. If optional CO2 suppression is supplied, then each box will also contain a keyed NORMAL / INHIBIT selector switch, and a green indicating status light with a push-to-

Revision 4 TR 08-03, Page 3 of 13

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Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03 test switch. When the selector switch is in the NORMAL position, the solenoids on the CO2 pilot cylinders are in service and the green light burns to indicate that the system is armed. When the selector switch is in the INHIBIT position the FM200 system is disarmed from the thermal detectors but is still armed from the hand switch pull station circuit. This allows work to be performed within the turbine compartment without accidentally setting off a smoke detector but still keeps the FM200 suppression system active in case of a fire alarm from a hand station. The green indicating light is off in the INHIBIT position and can be pushed to test the bulb. B.

FP4 Boxes: Outdoor fire protection panel boxes FP4-207 and FP4-212 are provided, with one located on each side of the turbine enclosure. These boxes are painted red for easy identification. A weatherproof reverberating horn and a hand switch pull station are mounted adjacent to each box and wired into the box. If optional FM200 suppression is supplied, then each box contains a keyed AUTO/MANUAL selector switch, and a green indicating status light with a push-to-test switch. When the selector switch is in the AUTO position, the solenoid at the FM200 cylinder is in service and the green light burns to indicate that the system is armed. When the selector switch is in the MANUAL position the FM200 system is disarmed from the smoke detectors but is still armed from the hand switch pull station circuit. This allows work to be performed within the PCR without accidentally setting off a smoke detector but still keeps the suppression system active in case of a fire alarm from a hand station. The green indicating light is off in the MANUAL position and can be pushed to test the bulb.

4.

Local Control: A two hand switch pull stations, HS206 and HS211, are located on the enclosure exterior. Both hand switches are on the same monitoring circuit with HS211 as the end of line device. HS211 has a 3.9K end of line resistor to monitor circuit continuity.

5.

Suppression: The generator enclosure is protected by an optional dual solenoid activated CO2 suppression system consisting of ten 100-pound cylinders. The two solenoids, SOV201 and SOV202, are energized when a discharge signal is activated by a thermal detector or a hand switch pull station within the turbine compartment protection zone. The CO2 suppression system can also be activated via mechanical hand wheel located atop both pilot CO2 cylinders. When the solenoids are activated they discharge the pilot cylinder they are attached to. Each pilot cylinder is connected to an initial discharge header with one slave cylinder. The pressure on the header will rupture the release disc on the slave cylinder, which will discharge into the initial release header. The initial CO2 discharge is vented to the generator compartment via three nozzles X209, X210 and X211. The initial discharge header activates a series of release devices that normally hold the compartments dampers open, causing the dampers to shut and seal the air intake opening. The extended discharge pipe header is connected to the initial discharge header through a check valve that allows flow from the pilot cylinders that discharges the other six slave cylinders. The extended discharge header vents to the enclosure through nozzle X209 only. The Control Panel is programmed to keep the solenoids energized for 10 minutes. The extended CO2 discharge will continue to discharge for 20 minutes. A CO2 discharge will activate pressure switches PS201 and PS202, which will alarm the main panel. Block valves with limit switches are provided on each CO2 header for isolating the cylinders when necessary. When a block valve is closed, the CO2 system is automatically inhibited. When the valve is opened the system returns to normal.

6.

Suppression: Two CO2 portable fire extinguishers are located inside the generator enclosure near each door.

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Procedure 17-4

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Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03

17.1

Main Fire Control Center (FCC-201) Overview

NOTE In the event of an alarm or fire, do not turn FCC-201 off.

1.

The Main Fire Control Center is installed inside a cabinet labeled FCC-201 which is located in the PCR. The basic components of this control center are the power supply, battery charger, batteries, and OnGuard FG-8800 series computer system manufactured by Allstec Corporation. The FG-8800 is in turn comprised of program input modules, gas modules, output modules and relay modules. Each component is briefly described below: A.

Power Supply - the power supplies are switching type, 120 VAC to 24 VDC.

B.

Battery Charger – LaMarche Mfg. Co. TPC-60-24V-U1 Power Cage with one TPM-30-24V-U1 Rectifier and one TPCDB1-60-24V Distribution Center 1) 2) 3)

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TPC-60-24V-U1 Power Cage – This component houses the rectifier and distribution center. Only 120 VAC power is to be supplied to the power cage. TPM-30-24V-U1 Rectifier – This component converts 120 VAC input to 24 VDC output with a maximum capacity of 30 A. TPCDB1-60-24V Distribution Center – This component displays the status of the power supply/ battery charger. There are seven single pole 10 Amp load disconnect breakers located on the distribution center that control the seven available 24 VDC output circuits. A 70 Amp battery disconnect breaker is provided to manually disconnect the battery bank for servicing or replacement services. All breaker trip conditions are monitored by the FCC-201. a. Digital display unit can be toggled to display the instantaneous DC output voltage and DC current draw. b. Trouble/Alarm LEDs LED SUMMARY

Color Green

Indication/Action Indicates general alarm/trouble conditions on power Supply. FCC-201 monitors summary alarm contacts and outputs power trouble condition to engine controller.

LODC1

Red

Indicates to user when the output voltage via battery or rectifier has dropped below the predetermined low DC voltage set point.

LODC2

Red

Indicates when battery capacity has dropped below safe operational voltages. A Low Voltage Load Disconnect automatically disconnects the load from system to prevent overly discharging and damaging the batteries. At this point, power will be lost to the FCC201 and all its components, and alarm/trouble conditions will only be indicated at the distribution center.

HI V

Red

Indicates to user when the output voltage via battery or rectifier has exceeded the predetermined high DC voltage set point.

Procedure 17-5

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Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03 LED LO A

Color Red

Indication/Action Indicates when no load is applied to the system. With no load, the FCC-201 is likely off, so alarm/trouble conditions will only be indicated at the distribution center.

C.

Batteries - Two 12 VDC, 100 amp batteries are wired in series to provide 24 VDC output. The batteries are located side by side inside the cabinet on a shelf.

D.

OnGuard FG-8800 Fire and Gas Control Panel – The FG-8800 contains the microprocessor, system operating software and the system configuration memory. The FG-8800 functions as the system information and control center processing all messages for any programmed unit. The unit is equipped with a touch screen monitor to display the following conditions: Fire Alarm – Red Gas Alarm – Blue Warning Alarm – Light Blue Fault Alarm – Yellow By pressing any of the previous alarm bars, the panel alarm buzzer will silence and display to the user what the condition is and its location in the plant (ie. GT A encl, GT B encl, Gen encl or PCR). This display provides buttons to silence and reset the alarm once the condition has been restored to normal. Communication cabling between the OnGuard FG-8800 and all modules uses four 18 AWG shielded conductors in a Class A loop. Shield/Drain wire is terminated at start of loop, floating through out system & left unterminated at end of loop. i. ii. iii.

iv.

17.2

Initiating Modules: FG-8800-1060 supervised input module provides four programmable channels, each supervised by 3.9K end of line resistors. Gas Modules: FG-880-1700 gas module provides four 4-20mA programmable channels capable of user defined Low, High, High-High gas alarm set points. Output Modules: FG-8800-1705 supervised output module provides four programmable 24VDC output channels. Each channel is individually protected with a 7.5A miniature automotive fuse and supervised by 3.9K end of line resistors. Relay Modules: FG-8800-1725 relay module provides four programmable form-C relay contacts.

Fire Protection System Checkout Procedures

Fire System Vendor (here-in-after referred to as Vendor) is fully responsible for the complete and final checkout of the fire protection system. Checkout consists of installation inspections, power-up of fire system for the first time, and functional testing of the equipment. Vendor must turn over all records and a final certificate to the client upon completion of the fire system commissioning. Vendor will furnish a commissioning report to PWPS.

NOTE After the system is operational do not open any of the pull boxes using the key. This will activate the system just as if the pull switch itself had been pulled.

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Procedure 17-6

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Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03

17.2.1 Pre-Checkout Items The following are action items that need to be completed and verified by site electricians before arrival of the Vendor for Commissioning and Start-up of the Fire System. 1.

2.

3.

PCR Board – Located inside FCC-201: A.

End of line resistors (EOL) – Remove only the EOL resistors that are for field devices used on the particular project, which are depicted on “Wiring FCC-201 I/O Layout” drawing from fire system vendor.

B.

Depending on the specific customer’s requirements several of the EOL resistors will remain in place.

GTA Board - Located in Gas Turbine enclosure A GTB Board - Located in Gas Turbine enclosure B GEN Board - Located in the Generator enclosure A.

End of line resistors (EOL) – Remove only the EOL resistors that are for field devices used on the particular project, which are depicted on “Wiring GTA, GEN & GTB I/O Layout” drawing from fire system vendor.

B.

Depending on the specific customer’s requirements several of the EOL resistors will remain in place.

Wiring to be verified by site electrician: A.

Complete point-to-point check of 100 percent of the fire system field wiring.

B.

Check for wire-to-wire shorts and ground faults on all circuits.

C.

Wiring color and polarity must be checked and consistent with project plan wiring color scheme.

D.

Notify the electrical contractor that the resistors are to be removed before the field cable is terminated and the resistor is to be reinstalled at the last device on the circuit per the drawings.

4.

Unit control system must be ready to receive signals from the FPS and site personnel must be available to verify signals going to the Station Monitor.

5.

To ensure proper and adequate sealing of outdoor devices, the fire system devices must be installed as required by the National Electric Code (NEC) NFPA Standard 70, any applicable local codes that may apply, equipment manufacturer’s requirements and common industry practices for outdoor locations.

6.

Unused conduit openings must be sealed with permanent plugs to insure no moisture can enter the device.

7.

For all outdoor connectors and fittings, insure a proper “rain-tight” and/or “rainproof” seal is provided.

8.

For any outdoor electrical device or junction box, insure that any direct water source (such as a enclosure door rain gutter end) does not discharge directly onto the electrical device or junction box. If, by its location, this does happen, install a locally procured or manufactured sheet metal protection shield (awning) for the device.

9.

Ensure secondary air fan louvers and attaching hardware are constructed and installed in accordance with PWPS drawings.

10. Operate each mechanism to ensure smooth and unobstructed movement. Make adjustments, as necessary, to ensure smooth and unobstructed movement.

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Procedure 17-7

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Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03 11. Align dampers for normal operation and simulate a CO2 dump by releasing the supporting cable. Complete release cycle at least 3 times. 12. Remove the discharge nozzles and blow down the piping using clean compressed air. Re-install nozzles. 13. Weigh each CO2 bottle as it is installed in the bottle rack. Record the bottle serial numbers and weights in the Sign-off Sheets. 14. Connect discharge heads and assure that none of the hoses are severely twisted or kinked. This will allow manual operation of the pilot discharge heads and the manual release of CO2 in the event of an emergency. 15. Do not connect and mount the electric solenoid valves on the CO2 cylinder pilot discharge heads. These are left disconnected to prevent accidental discharge. These will be connected after full load testing of the engine and after fire system commissioning.

17.2.2 Vendor Checkout of Fire System Installation in the Field 1.

Upon arrival at site, Vendor shall carefully inspect each CO2 and FM200 piping installation to verify they are in accordance with the project specific PWPS P&ID (xxxx-181-M501D) and the project specific Vendor mechanical drawings. Assure that check valves are installed in the correct direction and that all block valves are open or closed when the monitor switch and indicator so indicate.

2.

Verify that all bottle racks are properly anchored to the foundation and that each is properly grounded.

3.

Visually inspect fire hoses connecting bottle racks to enclosure to ensure they are properly installed, free of kinks and that minimum bend radii are satisfactory.

4.

Verify that all field wiring is routed and terminated per the drawings.

5.

Verify that the correct type of wiring specified for the project is installed.

6.

Verify that all cables are tagged correctly at both ends.

7.

Verify that all DC power circuits are color-coded correctly (WHITE or RED for positive; BLACK for negative).

8.

Verify that all end of line resistors are installed per the drawings. The majority end of line resistors are rated 3.9K. The drawings will also show end of line resistors at the main panel terminal boards for FUTURE circuits. These resistors should be installed at the factory and should be verified in the field.

9.

Inspect all seal-offs, vents and drains on panel boxes and interconnecting conduit to verify they are installed correctly and that drains are not sealed or plugged. Inspect conduit pull box covers to verify they are not loose and properly secured/sealed.

10. All discrepancies in construction, defects in workmanship, and equipment installation errors that are discovered by the Vendor during checkout (which are not the obligation of the vendor to remedy) shall be documented in an RFI and submitted by the Vendor to the PWPS project manager for action with one copy submitted to PWPS Quality Assurance. This RFI shall be submitted prior to the Vendor leaving the site.

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Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03

17.2.3 Vendor Power-Up of the Fire System 1.

After satisfactory completion of the inspections in section 17.2.2, and resolution of any issues that would prevent a safe start-up, Vendor shall proceed to power up the system.

2.

Check the wiring between the distribution panel and the main fire panel. Check all 24 VDC circuits from the two power supplies and the various terminal boards. Verify that correct D/C color-coding has been used (white or red for positive, black for negative). Verify that the wiring to the two 12 volt batteries has been installed. Verify that 120 VAC is supplied to the FPS via ACD-1 circuit 14.

3.

Allestec Start-up procedure: A.

B.

C.

Before powering up the FCC-201 the gas detector wiring MUST be verified to match the print by using an ohm meter to verify wire continuity of all components. If this step is not done, there is a high risk of damaging the transmitter and/or sensor. Power supply – Total Power Cage 24V-60A (TPC-60-24V-U1) 1) Make sure battery switch is in “OFF” position. 2) Make sure load breakers 1 thru 7 are in the “OFF” position. 3) Connect the battery jumper. 4) Turn “ON” rectifier #1. Powering up Allestec Panel (FG-8800) 1) Switch “ON” LDC #1. 2) Wait for FG-8800 to power up and OnGuard to initialize. The system will go into alarm until fully powered up. 3) Switch “ON” remaining LDC’s. • LDC #2 through LDC#7 for SP61 • LDC #2 through LDC #5 for MP25, Power Pac and ½ SP61’s. 4) Finally, turn battery switch to “ON” position. 5) Reset the “POWER SUPPLY TROUBLE” alarm. 6) Verify that the screen shows “MONITORING ALARMS ACTIVE”. 7) System is now fully powered and running.

4.

After the main panel has been powered-up and the voltages checked at various terminal blocks, the OnGuard FG-8800 display will identify all faults that exist on the system.

5.

Begin troubleshooting each fault shown on the OnGuard FG-8800 display. Troubleshooting should begin at the main panel termination where you check for loose wires and verify correct terminations. Disconnect the field circuit from the terminal board and ohm the circuit to verify the presence of the end of line resistor. Sometimes the end of line resistor termination is not making good contact because of the very small wires. If nothing is found wrong at the main panel begin to isolate the circuit into small segments beginning at the end of the circuit. Keep isolating the circuit into segments between junction boxes until the problem is found. Most faults will be a termination problem. Two people with radios will facilitate troubleshooting. One person at the main control panel can watch the display to see when the problem is isolated into a section of the circuit. When the problem is isolated, it is easier to find the problem. Once a problem has been identified, attempt to reset the fault. If it immediately returns, the problem circuit is still in fault and must be further isolated. Once the fault has been restored, any attempt to reset the panel will cause the panel to immediately return to the main OnGuard screen and flash “Monitoring Alarms Active”.

Note Upon reset of any fire alarm, power will be cut to all smoke detectors and optical flame detectors (if present) causing supervision faults. This is

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Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03 normal and the user should allow 40 seconds before attempting to reset this fault.

6. 7.

Verify that SM201 and SM202 are on circuit 1 and that SM203 and SM204 are on circuit 2. Combustible Gas Detector – Det-Tronics U9500 Setup and Calibration Procedures A. Initial Startup i. As stated in Step #3, before powering up the FCC-201 the wiring MUST be verified to match the print by using an ohm meter to verify wire continuity of all components. If this step is not done, there is a high risk of damaging the transmitter and/or sensor. ii. If the wiring is correct the FCC-201 may be powered up. iii. Once powered, the gas detectors have a “burn in”/”warm up” time of approximately 24 hours before attempting to calibrate. B. Calibration i. If this is the first calibration of the gas detector or is the a replacement sensor, the unit must “burn in”/”warm up” for approximately 24 hours before attempting to calibrate. If this is not done, the calibration will not work correctly. ii.

The gas detectors are calibrated using an automatic calibration procedure. To calibrate the detector, use the provided magnet, or a suitable replacement, and place it on the lower side of the display approximately two inches back from the window and hold it there until the display shows “ZERO CAL”. This will take approximately seven (7) seconds. During this time the display will show “RESET”, then will cycle through the setup settings, and then show the “ZERO CAL” once entered into the calibration mode. The magnet may now be removed. iii. Once in calibration mode, follow the action prompts on the display. a) When the display shows “ZERO CAL,” it is in the process of zeroing the detector. No zero gas is needed for this. b) After the detector has zeroed itself, the display will show “APLY GAS”. At this time, apply the calibration gas. c) Once the calibration gas is applied the display will show “GAS ON”. No further action is necessary at this time. d) If the calibration is successful the display will show “CAL OK’ then “RMV GAS”. At this time, the calibration gas is to be removed. e) A sensitivity reading “XXXX SPAN” will be displayed for seven seconds after the calibration gas removal that can be used to track sensor life. o XXXX = the sensitivity rating. o Any reading over 100 indicates the sensor is good. f) If the calibration is not successful, the display will show “RMV GAS”. Then the fault code will be displayed which can be found in Table 15 on page 30 of the manual or in this document on page 17-12. C. Calibrating Transmitter to FCC-201 i. Once the gas detector display returns to zero, the transmitter will need to be calibrated to the FCC201 following these steps. a) With OnGuard running, press “F5” b) Scroll to the gas detector node to be calibrate. On a o SwiftPac detectors are on Nodes 8-1 = G201A, 8-2 = G202A, 18-1 = G201B, 18-2 = G202B. o MobilePac detectors are on node 13-1 = G201, 13-2 = G202. c) Double click the node to bring up the channel enable window.

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Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03 d) Check the box to enable the channel to be calibrating and click the button labeled “SET PT/ NOT CALIBRATED” or “SET PT/ CALIBRATED” next to the channel being calibrated. e) Click the “RESET” button. f) Set the alarm points using the up/down arrows next to the High and High-High boxes. The standard set points are 20% High and 60% High-High. g) Click the “Calibrate” button. h) On the calibration screen click the “SET 0%” button. i) Apply the calibration gas to the gas detector being done and wait for the reading to stabilize. Then go back to the FCC-201 and click the “SET 50%” button. j) Remove the calibration gas from the gas detector and wait until the display goes below 20%. k) Go back to the FCC-201 and click “OK” on the screen. l) Click “Apply”, then “Save and Close” to save these settings. m) If calibrating more detectors go back to step one and repeat until all detectors have been calibrated. Notes: • When testing the detectors for correct alarm operation, lower the High-High alarm set point to 50% as the calibration gas will not go to 60% • The detectors must be recalibrated according to the maintenance schedule. • The detectors must be recalibrated any time a new sensor is installed. • When the electrical contractor receives the sensors, gather up all of the hand magnets and store in a safe place.

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Procedure 1711

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Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03

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Procedure 1712

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Commissioning Manual – Revision 4 TEMPORARY REVISION NO. 08-03

17.2.4 Vendor Functional Testing of Fire System 1.

Functionally test each alarm device and record on a test sheet as follows: A. Use an electric heat gun to actuate each thermal detector. The thermal detector should set off its FPS station’s strobe light and horn alarms. The appropriate alarm should sound and be identified at FCC-201. The strobe in the appropriate compartment should flash on all alarms. Each thermal detector should be checked to verify both its rate rise trigger of 40F/min and its temperature set point of 450F. B. Use the key and open each hand switch pull station cover. The pull station should set off its FPS station’s strobe light and horn alarms. The appropriate alarm should sound and be identified at FCC-201. C. Check the solenoids at the CO2 and FM200 stations to assure they energize when a thermal detector or hand switch is activated within the protection zone. There is approximately a 30 second time delay before the solenoid is energized if initialized by a thermal detector. You can hear the solenoid when it is activated and also visually see the actuating pin position change. D. Close each block valve at the CO2 and FM200 stations one at a time. The result should be an inhibit/manual indication at the appropriate FPS panel when the green indicating light goes off and the FCC-201 display will indicate an inhibit state. E. Turn the keyed selector switch at each FPS station to the INHIBIT position (for FP3 boxes) or MANUAL position (for FP4 boxes). The green indicating light should go off and the FCC201 display will indicate an inhibit/manual state. Apply a heat gun to at least one thermal detector in each protected zone and verify that the appropriate CO2 release solenoids do not energize. Open at least one hand switch pull station in each protected zone and verify the appropriate CO2 release solenoids energize. F. Apply the 50% LEL concentration Methane calibration gas to each gas detector and verify that a HIGH alarm (which is 20% LEL) is initiated. The HIGH-HIGH alarm has been set at 60% LEL so it will not alarm. Reprogram the FG-8800-1700 gas module HIGH-HIGH set point to 50% LEL. Reapply the calibration gas to each sensor. Both HIGH-HIGH alarms should be observed. Remove the calibration gas, allow sensor to clear below 20% LEL and reset gas alarms. Lastly, restore program gas module set points back to 60% LEL for each detector. G. This concludes the functional tests. Reset the system to normal.

2.

Complete commissioning report and submit to PWPS project manager along with certificate and all records. Report should be submitted to PWPS within 2 weeks of completion of checkout.

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TEMPORARY REVISION NO. 09-01

PROCEDURE 18 – HYDRAULIC START SYSTEM 18.0

Hydraulic Start System Checkout Procedures

Refer to PWPS drawing XXXX-181-M403.

CAUTION It is extremely important to assure that the hydraulic system does not become contaminated. Severe damage to the starter motor and/or pump will result. Assure that hydraulic supply piping has been adequately flushed prior to completing the following. The hydraulic start skid supplies filtered, cooled, de-aerated hydraulic fluid under very high pressure to the turbine mounted hydraulic starter motor. Prior to shipment, the skid and starter motors have been flushed and sealed per PWPS Specifications. Field run piping is to be considered contaminated until adequately flushed. Note that most start pacs have only one pump to start both engines. This procedure refers to two pumps in several areas to cover the system having 2 pumps. Mobile Pacs have a slightly different configuration for the start pac. It is mounted underneath the power trailer and does not have SOV103 or sov104. On a start command the motor is started by the soft start controller. When the control senses 275PSI on PT102 from the charge pump, the milliamp output from the control to the servo on the hydraulic pump ramps up to maximum over a predetermined tunable time period. The logic then acts to maintain a NH starter speed of 2850 RPM until the engine starts and reaches starter cutout speed. The Mobile Pac piping runs to the engine are much shorter so that it may not be necessary to add oil to the reservoir after the piping has been filled. The Mobile Pac piping is fitted with HBV101 which can be closed if adjustment of the output pressure is required. This valve must remain open for normal operation.

WARNING Extremely high hydraulic pressure (5000 PSI) is used in this system. Only trained personnel are to operate the equipment. All applicable safety procedures must be strictly followed. Severe personnel injury or death may result from carelessness. Assure that all applicable sections of the ten (10) steps listed below have been completed prior to completing this procedure since the engine may rotate while the system piping is being filled. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Purge/blow down and leak check piping Clean and inspect reservoirs and tanks Systems inspection Inspection gas turbine and auxiliary system junction boxes Ground grid MCC and motor rotation Strainers and filters NL and NH rotation Inlet filter, inlet plenum and engine inlet inspection Exhaust collector

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TEMPORARY REVISION NO. 09-01

The unit has been factory flushed, calibrated and tested. To reduce the possibility of contamination, the unit will not be disassembled in the field to recheck certain calibrations or settings. Pressure relief and control valves are factory set and should not require resetting in the field. Refer to Procedure 16A for switch calibrations. Set points are tabulated below for information. The alarms for tank levels and tank temperatures are individually annunciated in the control house. High filter differential pressures are paralleled and any high differential pressure will cause a single annunciation in the control house. High differential pressures are individually annunciated via an indicator lamp at the hydraulic start pack. A local test button is provided to test the indicator lamps. The local panel is powered by 24 VDC via circuit breaker DCD2 - 3 and fuses MTB1, FU5 and FU15. In addition, 125 VDC is supplied to SOV103 and SOV 104 via DCD1-5 and fuses MTB1, FU17 and FU23. (Mobile Pacs do not have SOV103 and SOV104) The electric motors are meggered and the motor start, run, rotation direction and overload instrumentation are checked as a part of procedure 9, MCC and Motor Rotation. The motors are started, and the solenoid control valves are cycled, automatically via the unit control to initiate an engine start. Local control of the system is not possible. Prior to energizing or attempting to operate the system: 1.

Perform the continuity and resistance checks as tabulated on the sign-off sheet.

2.

Verify operation of the SOV's by forcing the control outputs with the pumps off.

3.

Verify switch operation by lifting or applying jumpers to the inputs as noted.

4.

Verify pressure transducer operation by injecting a pressure signal as part of Procedure 16F, Pressure Transducer Calibration.

5.

Level switch operation is to be verified while the tank is being filled with hydraulic fluid. Connect an ohmmeter to observe contact operation as noted.

All referenced terminals are found in the junction box located on the hydraulic start skid. The solenoid operated valves function as follows: SOV-103 SOV-104

Energize to start engine "A" Energize to start engine "B"

During a normal start, Pump 1 and SOV103 will energize to start the "A" engine. After the engine is started, SOV104 will energize and start “B” engine. The Operator has the option to select which engine will start first.

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TEMPORARY REVISION NO. 09-01

18.1

Hydraulic Start System Instrumentation DEVICE TAG PDSH-101 PDSH-108 PDSH-102 PDSH-105 PDSH-103 PDSH-106 PDSH-104 PDSH-107 LSL-101 LSLL-102 TSH-101 TSHH-102 PT-101 PT-102

18.2

DESCRIPTION Suction Filter #1 High Diff. Pressure Suction Filter #2 High Diff. Pressure Charge Filter #1 High Diff. Pressure Charge Filter #2 High Diff. Pressure Supply Filter #1 High Diff. Pressure Supply Filter #2 High Diff. Pressure Return Filter #1 High Diff. Pressure Return Filter #2 High Diff. Pressure Reservoir Low Level Reservoir Low Low Level Reservoir Hi Temperature Alarm Reservoir Hi Hi Temperature Alarm Pressure Transmitter #1 Pressure Transmitter #2

SET POINT 1.5 PSID Rising 1.5 PSID Rising 35 PSID Rising 35 PSID Rising 35 PSID Rising 35 PSID Rising 35 PSID Rising 35 PSID Rising 40 Gal Falling 20 Gal Falling 160° F Rising 180° F Rising

TEST POINT TBA1-TBB1 TBA3-TBB3 TBA5-TBB5 TBA7-TBB7 TBA9-TBB9 TBA11TBB11 TBA13-TBB13 TBA15-TBB15 TBA18-TBB19 TBA20-TBB21 TBA22-TBB23 TBA24-TBB25 TBD 1-2 TBD 4-5

Test Operation CAUTION Prior to operating any system for testing or commissioning, verify proper valve position(s) in accordance with the test procedures and the P&ID drawings. For configurations using liquid fuel with no clutch to disengage the engine-driven pump during engine rotation, assure fuel system is fully commissioned and fuel is bled to the engine mounted fuel pump. Failure to do so could result in equipment damage.

1.

Check level gage on reservoir to assure a high level of operating fluid.

2.

Assure the two-(2) ball valves BAV101 and BAV102 between the oil tank and pump suctions are OPEN. Tag and lock open prior to extended, unattended operation. (There is only one ball valve for single pump installations.)

3.

Apply 24 VDC to the local panel by closing fuses MTB1, FU5, FU15, and energizing circuit breaker DCD2-3.

4.

Apply 125 VDC for the SOV’s by closing fuses MTB1, FU17. FU23 and energizing DLD1-5. (Not applicable to Mobile Pacs)

5.

Push to test each of the local indicator lamps for high filter differential pressure.

6.

Manually operate one of the hydraulic pumps.

7.

Observe and record system-operating pressures. Supply pressure from the charging pump as indicated on PT101 should be 350 PSI ± 50 PSI.

8.

Carefully inspect system for leaks. Correct as required.

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Pratt and Whitney Power Systems, Inc. Commissioning Manual – Revision 4

TEMPORARY REVISION NO. 09-01

9.

Fill the hydraulic supply piping to each engine. With one of the hydraulic pumps operating, energize SOV103 to supply hydraulic pressure to engine “A” and fill its supply piping. The charge pump is supplying this pressure. Carefully monitor the oil level in the reservoir. Add filtered hydraulic fluid, as required, to maintain the correct operating level.

10. Repeat step 9 to fill the piping on the “B” engine by energizing SOV104. 11. Steps 9 and 10 are not applicable to the Mobile Pac. The piping will fill by running the pump with HBV101 open. 12. Leak check all piping while filling piping and circulating oil. 13. Assure that all air is bled from the supply piping. 14. After piping has been filled, de-energize SOV’s and turn off pump. Fill oil reservoir, as required.

18.3

Starter Speed

The maximum starter speed is a function of the hydraulic starter outlet pressure. 2850 NH RPM is the speed set point. The control system may be adjusted to rotate the engine at a different speed if so directed by Engineering.

CAUTION Safety equipment, not limited to hardhat, safety glasses and ear protection, is required for this procedure. Tags must be cleared as required and replaced after the procedure has been completed. 1.

Starter solenoid power must be available; DCD1-5 must be closed.

2.

Condition circuits to provide power to the start solenoid valves. Reset the 86E and 86EA or 86EB lockout relays and the control system.

3.

Select "Spin Engine A (or B)" at the hydraulic system screen.

4.

Observe one hydraulic pump start and the engine rotate. Check for engine lube oil pressure (PT-612) and hydraulic pressure (PT-501).

5.

Note steady state starter speed (NH speed).

6.

While running on the starter, inspect the hydraulic pump skid, hydraulic starter, supply, return and bypass piping for leaks or abnormal operation.

7.

Record steady state operating data as tabulated on the Sign-off Sheet.

8.

Stop engine rotation.

9.

Secure systems as required, install tags as required.

10. Record results on the Sign-off Sheets.

18.3

Hydraulic Starter Output Pressure Adjustment

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Pratt and Whitney Power Systems, Inc. Commissioning Manual – Revision 4

TEMPORARY REVISION NO. 09-01

THE ADJUSTMENT PORT IS ON THE LOWER LEFT SIDE OF THE PUMP CASING FACING THE SIDE OF THE PUMP WITH THE ELECTRIC MOTOR TO THE RIGHT In the event that it is necessary to adjust the maximum pressure limiter on the hydraulic pump to change the engine rotation speed, proceed as follows: 1.

Verify that the pump inlet ball valve BAV101 on the reservoir is opened. Failure to open ball valve will cause damage to the pump.

2.

From the bucket in the control room start the Hydraulic pump/motor by turning breaker to “Hand” position.

3.

Confirm that the charge pressure on PT101 gauge rises to 350+/-50psi and stabilizes.

4.

Locate the manual override lever located on the lower right side of the pump housing.

5.

Do not energize the select flow solenoid valves (SOV103 or 104). By leaving these solenoid valves closed, the pump flow path to the engine start hydraulic motor will be blocked. This will allow the pump pressure to rise to the maximum setpoint of the pump pressure limiter. On Mobile Pacs, close HBV101.

6.

The “SUPPLY PRESSURE” gauge on the hydraulic start pac will indicate the current pump pressure limiter setting. Compare this reading with PT101 on the ICE Monitor

7.

Adjust the “B” port pressure limiter as required to achieve 4800+/- 50psi. Using a 13mm wrench, loosen the small outer locknut on the pressure limiter cartridge adjacent to the “B” port. This port is identified with a “B” cast into the pump housing. Insert a 4 mm Allen wrench into the pressure limiter adjustment screw. Turn the Allen screw until the desired pressure is reached. Clockwise adjustment of the screw will increase the setting while counter-clockwise adjustment will lower the setting. Each complete revolution of the adjustment screw will change the pressure by approximately 1350psi. Once the desired setting is reached, hold the Allen wrench stationary and tighten the locknut to 25in-lbs. Do not over-torque the locknut.

8.

Return the manual override lever to its normal position.

9.

Stop the hydraulic pump. Setting is now complete.

10. On Mobile Pacs, assure that HBV101 is open.

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PROCEDURE 19 - CHIP DETECTORS CHECKOUT PROCEDURE 19.0 Chip Detectors Checkout Procedure Refer to PWPS drawing XXXX-187-E101D, Sheets 42 and 46. There are three (3) chip detectors located on the lube oil skid: 1. XS601 on the gas generator lube oil return (has two (2) bowls and probes). 2. XS602 on the power turbine scavenge for bearing #7 3. XS603 on the power turbine scavenge for bearings #8 and #9. The above listed chip detectors should be checked for secure mounting and leaks during initial startup and during Lube Oil System functional checks. After the control and monitoring systems have been powered and checked, a closed loop check of the chip detectors may be completed. 1.

Inspect chip detectors and probes for proper installation.

2.

Inspect and clean the contacts on the probes.

3.

Control system must be powered and ready for operation.

4.

Clear and power circuits ACD1-17 (Engine "A") and ACD1-19 (Engine "B"). This will also power the PT/GG lube oil tank mist eliminator motors.

5.

Remove each probe and short across the gap with a screwdriver. After a 30-second delay, this will create an alarm condition, which will appear on the visual display and on the printout. Verify that the alarm is from the correct probe.

6.

Thoroughly clean probe and re-install.

7.

Check all four (4) detectors/probes to insure that they work properly and record test results on the Sign-Off Sheets.

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PROCEDURE 20 - AIRPAX TACH-PAK 3 OVERSPEED DETECTION MODULE CHECKOUT PROCEDURES 20.0 Airpax Tach-Pak 3 Overspeed Detection Module Checkout Procedures Refer to the Airpax Tach-Pak 3 instruction manual and PWPS drawing XXXX-187-E101D, Sheet 14.

NOTE The gas turbine must be shutdown for this procedure. The Airpax TACH-PAK 3 is not monitoring the application while constants are being entered. Review data display to insure relay is properly set up. Static Overspeed Check of the Airpax – Tach Pak

CAUTION The AirPax Tach-Pak 3 is polarity sensitive. It is essential, that in all testing, that positive be connected to positive and negative connect to negative.

20.1 Inputting Constant Values into AirPax Tach-Pak 3 1.

Open the protective cover. On the control panel press the up arrow key (⇑) to enter “Program Mode”. The blinking cursor will be located on the descriptor of the first constant (FS).

2.

Press the right arrow key (⇒) to move the cursor to the first digit.

3.

Press the up arrow key (⇑) until the desired value is displayed.

4.

Press the right arrow key (⇒) to move to the next desired value.

5.

Press the up arrow key (⇑) to set it to the desired value.

6.

Continue to set the remaining digits this way. When setting a sign, the display will toggle back and forth between blank for positive and "−" for negative values. Likewise, setting other digits that have only two (2) values, the display will toggle back and forth between those values.

7.

When the last digit has been set, press the right arrow key (⇒) to move the cursor back to the descriptor.

8.

Press the up arrow key (⇑) to increment to the next descriptor.

9.

Use the right arrow (⇒) and up arrow keys (⇑) to set its values in the manner just described.

10. Continue this process until all constants have been set. 11. After the last constant has been set, press the right arrow key ⇒ to move the cursor to the descriptor on the display.

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12. Press the up arrow key (⇑) until the word “store” appears. 13. Press the right arrow key (⇒). The display will go blank, indicating that the constants have been stored. 14. All tunable values for 50 and 60-Hz units are listed on the Sign-Off Sheets. Verify the correct 50Hz overspeed set point, 3300 or 3450 RPM, with the Project Manager. 15. Replace the external cover.

20.2 Verification of AirPax Tach-Pak 3 Procedure NOTE Terminal blocks TB1 and TB2 are located beneath the protective cover of the power supply TERMINAL BLOCK 2 Terminal

Use

TERMINAL BLOCK 1 Terminal

Use

1

+ 24 VDC ( In )

1

K1: Normally Closed

2

DC Common ( In )

2

K1: Common

3

Calibrate / Verify

3

K1: Normally Open

4

DC Common ( Out )

4

K2: Normally Closed

5

+12 VDC ( Out )

5

K2: Common

6

Relay Reset

6

K2: Normally Open

7

Signal +

7

K3: Normally Closed

8

Signal -

8

K3: Common

9

Shield

9

K3: Normally Open

10

Meter + ( 0-1 Ma )

10

K4: Normally Closed

11

DC Common ( analog & meter )

11

K4: Common

12

Analog + ( 0-20 / 4-20 Ma )

12

K4: Normally Open

13

AC Power Hot

14

AC Power Neutral

15

Ground

Table 20-1 AirPax Tach-Pak 3 Terminal Block Assignments 1.

Remove DC power is to the Tach-Pak 3

2.

Lift 1-7-C-92 wire number U14-630.

3.

Disconnect the speed pickup (ST008A) connected to terminals 7 and 8 on TB2.

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4.

Check resistance of the speed pickup (150 to 200-Ohms nominal) and verify shield is single-point connected as per XXXX-187-E101D, Sheet 14. The “A” engine is the default connection on TWINPAC™ and SWIFTPAC™ installations. Check and record ST008B resistance and ground readings on the Sign-Off Sheet.

5.

Connect signal generator to terminals 7 and 8 of TB2.

6.

Increase input frequency stopping just below 99 RPM. The overspeed should not reset.

7.

Continue to increase above 100 RPM. The overspeed switch should reset.

8.

Set the input at 3000 RPM (50 Hz) or 3600 RPM (60 Hz) and check the analog meter. It should correspond to the input RPM.

9.

Set input to 3300, 3450 or 3960 RPM depending on site configuration. At set point RPM the Tach-Pak 3 will cause 12-1x relay to drop out, causing 86E relay to trip.

10. Reconnect the wire number U14-630 to 1-7-C-92 that was lifted off in Step 3. 11. The green pushbutton reset for the Speed Relay is located on the front of the operator panel. This button will light green when the Speed Relay is reset (no trip). 12. The ICE monitor will annunciate NP Overspeed when detected.

NOTE For Tach-Pak 3 Technical Support call 1-800-643-0643

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PROCEDURE 21 – FLOW METERS 21.0 Flow Meters See drawing XXXX-187-E101D sheets 8, 9, 10 Each engine has a dedicated flow meter for liquid fuel, gas fuel and water injection flow depending on site configuration. SYSTEM FM1001 Liquid Fuel FM1101 Gas Fuel FM801 Water Injection

SENSOR TYPE

OUTPUT

Coriolis

4-20MA

Coriolis

4-20MA

Coriolis

4-20MA

OUTPUT RANGE & UNITS 0 – 20,000 PPH 0 – 17,250 PPH 0 – 20,000 PPH

DISPLAY

SECTION

ICE Monitor

21.1

ICE Monitor

21.2

ICE Monitor

21.3

21.1 FM1001 – Liquid Fuel Flow Meter 1.

General

Liquid fuel flow to each engine is measured by a Micro Motion series R sensing unit (CT117475-1) with an integrally mounted IFT 9703 series transmitter. The unit is horizontally mounted in the piping on the fuel flow metering skid. The transmitter supplies a 4-20ma signal directly to an analog input to the Micronet control at 1-6 channel 2 for the “A” engine and 1-6 channel 14 for the “B” engine. Flow is displayed on the ICE monitor in PPH. 24 VDC power for the meters is supplied via fuses 1A FU2 and FU7 for “A” and 2A FU2 and FU7 for “B”. The 4-20ma output range corresponds to 0 – 20,000 PPH. 2.

Field Setup

Refer to Vendor’s manual for full technical details. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10

Prior to powering the device, check wiring for shorts or grounds per the tabulation on the Sign-off Sheet. Inspect unit for correct installation and connection per the drawings. Confirm correct flow direction. Unit is factory calibrated, field calibration is not required. Assure that sensing tubes are filled with fuel before zeroing the meter. Assure that there is no flow through the meter. Valve off to the extent practical. Power the meter and allow it to warm up and temperature stabilize for 30 minutes. Using a HART communicator in “Diagnostics” mode, inject a 4 ma signal into the control. Adjust the offset on FM1001A(B) as necessary to display a zero flow. Using a HART communicator in “Diagnostics” mode, inject a 20 ma signal into the control. Adjust the gain on FM1001A(B) as necessary to display a 20,000PPH flow. NOTE: The meter should be factory set for the correct output units and range, 420ma corresponding to 0 – 20,000 PPH. This can be verified using a HART communicator.

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2.11

2.12 2.13

21.2

Zero the meter by removing the lower cover on the transmitter housing. Press and hold the zero button until the flashing red LED stops flashing and remains illuminated. After approximately one minute the LED will again flash once per second indicating that the zeroing process is complete and the flow meter is ready for operation. Replace the transmitter covers. Record results on the Sign-off Sheets.

FM1101 – Gas Fuel Flow Meter

1. General Gas fuel flow to each engine is measured by a Micro Motion series F sensing unit (CT118021-1) with an integrally mounted 1700 series transmitter. The unit is horizontally mounted in the piping on the gas fuel metering skid. The transmitter supplies a 4-20ma signal directly to an analog input to the Micronet control at 1-6 channel 1 for the “A” engine and 1-6 channel 14 for the “B” engine. Flow is displayed on the ICE monitor in PPH. 24 VDC power for the meters is supplied via fuses 1A FU1 and FU6 for “A” and 2A FU1 and FU6 for “B”. The 4-20ma output range corresponds to 0 – 17,250 PPH. Note that the device must be installed with the bowl pointing up. 2. Field Setup Refer to Vendor’s manual for full technical details. 2.1 Prior to powering the device, check wiring for shorts or grounds per the tabulation on the Sign-off Sheet. 2.2 Inspect unit for correct installation and connection per the drawings. 2.3 Confirm correct flow direction. 2.4 Unit is factory calibrated, field calibration is not required. 2.5 Assure that sensing tubes are filled with gas. 2.6 Assure that there is no flow through the meter. Valve off to the extent practical. 2.7 Power the meter and allow it to warm up and temperature stabilize for 30 minutes. 2.8 NOTE: The meter should be factory set for the correct output units and range, 420ma corresponding to 0 – 17,250 PPH. This can be verified using a HART communicator. 2.9 Using a HART communicator in “Diagnostics” mode, inject a 4 ma signal into the control. Adjust the offset on FM1101A(B) as necessary to display a zero flow. 2.10 Using a HART communicator in “Diagnostics” mode, inject a 20 ma signal into the control. Adjust the gain on FM1101A(B) as necessary to display a 17,250 PPH flow. 2.11 It is not necessary to zero the meter. 2.12 Replace the transmitter cover. 2.13 Record results on the Sign-off Sheets.

21.2

FM801 - Water Injection Flow Meter

1. General Water injection flow to each engine is measured by a Micro Motion series R sensing unit (CT117475-1) with an integrally mounted IFT 9703 series transmitter. The unit is horizontally mounted in the piping in the water injection skid downstream of SOV801. The transmitter supplies a 4-20ma signal directly to an analog input to the Micronet control at 1-6-A channel 7

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for the “A” engine and 1-6-B channel 22 for the “B” engine. Flow is displayed on the ICE monitor in PPH. 24 VDC power for the meters is supplied via fuses MTB2 FU5 and FU9 for “A” and MTB3 FU5 and FU9 for “B”. The 4-20ma output range corresponds to 0 – 20,000 PPH (0-72 GPM). 2.

Field Setup Refer to Vendor’s manual for full technical details. 2.1

Prior to powering the device, check wiring for shorts or grounds per the tabulation on the Sign-off Sheet. 2.2 Inspect unit for correct installation and connection per the drawings. 2.3 Confirm correct flow direction. 2.4 Unit is factory calibrated, field calibration is not required. 2.5 Assure that sensing tubes are filled with water before zeroing the meter. 2.6 Assure that there is no flow through the meter. Valve off to the extent practical. 2.7 Power the meter and allow it to warm up and temperature stabilize for 30 minutes.. 2.8 NOTE: The meter should be factory set for the correct output units and range, 420ma corresponding to 0 – 20,000 PPH. This can be verified using a HART communicator. 2.9 Zero the meter by removing the lower cover on the transmitter housing. Press and hold the zero button until the flashing red LED stops flashing and remains illuminated. After approximately one minute the LED will again flash once per second indication that the zeroing process is complete and the flow meter is ready for operation. 2.10 Replace the transmitter cover. 2.11 Record results on the Sign-off Sheets.

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PROCEDURE 22 - ALIGNMENT CHECKOUT PROCEDURE 22.0 Alignment Checkout Procedure NOTE PWPS Mechanical Field Assembly drawing XXXX-113-S000D and – S000B specifies the exact alignment requirements for each site. These PWPS drawings take precedence over this procedure.

22.1 Equipment and Tools Required. Special tools, equipment and consumables are shown below. SPECIAL TOOLS:

TOOL NUMBER

TOOL NAME

TC350-115 TC350-116

Cradle (1)* Rail (2 pieces) or

PWA 77582 TC350-117

Cradle Support Compressor (Lucas)(5) or

TC350-118 TC350-165

Compressor (Kop-flex)(3) Parallel bars

ADDITIONAL TOOLS:

CONSUMABLES:

Magnetic base (2) Dial indicator, 0 to 1-Inch (2 Required) ID Micrometer, 0 to 4-Inch or Equivalent Center Head SPECIFICATION NUMBER

CONSUMABLE NAME

PWA 521 PWA 586

Engine Oil Anti-seize compound

22.2 Preliminary Alignment Information CAUTION Do not remove either coupling when the engine is not installed. Damage to coupling may result. 1.

GG/PT output shaft alignment to driven equipment must be completed prior to collector box alignment.

2.

Rear coupling must be removed for GG/PT output shaft alignment to driven equipment. Note whether Kop-flex or Lucas tools are required. Clean peripherally machined surface on the driven equipment shaft for the indicator stylus to ride on.

3.

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4.

Collector box seals must be removed for GG/PT output shaft alignment to driven equipment and collector box alignment to diffuser. Identify them by number to ensure they will be reinstalled in the same location.

5.

Alignment must be done at a relatively constant ambient temperature.

6.

All alignment equipment and gages must be at ambient temperature and calibrated as necessary.

7.

Normally, at ambient conditions, there is a certain amount of misalignment. Use temperature compensation factors (See Paragraph 22.3.6, Section 5A) and blueprint tolerances to calculate results, which will reflect normal running dynamics and temperatures.

8.

Ensure that the output shaft is properly supported at all times.

9.

Directional references: A. Forward - Standing between the power turbine and driven equipment, looking toward the gas generator. B. Facing forward, view locations as a clock - 12 o’clock position is at the top of the GG, PT, etc., 3 o’clock is on the right side, 6 o’clock is at the bottom and 9 o’clock is on the left side. C. Front - Toward the inlet of the GG. D. Rear - Toward the driven equipment.

22.3 Gas Turbine/Power Turbine and Output Shaft Alignment 22.3.1 Output Shaft Alignment Preparation 1.

Obtain the required tolerances from site-specific drawings or blueprints.

2.

Mark and remove all front and rear collector box seals. Disconnect and cap number 8/9 scavenge and PT621 scavenge pressure sense lines where they exit the diffuser tunnel. Ensure associated pumps are turned off, tagged and locked out.

3.

Mount the alignment fixture.

22.3.2 Flange-mounted shaft support (“Spider”; Support, Cradle, PWA77582) 1.

Attach the two (2) upper supports of the alignment fixture to the fourth hole on either side of the 12 o’clock hole, and the lower support to the 6 o’clock hole on the diffuser rear flange.

2.

Place the cradle on top of the rail and adjust as necessary to support the rear of the output shaft.

3.

Remove the rear coupling from between the output shaft flange and the driven equipment shaft flange.

22.3.3 Long Tunnel-Rail (PWA P/N TC350-116) 1.

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Assemble the two (2) rail pieces together and attach the rear support to the rail.

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2.

Place the rail inside the tunnel and attach the rail to the flange inside the tunnel and the support to the outer diffuser flange.

3.

Place the cradle on top of the rail and adjust as necessary to support the rear of the output shaft.

4.

Remove the rear coupling from between the output shaft flange and the driven equipment shaft flange.

22.3.4 Output Shaft Centerline Run-Out CAUTION Always maintain rotation in the direction of normal power turbine rotation (CW or CCW). Do not reverse rotation. If the desired stop point is passed, go around again. 1.

Mount a vertical dial indicator securely to a magnetic base on the forward end of the output shaft so that the stylus is positioned on a bolt head on the rear face of the forward flange of the front coupling.

2.

Rotate the power turbine manually, in the proper (CW or CCW) direction, and make adjustments as necessary to remove the deflection of the output shaft within ± .001-inch FIR (Full Indicated Reading). This can be done using the thumbscrews and jackscrew adjustments on the cradle. It is essential to make this reading as small as possible since it has an amplified influence on the run-out readings at the generator end of the driveshaft. A. Zero the indicator at 12 o’clock (allow for plus and minus readings) then rotate the shaft and stop at 6 o’clock and read dial. Raise (if reading is positive) or lower (if reading is negative) the jackscrew to one-half (½) the indication on the dial. B. Zero the indicator at 3 o’clock (allow for plus and minus readings) then rotate the shaft and stop at 9 o’clock and read dial. Move the cradle to the left (if the reading is positive) or to the right (if reading is negative) with the thumbscrews to one-half (½) the indication on the dial. C. Zero the indicator at 12 o’clock (allow for plus and minus readings) then rotate the shaft and stop at 3 o’clock, 6 o’clock and 9 o’clock and record the dial readings. Repeat steps “A” and “B” if readings do not fall within the specified ± .001-inch FIR.

22.3.5 Peripheral Run-Out NOTE Throughout this procedure, be sure to maintain correct output shaft centerline alignment by referring back to the dial indicator mounted on the front end of the output shaft. Failure to do this will seriously affect the accuracy of the alignment. 1.

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Mount a horizontal dial indicator securely to a magnetic base on the rear end of the output shaft so that the stylus is positioned, across the coupling gap, on a peripherally machined surface of the driven equipment shaft.

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2.

Zero the indicator at 12 o’clock (allow for plus and minus readings) then rotate the output shaft in the proper (CW or CCW) direction as in “B”, above. Stop at 3 o’clock, 6 o’clock and 9 o’clock and record the dial reading at each position. Note whether positive or negative.

3.

Repeat Step 2 above two (2) additional times for a total of three (3) readings at each position. The readings should be repeatable all three times. Record the readings on the PWPS Sign-off Sheet. The 6 o’clock reading should approximately equal the sum of the 3 o’clock plus 9 o’clock readings.

22.3.6 Pin Gage Measurement The manufacturer of the driven equipment will establish the correct running position for the rotating element and often will stamp this dimension on the equipment itself (usually on or near a machined surface adjacent to the shaft). Once the driven equipment has been installed, the design position of the rotating element must be re-established.

NOTE Deviations from the original (design) pin gage dimension must be added to or subtracted from the axial measurements. Proper alignment is dependent on establishing the correct pin gage measurement. After the driven equipment has been operated minor deviations from the original pin gage dimension will occur and must be compensated for. This is accomplished as follows: 1.

Compare the actual pin gage with the design dimension. A. If the actual dimension is longer than the original pin gage, subtract the difference from the axial measurement. B. If the actual dimension is less than the original pin gage, add the difference to the axial measurement.

2.

This calculation determines if the power turbine is too close or too far away from the driven equipment, and will determine the amount of shim material will be required for final placement.

22.3.7 Axial Measurements This measurement measures the gap between the output shaft rear flange and the driven equipment shaft flange.

NOTE Throughout this procedure, be sure to maintain correct output shaft centerline alignment by referring back to the dial indicator mounted on the front end of the output shaft. Failure to do this will seriously affect the accuracy of the alignment. 1.

Clamp a straightedge onto the face of the output shaft rear flange.

2.

Rotate the output shaft in the proper (CW or CCW) direction to obtain gap measurements at 12 o’clock, 3 o’clock, 6 o’clock and 9 o’clock using an ID micrometer or equivalent. Be sure to include the thickness of the straightedge.

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NOTE At the 3 o’clock and 9 o’clock positions, the readings must be equal to within + 0.010-inch (0.254 mm) or – 0.010-inch. Readings at the 12 o’clock and 6 o’clock positions must differ as shown on site drawings. Additionally, the centerline of the output shaft must be − 0.188-inch ± 0.025-inch (0.635 mm) below the driven equipment shaft measured where the extension of the output shaft centerline meets the adapter plate. If not, shimming will be required. 3.

Repeat Step 2 above two (2) additional times for a total of three (3) readings at each position. The readings should be repeatable all three (3) times. Record the readings on the Sign-off Sheet.

4.

Refer to the site drawings or blueprints for the desired axial readings.

5.

The axial gap must be temperature compensated to account for the difference between actual and specified ambient temperature.

The correction factor is normally 0.0009-Inch (0.41148 mm) for each degree above or below 59° F (15° C). Record the readings on the Sign-Off Sheet.

22.3.8 Shim Adjustments The coupling flanges are brought into the desired alignment by adding or removing shims of the required thickness at the front and rear mounts or the front or sides of the keel pin plate on the mounting base. The calculations will determine how much and the direction of movement.

NOTE Engine and power turbine mounting bolts and keel block locking bolts are all torque to 120° ± 30° after snug (320 to 340-Ft/lb.)

22.3.8.1 Output Shaft Centerline Vertical Adjustment To move the output shaft centerline vertically: 1.

Add or remove shims under both front and/or both rear mounts depending on the amount of movement required.

22.3.8.2 Output Shaft Centerline Lateral Adjustments To move the output shaft centerline laterally (horizontally): 1.

Remove shims from under one front mount and install the same thickness under the other front mount,

and/or 2.

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Remove shims from one side of the keel block mount, move the keel block with the jackscrews and install the same thickness under the other side.

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22.3.8.3 GG/PT Forward or Reverse Adjustments To move the GG/PT forward or rearward: 1.

Add or remove shims in front of the keel block mount and move the keel block with the jackscrews.

22.3.8.4 Output Shaft Alignment Calculations LEGEND:

A1 L1 L2 V1 V2 V3 V4 V5 V6 V7

= = = = = = = = = =

Axial Movement Keel Block Lateral Movement GG Front Mount Lateral Movement PT Mount Vertical Movement I PT Mount Vertical Movement II Total PT Vertical Movement GG Front Mount Vertical Movement I GG Front Mount Vertical Movement II GG Front Mount Vertical Movement III Total GG Front Mount Vertical Movement

FORMULAS: A1: Axial Movement A1 = Corrected Axial Gap (12:00 + 3:00 + 6:00 + 9:00) _ Actual Axial Gap (12:00 + 3:00 + 6:00 + 9:00)

L1: Keel Block Lateral Movement L1 = (Actual 3:00 – 9:00 peripheral dims)+(Corrected 3:00 – 9:00 axial dims)X118.5-inch [Front to rear distance] 2 22.5-inch [Coupling diameter] L2: GG Front Mount Lateral Movement L2 = L1 + (Corrected 3:00 – 9:00 axial dims) X 114.265-Inch [Rear mount to coupling distance] 22.5-inch [Coupling diameter] L2 = ____________ in. (Remove shims from one front mount and install in other front mount)

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V1: PT Mount Vertical Movement I V1 = (Actual 12:00 – 6:00 peripheral dims) – (Design 12:00 – 6:00 peripheral dims) 2 2 V1 = ____________ in. V2: PT Mount Vertical Movement II V2 = (Corrected 12:00–6:00 axial dims) – (Design12: 00–6:00 axial dims) X 18.5-inch [Front to rear dist] 22.5-inch [Coupling diameter] 22.5-inch [Coupling diameter] V2 = ____________ in.

V3: Total PT Mount Vertical Movement V1 + V2 = ____________ in. V4: GG Front Mount Vertical Movement I V4 = V1 V5: GG Front Mount Vertical Movement II V5 = (Corrected 12:00–6:00 axial dims) – (Design12:00–6:00 axial dims) X 118.5-inch [Front to rear dist] 22.5-inch [Coupling diameter] 22.5-inch [Coupling diameter] V5 = ____________ in. V6: GG Front Mount Vertical Movement III V6 = (Corrected 12:00–6:00 axial dims)–(Design 12:00–6:00 axial dims)X114.265-inch (Rear to coupling distance) 22.5-inch [Coupling diameter] 22.5-inch [Coupling diameter] V6 = ____________ in.

V7: Total GG-Front Mount Vertical Movement V7 = (V4 + V5 + V6) 0.866

Rev. 4

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ILLUSTRATION:

1. Mounting Hardware 2. Output Shaft Tooling 3. Output Shaft Alignment 4. Right Side Elevation (Dimensions) 5. Peripheral Run-Out Measurements 6. Axial Gap Measurements 7. Pin Gage Measurements 8. Shim Locations 9. Equipment Moves 10. Keel Block Layout

Figure 22-1 Gas Generator / Power Turbine Alignment Illustrations

Rev. 4

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Figure 22-2 Mounting Hardware DRIVING EQUIPMENT DRIVEN EQUIPMENT BEFORE ALIGNMENT

DRIVING EQUIPMENT

0 + .001 FOR 360° ROTATION

DURING ALIGNMENT

DRIVING EQUIPMENT AFTER ALIGNMENT

DRIVEN EQUIPMENT

DRIVEN EQUIPMENT

Figure 22-3 Output Shaft Tooling

Rev. 4

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GENERATOR COUPLING ADAPTOR FLANGE FACE TURBINE COUPLING ADAPTOR FLANGE FACE REAR MOUNT AND KEEL BLOCK PLANE

FRONT MOUNT PLANE

DIMENSION “D”

114.265”

118.5”

LUCAS COUPLING DESIGN SPACE KOP-FLEX REAR MOUNT COUPLING PLANEDESIGN TO TURBINE SPACECOUPLING PLUS DIMENSION “D”

Figure 22-4 Output Shaft Alignment

Rev. 4

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12 O’CLOCK

OUTPUT SHAFT FLANGE

3 O’CLOCK

9 O’CLOCK

DRIVEN EQUIPMENT FLANGE 6 O’CLOCK NOTE: VIEWED FROM GG LOOKING TOWARDS DRIVEN EQUIPMENT

Figure 22-5 Right Side Elevation (Dimensions)

Rev. 4

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PARALLEL BAR

MEASURE AXIAL GAP

OUTPUT SHAFT COUPLING ADAPTOR

Figure 22-6 Peripheral Run-out Measurements

Rev. 4

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PIN GAUGE DISTANCE

DRIVEN EQUIPMENT FLANGE

MACHINED SURFACE

DRIVEN EQUIPMENT

Figure 22-7 Axial Gap Measurements

Rev. 4

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Figure 22-8 Pin Gage Measurements

Rev. 4

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Figure 22-9 Shim Locations and Equipment Moves

Rev. 4

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Figure 22-10 Shim Locations BOLTS

SHIMS

SHIMS BOLTS KEEL BLOCK JACK SCREW

(TOP VIEW)

BOLTS

JACK SCREW

SHIMS BOLTS

RETAINING NUT

JACK SCREW

Figure 22-11 Keel Block Layout

Rev. 4

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22.4 Collector Box Alignment (Vertical Exhaust) NOTE Mounting of the collector box differs for the SWIFTPAC™ configuration. Refer to PWPS Mechanical Field Assembly drawings XXXX-113-S000D and – S000B. Refer to Preliminary Alignment information contained in paragraph 22.2. 1.

Measure and record both front and rear gaps between the diffuser and collector box in the “as found” blanks of the sign-off section. They must fall within the blueprint (specification) limits. If not, proceed.

2.

Measure and record, in the “as found” blanks of the sign-off section, the axial offset of collector box with reference to the diffuser flanges (front and rear). They must fall within the blueprint (specification) limits. If not, proceed.

NOTE Collector box mounting hardware may be both rods and locking nuts on threaded ends or turnbuckle type devices. 3.

Loosen: A. All the self-locking nuts on the four (4) vertical support rods located at the corners of the collector box. B. The nuts securing the two (2) thrust rods on either side of the collector box. C. The hardware on the front side of the collector box securing the bottom of the box to the triangular support plate. This will allow the collector box to be moved into its proper position without restrictions.

4.

Disconnect and/or remove anything attached to the collector box that could affect movement during alignment. This includes bleed valve exhaust duct flex lines and 6th stage spent-air line(s) coming from the engine to either side of the collector box, inside the engine enclosure. Also, disconnect the No. 8 and 9 oil scavenge and pressure sense lines from the rear side of the collector box.

5.

Using the six turnbuckles, move the collector box to its proper position. A tape measure or “go/no-go” gages should be used to verify position. If the “go/no-go” gages are used, two sizes will be required to accommodate the front and rear of the collector box.

NOTE After each move, check for inadvertent counter-moves that may be caused by thermal distortion of the collector box or blueprint tolerances. The collector box may not stay positioned in the desired orientation.

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6.

Equalize the side-to-side (3 o’clock and 9 o’clock) measurements on both front and rear of the collector box. A. Align the vertical position, both front and rear, so that the gap at 12 o’clock is approximately 0.400-inch larger than the gap at 6 o’clock. B. Axially position the collector box so that the front side of the box (seal mounting area) is no more that 0.125-inch to the rear of the diffuser front flange (seal mounting area toward the engine). 1) In some cases, as per the NOTE above, the best possible placement may be to “split the difference”. Refer to the numbers recorded on the drawings in the sign-off section for the “as found” position. 2) Record all final measurements in the “as left” blanks of the sign-off section. Include horizontal dimensions (3 o’clock and 9 o’clock), vertical dimensions (12 o’clock and 6 o’clock) and axial dimensions (front and rear). 3) Tighten all the self-locking nuts on the four vertical support rods located at the corners of the collector box, the nuts securing the two thrust rods on either side of the collector box and the hardware (located on the front side of the collector box) securing the bottom of the collector box to the triangular support plate.

NOTE The upper self-locking nuts should be snug, not tightened. This is to account for thermal expansion to prevent the support rods from breaking. C. Recheck all measurements for movement. Re-adjust as necessary. 7.

Ensure that there is a minimum gap between the edge of the collector box seals and the bottom of the mating groove per Table 22-1.

NOTE All seals must be checked. FRONT SEALS

REAR SEALS

12:00

0.55 to 0.75-inch

12:00

0.60 to 0.80-inch

3:00

0.40 to 0.60-inch

3:00

0.40 to 0.60-inch

6:00

0.25 to 0.45-inch

6:00

0.20 to 0.40-inch

9:00

0.40 to 0.60-inch

9:00

0.40 to 0.60-inch

Table 22-1 Collector Box Seal Gap Measurements

Rev. 4

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A. Proceed as follows: 1) Insert the seals, one at a time, in their proper locations and bottom them out in the mounting groove. 2) With a suitable marker, trace edge of the mounting groove onto the seal. 3) Move the seal out to its mounting position, secure with at least two bolts, and trace the edge of the mounting groove again. Remove the seal and note the distance between the lines. 4) If the distance is too small, remove the seal and grind off the excess material. If the distance is too large, notify PWPS engineering. 8.

Install all front and rear collector box seals after ensuring dimensional compliance. Installation must be in the same location as removed.

9.

Reconnect the bleed valve exhaust duct flex lines and 6th stage spent-air line(s) coming from the engine to either side of the collector box, inside the engine enclosure. Also, reconnect the No. 8 and No. 9 oil scavenge and pressure sense lines at the rear side of the collector box.

22.5 Collector Box Alignment (Horizontal Exhaust) Refer to Preliminary Alignment Information in Paragraph 22.2. 1.

Measure and record both front and rear gaps between the diffuser and collector box in the “as found” blanks of the sign-off section. They must fall within the blueprint (specification) limits. If not, proceed.

2.

Measure and record, in the “as found” blanks of the sign-off section, the axial offset of collector box with reference to the diffuser flanges (front and rear). They must fall within the blueprint (specification) limits. If not, proceed.

3.

Loosen all the self-locking nuts on the four (4) vertical support rods located two front and two rear on the collector box; loosen the nuts securing the four (4) horizontal thrust rods two at the top and two at the bottom of the collector box Loosen three (3) axial tie rods, two securing the mid-section and one at the top of the collector box. This will allow the collector box to be moved into its proper position without restrictions.

4.

Disconnect and/or remove anything attached to the collector box which could affect movement during alignment. This includes bleed valve exhaust duct flex lines and 6th stage spent-air line(s) coming from the engine to either side of the collector box, inside the engine enclosure. Also, disconnect the No. 8 & 9 oil scavenge and pressure sense lines from the rear side of the collector box.

5.

Using the six turnbuckles, move the collector box to its proper position. A tape measure or “go/no-go” gages should be used to verify position. If the “go/no-go” gages are used, two sizes will be required to accommodate the front and rear of the collector box.

NOTE After each move, check for inadvertent counter-moves that may be caused by thermal distortion of the collector box or blueprint tolerances. The collector box may not stay completely positioned in the desired orientation.

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A. Equalize the side-to-side (3 o’clock and 9 o’clock) measurements on both front and rear of the collector box. B. Align the vertical position, both front and rear, so that the gap at 12 o’clock is approximately 0.400-inch larger than the gap at 6 o’clock. C. Axially position the collector box so that the front side of the box (seal mounting area) is no more that 0.125-inch to the rear of the diffuser front flange (seal mounting area toward the engine). 1) In some cases, per the NOTE above, the best possible placement may be to “split the difference”. Refer to the numbers recorded on the drawings in the sign-off section for the “as found” position. 2) Record all final measurements in the “as left” blanks of the sign-off section. Include horizontal dimensions (3 o’clock and 9 o’clock), vertical dimensions (12 o’clock and 6 o’clock) and axial dimensions (front and rear). 3) Tighten all the self-locking nuts on the four vertical support rods located at the corners of the collector box. Also tighten the nuts securing the two thrust rods on either side of the collector box and the hardware (located on the front side of the collector box) securing the bottom of the collector box to the triangle support plate.

Rev. 4

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COLLECTOR BOX ALIGNMENT ILLUSTRATIONS ILLUSTRATIONS:

1. Rear Seal Gap 2. Vertical Exhaust Collector Box 3. Horizontal Exhaust Collector Box

Rev. 4

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SEAL GAP

.12 + .12 AVERAGE ALL AROUND

M + .40 + .10

X

X + .10

M

REAR SEAL GAP NO SCALE

Figure 22-12 Seal Gap

Rev. 4

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FOUR VERTICAL TIE-RODS (2 FRONT, 2 REAR)

EXHAUST

TWO AXIAL TIE-RODS (FRONT ONLY)

THIS END ATTACHED TO ENGINE BASE

LOCATOR PLATE “HORIZINTAL RETRAINT”

Figure 22-13 Vertical Exhaust Collector Box

Rev. 4

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FOUR VERTICAL TIE-RODS (2 FRONT 2 REAR)

ENCLOSURE WALL

EXHAUST

THREE AXIAL TIERODS (FRONT ONLY)

THIS END ATTACHED TO ENGINE BASE

HORIZONTAL TIE-RODS (2 FRONT 2 REAR)

LOCATOR PLATE “HORIZONTAL RESTRAINT

Figure 22-14 Horizontal Exhaust Collector Box

Rev. 4

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PROCEDURE 23 – LUBE OIL FUNCTIONAL TEST 23.0 Lube Oil Systems Flush, Pressure Adjustment and Functional Test Checkout Procedures 23.1 Lube Oil Flush Procedure (Combined Free Turbine, Gas Generator Supply and Gas Generator Scavenge) NOTE Swift Pac and Mobile Pac units are flushed at the factory. Field flushing is NOT required.

23.2 Adjustment of PRV 23.2.1 Adjustment of Internal Gearbox PRV The PRV internal to the gearbox must be adjusted for maximum pressure via full clockwise (CW) adjustment, before the first start of a system. Refer to GG8 maintenance manual P/N 807421, section 8 for location and accessibility of adjustment. 1. Assure that the plastic vent plug is removed from the back side (side facing the turbine enclosure) of PDCV606, GG LO pressure control valve. 2. Carefully inspect the instrument tubing coming from the F606, GG LO supply filter assembly. 3. Assure that the high and low pressure sense tubing connections are correct.

23.2.2 Adjustment of Externally Mounted PRV The externally mounted PRV is a pilot operated device that shall be adjusted to maintain engine oil pressure as measured at PT612. Before first engine start, an initial adjustment should be made to the pilot valve to prevent over or under pressurization. Initial adjustment is: 1. Turn the adjusting screw fully counter clockwise (CCW) 2. By hand only, turn the adjusting screw clockwise until screw to spring contact can be felt. 3. Continue 2 1⁄2 to 3 more turns clockwise (CW). 4. After engine start, final adjustment should be made at idle speed. Adjust until pressure measured at PT612 is 46 ±4 PSIG. Oil pressure oscillation greater than ±3 PSI is not permitted.

23.3 Lube Oil Functional Test The purpose of this functional test is to verify that both the gas turbine and generator lube oil pumps will transfer to the back-up pumps, properly annunciate equipment malfunction or failure and initiate trips as necessary in the event of a pump failure.

October 6, 2006 Rev. 4 Homepage

Procedure 23 - 1 Previous Document

23.3.1 Set-Up 1. Reset all lockout relays. 2. Verify that the DC breakers are closed to both the gas turbine and generator DC lube oil pumps. 3. Open the doors to the MCC buckets to the gas turbine and generator AC lube oil pumps. 4. The test steps 1-7 can be completed at any time after the control system and lube oil systems are operational. This test will prove the basic functionality of the MCC lube oil system and control. A full function test is required but the system should be in an actual run sequence.

23.3.2 Gas Turbine “A” Lube Oil Pump Test: 1. Verify that both gas turbine “A” AC lube oil pumps are in AUTO mode. 2. Verify that gas turbine “A” DC lube oil pump is in AUTO mode. 3. On the ICE monitor, go to the flow diagram page for gas turbine “A” lube oil system. 4. In initiate a system test from the ICE Monitor screen. AC lube oil pump #1 should start. 5. Select switch pumps on the ICE monitor. The AC lube oil pumps should switch 6. Pull out the overload relay indicator on the running AC pump. (#2) The AC lube oil pumps should switch 7. Pull out the overload relay indicator on the running AC pump (#1). The test should abort. 8. Repeat test for gas turbine “B” and generator lube oil systems.

23.3.3 Full Function Test Full function tests can be completed after the checkout has proceeded to the point where a “Ready to Start” condition can be achieved on the unit. These tests may be completed as a portion of the Incomplete Sequence Tests, Procedure 28. 1. Initiate a “run” sequence.

CAUTION Do not attempt to rotate the engines or start the unit. The MCC overloads should be in the MANUAL position for this test. Put selector switches back in the AUTO position after the test. An “E” stop may be initiated after the LO systems have started. This will halt the start engine sequence but the LO systems will continue to operate. Reset the 86 lockout relays and the control system to continue with the functional test.

October 6, 2006 Rev. 4 Homepage

Procedure 23 - 2 Previous Document

Gas turbine ”A”, “B” and generator lube oil systems should start and run. One AC pump and the DC pump for that system should start. The DC pump should shut off after 20 seconds. 2. On the ICE monitor, go to the flow diagram page for gas turbine “A” lube oil system. 3. Select switch pumps on the ICE monitor. The AC lube oil pumps should switch. 4. Pull out the overload relay indicator on the running AC pump. The AC lube oil pumps should switch. 5. Pull out the overload relay indicator on the running AC pump. The DC lube oil pump should start and the lockout relays should trip (86EA, 86EB and 86E). 6. Reset the AC pump MCC bucket overload relays. AC pump should start and the DC pump should stop after 20 seconds. Reset the lockout relays and the control system. 7. Select switch pumps on the ICE monitor. The AC lube oil pumps should switch. 8. Pull out the overload relay indicator on the running AC pump. The AC lube oil pumps should switch. 9. Pull out the overload relay indicator on the running AC pump. The DC lube oil pump should start and the lockout relays should trip (86EA, 86EB and 86E). 10. Reset the AC pump MCC bucket and the lockout relays (86E, 86EA, 86EB). AC pump #1 should start and the DC pump should stop after 20 seconds. 11. Repeat the above steps, but fail the running pump by turning the operate switch on the MCC bucket from “AUTO” to “OFF” in place of pulling the overload. Alarms and trips should be similar to previous steps except without the overload alarm.

23.4 Gas Turbine “B” Lube Oil Pump Test Repeat steps 1 through 11, paragraph 23.3.3 above for gas turbine B lube oil system pumps.

23.5 Generator Lube Oil Pump Test Repeat Steps 1 through 11, paragraph 23.3.3 above for the generator lube oil system pumps

23.6 Generator Lube Oil System Test (Mobile Pac) Under Development

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Procedure 23 - 3 Previous Document

PROCEDURE 24 – COLD AIR BUFFER SYSTEM 24.0 Cold Air Buffer System Checkout Procedure

Refer to PWPS drawings XXXX-187-E101D and XXX-181-M502D

24.1 Overview The cold buffer air-cooling system cools the 13th stage engine air in a two-chamber, plate and fin, air to air, heat exchanger. During operation, engine airflow to the heat exchanger is constantly metered through orifice plates to separate chambers of the heat exchanger. The air is then piped to the #4 & #5 bearing compartment at 350° F, and to the #6 bearing compartment at 160° F. The hot engine air is cooled by ambient air forced upwards through the heat exchanger by a variable speed axial flow fan. Ambient air will exit the heat exchanger at approximately 315°F. The motor is driven by an Allen-Bradley 1305 variable frequency drive (VFD). The VFD has a set of terminals to receive the start command from the MicroNet controller (and a set of terminals to report an alarm condition to the MicroNet controller. There are two RTD’s on the heat exchanger output (return to engine) pipes. RTD TE1601 and RTD TE1602 report to the MicroNet controller and will initiate drive back. A PID Loop in the MicroNet Controller, which senses the temperature from RTD TE1601 on the air return to the #4 & #5 bearing compartment, controls the speed of the fan motor. The loop controller varies the speed of the fan via a 4-20 mA signal to the VFD. The VFD simply converts the signal for use by the motor.

24.2 Cold Buffer System Cleaning/Flushing This section applies to cold buffer system field fabricated piping only. Factory fabricated piping requires only cleaning with lint free media during assembly. See section 4.8.7.2.

24.3 Checkout 1. Megger all power cables, but do not megger VFD. Power cables may be unplugged at the MCC. 2. Check for the presence and proper layout of all electrical equipment associated with this system per the P&ID. Electrical components should consist of: A. Two RTD’s, normally located in the return heat exchanger piping, will be connected through a common junction box in the engine enclosure. Refer to PWPS drawing XXXX-187-E101D, Sheets 25 & 29. RTD TE1601A and RTD TE1601B shall be located on the #4 & #5 bearing compartment air return, connected to MicroNet controller. RTD TE1602A and RTD TE1602B shall be located on the #6 bearing compartment air return, connected to MicroNet controller. B. The heat exchanger MCC buckets 10A and 10B and the Allen-Bradley VFD, which are located in the buckets in the control room. The Mobiloe Pac uses MCC bucket 4B 3. Visually inspect for proper wiring of all components

October 2, 2006 Rev. 6 Homepage

Procedure 24- 1 Previous Document

4. Physically check all electrical connections in this system to assure they are tight and correct. 5. Perform continuity checks of all conductors to verify connections per the schematic. 6. Perform visual and mechanical checks of all switches and circuit breakers 7. Check and record motor resistances. 8. Check for any fan inlet obstruction. Clear fan intake area of any loose material that could be drawn into inlet. 9. Check for presence of rodent screen. Ensure screen is securely mounted. 10. Allen-Bradley Variable Frequency Drive Setup: A. MCC bucket molded case circuit breaker should be OFF. B. If not already done, install the Human Interface Module (HIM) by lowering the hinged panel and sliding the HIM into position. C. Remove the START COMMAND wires at HX1 / 7 and 8 or verify NO START COMMAND to the VFD. D. Close the MCC breaker. The fan should not rotate. If it rotates, shut off power and check junction box wiring.

NOTE If the HIM does not connect properly, follow the procedure on page 4-3 of the Allen-Bradley manual: STOP AT STEP 9. Continuing will initiate the power up procedure, which would reset operating parameters to factory defaults. E. Use the up or down arrow keys to enter the SETUP mode F. Scroll through the values to ensure that they correspond to the values below. Parameter names will appear in [brackets]; display text will appear in “quotes”. Refer to pages 5-1, 5-2, and 5-8 thru 5-13 of the Allen-Bradley manual. 1) Use the “UP” or “DOWN” arrow keys until “PROGRAM” shows on the LCD display. Press, “ENTER”. 2) Use the “UP” or “DOWN” arrow keys until “SETUP” shows on the LCD display. Press, “ENTER”. “RUN FWD/REV” will show on the LCD display. 3) Use the “UP” or “DOWN” arrow keys to check the tabulated values. Advanced Setup 4) Use the “UP” or “DOWN” arrow keys until “PROGRAM” shows on the LCD display. Press, “ENTER”.

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Procedure 24- 2 Previous Document

5) Use the “UP” or “DOWN” arrow keys until “ADVANCED SETUP” shows on the LCD display. Press, “ENTER”. 6) Use the “UP” or “DOWN” arrow keys to check the tabulated values. Input Mode Freq Select 1 Accel Time 1 Decel Time 1 Base Frequency Base Voltage Maximum Voltage Minimum Freq Maximum Freq Stop Select Current Limit Overload Mode Overload Current Sec Curr Limit Under Advance Set-Up steps 4 & 5 DC Boost Select 4 to 20 mA Loss Sel -

RUN FWD/REV 4-20 mA 30 sec 30 sec 60 Hz (always) 460 V (always) 460 V (always) 5 Hz (NOT 0 Hz) 85 Hz ramp 150% No Derating 7.83 amps 0% Fan Select #1 Min/Alarm

If these values are incorrect, change them to the above values. Follow directions in Chapter 5 of the Allen-Bradley manual for setting these parameters.

CAUTION The input, which controls the fan, can be changed from the SETUP mode. If Frequency Select is set to “4-20 mA”, the RTD will automatically control the fan when the Micronet sends a command and the permissive. However, if Frequency Select is changed to “Adapter 1”, the potentiometer on the HIM can be used to manually control the fan speed during checkout (if furnished). This parameter must be reset to 4-20 mA input prior to starting the engine. The base frequency, base voltage, maximum voltage will always be set at 60 Hz, 460 volts and 460 volts respectively, regardless of input voltage and frequency. G. Jumper terminals HX1 / 9 and 10 and verify VFD alarm on the monitor. 11. Heat exchanger fan energization, rotation, and speed control check: A. Unit controls are needed to check motor rotation. B. Under the scales on Citect scroll down to Cold Air Buffer C. Press the “Valve (A or B) Mode” button to select manual control of the selected fan. Press the “Discretes in Manual” button to place the discrete outputs in Manual (Breakers

October 2, 2006 Rev. 6 Homepage

Procedure 24- 3 Previous Document

to the DC pumps should be OFF to prevent the pumps from operating). Press the “Cold Buffer Enable” button to send the RUN command to the VFD. D. Place the curser over the SET POINT window, type in the requested setting from the keyboard and press ENTER. E. The fan will rotate at the selected speed. 13. Check all junction boxes to ensure they are correctly sealed and weatherproof. 14. Check that field piping is complete in accordance with field piping assembly drawings. Check for presence of all mechanical equipment associated with this system, and proper layout per the P&ID. 15. Lubricate the heat exchanger fan motor per vendor instructions. 16. Check all piping flanges for loose fasteners and all pipe hangers to ensure that temporary hangers have been removed. 17. Orifice kits are provided as a part of the XXX-138-M000B Bill of Materials as part number CT116811-x for the 2 inch piping and CT116812-x for the 1 1⁄2 inch lines. They may be listed as kits IPE24263-GR2 or IPE24351-GR2 or –GR3. 18. Insure installation of nominal orifice plates as provided with the system: 2-inch pipe, #4-5 line orifice, 0.880 inch diameter hole for FT8-1 installations and 0.821 inch diameter for FT8-3 installations. 1-1/2-inch pipe, #6 line orifice, P/N IPD22389-0320, 0.320 inch diameter hole for FT8-1 installations and 0.328 inch diameter for FT8-3 installations. PWPS supplies two kits with a selection of orifice plates in the event that a field adjustment is required. 19. Install insulation on piping as per drawings. 20. Check orifice installation size during procedure 37. Use the Excel Spreadsheet included in Appendix (?) to check pressure ratios. Record tabulated data on the spreadsheet. Use a minimum of three readings at the same steady state power level for calculations. Record readings at approximately 10 minute intervals at base load or highest attainable steady state load if lower than base after thermal stabilization is achieved. Change orifices as necessary after shutdown. Calculations must be rechecked after each orifice change. A. Prior to running the engine(s), install temporary pressure gages at the sample ports provided in the piping near TE1601 and TE1602. Use hoses rated for high temperature to locate the gages at an area that will not be affected by power turbine radiant heat during operation, preferably outside the enclosure. B. Measure the Cold Buffer Heat Exchanger return air pressures to the #4-5 compartment and #6 compartment using the temporary pressure gages. The target ratios of these pressures to Burner Pressure are as follows:

Return pressure to 4-5 Compartment

October 2, 2006 Rev. 6 Homepage

= 0.845 ± 0.02 for FT8-1

Procedure 24- 4 Previous Document

Burner Pressure

= 0.665 ± 0.015 for FT8-3

Return pressure to 6 Compartment Burner Pressure

= 0.320 ± 0.02 for FT8-1 & FT8-3

NOTES Burner Pressure (PT007) is listed as P3.0. “Return Pressures” from temporary gages and “Burner Pressure” must be in absolute pressure prior to calculating the ratio. If the pressure ratios are not within the values listed above, shutdown and change the orifices in the cold buffer air return lines as indicated on the spreadsheet then repeat item 19 until the correct ratios are achieved. Record orifice sizes in Sign-off Section. C. Insure the Cold Buffer fan is running in stable condition (Fan Driver is “AT SPEED” and not cycling from “AT SPEED” to “DECEL” and/or “ACCEL”). If hunting occurs, adjustment of ACCEL and DECEL times may be required. 21. After the pressure ratios have been set, the temperature of the 4/5 bearing compartment may require adjustment on FT8-3 engines. This si accomplished by installing Shield, Buffer Air, P/N IPD24531 on the heat exchanger exhaust. The plate may be trimmed in 1” segments as shown on the drawing to achieve a design temperature of 160° F indicated on TE1602. 22. Record all results including final orifice sizes on the Sign-off Sheets. Include a copy of the calculation spreadsheet.

October 2, 2006 Rev. 6 Homepage

Procedure 24- 5 Previous Document

PROCEDURE 25 – THRUST BALANCE 25.0 Power Turbine Thrust Balance (PTTB) Checkout Procedures Note: This section covers both valves with only limit switches for control and the newer valves using a combination of limit switches and a resolver for position control.

25.1 Active Power Turbine Thrust Balance (PTTB) System

PTTB

MOV 1701 PTTB PTTB

PTTB

Power Turbine Thrust Balance (PTTB) System 25.2 Overview To control thrust loading of the PT8 #8 bearing and to provide adequate cooling air flow, an active power turbine thrust balance control system is incorporated into the FT8. The purpose of this system is to control #8 bearing axial loading to 5,000-lbf nominal under all of the rating conditions. The balancing air pressure is modulated by control valve MOV1701. The system is referred to as the Power Turbine Thrust Balance (PTTB).

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25-1

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CAUTION

Extreme care must be taken in verifying and setting closed position calibrations on the valve cams and limit switches. Thrust balance will not function properly if the switches are incorrect. Refer to PWPS drawings IPE 22767 Field Piping, XXXX-187-E187D, Sheet 18, Sheet 20, Sheet 38 and Bettis EM800 Manual.

25.2

Electrical

The Bettis model EM-800 electric valve actuator is housed in a “NEMA 7” explosion proof housing. The actuator requires 220 VAC to release the spring-loaded electromechanical brake and drive the thrust balance mechanical butterfly valve open or closed. Power is supplied from the motor control center’s 110/220VAC distribution panel ACD1 breaker 39-41. 220VAC power is supplied to terminals 1 and 6 on the Bettis module.

WARNING

When valve is not commanded to move open or closed terminals 1 and 6 are HOT! 115 VAC to ground, 220VAC between terminals 1 and 6. The Bettis EM-800 220 Volt Motor drive circuit has two cam driven limit switches, LS1 and LS2 that drive and stop the motor at the end of travel. The circuit also contains a torque limit switch that interrupts the motor run if the motor over-runs and hits a mechanical stop.

CAUTION Do not adjust the torque limit switches. Refer to PWPS drawing XXXX-187-E101D, Sheets 18, 20 and 32. The outputs for counter clockwise (CCW) open rotation of the valve is sent from relay 1-10A/B, channel 21. Power is supplied to terminal 2 to supply power to the motor via the LS1 Switch. The output for clockwise (CW) close rotation of the valve is sent from relay1-10A/B channel 22. Power is supplied to terminal 3 to supply power to the motor via the LS2 Switch. The Bettis EM-800 valve actuator assembly has two auxiliary switches. AS#1 and AS#2 wired to the control system’s discrete input module. The discrete input control module sends out a 24 VDC signal and looks for it back as a true (Closed) condition. AS #1 and AS #2 electrically close to signal valve full open and full closed conditions. (See “Bettis Switch Numbering Convention” to identify Auxiliary Switches.) LS#2 interrupts the power to the actuator motor at 13 degrees from the butterfly valve’s mechanical full closed position. This is to ensure the butterfly valve never fully closes mechanically. Set this switch to open when reaching 13 degrees going clockwise toward zero (Valve Closed). LS#1 interrupts power to the actuator motor at 10 degrees from the butterfly valve’s mechanical full open position. This is to ensure the butterfly valve never fully opens mechanically. Set this switch to open when reaching 80 degrees going counter clockwise (CCW) toward 90 degrees (Valve Open) AS#1 (ZS1701O) closes to indicate the Bettis EM-800 valve actuator is at “full open” position. This is set at 15 degrees from the butterfly valve’s mechanical full open position. Set this switch to close when reaching 75 degrees going counter clockwise (CCW) toward 90 degrees (Valve Open) October 4, 2006 Rev. 5

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AS#2 (ZS1701C) indicates the Bettis EM-800 valve actuator is at “full closed” position. This is set at 18 degrees from the butterfly valve’s mechanical full closed position. Set this switch to open when reaching 18 degrees going counter clockwise (CCW) toward open. Torque switches within the EM-800 actuator perform a similar function to LS#1 and LS#2, interrupting power when the actuator motor is stalled, preventing overheating of the motor and damage to the valve stem. Torque switches are pre-set at the factory and require no adjustment. Transducer PT1701 PTTBS senses pressure in the thrust balance piping and is located in the right transducer box. Tag Numbers are as follows: PT1701 PTTBS, Power Turbine Thrust Balance Supplemental Pressure MOV1701 Power Turbine Thrust Balance Modulating Valve V1701O Open Command, Power Turbine Thrust Balance Modulating Valve V1701C Close Command, Power Turbine Thrust Balance Modulating Valve ZS1701O Open Discrete, Power Turbine Thrust Balance Modulating Valve ZS1701C Close Discrete, Power Turbine Thrust Balance Modulating Valve

25.3 System Checkout 25.3.1 Field Piping Check that the field piping is complete in accordance with field piping assembly drawings. Check for presence of all mechanical equipment associated with this system, and proper layout. Check all piping flanges for loose fasteners and all pipe hangers to ensure that temporary hangers have been removed.

25.3.2 Electrical Check for the presence and proper layout of all electrical equipment associated with this system per the above referenced drawings. Physically check all electrical connections in this system to assure they are tight and correct. Complete loop and ground resistance checks as tabulated in the Sign-off Sheets. Perform visual and mechanical checks of all switches and circuit breaker.

25.3.3 Modulating Valve and Actuator CAUTION

Do not apply more than the maximum rim pull rating of the handwheel. Rim pull should be no greater than 5 pounds for a 2,000-inch lb. actuator. Turn handwheel in the direction desired, as marked on the handwheel. Avoid rotation beyond the driven device’s operating quadrant. A force of greater than 5 lbs. to the actuator handwheel will result in damage to the valve stem. Watch the valve stem and watch the torque limit switches at all times while using the handwheel in performing the checkout. Stop rotating the handwheel at the first indication of the slightest resistance.

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Set limit switches on the actuator to the following: BETTIS DEVICE TERMINAL SWITCH TAG NUMBERS LS#1 LS#1 LS#2 LS#2 AS#1 AS#1 AS#2 AS#2

NONE NONE NONE NONE ZS1701O ZS1701O ZS1701C ZS1701C

COM-NO ON SWITCH COM-NO ON SWITCH 8–9 11 - 12

Open E 80º (CCW) 90º

SWITCH STATE CLOSED OPEN CLOSED OPEN CLOSED OPEN CLOSED OPEN

RANGE FIG. 1 A, B, C, D E B, C, D, E A D, E A,B,C A, B C, D, E

VALVE POSITION 0 - 80º 80º - 90º 13º - 90º 0º - 13º 75º - 90º 0º - 75º 0º - 18º 18º - 90º

D 75º

C B 18° A 13º

0º Closed (CW)

Rotation is viewed from above the actuator.

Bettis Switch Numbering Convention AS#2

Valve closed indication to control. Set to open at 18 degrees counter clockwise (CCW)

AS#1

Valve open indication to control. Set to close at 75 degrees counter clockwise (CCW).

LS#2

Stop drive motor closing valve. Set to open at 13 degrees clockwise (CW).

LS#1

Stop drive motor opening valve. Set to open at 80 degrees counter clockwise (CCW). Base of Actuator

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Switch 1 is on the bottom, switch 2 is next one up. Limit switches are always mounted below auxiliary switches. LS defined as limit switch. AS defined as auxiliary switch.

25.3.4 Controls/Software

1. Calibrate transducer PT 004 PTTB, Power Turbine Thrust Balance Pressure. 2. Calibrate transducer PT1701PTTBS, Power Turbine Thrust Balance Supplemental Pressure.

25.3.5 Test Operation After setting the limit switches the valve should be test operated electrically from the ICE Monitor.

NOTE

The unit must be shut down and the coast down timer must be expired prior to test operation of the valve.

25.3.5.1 Method 1 (Forcing the Discrete Outputs) With discrete outputs in manual, force the indicated open and close outputs and observe the corresponding feedback indicators. Observe the tabulated discrete inputs and the indications on the PTTB screen for the engine being tested. Valve Observe PTTB Screen Valve Action Force Output Observe Discreet Input Indication MOV1701A

Open Close

1-10-21 1-10-22

1-11-4-1-1 1-11-4-1-2

Engine A screen, valve open Engine A screen, valve closed

MOV1701B

Open Close

1-10-53 1-10-54

1-11-4-1-9 1-11-4-1-10

Engine B screen, valve open Engine B screen, valve closed

25.3.5.2 Method 2 (Operating the Valve from the Pushbuttons on the PTTB Screen). Operate the selected valve by pressing the “Manual Self Test” button on the ICE Monitor PTTB screen. Observe the indications as tabulated above.

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25.4 The following procedure is to be used for valves with a resolver (Reference TPMD373 Rev. C dated 9-20-06) PTTB CALIBRATION PROCEDURE TABLE OF CONTENTS SECTION 1.0 SCOPE 2.0 APPLICABLE DOCUMENTS 3.0 REQUIRED TEST EQUIPMENT/TOOLS 4.0 PTTB VALVE ASSEMBLER CALIBRATION 5.0FIELD CALIBRATION 6.0 SOFTWARE CALIBRATION 1.0 Scope 1.1 PURPOSE: This specification contains instructions to calibrate the FT8 Power Turbine Thrust Balance (PTTB) RVIT Rotary Variable Inductive Position Sensor (CT117948-1) into CT117451. This assembly consists of one electric valve actuator (CT117393-2, Bettis EM-800), valve adapter (CT117441), and 4” butterfly valve. 1.2 The electric valve actuator (MOV1701) incorporates a rotary position sensor CT117948-1 (ZT1701) connected via two gears, one on the 7/8” shaft of the actuator and the other on the rotary position sensor CT117948-1. ZT1701 produces a 4 -20 mA output and is scaled for 0- 94°. 1.3 Set the MOV1701’s LS (limit switches) and AS (auxiliary switches) to: LS#1 80°, LS#2 13°, AS#1 75°, AS#2 14°. Note: Software will be set as follows: AS#1 75°, AS#2 18°. 1.4 The Active Power Turbine Thrust (PTTB) System is to control the thrust loading and cooling of the PT8 #8 bearing. The purpose of this system is to control #8 bearing axial loading to 5,000-lbf nominal under all of the rating conditions. The balancing air pressure is modulated by the control valve MOV1701. The system is referred to as the Power Turbine Thrust Balance (PTTB).

2.0 Applicable Documents The following publications form a part of this specification to the extent specified herein; the latest issue shall apply as required. 2.1 IPE22767, Assy, PTTB, System October 4, 2006 Rev. 5

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2.2 IPD24165GR1, ASSEMBLY Kit, PTTB Position Feedback 2.3 CT117451, Assy, Valve and Actuator, PTTB 2.4 CT117948-1 RVIT Rotary Variable Inductive Position Sensor 2.5 XXXX-187-E101D Unit Control Schematics 2.6 National Fire Protection Association (NFPA) National Electrical Code 2005 2.7 Commissioning Manual (Rev 3) Procedure 25 2.8 IPE24421, Assy, PTTB, System

3.0 Required Test Equipment/Tools 3.11 8 - 28 VDC power supply 3.2 Digital Volt Meter (DVM) 3.3 Allen wrench set SIZE 9/64,7/64, and 3/32 3.4 Philip and Flat screwdriver 3.5 Wire stripper 3.6 Jumper leads with alligator clips 3.7 ALTEK Model 934 milliamp/voltage loop calibrator

4.0 PTTB Valve Assembler Calibration Caution: Valve Assembly must be firmly secured before proceeding 4.1 Locate PTTB valve and remove cover. 4.2 Install IPD24165GR1 (Assembly Kit, PTTB Position Feedback) on handwheel side of main 7/8” shaft using supplied hardware. Use existing tapped 8-32 threaded holes to install bracket base (Item 2) of IPD24165GR1. NOTE: Gears must be properly aligned and extra care must be taken to ensure positive gear meshing. Use Loctite 290 (CT115541) as requried per IPD24165GR1 for all hardware using lock washers. 4.3 Install CT118016-1 7/8” Bettis Gear onto the 7/8” shaft, position near the top with gear set screw housing orientation facing downward. Do not secure tightly until sensor has been set to 4mA. 4.4 Install a current meter in series with the terminated RED wire at the terminal block mounted on the IPD24165GR1 assembly. Polarity should be + on incoming field wire and - on the RED wire on the RVIT CT117948-1. Meter to be set to mA.

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4.5 Use 18 - 28 VDC power supply or ALTEK Model 934 milliamp/voltage loop calibrator to provide the excitation to allow a close loop 4mA current. REF: IPD24165GR1 wiring diagram. 4.6 Locate the handwheel on actuator and turn it slowly until the butterfly valve is completely at the closed position (when valve hit the mechanical stop). Inspect butterfly valve to ensure valve is set at the closed position. Caution: Avoid rotation beyond the butterfly’s mechanical stop or will result in damage to the valve stem. 4.7 Loosen set screw on 7/8 shaft and rotate until DVM reads 4ma then secure. NOTE: Make sure RVIT assembly gears are properly meshing and that all hardware is properly secured. CAUTION: make sure that the RVIT sensor is in the correct sector (ma will increase when RVIT is rotated CLOCKWISE. REF: Figure “A”, “B” & “C”. 4.8 Next rotate valve with handwheel until the current meter reads 20ma. The span will be 94 degrees. REF: Figure “A” & “B”. 4.9 Using Table 1 and a DVM that reads ma to set the following MOV1701’s LS (limit switches) and AS (auxiliary switches): LS#1 80° , LS#2 13°, AS#1 75°, and AS#2 14°. NOTE: to assist in setting the switches use the Ref: Figure C and table 1 as required and DO NOT ADJUST TORQUE LIMIT SWITCHES. 4.10 Re-install cover and secure. 4.11 Complete Form 1 and send with calibrated valve.

5.0 Field Calibration WARNING: POWER DOWN 220VAC AT MCC BEFORE WORKING AND POWER DOWN CONTROL SYSTEM ASSOCIATED I/O AND BEFORE DISCONNECTING WIRES OR ADDING. 5.1 Locate PTTB valve and remove cover. CAUTION: Use proper PPE when working HOT. Use caution not to short AI channel, if control system is used to set RVIT sensor. 5.2 Install IPD24165GR1 (Assembly Kit, PTTB Position Feedback) on handwheel side of main 7/8” shaft using supplied hardware. Use existing tapped 8-32 threaded holes to install bracket base (Item 2) of IPD24165GR1. NOTE: Gears must be properly aligned and extra care must be taken to ensure positive gear meshing. Use Loctite 290 (CT115541) as required per IPD24165GR1 for all hardware using lock washers. 5.3 Install CT118016-1 7/8” Bettis Gear onto the 7/8” shaft, position near the top with gear set screw housing orientation facing downward. Do not secure tightly until sensor has been set to 4ma.

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5.4 Install a current meter in series with the terminated RED wire at the terminal block mounted on the IPD24165GR1 assembly. Polarity should be + on incoming field wire and - on the RED wire on the RVIT CT117948-1. Meter to be set to ma. 5.5 Use 18 - 28 VDC power supply or the allocated I/O channel or ALTEK Model 934 milliamp/ voltage loop calibrator to provide the excitation to allow a close loop 4ma current. REF: IPD24165GR1 wiring diagram. 5.6 Locate the handwheel on actuator and turn it slowly until the butterfly valve is completely at the closed position (when valve hit the mechanical stop). If possible inspect butterfly valve inside piping to ensure valve is set at the closed position. Caution: Avoid rotation beyond the butterfly’s mechanical stop or will result in damage to the valve stem. 5.7 Loosen setscrew on 7/8 shaft and rotate until DVM reads 4ma then secure. NOTE: Make sure RVIT assembly gears are properly meshing and that all hardware is properly secured. CAUTION: make sure that the RVIT sensor is in the correct sector (mA will increase when RVIT is rotated CLOCKWISE. REF: Figure “A”, “B” & “C”. 5.8 Next rotate valve with handwheel until the current meter reads 20ma. The span will be 94 degrees. REF: Figure “A” & “B”. 5.9 Using Table 1 and a DVM that reads ma to set the following MOV1701’s LS (limit switches) and AS (auxiliary switches): LS#1 80° , LS#2 13°, AS#1 75°, and AS#2 14°. NOTE: to assist in setting the switches use the Ref: Figure C and table 1 as required. 5.10 Re-install cover and secure. 5.11 Record required data on the FT8 Commissioning Manual Sign-off Sheet.

6.0 Software Calibration In this section the valve is pulsed for the following duration (20, 40, 60, 80, 100, 120, 140, 160, 180, 200, 250, 300) milliseconds and the corresponding valve movement is obtained to develop the smart pulse table. Note: Start permissive on both engines will be lost until the calibration exercise is completed. 6.1 On the ICE Monitor locate and open the PTTB page for the valve being calibrated, See Figure D. 6.2 Initiate the valve calibration by pressing the “Start smart pulse cal” button. Once in the calibration mode, the “In Progress” LED under Pulse Test is illuminated. The calibration process takes approximately 10 minutes to complete. At the end of the calibration the “In Progress” LED will go out. 6.3 After the calibration is completed, open watch windows and note the values found at the following blocks:

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A-Valve PTTBSMTB_A.X2_VALUE.A_SW PTTBSMTB_A.X3_VALUE.A_SW PTTBSMTB_A.X4_VALUE.A_SW PTTBSMTB_A.X5_VALUE.A_SW PTTBSMTB_A.X6_VALUE.A_SW PTTBSMTB_A.X7_VALUE.A_SW PTTBSMTB_A.X8_VALUE.A_SW PTTBSMTB_A.X9_VALUE.A_SW PTTBSMTB_A.X10_VALUE.A_SW PTTBSMTB_A.X11_VALUE.A_SW PTTBSMTB_A.X12_VALUE.A_SW PTTBSMTB_A.X13_VALUE.A_SW

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B-Valve PTTBSMTB_A.X2_VALUE.B_SW PTTBSMTB_A.X3_VALUE.B_SW PTTBSMTB_A.X4_VALUE.B_SW PTTBSMTB_A.X5_VALUE.B_SW PTTBSMTB_A.X6_VALUE.B_SW PTTBSMTB_A.X7_VALUE.B_SW PTTBSMTB_A.X8_VALUE.B_SW PTTBSMTB_A.X9_VALUE.B_SW PTTBSMTB_A.X10_VALUE.B_SW PTTBSMTB_A.X11_VALUE.B_SW PTTBSMTB_A.X12_VALUE.B_SW PTTBSMTB_A.X13_VALUE.B_SW

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6.4 Repeat step 6.3 and once again note the values for the blocks above 6.5 Compare these values from both calibrations and ensure they are consistent. 6.6 Once the calibration is completed and verified to be correct, do the following using WWII application: Read value from PTTBSMTB_A.X2_VALUE.A_SW and enter it into PTTBSMTB_A.CORR_RATE.X_2 Read value from PTTBSMTB_A.X3_VALUE.A_SW and enter it into PTTBSMTB_A.CORR_RATE.X_3 Read value from PTTBSMTB_A.X4_VALUE.A_SW and enter it into PTTBSMTB_A.CORR_RATE.X_4 Read value from PTTBSMTB_A.X5_VALUE.A_SW and enter it into PTTBSMTB_A.CORR_RATE.X_5 Read value from PTTBSMTB_A.X6_VALUE.A_SW and enter it into PTTBSMTB_A.CORR_RATE.X_6 Read value from PTTBSMTB_A.X7_VALUE.A_SW and enter it into PTTBSMTB_A.CORR_RATE.X_7 Read value from PTTBSMTB_A.X8_VALUE.A_SW and enter it into PTTBSMTB_A.CORR_RATE.X_8 Read value from PTTBSMTB_A.X9_VALUE.A_SW and enter it into PTTBSMTB_A.CORR_RATE.X_9 Read value from PTTBSMTB_A.X11_VALUE.A_SW and enter it into PTTBSMTB_A.CORR_RATE.X_11 Read value from PTTBSMTB_A.X12_VALUE.A_SW and enter it into PTTBSMTB_A.CORR_RATE.X_12 Read value from PTTBSMTB_A.X13_VALUE.A_SW and enter it into PTTBSMTB_A.CORR_RATE.X_13

Repeat Para. 6.7 for Eng. B. 6.7 To enable the feedback logic, locate the blocks PTTB_INS_A.PTTB_FBON.IN for the A-Engine PTTB_INS_B.PTTB_FBON.IN for the B-Engine and change tunable from *FALSE to *TRUE. 6.8 Enable the auto-mode on PTTB valve page to realign unit for automatic valve operation.

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FIGURE A

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FIGURE B

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FIGURE C

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FIGURE D

TABLE 1 DATE: October 2006 Rev. 5 Homepage

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DEGREES 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

ma 4.00000 4.17021 4.34043 4.51064 4.68085 4.85106 5.02128 5.19149 5.36170 5.53191 5.70213 5.87234 6.04255 6.21277 6.38298 6.55319 6.72340 6.89362 7.06383 7.23404 7.40426 7.57447 7.74468 7.91489 8.08511 8.25532 8.42553 8.59574 8.76596 8.93617 9.10638 9.27660 9.44681 9.61702 9.78723 9.95745 10.12766 10.29787 10.46809

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Closed

LS2 AS2

DEGREES 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78

ma 10.80851 10.97872 11.14894 11.31915 11.48936 11.65957 11.82979 12.00000 12.17021 12.34043 12.51064 12.68085 12.85106 13.02128 13.19149 13.36170 13.53191 13.70213 13.87234 14.04255 14.21277 14.38298 14.55319 14.72340 14.89362 15.06383 15.23404 15.40426 15.57447 15.74468 15.91489 16.08511 16.25532 16.42553 16.59574 16.76596 16.93617 17.10638 17.27660

DEGREES 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94

ma 17.61702 17.78723 17.95745 18.12766 18.29787 18.46809 18.63830 18.80851 18.97872 19.14894 19.31915 19.48936 19.65957 19.82979 20.00000

LS1

Open

AS1

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PROCEDURE 26 - EVAPORATIVE COOLING AND HUMIDIFICATION UNIT INSTALLATION AND START-UP CHECKOUT PROCEDURES 26.0 Evaporative Cooling and Humidification Unit Installation and Start-up Checkout Procedures (If Installed) Refer to Munters/VAW Systems Installation, Operation and Maintenance Instructions Manual.

26.1 Checkout and Start-up 1.

Verify correct installation of evaporative cooler housing, media, feed, drain and bleed piping systems, pumps, valves, etc.

2.

Inspect for correct sealing of all seams to avoid air entrance and bypassing of media. Perform a light leak check from inside the clean air path.

3.

Ensure all debris has been removed from the upstream and, especially, the downstream sides of the evaporative cooler banks and that the troughs are wiped down clean.

4.

Disconnect pump motor leads at the Temperature Control Panel (TCP) and megger motors.

5.

Perform loop check of level switches

6.

Verify continuity across thermocouple

7.

Perform calibration and function testing of the Conductivity Controller and verify correct settings

8.

Check open the TCP internal supply breakers, energize power supply to the panel and check voltages at the internal panel breakers.

9.

Verify supply water meets the specified limits outlined by Munters. Customer to provide analysis results.

10. Perform flush of supply line up to float valve inlet connection utilizing system water then restore the connection. 11. Energize the TCP by closing the two internal breakers 12. To begin function checks of the system the “Gas Turbine Running” signal going to the TCP will have to be simulated and the ambient temperature will have to be greater than 50 °F (default setting of the High Temperature Setting in the PLC)

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13. Follow the PLC Inspection Checklist to function check the PLC and all associated equipment 14. With system in operation, check for leaks from all piping system and inspect flow of water over media to be evenly distributed and at a proper flow rate. 15. With system in operation check for water leakage between the media and the sidewall and where the piping penetrates the side plate. 16. Verify proper drainage through the overflow drains and that height of the drain is correct.

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PROCEDURE 27 - LIQUID AND GAS FUEL FORWARDING AND CONDITIONING SYSTEMS CHECKOUT 27.0 Liquid and Gas Fuel Forwarding and Conditioning Systems Checkout Procedures Refer to PWPS drawings XXXX-181-M201D and XXXX-181-M202D and vendor drawings.

CAUTION It is extremely important to ensure that the fuel system(s) do not become contaminated. Severe operational problems will result. Assure that fuel supply piping has been adequately flushed and blown down. See Procedure 04. The fuel system may vary in configuration between various sites and customers. Not all sites will have all PWPS supplied components. Refer to site specific PWPS drawings, supplied vendor drawings and other publications for detailed installation and commissioning details. This procedure should be used as a guideline only to record that essential steps, as per referenced materials, have been completed. The units are usually factory flushed, calibrated and tested. To reduce the possibility of contamination, the units will not be disassembled in the field to recheck certain calibrations or settings. Pressure relief and control valves are factory set and should not require resetting in the field. Refer to Procedure 16A for switch calibrations. Set points are listed in the Sign-Off Sheets. Prior to energizing or attempting to operate the system: 1.

Verify proper valve position in accordance with P&ID drawings or test procedures.

2.

Perform the continuity and resistance checks as tabulated on the sign-off sheet.

3.

Verify switch operation by lifting or jumpering inputs as noted.

4.

Level switch operation is to be verified while the vessel is being filled with fluid. Connect an ohmmeter to observe contact operation as noted.

5.

See the specific listing for each device in the Sign-Off Sheets.

27.1 Liquid Fuel Forwarding Skid Liquid fuel is delivered to the Liquid Fuel Conditioning skid via a self contained Liquid Fuel Forwarding Skid (CT116371-XXX). The skid contains two forwarding pumps, valves, instrumentation and a control panel. The skid is powered from a 380/408-VAC source which may differ between sites. The skid receives a run/stop signal from the power generating equipment when fuel is required. In the event of an equipment failure or malfunction on the skid, an alarm is sent to the control system. Starting, stopping and alternating pumps are managed locally by a controller which monitors operating parameters. See site specific PWPS drawings and vendor materials for commissioning and operating procedures. General commissioning requirements include, but are not limited to: 1.

Piping installation inspection.

2.

Flush field installed piping, as necessary.

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3.

Pressure test field installed piping, as necessary.

4.

Megger and resistance check pump motors.

5.

Calibrate pressure switches PSL421 and PLS422.

6.

Rotation check of pump motors.

7.

Set skid operating output pressure.

8.

Test and verify run/start signal to skid.

9.

Test and verify alarm signal from skid.

10. Check and set the local control junction box space heater thermostat, if installed.

27.2 Liquid Fuel Conditioning Skid (Duplex Filter Skid) Liquid fuel is delivered to the Liquid Fuel Metering skid via a self contained Liquid Fuel Conditioning skid, CT116793, Seaworthy Industrial Systems, Inc., Fleetguard/Nelson Fuel Filter, 98250F. The skid contains two (2) full capacity coalescing filters with automatic water drains, air vents and manual filter transfer valve. One (1) skid is required for each TWINPAC™, POWERPAC™, SWIFTPAC™ or MOBILEPAC™. 120-VAC power is supplied to the skid from the unit control house. Two (2) differential pressure switches, PDSH421 and PDSH422 monitor the pressure drop across each filter assembly and send an alarm to the control system at 12-PSI rising pressure across either filter. Each filter housing F421 and F422 contains a water sensing element, LSH421 and LSH422, and a water drain solenoid valve SOV421 and SOV422. Water is automatically drained from the filter housing. The online filter may be changed to the standby filter during unit operation with no interruption of gas turbine running by operating transfer valve TR421. General commissioning requirements include but are not limited to: 1. Piping installation inspection. 2. Verify correct fluid flow direction 3. Flush field installed piping as necessary. 4. Pressure test field installed piping as necessary. 5. Inspect/clean housing and install filter elements. 6. Verify air bleed operation. 7. Calibrate PDSH421 and PDSH422. 8. Test and verify alarm signal from skid. 9. Test-drain SOV operation. 10. Check and set the local control junction box space heater thermostat if installed.

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27.3 Liquid Fuel Heater Skid Liquid fuel fired sites in cold areas may have a liquid fuel heater skid. This is a self contained assembly with electric immersion heaters to raise the liquid fuel temperature. Fuel heater I/O may be included with balance of plant (BOP) items. See site specific PWPS drawings and vendor data. General commissioning requirements include but are not limited to: 1.

Piping installation inspection.

2.

Flush field installed piping as necessary.

3.

Pressure test field installed piping as necessary.

4.

Megger heater elements at 500-VDC to ensure a minimum of 10-Meg ohms to ground and between elements.

5.

Continuity resistance check of heater elements.

6.

Test and verify run/start signal to skid.

7.

Test and verify alarm signal from skid via TSH-1.

8.

Check and set the local control junction box space heater thermostat if installed.

27.4 Gas Fuel Scrubber Skid Gas fuel is supplied to the engines via a Dollinger C-Series Gas Pipeline Coalescing Filter skid designed to remove water, oil and solid contaminants from the system. See site specific PWPS drawings and vendor data. The skid will send various alarms to the control system as tabulated on the Sign-Off Sheets. General commissioning requirements include but are not limited to: 1.

Piping installation inspection.

2.

Verify correct fluid flow direction

3.

Flush field installed piping as necessary.

4.

Pressure test field installed piping as necessary.

5.

Test and verify alarm signals from skid.

6.

Check and set the local control junction box space heater thermostat if installed.

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PROCEDURE 28 - INCOMPLETE SEQUENCE STARTS CHECKOUT PROCEDURE 28.0 Incomplete Sequence Starts Checkout Procedure NOTE All previous procedures must be completed. All systems must be ready for normal operation and engine start. It is not necessary to bleed fuel to the engine; however it is necessary to assure that the fuel pump clutch does not engage if the engine is to be rotated.

28.1 Auxiliary Systems Start Sequence 1.

Turn hydraulic start-pac MCC breaker "OFF" and tag.

2.

Disable igniters by opening Breaker 9 in DCD1.

3.

Select starting fuel to be tested.

4.

If testing: A. Gas fuel; inject a gas pressure signal to simulate gas pressure at PT1101. B. Liquid fuel; ensure fuel is available and pumps are operating. If rotating the engine be aware of clutch status and fuel to engine.

5.

Reset the lockout relays.

6.

Reset the control system.

7.

Initiate a simulated single engine start.

8.

Observe the start sequence of the unit support systems on the "START" screen or on the "EVENTS" screen.

9.

Observe hydraulic pumps fail and unit trip on "Hydraulic Start Fail".

10. Restore all systems to normal conditions. Secure and tag as required

28.2 Engine Incomplete Sequence NOTE Engine and all systems must be ready for initial light-off. Fire protection system must be armed and ready for operation. Liquid fuel system must be ready for operation and fuel must be bled to the engine mounted fuel pump. 1.

Turn all auxiliary system main breakers "ON" and to "AUTO" at the MCC.

2.

Disable igniters by opening Breaker 9 in DCD1.

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3.

Open the fuel valves to the engine to be tested.

4.

Reset the lockout relays.

5.

Reset the control system.

6.

Initiate an engine start

7.

Observe start sequence of events as in section "A" above

8.

Observe hydraulic start system rotate engine to starter speed. Check for engine lube oil pressure (PT-612) and hydraulic pressure (PT-501).

9.

Observe unit trip on "Failure to Light Off".

10. Restore all systems to normal conditions. Secure and tag as required. 11. If starting on liquid fuel, check for evidence of fuel in the drain lines. 12. Record results on the Sign-Off Sheets.

28.3 Start Sequence of Events The start sequence of events is shown in Table 28-1.

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TIME / CONDITION

EVENT

0

Unit is shutdown or not in a start sequence. Control Reset and Ready-to-Start light illuminated

0+

Push start button

0++

Start horn(s) & Liq Fuel Pump Clutch actuate Start horn(s) off Start fuel system Start generator AC lube oil pump Start generator DC lube oil pump Start power turbine AC lube oil pumps Start power turbine DC lube oil pumps Start GG/PT lube oil cooling fan (Start gearbox vacuum pump)

10s 4s 2s 2s 24s

Stop generator DC lube oil pump

8s

Start ancillary systems (Secondary air fans) Stop engine heaters Stop generator and exciter space heaters

22s

Stop power turbine DC lube oil pumps

6s+18s to + fuel system permissive

Start engine “A” Start hydraulic pump #1

6s+18s to + fuel system permissive + hydraulic pump fail

Trip – Hydraulic Start Fail

Hydraulic pressure permissive

Rotate engine “A” Start Purge timer (default 90 seconds) Secondary Air Fans ON during last 30 seconds of purge. Energize igniters & open SOV1001 (LF) or SOV1101 (GF)

NH>1500 NH>2550 + purge time Start + 50s + NH4800

Light-off sense (GF)

Trip – Light-off fail (LF) Starter off Engine idle

Table 28-1 Start Sequence of Events

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PROCEDURE 29 – INITIAL LIGHT-OFF, POWER TURBINE START-UP AND BREAK-IN 29.0 Initial Light-off and PT Break-In Checkout Procedures WARNING Units fitted with SCR emissions control equipment will have different purge times. Verify correct purge times for engines “A” and “B” before attempting to start.

NOTES All previous procedures must be completed and any problems or discrepancies encountered must be resolved. All systems must be ready for operation. Assure that all required circuit breakers are "ON" and MCC control switches are in "AUTO". Assure that all required tags have been cleared. Personnel with two-way radios should be strategically located around the unit and lube oil systems to assure that unauthorized personnel are not in the area and to observe equipment operation. No personnel will be allowed in the enclosures or in the vicinity of the engine and power turbine enclosures during this procedure. GG oil pressure may be adjusted as required during step 24. 29.1 Process Overview Each engine will light off individually and break away its power turbine. Each engine will have the idle trim adjusted to the minimum acceptable NH speed during the break-in period. The NP overspeed via the Micronet will be adjusted to cause a NP overspeed trip at 350 RPM NP for each individual breakaway. The set point will be reset to normal for the remainder of the break-in period and for the actual overspeed tests in Procedure . On a twin pac, each engine will perform the initial start, breakaway and low speed trip. The OS set point will be reset to nominal and both engines will be run for the PT break-in period. On a power pac, the second engine steps will be omitted. Enclosure leak checks and inspections will be performed as soon as the first engine reaches idle speed and steady state NP operation. The second engine will then be started and the inspections repeated as necessary. If both engines cannot be run, each PT may be broken-in separately by uncoupling the non-running engine and operating the unit as a power pac. This will only be possible if the engines have individual exhaust stacks.

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29.2 Procedure 1. Ensure that the gas path purge timer, START_SEQ.PRG_TIME_A.IN for engine "A" or START_SEQB.PRG_TIME_A.IN for engine "B" is set to allow a minimum of 3 complete changes of air volume in the gas turbine flow path. (Default settings are 90 seconds.) This volume should include inlet house, gas turbine, ductwork, SCR or HRSG and exhaust stacks. This setting should be coordinated with the boiler purge cycle as required. The starter can be assumed to sweep the gas turbine at 9.4 PPS (4.26 kg/sec). 2. Reset 86E, 86EA or 86EB as required. 3. Reset the Micronet from the ICE monitor. 4. Select starting fuel from the ICE monitor. 5. Select Manual Operating Mode. 6. Access the engine start button for engine A or B and initiate a normal single engine start from the ICE monitor. 7. First start attempt: A. On the first start attempt the unit should be shutdown via emergency stop pushbutton as soon as light off is sensed (See ICE monitor screen)

NOTE Shutdown should be initiated before NH reaches 4600 RPM. 8. Access the engine enclosure, check for oil leaks, fuel leaks, etc. Listen during engine run down for rubbing and strange sounds. Check oil level in tank. Note it should have dropped slightly during the starter checkout as oil flowed into the gas generator bearings.

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Pratt and Whitney Power Systems, Inc. Commissioning Manual - Revision 4

TEMPORARY REVISION NO. 07-02 Please insert this Temporary Revision in the Commissioning Manual Rev 4, Procedure 29 – Initial LightOff, Power Turbine Start-up and Break-in, before page 29-3. The tunable in step 11. has been corrected to read SD_UN _FC.NPFAILINH.IN.

CAUTION Repeat steps for initial light off on a twin pac installation for the second engine. Do not proceed with the break in procedure until both GG's have achieved initial light off and are ready for further operation.

Figure 29 - 1 9. Select the "Scales" icon at the top of the main ICE screen and choose "PT Tests". 10. Select A or B engine for PT Break-Away Test, see Figure 29 - 1. •

Note that the NP overspeed set point is automatically set to 350 NP

11. Inhibit the NP failure shutdown, SD_UN _FC.NPFAILINH.IN. 12. Second start attempt:

A. Repeat steps to start one engine.

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CAUTION Repeat steps for initial light off on a twin pac installation for the second engine. Do not proceed with the break in procedure until both GG's have achieved initial light off and are ready for further operation.

Figure 29 - 1 9. Select the "Scales" icon at the top of the main ICE screen and choose "PT Tests". 10. Select A or B engine for PT Break-Away Test, see Figure 29 - 1. •

Note that the NP overspeed set point is automatically set to 350 NP

11. Inhibit the NP failure shutdown, SD_UN_FC.NP_FAILURE A or B 12. Second start attempt:

A. Repeat steps to start one engine.

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1) On the second start attempt, allow the gas generator to accelerate toward idle

until the power turbine starts to rotate. Monitor the free turbine shaft at the engine because the ICE Monitor and Tach may not record very low rpm. Check for unusual noises, leaks, etc. Allow the power turbine to accelerate and trip at 350 RPM via the Micronet overspeed.

CAUTION If the unit does not trip by 400 RPM, activate the emergency stop and resolve the problem before continuing.

B. Inspect both engine enclosures, lube oil skids, generator enclosure, hydraulic start

skid, etc. for leaks or abnormal conditions. Listen to the generator and power turbine rundowns.

13. If the engine achieves GG idle (7800-8200 NH) without breaking away the PT, allow the engine to remain at idle speed for one minute then initiate a stop via the emergency stop pushbutton. 14. After the trip, reset the controls and prepare to restart as soon as possible. Enter an additional "NH Idle Trim Value" of 800 RPM into the screen location using the blue arrow on the test screen in the predetermined values of +200, 400, 600, 800, followed by the "enter" key. 15. Repeat steps as in item 12. 16. If the PT breaks away, it will trip via NP overspeed at 350 NP RPM. If the PT does not break away, allow the engine to sit at this raised NH point for a maximum of one minute then stop by pressing the emergency stop pushbutton. 17. Inspect the equipment and repeat step 11 to break away this engine. This will be the third break away attempt. If the PT does not break away after the previous one minute at GG idle and one additional minute at GG idle plus 800 NH RPM, contact PWPS Customer Support Engineering for further instructions. DO NOT attempt to break away the opposite PT. If PWPS personnel are not available, allow the PT to cool for a minimum of 4 hours and repeat the procedure above.

NOTE Do not attempt any running above idle unless the overspeeds have been set and tested as above. 18. Lockout the first engine and unlock the second engine. 19. Repeat steps 1 through 13 for the second engine.

WARNING The following steps are to be completed by a responsible test person who will remain at the control panel at all times, within easy access of the emergency stop pushbutton. All attempts should be made to continue this procedure before the PT stops rotating.

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20. PT breakaway should be deselected by the engine trip. Select PT Break-In test from the screen in figure 1 for both engines. See Figure 29 - 2. 21. Initiate a twin pac start (Start Both). 22. Uninhibit SD_UN_FC.NP_FAILURE during the purge cycle. 23. Allow each GG to achieve stable GG idle, breakaway the generator and accelerate the rotor to a steady state RPM.

Figure 29 – 2 24. After the GG and NP speeds are at a steady state condition, inspect enclosures as required. Note steady state NH and NP. 25. Manually accelerate the power turbine to 2100 NP at a rate less than 600 RPM/Minute. The times and NP speeds required for thrust balance seal break-in are provided in Table 29-1 below. Hold the appropriate speeds, as shown in Table 29-1, for the required time to properly break-in the thrust balance seals.

CAUTION

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For additional overspeed protection, the unit trip button must be manned at all times. The NP speeds differ depending on configuration. Both 50-Hz and 60Hz speeds are listed in Table 29-1.

60-Hz CONFIGURATION Time In Minutes NP 5 2100 (See Note Below) 10 3000 15 3600 15 3950 10 3600 10 3000 20 2100 (See Note Below)

50-Hz CONFIGURATION Time In Minutes NP 5 2100 (See Note Below) 10 2600 15 3000 15 3250 10 3000 10 2600 20 2100 (See Note Below)

NOTE 2100 or minimum obtainable NP speed.

Table 29-1 Thrust Balance Seal Break-In 26. After the last dwell period at 2100 NP, initiate a stop by operating the emergency stop pushbutton. 27. Lockout both engines. 28. Observe GG, PT and generator coastdown. Note any abnormalities. 29. Record a Trend trace of NP speed during the break-in period. 30. Reset the tunables as required. Save tunables in the control. 31. Secure the unit as necessary. 32. Install tags on valves, breakers, switches, etc. as necessary.

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PROCEDURE 30 – OVERSPEED TEST 30.0 Overspeed Test Checkout Procedures CAUTION Do not attempt any run above idle unless the Airpax Tach-Pak 3 tunables have been set and tested per Procedure 20. NL and NH overspeed settings are fixed at 7650 and 12550 respectively. These “do not exceed” values cannot be tested using the engine. DO NOT TRY. The NP overspeed should be adjusted on an electrical generator application to be 3960 RPM (60 Hz) or 3300 RPM or 3450 RPM (50 Hz), depending upon the frequency. The 50 Hz machines have two different settings and are site specific. 3300 RPM is the normal setting, 3450 RPM is used if drop load requirements are included in the contract.

30.1 General Description The FT8 installation includes two independent power turbine (NP) overspeed detectors--the Woodward control software and the AirPax overspeed detection device. Each overspeed device is designed to detect an NP speed greater than 3960 rpm for 60-Hz installations or 3300 (3450) rpm for a 50-Hz operation (basically, 10 percent above the normal operating speed of 3600 rpm for 60 Hz and 3000 rpm for 50 Hz. 15% is used to achieve the 3450 rpm limit). Both overspeed tests must be performed and successfully tested during the commissioning of a unit.

CAUTION Simulation of overspeed tests is not acceptable.

30.2 Overspeed Settings 60 HZ 50 HZ

Micronet Micronet

3960 3300 (3450)

AirPax AirPax

3960 3300 (3450)

30.3 Preparations 1. Make sure the AIRPAX Speed Relay has been tested previously per Procedure 20. 2. Assure that all previous procedures have been completed and all discrepancies have been resolved. 3. Ensure that the area is cleared of all non-essential personnel and that personnel involved in the test procedure have been fully briefed regarding the test plan. 4. Coordinate locally as required to assure that the turbine/boiler (if so equipped) unit is adequately purged prior to each start. 5. Assure that all engine control trips or shutdowns are operational. 6. Prepare the unit and auxiliary systems to start and run.

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Procedure 30 - 1 Previous Document

7. Ensure that power to the MAVR is turned off and tagged to prevent building voltage on the generator. The switch is located on the back wall of the operating cabinet. 8. Verify that the control is set for the correct operating Freq. (50, 60 Hz). A. For 60 Hz For 60 Hz

NP_CNTL.SET_50HZ.B_NAME=F NP_CNTL.SET_60HZ.B_NAME=T

B. For 50 Hz For 50 Hz

NP_CNTL.SET_50HZ.B_NAME=T NP_CNTL.SET_60HZ.B_NAME=F

NOTE After selecting the O/S test, do not reset software or you will lose the selection. 9. Overspeed Test Procedure A. While the engine is shut down, clear all start permissives and confirm that both engines are ready to start.

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Procedure 30 - 2 Previous Document

B. Select “Overspeed Tests” from the main menu, as shown below.

C. Click to select the desired overspeed test (Woodward or AirPax). Note that when no test has been selected, the NP overspeed set-point is set to 3300, 3450 or 3960 rpm.

Also, note that an overspeed test can be selected only when both engines are indicating ready to start, but start has not been initiated. Once overspeed is selected, the ICE monitor

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Procedure 30 - 3 Previous Document

will indicate which overspeed test has been selected (in highlighted red text). During commissioning, both overspeed tests should be successfully demonstrated (the order of test selection is inconsequential). The NP overspeed test can be aborted at any time by simply pressing the “OFF” push-button.

D. This example uses a 60 Hz machine. If a 50 Hz machine is being tested, the corresponding overspeed trip points will be 3300 or 3450 RPM. If the Woodward control overspeed test is being selected, the following are expected: 1) NP overspeed trip set-point for the Woodward control is decreased 10 RPM from 3960 to 3950 (3300 to 3290 or 3450 to 3440 for 50 Hz machines) Confirm on monitor display. 2) The maximum NP reference is increased to 3970 ( 3310 or 3460 for 50 Hz machines) to allow the NP reference to move up in manual operation. 3) The NP overspeed trip set-point for the AirPax system is preset from the factory to 3960 (3300 or 3450 for 50 Hz). 4) By lowering the Woodward control set-point, overspeed detection by the Woodward control will occur at 3950 NP (3290 or 3440) before the AirPax set-point at 3960 (3300 or 3450).

E. Put the operating mode of the unit into Manual Mode and perform an engine start. F. Manually raise the NP reference speed toward the overspeed trip point, and confirm that the unit trips at 3950 (3290 or 3440) rpm NP speed as expected. Manually increase NP

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Procedure 30 - 4 Previous Document

speed to 3945 (3285 or 3435) rpm; then, raise the speed very slowly toward the target trip rpm. G. Similarly, if the AirPax overspeed test is selected, the following are expected: 1) NP overspeed trip set-point for the Woodward control is increased from 3960 to 3970 (3300 to 3310 or 3450 to 3460) rpm. Confirm on monitor display. 2) The maximum NP reference is increased 3970 (3310 or 3450) to allow the NP reference to move up in manual operation. 3) The NP overspeed trip set-point for the AirPax device is preset to 3960 (3300 or 3450) from the factory. 4) By increasing the Woodward control set-point to 3970 (3310 or 3450) rpm, overspeed detection will occur from the AirPax set-point of 3960 (3300 or 3450) rpm rather than the Woodward control overspeed set-point.

NOTE The AirPax switch receives a Np speed signal from a power turbine speed sensor. ST008A or ST008B. When testing the “A” engine, insure the Airpax is connected to ST008A and when testing the “B” engine insure the Airpax is connected to ST008B. Refer to PWPS drawing XXX-187-E101D, Sheet 14 for wiring. Restore wiring to ST008A (as shipped) after testing the “B” engine.

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Procedure 30 - 5 Previous Document

H. Again, confirm the operating mode of the unit is Manual Mode and perform an engine start. I.

Manually raise the NP reference speed toward the overspeed trip point and confirm that the unit trips at 3960 (3300 or 3450) rpm NP speed as expected. Manually increase the NP speed to 3950 ( 3290 or 3440) rpm; then, raise very slowly toward the target trip rpm.

J.

Reset the Overspeed S/R Reset (Green lighted button on the operating panel)

K. Record overspeed test results in Checkout Manual L. Reset the system for normal operation.

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PROCEDURE 31 – HIGH VOLTAGE SWITCHGEAR 31.0 High Voltage Switchgear The standard FT8 generating system includes high voltage switchgear including the main 52G breaker and instrumentation mounted in the control enclosure. Variations include a 4000 amp roll out breaker, a 5000 amp bolt in breaker, arc resistant (AR) enclosures, forced air breaker cooling, manual or motorized disconnect switches, bus and generator grounding switches and associated isolated phase bussing. See site specific drawings and Powell documentation.

WARNING CONTACT WITH ENERGIZED HIGH VOLTAGE COMPONENTS WILL CAUSE SEVERE INJURY OR DEATH. ONLY QUALIFIED PERSONS ARE TO WORK WITH THE HIGH VOLTAGE EQUIPMENT.

CAUTION Observe strict safety precautions when working with the high voltage components. Observe all warning signage. Follow established Lockout and Tagout procedures. Do not open or enter compartments with the switchgear energized. All compartment doors allowing access to exposed high voltage components are to be locked prior to energizing the switchgear. All baffles, guards and barriers are to be in place. Use adequate Personnel Protective Equipment as applicable.

31.1 Purpose The intent of this procedure is to provide a general checklist of items necessary to place the switchgear into service. Site specific drawings, procedures and vendor materials will take precedence over this procedure.

31.2 Unpacking and Receiving inspection 1.

On receipt of the control enclosure on site, carefully inspect all compartments for shipping damage, water or dirt incursion and loose parts. 2. After placing the control house on the foundation, remove factory installed shipping restraints on the potential transformer drawers. Check to assure drawers operate and lock freely. 3. Inspect the PT compartments. Assure that fuses are installed and firmly seated in the fuse holders. Verify PT fuse size per 1 & 3 line diagrams. 4. Remove factory installed shipping restraints on the removable 4000 amp circuit breaker. 5. Remove the 4000 amp breaker from the compartment and inspect for damage. 6. Inspect the MOC and TOC switches for free and proper operation. 7. Reinstall the breaker and rack into the operating position to check the operating mechanism. 8. Rack the breaker to the test position. 9. Bus bar connections and mounts are subject to loosening during shipment. Inspect and check all bus mounts for tightness. 10. Using a torque wrench, check all bus connections for tightness. Torque connections per the table in section 6.3. Assure that all boots, barriers and insulation are properly reinstalled after inspection and torquing. 12. Inspect the lightning arrestors and surge suppressor for damage or loose connections. 13. Inspect the cooling fans on forced air cooled installations.

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14. Check operating and locking mechanisms on AR switchgear for proper operating and locking. Assure the doors to the PT compartments and the 52G breaker compartment will not open when the PTs or the breaker are racked into the operating position. 15. Inspect the auxiliary transformer for shipping damage or water or dirt contamination. 16. Inspect transformer fused disconnect switch, fuses and fuse holders. Verify correct fuse size per the 1 and 3 line diagrams. 17. Inspect disconnect and/or grounding switches for proper operation. 18. Inspect and test operate all keyed interlocks on disconnect and grounding switches. Switchgear is to be isolated from all high voltages sources during this testing.

31.3

Testing

The control enclosure high voltage bus and switchgear is factory tested including hi pot insulation test and continuity and CT polarity test using primary injection. CT and PT testing other than insulation tests may be conducted in the field at the discretion and expense of the Customer. 1.

15KV switchgear should be field insulation tested prior to placing the equipment into service. The switchgear may be tested at 27 KVAC for one minute. DC hi pot testing may be conducted if required by the Customer. Use extreme caution and refer to all applicable Powell documentation prior to conducting the tests. Any deviations in procedure, test equipment or test voltages must have prior approval from PWPS Engineering. Any testing not specified in Powell documentation, on the drawings or in this procedure must have prior PWPS Engineering approval. Record test voltages and results on the Sign-off sheets.

2.

Record breaker opening and closing times on the sign-off sheets. Factory test results may be included or the breaker may be field tested at the discretion of the Customer.

3.

Record breaker cycles on the sign-off sheets as received and as commissioned, after the performance test.

4. Record the gap between the vacuum interrupter contact loading spring yolk and the locknut operating pushrod stud. The factory measurement is included on a tag on each phase vacuum interrupter bottle. See Powell documentation for complete details and instructions. 5. Prior to energizing the high voltage backfeed or building high voltage on the generator, prove the manual and electrical close and trip functions of the 52G breaker. 6. Verify correct breaker open and closed indicator light operation

31.4

Forced Air Cooling Fans (If equipped) Powering the capacitive trip circuit from ACD 1-38/40 also powers the breaker cooling fans. The primary and secondary fans are sequenced on as a function of primary breaker current. Assure that the sensing and timing relays are set per the values listed on the sign-off sheets. Test the primary cooling fan by pressing the test button on the front of the 52G breaker compartment door. The primary fans should operate. Hold the test button for a minimum of 20 seconds. If there is no alarm indicated on the control system, the fan sail switches are operating. The secondary cooling fans must be tested by installing a jumper between terminals XXX_XXX on the 88-1x relay.

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Pratt and Whitney Power Systems, Inc. Commissioning Manual – TPMD385

TEMPORARY REVISION NO. 08-01 PROCEDURE 32 – PROTECTIVE RELAY CALIBRATION AND TESTING 32.0

Protective Relay Calibration & Testing Checkout Procedures

The FT8 generating system incorporates devices designed and intended to be used for generating system protection and control. Installed hardware varies between sites and customers. A site specific list of hardware and customized settings is defined in XXX-189-E011L, List, Protective Relay Settings. Customized site settings are to be entered during factory or field commissioning using a laptop computer with applicable software programs as required. Other settings may be entered into the device using mechanical dials or switches depending on the device. The Beckwith solid-state digital relays are factory calibrated. Calibrations and operating points may be field verified. Relay inputs and outputs to the lockout relays should be checked during commissioning. Calibration of the protective relays is generally customer’s responsibility. This procedure may be modified at site to accommodate customer requirements.

32.1

Purpose

1.

To assure that the protective relays have been calibrated.

2.

To record protective relay calibration data and settings.

32.2 1.

Prerequisites Verify WATT and VAR Transducers (WT3801, VT3801) have been calibrated.

32.2.1 Qualified Personnel 1.

GSU operation personnel

2.

Generator/AVR representative

3.

Gas turbine qualified operator

4.

Customer’s calibration lab or qualified outside lab technician

32.2.2 Set-Up 1.

Electro mechanical and solid state relays are to be tested in the panel using the appropriate plugs and adapters.

32.2.3 Sequence 1.

Verify that all Beckwith relay settings are as shown on the Protective Relay Settings List, XXXX-189-E011L

2.

Record applicable local calibration data on the sign-off sheet

3.

Relay functional testing is to be locally coordinated and may be included with Procedures 33, 34 or 35 of this manual.

Dec 12/07 Temporary Revision 08-01

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Pratt and Whitney Power Systems, Inc. Commissioning Manual – TPMD385

TEMPORARY REVISION NO. 08-01 32.2.4 Auxiliary Transformer Lockout Relay 1. 2.

Verify 86AT and 86BF trips transmission system breaker(s) and gen breaker(s). Including additional circuit breakers connected to GSU high and low side plus power taps or feeds. Verify 86AT and 86BF ties into transmission system breaker backup protection. Such as 52L breaker failure.

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PROCEDURE 33 – SHORT CIRCUIT TEST 33.0 Short Circuit Test NOTE This procedure may be modified at site to accommodate customer’s requirements

33.1 Purpose The purpose of the short circuit test is to verify the CT polarities and readings used by the metering circuits, protective relays and AVR.

33.2 Prerequisites 33.2.1 Qualified Personnel 1. GSU operation personnel 2. Generator/AVR representative 3. Qualified gas turbine commissioning representative 4. Gas turbine qualified operator

33.3 Set-Up 1. GSU off 2. Shorting bars installed in back of switchgear or as agreed upon at the site.

NOTE Maximum current capability of links must be equal to or exceed the current rating of the switchgear. 3. AC power transferred to auxiliary 4. Remove DC trip circuit fuse block (Main Breaker Cabinet) 5. Using jumpers, condition the Sync Check relay and the 52CXG relays to allow manual closing of the main 52G breaker. 6. Computers connected to Beckwith relays as required 7. As an alternate procedure the two-line display on the Beckwith relay may be used to observe differential currents.

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33.4 Sequence 1. Close breaker 52G 2. Start gas turbine 3. Drive the generator to synchronous speed, 3000RPM (50 Hz) or 3600 RPM (60 Hz) 4. Turn on PMG using the switch in the cabinet behind the operator panel 5. Use raise/lower switch and drive to XXX amps (link dependent) 6. On Beckwith computer, verify equal CT amp readings on all CT’s 7. On Beckwith computer, verify no differential amp readings 8. It may be desirable to functionally check several other relay functions such as phase over current during the short circuit test. Follow the Brush procedure. Additional detailed requirements are to be determined at the site.

33.5 Shutdown 1. Drive amps to zero 2. Turn off AVR 3. Stop gas turbine 4. Trip breaker 5. Re-install DC trip circuit fuse block (Main Breaker Cabinet) 6. Remove jumper from the Sync Check relay and the 52CXG relay 7. Remove shorting bars 8. Restore GSU 9. Restore AC power to auxiliary transformer

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PROCEDURE 34 – PHASING AND SYNCHRONIZATION CHECKS 34.0 Phasing and Synchronizing Checks Checkout Procedures NOTE This procedure may be modified at site to accommodate customer’s requirements.

34.1 Purpose The purpose of the phasing checks is to verify the same phase rotation and correct phase-to-phase relationship for the generator and the system grid. This will also verify the correct operation of the synchroscope and synchronizing lights. After the manual synchronizing equipment has been verified, the operation of the automatic synchronizer will be checked. The 4000 amp breaker may be withdrawn from the breaker cabinet to facilitate a hot stick check as detailed below. The 5000 amp breaker is bolted in place and may not be withdrawn from the breaker cabinet. Alternate phase checking and verification si required.

34.2 Prerequisites 34.2.1 Qualified Personnel 1. GSU operation personnel 2. Generator/AVR representative 3. Gat turbine commissioning representative 4. Gas turbine qualified operator

34.2.2 Equipment 1. Personal protective Equipment (PPE) - Hard hat, high voltage gloves, high voltage hood with face shield, high voltage coveralls or jacket and bib overalls minimum. 2. Hot stick analog voltmeter minimum

34.3 Set-Up 1. GSU ON 2. Breaker in racked out position and plugged in to umbilical cord

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34.4 Sequence

1. Disconnect umbilical and remove breaker from cabinet 2. Lock open shutters in breaker cabinet 3. Start gas turbine 4. Drive generator to synchronous speed, 3000 RPM (50 Hz) or 3600 RPM (60 Hz) 5. Turn on AVR 6. Set generator voltage to agree with grid voltage using the Volt/Var Switch 90V 7. Set generator frequency to closely match grid frequency 8. Turn on Sync Switch (69ss) 9. Hot stick generator phase “A” to line phase “A” A. Observe that at a 12 o’clock synchroscope, the sync lights are off and the hot stick voltage = 0. B. Observe that at 3 and 9 o’clock synchroscope, the sync lights are on dim and the hot stick voltage = approximately bus nominal voltage. C. Observe that at a 6 o’clock synchroscope, the sync lights are on bright and the hot stick voltage = 2 x nominal line voltage.

NOTE Steps 1 through 8 have verified phasing and the manual synchronizing equipment. If the autosynchronizer is to be checked at this point continue with steps.

10. Turn off the AVR 11. Close the shutters in the breaker cabinet 12. Install the 52G breaker in the test position and connect the umbilical 13. Condition permissives for the breaker to close. Temporarily block the TOC switch to simulate the breaker in the racked in condition. (Refer to the system schematics.)

14. Turn on the AVR 15. Select “Automatic Operation” using the 43-2 mode select switch 16. Observe the lights on the auto-synchronizer illuminate

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Procedure 34 - 2 Previous Document

17. Observe the auto-synchronizer adjust frequency and voltage as required 18. When the voltage and frequency are matched within limits (four green LEDs illuminated on the XMC synchronizer), observe the red breaker close LED on the synchronizer illuminate and the breaker close when the synchroscope is at the 12 o’clock position.

NOTE The Np speed will increase after the breaker closes. Select “Manual Operation” using the 43-2 mode select switch and adjust speed using the 18-1 raise/lower switch.

19. Open the breaker manually using the 52CSG switch 20. Repeat steps 15 through 19, as required, observing the below synchronizer functions A. Match system from generator voltage and frequency low B. Match system from generator frequency low and voltage high C. Match system from generator frequency high and voltage low D. Match system from generator voltage and frequency high

21. Restore the system to normal operation. Assure that TOC switch is restored to normal. 34.5 Shutdown

1. Turn off AVR 2. Stop gas turbine 3. Close shutters in breaker cabinet (if required) 4. Re-install breaker.

DATE TBD Rev. 4 Homepage

Procedure 34 - 3 Previous Document

34.6

Alternate Method.

The following steps are an alternate method to verify phasing should it not be possible to “hot stick” across the 52G breaker.

34.6.1 Phasing and Synchronizing Checks Using the Installed Instrumentation 1. Assure that all checkout steps through overspeeds have been completed. 2. Assure that the AVR has been set up, the generator excited in manual and automatic, and the open circuit testing is complete. 3. Assure that the instrumentation and metering CTs and PTs have been checked and tested. 4. Assure that the instrumentation and metering PTs (PT-1, PT-2, PT-3, PT-4) are installed and operating. Read three phase bus voltage on the operator’s panel. 5. Read three phase voltage in switchgear cabinet 3 at V1, V2 and V3. 6. Using a laptop computer, inhibit the trip output functions from the Beckwith relays. 7. Open and tag the breaker on the HV side of the GSU. 8. Open and tag the line isolator to the breaker on the HV side of the GSU. 9. Assure that the generator voltage regulator is in “MANUAL”. 10. Rack in the 52G breaker (4000 amp installation) . 11. Condition circuits as tabulated below to close the 52G breaker and to avoid a customer trip, as required: A. Jumper terminals 25SC Sync Check relay and the 52CXG relay as required. See system schematics XXX-187-E306D sheet 1. B. Assure continuity between terminals R4-23 to R4-25. C. Lift R4-43 to avoid 86G1 trip from customer. D. Lift R4-45 to avoid 86G2 trip from customer. E. Lift R4-47 to avoid 86E trip from customer. F. Lift R4-39 to avoid 52G DC trip from customer. G. Lift R4-41 to avoid 52G Cap trip from customer. 12. Start an engine and bring the generator to synchronous speed. 13. Close the 52G breaker.

DATE TBD Rev. 4 Homepage

Procedure 34 - 4 Previous Document

14. Slowly raise the generator voltage to nominal bus voltage. 15. Read the phase sequence on terminals V1(A), V2(B), V3(C). 16. Read the phase sequence on terminals P1(A), P2(B), P3(C). This should be the same as #15. 17. Measure the voltage from V1 to P1, V2 to P2 and V3 to P3. All should be zero VAC. 18. Measure the voltage from V1 to P2, V1 to P3 and V2 to V3. All should be approximately 115 VAC. 19. Install the phase sequence meter on V1(A), V2(B), V3(C). Tape leads and leave in place. Record direction of rotation. 20. Turn on the synchroscope, using the 69SS switch. 21. Synchroscope needle should be at 1200 position and the synchronizing lights should not illuminate. 22. Measure the voltage between terminals 1 to 5 and 2 to 6 on the 25SC relay. Both should be zero VAC. 23. Measure the voltage between terminals 1 to 2 and 5 to 6. Both should be approximately 115 VAC. 24. Look at the front of the 25SC relay. The permissive and close breaker lights should be illuminated. 25. Operate the 69SS switch to “OFF”. 26. Reduce generator voltage to minimum. 27. Open the 52G breaker. 28. Restore wiring in steps 11.3 to 11.7. Leave the jumpers on the 25SC relay and 52CXG relay in place. 29. Restore the trip functions to the protective relays which were removed in step 6. 30. Rack the 52G breaker to the test position. 31. Mechanically operate the TOC switch and hold in place. 32. Release tag and close the HV disconnect to the HV breaker. 33. Release tag and close the HV breaker. 34. Read the phase sequence on the phase sequence meter. Rotation should be the same as in steps 15, 16 and 19. 35. Raise the generator voltage to nominal bus voltage.

DATE TBD Rev. 4 Homepage

Procedure 34 - 5 Previous Document

36. Operate the 69SS to “ON”. 37. Match generator voltage to bus voltage. Check all three phases. 38. Adjust the engine speed to cause the synchroscope to rotate slowly in the clockwise direction. 39. Measure the voltage from V1 to P1, V2 to P2 and V3 to P3. Voltage should be at the minimum value when the synchroscope needle is at the 12 O’clock position and maximum at the 6 O’clock position. 40. Attempt to close the breaker at 3, 6 and 9 O’clock positions. Breaker should not close. 41. Attempt to close the breaker at the 12 O’clock position. Breaker should close. 42. Open the 52G breaker. 43. Reset the breaker from the “START” screen. 44. Adjust generator voltage and frequency so that both are above bus values. 45. Operate the 90-VT Voltage Regulator Transfer switch to place the AVR in “AUTOMATIC”. 46. Operate the 43-2 Mode Select switch to select “AUTOMATIC” operation. The 25 automatic synchronizer should energize and the bus and generator voltage within limits lights should illuminate. 47. Observe the synchronizer send voltage and frequency lower pulses and adjust generator voltage and frequency to match bus voltage and frequency. Observe the appropriate LEDs illuminate when parameters are within limits. 48. Observe the red breaker close LED on the synchronizer illuminate and close the breaker when the synchroscope needle is at the 12 O’clock position. 49. Select “MANUAL” and open the breaker. 50. Reset the breaker from the “START” screen. 51. Adjust generator voltage high and frequency low compared to bus. 52. Select “AUTOMATIC”. 53. Observe the synchronizer send voltage lower and frequency raise pulses and adjust generator voltage and frequency to match bus voltage and frequency. Observe the voltage and frequency LEDs illuminate when parameters are within limits. 54. Observe the red breaker close LED on the synchronizer illuminate and close the breaker when the synchroscope needle is at the 12 O’clock position. 55. Select “MANUAL” and open the breaker. 56. Reset the breaker from the “START” screen. 57. Adjust generator voltage low and frequency low compared to bus.

DATE TBD Rev. 4 Homepage

Procedure 34 - 6 Previous Document

58. Select “AUTOMATIC”. 59. Observe the synchronizer send voltage raise and frequency raise pulses and adjust generator voltage and frequency to match bus voltage and frequency. Observe the voltage and frequency LEDs illuminate when parameters are within limits. 60. Observe the red breaker close LED on the synchronizer illuminate and close the breaker when the synchroscope needle is at the 12 O’clock position. 61. Select “MANUAL” and open the breaker. 62. Reset the breaker from the “START” screen. 63. Adjust generator voltage low and frequency high compared to bus. 64. Select “AUTOMATIC”. 65. Observe the synchronizer send voltage raise and frequency lower pulses and adjust generator voltage and frequency to match bus voltage and frequency. Observe the voltage and frequency LEDs illuminate when parameters are within limits. 66. Observe the red breaker close LED on the synchronizer illuminate and close the breaker when the synchroscope needle is at the 12 O’clock position. 67. Select “MANUAL” and open the breaker. 68. Reset the breaker from the “START” screen. 69. Turn them 69SS switch to the “OFF” position. 70. Remove the jumpers from the 25SC relay and the 52CXG relay. 71. Remove the block on the TOC. 72. Rack the breaker into the “CONNECTED” position. 73. Receive customer permission to synchronize and close the breaker on line. 74. Turn the 69SS switch to the “ON” position. 75. Adjust generator voltage to match bus voltage. 76. Operate the 52CS-C switch to the “CLOSE” position to close the 52G breaker. 77. Observe the breaker close and the machine pick up approximately 2 to 4 MW. 78. Turn the 69SS switch to the “OFF” position. 79. Demonstrate raise and lower control of voltage using the 90VC switch. 80. Demonstrate raise and lower power control using the 18-1 speed/load switch. 81. Open the 52G breaker.

DATE TBD Rev. 4 Homepage

Procedure 34 - 7 Previous Document

82. Select “PROGRAM LOAD” operation to 5 MW at a load rate of 2 MW/Minute from them “START” screen. 83. Select “AUTOMATIC” operation. 84. Observe the 52G breaker close and the machine pick up load to 5 MW. 85. Record the breaker close time. 86. Observe the 25 synchronizer power down approximately 1 minute after breaker closure. 87. Record results on the Checkout Manual Signoff Sheets.

DATE TBD Rev. 4 Homepage

Procedure 34 - 8 Previous Document

Pratt and Whitney Power Systems, Inc. Commissioning Manual - Revision 4

TEMPORARY REVISION NO. 07-04 Please Insert this Temporary Revision in the Commissioning Manual Rev 4, Procedure 35 Breaker Closure and On-Line AVR Tests before Page 35-1. This Procedure is being modified to included On-Line Protective Relay test and calculations for 27TN and 59D functions.

PROCEDURE 35 – BREAKER CLOSURE, ON-LINE AVR AND PROTECTIVE RELAY TESTS 35.0 Breaker Closure, On Line AVR and Protective Relay Tests Checkout Procedures NOTE This procedure may be modified at site to accommodate customer requirements.

35.1 Purpose 1. Verify generator breaker closure on line. 2. Verify that the AVR detects under excitation and that the condition clears when excitation returns to above set point. 3. Verify that the AVR limiter catches the voltage droop. 4. Verify manual and automatic operation of the AVR.

35.2 Prerequisites 35.2.1 Qualified Personnel 1. GSU operation personnel 2. Generator/AVR representative 3. Gas turbine qualified operator 4. Qualified gas turbine commissioning representative

March 30, 2007 Homepage

Page 1 of 2 Previous Document

Pratt and Whitney Power Systems, Inc. Commissioning Manual - Revision 4

TEMPORARY REVISION NO. 07-04 35.3 Set-Up 1. GSU on 2. Generator breaker ready for operation 3. AC power on unit auxiliary transformer 4. All protective relay testing completed to allow breaker closure 5. All gas turbine testing completed to allow breaker closure 6. All generator/AVR testing completed to allow breaker closure 7. Turn on AVR 8. Connect computer to AVR using Brush software.

35.4 Sequence 35.4.1 Breaker Closure 1. Ensure generator breaker is open and racked in to the normal operating position 2. Start gas turbine 3. Drive to synchronous speed 4. Turn on the 69SS synchronizing switch 5. Close breaker at 12 o’clock position (CW rotation of synchroscope) indicating light on sync check relay will indicate when breaker closure is allowed 6. Drive to 4 MW

35.4.2 AVR Testing 1. Follow procedures noted in the Brush Commissioning procedure. 2. Record test results on the Sign-off sheets.

35.4.3 Protective Relay Testing 1. Follow procedures noted in TPM375 located in the appendix of this manual. 2. Record test results on the “Test Data Collection sheet” located in TPM375. 3. Record completion of test on the Sign-off sheets.

March 30, 2007 Homepage

Page 2 of 2 Previous Document

PROCEDURE 35 – BREAKER CLOSURE AND ON-LINE AVR TESTS 35.0 Breaker Closure and On Line AVR Tests Checkout Procedures NOTE This procedure may be modified at site to accommodate customer requirements.

35.1 Purpose 1. Verify generator breaker closure on line. 2. Verify that the AVR detects under excitation and that the condition clears when excitation returns to above set point. 3. Verify that the AVR limiter catches the voltage droop. 4. Verify manual and automatic operation of the AVR.

35.2 Prerequisites 35.2.1 Qualified Personnel 1. GSU operation personnel 2. Generator/AVR representative 3. Gas turbine qualified operator 4. Qualified gas turbine commissioning representative

35.3 Set-Up 1. GSU on 2. Generator breaker ready for operation 3. AC power on unit auxiliary transformer 4. All protective relay testing completed to allow breaker closure 5. All gas turbine testing completed to allow breaker closure 6. All generator/AVR testing completed to allow breaker closure 7. Turn on AVR 8. Connect computer to AVR using Brush software.

October 6, 2006 Rev. 4 Homepage

Procedure 35 - 1 Previous Document

35.4 Sequence 35.4.1 Breaker Closure 1. Ensure generator breaker is open and racked in to the normal operating position 2. Start gas turbine 3. Drive to synchronous speed 4. Turn on the 69SS synchronizing switch 5. Close breaker at 12 o’clock position (CW rotation of synchroscope) indicating light on sync check relay will indicate when breaker closure is allowed 6. Drive to 4 MW

35.4.2 AVR Testing 1. Follow procedures noted in the Brush Commissioning procedure. 2. Record test results on the Sign-off sheets.

October 6, 2006 Rev. 4 Homepage

Procedure 35 - 2 Previous Document

PROCEDURE 36 – WATER INJECTION SYSTEM 36.0 Water Injection System Checkout Procedure The water injection system provides a means to lower the combustor flame temperature in the combustion chambers to control oxides of nitrogen. De-mineralized water is drawn from a storage tank, pressurized, sent directly to the fuel nozzles or mixed with fuel, injected into fuel nozzles and passes into the combustion chambers. Water injection also increases the mass flow through the power turbine thereby increasing the output power.

36.1 Checkout 1. Accomplish the following prior to pump operation: A. Check the oil level in the pump B. Ensure wiring is complete C. Ensure electrical grounding is complete D. Align all hand valves for normal operation E. Check inlet strainer for cleanliness if fitted. Assure that filter elements are installed in F801. F. Verify that the supply piping up to the pump suction has been flushed clean. G. Assure VFD setup per tabulation in the Sign-off Sheets. H. Check VFD tunables per tabulation in the Sign-off Sheets. 2. “Bump” the pump motors at the MCC to check for proper rotation. 3. Calibration – See section 16 A. Ensure calibration of PT 803. B. Ensure calibration of TE801 (RTD). C. Verify the operation of LSL801 by filling and draining the piping with de-mineralized water. Ensure that, at the control system, the switch (LSL801) opens and closes with the changing water level. D. From the control room (ICE MONITOR), cycle each of the solenoid operated drain (SOV1403, SOV1404, SOV1406, and SOV1407) valves and flow control valves (SOV801 & SOV802). Have an observer at the subject valve to confirm operation by listening for a “click” as the solenoid is cycled.

October 6, 2006 Rev. 4

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Procedure 36 - 1

Previous Document

4. Assure the system is flushed to the engine base and that the flow meter FM801 tubing is filled. See section 4. 5. Assure flow meter setup is correct and that flow meter is “zeroed”. See section 21. 6. Injecting water into the GG A. Recheck the pump(s) inlet strainer(s) and temporary flushing screens as applicable. B. Ensure water injection system is in AUTO prior to starting unit to check at what point in the start sequence the pump starts and to verify that the water does not come on prior to turn-on temperature. (See WTR_ON/OFF.EGT_GT.A_COMPARE for turn-on temperature) C. Start the gas turbine, synchronize, close the breaker and generate sufficient power (5-10 MW) to bring the EGT average temperature above water turn on temperature. D. Open the enclosure doors and check for leaks. E. Ensure that the water flow rate is at minimum flow for the 3 minute manifold fill time. Verify timer duration and check for proper water/fuel mixture ratios. F. Operate the unit up to base load with water injection in AUTO mode at the monitor. G. Reduce power to below the water turn-off temperature and verify that the control system turns the water OFF. The software turn-off point is set at 50° below the water turn-on temperature H. Increase power above the water turn-on temperature and verify that the water comes back ON at minimum flow and that it returns to the scheduled value after the 3 minute manifold fill time. I.

Verify that the water injection process can be enabled or stopped from the ICE Monitor by selecting either “Wet” or “Dry” operation from the Start/Stop screen.

7. Post Operation A. After gas turbine shutdown, recheck all piping connections to pumps and fuel nozzles for evidence of water leaks and repair as necessary. B. Recheck pump oil level at P801. C. Remove and inspect flushing screen (if installed) before the pump inlet filter. Do not reinstall this screen if there is no further evidence of foreign material in the system.

October 6, 2006 Rev. 4

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Procedure 36 - 2

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Pratt and Whitney Power Systems, Inc. Commissioning Manual - Revision 4

TEMPORARY REVISION NO. 07-03 Please insert this Tempoary Revision in the Commissioning Manual Rev 4, Procedure 36 - Water Injection System, before page 36-3. Tables 36-1 and 36-2 are being revised to match the VFD settings menu structure.

Table 36-1 VFD Parameter Block Values Level 1

Block Title

Parameter

P#

Adjustable Range

PWPS Default Settings

Factory

User Settings UNIT X A UNIT X B

Level 1 Blocks 1001 0 to MAX Speed 1002 0 to MAX Speed 1003 0 to MAX Speed 1004 0 to MAX Speed 1005 0 to MAX Speed 1006 0 to MAX Speed 1007 0 to MAX Speed 1008 0 to MAX Speed 1009 0 to MAX Speed 1010 0 to MAX Speed 1011 0 to MAX Speed 1012 0 to MAX Speed 1013 0 to MAX Speed 1014 0 to MAX Speed 1015 0 to MAX Speed 1101 0 to 3600 seconds ACCEL/DECEL RATE 1102 0 to 3600seconds 1103 0-OFF 3-60 1-20 4-80 2-40 5-100% 1104 0 to 3600 seconds ACCEL TIME #2 1105 0 to 3600 seconds DECEL TIME #2 S/C-CURVE #2 1106 0-OFF 3-60 1-20 4-80 2-40 5-100% 1201 0 to MAX Speed JOG SETTINGS JOG SPEED 1202 0 to 3600 seconds JOG ACCEL TIME 1203 0 to 3600 seconds JOG DECEL TIME JOG S-CURVE 1204 0-OFF 3-60 1-20 4-80 2-40 5-100% 1301 0-REMOTE ON KEYPAD SETUP KEYPAD STOP KEY 1-REMOTE OFF KEYPAD STOP MODE 1302 0-REGEN 1-COAST 1303 0-OFF, 1-ON KEYPAD RUN FWD 1304 0-OFF, 1-ON KEYPAD RUN REV 1305 0-OFF, 1-ON KEYPAD JOG FWD 1306 0-OFF, 1-ON KEYPAD JOG REV 1310 0.01 TO 10.00Hz KEYPAD SPD INC 1307 0-OFF, 1-ON 3 SPEED RAMP 1308 0-OFF, 1-ON SWITCH ON FLY LOC. HOT START 1309 0-OFF, 1-ON PRESET SPEEDS

PRESET SPEED #1 PRESET SPEED #2 PRESET SPEED #3 PRESET SPEED #4 PRESET SPEED #5 PRESET SPEED #6 PRESET SPEED #7 PRESET SPEED #8 PRESET SPEED #9 PRESET SPEED #10 PRESET SPEED #11 PRESET SPEED #12 PRESET SPEED #13 PRESET SPEED #14 PRESET SPEED #15 ACCEL TIME #1 DECEL TIME #1 S/C-CURVE #1

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0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 3.0s 3.0s OFF

3.0s 3.0s OFF

3.8s 3.9s

-

7.00Hz 3.0s 3.0s OFF

REMOTE ON REGEN ON ON ON ON 1.00Hz OFF(ON)* OFF(ON)* OFF(ON)*

OFF OFF

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Pratt and Whitney Power Systems, Inc. Commissioning Manual - Revision 4

TEMPORARY REVISION NO. 07-03 Table 36-1 VFD Parameter Block Values Level 1

Block Title INPUT

Parameter OPERATING MODE

COMMAND SELECT

ANA CMD INVERSE ANA CMD OFFSET ANA CMD GAIN CMD SEL FILTER

OUTPUT

PWR UP MODE OP DIGITAL OUT #1 DIGITAL OUT #2 DIGITAL OUT #3 (Relay Out #1) DIGITAL OUT #4 (Relay Out #2) ZERO SPD SET PT AT SPEED BAND SET SPEED POINT OVERLOAD SP UNDERLOAD SP ANALOG OUT #1

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P#

Adjustable Range

1401 0-Keypad 1-Standard Run 2-15 Speed 3-Fan Pump 2Wire 4-Fan Pump 3Wire 5-Serial 6-Process CTRL 7-3SPD ANA 2WIRE 8-3SPD ANA 3WIRE 9-EPOT - 2WIRE 10-EPOT - 3WIRE 1402 0-Potentiometer 1-0-10 VOLTS 2-0-5 VOLTS 3-4-20 mA 4-EXB PULSE FOL 5-10V EXB 6-4-20 mA EXB 7-3-15 PSI EXB 8-Tachometer EXB 9-None 1403 0-OFF, 1-ON 1404 -20.0 TO +20.0% (where ±0.5V=±20%) 1405 80.0% to 120% 1406 0-6 1407 1-Primary Mode, 2-Last 3-Local 1501 0-Ready 1-Zero Speed 1502 2-At Speed 3-At Set Speed 1503 4-Overload 5-Keypad Control 6-Fault 1504 7-Drive On 8-Reverse 9-Process Error 1505 0 to MAX Speed 1506 0-20Hz 1507 0 to MAX Speed 1512 0.00 TO 100.00% 1513 0.00 TO 100.00% 1508 0-Frequency 1-Freq Command 2-AC Current 3-AC Voltage 4-Torque (Load)

Factory Keypad

PWPS Default Settings

User Settings UNIT X A UNIT X B

Fan Pump 2Wire

Potentiometer 4-20 mA

OFF 0.00% 100% 3 Primary Mode Ready Zero Speed

Zero Speed Fault

At Speed

Fault

6.00Hz 2.00Hz 60.00Hz 50.00% 50.00% Frequency

70.00Hz

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Pratt and Whitney Power Systems, Inc. Commissioning Manual - Revision 4

TEMPORARY REVISION NO. 07-03 Table 36-1 VFD Parameter Block Values Level 1

Block Title

Parameter

OUTPUT (Cont.) ANALOG OUT #2

V/HZ AND BOOST

ANALOG #1 SCALE ANALOG #2 SCALE CTRL BASE FREQUENCY TORQUE BOOST DYNAMIC BOOST SLIP COMP ADJ V/HZ PROFILE

P#

Adjustable Range

Factory

User Settings UNIT X A UNIT X B

AC Current

1509 5-Power 6-Bus Voltage 7-Process Fdbk 8-Setpoint Cmd 9-Zero Cal 10-100% Cal 1510 10 - 160% 1511 10 - 160% 1601 50.00 - 400.00Hz

100.00% 100.00% 60.0Hz

1602 1603 1604 1605

2.50% 0.00% 0.00Hz Linear

0.0 - 15.0% 0.0 - 100% 0.00 - 6.00Hz 0-LINEAR, 1-33% SQR LAW, 2-67% SQR LAW, 3-100% SQR LAW, 4-3 POINTS 1606 0-100% V/HZ 3-PT VOLTS V/HZ 3-PT FREQUENC 1607 0-9.99Hz MAX OUTPUT VOLTS 1608 0-100 * Indicates a setting that is different in the manual.

PWPS Default Settings

70.00Hz

0.00% 0.00Hz 100.00%

TECH NOTES: 1. TO GET VFD DEFAULT PRESS DISP + ENTER PRESS RESET 2 TIMES TO EXIT 2. TO CLEAR THE REGISTER PRESS DISP + ENTER THEN PRESS SHIFT + RESET THEN PRESS SHIFT + ENTER (FAULT CLEARED) THEN PRESS RESET 2 TIMES TO EXIT

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Pratt and Whitney Power Systems, Inc. Commissioning Manual - Revision 4

TEMPORARY REVISION NO. 07-03 Table 36-2 - VFD Parameter Block Values Level 2

Block Title Level 2 Blocks OUTPUT LIMITS

Parameter

OPERATING ZONE

MIN OUTPUT FREQ MAX OUTPUT FREQ PK CURRENT LIMIT

P#

Adjustable Range

2001 0-STD CONST TQ 1-STD VAR TQ 2-QUIET CONST TQ 3-QUIET VAR TQ 2002 0 to MAX Frequency

0.00Hz

6.0Hz

2003 0 to MAX Frequency

60.00Hz

70.0Hz

2004 1A to Peak Rated Current

PK Control Rating 2500Hz

72.6A

2005 1-5kHz (Standard) 1-15kHz (Quiet) 2020 0-OFF, 1-ON REGEN LIMIT 2021 0 - 500 REGEN LIMIT ADJ MAX DECIMAL DISPLA 2101 0-5 2102 VALUE AT SPEED 1-65535/1-65535 UNITS OF MEASURE 2105 See Table 4-2. 2202 0-OFF, 1-ON EXTERNAL TRIP 2205 0-OFF, 1-ON LOCAL ENABLE INP 2 2206 0-Fault, 1-Current Limit then I T Response Hold, 2-Current Limit then Retry 2 2207 0.00% to 100.00% I T Trigger 2208 0.000 to 65.655 seconds Peak CURR Timer Foldback Gain 2209 0.01 to 10.00 RESTART AUTO/MAN 2301 0-Manual, 1-Automatic 2302 PWM FREQUENCY

CUSTOM UNITS

PROTECTION

MISCELLANEOUS

RESTART FAULT/HR RESTART DELAY LANGUAGE SELECT

SECURITY CONTROL

MOTOR DATA

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Factory

PWPS Default Settings

0-10 2303 0-120Seconds 2304 0-English, 1-Espanol 2305 FACTORY SETTINGS 0-NO, 1-STD Settings, 2-50Hz / 400Volts 2320 STAB CUTOFF FREQ 0-4.00Hz 2321 1-6 STABILITY GAIN 2401 0-Off SECURITY STATE 1-Local Security 2-Serial Security 3-Total Security 2402 ACCESS TIMEOUT 0-600 seconds 2403 0-9999 ACCESS CODE 2501 0-999 VOLTS MOTOR VOLTAGE MOTOR RATED AMPS 2502 0-999.9 2505 0-85% Rated Current MOTOR MAG AMPS MOTOR RATED SPD 2503 0-32767RPM MOTOR RATED FREQ 2504 50-400Hz

User Settings UNIT X A UNIT X B

STD CONST TQ

OFF 0Hz 0 0./01000 **** OFF OFF Fault

10.00% 0.000s 1.00 3.00* Manual 0

0s English NO

0.00Hz 1 0* OFF

0s 9999 Factory Set Factory Set Factory Set 1750RPM 60.0Hz

460V 67A 13.2A 3550RPM 4 of 6

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Pratt and Whitney Power Systems, Inc. Commissioning Manual - Revision 4

TEMPORARY REVISION NO. 07-03 Table 36-2 - VFD Parameter Block Values Level 2

Block Title Level 2 Blocks BRAKE ADJUST

PROCESS CONTROL

Parameter

P#

RESISTOR OHMS RESISTOR WATTS DC BRAKE VOLTAGE DC BRAKE FREQ BRAKE ON STOP BRAKE ON REVERSE STOP BRAKE TIME BRAKE ON START START BRAKE TIME PROCESS TYPE

2601 2602 2603 2604 2605 2606 2607 2608 2609 2715

FEEDBACK

INVERT FEEDBACK SETPOINT SOURCE

SETPOINT COMMAND SET PT ADJ LIMIT AT SETPOINT BAND PROCESS PROP GAIN PROCESS INT GAIN PROCESS DIFF GAIN INTEGRATOR CLAMP MINIMUM SPEED FOLLOW I:O RATIO ENCODER LINES

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Adjustable Range

0-255 OHMS 32767 WATTS 1.0 TO 15% 0.00 TO 400.00Hz 0-OFF, 1-ON 0-OFF, 1-ON 0.00 to 60.0 seconds 0-OFF, 1-ON 0.00 to 60.0 seconds 0-Forward Acting 1-Reverse Acting 2701 0-Potentiometer 1-0-10VOLTS 2-0-5 VOLTS 3-4-20mA 4-10V EXB 5-4-20mA EXB 6-3-15 PSI 7-TACHOMETER EXB 8-NONE 2702 0-OFF, 1-ON 2703 0-Setpoint Command 1-Potentiometer 2-0-10VOLTS 3-0-5 VOLTS 4-4-20mA 5-10V EXB 6-4-20mA EXB 7-3-15 PSI 8-Tachometer EXB 9-None 2704 -100% to +100% 2705 0-100% 2706 0-100% 2707 0-2000 2708 0-9.99Hz 2709 0-1000 2713 0-100% 2714 0-0 to MAX Speed 2710 1-65535:1-65535 2712 20-65535

Factory

PWPS Default Settings

User Settings UNIT X A UNIT X B

Factory Set 0 Factory Set 5.00% 6.00Hz OFF OFF 3.0s OFF 3.0s Forward Acting NONE

OFF NONE

0.00% 10% 10% 0 0.00Hz 0 100% 0.00Hz 1:1 1024

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Pratt and Whitney Power Systems, Inc. Commissioning Manual - Revision 4

TEMPORARY REVISION NO. 07-03 Table 36-2 - VFD Parameter Block Values Level 2

Block Title Level 2 Blocks SKIP FREQUENCY

SYNCHRO-START

Parameter

P#

SKIP FREQ #1 SKIP BAND #1 SKIP FREQ #2 SKIP BAND #2 SKIP FREQ #3 SKIP BAND #3 SYNCHRO-STARTS

2801 2802 2803 2804 2805 2806 2901

SYNC START FREQUENCY SYNC SCAN V/F SYNC SETUP TIME SYNC SCAN TIME SYNC V/F RECOVER

2902 2903 2904 2905 2906 2907

SYNC DIRECTION COMMUNICATIONS PROTOCOL

BAUD RATE

Adjustable Range

0-400.0Hz 0-50.0Hz 0-400.0Hz 0-50.0Hz 0-400.0Hz 0-50.0Hz 0-OFF, 1-Restarts Only, 1-All Starts 0-Max Frequency, 1-Set Frequency 5.0-100.0% 0.2-2.0 seconds 1.0-10.0 seconds 0.2-2.0 seconds 0-Sync Forward and Reverse 1-Sync Forward, 2- Sync Reverse

3001 0-RS-232 ASCII, 1-RS-485 ASCII 2-RS-232 BBP, 3-RS-485 BBP 3002 38.4KB, 3-57.6KB, 4-115.2KB, 5230.4KB 3003 0 - 31

DRIVE ADDRESS JP1 JP2 JP3 JP4 * Indicates a setting that is different in the manual. Jumper Settings

Factory

PWPS Default Settings

User Settings UNIT X A UNIT X B

0.0Hz 0.0Hz 0.0Hz 0.0Hz 0.0Hz 0.0Hz OFF MAX Frequency 10.00% 0.2s 2.0s 1.0s Sync FWD & REV

RS-232 BBP

9600

0 2 TO 3 1 TO 2 1 TO 2 1 TO 2

TECH NOTES: 1. TO GET VFD DEFAULT PRESS DISP + ENTER PRESS RESET 2 TIMES TO EXIT 2. TO CLEAR THE REGISTER PRESS DISP + ENTER THEN PRESS SHIFT + RESET THEN PRESS SHIFT + ENTER (FAULT CLEARED) THEN PRESS RESET 2 TIMES TO EXIT March 28, 2007

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Table 36-1 - VFD Parameter Block Values Level 1 (Sheet 1 of 3) Block Title

Parameter

P#

Adjustable Range

Factory

User Setting

PRESET SPEED #1 PRESET SPEED #2 PRESET SPEED #3 PRESET SPEED #4 PRESET SPEED #5 PRESET SPEED #6 PRESET SPEED #7 PRESET SPEED #8 PRESET SPEED #9 PRESET SPEED #10 PRESET SPEED #11 PRESET SPEED #12 PRESET SPEED #13 PRESET SPEED #14 PRESET SPEED #15

1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015

0 – Max Speed 0 – Max Speed 0 – Max Speed 0 – Max Speed 0 – Max Speed 0 – Max Speed 0 – Max Speed 0 – Max Speed 0 – Max Speed 0 – Max Speed 0 – Max Speed 0 – Max Speed 0 – Max Speed 0 – Max Speed 0 – Max Speed

0.00 Hz 0.00 Hz 0.00 Hz 0.00 Hz 0.00 Hz 0.00 Hz 0.00 Hz 0.00 Hz 0.00 Hz 0.00 Hz 0.00 Hz 0.00 Hz 0.00 Hz 0.00 Hz 0.00 Hz

ACCEL TIME #1

1101

0 to 3600 Seconds

3.0 sec

3.8 sec

DECEL TIME #1 S – CURVE #1 ACCEL TIME #2 DECEL TIME #2 S – CURVE #2

1102 1103 1104 1105 1106

0 to 3600 Seconds OFF, 20, 40, 60, 80, 100% 0 to 3600 Seconds 0 to 3600 Seconds OFF, 20, 40, 60, 80, 100%

3.0 sec OFF 3.0s 3.0s OFF

3.9 sec

JOG SETTINGS

JOG SPEED JOG ACCEL TIME JOG DECEL TIME JOG S – CURVE

1201 1202 1203 1204

0 – Max. Speed 0 to 3600 Seconds 0 to 3600 Seconds OFF, 20, 40, 60, 80, 100%

7 Hz 3.0s 3.0s OFF

KEYPAD SETUP

KEYPAD STOP KEY

1301

KEYPAD STOP MODE KEYPAD RUN FWD KEYPAD RUN REV KEYPAD JOG FWD KEYPAD JOG REV 3 SPEED RAMP SWITCH ON FLY LOC. HOT START

1302 1303 1304 1305 1306 1307 1308 1307

REMOTE OFF REMOTE ON REGEN, COAST OFF, ON OFF, ON OFF, ON OFF, ON OFF, ON OFF, ON OFF, ON

PRESET SPEEDS

ACCEL/DECEL RATE

October 6, 2006 Rev. 4

Homepage

REMOTE ON REGEN ON ON ON ON ON ON ON

OFF OFF

Procedure 36 - 3

Previous Document

Table 36-1 - VFD Parameter Block Values Level 1 (Sheet 2 of 3) Block Title

INPUT

OUTPUT

October 6, 2006 Rev. 4

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Parameter

P#

OPERATING MODE

1401

COMMAND SELECT

1402

ANA CMD INVERSE ANA CMD OFFSET

1403 1404

ANA CMD GAIN CMD SEL FILTER

1405 1406

DIGITAL OUT #1

1501

DIGITAL OUT #2

1502

DIGITAL OUT #3

1503

DIGITAL OUT #4

1504

ZERO SPD SET POINT AT SPEED BAND

1506 1507

Adjustable Range

Keypad Standard Run 15 Speed Fan Pump 2Wire Fan Pump 3Wire Serial Process CTRL 3SPD ANA 2WIRE 3SPD ANA 3WIRE EPOT – 2WIRE EPOT – 3WIRE Potentiometer 0 – 10 VOLTS 0 – 5 VOLTS 4 – 20 mA EXB PULSE FOL 10V EXB 4 – 20mA EXB 2 – 15 PSI Tachometer EXB None OFF, ON - 20.0 to + 20.0% (Where +/- 0.5V = +/- 20%) 80.0% to 120% 0–6 Ready Zero Speed At Speed At Set Speed Overload Keypad Control Fault Drive On Reverse Process Error 0 – 20 Hz 0 – MAX Speed

Factory

User Setting

Keypad

Fan Pump 2Wire

Potentiomet er

4 – 20ma

OFF 0.00% 100.00% 3 Ready

Zero Speed

Zero Speed

Fault

At Speed Fault

2.00 Hz 60 Hz

Procedure 36 - 4

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Table 36-1 - VFD Parameter Block Values Level 1 (Sheet 3 of 3) Block Title OUTPUT (Cont.)

V/HZ AND BOOST

Parameter

Factory

1508

ANALOG OUT #2

1509

ANALOG #1 SCALE ANALOG #2 SCALE

1510 1511

Frequency Freq. Command AC Current AC Voltage Torque (Load) Power Bus Voltage Process Fdbx Setpoint Cmd Zero Cal 100% Cal 10 – 100% 10 – 100%

CNTRL BASE FREQUENCY TORQUE BOOST DYNAMIC BOOST SLIP COMP ADJ V/HZ PROFILE

1601

50.00 – 400.00 Hz

60.0 Hz

1602 1603 1604 1605

0.0 – 15.0% 0.0 – 100% 0.0 – 6.00 Hz LINEAR 33% SQR LAW 57% SQR LAW 100% SQR LAW 3 POINTS

2.50% 0.00% 0.00 Hz LINEAR

Enters Level 2 Menu – See Table 34a – 2.

Press ENTER for programming exit.

Exit programming mode and return to display mode.

Homepage

Adjustable Range

ANALOG OUT #1

LEVEL 2 BLOCK

October 6, 2006 Rev. 4

P#

User Setting

Frequency

AC Current

100.00% 100.00%

Procedure 36 - 5

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Block Title

Table 36-2 - VFD Parameter Block Values Level 2 (Sheet 1 of 3) Parameter

P#

Adjustable Range

OPERATING ZONE

2001

MIN OUTPUT FREQ MAX OUTPUT FREQ PK CURRENT LIMIT

2002 2003 2004

PWM FREQUENCY

2005

REGEN LIMIT REGEN LIMIT ADJ

2006 2007

1 – 5 kHz (Standard) 1 – 15 kHz (Quiet) OFF, ON 0 – 500

CUSTOM LIMITS

MAX DECIMAL PLACES VALUE AT SPEED VALUE DEC PLACES VALUE SPEED REF UNITS OF MEASURE UNITS OF MEASURE 2

2101 2102 2103 2104 2105 2106

0–5 1 - 65536/1 - 65536 0 – 5 (Serial Only 1 to 65536 (Serial Only) See Table 4-2. See Table 4-2 (Serial Only)

PROTECTION

EXTERNAL TRIP LOCAL ENABLE INP

2201 2202

OFF, ON OFF, ON

MISCELLANEOUS

RESTART AUTO/MAN RESTART FAULT/HR RESTART DELAY LANGUAGE SELECT FACTORY SETTINGS

2301 2302 23-3 2304 2305

STABIL ADJ LIMIT STABILITY GAIN

2306 2307

Automatic, Manual 0 – 10 0 – 120 Seconds English, Espanol NO, STD Settings, 60Hz/400 Volts 0 – 1.5 Hz Bus Current Method: 0 – 9 Phase Current Method: 1 – 6

SECURITY STATE

2401

ACCESS TIMEOUT ACCESS CODE

OUTPUT LIMITS

SECURITY CONTROL

MOTOR DATA

BRAKE ADJUST

October 6, 2006 Rev. 4

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STD VAR TQ QUIET VAR TQ 0 – MAX Frequency 0 – MAX Frequency 1A to Peak Rated Current

Factory

User Setting

STD VAR TQ 0.00 Hz 60.0 Hz PK Control Rating 2500 Hz

13 Hz 72.6

OFF 0 Hz 0 00000/01000 0 00000/01000

OFF OFF Manual 0 0 Seconds English NO 1.00 Hz 1 1

2402 2403

OFF Local Security Serial Security Total Security 0 – 600 Seconds 0 – 9999

OFF

0 Seconds 9999

MOTOR VOLTAGE MOTOR RATED AMPS MOTOR RATED SPD

2501 2502 2503

0 – 999 VOLTS 0 – 999.9 0 – 32767 RPM

Factory Set Factory Set 1750 RPM

MOTOR RATED FREQ MOTOR MAG AMPS

2504 2505

50 – 4OO Hz 0 – 85% Rated Current

60.0 Hz Factory Set

RESISTOR OHMS RESISTOR WATTS DC BRAKE VOLTAGE

2601 2602 2603

0 – 255 OHMS 0 – 32767 WATTS 1.0 – 15%

Factory Set Factory Set 5.00%

460 67 3550 RPM 13.2

Procedure 36 - 6

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Table 36-2 - VFD Parameter Block Values Level 2 (Sheet 2 of 3) Block Title

Parameter

P#

Adjustable Range

BRAKE ADJUST (Continued)

DC BRAKE FREQ

2604

0.00 – 400.0 Hz

BRAKE ON STOP BRAKE ON REVERSE STOP BRAKE TIME BRAKE ON START START BRAKE TIME

2605 2606 2607 2608 2609

OFF, ON OFF, ON 0.0 – 60.0 Seconds OFF, ON 0.0 – 60.0 Seconds

PROCESS CONTROL

PROCESS FEEDBACK

2701

PROCESS INVERSE SETPOINT SOURCE

2702 2703

SETPOINT COMMAND SET PT ADJ LIMIT AT SETPOINT BAND PROCESS PROP GAIN PROCESS INT GAIN PROCESS DIFF. GAIN FOLLOW I:O RATIO FOLLOW I:O OUT ENCODER LINES

2704 2705 2706 2707 2708 2709 2710 2711 2712

Potentiometer 0 – 10 VOLTS 0 – 5 VOLTS 4 – 20 mA 10V EXB 4 – 20 Ma EXB 3 – 15 PSI Tachometer EXB NONE OFF, ON Setpoint Command Potentiometer 0 – 10 VOLTS 0 – 5 VOLTS 4 – 20 mA 10V EXB 4 – 20 mA EXB 3 – 15 PSI Tachometer EXB NONE - 100% to + 100% 0 – 100% 0 – 100% 0 – 2000 0 – 9.99 Hz 0 – 1000 1 – 65536:1 – 65536 1 – 65536 (Serial Only) 20 – 65536

SKIP FREQ #1 SKIP FREQ #1 SKIP FREQ #2 SKIP FREQ #2 SKIP FREQ #3 SKIP FREQ #3

2801 2802 2803 2804 2805 2806

0 – 400 Hz 0 – 50 Hz 0 – 400 Hz 0 – 50 Hz 0 – 400 Hz 0 – 50 Hz

SKIP FREQUENCY

October 6, 2006 Rev. 4

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Factory

User Setting

6.00 Hz OFF OFF 3.0 Seconds OFF 3.0 Seconds NONE

OFF NONE

0.00% 10% 10% 0 0.00 Hz 0 1:1 1 1024 PPR 0 Hz 0 Hz 0 Hz 0 Hz 0 Hz 0 Hz

Procedure 36 - 7

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Table 36-2 - VFD Parameter Block Values Level 2 (Sheet 3 of 3) Block Title SYNCHRO-START

COMMUNICATION S

Parameter

SYNC START FREQUENCY

2902

SYNC SCAN V/F SYNC SETUP TIME SYNC SCAN TIME SYNC V/F RECOVER SYNC DIRECTION

2903 2904 2905 2906 2907

5.0 – 100.0% 0.2 – 2.0 Seconds 1.0 – 10.0 Seconds 0.2 – 2.0 Seconds Sync Forward and Reverse, Sync Forward, Sync Reverse

10% 0.2 Seconds 2.0 Seconds 0.2 Seconds Sync FWD and REV

PROTOCOL

3001

RS – 232 ASCII

BAUD RATE

3002

DRIVE ADDRESS

3003

RS – 232 ASCII RS – 465 ASCII RE – 232 BBP RS – 485 BBP 9600, 18.2 KB, 36.4 KB, 57.8 KB, 115.2 KB, 230.4 KB 0 – 91

Press ENTER for programming exit.

Exit programming mode and return to display mode.

OFF, Restarts Only, Set Frequency MAX, Frequency, Set Frequency

Factory

2901

Enters Level 1 Menu - See Table 34a-1.

Homepage

Adjustable Range

SYNCHRO-STARTS

LEVEL BLOCK 1

October 6, 2006 Rev. 4

P#

User Setting

OFF MAX Frequency

9600 0

Procedure 36 - 8

Previous Document

PROCEDURE 37 – FULL LOAD DATA RUN 37.0 Initial Full Load Data Run NOTE: Portions of several other procedures may be completed, checked or verified during this run. 19 21 24 25 26 32 35 36

Chip detector function Flow Meters Cold Air Buffer Power Turbine Thrust Balance Evaporative Coolers Protective Relays On Line AVR Testing Water Injection

1. From Procedure 29, Initial Light Off & PT Break-in, stabilized idle setting should have been achieved and instrumentation readings checked out to insure all are working properly. Any instrumentation not working should be repaired prior to the initial full load data run. 2. Start the gas turbine and stabilize at Idle. A. Look in generator and gas turbine enclosures and check for any leaks. B. Check each of the bleed air lines (two 6th, three 8th and one 13th) to insure all are flowing. Lines should be hot. C. Increase power and stabilize at Sync Idle (power turbine at synchronous speed, but breaker not closed). For mechanical drive sites, run above GG Idle to where EPR = 1.3 to 1.4. (EPR = P5/P1.7) Grid Frequency 60 Hz 50 Hz

Synchronous Speed 3600 RPM 3000 RPM

Check the left and right low turbine cooling air lines (Section 01-17, Figure 5 of the GG8 Illustrated Parts Catalog) to make sure they are flowing 8th stage bleed air to the low turbine (pipes should be hot). Ensure that this air is always on above GG idle (NH = 7100-8800 RPM) and turned off below GG idle prior to proceeding. 3. Close the breaker and slowly accelerate to base load stopping at approximately 10MW steps to inspect equipment, print an analog data report or to complete other system tests. A. Watch #4-5 Cold Buffer Return Air Temp (TE-1601) and verify the Cold Air Buffer heat exchanger turns on at 200° F. B. At Base Load, check that all bleed valves are closed.

October 6, 2006 Rev. 4 Homepage

Procedure 37 - 1 Previous Document

C. At Base Load, verify Cold Air Buffer heat exchanger is regulating at 350° ± 15° F at TE1601. D. With Cold Buffer Heat Exchanger controlling the return air temperature to #4-5 bearing compartment, the air temperature to the #6 compartment (TE-1602) should be maintaining 150°-250° F. 4. Stabilize at base load for minimum of 15 minutes. Check Cold Air Buffer pressure ratios per Section 24. 5. At base load, take a full set of data as tabulated on the Sign-off Sheets from local indicating instrumentation. 6. Decelerate back to idle and shutdown. A. During decel, when TE1601 decreases to 200° F and TE1602 is below 175° F, insure that the Cold Buffer Heat Exchanger shuts off. B. Listen to gas turbine rundown when fuel is shutoff for any abnormal sounds. C. Fill in Data Sheets at Base Load for any other fuel or water combinations that have not been run to date (gas, liquid, gas with water, liquid with water). A record of data is required for any combination used. D. Printout the control analog screen at 10 MW steps and at base load. Include with “as built” Sign-off Sheets.

October 6, 2006 Rev. 4 Homepage

Procedure 37 - 2 Previous Document

PROCEDURE 39 – WATER WASH SYSTEM 39.0 Water Wash System Checkout Procedures Refer to PWPS drawing XXXX-181-M506D and Turbo Power Bulletin (TPB) No. 98M03.

CAUTION Per Field Note 96FN001, PROTECTING THE BLEED VALVE SYSTEM DURING WATER WASH, it is important to prevent water from entering the bleed system during gas generator water wash. For sites equipped with muscle air or shop air, assure that compressed air is ON to close the bleed valves to keep water from escaping through open bleed port.

39.1 Purpose The purpose of water conductivity of the water of the water introduced. readout. The standard placed side-by-side.

washing is to remove contaminants from the gas path until the coming out of the power turbine collector drain equals the conductivity Conductivity can be measured using a Fluke meter with micro-ohm vendor probes used with this meter are one centimeter apart when

A concern with the FT8 water washing is not to slow down the NL rotor such that the NL driven scavenge pump in the No. 1 bearing compartment in particular, is unable to scavenge the compartment. This NL lower limit is 151 rpm. NL speed is too slow if evidence of oil is found in the inlet or oil comes out of the No. 1 scupper. Table 1 gives the relationship between NL and NH during a water wash. The water flow rate controls the speed of NL and NH during a starter wash. This may vary from site to site depending on available water pressure and water nozzle installed. TABLE 39 - 1 (For Reference Purposes Only) STARTER ONLY Tt7 (° F) 60 60 60 60

NH (RPM) 1850 2550 3000 3250

NL (RPM) 155 550 760 830

NP (RPM) 0 0 0 0

The starter should be allowed to run after water is shut off until the NH returns to the dry-condition speed, approximately 2850 rpm. If not, the water will not transit the engine and flow out the inlet.

October 6, 2006 Rev. 4 Homepage

Procedure 39 - 1 Previous Document

If detergents are used, a sufficient volume of water must be flowed through the engine to ensure all detergent is flushed out. Indicators of residual detergent are abnormal conductivity and/or visible suds in the power turbine drain water.

1. Walk down and inspect the enclosure piping and the customer installed supply piping. A. Check for completeness compared to the P & I diagram. B. check that the drain valve, CV701, is installed in the correct direction. C. Ensure that the installed piping is the appropriate size, stainless steel pipe. If it is other than stainless steel: 1) Check that electric isolation flanges have been properly installed between all dissimilar metals. 2) Check with PWPS Engineering to ensure the non-stainless steel piping is acceptable for this application. D. Verify correct nozzle P/N per the P&ID.

2. Electrically check (ring it back through the control system, etc.) the solenoid valve, SOV701, and record the coil and coil-to-ground resistance. See section 16G.

3. Energize and cycle SOV701 several times to ensure proper operation. See section 16G. 4. Flush the entire water wash piping system as follows: (See Section 4) A. Remove ball valve BAV701 from inside the enclosure and, with temporary pipe and/or hose, route the 2” pipe outside the enclosure. Flush the entire piping system, from the customer’s supply to this point, with a minimum of four complete volume changes (volume of all piping, tanks, hoses, etc. must be considered). Flush at the highest permissible velocity (ten feet per second is ideal for water systems). Flushing is complete when a continuous flow of clean, clear water is observed. B. Reconnect ball valve BAV701 and disconnect the 2” flex hose from the inlet plenum at connection point W3. With temporary pipe and/or hose, route the 2” pipe outside the enclosure. Open the pressure-regulating valve, PRV701, to its maximum. Do this by loosening the jam-nut on the valve stem and turning the valve stem clockwise, to its stop. Electrically open the solenoid valve SOV701 and resume flushing. Continue flushing until a continuous flow of clean, clear water is observed, since the next operation will potentially inject water into the gas generator. At this point, have the water for water wash tested to ensure it conforms to the latest PWPS standards (see GG Maintenance Manual, Section 14, Standard Maintenance Practices, Field Cleaning Gas Generator and other applicable standards).

5. Disconnect the temporary flushing piping and reconnect the water wash piping to its original

configuration. Pay special attention to the inlet and exhaust of the spray nozzle and remove all foreign material from the nozzle.

6. Set the initial operating pressure on the pressure-regulating valve.

October 6, 2006 Rev. 4 Homepage

Procedure 39 - 2 Previous Document

CAUTION If the gas turbine has not yet rotated on the starter, stop here until rotation has been properly completed. A. Complete a full inlet plenum inspection for debris or contamination. Check that the drain plug has been removed from the plenum. B. Supply wash water to the WW system by turning on applicable BOP pumps and opening required valves. If using a PWPS supplied WW cart, assure that the tank is full, the valve line up is correct and the supply pump is ON. C. Manually open SOV701 to flow water through the nozzle. D. Adjust the regulator to maintain 30 PSIG on the PI701 gage. When 30 PSIG is set, secure the jam-nut on PRV701.

NOTE This is an initial setting. Readjustment may be required during the actual water wash to maintain 1500 to1900 rpm NH speed.

7. Initiate a water wash from the control screen. A. Open the pull down menu under the PUMP icon. B. Select either ENGINE A or ENGINE B C. Assure that the following are satisfied: 1) EGT wash permissive 2) Muscle air permissive 3) Coast-down complete 4) Engine Ready-to-Start D. Select WATER WASH (NOTE: an option may be DETERGENT WATER WASH) E. Click on the WATER WASH checkmark to open the ON_OFF pushbutton window. F. Select ON. G. Observe three wash and soak cycles as well as the final drying cycle during which the engine is started to idle, runs for 5 minutes and shuts down. Confirm that the “Ready to Start” is available on the start screen once the wash has progressed to the drying cycle. H. Record results and observations on the Sign-off Sheets.

NOTE If, during the wash cycle, the actual NH speed falls below 1500 rpm, adjustment of the pressure-regulating valve will be required. Adjust PRV701 to maintain a steady state 1500-1900 rpm NH speed during the wash cycle with water flowing.

October 6, 2006 Rev. 4 Homepage

Procedure 39 - 3 Previous Document

PROCEDURE 40 – PERFORMANCE TESTING 40.0 Performance Testing Checkout Procedures Near the end of the commissioning process, the engines must be tested for performance. At a minimum, the customer expects power output and heat rate levels as stipulated in the contract. For some installations, the contract guarantees include exhaust heat flow, and atmospheric emissions as well. The performance test provides a means to demonstrate that the installed gas turbine meets the contractual performance requirements. Third party contractors usually perform the thermal performance and emissions compliance testing.

40.1 Customer’s Responsibilities 1. In order to expedite the performance testing and to avoid any unnecessary on-site delays, the mobilization of PWPS performance testing personnel to the site should be synchronized to the completion of the tasks listed in Table 40 – 1, PWPS Thermal Performance Test Site Readiness Checklist. The items shown on the checklist shall be accomplished before the arrival of PWPS performance testing personnel. 2. To ensure the prompt arrival of PWPS performance-testing personnel to the site, the customer shall notify the PWPS Site Manager at least one week prior to the expected completion of the tasks listed in Table 40-1. 3. A customer representative must be on hand to witness the test. The witness should initial each of the test data sheets as an acknowledgement that the test was conducted according to agreed upon procedure. 4. A detailed site specific testing procedure is provided to the customer prior to testing. 5. Any deviations to the project performance testing procedure must be agreed upon, in writing, by the customer and PWPS. 6. Provide all craft labor, operators, fuels, water, electricity, etc. required to support installation of test equipment, pre-test activities, running of tests, and demobilization.

October 6, 2006 Rev. 4 Homepage

Procedure 40 - 1 Previous Document

40.2 Performance Testing Crew Responsibilities In addition to the normal Site Commissioning and Technical Advisor, PWPS typically supplies a performance test crew consisting of a test coordinator and a test technician for conduct of the testing.

TASK 1 2 3

4 5 6A (With CEMS)

6B (Without CEMS) 7 8

9

ACTION ITEMS Pretest fuel sample has been taken, sent to the specified independent laboratory for analysis and analysis has been returned. All generator testing and commissioning has been completed. The unit has reached base load in its COMPLETED state. For example; if water injection is required for operation, unit should have reached base load with water injection system in service. If the unit is guaranteed with inlet conditioning (foggers, evaporative coolers) in operation, those systems must be fully operational as well. The unit auxiliary has been loaded and placed in service such that the auxiliary power may be measured through the auxiliary power test switch. Control system data logger software has been installed. For sites with a Continuous Emissions Monitoring System (CEMS), CEMS system has been made operational before arrival of the PWPS performance testing personnel. Site personnel who can calibrate the CEMS should be available during “power and heat rate” performance testing. For sites without CEMS, arrival day of performance testing personnel should be coordinated such that emissions monitoring personnel will have their equipment setup and will be ready for monitoring by the third day of testing (See Typical Performance Testing Schedule, Table 39 - 2). Unit fuel flow metering (customer meters tied into control software) and unit power metering is functional, calibrated and in operation. PWPS supplied orifice plate flow metering sections (natural gas) or turbine meters (fuel oil) have been properly installed and leak checked in accordance with PWPS/PGT Orifice Flow Section Installation Guidelines, TIN 2002-1622. CAUTION Do not disassemble or remove orifice in the field. Do not remove the plug that holds the straightening section in place upstream of the orifice. All temporary performance test equipment has arrived on site.

COMPLETED DATE/INITIAL / /

/ / /

/

/ /

/

Table 40 – 1 PWPS Thermal Performance Test Site Readiness Checklist

October 6, 2006 Rev. 4 Homepage

Procedure 40 - 2 Previous Document

The test coordinator will be responsible for the following: 1. The test coordinator will be responsible for directing all pre-test preparatory activities in accordance with the test procedure. This includes ensuring the proper installation of all test instrumentation and the completion of all pre-test checklist activities 2. The test coordinator will be responsible for conducting the required engine tuning in accordance with the test procedure. 3. The test coordinator will be responsible for conducting the performance test in accordance with the test procedure. This includes determining when testing can commence, monitoring all test conditions and taking necessary corrective actions to ensure that testing meets test procedure requirements, securing the approval of all parties to the test for any deviations from the test procedure should this be required, and aborting the test when test conditions warrant. 4. The test coordinator will be responsible for preliminary analysis of performance test results while on-site and timely reporting of these results to PWPS following a test. 5. The test coordinator will ascertain the preliminary test results to the designated Project Manager prior to finalizing testing activities. The test technician will support the following on-site testing activities: 1. Supports the installation of all temporary test instrumentation and will support check-out of this instrumentation to assure proper operation for the test. 2. Supports the completion of pre-test checklist activities to ensure the proper disposition of the units for testing. 3. Supports the conduct of the test including the collection of manually recorded and electronically recorded test data and the collection of fuel samples. 4. Supports the removal of all temporary test instrumentation prior to demobilizing from the site.

40.3 Calibrate Field Instruments Before performance testing can be accomplished, all calibrations of unit station instrumentation must be completed in accordance with the PWPS Commissioning Manual.

40.4 Collect Fuel Sample PWPS will manage the collection of all fuel samples, shipment of those samples to a qualified laboratory for analysis, and compilation of the analysis results for use in the development of the test report. In order to reduce the uncertainty of the test results and to minimize the risk associated with the loss or improper analysis of individual samples, multiple fuel samples will be collected and analyzed. Fuel samples are to be collected at the block and bleed valve tee to PT1101. Provisions for temporary tubing and valves to collect the samples are to be installed prior to testing. A detailed description of the fuel supply methods and requirements is included in the project performance test procedure.

40.5 Testing Procedure A detailed, site specific testing procedure will be provided to the customer approximately 30 days prior to the start of the scheduled test. A typical PWPS performance testing schedule is provided in Table 40 – 2.

October 6, 2006 Rev. 4 Homepage

Procedure 40 - 3 Previous Document

All times are estimated. This is a typical schedule and is included for reference only. The actual schedule will be modified as necessary to accommodate site and Customer requirements.

40.6 Formal Performance Test Conduct the formal performance test only after all instruments are calibrated and after any necessary engine tuning has been completed. The formal performance test serves to demonstrate that the equipment meets guarantees.

DAY ONE HOURS REQ’D 1 2 5 0.5 3.5 12

ITEM Meet with site personnel Unpack equipment (verify that all equipment shipped has arrived, record and confirm serial numbers) Install transmitters (including running of stainless tubing to instrumentation) Record Site Information and serial numbers (per Pre-Test Data Sheet 1) Installation of power meters for gross and auxiliary (with the help of a site electrician TOTAL

DAY TWO HOURS REQ’D 1 2 6.5 1 0.5 1 12

October 6, 2006 Rev. 4 Homepage

ITEM Confirm proper installation of orifice flow meter sections and leak check (Pre-Test Checklist 2) Tie in to electrical cabinet for measurement of EGTs with the help of a site electrician Complete installation of equipment, connect all equipment to data acquisition system, create data acquisition channel list Perform Pre-Test Checklist 1 “before running engines” items Bring engines to significant load Perform checkouts with the turbines in operation (EGT, compressor bleed valves, JEM meter, TE010, PT006) TOTAL

Procedure 40 - 4 Previous Document

Figure 40 – 2

Typical PWPS Performance Testing Schedule (Sheet 1 of 2) DAY THREE

HOURS REQ’D 1 1 0.5 2 0.25 0.5 0.25 0.5 0.25 0.5 0.25 0.5 0.25 0.25 0.5 0.25 0.5 0.25 0.5 2 12

Turbine warm-up 100% Load EGT Trim 100% Load Water Injection Tuning 100% Load Preliminary Test Reduce Load / Stabilization 85% Load Water Injection Tuning Reduce Load / Stabilization 95% Load Preliminary Test Reduce Load / Stabilization 90% Load Preliminary Test Reduce Load / Stabilization 65% Load Water Injection Tuning Reduce Load / Stabilization Reduce Load / Stabilization 80% Load Preliminary Test Reduce Load / Stabilization 70% Load Preliminary Test Reduce Load / Stabilization 50% Load Water Injection Tuning Collection of Data / Email to PWPS TOTAL

ITEM

DAY FOUR HOURS REQ’D 1 2 0.25 0.5 0.25 0.5 0.25 0.5 0.25 0.5 0.5 0.5 5 12

Turbine warm-up 100% Load Performance Test Reduce Load / Stabilization 95% Load Performance Test Reduce Load / Stabilization 90% Load Performance Test Reduce Load / Stabilization 80% Load Performance Test Reduce Load / Stabilization 70% Load Performance Test Data Verification Collection of Data / Email to PWPS Equipment Teardown / Packing TOTAL

Figure 40 – 2

October 6, 2006 Rev. 4 Homepage

ITEM

Typical PWPS Performance Testing Schedule (Sheet 2 of 2)

Procedure 40 - 5 Previous Document

FT8 COMMISSIONING MANUAL APPENDIX A Glossary Abbreviations

December 15 2002 Rev 3

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APP – A - 1

Previous Document

GLOSSARY Axial Measurement

The measured distance between the rear end of the output shaft and the front end of the driven equipment shaft.

Centerline Offset

See Peripheral Measurements.

Collector Box

A structure used to contain the exhaust gases exiting the power turbine.

Collector Box Seals

Mechanical seals used to help contain the exhaust gases. They are mounted between the collector box and diffuser and differ front and rear of the collector box.

Coupling

A mechanical link between two rotating objects.

Coupling Spacer Shaft

See Output Shaft.

Diffuser

The inner part of the collector box attached to the power turbine that collects and diverts the exhaust gases.

Driven Equipment

Equipment that is driven by the combination gas generator and power turbine. (i.e. electric generator or compressor)

Driving Equipment

The combination of gas generator and power turbine (FT8).

FIR

(Full Indicated Reading) The total run-out, positive and negative, of the unit being measured.

Front Mounts

The mounting structure, located on both sides, used to support the front end of the gas generator.

Gas Generator

An industrial gas turbine engine.

Keel Pin

The mounting structure located directly beneath the power turbine used for stabilization.

Output Shaft

The shaft connecting the power turbine to the driven equipment.

Peripheral Measurement

The measured difference between the centerlines of the output shaft and of the driven equipment shaft.

Pin Gage

A measuring tool used to compare original or design dimensions with present dimensions.

December 15 2002 Rev 3

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APP – A - 2

Previous Document

Power Turbine

An industrial version of a free turbine, mounted on the rear of a gas generator, used to drive an electrical generator or compressor.

Rear Mounts

The mounting structure, located on both sides of the rear of the gas turbine, used to support the rear of the gas generator.

Run Out

A radial or circumferential measurement used to check for deviations from an object’s centerline.

Shim Pack

A collection of metal shims of varying thickness, glued together for ease of handling, which can be easily separated for a specific thickness. There are three types of shim packs: one for the front and rear gas generator mounts, one for the keel block sides and one for the keel block front.

December 15 2002 Rev 3

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APP – A - 3

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ABBREVIATIONS ABBR ABS AC ACCEL ACM AP ARC ARP AS AUTO ß° BAV BFV BP BS BV C °C Ca Cu CONT CP CPR cS CSD CV DA Dba DCS DECEL DMM DV EGT EJ ENG EPR EPR EV EXV F FC FCU FCV December 15 2002 Rev 3

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Abbreviation Absolute Air Cooler Acceleration Accumulator Access Port Air Receiver Aerospace Recommended Practice Air Starter Automatic Beta Dot Ball Valve Butterfly Valve Breather Pressure Smoke Detector Breather Valve Compressor Degree Celsius Calcium Copper Continuous Chip Detector Compressor Pressure Ratio Centistoke Constant Speed drive Check Valve De-aerator Decibel Digital Control System Deceleration Digital Multi-meter Dump Valve Exhaust Gas Temperature Expansion Joint Engine P5/P1.7 Engine Pressure Ratio Valve Coil Exhaust Valve Filter Failed Closed Fuel Control Unit Fuel Control Valve APP – A - 4

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FD FE FG FLV FO FO FOD FP FPT FR FSV FT FV FY GAL GC GLV GP GRD GS GV H HC Hg HMS HPC HPP HPT HS HX IBP IGHP IGN IN K K KPa LAH LAHH LB LB/HR LE LG LPC LPT December 15 2002 Rev 3

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Fuel Drain Flow Element Flow Gas Float Valve Failed Open Flow Orifice Foreign Object Damage Fuel Dump Female Pipe Thread Filter Regulator Flow Stop Valve Flow Transducer Fire Valve Valve Controller Gallon Gas Cylinder Globe Valve Gearbox Pump Ground Gas Detector Gate Valve Heater Halon Cylinder Mercury Humidistat High Pressure Compressor Hydraulic Power Pack High Pressure Turbine Hand Switch Heat Exchanger Initial Boiling Point Ideal Gas Horsepower Ignition Inch Constant Potassium Kilo Pascal Level Alarm High Level Alarm High-High Pound Pounds Per Hour Level Element Level Gage Low Pressure Compressor Low Pressure Turbine APP – A - 5

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LRU LSL LSH LSHH LSLL LT LVDT M MAP MAX Mb MGB MILS MOP MOV MPT MPV MTS MU N Na NA NH NL NP NV OD OME OSHA OVLD P P P&D P&W PAL PALL Pamb Pb PcP PCV PDAH PDCV PDI PDIS PDSH December 15 2002 Rev 3

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Line Replaceable Unit Level Switch Low Level Switch High Level Switch High-High Level Switch Low-Low Level Transducer Linear Variable Differential Transformer Motor Muscle Air Pack Maximum Millibars Main Gearbox Thousandths of an inch Main Oil Pump Motor Operated Valve Male Pipe Thread Multi-Port Valve Magnetic Trip Setting Muffler Rotational Speed in RPM or Percent RPM Sodium Not Applicable High Pressure Compressor Rotational Speed Low Pressure Compressor Rotational Speed Power Turbine Rotational Speed Needle Valve Outside Diameter Oil Mist Eliminator Occupational Safety & Health Administration Overload Pressure Pump Pressurizing and Dump Valve Pratt & Whitney Pressure Alarm Low Pressure Alarm Low-Low Ambient Pressure Lead Pressure Cooling Pressure Pressure Control Valve Pressure Differential Alarm High Pressure Differential Control Valve Pressure Differential Indicator Pressure Differential Indicating Switch Pressure Differential Switch High APP – A - 6

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PI PLC PNEU PPH PRV Ps P2.5 P2.8 P3 psi psia psid psig PS PSH PSHH PSL PSLL PSV PT P1.7 P5 QD P5 R RCV REF RO RPM RS RTD RVDT SAH SAL SI SOP SOV SP ST STR SV T TACH TAH TAHH December 15 2002 Rev 3

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Pressure Indicator Power Logic Control Pneumatic Pounds per Hour Pressure Regulating Valve Static Pressure 6th Stage Air Static Pressure 8th Stage Air Static Pressure 13th Stage Air Static Pressure Pounds per Square Inch Pounds per Square Inch Absolute Pounds per Square Inch Differential Pounds per Square Inch Gage Pressure Switch Pressure Switch High Pressure Switch High-High Pressure Switch Low Pressure Switch Low-Low Pressure Safety Valve Pressure Transducer Inlet Total Pressure Total Turbine Discharge Pressure Quick Disconnect Total Pressure Station 5 Pneumatic Release Re-circulating Control Valve Reference Restricting Orifice Revolutions per Minute Flame Detector Resistive Temperature Device Rotational Variable Differential Transformer Speed Alarm High Speed Alarm Low Speed Indicator Scavenge Oil Pump Solenoid Valve Separator Speed Transmitter Strainer Servo Valve Thermostat Tachometer Temperature Alarm High Temperature Alarm High-High APP – A - 7

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TAL Tamb TC TCA TCV TE TEC TI TK TOBI TRV TS TTB T1.7 T5 US UVS V VAC VAH VAHH VDC VI V/O VP VSH VSV VT Wf Wft W/O WS WW X XA XJ XS XY ZA ZC ZS ZT » ¯ Ù December 15 2002 Rev 3

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Temperature Alarm Low Ambient Temperature Test Connection Turbine Cooling Air Temperature Control Valve Temperature Element Turbine Exhaust Case Temperature Indicator Tank Tangential On Board Injection Transfer Valve Temperature Switch Turbine Thrust Balance Total Inlet Temperature Total Turbine Discharge Temperature United States Ultra Violet Switch Vanadium Volts Alternating Current Vibration Alarm High Vibration Alarm High-High Volts Direct Current Vibration Indicator Volume by % Vacuum Pump Vibration Switch High Variable Stator Vane Vibration Transducer Rate of Fuel Flow Fuel Flow Temperature Weight by % Weight Transducer Water Wash Nozzle Unclassified Alarm Nozzle Jet Unclassified Switch Nozzle Spray Position Alarm Position Controller Position Switch Position Transducer Approximately Below Delta, Differential, Finite Difference APP – A - 8

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°C °F < = > % d Q @

December 15 2002 Rev 3

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Above Degrees Celsius Degrees Fahrenheit Less Than Equal, Equivalent Greater Than Percent Delta, Relative Pressure Ratio Theta, Relative Temperature Ratio At

APP – A - 9

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FT8 COMMISSIONING MANUAL APPENDIX B Fluids and Lubricants List PWPS Specifications: · PWPS Service Bulletin No. 6 – Oil, Lubricant (Synthetic – Approval of, And Sampling Procedure · FR-1 Gas Turbine Liquid Distillate Fuel Requirements · FR-2 Gas Turbine Natural Gas Requirements · TPM-AR-1 Gas Turbine Injection Water Requirements · TPM-AR-2 Potable Water Quality Specification

December 15 2002 Rev 3 Homepage

APP – B - 1

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FLUIDS, LUBRICANTS AND SOLVENTS LIST Where Used

Product Identification

TPM P/N

Hydraulic Starter

Mobil DTE-13M

CT117529-1

Gas Turbine Lube Oil

Mobil Jet Oil 254

CT116675

Generator Lube Oil

Mobil DTE Light Oil ISO VG 32

CT116676

Motor Bearing Grease

Shell Dolium R or Chevron SRI

Water Injection Pump

Mobil DTE Light Oil ISO VG 32

Anti-Seize Lubricant

FEL-PRO C 200

CT116676

SOLVENTS Igniter

1,1,1 Trichloroethene

PMC 9056

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A United Technologies Company Turbo Power and Marine Systems, Inc.

SERVICE BULLETIN REVISION NOTICE NO. 6 REVISION U

TITLE Oil, Lubricant (Synthetic) - Approval Of, And Sampling Procedure For

MODEL APPLICATION FT3C, GG3C, GG4A, GG4C, FT4, FT4A, FT4C, FT4C-3F, FT4A-9B, FT12, GG12, GG8, PT8

THIS IS A COMPLETE REISSUE - The subject attached Bulletin

No. 6U constitutes the complete instruction. The contents are in accordance with the following list of effective pages.

REASON FOR REVISION To add the statement that Mobil Jet 254 is the preferred oil used on all GG4 and GG8 models. A copy of this Revision Notice and any further revision notices must be filed as a permanent record with your copy of the subject bulletin.

PAGE

REVISION NO.

1 thru 11

U

DATE March 10/98

Distribution Code

4101, 4102, 4103, 4104, 4105, 4106, 4107, 4108, 4109, 4111 Date

March 10/97

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Page 1 of 1

RTurbo Power and Marine Systems, Inc.

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A United Technologies Company Turbo Power and Marine Systems, Inc.

SERVICE BULLETIN NO. 6 REVISION U

TITLE Oil, Lubricant (Synthetic) - Approval Of, And Sampling Procedure Of

MODEL AFFECTED FT4, GG4, FT3, GG3, FT12, GG12, PT8, GG8

BULLETIN INDEX LOCATOR 00-00

MANUFACTURER’S RECOMMENDATION RECOMMENDED

Distribution Code

Internal Reference No.

4101, 4102, 4103, 4104, 4105, 4106, 4107, 4108, 4109, 4111

DDD/JS

Date April 14/64 Revision U - March 10/98

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RTurbo Power and Marine Systems, Inc.

No EC None Page 1 of 11

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Turbo Power and Marine Systems, Inc. SB No. 6 Revision U 1. Planning Information A. MODELS AFFECTED This publication supersedes Turbo Power Service Bulletin No. 6, Revision T B. REASON FOR BULLETIN PART I:

PART II:

To ensure the proper lubricants for PWTM gas turbine engines and free turbines used in industrial and marine applications by providing a list of approved oils and their sources. To provide detailed procedures for controlling oil quality through a program of sampling and analysis.

C. REASON FOR REVISION To add the statement that Mobil 254 is the preferred oil for use on all GG4 and GG8 models. D. MANUFACTURER’S RECOMMENDATION (1) Recommended E. REFERENCES None F. PUBLICATIONS AFFECTED GG3C GG3C

Service Manual Overhaul Manual

493031 493032

GG4A GG4A

Service Manual Overhaul Manual

544025 544026

GG4C GG4C

Maintenance Manual Overhaul Manual

729002 729003

FT3C

Service Manual

516009

FT4A FT4A/FT4C

Service Manual Overhaul Manual

516010 599129

FT4A

Marine Parts Catalog

547055

FT4C

Maintenance Manual

729005

FT4C-3F FT4C-3F

Maintenance Manual Overhaul Manual

757433 757432

Date April 14/64 Revision U - March 10/98

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Turbo Power and Marine Systems, Inc. SB No. 6 Revision U FT4A-9B

Maintenance Manual

783475

GG8 GG8

Shop Manual Maintenance Manual

807422 807421

PT8 PT8

Shop Manual Maintenance Manual

807425 807424

G. SPECIAL TOOLS No new Tool(s) are necessary. H. ADDED DATA Not applicable. END OF SECTION 1

Date April 14/64 Revision U - March 10/98

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Turbo Power and Marine Systems, Inc. SB No. 6 Revision U 2. Accomplishment Instructions PART I APPROVED OILS: A. The brands of oils listed in the following table comply with Pratt & Whitney Specification PWA 521C for use in Pratt & Whitney marine and industrial turbine engines. B. Use of oils other than those listed is not recommended. C. Different brands of oil should not be mixed. APPROVED LUBRICATION OILS

APPLICABLE ENGINE MODELS

*Vendor Name of Oil

GG3C, GG12A, GG4A, GG4C, GG8, FT3C FT12A FT4A FT4C PT8

1

Aero Shell Turbine Oil 500

A

A

A

A

1

Aero Shell Turbine Oil 560

A

A

A

A

2

AMOCO Jet II

A

A

A

A

3

Esso Turbo Oil 2380

A

A

A

A

3

Exxon Turbo Oil 2380

A

A

A

A

4

Mobil Jet Oil II

A

A

A

A

4

Mobil Jet Oil 254

A

A

A+

A+

5

Anderol STL

A

A

A

A

7

Royco Turbine Oil 500

A

A

A

A

7

Royco Turbine Oil 560

A

A

A

A

1

Aero Shell Turbine Oil 555

E

E

E

E

6

Castrol 5000

E

E

E

E

3

Esso Turbo Oil 25

E

E

E

E

3

Exxon Turbo Oil 25

E

E

E

E

5

Anderol Jet II

E

E

E

E

Date April 14/64 Revision U - March 10/98

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A

A+

A

Page 4

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Turbo Power and Marine Systems, Inc. SB No. 6 Revision U D. Oils marked “A” are approved for use in engine models indicated. NOTE: Service experience has shown that when Mobil Jet 254 lubricating oil is used, there is improved oil life, increased gear pump life and improved gas turbine internal oil wetted parts condition. The use of Mobil Jet 254 is preferred. A plus sign (+) next to the letter in the approved lubrication oils section will identify these approved models. E. Oils marked “E” are approved for service evaluation only. Recognized use of these oils is subject to a separate agreement between the customer and Turbo Power and Marine Systems, Inc. Engines under warranty are not eligible for service evaluation. *See Vendor Codes on page 5. Vendor by Code No. 1

Shell Oil Company Industrial Sales Department One Shell Plaza Houston, Texas 77001

2

American Oil Company 500 North Michigan Avenue Chicago, Illinois 60611

3

Exxon Company, U.S.A. P.O. Box 2180 Houston, Texas 77001 OR Esso International Division Exxo Corporation 1251 Avenue of the Americas New York, New York 10020

4

Mobil Oil Corporation 3225 Gallows Road Fairfax, Virginia 22037

5

Huls America Inc. P.O. Box 456 Piscataway, New Jersey 08855-0456

Date April 14/64 Revision U - March 10/98

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Turbo Power and Marine Systems, Inc. SB No. 6 Revision U 6

Castrol Limited Burmah House Pipers Way Swindon Wiltshire SN31RE, England

7

Royco Lubricants, Inc. Merry Lane P.O. Box 518 East Hanover, New Jersey 07936

PART II OIL QUALITY CONTROL A. Purpose. (1) The chemical deterioration of synthetic lubricants in service is usually caused by thermal and oxidation breakdown due to environmental factors rather than deficiencies in the temperature increase. As little as 25_F increase in the oil system environment can make a significant difference in the rate of oil deterioration. Oil condition monitoring is, therefore, intended to provide a means by which the operator can obtain maximum utilization of his lubricant, and at the same time avoid the secondary problems which may affect his engine or free turbine if it is operated inadvertently on severely degraded oil. A periodic oil condition check becomes a valuable diagnostic procedure to be used in conjunction with other routine engine maintenance. It is helpful in avoiding unscheduled engine shutdowns, which might be caused by oil related problems such as reduced cooling of bearings due to excessive oil viscosity, objectionable deposits, and corrosion in certain areas of the engine and free turbine lubrication systems.

Date April 14/64 Revision U - March 10/98

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Turbo Power and Marine Systems, Inc. SB No. 6 Revision U B. Analysis Requirements. (1) Two key laboratory inspection checks of oil samples are Kinematic Viscosity (ASTM method D445) and Total Acid Number (TAN) (ASTM method D664 using titration end point of Ph 11.0) or equivalent measurements made by other than ASTM equipment which will establish whether any substantial chemical or physical changes have occurred, which would necessitate an oil drain. Measurements of these two properties can be made in the operator’s own facility or in an independent testing laboratory, whichever is more convenient. Commercial field type instruments for measuring oil viscosity and total acid number are available. Although the field monitoring units lack the precision of laboratory testing, they do provide the first indication of oil degradation and are well suited for an “on the site,” pass-fail system of oil condition monitoring. C. Oil Monitoring Kits. (1) Oil condition for all engine models may be monitored by certain types of field instruments which measure viscosity and total acid number by use of apparatus and procedures which are different from the ASTM methods. (2) Advice on these various monitoring devices can be obtained from the operator’s oil supplier. The suitability of a specific kit; however, should be confirmed through Turbo Power and Marine Systems, Inc. D. Sampling. (1) Engine oil samples may be taken from the main oil tank drain valve, main accessory gearbox drain or main oil tank fill port. Samples should be taken as soon as possible after shutdown. (2) Free turbine oil sample may be taken in a similar manner. NOTE: Care must be exercised to ensure that the sample taken is representative of the oil being circulated and not from a dead ended location. Date April 14/64 Revision U - March 10/98

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Turbo Power and Marine Systems, Inc. SB No. 6 Revision U (3) Oil samples should be put in clean, dry containers to avoid false readings on the oil monitoring devices. Such containers may be obtained from laboratory supply houses, commercial testing companies or the oil supplier. Sample containers should be properly labeled, and identified as follows: (a) Station and location (b) Engine / free turbine type and serial number (c) Date and time sample taken (d) Brand of oil (e) Total running time on oil (f) Amount of oil added since last sample (4) Sampling procedure. (a) GG3C,FT3C, GG12,FT12 Models: 1

100 cc samples are recommended to be taken at 500 hour intervals or more frequently if degradation limits are being approached. (See paragraph G.3)

2

Whenever the oil has been drained due to an oil sample exceeding degradation limits, the first sample following the drain must be taken at 100 hours or less to verify that the oil condition is satisfactory before resuming the normal 500 sampling interval.

3

A new installation should be sampled at 10 hours or less to verify that the oil is not contaminated, and to establish base lines for viscosity and acid number.

(b) GG4/FT4, GG8/PT8 Models: 1

100 cc samples are recommended to be taken at 500 hour intervals or more frequently if degradation limits are being approached. (See paragraph G.3)

Date April 14/64 Revision U - March 10/98

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Turbo Power and Marine Systems, Inc. SB No. 6 Revision U 2

Whenever the oil has been drained due to an oil sample exceeding degradation limits, the first sample following the drain must be taken at 100 hours to verify that the oil condition is satisfactory before resuming the normal 500 sampling interval.

3

A new installation should be sampled at 10 hours or less to verify that the oil is not contaminated, and to establish base lines for viscosity and acid number.

(c) Free Turbine (FT3, FT12, and FT4): 1

100 cc samples are recommended to be taken at 600 hour intervals or more frequently if degradation limits are being approached. (See paragraph G.3)

2

Whenever the oil has been drained due to an oil sample exceeding degradation limits, the first sample following the drain must be taken at 200 hours or less to verify that the oil condition is satisfactory before resuming the normal 600 sampling interval.

3

A new installation should be sampled at 10 hours or less to verify that the oil is not contaminated, and to establish base lines for viscosity and acid number.

E. Draining and Refilling Oil System. (1) If an oil sample exceeds the degradation limits, drain oil from the engine or free turbine and all external components of the station oil system, making sure that all low points in the system are drained as completely as possible. Clean or replace all filters in system as applicable. (2) Fill supply tank approximately 2/3 full with an approved brand of lubricating oil. (3) Start and idle engine for 10 to 15 minutes. (4) Drain oil and check filters per paragraph E(1). (5) Fill oil system with same brand of oil and tag oil system indicating brand of oil being used. Date April 14/64 Revision U - March 10/98

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Turbo Power and Marine Systems, Inc. SB No. 6 Revision U F. Procedure For Change To A Different Brand Of Oil (Includes fully approved and service evaluation category oils). (1) Drain oil from engine or free turbine and all external components of the station oil system. (2) Fill tank to 2/3 capacity with the new oil. (3) Idle engine for 2 to 5 minutes. (4) Drain oil. (5) Fill oil system with new oil and mark tank with suitable label. (6) Within first 25 hours the main oil pressure signs of loosening of engine from the prior G. Oil Degradation Limits.

after conversion to a new oil, filter must be checked for any deposits which may be in the oil used.

(1) Satisfactory oil performance can be expected if the following limits are not exceeded. Kinematic Viscosity @ 100_F Max Change From New Oil Level

Total Acid No. Max

Oil Brands

Engine Models

All Brands

GG4 / FT4

+25% - 10%

2.0

Marked

GG3 / FT3

+25% - 10%

2.0

A or E

GG12 / FT12

+25% - 10%

2.0

GG8 / PT8

+25% - 10%

2.0

(2) If the preceding limits are exceeded, the lubrication system must be drained, flushed, and refilled as soon as operating conditions permit. (3) Oil sampling intervals should be decreased from 500 hours to 200 hours on GG3/FT3 and GG12/FT12 models and from 500 hours to 100 hours on the GG4/FT4 and GG8/FT8 models if the oil degradation limits are approached, so that the trend of oil property changes can be closely monitored.

Date April 14/64 Revision U - March 10/98

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Turbo Power and Marine Systems, Inc. SB No. 6 Revision U NOTE: Any operator who has engines that accumulate less than 500 hours in any given calendar year should take an oil sample at least once a year to determine if oil is in satisfactory condition. H. Engine or Free Turbine Oil History. (1) In order to fully utilize oil condition monitoring results, and to diagnose certain types of suspected oil related engine or free turbine malfunctions, an overall summary should be maintained of the following items: (a) Date sample taken (b) Date sample tested (c) Degradation data (d) Engine or free turbine time since shop repair or overhaul (TSO). (e) Time since oil drain (TSOD) (f) Engine or free turbine serial number (g) Date of oil drains (h) Record of oil addition

Date April 14/64 Revision U - March 10/98

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Pratt & Whitney A United Technologies Company

PWPS SPECIFICATION

Pratt & Whitney Power Systems, Inc.

RELEASED

FR-1

SHEET

REV E

OF

1 6

ISSUED BY : P. Lavendier

DATE: 8/18/95

REVISE BY : D. Tougas

DATE: 3/29/06

REFERENCE :

REV:

GAS TURBINE LIQUID DISTILLATE FUEL REQUIREMENTS GENERAL This document provides the requirements and general guidelines for light and medium hydrocarbon liquid distillate fuels which can be burned satisfactorily in PWPS/P&W aeroderivative industrial gas turbines. Industrial gas turbines are capable of burning a variety of liquid fuels providing they have appropriate fuel delivery, injection and combustion systems for each class of fuel. Distillate liquid fuels are complex hydrocarbon mixtures processed from a wide variety of basic crude oil stocks, and have a broad range of property values. In some cases, such as gasoline, the hydrocarbon fraction may undergo further processing and acquire additives or, as with naphtha, may be offered for use in the as-distilled form. This document recognizes three general categories of distillate fuels as defined by ANSI/ASME B 133.7M which may be employed in properly configured PWPS/P&W gas turbines. Category a is No. 0-GT fuels such as light naphtha, gasoline, and JP-4/ Jet B fuels which are highly volatile and require special handling and fuel system design. Categories b and c are No. 1-GT and No. 2-GT such as light to medium kerosene and diesel fuels which can be burned in the standard gas turbine, providing all fuel properties specified in the following Table 1 are met. Fuel treatment or conditioning, including heating, may be necessary to satisfy these requirements. Residual, ash bearing fuels, and blends of distillate and residual fuels are not suitable for aeroderivative gas turbines. Industrial fuels may be obtained from a large number of producers with a broad range of properties. Contamination in transport and deterioration in storage are common problems. Poor and contaminated fuels greatly affect the performance and durability of gas turbines. Therefore, it is imperative for the gas turbine user to install a proper fuel system design and institute an effective fuel quality management program to insure and maintain clean, high quality fuels.

GUIDELINES FOR EFFECTIVE FUEL QUALITY MANAGEMENT The fuel management system should be designed and in place prior to the site start-up. The following considerations should be addressed: 1) The fuel type is generally chosen on the basis of cost and availability, however, the effects of fuel on gas turbine operation and life cycle economics should be considered. Normally, high viscosity fuels such as heavy diesel are less expensive initially, but usually impact engine life and increase overall life cycle costs. Some fuels can be made usable through treatment and/or conditioning, and the cost of these processes should be factored into the overall economics. Possible treatment processes are water wash, heating, filtration, and centrifuge or cyclone separation. 2) The transport path between the fuel producing location and the customer's unloading/ storage area should be analyzed for possible contamination potential. Dedicated transport containers are highly

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Pratt & Whitney A United Technologies Company

PWPS SPECIFICATION

Pratt & Whitney Power Systems, Inc.

RELEASED

FR-1

SHEET

REV E

OF

2 6

ISSUED BY : P. Lavendier

DATE: 8/18/95

REVISE BY : D. Tougas

DATE: 3/29/06

REFERENCE :

REV:

GAS TURBINE LIQUID DISTILLATE FUEL REQUIREMENTS recommended. 3) The fuel storage equipment should be properly designed and sized and should be free of any contaminating or corrosive materials. Fuel storage time versus tank capacity should be balanced. Sufficient time should be allowed for incoming fuel to settle. The fuel for the gas turbine should not be removed from the bottom of the tanks, so as to avoid picking up heavy bottom ends. Tanks should be regularly drained from the bottom to remove the sediment. 4) The on-site conditioning and treatment systems should clean the impurities from the fuel and maintain high quality as it forwards the fuel to the gas turbine. The design should consider the quantity, placement and filtration efficiency of the filters. 5) The requirement for fuel preheating, if necessary, should be considered. Preheating is required for viscosity enhancement of heavy fuels and wax removal from high cloud point (waxy) fuels. 6) Safety requirements should be considered in the initial design phase, particularly if the fuel is one of the highly volatile Category a type fuels. 7) Contaminants brought in with the incoming gas turbine airflow should be considered. Proper air filtration is required. It is the normal practice to subtract the incoming air contaminants from the allowable fuel contaminant limit through a formula given in Note 7 of Table 1. The operators of PWPS/P&W equipment must comply with all aspects of this specification, and ensure compliance by regularly taking and analyzing liquid fuel samples. Contaminants not normally present in the fuel at the production site may be introduced as a result of contact with sea water, other fuels, or insufficiently cleaned equipment during the transportation, handling and storage phases. If the fuel arriving at the user location falls out of compliance with the specification, and can not be made compliant by treatment, then the fuel supplier should be contacted immediately for a corrective action. Even a short period of operation with fuel of excess contaminants (salts, trace metals, particulates, wax. etc.) could seriously impact the gas turbine life and performance. To further insure high quality fuel and continuous compliance, a regular maintenance program must be adopted for all on-site fuel handling, storage, conditioning and treatment systems. Regular replacement of filter elements, periodic draining of water, removal of sediments from the tanks, lines and sumps, and replacement of treatment fluids, etc., should be planned for and implemented. PWPS/P&W requests review of the customer's final overall fuel management system design. PWPS bulletin no. 97M01 entitled “Distillate Fuel System Recommendations” is available for further details on implementing a quality fuel system. Additional guidance can be obtained by contacting your PWPS/P&W Marketing representative.

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Pratt & Whitney A United Technologies Company

PWPS SPECIFICATION

Pratt & Whitney Power Systems, Inc.

RELEASED

FR-1

SHEET

REV E

OF

3 6

ISSUED BY : P. Lavendier

DATE: 8/18/95

REVISE BY : D. Tougas

DATE: 3/29/06

REFERENCE :

REV:

GAS TURBINE LIQUID DISTILLATE FUEL REQUIREMENTS RECOMMENDED DISTILLATE FUELS The following liquid distillate fuels can be used in the gas turbine, if the fuel property requirements listed in Table 1 are met for the fuel delivered to the inlet of gas turbine.

Category a (No. 0-GT):

Naphtha Fuels, Unleaded gasoline types, wide-cut fuels of the JP-4 (MIL-T-5624), and Jet B (ASTM D 1655) types - SEE NOTE 3

Category b (No. 1-GT):

Kerosene or other distillates of the JP-5 (MIL-T-5624); Jet A and A-1 (ASTM D1655); No. 1-D diesel fuel (ASTM D975); No. 1 fuel oil (ASTM D 396); and No. 1 GT gas turbine fuel oil (ASTM D2880) types.

Category c (No. 2-GT):

Distillates of the No. 2 diesel fuel (ASTM D975) No. 2 fuel oil (ASTM D 396), No. 2 GT gas turbine, and marine diesel (MIL-F-16884) types.

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PWPS

Pratt & Whitney A United Technologies Company

FR-1

SPECIFICATION

Pratt & Whitney Power Systems, Inc.

RELEASED

SHEET

REV E

OF

4 6

ISSUED BY : P. Lavendier

DATE: 8/18/95

REVISE BY : D. Tougas

DATE: 3/29/06

REFERENCE :

REV:

GAS TURBINE LIQUID DISTILLATE FUEL REQUIREMENTS TABLE 1: GAS TURBINE LIQUID FUEL PROPERTY REQUIREMENTS Property Viscosity - cSt: Max. (for category a, b, and c) Min. at 100 °F (37.8°C) (for category a) Min. at 100 °F (37.8°C) (for category b&c)

Limit

NOTE(S)

Test Method (Note 1)

6.0 max. for starting, 12.0 max. for operation 0.5 min. 1.0 min

2

ASTM D445

3

ASTM D445 ASTM D445

Combined Free Water and Sediment, vol. % Particle Contamination, mg/L

0.1 max. 2.7 max.

4

Particle Size - microns (micrometer)

20 max

13

Hydrogen - % by weight

12.4 min

5

ASTM D1018

Metal Contaminants - ppm by wt. Vanadium (V) Sodium (Na) + Potassium (K) Calcium (Ca) Lead (Pb) Copper (Cu)

0.5 max. 0.5 max. 2.0 max. 0.5 max. 0.02 max.

6, 7, 14 6, 7, 14 6, 7, 14 6, 7, 14 6&7

ASTM D3605 ASTM D3605 ASTM D3605 ASTM D3605 ASTM D6732

Copper corrosion

No.1 max.

8

ASTM D130

To be reported 12.5 max. 12.5 max.

9

ASTM D93 ASTM D323 ASTM D5191

100 °F (37.7°C) min. or local regulatory limit 25 °F (14°C) below GT inlet fuel temp. 0.25 max.

10

ASTM D93

Sulfur, % by mass

1.3 max.

11, 12

Ash, % by mass

0.01 max.

ASTM D482

Net Heating Value, Btu/lb (kcal/kg)

To be reported

ASTM D4809

Specific Gravity

To be reported

ASTM D1298

Fuel Category a (only) Flash Point, °F (°C) Reid Vapor Pressure, psi or Vapor Pressure by Mini- method, psi Fuel Category b and c (only) Flash Point, °F (°C) Cloud Point, °F (°C) Carbon Residue (on 10% bottoms), %

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ASTM D2709 ASTM D2276 or ASTM D5452

ASTM D2500 ASTM D524 ASTM D4294

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PWPS SPECIFICATION

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RELEASED

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ISSUED BY : P. Lavendier

DATE: 8/18/95

REVISE BY : D. Tougas

DATE: 3/29/06

REFERENCE :

REV:

GAS TURBINE LIQUID DISTILLATE FUEL REQUIREMENTS NOTES TO REQUIREMENTS (TABLE 1) NOTE 1 The most recent revision of the ASTM test method should be used insofar as practicable. An equivalent test method may be used in lieu of ASTM test method, if approved by PWPS/P&W. NOTE 2 Maximum fuel viscosity at gas turbine fuel pump inlet shall be 6.0 cSt for starting and 12.0 cSt during operation. Fuel may be heated, to a maximum of 160 deg F (71C), to meet this requirement. NOTE 3 In order to operate FT8 with Category a fuels, such as naphtha, specially designed PWPS/P&W fuel system components are required. NOTE 4 The fuel delivered to the inlet of the gas turbine is to have a sediment level less than 10 mg./gallon of fuel. However, for practical extended fuel filter life, the fuel should have lower sediment levels NOTE 5 Minimum hydrogen percentage by weight is 12.4; however, for optimum combustion, higher hydrogen percentage is recommended. NOTE 6 To achieve the level of sensitivity required for the detection of some of these metals, the furnace atomic absorption method may be necessary. Since some trace metals can have harmful effects on gas turbine operation, it is necessary to impose limitations. Higher levels of Table 1 metallic levels, even for short period, will increase the gas turbine maintenance costs. NOTE 7 Limits of metal contaminants in Table 1 assume no contaminants in the inlet air or injected water. For operation with contaminants in the inlet air or injected water, the maximum allowable limit of any particular contaminant in the fuel must be reduced according to the following formula: Af = Lf - [Cair X (air/fuel weight ratio)] - [Cwater X (water/fuel weight ratio)] where,

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Af Lf Cair Cwater

= Maximum allowable contaminant in the fuel, ppm by wt. = Contaminant Limit as called out in Table 1, for example 0.2 for (Na+K) = Contaminant in inlet air, ppm by wt. = Contaminant in injection and/or evaporative cooling water, ppm by wt.

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PWPS SPECIFICATION

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ISSUED BY : P. Lavendier

DATE: 8/18/95

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DATE: 3/29/06

REFERENCE :

REV:

GAS TURBINE LIQUID DISTILLATE FUEL REQUIREMENTS NOTE 8 Copper corrosion test conditions are 2 hours at 212 deg F (100 deg C). NOTE 9 No flash point limitation is specified; however, local regulatory limits and safety regulations must be met. NOTE 10 The cloud point shall be at least 25 degrees F below the anticipated gas turbine fuel inlet temperature. To meet this requirement, additional fuel heating, to a maximum of 160 degrees F (71C), may be needed. NOTE 11 Sulfur content limits Below 1.3% WT. are imposed when: a) The local regulatory limits of sulfur oxides exhaust emissions are exceeded; then the fuel sulfur content must be reduced until the local regulatory limits are satisfied. For instance, the USA EPA limits fuel Sulphur content to 0.8% for SO2 emissions control, but local codes vary widely. b) If exhaust heat recovery equipment is employed; then the equipment manufacturer's limit may apply. NOTE 12 High sulfur fuels will impact hot section repair interval dependent on the amount of alkalai metals present. The combination of high sulfur and high alkalais must be avoided. NOTE 13 Maximum particle size to be controlled by filtration with a β20 ratio of 200. NOTE 14 Use of a graphite furnace atomic absorption apparatus may be required to obtain a sufficiently low detection limit.

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PWPS SPECIFICATION

Pratt & Whitney Power Systems, Inc.

RELEASED

FR-1

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REV E

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ISSUED BY : P. Lavendier

DATE: 8/28/95

REVISE BY : D. Tougas

DATE: 3/29/06

REFERENCE :

REV:

GAS TURBINE LIQUID DISTILLATE FUEL REQUIREMENTS REV SHEETS LET AFFECTED

A

1-4

B

SHEETS ADDED

DESCRIPTION

REV BY

APPVD

& DATE

& DATE

1) Added 1.7 cs lower limit of viscosity 2) Changed NA + K limit to 0.2 ppm 3) Added sulfur limit to 1.3% max. 4) Changed format to FrameMaker 5) Revised verbiage to put more stringent requirements for fuel management 6) Updated test procedures to current standard

P. Lavendier 8/18/95 EC#8352

Completely re-written and updated to allow the use of Naptha Fuels, lower min viscosities. Max allowable fuel viscosities were changed to be based on actual operating temperatures, rather than a fixed temperature.

EC#9025 T. Fox/D. Dalal 2/11/98

C

All

Updated Logo to new PWPS Logo. Updated all TPM references to PWPS references.

EC#9925 L. DiSalvo 7/23/01

D

4

1) Changed Free Water to Combined Free water and sediment. changed limit to 0.1% max by volume. Changed Test Method to ASTM D2709. 2) Changed sediment to Particulate Contamination. Removed metric unit (mg/l) (2.7) from Limit. Changed test method to ASTM D2276 or D5452. 3) Added Note 13 to Particle size 4) Removed Test Method IP288. 5) Added Test Method ASTM 4809 to Net Heating Valve. 6) Made various typographical changes. Added Note 13 regarding filtering.

EC#10620 D. Tougas 7/8/03

4 5&6

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PWPS SPECIFICATION

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ISSUED BY : P. Lavendier

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DATE: 3/29/06

REFERENCE :

REV:

GAS TURBINE LIQUID DISTILLATE FUEL REQUIREMENTS REV SHEETS LET AFFECTED

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SHEETS ADDED

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& DATE

In Table 1: Revised Particle Contamination from mg/gal. to EC#11755 mg/L and changed Limit from 10.0 to 2.7. D. Tougas In Table 1: under Metal Contaminants revised the Limit & 3/29/06 Notes for the following: Vanadium from 0.2 to 0.5 and added Note 14. Sodium from 0.2 to 0.5 and added Note 14. Lead from 0.1 to 0.5 and added Note 14. Added ASTM desginations for all in Test Method. In Table 1: Revished Ash,% mass from 0.005 max. to 0.01 max. In Table 1: Added the word min. for flash point limit. Added the word max. for Sulpher limit. Added Note 14.

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PWPS SPECIFICATION

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REVISE BY : L. DiSalvo/J. Kennedy

DATE: 7/23/01

REFERENCE :

REV:

GAS TURBINE NATURAL GAS FUEL REQUIREMENTS GENERAL This document provides the requirements and application guidelines for natural gas fuels which can be fired satisfactorily in PWPS/P&W gas turbines without fuel system modification. The term gas fuel can refer to a range of fuels which are normally in the gas state in gas turbine operational use. These range from low BTU content types such as coke oven gas to high BTU types such as propane. Because of the wide variation of gas fuels in ignition and combustion properties, as well as volume throughput requirements, their combustor and fuel delivery systems may differ widely. The fuel specification must be matched to the gas generator design. The most common gas fuels used are those of the natural gas family. For satisfactory use in gas turbines, these fuels must meet minimum specifications so as to avoid combustion and fuel system problems, as well as hot section corrosive damage. In addition to reviewing the composition and contaminants of the gas fuels being considered for use, the customer is urged to institute good fuel management, handling and treatment systems. A fuel that might not meet the requirements at the engine fuel inlet location may be treated prior to that location. Present gas turbine combustion systems are comprised of conventional types which may or may not employ water injection to reduce oxides of nitrogen (NOx) emission, or Dry Low NOx (DLN) types which control NOx emissions without water. The latter are more sensitive to certain fuel properties than conventional systems and therefore have more stringent limits on some properties, as noted in the following specification.

GUIDELINES FOR EFFECTIVE FUEL MANAGEMENT The first step in designing an effective fuel management system is to identify the composition and contaminants in the gaseous fuels being considered for use in PWPS/P&W aeroderivative gas turbines. The gas analysis performed to analyze the gas composition and contaminants should include, as a minimum, all properties listed in Table 1. Clean, dry fuel is required for safe and durable operation of a gas turbine. The minimum and maximum limits of gas fuel supply temperature are listed in Table 1. The gas supply to the site should be evaluated to prevent any liquid from accumulating in the off site piping and then flooding the site fuel systems with large volume of liquids. In reviewing the gas composition, the presence of corrosion-producing substances such as alkali metals (sodium, potassium, etc.), sulfur compounds, etc. should be noted so that proper precautions can be taken to minimize gas turbine and/or fuel system corrosion. When exhaust recovery equipment is utilized, there will be further requirements for fuel sulfur limit to minimize corrosion of the cold end surfaces.

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DATE: 7/23/01

REFERENCE :

REV:

GAS TURBINE NATURAL GAS FUEL REQUIREMENTS The contaminants in natural gas are normally introduced as a result of production and transportation processes. These contaminants may include tar, resins, water, salt water, rust (iron oxide), sand, lubricating oil, crude oil, gas hydrates, ice, construction debris, etc. Widely distributed gaseous fuels such as natural gas are usually cleaned prior to distribution. Water with its associated pipeline corrosion and condensate are probably the largest contaminants occurring in the gas distribution systems. The design of an adequate fuel handling/treatment system is based on the actual gas composition and the contaminants present in the gas fuel delivered to the site. The following considerations should be addressed in the design of an effective gas fuel management system: • • • • •

Pressure reducing station Type of filtration systems such as inertial separators (scrubbers), gas separator, coalescing filter, or filter separator to remove liquid and/or solid contaminants Fuel handling system materials that are compatible with the gaseous fuel properties Fuel heating to raise the temperature of the gas sufficiently above the hydrocarbon and moisture dew points Safety precautions for handling the fuel

To protect the power plant equipment, a fuel testing program to periodically measure contaminant removal from the fuel and perform maintenance on the fuel filtration system is recommended. This is an important step in ensuring that the proper quality fuel is provided to the gas turbine. PWPS/P&W fuel requirements of Table 1 are the allowable limits of fuel properties. The operators of the PWPS/P&W equipment must comply with all aspects of this specification, and confirm compliance through analysis of gas fuel samples taken regularly. Additional detailed guidance can be obtained through a PWPS/ P&W representative.

OTHER GASEOUS FUELS The standard model gas turbine is optimized to operate on gaseous fuels within this specification. The gas turbine has the basic capability of operating on a range of fuels outside of this specification, but may require modifications to fit the specific application. Such modifications could include fuel system component re-sizing, additional safety equipment, fuel pre-heating or gasification equipment, and engine controls adjustment. To judge the suitability of other gaseous fuels for a given application, please contact the PWPS/P&W Marketing Department.

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SPECIFICATION

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REFERENCE :

REV:

GAS TURBINE NATURAL GAS FUEL REQUIREMENTS TABLE 1: GAS TURBINE GASEOUS FUEL REQUIREMENTS

COMBUSTOR TYPE NOTE(S)

Test Method (Note 1)

800-1200 (30 - 45)

2

ASTM D3588

1040-1350 (39 - 50)

1040-1350 (39 - 50)

2, 3

ASTM D3588

Hydrogen Gas (H2) Content, % Vol. Max

Note 4

1.0

5

ASTM D1945

Carbon Monoxide (CO) Content,% Vol

Note 6

Note 6

6

ASTM D1946

Total Particulate, PPM WT. MAX.

30

30

5, 7, 10

ASTM D2009

Max Particle Size, Microns (Micrometre)

10

10

-

ASTM D2009

Max Gas Supply Temp, °F (°C)

300 (149)

300 (149)

5

-

Min. Gas Supply Temp, °F (°C)

32 (0)

32 (0)

5

-

Min Gas Fuel Superheat Above Hydrocarbon Dew Pt, °F (°C)

+28 (+16)

+50 (+28) Note 13

5

-

Min Gas Fuel Superheat Above Moisture Dew Pt, °F (°C)

+28 (+16)

+50 (+28)

5

-

Total Sulfur Content,% Wt Max

Note 8

Note 8

5, 10, 8

ASTM D1072 or ASTM D3246

0.2

0.2

5, 10

ASTM D3605

Note 10

Note 10

5, 11

ASTM D1142

Not Applicable

2.2

12

Property

A

B

Conventional

DLN

Lower Heating Value (LHV) BTU/SCF (MJ/m3)

800-1200 (30 - 45)

Wobbe Index, BTU/SCF (MJ/m3)

Total Metals, PPM Wt, Max Sodium + Potassium Water Content Flammability Ratio (UFL/LFL), MIN

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PWPS

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SPECIFICATION

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REV:

GAS TURBINE NATURAL GAS FUEL REQUIREMENTS

NOTES TO REQUIREMENTS (TABLE 1) NOTE 1 The most recent revision of the ASTM test method should be used insofar as practicable. Equivalent test method may be used in lieu of ASTM test method if approved by PWPS/P&W. NOTE 2 At standard conditions of 60° F (15.6° C) 1 atm (101.3 KPa). NOTE 3 Wobbe Index = LHV/SQRT(S.G. *(Tgf+460)/520) OR Wobbe Index = LHV/SQRT(S.G. *(Tgc+273)/288.6) (corr. to 60° F) (corr. to 15.6° C) Where: Tgf = inlet gas temperature, °F S.G = specific gravity relative to air LHV in BTU / SCF

Where: Tgc = inlet gas temperature, °C S.G = specific gravity relative to air LHV in MJ/m3 (note 2)

NOTE 4 Hydrogen content up to 4% vol. may be used. Higher amounts of hydrogen content can be used but should be approved by PWPS/P&W and must satisfy all applicable safety codes for the fuel system. NOTE 5 At the inlet to the gas turbine fuel plate or at gas turbine enclosure interface, if the enclosure is provided by PWPS. NOTE 6 Fuel CO content will increase CO output, thus CO fuel content may require control to meet guarantee exhaust emissions levels. NOTE 7 Particulates are composed of any solids in the gas fuel stream, including sand, rust, clay, coke, tar, iron sulfide, etc. NOTE 8 Total sulfur includes hydrogen sulfide (H2S), mercaptans, carbon disulfide(CS2), carbonyl sulfide(COS), thiopene, sulfur oxides, etc.

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DATE: 7/23/01

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REV:

GAS TURBINE NATURAL GAS FUEL REQUIREMENTS

NOTE 9 Limits on fuel sulfur are imposed when: a) The local regulatory limits of sulfur oxides exhaust emissions are exceeded, then the fuel sulfur content must be reduced until the local regulatory limits are satisfied. b) When exhaust heat recovery equipment is employed, the equipment manufacturer's limits will apply. NOTE 10 The allowable gas fuel contaminants shall be debited by the amounts of that contaminants entering with the inlet airflow (type A&B combustor) and water injection flow (type A combustor): Allowable fuel limit = Overall limit - (Air/Fuel x Inlet Air Level) -(Water/Fuel x Water Level) NOTE 11 Gas Hydrates are not allowed, therefore water content should be below the concentration which would allow gas hydrates to form at the operating temperature and pressure. Fuel heating is allowed to bring gas fuel temperature above the moisture saturation (dew) point. NOTE 12 Flammability limits at 1 atm (101.3 KPa) and 77 Deg. F (25 Deg. C). NOTE 13 FOR DRY LOW NOx (DLN) COMBUSTORS ONLY: • Hydrocarbon dew points are to be evaluated from ambient pressure up to the maximum gas turbine inlet pressure • Dew points will be based on extended analysis to C14 level according to method of GPA 2286-95. • Gas samples shall be taken per method of GPA 2166-86. • Concentrations should be determined to an accuracy of 10 PPM or less. • The maximum expected dew point line during the operating period, must be used to establish the minimum required fuel temperature at the gas turbine inlet

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DATE: 7/23/01

REFERENCE :

REV:

GAS TURBINE NATURAL GAS FUEL REQUIREMENTS

REV SHEETS LET AFFECTED

SHEETS ADDED

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& DATE

& DATE

A

All

3&4

Specification completely re-written incorporating Gas Turbine Gaseous Fuel Requirements for “Dry Low Nox”. Title was “Gas Turbine Gaseous Fuel Requirements”. Proprietary box was removed.

EC#8975 D. J. Dalal 10/28/97

B

All

5

In table sht 3 deleted “absolute” in max. particle size Changed MJ/nm3 to MJ/m3

EC#9012 D.J. Dalal/T. Fox 12/22/97

C

3 5

In table sht 3, added note 13 in column B Added note 13 requirements for H/C dew point.

EC#9077 T. Fox 8/20/98

D

All

Updated Logo to new PWPS Logo. EC#9925 Updated all TPM references to PWPS references. L. DiSalvo In Table1: J. Kennedy 1. Change test method for CO from ASTM D2099 to ASTM 7/23/01 D1946. 2. Added ASTM D3246 as an alternate test method for total sulfer content.

3

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DATE: 11-14-72

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GAS TURBINE INJECTION WATER REQUIREMENTS GENERAL The amount of oxides of nitrogen (NOx) produced by a gas turbine engine can be significantly reduced by injecting water or steam during operation. However, the quality of water available may be such that continuous usage could have adverse effects on long term engine maintenance. It is recommended that the customer follow a good water management program. Basically, this would consist of analyzing the water (or steam) available and providing monitoring and/or treatment equipment as required. GUIDELINES FOR EFFECTIVE WATER MANAGEMENT The customer’s initial step in water management is to determine the quality of water or steam that is available for utilization in gas turbines. He should then institute treatment, if required, to bring the water up to an acceptable quality level. This may involve floc treatment, filtering, demineralizing, chemical treatment or vaporizing. Generalizations as to treatment systems are usually avoided because of the variations in water quality from one area to another. Samples of the water (ASTM D510) or steam (ASTM D1066) should be analyzed before a water management system is finalized. The contaminants generally found in water depend on the source of the water. The dirtier the water, the more it should be cleaned before usage in gas turbine engines. There are three major levels of water purity: 1.

Natural water comes from rivers, streams, lakes or wells. This water tends to be high in particulate matter and chemical content. It is highly unlikely that natural water could be used in gas turbine engines on a continuous basis without treatment. The ordinary levels of minerals and metals found in even good well water are sufficient to cause deposit buildup and corrosion in the gas turbine hot section.

2.

Treated water includes facility prepared or municipal potable water, softened or demineralized boiler makeup water and processed natural water. The quality level of treated water will depend on the amount and type of treatment used. Analyses should be performed to determine whether the water is acceptable for continuous gas turbine usage without further treatment.

3.

Condensate quality is achieved by properly vaporizing either natural or treated water. This vapor may then be condensed, depending on whether steam or water injection is to be used. Water of this quality can be obtained by using a gas turbine waste heat boiler or by extracting steam or condenser water from a steam power plant. In either case, care must be exercised so that impurity carryover is held to acceptable levels. Condensate quality water will ordinarily be acceptable for continuous gas turbine usage.

When the nature and quantity of the water impurities have been determined, a system design can be established. Undissolved solids are normally removed with filters or separators. Ion exchange resins may be used for removal of many of the dissolved solids. However, in some cases, it may be necessary to include chemical treatment of the water. The trade-offs between removal of impurities and chemical treatment to minimize adverse effects would have to be made for each installation. Chemicals may also be used to control other properties such as pH and to inhibit the formation of boiler scale. Individual assessment can be made by PWPS to judge the suitability of various chemical additives.

Handling and storage should also be considered as part of any water management system. Storage tanks, pumps, vaporizors and plumbing should be such that they do not add significantly to water contamination. This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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SPECIFICATION

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REV:

GAS TURBINE INJECTION WATER REQUIREMENTS In order to protect the customer’s equipment, a program which periodically measures the water supplied to the gas turbine is recommended. This is an important step in ensuring low maintenance operation of gas turbines. If undesirable water is detected, immediate corrective action should be taken. This may involve changing the basic source of water supplied to the facility or performing maintenance on the water handling system. In order to prevent undesirable water from reaching the gas turbine, a periodic maintenance program is recommended. This will ensure water quality as it passes through the handling, storage and filtration equipment. Items such as periodic filter element replacement and draining sediment from filters and storage tank sumps are also recommended. Additional detailed guidance can be obtained through the appropriate PWPS representative. See Table 1 below for water property requirements which must be met at the inlet interface with PWPS’s water injection skid. TABLE 1. WATER PROPERTY REQUIREMENTS I.

Continuous Usage The requirements below are for either 1) liquid treated water or 2)condensate of the steam delivered to the gas turbine for continuous usage: Property 1. Total Solids (ppm)

Limit

Test Method (See Note 1 & 2)

Test Location (See Note 3)

5.00

ASTM D5907

Grab

Dissolved Solids (ppm)

3.00

Sodium (ppm)

0.10

ASTM D2791

In-Line

Silica (ppm)

0.10

ASTM D859

Grab

2. Particle Size (microns)

10 max.

ASTM F312

Grab

3. Conductivity (micromho/cm)

1.0 max

ASTM D5391

In-Line

1.5 max.

Grab

II. Intermittent Usage Intermittent injection of water for power augmentation does not require the same quality level as continuous injection. Water should be of such purity that its level of total dissolved and undissolved solids is not greater than 10 parts per million. III. Water Wash Engine gas path water washing may be done with clean, clear drinking quality water. Since this procedure involves motoring the engine with the starter only, deposits of solids are negligible. Ignition is not accomplished until the engine has been drained and purged.

This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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REV:

GAS TURBINE INJECTION WATER REQUIREMENTS NOTES TO REQUIREMENTS Note 1: The latest issue of the ASTM test methods should be used insofar as practicable. If applicable, equivalent test methods may be used in lieu of ASTM test methods. Note 2: Alternate test methods to be agreed upon by customer and PWPS. Note 3: Grab samples should be at least 4 liters for lab analysis.

This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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GAS TURBINE INJECTION WATER REQUIREMENTS REV SHEETS LET AFFECTED

A

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SHEETS ADDED

DESCRIPTION

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& DATE

Added to last sentence before Table 1: “which must be met RMS at the inlet interface with PWPS’s water injection skid.” 2/3/93 Table 1, I: 1) Added “treated” to sentence. 2) Changed pH range from 7.0-8.5 to 6.0 -8.5 3) Added requirement 4, conductivity

B

1, 2, 3

C

All 2,3

D

2

1) Revised test methods to the latest ASTM specifications 2) Deleted PH requirement 3) In Table 1, Conductivity was .27.

P. Lavendier 12/19/96 EC#8757

Updated Logo to new PWPS Logo. Updated all TPM references to PWPS references. 1. Add "ASTM F312" to test method for particle size. 2. Change Note 2 to add "Alternate".

EC#9925 L. DiSalvo J. Kennedy 7/23/01

In Table 1 changed the following: EC11332 It. 1- added (ppm) to Total Solids, chgd. Limit to 5.00 & D. Tougas chgd. ASTMD1888 to D5907. Added line for Dissolved 4/13/05 solids. Chgd. Limit for Silica from 0.02 to 0.1 It. 3 - Chgd. Limit 1.5 max to 1.0 max & 1.0 max to 1.5 max. Chgd. Test Loc. Grab to In-Line & In-Line to Grab.

This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM-AR-2

PWPS SPECIFICATION

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POTABLE WATER QUALITY SPECIFICATION PHYSICAL Color Ph Temperature Total Dissolved Solids * Threshold Odor Number Turbidity

MAXIMUM PERMITTED LEVELS 15 Units 6.4 - 8.5 75°F (25°C) 500 mg/l 2 5 units

INORGANIC Arsenic Barium Cadmium Chlorides Chromium Copper Cyanide Fluoride Iron Lead Magnesium Maganese Mercury Nitrite Nitrogen Nitrite plus Nitrite Nitrogen Selenium Silver Sodium Sulfate Zinc

MILLIGRAMS/LITER 0.05 1 0.01 250 0.05 1.0 0.2 2.0 0.3 0.05 125 0.05 0.002 1.0 (as N) 10.0 (as N) 0.01 0.05 20 250 5.0

*Samples should be at least 2 liters for lab analysis.

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Pratt and Whitney Power Systems, Inc. Commissioning Manual - Revision 4

TEMPORARY REVISION NO. 07-01-Figures Please insert this Temporary Revision 07-01-Figures in the Commissioning Manual Rev 4, at the end of the Commissioning Manual.

March 15, 2007

Temporary Revision 07-01 Figures

Figure 1

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Figure 2

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Figure 3

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Figure 4

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Figure 5

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Figure 6

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172.16.0.111

Figure 7

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Figure 8

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Figure 9

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Figure 10

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Figure 11

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Figure 12

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Figure 13

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Figure 14

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Figure 15

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Figure 16

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Figure 17

Temporary Revision 07-01 Figures

Figure 18

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Pratt and Whitney Power Systems, Inc. Commissioning Manual - Revision 4

TEMPORARY REVISION NO. 07-04-TPM375 Please insert this Temporary Revision in the Commissioning Manual Rev 4, at the end of the Commissioning Manual. The specificationTPM375 is being added to supplement Procedure 35 – Breaker Closure and On-Line AVR Tests. The specification outlines the procedure for the Protective Relay 27TN and 59D functions.

March 30, 2007

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TEST & CALCULATION PROCEDURE, BECKWITH M-3425A GENERATOR PROTECTION RELAY 27TN AND 59D FUNCTIONS 1.0

Scope 1.1

System Overview The stator windings of three-phase generators must be protected from ground faults that may occur during operation. Because generator neutrals are generally grounded through a high resistance, the ground fault current is restricted, greatly reducing coil and iron damage at the fault point. None the less, it is important to detect any ground fault immediately and clear the fault by shutting down the generator in a controlled manner. Stator ground faults are detected by continuously measuring the fundamental frequency (50 or 60 Hz) voltage that appears across the generator's grounding resistor, comparing this voltage to a set point value, and tripping the generator if the voltage exceeds the set point. This function is provided in the Beckwith M-3425A Generator Protection Relay and is given the functional designation 59N, Neutral Overvoltage. Stator ground faults that occur in the mid sections of the windings or near the output terminals produce sufficient phase voltage unbalance to successfully operate the 59N relay element. However, if the ground fault is located within the 5% of the windings closest to the neutral, fundamental frequency voltages are not unbalanced sufficiently to operate the 59N function. To detect these faults, other detection methods are available that take advantage of the normal third harmonic (150 or 180 Hz) voltage that is always present while the generator is in operation. These functions, the Neutral Third Harmonic Undervoltage (27TN), and Third Harmonic Voltage Differential (59D) are also available in the M-3425A protection package.

1.2

Document Overview The purpose of this document is to describe the tests needed to: 1) determine which third harmonic detection element, 27TN or 59D, in the M-3425A Generator Protection Relay, is most appropriate for providing generator stator ground fault protection near the neutral terminals, and, 2) provide the necessary data to set the appropriate relay element to provide this protective function. This document also covers the calculations, logic settings and relay connections for the 27TN and 59D functions of the Beckwith M-3425A relay package. This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TEST & CALCULATION PROCEDURE, BECKWITH M-3425A GENERATOR PROTECTION RELAY 27TN AND 59D FUNCTIONS 2.0

Referenced Documents Beckwith M-3425A Generator Protection Relay Instruction Book, M-3425A-IB-01MC6, 01/06

3.0

Discussion of Generator Ground Fault Protection Methods 3.1

Neutral Fundamental Frequency Overvoltage (59N) Current flowing in the neutral of a wye-connected generator is normally low, consisting of the fundamental-frequency unbalance current due to phase unbalances and triplen harmonic currents, primarily the third harmonic. When a fault occurs in the generator winding the balance is disrupted and significant fundamental-frequency current can flow. This current is intentionally limited to approximately 10 amperes by a grounding resistor in the secondary of the neutral grounding transformer. By monitoring the fundamental-frequency voltage across the grounding resistor, ground fault detection can be achieved. This is the function of the 59N relay element. By proper selection of the grounding transformer turns ratio, the grounding resistor ohmic value and the pickup setting of the 59N relay, ground faults can be detected in 95% of the winding, measured from the generator output terminals. A typical pickup setting for the 59N element is 5 volts. Winding ground faults within 5% of the neutral do not produce sufficient unbalance to operate this relay element.

3.2

Neutral Third Harmonic Undervoltage (27TN) The induced voltage in the air gap of a synchronous machine will normally contain harmonic voltages in addition to the fundamental-frequency voltage. Depending on the pole pitch of the windings, certain harmonics may be suppressed. However, in general, the triplen harmonics, third, ninth, fifteenth, etc. are present with the third being the most prominent. These harmonic voltages produce harmonic currents that flow through the generator neutral connection. Thus, the voltage across the generator grounding resistor also may have these harmonics present. These harmonics are present whenever the generator is in operation. During a ground fault, the level of the residual harmonic voltage at the generator neutral resistor and at the generator terminals may be reduced. By monitoring the level of third harmonic voltage across the generator neutral grounding resistor, protection for stator ground faults near the neutral may be obtained. The addition of a third-harmonic neutral undervoltage relay (27TN) to the 59N function will provide ground fault protection for 100% of the stator windings The level of third harmonic voltage at the neutral resistor will generally vary with generator MW and MVAR loading and with terminal voltage. In order to effectively apply this protection, the minimum level of third-harmonic voltage must be known so that the 27TN relay element can be set This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TEST & CALCULATION PROCEDURE, BECKWITH M-3425A GENERATOR PROTECTION RELAY 27TN AND 59D FUNCTIONS below this level. The variation of third harmonic voltage with MW, MVAR and generator voltage must be determined by test. 3.3

Third Harmonic Voltage Differential (59D) The third harmonic voltage induced in the air gap appears at both the output and neutral ends of each winding. The ratio of third harmonic voltage at the generator terminals, V3X, to that at the neutral, V30, remains relatively fixed as generator loading and voltage are varied. A ground fault in the winding will alter this ratio. This change in the V3X/V30 ratio is an indicator of a ground fault in the winding. The 59D relay element monitors this ratio and will trip the generator if the ratio drops below a set point level. Note that the 59D function requires a voltage source from the generator terminals that will provide a true measure of zero-sequence voltage and third harmonics. If a set of phase-to-neutral connected potential transformers (PTs) is used at the generator terminals, a secondary winding of these PTs can be connected in broken delta to provide a source for the 59D function. This voltage is connected to the VX input on the M-3425A relay. Alternatively, the third harmonic voltage can be derived (calculated) within the relay from the three phase-to-neutral voltages. The 59D function cannot be used if the only source of generator terminal voltage is from phase-to-phase connected PTs; either a three-phase set or two PTs connected in open-delta. For these cases, the 27TN function must be used to provide ground fault protection for the neutral ends of the stator windings. Phase-to-phase connected PTs are not a source of zero-sequence or third harmonic voltages.

4.0

Test Procedure and Data Collection Data for selecting which method of 100% ground fault protection (27TN or 59D) is to be used and for calculating the appropriate settings must be obtained after the generator has been commissioned and placed in service. This data cannot be obtained from factory tests. The data will be collected through the M-3425A relay metering function. These tests will determine the minimum level of third-harmonic voltage that is produced during normal generator operation. The tests described herein should be performed after the M-3425A relay has been tested and placed in service. The 27TN and 59D functions should be blocked while these tests are performed. The M-3425A relay is used during these tests as the primary tool for collecting third-harmonic voltage data under various generator operating conditions. During these tests, all protective functions in the M-3425A relay, including the 59N function should be in service, except for the 27TN and 59D functions. This is an acceptable risk since 95% of the generator stator windings are protected from ground faults by the 59N function. The only risk is for a ground fault to occur near the neutral that goes undetected during the test period. The energy in such a fault would be This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TEST & CALCULATION PROCEDURE, BECKWITH M-3425A GENERATOR PROTECTION RELAY 27TN AND 59D FUNCTIONS very low, limited by the generator grounding resistor and driven only by less than 5% of generator voltage. As a point of reference, most utility generators do not have 100% ground fault protection installed, unless they are new or recently upgraded. 4.1

Test Procedure 4.1.1

M-3425A Relay Auto-Calibration If not already performed during relay commissioning, conduct the Third Harmonic Calibration test described on page 6-77 of the M-3425A Instruction Book. This will require a 10 volt, 180 Hz (150 Hz for 50 Hz relay) test voltage source. Although the relay is calibrated at the factory, this test will provide further assurance that the third harmonic voltages displayed on the relay HMI panel are correct.

4.1.2

Generator No-Load Tests With the M-3425A Relay in service and its 27TN and 59D functions disabled, bring the generator to full speed, no load. Apply the generator field and allow generator voltage to stabilize. The generator voltage regulator should be in the automatic (regulating) mode. 4.1.2.1

Using the M-3425A Relay front panel HMI, record the generator phase voltages, zero-sequence voltage and third-harmonic neutral voltage. These are available through the Status/Voltage Status menu. Use the Test Data Collection Sheet in Appendix A to record the voltage values. (Note: If Wye-connected PTs with a broken delta (3V0) secondary winding connection are available at the generator output terminals, the 59D function can be used with the 3V0 voltage as a direct input to the VX terminals of the M-3425A relay. The third harmonic voltage level at the VX input is not displayed through the relay front panel HMI. For this application, a frequency-selective voltmeter should be used to monitor the third harmonic voltage at the VX terminals for each test condition.)

4.1.2.2

4.1.3

If possible, vary the generator terminal voltage and record additional voltage values. In no case exceed 105% or drop below 90% of generator nameplate voltage.

Generator Minimum-Load Tests With the M-3425A Relay still in service and its 27TN and 59D functions disabled, synchronize the generator to the system and bring it to minimum load. This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TEST & CALCULATION PROCEDURE, BECKWITH M-3425A GENERATOR PROTECTION RELAY 27TN AND 59D FUNCTIONS

4.1.4

4.1.3.1

Using the M-3425A Relay front panel HMI, record the generator phase voltages, zero-sequence voltage and third-harmonic neutral voltage. Also record the generator real power (MW) and reactive power (MVAR) which are available through the Status/Power Status menu.

4.1.3.2

Adjust the generator MVAR output by varying the voltage regulator set point voltage. Observe all generator and system voltage operating restrictions. Caution should be taken when reducing the generator voltage to assure that the generator remains in synchronism. The voltage regulator should be in the automatic mode with all over and under excitation limiters functioning. Using the M-3425A Relay front panel HMI, record the generator phase voltages, zero-sequence voltage and third-harmonic neutral voltage at several generator MVAR output levels. The objective is to find the minimum third-harmonic neutral voltage under a wide range of operating conditions.

Generator Partial-Load Tests With the M-3425A Relay still in service and its 27TN and 59D functions disabled, increase the load on the generator to a point approximately half way between minimum load and full load.

4.1.5

4.1.4.1

Using the M-3425A Relay front panel HMI, record the generator phase voltages, zero-sequence voltage and third-harmonic neutral voltage. Also record the generator real power (MW) and reactive power (MVAR).

4.1.4.2

Keeping the generator real power output fixed, adjust the generator MVAR output by varying the voltage regulator set point voltage. Observe all generator and system voltage operating restrictions. Caution should be taken when reducing the generator voltage to assure that the generator remains in synchronism. The voltage regulator should be in the automatic mode with all over and under excitation limiters functioning. Using the M-3425A Relay front panel HMI, record the generator phase voltages, zero-sequence voltage and third-harmonic neutral voltage at several generator MVAR output levels. The objective is to find the minimum third-harmonic neutral voltage under a wide range of operating conditions.

Generator Full-Load Tests With the M-3425A Relay still in service and its 27TN and 59D functions disabled, increase the load on the generator to full load. This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TEST & CALCULATION PROCEDURE, BECKWITH M-3425A GENERATOR PROTECTION RELAY 27TN AND 59D FUNCTIONS 4.1.5.1 5.0

Repeat the tests described in 4.1.4.1 and 4.1.4.2 with the generator at full load and record all values on the Test Data Collection Sheet

Determination of which Function is to Be Used The test data can be used to determine which of the 59D or 27TN functions should be used to provide stator ground fault protection near the neutral. The flow chart in Appendix B summarizes the analysis needed to determine which function can be used. If all third harmonic voltages are less than 0.5 volt, there is insufficient signal to reliably use either the 59D or 27TN functions. This could occur, for example, with a two-thirds pitch wound generator where all triplen harmonics are suppressed. For these cases, the only practical method to provide 100% stator ground fault protection is with a low-frequency current injection mode. The M-3425A relay has an optional 64S function specifically designed to operate with 20Hz injection schemes. If Y-connected PTs are not available at the generator terminals, the 59D function cannot be used. If Yconnected PTs are available and a broken-delta PT secondary connection is available, the 59D function can be used with the generator terminal third harmonic voltage measured directly and connected to the VX input of the M-3425A relay. If Y-connected PTs are available and a broken-delta PT secondary connection is not available, the 59D function can still be used as long as the minimum third-harmonic voltage is greater than 1.0 volt. In this case, the third-harmonic voltage is calculated by the relay from the sum of the three phase-to-neutral voltages. This calculation is not reliable if the third-harmonic voltage is less than 1.0 volt.

6.0

59D Calculations and Settings There are five settings associated with the 59D function: 59D RATIO - This is the ratio of the third harmonic voltage at the generator terminals to the third harmonic voltage at the generator neutral. From the test data on the Appendix A data collection sheet, calculate this ratio for each data point. Set the 59D RATIO at 50% of the minimum calculated ratio. 59D LINE SIDE VOLTAGE - Select VX if the generator terminal third harmonic voltage is derived directly from a broken-delta PT secondary connection that is wired to the VX input terminals of the relay. Select 3V0 if a broken-delta connection is not available, in which case the relay will calculate the thirdharmonic voltage from the phase voltages. 59D POS SEQ VOLT BLK - Should be ENABLED.

This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TEST & CALCULATION PROCEDURE, BECKWITH M-3425A GENERATOR PROTECTION RELAY 27TN AND 59D FUNCTIONS 59D POS SEQ VOLT BLK - Set to 80 % of the NOMINAL VOLTAGE entered during the Relay System Setup phase of relay commissioning. 59D DELAY - Set to 300 cycles (5 seconds). 7.0

27TN Calculations and Settings There are four settings associated with the 27TN function, plus the 27TN blocking functions, if needed. First, determine if blocking of the 27TN function is needed. Blocking is required if the minimum third harmonic voltage at the neutral is less than 0.5 volt. If this is the case, use the procedure in Appendix C-2 to plot the P,Q points for those test data points where the minimum third harmonic voltage at the neutral is less than 0.5 volt. Select a blocking strategy from Appendix C-1. 27TN PICKUP - From the test data, determine the minimum third harmonic voltage at the neutral for which the 27TN element must operate (not blocked). Set the 27TN PICKUP at 50% of this value, but in no case less than 0.3 volts. 27TN POS SEQ VOLT BLK - Should be ENABLED. 27TN POS SEQ VOLT BLK - Set to 80 % of the NOMINAL VOLTAGE entered during the Relay System Setup phase of relay commissioning. 27TN DELAY - Set to 300 cycles (5 seconds). 27TN Blocking Settings: Set as needed, based on Appendix C. Enable only those needed for blocking P-Q levels for which third harmonic voltage is too low.

This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TEST & CALCULATION PROCEDURE, BECKWITH M-3425A GENERATOR PROTECTION RELAY 27TN AND 59D FUNCTIONS

BLOCKING FUNCTION

ENABLE or DISABLE

SETTING

FWD POWER BLK

p.u.

REV POWER BLK

p.u.

LEAD VAR BLK

p.u.

LAG VAR BLOCK

p.u.

LEAD PF BLK LAG PF BLK BAND FWD PWR BLK

LO B FWD PWR BLK

p.u.

HI B FWD PWR BLK

p.u.

This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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