00 Ta - S 41 002 001

B
A
REV.
15 JUL. 2015
15 MAY 2015
DATE
REVISED AS MARKED
ISSUE FOR APPROVAL
DESCRIPTION
H. H. KIM
H. H. KIM
DESIGNED
Y. K. OH
Y. K. OH
CHECKED
S. W. KIM
S. W. KIM
APPROVED
OWNER
PROJECT
JEDDAH SOUTH THERMAL POWER PLANT STAGE-I

ENGINEER
CONTRACTOR
SUBCONTRACTOR
VENDOR INTERNAL DOC.NO

N/A
THIS DOCUMENT IS NOT TO BE USED FOR

CONSTRUCTION OR FOR ORDERING MATERIAL UNTIL
CERTIFIED AND DATED.THE CONTRACTOR HHI
CONFIRMS FULLY COMPLIANCE WITH THE O/ES
COMMENTS. NO OTHER CHANGES HAD BEEN MADE ON
THE DOCUMENT. THE CONTRACTOR MAY SUBMIT THE
DOCUMENTS AS FOR CONSTRUCTION
APPROVAL/CERTIFICATION INFORMATION
DOC. NO :
REV. NO :
DOCUMENT TITLE
PLANT START-UP & OPERATIONAL TEST PROCEDURE

CONTRACT NO.
DOCUMENT NO.
NO. OF
PAGES
REV.
31121106/00
00-TA_-S-41-002-001
136
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
TABLE OF CONTENTS
1
INTRODUCTION .............................................................................................................................3
DEFINITIONS/ABBREVIATIONS ................................................................................................4
PLANT CONFIGURATION ............................................................................................................5
START-UP AND OPERATIONAL TESTS .....................................................................................8
LIST OF SPECIFIC START-UP & OPERATIONAL TEST SHEETS ...................................... 11
APPENDICES
A. STEAM TURBINE OVERSPEED TRIP TEST PROCEDURE (OPT-001)
B. UNIT STABILITY RUN TEST PROCEDURE (OPT-002)
C. UNIT START-UP & SHUTDOWN TEST PROCEDURE (OPT-003)
D. UNIT LOAD REJECTION TEST PROCEDURE (OPT-004)
E. UNIT RUNBACK TEST PROCEDURE (OPT-005)
F. GRID CODE COMPLIANCE TEST PROCEDURE (OPT-006)
G. ISLAND OPERATION TEST PROCEDURE (OPT-007)
H. HEATER OUT-OF-SERVICE TEST PROCEDURE (OPT-008)
Page 2 of 136
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
INTRODUCTION
1.1 General
Saudi Electricity Company - Western Operating Area (hereinafter referred to as SEC-WOA) is
constructing a new Jeddah South Thermal Power Plant, Stage I (JSTPP-I), which is located on the Red
Sea coast approximately 70 km to the south of the city of Jeddah in the Kingdom of Saudi Arabia.
Hyundai Heavy Industries Co., Ltd. (hereinafter referred to as HHI) is participating in this project as
Engineering, Procurement, Construction and Commissioning Contractor. The project will include the
construction of four new conventional oil fired thermal generating units, each producing a minimum
net electrical plant output of about 660 MW respectively at Stage I, with further two stages being
constructed in the future with four and two units, respectively. The electrical output from the JSTPP-I
will be exported to the grid system via a new 380 kV GIS substation to be also constructed by HHI.
Each unit will be provided with a once-through type, sliding pressure control, balanced draft, heavy
fuel oil or heavy crude oil fired steam generating unit with electro-static precipitators, and a multicylinder, double casing, tandem compound, reheat condensing type steam turbine generator set.
Cooling of the steam surface condensers and plant auxiliaries will be provided by a seawater oncethrough cooling system. The cooling water discharge will be used for flue gas desulphurization (FGD)
and then discharged via culvert to the sea.
The plant will be capable of firing on heavy fuel oil and heavy crude oil. The distillate fuel oil will be
used for start up purposes. The heavy fuel oil and heavy crude oil will be delivered to the site by sea
tanker and will be unloaded at the loading platform. Distillate oil will be delivered to the site by road
tanker. The RO (reverse osmosis) plant and water treatment plant will produce the water to be used for
this project. The necessary potable (drinking) water, demineralized water (for make up to the boiler)
and service water for general use on site can also be produced inside.
1.2 Requirements
The main purpose of this document is to describe the start-up and operational testing requirements and
procedures for the power units in JSTPP-I Project that will serve as a guideline document for
performing the start-up test and operational tests together with other commissioning procedures.
The testing procedures are based upon the requirements of the EPC Contract, Vol. 1 technical
specification clause 11.2.4 Tests on Completion, and include various types of tests for startup/shutdown operation, normal and transient conditions under which the plant is proposed to be
designed to operate, limitations imposed on the plant operations and start-up/shutdown requirements.
Page 3 of 136
DEFINITIONS/ABBREVIATIONS
APS
AVR
BCP
BMCR
BMS
BOP
CCCW
CCR
DCS
DEH
DFO
EOST
ESD
FCB
FDF
FGD
FWH
GRF
GV
HCO
HFO
HMI
ICV
IDF
MCWP
MFT
MSV
OPC
RAH
RO
RSV
SAH
SGR
STG
TCS
TPS
TMCR
UCC
VWO
WS
WSDH
Auto Plant Start-up

Auto Voltage Regulator
Boiler Circulation Pump
Boiler Maximum Continuous Rating
Burner Management System
Balance of Plant
Closed Circuit Cooling Water
Central Control Room
Distributed Control System
Digital Electro-Hydraulic
Distillate Fuel Oil
Electrical Overspeed Test
Emergency Shutdown
Fast Cut Back
Forced Draft Fan
Flue Gas Desulfurization
Feed Water Heater
Gas Recirculation Fan
Governor Valve
Heavy Crude Oil
Heavy Fuel Oil
Human Machine Interface
Intercept Control Valve
Induced Draft Fan
Main Cooling Water Pump
Master Fuel Trip
Main Stop Valve
Overspeed Protection Controller
Regenerative Air Heater
Reverse Osmosis
Reheat Stop Valve
Steam Air Heater
Separate Gas Recirculation
Steam Turbine Generator
Turbine Control System
Turbine Protection System
Turbine Maximum Continuous Rating
Unit Coordinate Control
Valve Wide Open
Water Separator
Water Separator Drain Header
Page 4 of 136
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
PLANT CONFIGURATION
3.1 General
The plant consists of four conventional oil fired thermal generating units which has net electrical plant
output of about 660 MW. Major systems/components of the plant are;
Steam Turbine Generator & Auxiliaries and Condensing system
Boiler and Ancillary Plant
Selective Catalytic Reduction Plant
Electrostatic Precipitator
Flue Gas De-Sulfurization Plant
Feed Water heating System
Boiler Feed Water Pumps
Condensate System
Auxiliary Steam System and Drain Collection System
Circulating Water System
Seawater Intake System
Electro-chlorination System
Plant Closed Circuit Cooling Water System
Fuel Oil System
Compressed Air System
Seawater Desalination Plant (RO)
Demineralized Water system
Condensate Polishing System
Demineralized Make-up Water System
Potable Water System
Service Water system
Waste Water Treatment System
Steam and Water Sampling System
Chemical Dosing System
Hydrogen Generation Plant
Etc.
Specific description and technical data for each system/component can be seen from system
description and equipment sizing report for the individual system.
Page 5 of 136
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
3.2 Number of Units
Number of Boiler : 4
Number of Steam Turbine Generator : 4
Each boiler / steam turbine set is unitized independently.
3.3 Fuel
Ignition Fuel : Distillated Fuel Oil (DFO)
Main Fuel : Heavy Fuel Oil (HFO) & Heavy Crude Oil (HCO)
3.4 Site Condition

The plant will be operated safely and reliably over the full range of site ambient conditions listed
below;
Item No
Description
1.
SITE AMBIENT DATA
1.1
Site location
1.2
Site elevation (above sea level)
Particulars
Jeddah south approximately 70 km

South of Jeddah on the Red Sea coast
m
3.6 (not less than)
Design ambient conditions (Site rating):

1.3
Design ambient pressure
mbar
1.4
Design ambient temperature (dry bulb)
1.5
Design relative humidity
1013
40C (for Performance Guarantee)
30
Ambient temperature (dry bulb):

1.6
Highest maximum (recorded)
50
1.7
Maximum yearly average
35
1.8
Maximum daily average
35
1.9
Design maximum temperature
50
1.10
Max. metal temperature under the sun
85
1.11
Lowest minimum (recorded)
1.12
Design minimum temperature
Relative humidity:
1.13
Maximum (recorded at 40C)
100
1.14
Minimum
Page 6 of 136
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
Item No
1.15
Description
Yearly average
Particulars
%
70
Precipitation:
1.16
Mean annual rainfall
mm
102 mm
1.17
Max 24 hour rainfall
mm
111 mm
Wind speed:
1.18
Prevailing direction
North Westerly
1.19
Average wind speed
m/s
3.7
1.20
Max 10 yr wind speed
m/s
24.7
1.21
Max recorded wind speed
m/s
40
Basic Wind Speed
m/s
42 (ASCE 7-05)
Air quality:
1.22
Air pollution
*Please read note below
Seismic:
1.23
Seismic Design Factor for JSTPP-I
Seismic loading as per UBC97

Seismic Zone: 2A
Soil Profile Type : D
Design ambient temperature dry bulb will be 50 oC.

For the performance guarantees, the following reference site condition will be applied;
Ambient temperature : 40 oC
Barometric pressure : 1013 mbar
Relative humidity : 30%
System frequency 60 Hz
Power factor 0. 85
Circulating water temperature: 31 oC
Fuel: Heavy Fuel Oil
Fuel Heating Value (HHV): 42,333 kJ/kg
Page 7 of 136
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
START-UP AND OPERATIONAL TESTS

The Start-up and operational tests shall include as tabled below. These lists are referred from the EPC
Contract, Vol. 1 technical specification clause 11.2.4 Tests on Completion.
The object of these tests is to demonstrate the fitness for purpose of the plant prior to take-over by the
Company (Saudi Electricity Company). The scope of tests will include the following and any other
tests the Company/Engineer may reasonably require to demonstrate the fitness for purpose of the plant;
Each test shall be performed as per attached test sheets and dedicated procedures in Section 4.
S/N
Description of the Test
Reference Document
demonstration of starting, shutdown and transient

characteristics including load changes at designated
load rate under hot, warm and cold conditions. This
shall include a successful demonstration of the one
push button' start up and shutdown of the plant
Plant Start-up and Operational Test

(OPT-003)
performance of the governing system and protective

devices

(OPT-002)
grid compliance testing including MVAr capability,

frequency response at designated rates for remote load
despatch and AVR testing

(OPT-006)
demonstration of steam temperature and pressure

characteristics at various loads, as shown in the heat
balances (except for those included in the guarantees)

(OPT-002)
unit load control tests

(OPT-002)
very hot start-up

(OPT-003)
hot start-up

(OPT-003)
Warm hot start-up

(OPT-003)
cold start-up

(OPT-003)
load rejection tests

(OPT-004)
Page 8 of 136

S/N
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
Reference Document
20 per cent load rejection test (MSL)

(OPT-004)
50 per cent load rejection test

(OPT-004)

(OPT-004)

(OPT-004)
unit run back tests

(OPT-005)
MCWP runback

(OPT-005)
BFP runback

(OPT-005)
BCP runback

(OPT-005)
CEP runback

(OPT-005)
ID fan runback

(OPT-005)
FD fan runback

(OPT-005)
Air heater runback

(OPT-005)
Load limitation on loss of HFO pump

(OPT-005)
Loss of GR fan demonstration

(OPT-005)
fast cut back test

(OPT-004)
minimum continuous load operation

(OPT-002)
Page 9 of 136

S/N
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
Reference Document
aa
top heater out of service demonstration

(OPT-008)
bb
one (1) HP heater and one (1) LP heater out of service

demonstration

(OPT-008)
cc
safe shut down demonstration

(OPT-003)
dd
automatic shut down sequence demonstration

(OPT-003)
ee
noise level measurement.
Refer to Noise Test Procedure, document

no.: 00-TA_-S-41-006-001.
Note 1. Each operational test shall be performed as per the related OPT sheets and dedicated
procedures.
Note 2. Each operational test shall be performed as per site test schedule
Note 3. Test schedule and sequence can be revised as per site test condition.
Note 4. As already agreed, some of the operational tests will be carried out after summer operation.
Page 10 of 136
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
LIST OF SPECIFIC START-UP & OPERATIONAL TEST SHEETS

5.1
Steam Turbine Overspeed Trip Test Procedure (OPT-001)
5.2
Unit Stability Run Test Procedure (OPT-002)
5.3
Unit Start-up & Shutdown Test Procedure (OPT-003)
5.4
Unit Load Rejection Test Procedure (OPT-004)
5.5
Unit Runback Test Procedure (OPT-005)
5.6
Grid Code Compliance Test Procedure (OPT-006)
5.7
Island Operation Test Procedure (OPT-007)
5.8
Heater Out-of-Service Test Procedure (OPT-008)
Page 11 of 136
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
APPENDIX A
STEAM TURBINE OVERSPEED TRIP TEST PROCEDURE (OPT-001)
Page 12 of 136
B
A
REV.
15 JUL. 2015
15 MAY 2015
DATE
REVISED AS MARKED
ISSUE FOR APPROVAL
DESCRIPTION
H. H. KIM
H. H. KIM
DESIGNED
Y. K. OH
Y. K. OH
CHECKED
S. W. KIM
S. W. KIM
APPROVED
OWNER
PROJECT

ENGINEER
CONTRACTOR
SUBCONTRACTOR

N/A

DOC. NO :
REV. NO :
DOCUMENT TITLE
ST NO-LOAD & OVERSPEED TRIP TEST PROCEDURE

CONTRACT NO.
DOCUMENT NO.
NO. OF
PAGES
REV.
31121106/00
OPT-001
15
Doc. No. : OPT-001

Rev. No. : B
CONTENTS
1. OBJECTIVE ......................................................................................................................................3
2. PREREQUISITES .............................................................................................................................3
3. SAFETY/PRECAUTION .................................................................................................................4
4. TEST STEP ........................................................................................................................................4
5. TEST ACCEPTANCE EVALUATION............................................................................................9
Page 2 of 15
1.
Doc. No. : OPT-001

Rev. No. : B
OBJECTIVE
The objective of this procedure is to describe the steps necessary to perform the initial Steam Turbine
Overspeed Trip Test of the JSTPP-I Project. The purpose of the overspeed test is to verify the Electric
Over-Speed Trip (EOST) function that will stop the steam supply to the turbine and prevent the
turbine from overspeeding. Steam turbine overspeed trip test is performed to verify proper function
and operation of the steam turbine overspeed protection devices.
The test determines that the Plant is to satisfy the Contractual Requirements pursuant to the various
Clauses in the EPC Contract Vol. 1 Technical Specification as follows.
A dedicated turbine trip system shall be provided for overspeed trip (electrical triplex).
2.
PREREQUISITES
Prior to perform the overspeed trip test, Main EOST Module Test (MEOST) and Back-Up EOST
Module Test (BEOST) shall be performed to verify the EOST functions properly working. In addition,
turbine no-load tests such as OPC (Overspeed Protection Controller), governor lower/upper speed
limits, EOST (Electrical Over-Speed Trip Test) shall be performed.
(1)
The unit synchronization by DEH is satisfactorily completed.
(2)
The following turbine auxiliary systems are in operation and no major deficiencies are
preventing the normal operation of the systems.
a.
Turbine Lube Oil & EH Oil Supply System
b.
Turbine Gland Steam System
c.
Condenser Air Removal System (Condenser Vacuum System)
d.
HP & LP Extraction Steam System, etc.
e.
Closed Circuit Cooling Water System
f.
Instrument Air System
g.
Circulating Water System
(3)
All protective and monitoring instruments are properly lined up.
(4)
Operate the unit at more than 20% load (> 145 MW) for more than 7 hours with hot reheat
steam (IPT inlet steam) temperature > 400 C before taking the unit off-line for EOST. (on load
heat soaking operation)
(5)
Turbine valve transfer from MSV to GV is satisfactorily completed. Confirm GV controls the
speed and load properly.
(6)
There is no abnormality on boiler operation condition.
(7)
There is no abnormality on generator operation condition.

Page 3 of 15

(8)
3.
(2)
4.
Establish the temporary communication between Control Room and Turbine local.
SAFETY/PRECAUTION
(1)
Doc. No. : OPT-001

Rev. No. : B
Safety
a.
No work will be undertaken, regardless of the urgency, unless it fully complies with site
safety and environmental procedures.
b.
Before the start of any testing, it should be confirmed that all power supplies to the system
have been isolated or that they are in a known condition. The commissioning engineer is
responsible for the safety of those personnel working on the system. Check for the
presence of harmful electrical or mechanical potential energy before starting work.
c.
Confined or enclosed space entry procedures are to be reviewed and adhered to by all
personnel involved where applicable.
d.
Project Lockout/Tag-out (LOTO) procedures must be adhered to.
e.
All personnel directly involved with the testing will attend a kickoff safety meeting to
review the dangers. Ensure that all personnel understand the process and the operation.
Any conditions deemed to affect the safe operation of the unit should be immediately
reported to the Start-up Manager or Lead Commissioning Engineer to determine
appropriate action.
f.
Remove all welding leads, electrical cords and air hoses from the piping, to prevent
accidental releases of energy as a result of the pipe movements pinching a wire or hose.
Precautions
Particular attention should be given to normal operating conditions of the system, its equipment,
and components to detect variations from their normal conditions and function. Abnormal
conditions, alarms, or malfunctions are to be investigated and corrected as soon as possible and
reported to the Start-Up Manager or Lead Commissioning Engineer.
a.
The vibration of the steam turbine and the generator should be monitored closely during
this operation.
b.
System Walk-down and Area Preparation should be done before the test.
c.
Verify that all site personnel have been made aware that the overspeed trip test is
proceeding.
d.
Verify that the Plant Emergency response plan is prepared and ready to be activated.
TEST STEP
(1)
Main EOST Module Test

a.
Select the "MAIN EOST" button on the TURBINE TEST PANEL screen or "MAIN
EOST TRIP TEST" button on the TURBINE PROTECTION TEST OPERATION
Page 4 of 15
Doc. No. : OPT-001

Rev. No. : B
WINDOW screen.
b.
Confirm the "PERMIT" is established and select the "IN" button.
c.
Confirm the "SV-1" is selected.

Note: When other solenoid valve function is confirmed, select the solenoid valve No. and EXEC.
d.
Confirm the "OPE TEST PERMIT" is established in each loop plate of "MAIN EOST
TEST-1,2,3"
e.
Select the MAIN EOST TEST-1 and push "EOST OPE TEST" and EXEC.
f.
Select the "VARIABLE" or "FIX".

"VARIABLE": The speed can be simulated variably by pressing ().
"FIX": The speed is simulated at 3,960 rpm (110%).
(2)
g.
Confirm "OPERATE" indication becomes red when the turbine speed is simulated at
3,960 rpm (110%).
h.
Select "Reset" and execute it confirm speed return to 3,600 rpm.
i.
Confirm the "OPE TEST PERMIT" is established in each loop plate of "MAIN EOST
TEST-1,2,3"
Back-Up EOST Module Test

a.
Select the "BACK UP EOST" button on the TURBINE TEST PANEL screen or "BACK
UP EOST TRIP TEST" button on the TURBINE PROTECTION TEST OPERATION
WINDOW screen.
b.
c.

Note: When other solenoid valve is confirmed select the solenoid valve No. and EXEC.
d.
Confirm the "OPE TEST PERMIT" is established in each loop plate of "BACK UP EOST
TEST-1, 2, 3".
e.
Select the BACK UP EOST TEST-1 and push "EOST OPE TEST" and EXEC.
f.

"FIX": The speed is simulated at 3,996 rpm (111 %).
(3)
g.
3,996 rpm (111 %).
h.
Select "Reset" and execute it confirm speed returns to 3,600rpm.
i.
Confirm the "OPE TEST PERMIT" is established in each loop plate of "BACK UP EOST
TEST-1, 2, 3".
Electrical Over-Speed Test (MEOST & BEOST)

a.
Confirm that turbine speed is controlled by GV at 3,600 rpm.
b.
Depress the "ACTUAL EOST" Test pushbutton on the Turbine Test Panel screen.
Note: When "ACTUAL EOST" pushbutton is depressed, the governor upper limit and OPC function
Page 5 of 15
Doc. No. : OPT-001

Rev. No. : B
will be bypassed automatically in the DEH to prevent the turbine speed up from interruption.
c.
Increase the turbine speed by "GOV SETTER" on the Turbine Operation Panel screen, and
manually modulate speed rate around 360 rpm/min.
d.
Confirm the turbine speed starts to increase, and carefully monitor the following during
speeding.
Turbine-generator bearing vibration.
Bearing metal and drain oil temperature.
Turbine shaft position.
Differential expansion HIP and LP -A/B.
e.
Announce the turbine speed every 50 rpm during speed up to alert all attending personnel.
f.
Take note the turbine speed when the turbine tripped.

Note: Set point of MEOST is 110% (3,960 rpm).
g.
If the turbine does not trip < 111% (3,996 rpm) of rated speed, manually trip the turbine by
emergency trip PB. Accordingly, the MEOST set point should be adjusted by DEH.
h.
If MEOST is successfully completed, reset the turbine when the turbine speed is< 3,600
rpm and increase the turbine speed to 3,600 rpm.
i.
Perform BEOST (Back-Up EOST) same as above procedure. Set point of BEOST is 111%
(3,996 rpm).
Note: Setting of MEOST is changed to l12% (4,032rpm) temporarily by using DEH maintenance
tool during BEOST actual test.
(4)
Governor Lower Limit Speed Confirmation

a.
Confirm the turbine speed is controlled by GV at 3,600 rpm.
b.
Decrease the turbine speed as low as possible by "GOV SETTER" on the TCS Operation
Panel screen.
c.
Confirm the turbine speed starts to decrease, and carefully monitor the following during
speed-down.
Turbine-generator bearing vibration
Turbine-generator bearing metal temperature
Turbine rotor position
Differential expansion HIP and LP-A/B
d.
Announce the turbine speed every 50 rpm during speed down to alert all attending
personnel.
e.
Confirm the turbine speed is maintained not less than 3,384 rpm (94% of turbine rated
speed) at minimum "Governor" demand and it is not possible to decrease this speed any
further.
f.
Increase the turbine speed to 3,600 rpm by "GOV SETTER" on TCS Operation Panel
screen.
Page 6 of 15

(5)
(6)
Doc. No. : OPT-001

Rev. No. : B
Governor Upper Limit Speed Confirmation (Speed Variation Test)

a.
Confirm the turbine speed is controlled by GV at 3,600 rpm.
b.
Increase the turbine speed as much as possible by "GOV SETTER" on the TCS Operation
Panel screen.
c.
speed up.
All bearing metal and drain oil temperatures
d.
e.
Confirm the turbine speed is maintained not more than 3,816 rpm (106% of turbine rated
speed) at maximum "Governor" demand and it is not possible to increase this speed any
further.
f.
Decrease the turbine speed to 3,600 rpm by "GOV SETTER" on TCS Operation Panel
screen.
OPC Module Test

OPC Test (Speed)
a.
Select the "OPC TEST" button on the TURBINE TEST PANEL screen.
b.
Select the "OPC TEST-1 (SPEED)'' and push "TEST" then EXEC.
c.

"FIX": The speed is simulated at 3,852 rpm (107%).
d.
3,852 rpm (107%).
e.
Push "TEST RESET" then EXEC.
f.
Confirm "OPC TEST-2 (SPEED)'' and "OPC TEST-3 (SPEED)'' as same as "OPC TEST-1
(SPEED)'' procedure.
OPC Test (LOAD)

a.
Select the "OPC TEST-I (LOAD)" and push "TEST" then EXEC.
b.

"VARIABLE": The load unbalance can be simulated variably by pressing ().
"FIX": The load unbalance is simulated at 60%.
c.
Confirm "OPERATE" indication becomes red when the load unbalance is simulated at
60%.
d.
Push "TEST RESET" then EXEC.
e.
Confirm "OPC TEST-2 (LOAD)" and "OPC TEST-3 (LOAD)" as same as "OPC TEST-1
Page 7 of 15
Doc. No. : OPT-001

Rev. No. : B
(LOAD)" procedure.
(7)
(8)
OPC Actual Test

a.
OPC will fully close the GV's & ICV's when the turbine over-speed or load deviation
between turbine and generator is detected in the DEH. OPC Off-Load is to confirm that
GV's and ICV's are fully closed when the turbine speed increases up to 3,852 rpm which is
equivalent to 107% of rated speed.
b.
Bypass the governor upper limit function by simulation at DEH to enable the speed up.
c.
Increase the turbine speed to 3,852 rpm (107% of rated speed) by "GOV SETTER" on the
TCS Operation Panel screen and modulate speed rate around 360 rpm/min.
d.
speed up.
Bearing metal and drain oil temperature
e.
f.
Take note the turbine speed when OPC operated (GV's & ICV's closed fully) and alarm
indication at control room monitor screen.
g.
Decrease the turbine speed to 3,600 rpm by "GOV SETTER" on TCS Operation Panel
screen.
h.
Restore the governor upper limit circuit in the DEH.
TRIP SV TEST
a.
Select the "TRIP SV TEST" button on the TURBINE PROTECTION TEST OPERATION
WINDOW screen.
b.
c.

Note: When you confirm other solenoid valve, select the solenoid valve No. and EXEC.
d.
Select the "GO" and EXEC.
e.
Confirm the selected solenoid valve opens.
f.
Confirm the turbine trip test oil pressure increase (SV-1 or SV-3 open) or Decrease (SV-2
or SV-4 open).
g.
Select "OUT" and EXEC. And confirm the selected solenoid valve is closed. (test
complete)
Page 8 of 15
5.
TEST ACCEPTANCE EVALUATION

Refer to Attachments
Attachment #1 Turbine No-Load and Overspeed Trip Test Record Sheet
Attachment #2 - Turbine No-Load and Overspeed Trip Test Schedule
Attachment #3 Turbine Operation and Test Panel Screen
Page 9 of 15
Doc. No. : OPT-001

Rev. No. : B
Attachment #1
Steam Turbine No-Load and Overspeed Trip Test Record Sheet (OPT-001)
1. Test Purpose
: Below test will be conducted to verify proper function and operation of the steam turbine overspeed protection devices
2. Test Sheet - Turbine No-Load and Overspeed Trip Test
No.
Design Value
Setting Items
rpm
2.1 Main EOST (Set: 110%)
110
3,960
2.2 Back-up EOST (Set: 111%)
111
3,996
3.1 Lower Limit ( < -6%)
94
3,384 +0-10
3.1 Upper Limit ( > +6%)
106
3,816 +10-0
Results
Remarks
1 EOST Module Test and Function Test

2 Overspeed Trip Test (Actual)
3 Governor Speed Control Range
4 OPC Module Test (Load/Speed)

5 OPC Off-Load Actual Test (107%)
Unbalance 60%
107
1 of 2
3,852 +10-10
(JSTPP-I) OPT-001
Comments:
2 of 2
(JSTPP-I) OPT-001
Attachment B:
Attachment
#2 - Turbine no-Load and Overspeed Test Schedule
...
~
~
ell
..0
DATE :
...
0.
3.2: NO-LOAD & EOST TEST SCHEDULE (WARM MODE)

'
-1000
625
9
r1
-800
:::>
u
500
-600
ri1
U)
-400
::r:
ri1
375
0
ri1
-200
j:Q
125
20% (140MW)
7 Hrs or More
100.0
900.
TIM E (O'CLOCK)
ITEM~RS
AI
Initial Synchronization
3
4 Ini tial Load Operation
5 Valve Transfer
6 Heat Soak Operation before EOST (7 hours or more)
Unit Off Line
8
9
Overspeed T rip Test (EOST) Module Test

Overspeed Trip Test (M/B EOST) Actual
10 No Load Test (Govemor Upper/Lower Limit)

OPC Module Test (Speed/Load)
OPC Actual Test
Re-synchronization
4
7
13
2 Reached 3,600 rpm
11
12
13
14
1 Turbine Start Up (Wann Mode)
COPY TO
500 rpm
25% ( 175 MW)
RH STEAM > 400 oc
1800'
360 rpm/min
j:Q
200.0
50% (350 MW) ~

14
ri1
:( 12
II
z
.......
z........
250
lOl
:::>
300.
ri1
ri1
~ 2700
P-.
ri1
.......
3600
:::>
~
ri1
ri1
400
~
P-.
~
zr1
Q
z
0
~
~
ri1
3,600 rpm
10
12
11
13
14
~
~
s
0
CJ
L::..
p
c::::=J
[::J
r:::::=J
c:=
~
Load up to 25% (1 75 MW)
PM060-921 00-3063
Page II
Attachment #3 - Turbine Operation and Test Panel Screen

CruReltiE oPERAr1oN PANEL
PROTECTION
TEST
PANEL
c;:::,
8i
~
.......
I CoNTROL MODE)
c;:::,
'?
(..,
TRIP/RESET
62G
I OUT
I PARA I SEQ I
ircsiDcsl
c;:::,
PARA/SEQ
Al's
I -;-N-ul
TEST
PANEL
.&;;..
w
~
&
{1)
I COLD I WARM I HOT I
-~
0
TURBINESPEED
GENERATOR MW
Ro
...,
GENERATOR r:w
SPEED
s:
{1)
rpm
Vl
......
MW
""C
=i
(/)
{1)
........
Ill
(i5
I
S:OT
SPEEDSET
~1ASTER DEM~ND
REFE11ENCE
rpm
MASTER I TCSMOifEJ
TCS DEMAND
0.0
rpm
[ STRESS CONTROL
STRESS DEV m.1P
0.0
deg
[/)
(')
STRESS LD'1D RATE
0.00
%'m1n
IT~~ I~STERI
9
........
w
---
c(/)
~
(/)
SET
-i
rpm/min
II
-,
0.0
su
I
SCT
LL SET
0.0
GOY SPEED SET
SET
PERMIT!
Iou~-T~
rVALVE TRANSFE!J
(AUTO FOLLOW SEJ
I GV B ~S
MSv BIAS
rpm
IPR:=J
fviSP
IPR SET
HOLD~ ~o-] ~A~TA~~
?-
c:oov SET
[si'EEDR;\resE'r]
-i
0.0
0.0
Ef~o-~-~;;r-~N
su
AUTO
0.0
(VACUUM UNLOADER)
V U ~EI
VACUU!Ii
0.0
0.0
[ou~l~
a
n
PMO&D-61150-0202
14
,.
a~
0\
'?
~
.._
a
'?
.......
(CONTROl: MODEl
I TCS
a
~
DCS
TRIP/RESET
r--
TURBINE TEST PANEL
52G
PARA/SEQ
I PARA I
PROTECTION
TEST
PANEL
SEQ I
OUT
IN
ATS
I OPERATION
I
I
P~NEL
I COLD
,.,
!
~s
(1)
I WARM r_ HOT
(1)
-~
0
TURBINE S-PEED)
SPEED
GENERATOR MW
Ro
...,
GENERATOR J/.W
5:
=i
(1)
rpm
CZl
.......
""C
MW
(f)
OJ
Ci5
(1)
MSV-LH
II
MSV-RH
GV-LH
GV-RH
m
)>
RSV /ICV-LH
RESET
.,..,.I
START
LJ ........ il!lol--1
RSVJICV-RHJ
I RESET
OPC
-,
tZl
---(1)
START I
ICV-RH PosmoN
z0
I TESTINI
I..J.)
1ii1Neos1]
(f)
-I
TEST INI
m
(f)
r
-I
I BACKUPEOST I
I TESTINI
RSV-LH RSVRH
OPEN . OPEN
?
_.
OPEN I OPEN
OPEN I OPEN
OPEN I OPEN
CLOSE I CLOSE
CLOSE I CLOSE
CLOSE I CLOSE
i OPEN
OPEN
OPEN I OPEN
I ACTUALEOSTJ
CLOSE
CLOSE I CLOSE
I TESTINI
CLOSE
CLOSE
CLOSE
,.
J
~
a
(")
PM060'11115D-0202
15
I TURBINE PROTECTION TEST OPERATION WINDOW
"'1M"'
~
0\
'?
~
.........
a
'?
v..,
a
~
TRIP TEST CONDITION
SV1,3
OPERATED
SV-2,4
OPERATED
I TURBINE CONDITIONI
STATUS
ABNORMAL
~-
~
~
TURBINE
RESET
TURBINE
TRIPPED
~
.....
TRIP
SOLENOID
ABNORMAL
SENSOR
DEVIATION
HIGH
TRIP BLOCK
PRESS.
NORMAL
&
Ro
....,
(!)
s::
MAIN EOST
BACK UP EOST
BACKUP
EOST-1
BACKUP
EOST-2
[fRIP TEST sv SELECTION
~
""C
=i
(/)
IJJ
MAIN EOST1 I MAIN EOST2 I MAIN EOST-3
(/)
BACKUP
EOST3
SV-1
SV-2
CZl
SV-3
SV-4
g
b
---
(/)
TRIP sv TEST
IVAC/BRG OIL TIIIP 'IBT I
-i
c:!
(/)
I SIMPLIFIED TRIP OIL SYSTEM I

DETECT SV-1,3
-i
0
EMERGENCY
TRIP OIL
'/ tl '-/
1.---...,Y.
TSHY:sv.:Joos
TSHY~.oe
X
--------
SV-4
-T I
______ _
SV2
SV-3
DETECT SV-2,4
\_!?!_!_~!'
~~!L~",j
1 - - -......
'""'
TSHY:SV-3004
0)
:
1
I
I
X--------{
TSHY:SV-3oo7
II
~---------------~----I
[:WN EOST TRIP
tisi]
,.
I
E::STTRPlUT -]
BB
an
DRAIN
PM060-6115D-0202
16
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
APPENDIX B
UNIT STABILITY RUN TEST PROCEDURE (OPT-002)
Page 28 of 136
B
A
REV.
15 JUL. 2015
15 MAY 2015
DATE
REVISED AS MARKED
ISSUE FOR APPROVAL
DESCRIPTION
H. H. KIM
H. H. KIM
DESIGNED
Y. K. OH
Y. K. OH
CHECKED
S. W. KIM
S. W. KIM
APPROVED
OWNER
PROJECT

ENGINEER
CONTRACTOR
SUBCONTRACTOR

N/A

DOC. NO :
REV. NO :
DOCUMENT TITLE
UNIT STABILITY RUN TEST PROCEDURE

CONTRACT NO.
DOCUMENT NO.
NO. OF
PAGES
REV.
31121106/00
OPT-002
Doc. No. : OPT-002

Rev. No. : B
CONTENTS
1. OBJECTIVE ......................................................................................................................................3
2. PREREQUISITES .............................................................................................................................3
4. GENERAL TEST OUTLINE ...........................................................................................................4
5. TEST ACCEPTANCE .......................................................................................................................4
6. ATTACHMENT.................................................................................................................................5
Page 2 of 8
1.
Doc. No. : OPT-002

Rev. No. : B
OBJECTIVE
The objective of this procedure is to give the instructions for conducting the Unit Stability Run Test of
the JSTPP-I Project. The test determines that the Unit is to satisfy the Contractual Requirements
pursuant to the Clause 11.2.4 in EPC Contract Vol.1 Technical Specification as follows.
Clause 11.2.4 Test on completion

d. demonstration of steam temperature and pressure characteristics at various loads, as shown
in the heat balances (except for those included in the guarantees)
z.
2.
PREREQUISITES
(1)
(2)
(3)
(4)
(5)
(6)
3.
B
minimum continuous load operation
All Controls of respective Unit are switched to automatic mode. The Power Unit is ready to
start the boiler and the Steam Turbine Generator.
The turbine auxiliary systems are in operation and no major deficiencies are preventing the
normal operation of the systems.
There is no abnormality on major BOP system operation condition.
SAFETY/PRECAUTION
(1)
Safety
a.
b.
c.
d.
e.
Page 3 of 8
Doc. No. : OPT-002

Rev. No. : B
appropriate action.
f.
(2)
4.
Precautions
a.
this operation.
b.
c.
Verify that all site personnel have been made aware that the overspeed trip test is
proceeding.
d.
e.
Restrict access around the equipment to critical personnel.
f.
All work inside the power block during testing must be approved by the Start-up Manager
or Lead Commissioning Engineer.
g.
Off-limit areas are clearly marked.
GENERAL TEST OUTLINE

The test consists of thirteen (13) steps to demonstrate operating stability and capabilities. Also, the
test is carried out to verify loading rate.
In the Unit stability run test, capabilities and stabilities of the ST generators will be demonstrated at
various ST load (20% - MSL, 30%, 50%, 75%, TMCR and VWO). Also the loading/unloading rate
will be verified during this test.
Please refer to the test program for the detail activities of the Unit stability run test.
5.
TEST ACCEPTANCE
Please refer to the test program for Unit stability run test.
Page 4 of 8
6.
ATTACHMENT
Unit Stability Run Test Program Sheet.
Page 5 of 8
Doc. No. : OPT-002

Rev. No. : B
Unit Stability Run Test Program (OPT-002)

Unit No :
Test Record
Seq. no.
Operation Mode
Description
Acceptance Criteria
STG (
on turning gear
Start
ST TMCR
ST load down
to 75% load
ST kept on turning gear
Turning gear operation
Start the unit and reach TMCR
No unit trip
Keep the ST at TMCR for 30 mins
No unit trip
- Frequency Range
58.8 - 60.5 Hz
- Voltage Range
90 - 110%
- Power Factor
0.85 ~ 0.95
Operating Stability Check
No unit trip
- Frequency Range
58.8 - 60.5 Hz
- Voltage Range
90 - 110%
- Power Factor
0.85 ~ 0.95
MS
Pressure
MS Temp.
HRH
Pressure
Remarks
HRH Temp
- Unloading Rate
ST load down
to 50% load
No unit trip
- Frequency Range
58.8 - 60.5 Hz
- Voltage Range
90 - 110%
- Power Factor
0.85 ~ 0.95
- Unloading Rate
ST load down
to 30% load
No unit trip
- Frequency Range
58.8 - 60.5 Hz
- Voltage Range
90 - 110%
- Power Factor
0.85 ~ 0.95
- Unloading Rate
ST load down
to 20% load
(MSL)
Keep the ST at MSL for 30 mins.
No unit trip
- Frequency Range
58.8 - 60.5 Hz
- Voltage Range
90 - 110%
- Power Factor
0.85 ~ 0.95
- Unloading Rate
1 of 3
(JSTPP-I) OPT-002

Unit No :
Test Record
Seq. no.
Operation Mode
Description
Acceptance Criteria
STG (
ST load up
to 30% load
No unit trip
- Frequency Range
58.8 - 60.5 Hz
- Voltage Range
90 - 110%
- Power Factor
0.85 ~ 0.95
MS
Pressure
MS Temp.
HRH
Pressure
Remarks
HRH Temp
- Loading Rate
ST load up
to 50% load
No unit trip
- Frequency Range
58.8 - 60.5 Hz
- Voltage Range
90 - 110%
- Power Factor
0.85 ~ 0.95
- Loading Rate
10
ST load up
to 75% load
No unit trip
- Frequency Range
58.8 - 60.5 Hz
- Voltage Range
90 - 110%
- Power Factor
0.85 ~ 0.95
- Loading Rate
11
ST load up
to TMCR load
No unit trip
- Frequency Range
58.8 - 60.5 Hz
- Voltage Range
90 - 110%
- Power Factor
0.85 ~ 0.95
- Loading Rate
12
13
ST load up
to VWO
Unit Shutdown
Keep the ST at VWO for 30 mins.
No unit trip
- Frequency Range
58.8 - 60.5 Hz
- Voltage Range
90 - 110%
- Power Factor
0.85 ~ 0.95
ST Shutdown
No unit trip
2 of 3
(JSTPP-I) OPT-002

Unit No :
Test Record
Seq. no.
Operation Mode
Description
Acceptance Criteria
STG (
MS
Pressure
MS Temp.
HRH
Pressure
Remarks
HRH Temp
Comments:
3 of 3
(JSTPP-I) OPT-002
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
APPENDIX C
UNIT START-UP & SHUTDOWN TEST PROCEDURE (OPT-003)
Page 37 of 136
B
A
REV.
15 JUL. 2015
15 MAY 2015
DATE
REVISED AS MARKED
ISSUE FOR APPROVAL
DESCRIPTION
H. H. KIM
H. H. KIM
DESIGNED
Y. K. OH
Y. K. OH
CHECKED
S. W. KIM
S. W. KIM
APPROVED
OWNER
PROJECT

ENGINEER
CONTRACTOR
SUBCONTRACTOR

N/A

DOC. NO :
REV. NO :
DOCUMENT TITLE
START-UP & SHUTDOWN TEST PROCEDURE

CONTRACT NO.
DOCUMENT NO.
NO. OF
PAGES
REV.
31121106/00
OPT-003
14
Doc. No. : OPT-003

Rev. No. : B
CONTENTS
1. OBJECTIVE ......................................................................................................................................3
2. PREREQUISITES .............................................................................................................................3
4. TEST ...................................................................................................................................................4
4.1 COLD START ...........................................................................................................................4
4.2 WARM START .........................................................................................................................4
4.3 HOT START..............................................................................................................................4
4.4 VERY HOT START .................................................................................................................5
4.5 SHUTDOWN .............................................................................................................................5
6. ATTACHMENT.................................................................................................................................5
6.1 STARTUP & SHUTDOWN CURVES ....................................................................................5
6.2 UNIT START-UP & SHUTDOWN TEST SHEETS .............................................................5
Page 2 of 14
1.
Doc. No. : OPT-003

Rev. No. : B
OBJECTIVE
Unit Start-up and Shutdown Test will be conducted to verify the stability of the Plant start-up and shut
down operation.
The objective of this procedure is to give the instructions for conducting the Unit Runback Test of the
JSTPP-I Project. The test determines that the Unit is to satisfy the Contractual Requirements pursuant
to the Clause 11.2.4 in EPC Contract Vol.1 Technical Specification as follows
2.
PREREQUISITES
(1)
(2)
(3)
(4)
(5)
(6)
3.
B
SAFETY/PRECAUTION
(1)
(2)
Safety
a.
b.
c.
d.
e.
appropriate action.
f.
Precautions
Page 3 of 14
Doc. No. : OPT-003

Rev. No. : B
4.
a.
All activities required to carry out this test will be done in close co-ordination with the
Load Dispatch Center (LDC)
b.
this operation.
c.
d.
Verify that all site personnel have been made aware that the test is proceeding.
e.
f.
g.
h.
TEST
4.1
COLD START
(1) Cold Start-up Command will be initiated.

(2) After Start-up, Unit will be operated based on the attached Start-up & Shutdown curves.
Note that this test will be done after summer operation.
4.2
WARM START
(1) Warm Start-up Command will be initiated.

4.3
HOT START
(1) Hot Start-up Command will be initiated.

Page 4 of 14

4.4
Doc. No. : OPT-003

Rev. No. : B
VERY HOT START
(1) Very Hot Start-up Command will be initiated.

(2) After Start-up, Unit will be started, but no separate start-up curve is based but the curve will be
produced based on the test result.
4.5
SHUTDOWN
(1) Shutdown Command will be initiated.

(2) After Command, Unit will be shutdown based on the attached Shutdown curves.
5.

The test results will be documented according to the attached sheets and trend curves from the DCMS,
if required. Test is deemed successful if the actual start-up time is within the time specified in the
start-up curves.
6.
ATTACHMENT
6.1
STARTUP & SHUTDOWN CURVES
6.2
UNIT START-UP & SHUTDOWN TEST SHEETS
Page 5 of 14
Attachment #1 - Startup & Shutdown Curves

PROJECT : Jeddah South Thermal Power Plant
COLDSTARTUPCURVE
FOR INFORMATION ONLY
600.0
300
500.0
250
HP Steam Press
HRH Steam Temp
400.0
200
150
300.0
HFO Flow
HP Steam Flow
3600 RPM
100
ST Load
200.0
HRH Steam Flow
Temperature(degC),SteamFlow(ton*10/hr)
Speed(%),Load(%),SteamPress(barg),OilFlow(T/H)
HP Steam Temp
Heat Soak @ 2400 RPM

ST Speed
HRH Steam Press
50
100.0
Rub Check
@ 500 RPM
DFO Flow
0.0
0
0
60
120
180
240
300
360
420
480
540
600
OperationTime(Min.)
Light Off
Revised on 2015/02/09
ST Roll Off
Synchronization
Note1.TheStartup Curvecanbechangeddependingonsitecondition
Note 2. Thestabilizingtimeto meetthewaterandsteampurityisnotconsideredandthetimeshallbevarieddependingonsitecondition.

WARMSTARTUPCURVE
600.0
300
500.0
250
HP Steam Press
HRH Steam Temp
400.0
200
150
300.0
HFO Flow
HP Steam Flow
ST Load
3600 RPM
100
200.0
HRH Steam Flow
HP Steam Temp

ST Speed
HRH Steam Press
50
DFO Flow
100.0
Rub Check
@ 500 RPM
0.0
0
0
60
120
180
240
300
360
420
OperationTime(Min.)
Light Off
ST Roll Off
Synchronization
HOTSTARTUPCURVE
600.0
300
500.0
250
HP Steam Press
HP Steam Temp
400.0
200
150
300.0
HFO Flow
HP Steam Flow
3600 RPM
ST Load
100
200.0
ST Speed
HRH Steam Flow
HRH Steam Temp
100.0
50
DFO Flow
Rub Check
@ 500 RPM
HRH Steam Press
0.0
0
0
60
ST Roll Off
120
Synchronization
180
240
OperationTime(Min.)
Light Off
SHUTDOWNCURVE
600.0
300
HP Steam Temp
500.0
250
200
400.0
150
300.0
HP Steam Flow
ST Load
HP Steam Press
200.0
100
Load(%),SteamPress(barg)
HRH Steam Temp
HRH Steam Flow
HRH Steam Press

100.0
50
0.0
0
-20
20
40
60
80
100
120
GCB Open
Start to shutdown
First made on 2015/02/09
Note1.TheShutdownCurvecanbechangeddependingonsitecondition
140
OperationTime(Min.)
Unit Startup and Shutdown Test Sheet (OPT-003)

Unit Number (
Attachment #2
)
Unit Operation Mode
Seq. no.
Check Items
Desired level
Test Record
Remarks
Boiler - Steam Turbine

Cold Start-up
1
Stop (Cooled down)
Startup (Cold)
ST Admission
Auto SYNC & Loading to 10% & Hold
ST Loading up to 20% & Hold
Loading to TMCR
Stabilizing
Shutdown
See note 2, 3
Time from Start to TMCR
540 min
See note 4
Unspecified
Note 1. This test will be done after summer operation.

Note 2. Startup modes shall be based on shutdown time OR ST metal temperature.
Note 3. Startup time test shall be performed during APS(Auto Plant Startup & Shutdown)
tuning period but can be done during other test period as available in accordance
with site test condition.
Note 4. The stabilizing time to meet the water & steam purity is not considered,
and the time shall be varied depending on site condition
Classification
Shutdown Time
ST HP Metal Temperature
Cold Start
More than 72 hrs
Warm Start
10 hrs T 72 hrs
Hot Start
2 hrs T 10 hrs
80% of full load value
Hot Start
Less than 2 hrs
40% of full load value,

HP Separator < 100 oC
40% & 80% of full load value,
Comments:
1 of 5
(JSTPP-I) OPT-003

Unit Number (
)
Unit Operation Mode
Seq. no.
Check Items
Desired level
Test Record
Remarks

Warm Start-up
1
Stop
Startup (Warm)
ST Admission
Loading to TMCR
Stabilizing
Shutdown
See note 2, 3
360 min
See note 4
Unspecified

Classification
Shutdown Time
Cold Start
More than 72 hrs

Warm Start
10 hrs T 72 hrs

Hot Start
2 hrs T 10 hrs
Hot Start
Less than 2 hrs
Comments:
2 of 5
(JSTPP-I) OPT-003

Unit Number (
)
Unit Operation Mode
Seq. no.
Check Items
Desired level
Test Record
Remarks

Hot Start-up
1
Stop
Startup (Hot)
ST Admission
Loading to TMCR
Stabilizing
Shutdown
See note2, 3
180 min
See note 4
Unspecified
Very Hot Start-up

1
Stop
Startup (Hot)
ST Admission
Loading to TMCR
Stabilizing
Shutdown
See note2, 3
Unspecified
See note 4
Unspecified
3 of 5
(JSTPP-I) OPT-003

Unit Number (
)
Unit Operation Mode
Seq. no.
Check Items
Desired level
Test Record
Remarks
Note 1. This test will be done before summer operation.
Classification
Shutdown Time
Cold Start
More than 72 hrs
Warm Start
10 hrs T 72 hrs
Hot Start
2 hrs T 10 hrs
Hot Start
Less than 2 hrs

Comments:
4 of 5
(JSTPP-I) OPT-003

Unit Number (
)
Unit Operation Mode
Seq. no.
Check Items
Desired level
Test Record
Remarks

Shutdown
1
Startup to TMCR
Stabilizing
Shutdown
Unspecified
Classification
Shutdown Time
Cold Start
More than 72 hrs

Warm Start
10 hrs T 72 hrs
Hot Start
2 hrs T 10 hrs
Hot Start
Less than 2 hrs

Comments:
5 of 5
(JSTPP-I) OPT-003
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
APPENDIX D
UNIT LOAD REJECTION TEST PROCEDURE (OPT-004)
Page 52 of 136
B
A
REV.
15 JUL. 2015
15 MAY 2015
DATE
REVISED AS MARKED
ISSUE FOR APPROVAL
DESCRIPTION
H. H. KIM
H. H. KIM
DESIGNED
Y. K. OH
Y. K. OH
CHECKED
S. W. KIM
S. W. KIM
APPROVED
OWNER
PROJECT

ENGINEER
CONTRACTOR
SUBCONTRACTOR

N/A

DOC. NO :
REV. NO :
DOCUMENT TITLE
LOAD REJECTION TEST PROCEDURE

CONTRACT NO.
DOCUMENT NO.
NO. OF
PAGES
REV.
31121106/00
OPT-004
10
Doc. No. : OPT-004

Rev. No. : B
CONTENTS
1. OBJECTIVE ......................................................................................................................................3
2. PREREQUISITES .............................................................................................................................3
4. TEST STEP ........................................................................................................................................5
6. SIGNALS TO BE MEASURED .......................................................................................................5
7. ATTACHMENTS ..............................................................................................................................6
7.1 SINGLE LINE DIAGRAMS ....................................................................................................6
7.2 LOAD REJECTION TEST SHEET .......................................................................................6
Page 2 of 10
1.
Doc. No. : OPT-004

Rev. No. : B
OBJECTIVE
The objective of this procedure is to give the instructions for conducting the Load Rejection Test of
the JSTPP-I Project. The test determines that the Unit is to satisfy the Contractual Requirements
pursuant to the Clause 11.2.4 in EPC Contract Vol.1 Technical Specification as follows.

j.
load rejection tests
k.
20 per cent load rejection test (MSL)
l.
m. 75 per cent load rejection test

n.
y.
fast cut back test
The purpose of the test is to verify the governor function to sustain a load rejection to prevent the
turbine from overspeed tripping and capable of dumping load of 20%, 50%, 75% and 100% TMCR
without turbine trip.
2.
PREREQUISITES
Following should be confirmed before the load rejection test;
(1)
Items to be confirmed during the Turbine No-Load Tests;

a. Turbine electrical overspeed tests (EOST) have been performed successfully and found to
trip the turbine at approximately 110%/111% of turbine rated speed, i.e., 3960/3996 rpm.
b. Valve transfer (MSV to GV) test has been satisfactorily completed during no-load operation
and verified that speed control by GV is satisfactory.
c. During the OPC test at no-load conditions, the operations of GVs and ICVs are
satisfactorily and found closing at 107% (3852 rpm) speed approximately.
d. Turbine valves MSV, GV and ICV characteristics are set as per the control setting data
sheets.
e. Lube oil pumps auto start test is completed satisfactorily.
f.
(2)
Protective device test has been performed satisfactorily.
Pre-requisite Checks
a. The Steam Turbine stabilizes at the test load (20%, 50%, 75%, or 100% TMCR). Operate
the unit at least 30 minutes before start the test.
b. Keep the turbine inlet steam conditions constant.
c. Verify the boiler controls, turbine controls, condensate flow controls are in Auto for the
load rejection tests.
Page 3 of 10
Doc. No. : OPT-004

Rev. No. : B
d. Verify that temporary communication channels are available between Central Control
Room and Turbine local and Generator local.
e. Perform turbine valve stem freedom test and verify the MSV, GV, RSV and ICV are
operating properly. But this stem freedom test is not necessary for 20% load rejection test.
f.
Verify the communication channel with load dispatch center is operating properly and the
coordination in-between is well arranged.
g. Verify AVR is in Auto.

h. Verify the DEH load limiter is in Auto. (Load limiter to be governor auto-follow mode)
3.
SAFETY/PRECAUTION
(1)
(2)
Safety
a.
b.
c.
d.
e.
appropriate action.
f.
Precautions
a.
b.
this operation.
c.
d.
Page 4 of 10
4.
Doc. No. : OPT-004

Rev. No. : B
e.
f.
g.
h.
TEST STEP
After confirmation of the unit readiness to dump the load, proceed as follows;
5.
(1)
The Steam Turbine operates with Partial Load (20%, 50%, 75% TMCR) or Full Load (100%
TMCR).
(2)
Start countdown from 10 seconds and open the ST Generator Circuit Breaker (GCB) manually
in order to initiate the load rejection.
(3)
The Steam Turbine speed may momentarily rise, but should not activate overspeed trip.
(4)
The Steam Turbine may go to Full Speed No Load (FSNL) or may trip to coasting down but not
because of any abnormal situation of the steam turbine.
(5)
Boiler should not be tripped but fast cut back to its predetermined load.
(6)
After steady state condition of the turbine is achieved, re-synchronize the unit to the grid, and
confirm the load is picked up to 10% TMCR load. Increase the load as soon as possible and
return back to the load before the test if further test is scheduled.

Load rejection test will be deemed successful if the followings are satisfied;
6.
(1)
Turbine peak speed is restricted within overspeed limits, i.e., 3960 rpm (110% of rated speed).
(2)
Steam turbine does not trip by abnormal steam turbine situation.
(3)
Boiler continues to operate at its predetermined load (20% load or 40% load) after the steam
turbine GCB opens.
SIGNALS TO BE MEASURED
The following signal to be measured;
(1)
Actual generator power output
(2)
Turbine speed
(3)
GV control demand
(4)
GV#1/#2/#3/#4 actuator position

Page 5 of 10

(5)
ICV#1/#2/#3/#4 actuator position
(6)
OPC solenoid valve position
(7)
Generator voltage
(8)
Generator current
(9)
Power factor
Doc. No. : OPT-004

Rev. No. : B
(10) Exciter field voltage

(11) Exciter field current
(12) Main steam temperature
(13) HP turbine exhaust steam temperature
(14) Hot reheat steam temperature
(15) Condenser vacuum
(16) Main steam pressure
(17) HP exhaust steam pressure
(18) Hot reheat steam pressure
(19) Highest vibration with bearing no.
(20) Highest bearing metal temperature with bearing no.
(21) HIP turbine differential expansion
(22) LP turbine differential expansion
7.
ATTACHMENTS
7.1
SINGLE LINE DIAGRAMS

Please see the Key Single Line Diagram (Drawing no.: 10-BYA-E-13-001-001_Rev.1)
7.2
LOAD REJECTION TEST SHEET
Page 6 of 10
Load Rejection Test Sheets (OPT-004)

Unit No :
Seq. no.
Unit Operation Mode
Startup
Auto SYNC & Min. Load
Loading to 20% TMCR
Partial Load Run(20%)
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
See note 1
- 10% TMCR
See note 2
Stabilization
See note 3
MW :
Load Rejection (Partial load)
Load Rejection (20% Load Rejection)
ST Re-start to FSNL during coasting down
Loading to 50% TMCR
Partial Load Run (50% TMCR)
- Turbine Over Speed
110%
- Steam Turbine
May or May not Trip
- Boiler
no Trip.
FCB to 20% load
See note 5
Stabilization
See note 3
MW :
10
11
110%
- Steam Turbine
May or May not Trip
- Boiler
no Trip.
FCB to 40% load
See note 5
1 of 3
(JSTPP-I) OPT-004

Unit No :
Seq. no.
Unit Operation Mode
12
13
Loading to 75% TMCR
14
Partial Load Run (75% TMCR)
Running
Time (min)
Check Items
Desired level
Test Record
Stabilization
Remarks
See note 3
MW :
15
16
17
18
Loading to TMCR
19
TMCR Run
110%
- Steam Turbine
May or May not Trip
- Boiler
no Trip.
FCB to 40% load
See note 5
Stabilization
See note 4
MW :
Load Rejection (Full load)
20
Load Rejection (100% Full Load Rejection)
21
ST coasting down
22
ST Shutdown
Test Duration(Net)
110%
- Steam Turbine
May or May not Trip
- Boiler
no Trip.
FCB to 40% load
See note 5
0.00
Note 1. Startup time shall be varied with site condition.

Note 2. Minimum load is typically 10% load but actual value may vary with site test condition.
Note 3. Minimum stabilization time is 30 minutes.
Note 4. Full load rejection test shall be substituted by partial load rejection OR simulation report, if the Grid operating condition does not allow actual test.
Note 5. After load rejection, load of other ST (if available) may be increased automatically by MW control system.
Other ST (if available) should be operated on any partial load befor the test.
2 of 3
(JSTPP-I) OPT-004

Unit No :
Seq. no.
Unit Operation Mode
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
Comments:
3 of 3
(JSTPP-I) OPT-004
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
APPENDIX E
UNIT RUNBACK TEST PROCEDURE (OPT-005)
Page 63 of 136
B
A
REV.
15 JUL. 2015
15 MAY 2015
DATE
REVISED AS MARKED
ISSUE FOR APPROVAL
DESCRIPTION
H. H. KIM
H. H. KIM
DESIGNED
Y. K. OH
Y. K. OH
CHECKED
S. W. KIM
S. W. KIM
APPROVED
OWNER
PROJECT

ENGINEER
CONTRACTOR
SUBCONTRACTOR

N/A

DOC. NO :
REV. NO :
DOCUMENT TITLE
UNIT RUNBACK TEST PROCEDURE

CONTRACT NO.
DOCUMENT NO.
NO. OF
PAGES
REV.
31121106/00
OPT-005
16
Doc. No. : OPT-005

Rev. No. : B
CONTENTS
1. OBJECTIVE ......................................................................................................................................3
2. PREREQUISITES .............................................................................................................................3
4. TEST STEP & ACCEPTANCE EVALUATION ............................................................................4
4.1 MCWP RUNBACK...................................................................................................................4
4.2 BFP RUNBACK ........................................................................................................................5
4.3 BCP RUNBACK........................................................................................................................5
4.4 CEP RUNBACK........................................................................................................................5
4.5 ID FAN RUNBACK ..................................................................................................................5
4.6 FD FAN RUNBACK .................................................................................................................6
4.7 AIR HEATER RUNBACK ......................................................................................................6
4.8 LOAD LIMITATION ON LOSS OF HFO PUMP ................................................................6
4.9 LOSS OF GR FAN DEMONSTRATION ...............................................................................7
6. ATTACHMENTS ..............................................................................................................................7
6.1 UNIT RUN BACK TEST SHEETS .........................................................................................7
Page 2 of 16
1.
Doc. No. : OPT-005

Rev. No. : B
OBJECTIVE
The objective of this procedure is to give the instructions for conducting the Unit Runback Test of the
JSTPP-I Project. The test determines that the Unit is to satisfy the Contractual Requirements pursuant
to the Clause 11.2.4 in EPC Contract Vol.1 Technical Specification as follows.

o.
Unit run back tests
p.
MCWP runback
q.
BFP runback
r.
BCP runback
s.
CEP runback
t.
ID fan runback
u.
FD fan runback
v.
Air heater runback
w. Load limitation on loss of HFO pump

x.
2.
PREREQUISITES
(1)
(2)
(3)
(4)
(5)
(6)
3.
Loss of GR fan demonstration
The Steam Turbine operates with more than 75% TMCR load.
SAFETY/PRECAUTION
(1)
Safety
a.
b.
Page 3 of 16
(2)
4.
Doc. No. : OPT-005

Rev. No. : B
c.
d.
e.
appropriate action.
f.
Precautions
a.
b.
this operation.
c.
d.
e.
f.
g.
h.
TEST STEP & ACCEPTANCE EVALUATION

4.1
MCWP RUNBACK
(1)
(2)
Trip one of the Main Cooling Water Pumps (MCWP).
(3)
Load down manually the steam turbine and boiler to 60% TMCR and check the condenser if
the condenser operating pressure is stabilized.
(4)
Boiler and steam turbine should not be tripped in this situation.
(5)
The MCWP runback test will be deemed successful if the boiler/steam turbine do not trip at this
manual runback condition and the condenser operating pressure is stabilized at 60% TMCR
load. (no alarm by condenser pressure high)
Page 4 of 16
Doc. No. : OPT-005

Rev. No. : B
4.2
BFP RUNBACK
(1)
(2)
Trip one of the Boiler Feed Pumps (BFP).
(3)
Boiler will immediately run back to its 40% load and the steam turbine load will be stabilized at
its corresponding load.
(4)
Boiler and steam turbine will not be tripped in this situation.
(5)
The BFP runback test will be deemed successful if the boiler runs back to its 40% load and the
steam turbine is stabilized at its corresponding load.
Note that the performance of Unit #4 runback test will be reviewed by O/E, and this runback test in
other Units may be postponed to be conducted after Summer Operation.
4.3
BCP RUNBACK
Boiler Circulating Pump trip when required to be operated will not cause the boiler runback and it
will only delay in Unit start-up. Therefore, no test will be conducted for BCP runback.
4.4
CEP RUNBACK
(1)
(2)
Trip one of 3 x 50% condensate extraction pumps (CEP).
(3)
Standby CEP will be started immediately so that the condensate pressure can be recovered,
thereby no impact in the steam-water cycle will be made.
(4)
However, in case the standby pump fails to start, Boiler will immediately run back to its 40%
load and the steam turbine load will be stabilized at its corresponding load.
(5)
(6)
The CEP runback test will be deemed successful if the standby CEP starts immediately to
recover the condensate pressure. Test will also be deemed successful if Boiler immediately runs
back to its 40% load and the steam turbine load is stabilized at its corresponding load in case
the standby CEP fails to cut in.
4.5
ID FAN RUNBACK
(1)
(2)
Trip one of the ID Fans.
(3)
(4)

Page 5 of 16

(5)
Doc. No. : OPT-005

Rev. No. : B
The ID Fan runback test will be deemed successful if the boiler runs back to its 40% load and
the steam turbine is stabilized at its corresponding load.
4.6
FD FAN RUNBACK
(1)
(2)
Trip one of the FD Fans.
(3)
(4)
(5)
The FD Fan runback test will be deemed successful if the boiler runs back to its 40% load and
the steam turbine is stabilized at its corresponding load.
4.7
AIR HEATER RUNBACK
(1)
(2)
Trip one of the Regenerative Air Heaters.
(3)
(4)
(5)
The Regenerative Air Heater runback test will be deemed successful if the boiler runs back to
its 40% load and the steam turbine is stabilized at its corresponding load.
4.8
LOAD LIMITATION ON LOSS OF HFO PUMP
(1)
(2)
Trip one of 3 x 50% main fuel oil pumps.
(3)
Standby fuel oil pump will be started immediately so that the fuel oil discharge pressure can be
recovered, thereby no impact in the main fuel oil supply system will be made.
(4)
However, in case the standby pump fails to start, Boiler will immediately run back to its 40%
load and the steam turbine load will be stabilized at its corresponding load.
(5)

Page 6 of 16
5.
(6)
The Loss of main fuel oil pump test will be deemed successful if the standby pump starts
immediately to recover the fuel oil discharge pressure. Test will also be deemed successful if
Boiler immediately runs back to its 40% load and the steam turbine load is stabilized at its
corresponding load in case the standby pump fails to cut in.
4.9
LOSS OF GR FAN DEMONSTRATION
(1)
(2)
Trip one of the Gas Recirculation (GR) Fans.
(3)
The other GR fan will compensate as much as possible. However, the reheat steam temperature
will decrease and subsequently the steam turbine load will decrease in accordance. (In this case,
the steam turbine load can be maintained if more fuel is supplied to the boiler manually.)
(4)
NOx will be increased but the SCR still can meet the NOx guarantee at the stack.
(5)
The Loss of the GR fan will be deemed successful if the NOx guarantee level can be met at the
stack by SCR. Reheater temperature decrease and subsequent steam turbine load reduction is
acknowledged.

Refer to Section 4.1 to 4.9.
6.
Doc. No. : OPT-005

Rev. No. : B
ATTACHMENTS
6.1
UNIT RUN BACK TEST SHEETS
Page 7 of 16
Unit Run Back Test Sheets (OPT-005) - Main Cooling Water Pump Runback
Unit No :
Seq. no.
Unit Operation Mode
Startup / Auto SYNC & Min. Load
Loading up ST more than 75% TMCR
Run ST for stabilisation
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
See note 2
Unit Run Back
Trip one of MCWPs
- Steam Turbine
More than 60% TMCR
- Boiler
no Trip.
See note 3
ST Load up for other tests or ST shutdown.

Test Duration(Net)
0.00

Note 3. If the ST load is less than 60% before MCWP runback test, then the ST will maintain its previous load.
Note 4. As the cooling water lines for each unit is interconnected with the adjacent unit, as subsequent units are constructed/commissioned/operated, the impact by one MCWP will be
reduced if the test is done with the interconnection valve open.
Comments:
1 of 9
(JSTPP-I) OPT-005
Unit Run Back Test Sheets (OPT-005) - BFP Runback

Unit No :
Seq. no.
Unit Operation Mode
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
See note 2
Unit Run Back
Trip one of BFPs
- Steam Turbine
- Boiler
around 40% TMCR

Runback to 40%
BMCR

Test Duration(Net)
0.00

Comments:
2 of 9
(JSTPP-I) OPT-005
Unit Run Back Test Sheets (OPT-005) - BCP Runback - Test Not Necessary
Unit No :
Seq. no.
Unit Operation Mode
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
Comments:
3 of 9
(JSTPP-I) OPT-005
Unit Run Back Test Sheets (OPT-005) - CEP Runback

Unit No :
Seq. no.
Unit Operation Mode
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
See note 2
If standby CEP cut in
Trip one of CEPs
- Steam Turbine
No change
- Boiler
No change
If standby CEP can't cut in

5
Trip one of CEPs
- Steam Turbine
around 40% TMCR
- Boiler
Runback to 40% BMCR

Test Duration(Net)
0.00

Comments:
4 of 9
(JSTPP-I) OPT-005
Unit Run Back Test Sheets (OPT-005) - ID Fan Runback

Unit No :
Seq. no.
Unit Operation Mode
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
See note 2
Unit Run Back
Trip one of ID Fans
- Steam Turbine
around 40% TMCR
- Boiler
Runback to 40% BMCR

Test Duration(Net)
0.00

Comments:
5 of 9
(JSTPP-I) OPT-005
Unit Run Back Test Sheets (OPT-005) - FD Fan Runback

Unit No :
Seq. no.
Unit Operation Mode
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
See note 2
Unit Run Back
Trip one of FD Fans
- Steam Turbine
around 40% TMCR
- Boiler
Runback to 40% BMCR

Test Duration(Net)
0.00

Comments:
6 of 9
(JSTPP-I) OPT-005
Unit Run Back Test Sheets (OPT-005) - Air Heater Runback

Unit No :
Seq. no.
Unit Operation Mode
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
See note 2
Unit Run Back
Trip one of Air Heaters
- Steam Turbine
around 40% TMCR
- Boiler
Runback to 40% BMCR

Test Duration(Net)
0.00

Comments:
7 of 9
(JSTPP-I) OPT-005
Unit Run Back Test Sheets (OPT-005) - Load Limitation on Loss of One HFO Pump
Unit No :
Seq. no.
Unit Operation Mode
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
See note 2
If standby main fuel oil pump cut in
Trip one of Main Fuel Oil Pumps
- Steam Turbine
No change
- Boiler
No change
If standby main fuel oil pump can't cut in

5
Trip one of Main Fuel Oil Pumps
- Steam Turbine
around 40% TMCR
- Boiler
Runback to 40% BMCR

Test Duration(Net)
0.00

Comments:
8 of 9
(JSTPP-I) OPT-005
Unit Run Back Test Sheets (OPT-005) - Loss of GR Fan Demonstration

Unit No :
Seq. no.
Unit Operation Mode
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
See note 2
Unit Run Back
Trip one GR Fans
- Steam Turbine
No criteria
- Boiler
No criteria
- Hot RH steam temperature No criteria

- NOx at CEMS
5
within the guarantee value

Test Duration(Net)
0.00

Comments:
9 of 9
(JSTPP-I) OPT-005
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
APPENDIX F
GRID CODE COMPLIANCE TEST PROCEDURE (OPT-006)
Page 80 of 136
15 JUL. 2015
REVISED AS MARKED
H. H. KIM
Y. K. OH
S. W. KIM
15 MAY 2015
ISSUE FOR APPROVAL
H. H. KIM
Y. K. OH
S. W. KIM
REV.
DATE
DESCRIPTION
DESIGNED
CHECKED
APPROVED
OWNER
PROJECT

ENGINEER
CONTRACTOR
SUBCONTRACTOR

N/A

DOC. NO :
REV. NO :
DOCUMENT TITLE
GRID CODE TEST PROCEDURE

CONTRACT NO.
DOCUMENT NO.
NO. OF
PAGES
REV.
31121106/00
OPT-006
34
Doc. No. : OPT-006

Rev. No. : B
CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
OBJECTIVE ......................................................................................................................................3
PREREQUISITES .............................................................................................................................3
SAFETY/PRECAUTION .................................................................................................................3
GRID CODE COMPLIANCE AND TEST EQUIPMENT ...........................................................5
GRID CODE CONSULTATION WITH THE TRANSMISSION AUTHORITY .......................7
ROLE OF SEC/TRANSMISSION AUTHORITY .........................................................................7
RESPONSIBILITIES OF HHI ........................................................................................................7
GRID CODE TEST REQUIREMENTS .........................................................................................8
8.1 FREQUENCY VARIATIONS (SAGC, CL. NO.: 2.4.2.2) ....................................................8
8.2 VOLATAGE VARIATIONS (SAGC, CL. NO.: 2.4.3) ..........................................................9
9.
GRID CODE TESTING WORK SCOPE .....................................................................................10

9.1 ELECTRICAL TESTS ...........................................................................................................10
9.2 FREQUENCY/MW RESPONSE TESTS .............................................................................10
10.
ELECTRICAL TESTS.................................................................................................................... 11
10.1 MAGNETIZATION CURVE TEST PROCEDURE ...........................................................11
10.2 OPEN CIRCUIT AVR STEP TEST PROCEDURE ...........................................................13
10.3 PSS (POWER SYSTEM STABILIZER) TEST PROCEDURE .........................................15
10.4 OVEREXCITED REACTIVE POWER TEST PROCEDURE..........................................16
10.5 UNDEREXCITED REACTIVE POWER TEST PROCEDURE .......................................18
10.6 UNDEREXCITED LIMITER (UEL) TEST PROCEDURE ..............................................20
10.7 OVEREXCITED LIMITER (OEL) TEST PROCEDURE .................................................23
11.
FREQUENCY/MW RESPONSE ...................................................................................................26

11.1 PRIMARY RESPONSE TEST PROCEDURE ....................................................................26
11.2 SECONDARY RESPONSE TEST PROCEDURE ..............................................................29
11.3 UNIT DROOP TEST PROCEDURE ....................................................................................32
12.
REFERENCE DOCUMENTS........................................................................................................34
Page 2 of 34
Doc. No. : OPT-006

Rev. No. : B
1.
OBJECTIVE
The objective of this procedure is to give the instructions for conducting the grid code compliance
testing of the JSTPP-I Project.
The test determines that the Unit is to satisfy the Contractual Requirements pursuant to the Clause
11.2.4 in EPC Contract Vol.1 Technical Specification as follows.

c.
2.
PREREQUISITES
(1)
(2)
(3)
(4)
(5)
(6)
3.
SAFETY/PRECAUTION
(1)
grid compliance testing including MVAr capability, frequency response at designated rates
for remote load despatch and AVR testing
Safety
a.
b.
c.
d.
e.
appropriate action.
Page 3 of 34
Doc. No. : OPT-006

Rev. No. : B

f.
(2)
Precautions
a.
b.
this operation.
c.
d.
e.
f.
g.
h.
Page 4 of 34
Doc. No. : OPT-006

Rev. No. : B
4.
GRID CODE COMPLIANCE AND TEST EQUIPMENT

Grid code tests are designed to demonstrate the dynamic performance capabilities of the supplied
turbine generator unit with grid code requirement.
The grid code test shall be carried out at the direction of the HHI Commissioning Manager at a time,
which is mutually agreed upon by the SEC, TSP (Transmission Service Provider) and the HHI
Commissioning Manager.
The Grid Code Compliance Testing scope of equipment during commissioning of the plant shall cover,
but not limited to the following listed in the below outline. The equipment nameplate information is as
follows;
Steam Turbine
Manufacturer
MITSUBISHI HEAVY INDUSTRIES, Co., Ltd.
Type
TC4F-40
ST#01 : 1600, ST#02 : 1599,
ST#03 : 1598, ST#04 : 1597
3600 RPM
Serial Number
RPM
ST Generator
Manufacturer
MITSUBISHI ELECTRIC CORPORATION
Type
MBK
STG#01 : 13JUGC01,
STG#02 : 13JUGB01,
STG#03 : 13JUGA01,
STG#04 : 13JUG901
891000 kVA
Serial Number
Rating
Field Current
19.785 kA
Field Voltage
26000 Volts
Power Factor
0.85
Excitation System
Manufacturer
MITSUBISHI ELECTRIC CORPORATION
Type
PPT Ratings
OIL
STG
26kV - 850V, 6830kVA
Transformer Impedance
Z = 11%
Page 5 of 34
Doc. No. : OPT-006

Rev. No. : B
GSUT
Manufacturer
HITACHI, JAPAN
Rating
904,000 kVA
Voltage
380/26 kV
Cooling
ODAF@50 degree C
Impedance
14@904MVA base
Page 6 of 34
Doc. No. : OPT-006

Rev. No. : B
5.
GRID CODE CONSULTATION WITH THE TRANSMISSION AUTHORITY

This scope includes the following task items:
a. Conducting site visits/coordination meetings with SEC, TSP or its authorized representative(s).
6.
7.
b.
Test plan schedule/plan development
c.
Conduct the Grid Code tests
d.
Testing and final report follow-up meeting
ROLE OF SEC/TRANSMISSION AUTHORITY

a.
Coordination of testing.
b.
Review of test plan procedures.
c.
Onsite witnessing of relevant or required tests.
d.
Ensure communications are clear between HHI and SEC/TSP before grid code test.
e.
Review and provide feedback on any data, including test procedures and reports.
RESPONSIBILITIES OF HHI
a.
Develop the test procedure
b.
Secure proper test clearance and /or approval from the transmission system operator/
owner/administrator.
c.
Ensure that appropriate MHI/MELCO Excitation, Controls & DCS Technical Advisor support is
available to support the grid code test team.
d.
Conduct the test under the witness of SEC/TSP.
e.
Coordination of testing.
f.
Report preparation and submission to SEC/TSP
Page 7 of 34
Doc. No. : OPT-006

Rev. No. : B
8.
GRID CODE TEST REQUIREMENTS

In order to conduct the grid code compliance test, the Transmission system performance should be
maintained within the limits and ranges specified in the Minimum National Power Quality Standards
for the Saudi Arabian Grid Code (SAGC).
Grid code Tests will be conducted with normal generator control settings applied. The following test
items are included in the Saudi Arabian Grid Code (SAGC).
a.
Active Power Control (power factor, frequency, voltage)
b.
Unit Governor Droop Measurement. (SAGC, Cl. No.: 2.5.5.10)
c.
Automatic Voltage Regulation (SAGC, Cl. No.: 2.5.5.11)
d.
Reactive Power Capability (SAGC, Cl. No.: 4.9.7.8)
e.
Primary Response Test (SAGC, Cl. No.: 4.9.7.9)
f.
First Start Capability Test (SAGC, Cl. No.: 4.9.7.10)
g.
Black Start (SAGC, Cl. No.: 4.9.7.11). Not Applicable for JSTPP-I
h.
Declared Data Capability Test (SAGC, Cl. No.: 4.9.7.12)
i.
Capacity/Synchronizing/Ramp Rate Test (SAGC, Cl. No.: 4.9.7.13)
j.
Power System Stabilizer (PSS) (SAGC, Cl. No.: 4.9.7.14)
k.
System Service Acceptability Test (SAGC, Cl. No.: 4.9.7.15)
Note:
Ramp rate: The rate, expressed in megawatts per minute, at which generating Unit can increase or
decrease its Power output.
8.1
FREQUENCY VARIATIONS (SAGC, CL. NO.: 2.4.2.2)
The Transmission System shall have a nominal frequency of 60Hz and R-Y-B counter-clock-wise
phase rotation.
Below Nominal Frequency
(Hz)
Above Nominal frequency

(Hz)
Operation Requirement
59.9
60.1
normal grid operation
58.8 - 60.0
60.0 - 60.5
continuous
57.5 - 58.7
60.6 - 61.5
for a period of 30 minutes
57.0 - 57.4
61.6 - 62.5
for a period of 30 seconds
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8.2
VOLATAGE VARIATIONS (SAGC, CL. NO.: 2.4.3)
Nominal Voltage (kV)
Nominal Range
Maximum 30 minutes Over-voltage

(Post Contingency Range)
110 kV
+/- 5%
+ 10%
115 kV
+/- 5%
+ 10%
132 kV
+/- 5%
+ 10%
230 kV
+/- 5%
+ 10%
380 kV
+/- 5%
+ 10%
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Rev. No. : B
9.
GRID CODE TESTING WORK SCOPE
9.1
ELECTRICAL TESTS
Test
Description (detailed procedures included below)
1) Magnetization Curve Test
Measure generator open circuit magnetization curves
2) Open Circuit AVR Step Test
Measure open circuit dynamic response of generatorexcitation-voltage regulator systems
3) Power System Stabilizer Test Review results of Power System Stabilizer (PSS) tuning and
and Field Tuning
field re-tuning (as needed)
4) Over-excited Reactive Power Confirm over-excited reactive power capability of generators
Test
and excitation systems
5) Under-excited Reactive Power
Test
Confirm under-excited reactive

generators and excitation systems
6) UEL Test
Confirmation of Underexcited Limiter (UEL) function
7) OEL Test
Confirmation of Overexcited Limiter (OEL) function
9.2
power
capability
of
FREQUENCY/MW RESPONSE TESTS

Test
Description (detailed procedures included below)
1) Primary Response Test
Demonstrate primary response of turbine-generators (real power

output) to variations of grid frequency
2) Secondary Response Test
Demonstrate secondary response of turbine-generators (real

power output) to variations of grid frequency
3) Unit Governor Droop Test
Measure steam turbine governor droop
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10.
ELECTRICAL TESTS
10.1 MAGNETIZATION CURVE TEST PROCEDURE
10.1.1 Test Objective
To measure generator open circuit magnetization curve and to compare it with design
curve.
10.1.2 Documented Result
Generator Magnetization Curve - plot of generator stator voltage (kV) against field
current (Amps).
10.1.3 Signals to be Measured
a.
Field current
b.
Field voltage
c.
Stator voltage
d.
Frequency of stator voltage
All signals will be recorded manually from the MEC700 control panel. All signals will be
recorded in a trend file within the MEC700 or Mitsubishi DIASYS Netmation controller
as appropriate.
10.1.4 Initial Operating Condition
a.
Turbine generator is rotated at full speed no load
b.
All the terminals are disconnected from loads and grid.
c.
Generator Circuit Breaker (GCB), open
d.
Generator terminal voltage at nominal value
e.
The field current is set to zero first.
10.1.5 Test Disturbances / Operational Steps

a.
Start trend recording
b.
Lower generator stator voltage to a value below 40 percent
c.
Note all measured values
d.
Raise stator voltage by an increment of approximately 3 percent
e.
Allow field current and stator voltage to settle
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f.
Repeat steps c to e until stator voltage reaches 108 percent or 0.25 kV below
lowest volts/Hz protection setting
g.
Lower stator voltage by an increment of approximately 3 percent
h.
Allow field current and stator voltage to settle
i.
Note all measured values
j.
Repeat steps g to i until stator voltage reaches 6 kV
k.
Continue steps g to i if possible until stator voltage reaches 20% percent nominal
l.
Save trend recording
m. Return stator voltage to normal value

n.
End of test
10.1.6 Special Protection Points

a.
Note settings of all Volts/Hz protections before starting test
b.
All generator protections should be in service with normal settings.
10.1.7 Test Criteria

Test success is determined by complete test execution.
Test data will be compared against the design open circuit saturation characteristic of the
generator. Any significant (>10%) differences between the Test and Design curves will
be noted. Test data will be the benchmark of the as-installed open circuit saturation
characteristic.
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10.2
OPEN CIRCUIT AVR STEP TEST PROCEDURE

To measure open circuit dynamic response of generator-excitation-voltage regulator
system.
Transient response plots of generator stator voltage, field voltage, and field current
versus time.
10.2.3 Signals to be Measured:
a.
Field current
b.
Field voltage
c.
Stator voltage
d.
Frequency of stator voltage at AVR out
All signals will be recorded in a high-speed trend file within the MEC700 or Mitsubishi
DIASYS Netmation as appropriate. Sampling rate must be at least 60 samples per second.
10.2.4 Initial Operating Condition:
a.
Turbine generator is rotated at the full speed no load.
b.
All the terminals are disconnected from loads and grid.
c.
Generator Circuit Breaker (GCB) open
d.
Generator terminal voltage at nominal value
10.2.5 Test Disturbances / Operational Steps:

a.
b.
Record undisturbed operation for 3 seconds
c.
Apply 1.0 percent voltage reference step to voltage regulator reference
d.
Hold reference signal constant for 7 seconds
e.
Remove reference step
f.
Record for 7 seconds
g.
Save trend file
h.
Repeat steps a to g with use regulator reference steps of 2 percent and 3 percent
i.
End Test
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10.2.6 Special Protection Points:
a.
Note settings of all Volts/Hz protections before starting test
b.

Test success is determined by complete test execution.
Test data will be compared against the design value. Any significant (>10%) differences
between the Test and Design values will be noted.
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10.3 PSS (POWER SYSTEM STABILIZER) TEST PROCEDURE

Measure dynamic response of generator-excitation-voltage regulator system with unit
synchronized (with and without PSS in-service).
10.3.2 Signals to be Measured:
a.
MW
b.
MVAr
c.
Field voltage
d.
Stator voltage
e.
PSS output signal
All signals will be recorded in a high-speed trend file within the MEC700 or Mitsubishi
DIASYS Netmation as appropriate. Sampling rate must be at least 60 samples per second.
10.3.3 Initial Operating Condition:
a.
Turbine generator at 80 percent or higher real power loading
b.
Turbine generator MVAr output between 5% under-excited and 15% over-excited.
c.
Generator terminal voltage at value acceptable to grid operator and as close as

practical to rated value.

MELCO/MHI to submit its standard test procedure document for PSS or as per IEEE421.5 described Model PSS2B. (to be updated later)
10.3.5 Special Protection Points:
Successful completion of this test is determined by demonstration of stable operation for
PSS gain = 3 times nominal value.
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10.4 OVEREXCITED REACTIVE POWER TEST PROCEDURE

To confirm overexcited reactive power capability of generator and excitation system.
Plots versus time of:
a.
Generator stator voltage
b.
Generator MW
c.
Generator MVAr
d.
Field voltage
e.
Field current
f.
Generator cold steam temperature
g.
Selected generator RTD temperatures

a.
Field current
b.
Field voltage
c.
Stator voltage
d.
Generator MW
e.
Generator MVAr
f.
Generator cold gas temperature
g.
All signals will be recorded in a trend file within the Mitsubishi DIASYS Netmation as
appropriate. Sampling rate must be at least 60 samples per second.
a.
The grid operator must be advised of the intent of this test to take the generator to
maximum delivery of reactive power to the grid and the grid must be prepared to
accept the maneuvers of this test.
b.
Turbine generator at TMCR.
c.
Generator terminal voltage at value acceptable to grid operator but as close as

practical to rated value.
d.
Power system stabilizer may be in or out of service as appropriate for prevailing

grid conditions.
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a.
b.
Increase generator MVAr output to the rated value corresponding to the present
value of base load MW output. This MVAr value is specified by the generator
capability curve. The increase of generator MVAr should be accomplished by a
succession of adjustments to the voltage regulator reference set point and changes of
generator step up transformer tap so that variations of generator terminal voltage
and bus voltage are minimized.
c.
Maintain the generator at base load and rated MVAR output for enough time period
until temperature readings stabilize.
d.
Return the generator MVAr to normal operating range by the reverse of the
procedure of step b.
e.
End of test.

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10.5 UNDEREXCITED REACTIVE POWER TEST PROCEDURE

10.5.1 Objective
To confirm underexcited reactive power capability of generator and excitation system.
Plots versus time of
a.
Generator stator voltage
b.
Generator MW
c.
Generator MVAr
d.
Field voltage
e.
Field current
f.
g.

a.
Field current
b.
Field voltage
c.
Stator voltage
d.
Generator MW and MVAr
e.
f.
All signals will be recorded in a trend file within the Mitsubishi DIASYS Netmation and
MEC700 as appropriate. Sampling rate must be at least 4 samples per second
a.
The grid operator must be advised of the intent of this test to take the generator to
maximum intake of reactive power to the grid and the grid must be prepared to
accept the maneuvers of this test.
b.
The under excitation limiter function of the excitation system must have been
commissioned and set as required before this test is executed.
c.
The steps specified below will be executed at base load and at minimum operating
load.
d.
Generator terminal voltage at value acceptable to grid operator but as close as

practical to rated value
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e.
Power system stabilizer may be in or out of service as appropriate for prevailing

grid conditions

a.
b.
Decrease generator negative MVAr output to the underexcited rated value

corresponding to the present value of base load MW output. This MVAr value is
specified by the excitation system underexcited reactive limit curve. The change of
generator MVAr should be accomplished by a succession of adjustments to the
voltage regulator reference set point and changes of generator step up transformer
tap so that variations of generator terminal voltage and bus voltage are minimized.
Continue decreasing voltage regulator reference setting until the underexcited
reactive power limit acts to prevent further decrease, or until the MVAR value
specified by the generator capability curve is reached. When the underexcited
reactive power limit (UEL) operates, increase the voltage regulator reference set
point slightly to clear the UEL.
c.
Maintain the generator at this MW and MVAr output for the desired duration.
d.
Return the generator MVAr to normal operating range by the reverse of the
procedure of step b.
e.
End of test.

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10.6 UNDEREXCITED LIMITER (UEL) TEST PROCEDURE

a. To verify that the Under-Excited Limiter (UEL) performs its limiting function when
voltage control or operator action attempts to move MVAR loading further into the
underexcited (leading MVAr) mode of operation.
b. To verify that that the values of the UEL curve are appropriately set and adjusted for
applications of terminal voltage and/or hydrogen pressure & temperature correction
at the test load point(s).
Plots versus time of the following signals that demonstrate limiting action of UEL;
a.
Generator terminal voltage
b.
Field voltage
c.
Field current
d.
Generator MW
e.
Generator MVAr
f.
UEL active boolean

a.
b.
Field voltage
c.
Field current
d.
Generator MW
e.
Generator MVAr
f.
UEL limit as adjusted by voltage and/or Hydrogen pressure/temperature
g.
UEL active boolean
All signals will be recorded in a trend file within the MEC700 using the control system
toolbox block capture function.
It is recommended to capture the above quantities as well as generator stator, rotor,
collector, cold & hot gas, cooling water and ambient temperature profiles in a real time
trend file recording at a minimum rate of 4 samples per second - these can be found on
the Mitsubishi DIASYS Netmation screen generator temperature monitoring.
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UEL function test
a.
Generator at unity power factor and rated terminal voltage.
b.
MEC700 excitation system and PSS is commissioned and in service.
c.
Generator cooling temperatures, hydrogen purity, hydrogen temperature and

pressure are within Mitsubishi (MHI/MELCO) recommended ranges.
d.
All protective functions of excitation system, generator and plant as well as

associated protective relays are at normal settings, functioning and active.
UEL settings confirmation

a.
Grid operator is prepared to handle the large reactive load imposed on the system by
this test and has given permission to proceed.
b.
Generator available for part load (as required) and full MW load. Reactive Power
output is set to rated leading power factor.
c.
Generator terminal voltages are at rated value.
d.
For generator terminal fed auxiliary systems, ensure that aux bus voltages are above
95% when unit is at rated leading load conditions.
e.
f.

g.
All protective functions of excitation system and protective relays are at normal
settings and functioning.

UEL Function Test
a.
Start trend recording.
b.
Adjust UEL settings to just below unit operation level.
c.
Configure block collected mode and signals (for MEC700 use PSS test capture
buffer).
d.
Command a 2% reduction in AVR reference set point, hold for 10 seconds and
return to original AVR reference setting.
e.
Confirm that UEL alarm is received on Mitsubishi DIASYS Netmation and on plant
alarm loggers.
f.
Restore UEL settings to their original values.
g.
End of test.
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UEL Settings Confirmation Test
a.
On test PC or back desk HMI, UEL condition can be confirmed by numeric value
one test PC.
b.
On test PC or back desk HMI, configure signals to be collected and begin trend
recording.
c.
Configure block collected mode and signals (for MEC700 use PSS test capture
buffer).
d.
Adjust generator loading, using any combination of GSUT OLTC tap changes,
Mitsubishi DIASYS Netmation set point adjustments (it may be beneficial to switch
to MVAr control mode -if available) or MEC700 set point adjustments to obtain
rated leading power factor mode of operation. Allow load to settle for 5 minutes.
Note: It important during this load change that the auxiliary bus voltages be
monitored to assure that this voltage does not violate 95% of nominal rating.
e.
Command a 2% reduction in AVR reference set point, hold for 10 seconds and
return to original AVR reference setting - evaluate results to ensure that the value of
MVAr limited by the UEL is consistent with the curve settings.
f.
Confirm that UEL alarm is received (and cleared) on Mitsubishi DIASYS

Netmation and on plant alarm loggers.
g.
Restore unit to original, pre-test MW & MVAr loading conditions.
h.
End of Test
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Rev. No. : B
10.7 OVEREXCITED LIMITER (OEL) TEST PROCEDURE

a. To verify that the Over-Excited Limiter (OEL) performs its limiting function when
voltage control or operator action attempts to move MVAr loading further into the
Overexcited (lagging MVAr) mode of operation.
b. To allow measurement of the exciter ceiling voltage.
Plots versus time of the following signals that demonstrate limiting action of OEL;
a.
b.
Field voltage
c.
Field current
d.
Generator MW
e.
Generator MVAr
f.
OEL active boolean

a.
b.
Field voltage
c.
Field current
d.
Generator MW
e.
Generator MVAr
f.
OEL active boolean
All signals will be recorded in a trend file within the MEC700 using the Control System
Toolbox block capture function.
It is recommended to capture the above quantities as well as generator stator, rotor,
collector, cold & hot gas, cooling water and ambient temperature profiles in a real time
trend file recording at a minimum rate of 4 samples per second - these can be found on
the Mitsubishi DIASYS Netmation screen generator temperature monitoring.
OEL Function Test
a.
Grid operator is prepared to handle the large reactive load imposed on the system by
this test and has given permission to proceed.
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Rev. No. : B

b.
Generator at unity power factor and rated terminal voltage.
c.
d.

e.
All protective functions of excitation system, generator and plant as well as

associated protective relays are at normal settings, functioning and active.
f.
Generator available for part load (as required) and full MW load. Reactive power
output is set to rated leading power factor.
g.
Generator terminal voltages are at rated, nominal value.
h.
For generator terminal fed auxiliary systems, ensure that aux bus voltages are above
95% of nominal.

OEL Function Test
a.
Configure the control system toolbox trend recorder to collect at least the signals
noted in Section 8.7.3 at a sampling period of 32 msec.
b.
Configure the test capture buffer to collect these signals at high speed sampling rates.
c.
Set unit load at 75% TMCR MW, 0 (zero) MVAR (unity power factor), rated
terminal voltage. Note Generator field current at this level _______ A (DC).
d.
Generator to be in AVR mode (GEN MODE = OFF) on the ST HMI display.
e.
Ensure Mitsubishi DIASYS Netmation MVAr control mode can accept MVAr setpoint
f.
Start MEC700 real time trender
g.
Open the ecb file, find and set the following constants:
1)
FcrRefLo to field current as above + 75 amperes = ________A(DC)
2)
OEL_PU to field current as above + 100 amperes = ________A(DC)
3)
OEL_Inf to field current as above + 125 amperes = _________A(DC)
4)
OELIimitLev = 40%
Note: These changes have the effect of lowering the OEL diagram trip curves so
that the OEL now takes effect at much lower (safer) levels.
h.
With the permission of the control room, increase MVAr loading by an additional
250 - 300 amperes of field current. This can be done through a combination of
GSUT OLTC tap changes and raising the terminal voltage of the generator.
i.
In the "OEL" diagram, as the unit crosses the oel_pu pickup level, the 'blue dot' will
begin to drift off of the 'y'-axis and toward the curves. As soon as it hits the curve, it
will quickly track back to the 'y'-axis, demonstrating the OEL is in service, the field
current regulator is actually in control and the output is being clamped, held low by
the OEL regulator.
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Rev. No. : B

j.
Once the unit has settled at its new operating point, put the Unit in MVAr control at
the settled upon value of generator load MVAr. Set the operating MVAr set-point
after FCR initiation (GEN MODE = MVAr).
k.
Set AVR voltage set point to current terminal voltage.
l.
Turn unit over to AVR mode (GEN MODE = OFF) - this should provide a bumpless
transfer.
m. Return GSUT OLTC taps back to their original value - generator voltage will hold
constant and MVAr load will reduce with each step.
n.
As needed return generator terminal voltage to rated conditions by adjusting the

MEC700 voltage set point back towards unity power factor, and 100% terminal
voltage.
o.
Stop and save trend recorder files. Restart trend files.
p.
Restore OEL settings to their original values.
Ceiling Test
a.
Generator at rated lagging power factor and rated terminal voltage.
b.
Confirm that generator field current is at or below rated value.
c.
Note pre-test conditions manually.
d.
e.
Configure block collected mode and signals (for the MEC700 use PSS test capture
buffer).
f.
Command a 10% increase in AVR reference setpoint, hold for 0.1 seconds and
return to original AVR reference setting.
g.
Review test recordings for maximum exciter field voltage.
h.
End of Test.
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Rev. No. : B
11.
FREQUENCY/MW RESPONSE
11.1 PRIMARY RESPONSE TEST PROCEDURE
To measure primary response of turbine-generator power to variations of grid frequency.
Transient response plots versus time of
a.
Steam turbine generator MW
b.
Steam turbine shaft speed
c.
Steam turbine governor valve command
d.
LP Steam turbine exhaust pressure

Steam turbine signals
a.
Turbine shaft speed
b.
Generator MW
c.
Steam turbine governor valve demand/position
d.
LP Steam turbine exhaust pressure
e.
HP inlet pressure
f.
IP inlet pressure
Plant Load Controller (DCS) signals

a.
Plant load reference
b.
Frequency
c.
Plant output
d.
Boiler fuel flow
e.
Steam extraction MOV position
All steam turbine and plant load controller signals will be recorded in a trend file within
the Mitsubishi DIASYS Netmation controllers or in DCS. Sampling rate must be at least
1 sample per second.
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Rev. No. : B

Tests will be made at various initial output levels as given in table 1 below. PSS may be
in or out of service as appropriate. The turbine master should be changed to Manual
mode, and keep the turbine master demand at that time.
Tests will be initiated by injecting incremental signals into the speed reference summing
point of the governor to simulate the effect of variations of grid frequency on the turbinegenerator. These injected signals will have the forms shown in figures 1 and 2; the
amplitude of the signals will be as given in Table 1 below.
The following test steps will be executed for each individual case given in Table 1.
a.
b.
Record undisturbed operation for 30 seconds.
c.
Apply the injected test signal.
d.
Record for the duration of the test signal and for 60 seconds after it is fully removed.
e.
Save trend file.
f.
End of the test.

All generator protections should be in service with normal settings
Notes
a.
Test cases 1 - 6 demonstrate the ability of the steam turbines to provide primary
regulating response to changes of grid frequency when the turbine is operating at
part load and changes in frequency do not call for increases of output above TMCR.
b.
Cases 7 - 9 demonstrate the ability of the steam turbines to provide primary

regulating response to changes of grid frequency when the turbine is operating at
MCR and changes of frequency call for transient excursions of output above TMCR.
c.
Cases 10 - 12 confirm the way in which primary response is transferred to

secondary response.
Figure 1 Test Injection Signal Form 1

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Rev. No. : B
Time
Figure 2 Test Injection Signal Form 2
Table 1 Test Conditions and Amplitudes
Cases
/Test
Initial
Test
Test
Ramp on
Ramp off
Hold
Power
Form
Frequency
Time, Ta
Time, Tc
Time, Tb
Hz
sec.
sec.
sec.
MW
1
80% TMCR
0.05
10
60
80% TMCR
0.1
10
60
80% TMCR
0.1
10
10
60
90% TMCR
0.05
10
60
90% TMCR
0.1
10
60
90% TMCR
0.1
10
10
60
TMCR
0.05
10
60
TMCR
0.1
10
60
TMCR
0.1
10
10
60
10
80% TMCR
0.1
600
11
95% TMCR
0.1
600
12
TMCR
0.1
600
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11.2 SECONDARY RESPONSE TEST PROCEDURE

To demonstrate Secondary response of turbine to variations of turbine load reference.
Transient response plots versus time of
a.
Steam turbine generator MW
b.
Turbine shaft speed
c.
d.
Steam turbine exhaust pressure

Steam Turbine Signals
a.
Turbine shaft speed
b.
Generator MW
c.
d.
Steam turbine exhaust pressure
e.
HP inlet pressure
f.
IP inlet pressure
Plant DCS Signals

a.
Plant load reference
b.
Frequency
c.
Plant output
d.
Boiler fuel flow
e.
Steam extraction MOV position
All steam turbine signals will be recorded in a trend file within the Mitsubishi DIASYS
Netmation controllers. Sampling rate must be at least 1 sample per second.
The DCS signals will be recorded as trend files in the DCS with sampling at a rate of at
least 1 sample per second.
Plant output at 80 percent of TMCR and normal MVAR. PSS may be in or out of service
as appropriate.
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Tests will be executed by making adjusting the plant load reference setting at the
ordinary control room operator's console. Output changes of up to 7 percent of TMCR
(~50 MW) will be requested by the normal method of operator entry of new load settings.
The following test steps will be executed for each individual test given in Table 2 below.
a.
Steam turbines will be in preselected load control mode.
b.
c.
Record undisturbed operation for 60 seconds.
d.
Apply the first change of power reference setting as given in table 2.
e.
Hold the load reference steady for 2 minutes.
f.
Apply the next change of power reference setting as given in table 2.
g.
Hold the load reference for 2 minutes.
h.
Repeat steps e, f until all changes given in table 2 have been made.
i.
Save the recording files.
j.
End of test

All generator protections should be in service with normal settings
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Table 2
Test Conditions and Amplitudes

Initial
New Load
Power
Setting
% TMCR
% TMCR
63
68
68
74
74
80
80
87
87
94
94
100
100
94
94
87
87
80
10
80
74
11
74
68
12
68
63
Test
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11.3 UNIT DROOP TEST PROCEDURE

To measure steam turbine governor droop.
Plot of variation of turbine generator power output versus difference between actual
turbine speed and turbine speed reference setting. The value of governing droop over the
operational load range will be derived from the plot.
a.
Steam turbine speed-load reference
b.
Turbine shaft speed
c.
Steam turbine governor valve position
d.
Generator power output for steam turbine
Signals will be recorded in trend files within the Mitsubishi DIASYS Netmation steam
turbine controller.
Data will be recorded at 1 sample per second.
Steam turbine generator is synchronized to the grid and the unit is operated at
approximately 80 percent TMCR for the present conditions.
Power system stabilizers may be in or out of service as appropriate for the grid
conditions at the time.
a.
Choose a unit output setting close to the initial unit output and set the load reference
to that value.
b.
Place steam turbine if appropriate, in "droop" mode.
c.
Leave the unit load control setpoint unchanged for sufficient time for the grid
frequency to change at a gentle rate by a readily measurable amount, preferably
more than 0.2 Hz.
d.
If grid frequency makes a rapid change, continue to record for at least 30 minutes
after the frequency has settled down again.
e.
Save the trend files.
Page 32 of 34
Doc. No. : OPT-006

Rev. No. : B


Notes:
Proper implementation of the overall droop relationship of a steam turbine generator
unit depends on the coordination of the frequency bias of the unit load controller with
the droop of the steam turbine governors.
The ideal case for this test is a period in which the grid frequency drifts gently upward
or downward. A gradual change of grid frequency of the order of 100 mHz in one
hour or more is an ideal 'input' for this test.
It is important to make clear to the plant and grid operators that the plant must be left
under the influence solely of its plant load controller, with unchanged load reference,
for the duration of the test.
Page 33 of 34
Doc. No. : OPT-006

Rev. No. : B
12.
REFERENCE DOCUMENTS
The Saudi Arabian Grid Code, Issue: 01, Rev.: 00, May 2007
Page 34 of 34
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
APPENDIX G
ISLAND OPERATION TEST PROCEDURE (OPT-007)
Page 115 of 136
B
A
REV.
15 JUL. 2015
15 MAY 2015
DATE
REVISED AS MARKED
ISSUE FOR APPROVAL
DESCRIPTION
H. H. KIM
H. H. KIM
DESIGNED
Y. K. OH
Y. K. OH
CHECKED
S. W. KIM
S. W. KIM
APPROVED
OWNER
PROJECT

ENGINEER
CONTRACTOR
SUBCONTRACTOR

N/A

DOC. NO :
REV. NO :
DOCUMENT TITLE
ISLAND OPERATION TEST PROCEDURE

CONTRACT NO.
DOCUMENT NO.
NO. OF
PAGES
REV.
31121106/00
OPT-007
11
Doc. No. : OPT-007

Rev. No. : B
CONTENTS
1. OBJECTIVE ......................................................................................................................................3
2. PREREQUISITES .............................................................................................................................3
4. TEST STEP ........................................................................................................................................4
6. ATTACHMENTS ..............................................................................................................................5
Page 2 of 11
1.
Doc. No. : OPT-007

Rev. No. : B
OBJECTIVE
The objective of this procedure is to verify the island operation of the Unit.
The test determines that the Unit is to satisfy the Contractual Requirements pursuant to the Clause
6.1.2 in EPC Contract Vol.1 Technical Specification as follows; A full load rejection to plant auxiliary
power demand shall not cause the turbine generator to trip, but shall trip only the associated HV
breaker, keeping the T/G unit in islanded operation to maintain power supply to unit and station
auxiliary services as appropriate.
2.
PREREQUISITES
(1)
(2)
(3)
(4)
(5)
(6)
3.
SAFETY/PRECAUTION
(1)
All Controls of respective Power Unit are switched to automatic mode. The Steam Turbine
operates with more than 75% TMCR load.
Safety
a.
b.
c.
d.
e.
appropriate action.
f.
Page 3 of 11
(2)
4.
Doc. No. : OPT-007

Rev. No. : B
Precautions
a.
b.
this operation.
c.
d.
e.
f.
g.
h.
TEST STEP
Opening the high voltage circuit breakers in the substation on a Unit, the unit is disconnected from the
power grid and drops the unit load source to its own auxiliary load; however, large amounts of energy
continue to enter the unit and the potential exists for the unit to overspeed. The unit should not be
tripped by overspeed and should be kept in operation feeding the necessary power to its own and
common auxiliary load.
(1)
Open the both 380kV high voltage line breakers. (Coordination with Substation and LDC).
(2)
Receive the unit island signal from open status of high voltage line breakers.
(3)
The steam turbine will continue to run with its generator circuit breaker closed and follow the
house load. Observe the steam turbine generator operates as expected and within the limits.
Verify the steam turbine generator returns to normal operating speed (3600 rpm) supporting the
house load.
(4)
Record the operating condition in the test sheet and print out the trend curves from DCMS.
ST generator MW output, Unit auxiliary load, ST generator speed, breaker status, ST steam
admission valve positions, boiler fuel flow, feedwater flow, main/reheat steam pressure &
temperature, ST exhaust pressure etc.
Page 4 of 11
5.
6.
Doc. No. : OPT-007

Rev. No. : B

The test results will be documented according to the attached sheets and trend curves from the DCMS,
if required.
The island operation test will be deemed successful if the power unit can operate at its island
operation mode without turbine trip.
ATTACHMENTS
Attachment #1 - Island Operation Test Sheets

Attachment #2 - Island Operation Concept Presentation
Attachment #3 - Single Line Diagrams for Power Station and Substation.
Page 5 of 11
Attachment #1
Island Operation Test Sheet (OPT-007)
1. Test Purpose
: Below test will be conducted to verify stable island operation of the Unit, following a load disconnection between Substation and Power plant.
: Island mode test means that both 380kV high voltage line breakers of the steam turbine will be opened simultaneously and ST will go to certain load to feed house load.
2. Test Sheet
Seq. no.
Plant Unit Operation Mode
Check Items
STG in operation at more than 75% TMCR.
Operating Condition
Open both 380kV High Voltage line breakers of the ST simultaneously.
Line Breakers
ST will follow the house load.
ST
Acceptance Criteria
Test Result
Remarks
Normal
Open
House load operation
Note 2

Note 2. Island Operation will be maximum one(1) hour.
Comments:
1 of 1
(JSTPP-I) OPT-007
Attachment #2
(JSTPP-I) Unit Island Operation Test Concept (OPT-007)
HHR-1
CKT-1(C-11)
AL-ADEL
CKT-1(C-8)
MHR
CKT-1(C-3)
C5.A
C5.B
C5.C
C4.A
C4.B
C4.C
C3.A
C3.B
C3.C
C3
GSUT02
GSUT01
UAT01
CAT01
UAT02
52G
ST01
C8.A
C8.B
C8.C
C8
C7
GSUT04
GSUT03
CAT02
52G
C7.A
C7.B
C7.C
C6.A
C6.B
C6.C
C6
C5
C4
HHR-1
CKT-2(C-9)
AL-ADEL
CKT-2(C-3)
MHR
CKT-2(C-8)
ST02
Island Mode Test

* Readiness
1.
Close communication among power plant, substation and
grid (LDC/TSP)
2.
The ST is running in normal condition.
* Island test
1.
Open both 380 kV line breakers (C4.B & C4.C) at the same
time
2.
Unit #1 in Island mode. Steam turbine will keep running
under isochronous mode with house load for Island
operation.
3.
Keep one(1) hour island operation maximum.
UAT03
CAT03
CAT04
UAT04
52G
52G
ST03
ST04
Restoration After Island Mode

1. Close 380 kV line breakers C4.B and C4.C one by one
manually under the communication between power plant and
substation. (Manual re-synchronisation)
Doc. No. : 00-TA_-S-41-002-001

Rev. No. : B
APPENDIX H
HEATER OUT-OF-SERVICE TEST PROCEDURE (OPT-008)
Page 127 of 136
B
A
REV.
15 JUL. 2015
15 MAY 2015
DATE
REVISED AS MARKED
ISSUE FOR APPROVAL
DESCRIPTION
H. H. KIM
H. H. KIM
DESIGNED
Y. K. OH
Y. K. OH
CHECKED
S. W. KIM
S. W. KIM
APPROVED
OWNER
PROJECT

ENGINEER
CONTRACTOR
SUBCONTRACTOR

N/A

DOC. NO :
REV. NO :
DOCUMENT TITLE
HEATER OUT-OF-SERVICE DEMONSTRATION PROCEDURE

CONTRACT NO.
DOCUMENT NO.
NO. OF
PAGES
REV.
31121106/00
OPT-008
Doc. No. : OPT-008

Rev. No. : B
CONTENTS
1. OBJECTIVE ......................................................................................................................................3
2. PREREQUISITES .............................................................................................................................3
4. TEST STEP & ACCEPTANCE EVALUATION ............................................................................4
4.1 TOP HEATER OUT OF SERVICE DEMONSTRATION ...................................................4
4.2 ONE (1) HP & ONE (1) LP FEEDWATER HEATER OUT OF SERVICE
DEMONSTRATION .................................................................................................................5
6. ATTACHMENTS ..............................................................................................................................5
6.1 HEATER OUT-OF-SERVICE TEST SHEETS .....................................................................5
Page 2 of 9
1.
Doc. No. : OPT-008

Rev. No. : B
OBJECTIVE
The objective of this procedure is to give the instructions for conducting the heater out-of-service
demonstration of the JSTPP-I Project. The test determines that the Unit is to satisfy the Contractual
Requirements pursuant to the Clause 11.2.4 in EPC Contract Vol.1 Technical Specification as follows.

aa. Top heater out of service demonstration
bb. One (1) HP heater and one (LP) heater out of service demonstration
2.
PREREQUISITES
(1)
(2)
(3)
(4)
(5)
(6)
3.
The Steam Turbine operates at TMCR load.

There is no abnormality on heater operation condition.
SAFETY/PRECAUTION
(1)
Safety
a.
b.
c.
d.
e.
appropriate action.
f.
Page 3 of 9
Doc. No. : OPT-008

Rev. No. : B
(2)
4.
Precautions
a.
b.
this operation.
c.
d.
e.
f.
g.
h.
TEST STEP & ACCEPTANCE EVALUATION

4.1
TOP HEATER OUT OF SERVICE DEMONSTRATION
(1)
(2)
Open heater bypass MOV for external desuperheater and HP feedwater heater #8.
(3)
Close heating steam supply MOV for external desuperheater and HP feedwater heater #8.
(4)
Close HP feedwater #8 inlet isolation MOV and then close external desuperheater outlet MOV.
(5)
Open heater bypass MOV for HP feedwater heater #7 and HP feedwater heater #6.
(6)
Close heating steam supply MOV for HP feedwater heater #7 and HP feedwater heater #6.
(7)
Close HP feedwater #6 inlet isolation MOV and then close HP feedwater heater #7 outlet MOV.
(8)
Check if the steam turbine load can be maintained at TMCR.
(9)
The top heater out of service demonstration will be deemed successful if the steam turbine can
maintain its load at TMCR in this situation.
Page 4 of 9
5.
4.2
ONE (1) HP & ONE (1) LP FEEDWATER HEATER OUT OF SERVICE

DEMONSTRATION
(1)
(2)
Open heater bypass MOV for external desuperheater and HP feedwater heater #8.
(3)
Close heating steam supply MOV for external desuperheater and HP feedwater heater #8.
(4)
Close HP feedwater #8 inlet isolation MOV and then close external desuperheater outlet MOV.
(5)
Open heater bypass MOV for LP feedwater heater #4.
(6)
Close heating steam supply MOV for LP feedwater heater #4.
(7)
Close HP feedwater #4 inlet isolation MOV and then close HP feedwater #4 outlet isolation
MOV.
(8)
The one (1) HP & one (1) LP feedwater heaters out of service demonstration will be deemed
successful if the steam turbine does not trip and can maintain its load as stable as possible. The
actual steam turbine load will be noted.

Refer to Section 4.1 to 4.2.
6.
Doc. No. : OPT-008

Rev. No. : B
ATTACHMENTS
6.1
HEATER OUT-OF-SERVICE TEST SHEETS
Page 5 of 9
Heater Out-of-Service Demonstration Sheets (OPT-008) - Top Heater Out-of-service

Unit No :
Seq. no.
Unit Operation Mode
Loading up ST at TMCR
Open heater bypass MOV for external desuperheater

and HP feedwater heater #8.
Close heating steam supply MOV for external

desuperheater and HP feedwater heater #8.
Close HP feedwater #8 inlet isolation MOV and then

close external desuperheater outlet MOV
Open heater bypass MOV for HP feedwater heater #7

and HP feedwater heater #6.
Close heating steam supply MOV for HP feedwater

heater #7 and HP feedwater heater #6.

close HP feedwater heater #7 outlet MOV.
10
Check if the steam turbine load can be maintained at

TMCR
11
The top heater out of service demonstration will be

deemed successful if the steam turbine can maintain
its load at TMCR in this situation
12

Test Duration(Net)
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
See note 2
- Steam Turbine
TMCR
0.00

1 of 4
(JSTPP-I) OPT-008
Heater Out-of-Service Demonstration Sheets (OPT-008) - Top Heater Out-of-service

Unit No :
Comments:
2 of 4
(JSTPP-I) OPT-008
Heater Out-of-Service Demonstration Sheets (OPT-008) - One (1) HP & One (1) LP Heaters Out-of-service
Unit No :
Seq. no.
Unit Operation Mode
Loading up ST at TMCR
Open heater bypass MOV for external desuperheater

and HP feedwater heater #8
Close heating steam supply MOV for external

desuperheater and HP feedwater heater #8.

close external desuperheater outlet MOV
Open heater bypass MOV for LP feedwater heater #4.
Close heating steam supply MOV for LP feedwater

heater #4.

close HP feedwater #4 outlet isolation MOV.
10
The one (1) HP & one (1) LP feedwater heaters out of

service demonstration will be deemed successful if the
steam turbine does not trip and can maintain its load
as stable as possible. The actual steam turbine load
will be noted.
11

Test Duration(Net)
Running
Time (min)
Check Items
Desired level
Test Record
Remarks
See note 2
- Steam Turbine
Load not specified.
0.00

3 of 4
(JSTPP-I) OPT-008
Heater Out-of-Service Demonstration Sheets (OPT-008) - One (1) HP & One (1) LP Heaters Out-of-service
Unit No :
Comments:
4 of 4
(JSTPP-I) OPT-008

00 Ta - S 41 002 001

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JEDDAH SOUTH THERMAL POWER PLANT STAGE-I

VENDOR INTERNAL DOC.NO

THIS DOCUMENT IS NOT TO BE USED FOR

PLANT START-UP & OPERATIONAL TEST PROCEDURE

PLANT START-UP & OPERATIONAL TEST PROCEDURE

Doc. No. : 00-TA_-S-41-002-001

PLANT CONFIGURATION ............................................................................................................5

START-UP AND OPERATIONAL TESTS .....................................................................................8

LIST OF SPECIFIC START-UP & OPERATIONAL TEST SHEETS ...................................... 11

PLANT START-UP & OPERATIONAL TEST PROCEDURE

Doc. No. : 00-TA_-S-41-002-001

PLANT START-UP & OPERATIONAL TEST PROCEDURE

Auto Plant Start-up

Doc. No. : 00-TA_-S-41-002-001

PLANT START-UP & OPERATIONAL TEST PROCEDURE

Doc. No. : 00-TA_-S-41-002-001

Steam Turbine Generator & Auxiliaries and Condensing system

Boiler and Ancillary Plant

Selective Catalytic Reduction Plant

Flue Gas De-Sulfurization Plant

Feed Water heating System

Boiler Feed Water Pumps

Auxiliary Steam System and Drain Collection System

Circulating Water System

Seawater Intake System

Plant Closed Circuit Cooling Water System

Fuel Oil System

Compressed Air System

Seawater Desalination Plant (RO)

Demineralized Water system

Condensate Polishing System

Demineralized Make-up Water System

Potable Water System

Service Water system

Waste Water Treatment System

Steam and Water Sampling System

Chemical Dosing System

Hydrogen Generation Plant

Doc. No. : 00-TA_-S-41-002-001

PLANT START-UP & OPERATIONAL TEST PROCEDURE

3.2 Number of Units

Number of Steam Turbine Generator : 4

Each boiler / steam turbine set is unitized independently.

Ignition Fuel : Distillated Fuel Oil (DFO)

3.4 Site Condition

SITE AMBIENT DATA

Site elevation (above sea level)

Jeddah south approximately 70 km

3.6 (not less than)

Design ambient conditions (Site rating):

Design ambient pressure

Design ambient temperature (dry bulb)

Design relative humidity

Ambient temperature (dry bulb):

Highest maximum (recorded)

Maximum yearly average

Maximum daily average

Design maximum temperature

Max. metal temperature under the sun

Lowest minimum (recorded)

Design minimum temperature

Maximum (recorded at 40C)