Escolar Documentos
Profissional Documentos
Cultura Documentos
OWNER
PP-BETASURYA
PROJECT TITLE
BOP CONTRACTOR
DOCUMENT TITLE
SC13003-C9001-U10-0002 00 28-AUG-15 70
CHAPTER 1
INTRODUCTION
This document provides the Commissioning Plan & Procedure with start-up sequence for the
Mechanical Balance of Plant equipments for the 120 MW CCPP.
The start-up and operation of the mechanical balance of plant equipments is based on the
requirements of the main plant machinery and is always in conjunction with the same. The sequence /
procedure provided here shall be altered or adjusted to the needs of the Main plant machinery and
equipments.
This document, hence, is not a complete procedure for the start-up of the power plant but only a small
part of the entire plant start-up sequence / procedure and needs to be read accordingly.
The Mechanical Balance of Plant system includes the following systems / components
Subsequently, for the Combined Cycle Mode of Operation of the Power plant, the order of sequence for
the other MBOP equipments / packages is envisaged to be as under -
6. Main Cooling water system
7. Balance of Demin Water System for Closed circuit cooling
8. Feed Water system
9. Condensate system
10. Steam system
11. Steam and Water Analysis System
12. Chemical Dosing System
For the start-up of the Power plant, the following MBOP equipments / packages are required to / can be
started independently, preferably before start of other activities, without any co-relation with any other
packages -
Potable Water system
Service Water system
Fire fighting system
Waste water treatment system
Nitrogen storage and purge system
The following systems / packages are required to be commissioned and in operation to start the
Combined Cycle Power Plant in Simple-cycle mode -
Objective
The Plant Compressed Air system is supplied to provide / meet the service and instrument air
requirements of the CCPP, i.e. service air at various points in the power plant for cleaning /
maintenance purpose and instrument air for operation of control valves, solenoid valves, pneumatic
equipments, etc. The system consists of electrically operated air compressors (1 working + 1 standby)
for instrument air needs, 1 working electrically operated air compressor for service air needs, air driers
PROJECT: 120MW COMBINED CYCLE POWER PLANT
PROJECTID: SC13003
TANJUNG UNCANG, INDONESIA
PREPAREDBY VERIFIEDBY APPROVEDBY DATE: 10.08.2015
MP PSB PSB SHEET: 3 of 70
(1 working + 1 standby) for instrument air, air receivers (service air and instrument air) and all other
required auxiliaries and accessories.
Operating Philosophy
The air compressors are electrical motor driven with individual PLC control. There are 3 nos.
compressors and are programmed in the PLC to operate as per plant air requirement. The compressed
air from the service air compressor is fed to service air receiver from where all the service air
requirement of the plant is distributed. The compressed air from the instrument air compressors is fed
to the air driers, which remove the moisture from the air and make suitable for instrument
requirement. The dried air is fed to the instrument air receiver from where it is distributed to the entire
CCPP.
Reference Documents
The following inputs are required for the commissioning and operation of the system.
The following checks are required to be done before commissioning of the system.
Commissioning Procedure
The following procedure describes in short the start-up sequence / procedure for the system.
Alarms, closed loops, which are configured in the DCS, shall be checked after pre-commissioning and /
or commissioning before start of commercial operation.
The function of the Closed Cooling Water (CCW) system is to provide a continuous supply of cooling
water to the Closed circuit cooling water (CCCW) heat exchangers for cooling of the following
consumers:
GTG lube oil and generator coolers (separate CCW system for each of the GTGs),
STG lube oil and generator coolers,
BFWPs (part of STG CCCW system),
HRSG re-circulation pumps (part of STG CCCW system)
CCW system removes the waste heat rejected in the above areas.
Each of the Closed Circuit Cooling Water systems (One system of GTG1, One system for GTG2, One
system for STG) consists of One (1) working and one (1) standby Cooling Circulation Water Pumps
(CCWP) along with drive motors to circulate the cooling water within the system, expansion tank, Fin
fan coolers (2 sets - 1 working + 1 standby) assembly, necessary piping and auxiliary systems.
Operating Philosophy
One of the 2 nos. cooling circulation water pumps shall operate continuously, to circulate the cooling
water through one set of oil coolers and generator coolers of one GTG / STG and the Fin fan cooler
assembly at required pressure. The cooling water shall get heated to higher temperatures in the GTG /
STG coolers and this hot water shall be cooled back to lower temperatures in the Fin fan cooler
assembly, which consists of finned tube bundles and blowers to reject this heat into the atmosphere.
The following inputs are required for the commissioning and operation of the system.
Pre-Commissioning Checks
The following checks are required to be done before commissioning of the system.
Commissioning Procedure
The following procedure describes in short the start-up sequence / procedure for the system.
1. The closed circuit system shall be filled / topped up with fresh DM water from the DM water
system through the flow control valve bypass line. The topmost vent in the line shall be kept
open for venting of air trapped inside the lines.
2. Once the system is filled with DM water, the air inlet shall be charged through the pressure
control valve to achieve the desired pressure (say, 3 bar).
3. One of the circulating water pumps shall be turned on and the water shall be circulated in the
system.
4. Upon start of the GTG / STG, the return cooling water shall be hot. The fin fan coolers (3 nos. for
each set) shall be turned on to reduce the temperature to the desired level.
5. The water level in the expansion tank shall be maintained by the level control valve and the
pressure shall be maintained by the pressure control valve.
6. Individual valves at inlet of each of the equipments to be checked.
7. All alarms, interlocks and trips to be checked as per the list below.
The following checks are required to be done for the pre-commissioning and commissioning of the
pumps -.
Objective
The Plant Demin water system is supplied to provide / meet all the De-mineralized water requirements
of the CCPP, ie. HRSG make-up feed water (through condensate tank), closed circuit cooling water
make-up, GTG washing water.
Operating Philosophy
The DM water tank shall be filled and the normal operating level shall be maintained by operating one
of the DM water transfer pumps (located in the Water treatment plant) vide on-off operation based on
low and high level in the tank.
One of the DM water make-up pumps shall operate continuously to feed Demin water at various points
in the CCPP at required pressure. A flow control valve is installed to ensure minimum flow re-circulation
for the pump. The DM water make-up pump shall also have protection from dry run by providing
interlock with DM water tank level transmitter for extra low level trip.
Reference Documents
The following inputs are required for the commissioning and operation of the system.
The following checks are required to be done before commissioning of the system.
The following procedure describes in short the start-up sequence / procedure for the system.
1. 2 nos. DM make-up pumps installed at the Demin tank shall be checked thoroughly first. Before
the start of the pumps, the suction valves to be turned open manually. All the necessary checks
required for the pumps to be carried out. (Details of the procedure / check list for pumps
provided separately below). The operation of the pumps locally as well as through DCS panel to
be checked.
2. Minimum re-circulation valve installed on the DM make-up pumps outlet return line shall be
checked for operation, locally and through DCS.
3. The calibration of the flow transmitters to be checked and connection to the DCS to be ensured.
4. The DM water piping to various points in the plant to be checked for leakages and supports.
5. The manual valves in the lines to be checked for proper operation. Leakages to be checked.
Drains to be opened and lines to be flushed.
6. Individual valves at inlet of each of the equipments to be checked.
7. All alarms, interlocks and trips to be checked as per the list below.
Alarms, interlocks, trips, closed loops, which are configured in the DCS, shall be checked after pre-
commissioning and / or commissioning before start of commercial operation.
The following closed loops are to be checked in the DCS for auto control action -
The following checks are required to be done for the pre-commissioning and commissioning of the
pumps:-
The following checks are required to be done for the pre-commissioning and commissioning of the
pneumatic control valves -
Objective
The Natural Gas Conditioning and Metering system is provided to supply regulated pressure and
metered flow of Natural gas to the 2 nos. GTGs of the CCPP. The gas skid system consists of natural gas
meters, control valves, emergency shut-off valve, filters, and all other required auxiliaries and
accessories. Gas leakage detectors are also installed in the system for emergency shutdown of the plant
in case of any leakage of gas.
Operating Philosophy
The emergency shut-off valve shall operate in case of emergency shut-down of the plant and in case of
any fire detection / gas leakage detection near the natural gas skid. The coalescing filters (1 working and
1 stand-by) shall filter all moisture and contaminants from the natural gas. The gas flow metes (1
working and 1 standby) shall continuously monitor and record the gas consumption of the CCPP. The
gas control valves (1 working and 1 hot standby) shall reduce and control the pressure of natural gas at
the outlet of the gas skid (to the inlet of gas compressors). Solenoid operated valves are provided to
select / control the working and standby equipments.
Note: All the instruments and electrical equipments in the system are designed for Ex-proof
classification, ie. IEC Zone 1, Group IIA/IIB, T3.
Reference Documents
The following inputs are required for the commissioning and operation of the system.
The following procedure describes in short the start-up sequence / procedure for the system.
1. The natural gas skid shall be checked thoroughly for completeness of all joints. All the necessary
checks required for the valves& filters to be carried out. (Details of the procedure / check list for
valves provided separately below).
2. The natural gas lines connecting the existing power plant to the new CCPP system to be checked
for any leakages. Pipe supports to also be checked whether properly and sufficiently installed.
3. Nitrogen gas purging shall be done to initially clean / purge the piping and system with inert gas
using the nitrogen purging system.
4. Interlocks for the emergency shut-off valve to be checked for proper operation.
5. Operation of all solenoid valves installed shall be checked thoroughly. Before the start of the
system, the manual valves to be turned open manually. All the necessary checks required for
the solenoid valves to be carried out. (Details of the procedure / check list for solenoid valves
provided separately below). The operation of these valves locally as well as through DCS panel
to be checked.
6. Coalescing filters to be cleaned, checked and installed back. Operation of drain valves, locally
and through DCS, to be checked.
7. The calibration of the flow meters to be checked and connection to the DCS to be ensured.
8. The gas leakage detection sensors cabling to DCS to be checked.
9. The manual valves in the lines to be checked for proper operation. Leakages to be checked.
Drains to be opened and lines to be flushed.
10. Individual valves at each of the equipments to be checked. Pressure safety valve operation to
be checked.
11. All alarms, interlocks and trips to be checked as per the list below.
The following checks are required to be done for the pre-commissioning and commissioning of the
pneumatic control valves -
Objective
The Closed drain and vent system is provided to safely vent and drain all the vent gases / drains from
the plant. The system consists of closed drain drums (2 nos.) and all required auxiliaries and accessories.
Operating Philosophy
The vent and condensate drains from the plant are connected to the closed drain drum, where the
filters separate out the gases and condensate. The gases escape to the vent stack and the condensate is
drained out via a condensate pump. The condensate level in the tank shall be maintained through a
level switch which shall operate the drain pump to drain out the condensate into the WWTP. Additional
sump (submersible) pump is also installed in the pit to pump the rain water / drains into the WWTP.
Note: All the instruments and electrical equipments in the system are designed for Ex-proof
classification, i.e. IEC Zone 1, Group IIA/IIB, T3.
Reference Documents
The following inputs are required for the commissioning and operation of the system.
The following checks are required to be done before commissioning of the system.
Commissioning Procedure
The following procedure describes in short the start-up sequence / procedure for the system.
1. There are 2 nos. of closed drain drums in the plant with all the natural gas drains and vents
connected to the same.
Alarms, closed loops, which are configured in the DCS, shall be checked after pre-commissioning and /
or commissioning before start of commercial operation.
The following closed loops are to be checked in the DCS for auto control action -
The following checks are required to be done for the pre-commissioning and commissioning of the
pumps -
ADDITIONAL MBOP SYSTEMS FOR COMBINED CYCLE MODE OF OPERATION OF THE CCPP:
The following additional systems / packages are required to be commissioned and in operation to start
the Combined Cycle Power Plant in Combined-cycle mode -
Objective
The function of the cooling water system is to condense the steam received by the condenser from the
exhaust of steam turbine. The cold water shall be pumped through the condenser by Centrifugal type
Cooling water pumps where the cold water shall pick up the latent heat delivered by the condensation
of steam. This hot water returning from the Condenser shall be cooled in a Cooling tower designed for
sea water application.
This system consists of 2 (two)nos. (1w+1s)x 100% capacity of (Main Cooling Water) MCW pumps along
with electrical drive motors that shall pump sea water from existing header at a pressure of 2.5 bar(g) at
pump outlet to the condenser and back to the Cooling tower.
Operating Philosophy
One of the 2 nos. main cooling water pumps shall operate continuously to feed sea water for cooling
requirement of the steam condenser in the CCPP at required pressure. The other pump shall remain as
standby. Each of the pumps shall have protection from dry run with the help of a suction pressure
transmitter. A differential pressure switch is also installed across the inlet strainer for indication of
cleaning time.
Reference Documents
The following inputs are required for the commissioning and operation of the system.
The following checks are required to be done before commissioning of the system.
Commissioning Procedure
The following procedure describes in short the start-up sequence / procedure for the system.
1. The Cooling tower shall first be commissioned as per the procedure described elsewhere in this
document / annexure.
2. The operation of the main cooling water pumps to be checked locally and from the DCS room.
3. The operation of the inlet / outlet valves of the pumps, inlet / outlet valves at the surface
condenser, (through operator console of valve actuator) and through DCS from the DCS room.
4. The main sea water piping to the surface condenser to be checked for leakages and supports.
5. The manual drain / vent valves in the lines to be checked for proper operation. Leakages to be
checked. Drains to be opened and lines to be flushed.
6. Individual valves at inlet of each of the equipments to be checked.
7. All alarms, interlocks and trips to be checked as per the list below.
Alarms, interlocks, trips, which are configured in the DCS, shall be checked after pre-commissioning and
/ or commissioning before start of commercial operation.
The following interlocks and trips are required to be checked in the DCS -
The following checks are required to be done for the pre-commissioning and commissioning of the
pumps -
The following checks are required to be done for the pre-commissioning and commissioning of the
motorized valves -.
Objective
The circulating cooling water which get heated in the Surface Condenser of the STG is supposed to be
cooled back to normal temperature. This is done in a Cooling tower. Since the water used for cooling is
sea water for this project, the cooling tower is designed for cooling of circulating sea water using
atmospheric air and forced draft fans.
Operating Philosophy
Reference Documents
Pre-Commissioning Checks
Commissioning Procedure
Objective
The Feed Water system is provided to supply feed water to the HRSGs for production of high pressure
steam. The system consists of boiler feed water pumps (BFWPs), to pump feed water from deaerator to
the HP drum), and all other required auxiliaries and accessories.
Operating Philosophy
One nos. working and one nos. standby BFWPs are provided for each HRSG with a rated flow of 78
m3/hr and head of 1018 m. One of the 2 nos. BFWPs shall operate continuously to supply high pressure
feed water to the HP steam drum at required pressure. The other pump shall remain as standby. Each
of the pumps shall have protection from dry run with the help of level transmitter signal from the LP
Drum (deaerator). A differential pressure switch is also installed across the inlet strainer for indication
of strainer choking and hence safe operation of the pumps.
Reference Documents
The following inputs are required for the commissioning and operation of the system.
The following checks are required to be done before commissioning of the system.
Commissioning Procedure
The following procedure describes in short the start-up sequence / procedure for the system.
1. All the motorized valves in the lines to be checked for operation locally (through operator
console of valve actuator) and through DCS from the DCS room. (Details of the procedure /
check list for motorized valves provided separately below).
2. The operation of the Boiler feed water pumps to be checked locally and from the DCS room.
(Details of the procedure / check list for pumps provided separately below).
3. The bearing temperatures of the pumps and motors, winding temperatures of the motors ,
mechanical seals, balancing lines, vibrations, etc. to be checked as per pump requirement.
4. The operation of the Auto minimum re-circulation valve of each of the pumps to be checked as
per the O&M manuals.
5. The feed water piping from and to various points to be checked for leakages and supports.
6. The manual drain / vent valves in the lines to be checked for proper operation. Leakages to be
checked. Drains to be opened and lines to be flushed before start of the pumps.
7. Individual valves at inlet of each of the equipments to be checked.
8. All alarms, interlocks and trips to be checked as per the list below.
Alarms, interlocks, trips, which are configured in the DCS, shall be checked after pre-commissioning and
/ or commissioning before start of commercial operation.
The following checks are required to be done for the pre-commissioning and commissioning of the
pumps - 01LAB10-AP110A.
The following checks are required to be done for the pre-commissioning and commissioning of the
motorized valves - 01LAB10-CG101.
NA
Objective
The Steam system portion of the MBOP is supplied to meet the on / off and auxiliary steam
requirements of the CCPP. The system consists of motorized operated on / off steam valves, flow
meters, and all other required auxiliaries and accessories.
Operating Philosophy
Based on the operation requirement of the HRSGs and the STG, the valves shall be turned on / off to
meet the steam requirements of the main and auxiliary equipments.
Reference Documents
The following inputs are required for the commissioning and operation of the system.
The following checks are required to be done before commissioning of the system.
The following procedure describes in short the start-up sequence / procedure for the system.
1. The Steam lines connecting the HRSGs to the STG system to be checked as per the ASME code.
Pipe supports to also be checked whether properly and correctly installed.
2. Operation of the control valves station (turbine bypass PRDSH station) to be checked, locally
and through DCS. (Details of the procedure / check list for pneumatic control valves provided
separately below and also PRDSH vendor Manual to be followed).
3. Operation of the motorized valves to be checked, locally and through DCS. (Details of the
procedure / check list for motorized valves provided separately below).
4. The manual valves in the lines to be checked for proper operation. Leakages to be checked.
Drains to be opened and lines to be flushed initially.
5. Individual valves at inlet of each of the equipments to be checked.
6. All alarms, interlocks and trips to be checked as per the list below.
Alarms, interlocks, trips, closed loops, which are configured in the DCS, shall be checked after pre-
commissioning and / or commissioning before start of commercial operation.
The following closed loops are to be checked in the DCS for auto control action -
The following checks are required to be done for the pre-commissioning and commissioning of the
pneumatic control valves - 03MAB10-CG010
SN Particular Check Confirm Remark
1 Supports Inspect and check the sturdiness and
rigidness of the supports for each of
these valves
2 Actuator Check actuator fitment is intact and
has not loosened during
transportation / installation
3 Nozzle flanges Check the connections of the various
nozzles whether as per requirement
and whether tight
4 Auxiliaries Check whether the valve auxiliaries
are installed, ie. Valve actuator
positioned, position feedback
transmitter, pointer
5 Electrical Check that the electrical power and
Connections signal cabling in the terminal box is
installed properly and that
connections are terminated as per
the requirement.
6 Pneumatic Check the connections of the
connections pneumatic instrument air for the
actuator, the pressure of the air, the
air release, etc.
7 Operation Check the operation of the valve
during on / off command from local
controller and from DCS and confirm.
8 Noise Check for any abnormal noise /
sound of the valve during operation
PROJECT: 120MW COMBINED CYCLE POWER PLANT
PROJECTID: SC13003
TANJUNG UNCANG, INDONESIA
PREPAREDBY VERIFIEDBY APPROVEDBY DATE: 10.08.2015
MP PSB PSB SHEET: 45 of 70
Checklist for Motorized Valves
The following checks are required to be done for the pre-commissioning and commissioning of the
motorized valves - 03LBA10-CG101.
Objective
The Steam and Water Analysis (SWAS) system is provided to monitor the pH, Conductivity, Silica,
dissolved Oxygen, Iron content in feed water, condensate and steam circuit of the HRSG in the CCPP.
The system consists of a packaged panel mounted system consisting of sample coolers, analyzers,
refrigerant system for cooling, etc. and all other required auxiliaries and accessories.
Operating Philosophy
The Steam and Water analysis system automatically draws out sample from various points connected to
the HRSG feed water and steam circuits and with the help of analyzers, provides all the above data to
the plant DCS for indication and alarms. Normal cooling water is first used for cooling the samples and
followed by refrigerated cooling to maintain sample temperature to </=25oC.
Reference Documents
The following inputs are required for the commissioning and operation of the system.
Pre-Commissioning Checks
The following checks are required to be done before commissioning of the system.
Commissioning Procedure
The following procedure describes in short the start-up sequence / procedure for the system.
1. The sampling lines connecting the SWAS system to various points in the plant to be checked as
per code. Pipe supports to also be checked whether properly and correctly installed.
2. Closed Circuit Cooling water lines connecting the SWAS system to be checked as per the
requirement. Pipe supports to also be checked whether properly and correctly installed.
3. The manual valves in the lines to be checked for proper operation. Leakages to be checked.
Drains to be opened and lines to be flushed initially.
4. Individual valves at inlet of each of the equipments to be checked.
5. All alarms, interlocks and trips to be checked as per the list below.
6. O&M Manual shall be followed for commissioning of the SWAS system.
Alarms, interlocks, trips, closed loops, which are configured in the DCS, shall be checked after pre-
commissioning and / or commissioning before start of commercial operation.
The following closed loops are to be checked in the DCS for auto control action -
The minimum checks required to be done for the pre-commissioning and commissioning of the SWAS
system shall be done as per SWAS O&M manual.
Objective
The Chemical Dosing System (HP and LP) is provided to dose respective chemicals (for pH correction and
Oxygen scavenging) in the HRSG of the CCPP. The system consists of a packaged skid mounted units
consisting of dosing tank, stirrer, dosing pumps, valves, and all other required auxiliaries and
accessories.
Operating Philosophy
The Chemical dosing tanks shall be filled with respective solutions (chemicals) manually and ensured
that the tanks are always full (with the help of level gauge). A stirrer in the tank ensures that the
solution is always homogenous and flow able. The dosing pumps are positive displacement pumps that
dose small amount of the chemical in the respective circuit. The quantity of chemical is varied based on
the requirement by varying the speed of the pump with the help of variable frequency drive. There are
2 nos. LP dosing systems for oxygen scavenging and pH dosing in LP drum, and 1 no. HP dosing system
for pH correction in HP drum.
Reference Documents
The following inputs are required for the commissioning and operation of the system.
The following checks are required to be done before commissioning of the system.
Commissioning Procedure
The following procedure describes in short the start-up sequence / procedure for the system.
1. There are three (3) types of dosing chemicals to be dosed in both the HRSGs, ie. there are 2 nos.
of LP dosing skids and 1 no. HP dosing skid. Each of the skid is provided with 2 pumps for each
HRSG.
2. The dosing lines connecting the dosing system to the various points in the plant system to be
checked for any leakages. Pipe supports to also be checked whether properly and sufficiently
installed.
3. Dosing installed at the dosing skids shall be checked thoroughly first. Before the start of the
pumps, the suction valves to be turned open manually. All the necessary checks required for the
pumps to be carried out. (Details of the procedure / check list for pumps provided separately
below). The operation of the pumps locally as well as through DCS panel to be checked.
4. The manual valves in the lines to be checked for proper operation. Leakages to be checked.
Drains to be opened and lines to be flushed initially.
5. Individual valves at inlet of each of the equipments to be checked.
6. All alarms, interlocks and trips to be checked as per the list below.
Alarms, interlocks, trips, closed loops, which are configured in the DCS, shall be checked after pre-
commissioning and / or commissioning before start of commercial operation.
The following checks are required to be done for the pre-commissioning and commissioning of the
pumps -01QLC10-AP100, 01QLC10-AP200.
The following MBOP systems / packages can be commissioned independently and shall be in operation
during the Simple as well as Combined Cycle mode of operation of the Power Plant -
Objective
The Plant Potable water system is supplied to provide / meet the potable water requirements of the
CCPP, ie. at warehouse, workshop, guard house, admin building, switchyard. The system consists of
potable water storage tank, potable water pumps (1 w + 1 s) to pump potable water from tank to
various battery limits in the CCPP with a rated flow of 4 m3/hr and pressure of 5.5barg, and all other
required auxiliaries and accessories.
Operating Philosophy
The Potable water tank shall be filled and the normal operating level shall be maintained by a flow
control valve at inlet based on level transmitter measurement in the tank. One of the potable water
pumps (installed on the tank) shall operate continuously to feed potable water at various points in the
CCPP at required pressure. A flow control valve is installed to ensure minimum flow re-circulation for
the pump. The pump shall also have protection from dry run by providing interlock with tank level
transmitter for extra low level trip.
Reference Documents
The following inputs are required for the commissioning and operation of the system.
The following checks are required to be done before commissioning of the system.
Commissioning Procedure
The following procedure describes in short the start-up sequence / procedure for the system.
1. The Potable water tank is fed with service water tapped from the existing service water
pipeline.
2. Operation of the inlet control valve station to be checked, locally and through DCS. (Details of
the procedure / check list for pneumatic control valves provided separately below).
3. The potable water line connecting the tie-in point to the new CCPP potable water tank to be
checked for any leakages. Pipe supports to also be checked whether properly and sufficiently
installed.
4. 2 nos. Potable water pumps installed at the Potable water tank shall be checked thoroughly
first. Before the start of the pumps, the suction valves to be turned open manually. All the
necessary checks required for the pumps to be carried out. (Details of the procedure / check list
Alarms, interlocks, trips, closed loops, which are configured in the DCS, shall be checked after pre-
commissioning and / or commissioning before start of commercial operation.
The following closed loops are to be checked in the DCS for auto control action -
The following checks are required to be done for the pre-commissioning and commissioning of the
pumps -00GKB10-AP110A.
The following checks are required to be done for the pre-commissioning and commissioning of the
pneumatic control valves - 00GKC10-CG001
Objective
The Plant Service water system is supplied to provide / meet all the Service water requirements of the
CCPP, ie. at warehouse, workshop, GTG 1 and 2, HRSG 1 and 2, STG, Fuel Gas Compressor. The system
consists of Service (cum Fire) water storage tank, service water pumps (1 w + 1 s) to pump service water
from tank to various battery limits in the CCPP with a rated flow of 4 m3/hr and pressure of 4 barg, and
all other required auxiliaries and accessories.
Operating Philosophy
The Service water tank shall be filled and the normal operating level shall be maintained by a flow
control valve at inlet based on level transmitter measurement in the tank. One of the Service water
pumps (installed on the tank) shall operate continuously to feed service water at various points in the
CCPP at required pressure. A flow control valve is installed to ensure minimum flow re-circulation for
the pump. The service water pump shall also have protection from dry run by providing interlock with
tank level transmitter for low level trip.
Reference Documents
The following inputs are required for the commissioning and operation of the system.
The following checks are required to be done before commissioning of the system.
The following procedure describes in short the start-up sequence / procedure for the system.
1. The Service water tank is fed with service water tapped from the existing service water pipeline.
2. Operation of the inlet control valve station to be checked, locally and through DCS. (Details of
the procedure / check list for pneumatic control valves provided separately below).
3. The service water line connecting the tie-in point to the new CCPP service water tank to be
checked for any leakages. Pipe supports to also be checked whether properly and sufficiently
installed.
4. 2 nos. Service water pumps installed at the Service water tank shall be checked thoroughly first.
Before the start of the pumps, the suction valves to be turned open manually. All the necessary
checks required for the pumps to be carried out. (Details of the procedure / check list for pumps
provided separately below). The operation of the pumps locally as well as through DCS panel to
be checked.
5. Minimum re-circulation valve installed on the pumps outlet return line shall be checked for
operation, locally and through DCS. (Details of the procedure / check list for pneumatic control
valves provided separately below).
6. The calibration of the flow transmitters to be checked and connection to the DCS to be ensured.
7. The service water piping to various points in the plant to be checked for leakages and supports.
8. The manual valves in the lines to be checked for proper operation. Leakages to be checked.
Drains to be opened and lines to be flushed.
9. Individual valves at inlet of each of the equipments to be checked.
10. All alarms, interlocks and trips to be checked as per the list below.
Alarms, interlocks, trips, closed loops, which are configured in the DCS, shall be checked after pre-
commissioning and / or commissioning before start of commercial operation.
The following checks are required to be done for the pre-commissioning and commissioning of the
pumps -00SGA10-AP010A.
The following checks are required to be done for the pre-commissioning and commissioning of the
pneumatic control valves - 00PCB10-CG001
Objective
The Fire Fighting System is provided as per statutory requirements of the plant. The system consists of
fire hydrant system, sprinklers, smoke detectors, deluge system, CO 2 extinguishers, and all other
required auxiliaries and accessories. This system is operated by a dedicated PLC based control panel and
signals are provided to plant DCS through Modbus communication only for monitoring purpose.
Operating Philosophy
A separate fire control panel shall be provided for monitoring and operation of the fire fighting system
for the plant, the details of which are presented in another specific document related to fire fighting
system.
The details of the I/P addresses and various I/Os from the Fire fighting system panel to the DCS shall be
indicated separately in document related to Fire detection Panel and Detector datasheet - .
The O&M manual of the Fire Fighting system shall provide the guidelines for the start-up, pre-
commissioning, checks, commissioning procedure for the same. The OEM supplier shall provide
assistance and guidance for the commissioning of this system.
The following inputs are required for the commissioning and operation of the system.
Objective
A nitrogen purge system is provided in the CCPP for purging requirement of all equipments in the plant
and for storage of the equipments for longer durations. The system consists of a nitrogen bottle storage
rack, pressure regulators, and all other required auxiliaries and accessories.
Operating Philosophy
The nitrogen line pressure regulating valves are self-actuated type with pressure set point as required at
the respective equipments (for purging). Pressure transmitter and gauge are provided to ensure safe
operation of nitrogen system.
The O&M manual of the Nitrogen purge system shall provide the guidelines for the start-up, pre-
commissioning, checks, commissioning procedure for the same. The OEM supplier shall provide
assistance and guidance for the commissioning of this system.
Reference Documents
The following inputs are required for the commissioning and operation of the system.
Alarms, interlocks, trips, which are configured in the DCS, shall be checked after pre-commissioning and
/ or commissioning before start of commercial operation.
The following checks are required to be done for the pre-commissioning and commissioning of the
motorized valves