00-TA_-S-41-002-001

B 15 JUL. 2015 REVISED AS MARKED H. H. KIM Y. K. OH S. W. KIM A 15 MAY 2015 ISSUE FOR APPROVAL H. H. KIM Y. K. OH S. W. KIM

REV. DATE DESCRIPTION DESIGNED CHECKED APPROVEDOWNER

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/E’S 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 B

Doc. No. : 00-TA_-S-41-002-001 PLANT START-UP & OPERATIONAL TEST PROCEDURE Rev. No. : B

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TABLE OF CONTENTS

1 INTRODUCTION ............................................................................................................................. 3

2 DEFINITIONS/ABBREVIATIONS ................................................................................................ 4

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

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

5 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)


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1 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 multi-cylinder, 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 once-through 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 start-up/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.


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2 DEFINITIONS/ABBREVIATIONS

APS Auto Plant Start-up

AVR Auto Voltage Regulator

BCP Boiler Circulation Pump

BMCR Boiler Maximum Continuous Rating

BMS Burner Management System

BOP Balance of Plant

CCCW Closed Circuit Cooling Water

CCR Central Control Room

DCS Distributed Control System

DEH Digital Electro-Hydraulic

DFO Distillate Fuel Oil

EOST Electrical Overspeed Test

ESD Emergency Shutdown

FCB Fast Cut Back

FDF Forced Draft Fan

FGD Flue Gas Desulfurization

FWH Feed Water Heater

GRF Gas Recirculation Fan

GV Governor Valve

HCO Heavy Crude Oil

HFO Heavy Fuel Oil

HMI Human Machine Interface

ICV Intercept Control Valve

IDF Induced Draft Fan

MCWP Main Cooling Water Pump

MFT Master Fuel Trip

MSV Main Stop Valve

OPC Overspeed Protection Controller

RAH Regenerative Air Heater

RO Reverse Osmosis

RSV Reheat Stop Valve

SAH Steam Air Heater

SGR Separate Gas Recirculation

STG Steam Turbine Generator

TCS Turbine Control System

TPS Turbine Protection System

TMCR Turbine Maximum Continuous Rating

UCC Unit Coordinate Control

VWO Valve Wide Open

WS Water Separator

WSDH Water Separator Drain Header


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3 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.


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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 Particulars

1. SITE AMBIENT DATA

1.1 Site location Jeddah south – approximately 70 km South of Jeddah on the Red Sea coast

1.2 Site elevation (above sea level) m 3.6 (not less than)

Design ambient conditions (Site rating):

1.3 Design ambient pressure mbar 1013

1.4 Design ambient temperature (dry bulb) 40°C (for Performance Guarantee)

1.5 Design relative humidity % 30

Ambient temperature (dry bulb):

1.6 Highest maximum (recorded) °C 50

1.7 Maximum yearly average °C 35

1.8 Maximum daily average °C 35

1.9 Design maximum temperature °C 50

1.10 Max. metal temperature under the sun °C 85

1.11 Lowest minimum (recorded) °C 3

1.12 Design minimum temperature °C 5

Relative humidity:

1.13 Maximum (recorded at 40°C) % 100

1.14 Minimum % 5


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Item No Description Particulars

1.15 Yearly average % 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

Basic Wind Speed

m/s

m/s

40

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


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4 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

a 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)

b performance of the governing system and protective devices


c grid compliance testing including MVAr capability, frequency response at designated rates for remote load despatch and AVR testing


d demonstration of steam temperature and pressure characteristics at various loads, as shown in the heat balances (except for those included in the guarantees)


e unit load control tests Plant Start-up and Operational Test (OPT-002)

f very hot start-up Plant Start-up and Operational Test (OPT-003)

g hot start-up Plant Start-up and Operational Test (OPT-003)

h Warm hot start-up Plant Start-up and Operational Test (OPT-003)

i cold start-up Plant Start-up and Operational Test (OPT-003)

j load rejection tests Plant Start-up and Operational Test (OPT-004)


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k 20 per cent load rejection test (MSL) Plant Start-up and Operational Test (OPT-004)

l 50 per cent load rejection test Plant Start-up and Operational Test (OPT-004)

m 75 per cent load rejection test Plant Start-up and Operational Test (OPT-004)

n 100 per cent load rejection test Plant Start-up and Operational Test (OPT-004)

o unit run back tests Plant Start-up and Operational Test (OPT-005)

p MCWP runback Plant Start-up and Operational Test (OPT-005)

q BFP runback Plant Start-up and Operational Test (OPT-005)

r BCP runback Plant Start-up and Operational Test (OPT-005)

s CEP runback Plant Start-up and Operational Test (OPT-005)

t ID fan runback Plant Start-up and Operational Test (OPT-005)

u FD fan runback Plant Start-up and Operational Test (OPT-005)

v Air heater runback Plant Start-up and Operational Test (OPT-005)

w Load limitation on loss of HFO pump Plant Start-up and Operational Test (OPT-005)

x Loss of GR fan demonstration Plant Start-up and Operational Test (OPT-005)

y fast cut back test Plant Start-up and Operational Test (OPT-004)

z minimum continuous load operation Plant Start-up and Operational Test (OPT-002)


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aa top heater out of service demonstration Plant Start-up and Operational Test (OPT-008)

bb one (1) HP heater and one (1) LP heater out of service demonstration


cc safe shut down demonstration Plant Start-up and Operational Test (OPT-003)

dd automatic shut down sequence demonstration Plant Start-up and Operational Test (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.


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5 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)


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APPENDIX A

STEAM TURBINE OVERSPEED TRIP TEST PROCEDURE (OPT-001)



PROJECT


ENGINEER

CONTRACTOR

SUBCONTRACTOR


N/A



DOCUMENT TITLE

ST NO-LOAD & OVERSPEED TRIP TEST PROCEDURE


31121106/00 OPT-001 15 B

Doc. No. : OPT-001 ST NO-LOAD & OVERSPEED TRIP TEST PROCEDURE Rev. No. : B

Page 2 of 15

CONTENTS

1. OBJECTIVE ...................................................................................................................................... 3

2. PREREQUISITES ............................................................................................................................. 3

3. SAFETY/PRECAUTION ................................................................................................................. 4

4. TEST STEP ........................................................................................................................................ 4

5. TEST ACCEPTANCE EVALUATION ............................................................................................ 9


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1. 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.


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(8) Establish the temporary communication between Control Room and Turbine local.

3. SAFETY/PRECAUTION

(1) 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.

(2) 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.

4. 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

B


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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%).

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"

(2) 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.



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. Select the "VARIABLE" or "FIX".


"FIX": The speed is simulated at 3,996 rpm (111 %).

g. Confirm "OPERATE" indication becomes red when the turbine speed is simulated at 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".

(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 6 of 15

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 7 of 15

(5) 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. Confirm the turbine speed starts to increase, and carefully monitor the following during speed up.


All bearing metal and drain oil temperatures



d. Announce the turbine speed every 50 rpm during speed up to alert all attending personnel.

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.

(6) 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. Select the "VARIABLE" or "FIX".


"FIX": The speed is simulated at 3,852 rpm (107%).

d. Confirm "OPERATE" indication becomes red when the turbine speed is simulated at 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. Select the "VARIABLE" or "FIX".

"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 8 of 15

(LOAD)" procedure.

(7) 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. Confirm the turbine speed starts to increase, and carefully monitor the following during speed up.


Bearing metal and drain oil temperature



e. Announce the turbine speed every 50 rpm during speed up to alert all attending personnel.

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.

(8) TRIP SV TEST

a. Select the "TRIP SV TEST" button on the TURBINE PROTECTION TEST OPERATION WINDOW screen.



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 9 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

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

% rpm

1 EOST Module Test and Function Test

2

2.1 Main EOST (Set: 110%) ≤ 110 ≤ 3,960

2.2 Back-up EOST (Set: 111%) ≤ 111 ≤ 3,996

3

3.1 Lower Limit ( < -6%) 94 3,384 +0-10

3.1 Upper Limit ( > +6%) 106 3,816 +10-0

4 OPC Module Test (Load/Speed) Unbalance 60%

5 OPC Off-Load Actual Test (107%) 107 3,852 +10-10

Governor Speed Control Range

Overspeed Trip Test (Actual)

Design ValueNo. Setting Items Results Remarks

1 of 2 (JSTPP-I) OPT-001

A409642

텍스트 상자

Attachment #1

Comments:


Attachment B:

... ~ 8 DATE : ell

..0 p ~ 0. s ... 3.2: NO-LOAD & EOST TEST SCHEDULE (WARM MODE)

' I I

-1000 625

r£1 9 lOl :( 12 ~ 3,600 rpm

~ 2 8 I I

~ -800 ~ 500 400 3600

ri1 ~ ~ I 50% (350 MW) ~ :::> P-. :::> ri1 u ~ P-.

~ ri1 14

~ -600 ri1 375 :::> 300. ~ 2700 ~ 0 360 rpm/min

~ ~ ri1 ri1 ri1 z 20% (140MW) U) ri1 z .......

7 Hrs or More 25% (175 MW) ~ z ::r: ........ j:Q

r£1 -400 ri1 250 ~ 200.0 ~ 1800' RH STEAM > 400 oc

Q ~ 6 z ri1 ~ 0 z u .......

-200 j:Q 125 100.0 900. ~ 4

~ 500 rpm 3 7

13 0 0 0 0

5

~ TIME (O'CLOCK) A 1 2 3 5 7 9 10 11 12 13 14

ITEM~RS I

1 Turbine Start Up (Wann Mode) ~ 2 Reached 3,600 rpm ~

COPY TO 3 Initial Synchronization s 4 Ini tial Load Operation 0

5 Valve Transfer CJ

6 Heat Soak Operation before EOST (7 hours or more)

7 Unit Off Line L::..

8 Overspeed Trip Test (EOST) Module Test p 9 Overspeed Trip Test (M/B EOST) Actual c::::=J

10 No Load Test (Govemor Upper/Lower Limit) [::J

11 OPC Module Test (Speed/Load) r:::::=J

12 OPC Actual Test c:= 13 Re-synchronization ~ 14 Load up to 25% (1 75 MW)

PM060-921 00-3063 Page II

A409642

텍스트 상자

Attachment #2 - Turbine no-Load and Overspeed Test Schedule

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I TURBINESPEED I I GENERATOR MW I SPEED GENERATOR r:w

0 rpm 0 MW

[ SPEEDSET I I MASTER I TCSMOifEJ

S:OT REFE11ENCE ~1ASTER DEM~ND TCS DEMAND

0 rpm 0 rpm 0.0 % 0.0 %

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0 rpm/min

[ HOLD~ ~o-] ~A~TA~~

I GOY SPEED SET I r VALVE TRANSFE!J (AUTO FOLLOW SEJ

MSv BIAS

0.0 %

I GV B ~S

0.0 % su 0.0 % SET 0 rpm

l PERMIT! Ef~o-~-~;;r-~N I AUTO I

PROTECTION TEST

PANEL

TEST PANEL

L Al's I

I OUT I -;-N-ul I COLD I WARM I HOT I

[ STRESS CONTROL I STRESS DEV m.1P

0 deg

STRESS LD'1D RATE

0.00 %'m1n

I IPR:=J

IPR SET fviSP

0 0

I ou~-T~ (VACUUM UNLOADER)

V U ~EI VACUU!Ii

0.0 0.0

[ou~l~

PMO&D-61150-0202 14

.&;;..

w ~ & s· {1)

0

~ -· 0 ~

Ro ..., {1) Vl ...... ""C § {1) ........ [/) (')

~ 9 ........

--w

~ ~ s a n

,.

A409642

사각형

A409642

사각형

A409642

텍스트 상자

Attachment #3 - Turbine Operation and Test Panel Screen

~ a 0\ '? ~ .._ a '? ....... a ~

? _. w

5: =i (f) c OJ Ci5 I

I m )>

~ z 0 c (f) -I ~ m (f)

r -I 0

I TURBINE TEST PANEL I

(CONTROl: MODEl I TRIP/RESET I r-- 52G -1

I TCS I DCS I

I TURBINE S-PEED)

SPEED

0 rpm

I MSV-LH II MSV-RH I I GV-LH I I GV-RH I

OPEN . OPEN OPEN I OPEN OPEN I OPEN

CLOSE CLOSE CLOSE I CLOSE CLOSE I CLOSE

I PARA/SEQ I

I PARA I SEQ I

I GENERATOR MW I GENERATOR J/.W

RSV-LH RSV·RH

OPEN I OPEN

CLOSE I CLOSE

0 MW

I RSV /ICV-LH I

I RESET I START I .,..,.I LJ ........ il!lol--•1

i OPEN OPEN i

CLOSE CLOSE

I

PROTECTION I OPERATION TEST I

P~NEL ! PANEL I

I ATS I OUT I IN I I COLD I WARM r_ HOT I

I RSVJICV-RHJ

I RESET I START I

I ICV-RH PosmoN I

OPEN I OPEN

CLOSE I CLOSE

I OPC -,

I TESTINI

1 ii1Neos1]

I TEST INI

I BACKUPEOST I

I TESTINI

I ACTUALEOSTJ

I TESTINI

PM060'11115D-0202 15

,., w

~ s· (1)

0 (1)

~ -· 0 ~

Ro ..., (1) CZl ....... ""C § (1) -tZl

~ (1)

~ -N

--I..J.)

~

J a (")

,.

A409642

사각형

A409642

사각형

~ a 0\ '? ~ ......... a '? v.., a ~

~ ~ -~

s:: =i (/) c IJJ (/) I

I m

~ z 0 c (/) -i c:! m (/)

r -i 0

I TURBINE PROTECTION TEST OPERATION WINDOW I

I STATUS J

I TRIP TEST CONDITION J I ABNORMAL I

SV·1,3 OPERATED

SV-2,4 OPERATED

TRIP BLOCK PRESS.

NORMAL

SENSOR DEVIATION

HIGH

TRIP SOLENOID

ABNORMAL

I MAIN EOST I I BACK UP EOST J

MAIN EOST·1 I MAIN EOST·2 I MAIN EOST-3 BACKUP EOST-1

BACKUP EOST-2

BACKUP EOST·3

I SIMPLIFIED TRIP OIL SYSTEM I

EMERGENCY TRIP OIL

DETECT SV-1,3 0) DETECT SV-2,4 \_!§?!_!_~!' ______ _

~~!L~",j

'/ tl '-/ 1---...... '""' X ·--------• TSHY:SV-3004 TSHY~.®oe : SV-3 SV-4 1

SV·2

I I

1.---...,Y. f X--------{ TSHY:sv.:Joos - - TSHY:SV-3oo7 I

T I I I

~---------------~----· I +

DRAIN

I TURBINE CONDITION I

TURBINE TRIPPED

TURBINE RESET

[fRIP TEST sv SELECTION I

SV-1 I SV-2

SV-3 I SV-4

I TRIP sv TEST I I VAC/BRG OIL TIIIP 'IBT I

B B [:WN EOST TRIP tisi] E::STTRPlUT -]

BB PM060-6115D-0202 16

"'"' 1M

~ & ~-

~ ~ ~ ..... 0 ~

Ro ...., (!)

~ ""C

[ CZl

~ g b ---~

I a n

,.

A409642

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A409642

사각형


of 136

APPENDIX B

UNIT STABILITY RUN TEST PROCEDURE (OPT-002)



PROJECT


ENGINEER

CONTRACTOR

SUBCONTRACTOR


N/A



DOCUMENT TITLE

UNIT STABILITY RUN TEST PROCEDURE


31121106/00 OPT-002 8 B

Doc. No. : OPT-002 UNIT STABILITY RUN TEST PROCEDURE Rev. No. : B

Page 2 of 8

CONTENTS

1. OBJECTIVE ...................................................................................................................................... 3

2. PREREQUISITES ............................................................................................................................. 3


4. GENERAL TEST OUTLINE ........................................................................................................... 4

5. TEST ACCEPTANCE ....................................................................................................................... 4

6. ATTACHMENT ................................................................................................................................. 5


Page 3 of 8

1. 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. minimum continuous load operation

2. PREREQUISITES

(1) All Controls of respective Unit are switched to automatic mode. The Power Unit is ready to start the boiler and the Steam Turbine Generator.

(2) The turbine auxiliary systems are in operation and no major deficiencies are preventing the normal operation of the systems.

(3) All protective and monitoring instruments are properly lined up. (4) There is no abnormality on boiler operation condition. (5) There is no abnormality on generator operation condition. (6) There is no abnormality on major BOP system operation condition.


(1) Safety





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

B

B


Page 4 of 8

appropriate action.



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.

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.

4. 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 5 of 8

6. ATTACHMENT

Unit Stability Run Test Program Sheet.

Unit Stability Run Test Program (OPT-002)

Unit No :

STG ( )MS

PressureMS Temp.

HRHPressure

HRH Temp

1 on turning gear ST kept on turning gear Turning gear operation

2 Start 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




- Unloading Rate





- Unloading Rate





- Unloading Rate

Keep the ST at MSL for 30 mins. No unit trip




- Unloading Rate

Acceptance Criteria

Test Record

5ST load downto 50% load

Remarks

3 ST TMCR


DescriptionSeq. no. Operation Mode



(MSL)



Unit No :

STG ( )MS

PressureMS Temp.

HRHPressure

HRH TempAcceptance Criteria

Test Record

RemarksDescriptionSeq. no. Operation Mode





- Loading Rate





- Loading Rate





- Loading Rate





- Loading Rate

Keep the ST at VWO for 30 mins. No unit trip




13 Unit Shutdown ST Shutdown No unit trip

11ST load up

to TMCR load

9ST load upto 50% load



12ST load up

to VWO



Unit No :

STG ( )MS

PressureMS Temp.

HRHPressure

HRH TempAcceptance Criteria

Test Record

RemarksDescriptionSeq. no. Operation Mode

Comments:



of 136

APPENDIX C

UNIT START-UP & SHUTDOWN TEST PROCEDURE (OPT-003)



PROJECT


ENGINEER

CONTRACTOR

SUBCONTRACTOR


N/A



DOCUMENT TITLE

START-UP & SHUTDOWN TEST PROCEDURE


31121106/00 OPT-003 14 B

Doc. No. : OPT-003 START-UP & SHUTDOWN TEST PROCEDURE Rev. No. : B

Page 2 of 14

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 3 of 14

1. 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) Safety







(2) Precautions Particular attention should be given to normal operating conditions of the system, its equipment,

B

B


Page 4 of 14

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. All activities required to carry out this test will be done in close co-ordination with the Load Dispatch Center (LDC)

b. The vibration of the steam turbine and the generator should be monitored closely during this operation.

c. System Walk-down and Area Preparation should be done before the test.

d. Verify that all site personnel have been made aware that the test is proceeding.

e. Verify that the Plant Emergency response plan is prepared and ready to be activated.

f. Restrict access around the equipment to critical personnel.

g. All work inside the power block during testing must be approved by the Start-up Manager or Lead Commissioning Engineer.

h. Off-limit areas are clearly marked.

4. 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 5 of 14

4.4 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.


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

B

0.0

100.0

200.0

300.0

400.0

500.0

600.0

0

50

100

150

200

250

300

0 60 120 180 240 300 360 420 480 540 600

Tempe

rature ( de

g C ), Steam Flow ( ton*

10/hr )

Speed (%

), Load

(%), Steam Press (b

arg), O

il Flow

(T/H

)

Operation Time (Min.)

COLD START‐UP CURVE

Light Off

PROJECT : Jeddah South Thermal Power Plant

Revised on 2015/02/09

FOR INFORMATION ONLY

ST Speed

ST Load

HRH Steam Temp

HP Steam Flow

HP Steam Press

Note 1. The Start‐up Curve can be changed depending on site conditionNote 2. The stabilizing time to meet the water and steam purity is not considered and the time shall be varied depending on site condition.

ST Roll Off

HRH Steam Flow

HRH Steam Press

Synchronization

Heat Soak @ 2400 RPM

3600 RPM

Rub Check @ 500 RPM

HP Steam Temp

DFO Flow

HFO Flow

A409642

텍스트 상자

Attachment #1 - Startup & Shutdown Curves

0.0

100.0

200.0

300.0

400.0

500.0

600.0

0

50

100

150

200

250

300

0 60 120 180 240 300 360 420

Tempe

rature ( de


10/hr )

Speed (%

), Load

(%), Steam Press (b

arg), O

il Flow

(T/H

)


WARM START‐UP CURVE

Light Off




ST Speed

ST Load

HRH Steam Temp

HP Steam Flow

HP Steam Press


ST Roll Off Synchronization


3600 RPM

Rub Check @ 500 RPM

HP Steam Temp

HFO Flow



HRH Steam Flow

HRH Steam Press

DFO Flow

0.0

100.0

200.0

300.0

400.0

500.0

600.0

0

50

100

150

200

250

300

0 60 120 180 240

Tempe

rature ( de


10/hr )

Speed (%

), Load

(%), Steam Press (b

arg), O

il Flow

(T/H

)


HOT START‐UP CURVE

Light Off




ST Speed

ST Load

HRH Steam Temp

HP Steam Flow

HP Steam Press


ST Roll Off

HRH Steam Flow

HRH Steam Press

Synchronization

3600 RPM

Rub Check @ 500 RPM

HP Steam Temp


DFO Flow

HFO Flow

0.0

100.0

200.0

300.0

400.0

500.0

600.0

0

50

100

150

200

250

300

-20 0 20 40 60 80 100 120 140

Tempe

rature ( de


10/hr )

Load

(%), Steam Press (b

arg)


SHUTDOWN CURVE

Start to shutdown


First made on 2015/02/09


ST Load

HRH Steam Temp

HP Steam FlowHP Steam Press

Note 1. The Shutdown Curve can be changed depending on site condition

HRH Steam Flow

HRH Steam Press

HP Steam Temp

GCB Open

Unit Startup and Shutdown Test Sheet (OPT-003)

Unit Number ( )

1 See note 2, 3

2

3

4

5

7

8

9 Unspecified

Note 1. This test will be done after summer operation.

Comments:

ST Admission

Auto SYNC & Loading to 10% & Hold

Loading to TMCR

Check Items Test Record Remarks

≤ 540 min

Cold Start-up

Stop (Cooled down)

See note 4

Stabilizing

Shutdown

Startup (Cold)

ST Loading up to 20% & Hold

Boiler - Steam Turbine

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 accordancewith 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

Seq. no. Desired levelUnit Operation Mode

Time from Start to TMCR

Classification Shutdown Time ST HP Metal Temperature

Cold Start More than 72 hrs ≤ 40% of full load value,

HP Separator < 100 oC

Warm Start 10 hrs ≤ T ≤ 72 hrs40% ≤ & ≤ 80% of full load value,


Hot Start 2 hrs ≤ T ≤ 10 hrs ≥ 80% of full load value

Hot Start Less than 2 hrs ≥ 80% of full load value


A409642

텍스트 상자

Attachment #2


Unit Number ( )

1 See note 2, 3

2

3

4

5

5

6

7 Unspecified


Comments:

RemarksBoiler - Steam Turbine

Seq. no.Unit Operation Mode

Check Items Desired level Test Record

Warm Start-up

Stop

Startup (Warm)

Time from Start to TMCR ≤ 360 min See note 4




Shutdown

ST Admission



Loading to TMCR

Stabilizing










Unit Number ( )

1 See note2, 3

2

3

4

5

5

6

7 Unspecified

1 See note2, 3

2

3

4

5

5

6

7 Unspecified




Hot Start-up

Stop

Startup (Hot)

Time from Start to TMCR ≤ 180 min See note 4

ST Admission



Loading to TMCR

Stabilizing

Shutdown

Very Hot Start-up

Stop

Startup (Hot)

Time from Start to TMCR Unspecified See note 4

ST Admission



Loading to TMCR

Stabilizing

Shutdown



Unit Number ( )




Note 1. This test will be done before summer operation.

Comments:













Unit Number ( )

1

2

3 Unspecified

Comments:

Desired level Test Record

Stabilizing


Shutdown

Startup to TMCR


Check Items


Shutdown










of 136

APPENDIX D

UNIT LOAD REJECTION TEST PROCEDURE (OPT-004)



PROJECT


ENGINEER

CONTRACTOR

SUBCONTRACTOR


N/A



DOCUMENT TITLE

LOAD REJECTION TEST PROCEDURE


31121106/00 OPT-004 10 B

Doc. No. : OPT-004 LOAD REJECTION TEST PROCEDURE Rev. No. : B

Page 2 of 10

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 3 of 10

1. 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.

Clause 11.2.4 Test on completion

j. load rejection tests

k. 20 per cent load rejection test (MSL)

l. 50 per cent load rejection test

m. 75 per cent load rejection test

n. 100 per cent load rejection test

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 GV’s and ICV’s 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. Protective device test has been performed satisfactorily.

(2) 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 4 of 10

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)


(1) Safety












B


Page 5 of 10





4. TEST STEP

After confirmation of the unit readiness to dump the load, proceed as follows;

(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;

(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.

6. 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 6 of 10

(5) ICV#1/#2/#3/#4 actuator position

(6) OPC solenoid valve position

(7) Generator voltage

(8) Generator current

(9) Power factor

(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

Load Rejection Test Sheets (OPT-004)

Unit No :

1 Startup See note 1

2 Auto SYNC & Min. Load - 10% TMCR See note 2

3 Loading to 20% TMCR

4 Partial Load Run(20%) StabilizationSee note 3MW :

Load Rejection (Partial load)

- Turbine Over Speed ≤ 110%

- Steam Turbine May or May not Trip

- Boilerno Trip.FCB to 20% load

See note 5

6 ST Re-start to FSNL during coasting down

7 Auto SYNC & Min. Load


9 Partial Load Run (50% TMCR) StabilizationSee note 3MW :





See note 5


RemarksDesired levelRunning

Time (min)

10 Load Rejection (50% Load Rejection)

Load Rejection (20% Load Rejection)5

Test RecordCheck ItemsUnit Operation ModeSeq. no.



Unit No :


Time (min)Test RecordCheck ItemsUnit Operation ModeSeq. no.



14 Partial Load Run (75% TMCR) StabilizationSee note 3MW :





See note 5



18 Loading to TMCR

19 TMCR Run StabilizationSee note 4MW :

Load Rejection (Full load)




See note 5

21 ST coasting down

22 ST Shutdown

Test Duration(Net) 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.

15 Load Rejection (75% Load Rejection)

20 Load Rejection (100% Full Load Rejection)

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.

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.



Unit No :


Time (min)Test RecordCheck ItemsUnit Operation ModeSeq. no.

Comments:



of 136

APPENDIX E

UNIT RUNBACK TEST PROCEDURE (OPT-005)



PROJECT


ENGINEER

CONTRACTOR

SUBCONTRACTOR


N/A



DOCUMENT TITLE

UNIT RUNBACK TEST PROCEDURE


31121106/00 OPT-005 16 B

Doc. No. : OPT-005 UNIT RUNBACK TEST PROCEDURE Rev. No. : B

Page 2 of 16

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 3 of 16

1. 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. Loss of GR fan demonstration

2. PREREQUISITES

(1) The Steam Turbine operates with more than 75% TMCR load. (2) The turbine auxiliary systems are in operation and no major deficiencies are preventing the

normal operation of the systems. (3) All protective and monitoring instruments are properly lined up. (4) There is no abnormality on boiler operation condition. (5) There is no abnormality on generator operation condition. (6) There is no abnormality on major BOP system operation condition.


(1) Safety



B

B


Page 4 of 16














4. TEST STEP & ACCEPTANCE EVALUATION

4.1 MCWP RUNBACK

(1) The Steam Turbine operates with more than 75% TMCR load.

(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 5 of 16

4.2 BFP RUNBACK


(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


(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.


(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


(2) Trip one of the ID Fans.




Page 6 of 16

(5) 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


(2) Trip one of the FD Fans.



(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


(2) Trip one of the Regenerative Air Heaters.



(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


(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.



Page 7 of 16

(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


(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. ATTACHMENTS

6.1 UNIT RUN BACK TEST SHEETS

B

Unit Run Back Test Sheets (OPT-005) - Main Cooling Water Pump Runback

Unit No :

1 Startup / Auto SYNC & Min. Load

2 Loading up ST more than 75% TMCR

3 Run ST for stabilisation See note 2

Unit Run Back

- Steam Turbine More than 60% TMCR See note 3

- Boiler no Trip.

5 ST Load up for other tests or ST shutdown.




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:


Time (min)

Trip one of MCWPs4

Test RecordCheck ItemsUnit Operation ModeSeq. no.


Unit Run Back Test Sheets (OPT-005) - BFP Runback

Unit No :




Unit Run Back

- Steam Turbine around 40% TMCR

- BoilerRunback to 40%BMCR





Comments:

Remarks

4 Trip one of BFPs

Seq. no. Unit Operation ModeRunning

Time (min)Check Items Desired level Test Record


Unit Run Back Test Sheets (OPT-005) - BCP Runback - Test Not Necessary

Unit No :

Comments:

RemarksSeq. no. Unit Operation ModeRunning



Unit Run Back Test Sheets (OPT-005) - CEP Runback

Unit No :




If standby CEP cut in

- Steam Turbine No change

- Boiler No change

If standby CEP can't cut in


- Boiler Runback to 40% BMCR





Comments:

Check Items Desired level Test Record Remarks

4 Trip one of CEPs

5 Trip one of CEPs


Time (min)


Unit Run Back Test Sheets (OPT-005) - ID Fan Runback

Unit No :




Unit Run Back







Comments:

Remarks

4 Trip one of ID Fans




Unit Run Back Test Sheets (OPT-005) - FD Fan Runback

Unit No :




Unit Run Back







Comments:

Remarks

4 Trip one of FD Fans




Unit Run Back Test Sheets (OPT-005) - Air Heater Runback

Unit No :




Unit Run Back







Comments:

Remarks

4 Trip one of Air Heaters




Unit Run Back Test Sheets (OPT-005) - Load Limitation on Loss of One HFO Pump

Unit No :




If standby main fuel oil pump cut in

- Steam Turbine No change

- Boiler No change

If standby main fuel oil pump can't cut in







Comments:

Test Record Remarks

4 Trip one of Main Fuel Oil Pumps

5 Trip one of Main Fuel Oil Pumps


Time (min)Check Items Desired level


Unit Run Back Test Sheets (OPT-005) - Loss of GR Fan Demonstration

Unit No :




Unit Run Back

- Steam Turbine No criteria

- Boiler No criteria

- Hot RH steam temperature No criteria

- NOx at CEMS within the guarantee value





Comments:

Remarks

Trip one GR Fans4





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APPENDIX F

GRID CODE COMPLIANCE TEST PROCEDURE (OPT-006)

B 15 JUL. 2015 REVISED AS MARKED H. H. KIM Y. K. OH S. W. KIM

A 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



DOCUMENT TITLE

GRID CODE TEST PROCEDURE


31121106/00 OPT-006 34 B

Doc. No. : OPT-006 GRID CODE TEST PROCEDURE Rev. No. : B

Page 2 of 34

CONTENTS

1. OBJECTIVE ...................................................................................................................................... 3

2. PREREQUISITES ............................................................................................................................. 3


4. GRID CODE COMPLIANCE AND TEST EQUIPMENT ........................................................... 5

5. GRID CODE CONSULTATION WITH THE TRANSMISSION AUTHORITY ....................... 7

6. ROLE OF SEC/TRANSMISSION AUTHORITY ......................................................................... 7

7. RESPONSIBILITIES OF HHI ........................................................................................................ 7

8. 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 3 of 34

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. Clause 11.2.4 Test on completion

c. grid compliance testing including MVAr capability, frequency response at designated rates for remote load despatch and AVR testing

2. PREREQUISITES





(1) Safety






B

B


Page 4 of 34












Page 5 of 34

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

Serial Number ST#01 : 1600, ST#02 : 1599, ST#03 : 1598, ST#04 : 1597

RPM 3600 RPM

ST Generator

Manufacturer MITSUBISHI ELECTRIC CORPORATION

Type MBK

Serial Number

STG#01 : 13JUGC01, STG#02 : 13JUGB01, STG#03 : 13JUGA01, STG#04 : 13JUG901

Rating 891000 kVA

Field Current 19.785 kA

Field Voltage 26000 Volts

Power Factor 0.85

Excitation System

Manufacturer MITSUBISHI ELECTRIC CORPORATION

Type OIL

PPT Ratings STG 26kV - 850V, 6830kVA

Transformer Impedance Z = 11%


Page 6 of 34

GSUT

Manufacturer HITACHI, JAPAN

Rating 904,000 kVA

Voltage 380/26 kV

Cooling ODAF@50 degree C

Impedance 14@904MVA base


Page 7 of 34

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).

b. Test plan schedule/plan development

c. Conduct the Grid Code tests

d. Testing and final report follow-up meeting

6. 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.

7. 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 8 of 34

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


Page 9 of 34

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%


Page 10 of 34

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 generator-excitation-voltage regulator systems

3) Power System Stabilizer Test and Field Tuning

Review results of Power System Stabilizer (PSS) tuning and field re-tuning (as needed)

4) Over-excited Reactive Power Test

Confirm over-excited reactive power capability of generators and excitation systems

5) Under-excited Reactive Power Test

Confirm under-excited reactive power capability of generators and excitation systems

6) UEL Test Confirmation of Underexcited Limiter (UEL) function

7) OEL Test Confirmation of Overexcited Limiter (OEL) function

9.2 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


Page 11 of 34

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


Page 12 of 34

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.


Page 13 of 34

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:


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


Page 14 of 34

10.2.6 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.


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.


Page 15 of 34

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 IEEE-421.5 described Model “PSS2B”. (to be updated later)

10.3.5 Special Protection Points:

All generator protections should be in service with normal settings.


Successful completion of this test is determined by demonstration of stable operation for PSS gain = 3 times nominal value.


Page 16 of 34

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


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.


Page 17 of 34



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.




Page 18 of 34

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. Generator cold gas temperature



a. Field current

b. Field voltage

c. Stator voltage

d. Generator MW and MVAr

e. Generator cold gas temperature

f. Selected generator RTD temperatures

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


Page 19 of 34

e. Power system stabilizer may be in or out of service as appropriate for prevailing grid conditions



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.




Page 20 of 34

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



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.


Page 21 of 34


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. MEC700 excitation system and PSS is commissioned and in service.

f. Generator cooling temperatures, hydrogen purity, hydrogen temperature and pressure are within Mitsubishi (MHI/MELCO) recommended ranges.

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.


Page 22 of 34

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


Page 23 of 34

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;


b. Field voltage

c. Field current

d. Generator MW

e. Generator MVAr

f. OEL active boolean



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.


Page 24 of 34

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

c. MEC700 excitation system and PSS is commissioned and in service.

d. Generator cooling temperatures, hydrogen purity, hydrogen temperature and pressure are within Mitsubishi (MHI/MELCO) recommended ranges.

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 set-point

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.


Page 25 of 34

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. Start trend recording.

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.


Page 26 of 34

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.


Page 27 of 34


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 turbine-generator. 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. Start trend recording.

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


Page 28 of 34

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

MW Hz sec. sec. sec.

1 80% TMCR 1 0.05 0 10 60

2 80% TMCR 1 0.1 0 10 60

3 80% TMCR 2 0.1 10 10 60

4 90% TMCR 1 0.05 0 10 60

5 90% TMCR 1 0.1 0 10 60

6 90% TMCR 2 0.1 10 10 60

7 TMCR 1 0.05 0 10 60

8 TMCR 1 0.1 0 10 60

9 TMCR 2 0.1 10 10 60

10 80% TMCR 1 0.1 0 0 600

11 95% TMCR 1 0.1 0 0 600

12 TMCR 1 0.1 0 0 600


Page 29 of 34

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


d. Steam turbine exhaust pressure


Steam Turbine Signals

a. Turbine shaft speed

b. Generator MW


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.


Page 30 of 34


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. Start trend recording.

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


Page 31 of 34

Table 2 Test Conditions and Amplitudes

Test

Initial New Load

Power Setting

% TMCR % TMCR

1 63 68

2 68 74

3 74 80

4 80 87

5 87 94

6 94 100

7 100 94

8 94 87

9 87 80

10 80 74

11 74 68

12 68 63


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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.


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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.


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12. REFERENCE DOCUMENTS

The Saudi Arabian Grid Code, Issue: 01, Rev.: 00, May 2007


of 136

APPENDIX G

ISLAND OPERATION TEST PROCEDURE (OPT-007)



PROJECT


ENGINEER

CONTRACTOR

SUBCONTRACTOR


N/A



DOCUMENT TITLE

ISLAND OPERATION TEST PROCEDURE


31121106/00 OPT-007 11 B

Doc. No. : OPT-007 ISLAND OPERATION TEST PROCEDURE Rev. No. : B

Page 2 of 11

CONTENTS

1. OBJECTIVE ...................................................................................................................................... 3

2. PREREQUISITES ............................................................................................................................. 3


4. TEST STEP ........................................................................................................................................ 4


6. ATTACHMENTS .............................................................................................................................. 5


Page 3 of 11

1. 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) All Controls of respective Power Unit are switched to automatic mode. The Steam Turbine operates with more than 75% TMCR load.




(1) Safety







B

B


Page 4 of 11










4. 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 5 of 11


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.

6. ATTACHMENTS

Attachment #1 - Island Operation Test Sheets Attachment #2 - Island Operation Concept Presentation Attachment #3 - Single Line Diagrams for Power Station and Substation.

B

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

1 STG in operation at more than 75% TMCR. Operating Condition Normal

2 Open both 380kV High Voltage line breakers of the ST simultaneously. Line Breakers Open

3 ST will follow the house load. ST House load operation Note 2


Note 2. Island Operation will be maximum one(1) hour.

Comments:

Seq. no. Plant Unit Operation Mode Check Items Acceptance Criteria Test Result Remarks


A409642

텍스트 상자

Attachment #1

* Readiness1. Close communication among power plant, substation and

grid (LDC/TSP) 2. The ST is running in normal condition.

* Island test1. Open both 380 kV line breakers (C4.B & C4.C) at the same

time2. 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.

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)

(JSTPP-I) Unit Island Operation Test Concept (OPT-007)

Island Mode Test Restoration After Island Mode

52G

C4

AL-ADELCKT-1(C-8)

MHRCKT-1(C-3)

ST01

UAT01 CAT01

GSUT01

C3

52G

C5

HHR-1CKT-1(C-11)

ST02

UAT02CAT02

GSUT02

52G

C7

AL-ADELCKT-2(C-3)

ST03

CAT03

GSUT03

C6

52G

C8

HHR-1CKT-2(C-9)

ST04

UAT04CAT04

GSUT04

MHRCKT-2(C-8)

UAT03

C6.AC6.BC6.C

C3.A

C3.BC3.C

C4.AC4.BC4.C

C5.AC5.BC5.C

C7.AC7.BC7.C

C8.AC8.BC8.C

A409642

텍스트 상자

Attachment #2

HHI-119027

다각형 선


of 136

APPENDIX H

HEATER OUT-OF-SERVICE TEST PROCEDURE (OPT-008)



PROJECT


ENGINEER

CONTRACTOR

SUBCONTRACTOR


N/A



DOCUMENT TITLE

HEATER OUT-OF-SERVICE DEMONSTRATION PROCEDURE


31121106/00 OPT-008 9 B

Doc. No. : OPT-008 HEATER OUT-OF-SERVICE DEMONSTRATION PROCEDURE Rev. No. : B

Page 2 of 9

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 3 of 9

1. 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) The Steam Turbine operates at TMCR load. (2) The turbine auxiliary systems are in operation and no major deficiencies are preventing the

normal operation of the systems. (3) All protective and monitoring instruments are properly lined up. (4) There is no abnormality on boiler operation condition. (5) There is no abnormality on heater operation condition. (6) There is no abnormality on major BOP system operation condition.


(1) Safety






f. Remove all welding leads, electrical cords and air hoses from the piping, to prevent

B

B


Page 4 of 9

accidental releases of energy as a result of the pipe movements pinching a wire or hose.










4. TEST STEP & ACCEPTANCE EVALUATION

4.1 TOP HEATER OUT OF SERVICE DEMONSTRATION

(1) The Steam Turbine operates at TMCR load.

(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 5 of 9

4.2 ONE (1) HP & ONE (1) LP FEEDWATER HEATER OUT OF SERVICE DEMONSTRATION

(1) The Steam Turbine operates at TMCR load.

(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. ATTACHMENTS

6.1 HEATER OUT-OF-SERVICE TEST SHEETS

B

Heater Out-of-Service Demonstration Sheets (OPT-008) - Top Heater Out-of-service

Unit No :


2 Loading up ST at TMCR


4Open heater bypass MOV for external desuperheaterand HP feedwater heater #8.

5Close heating steam supply MOV for externaldesuperheater and HP feedwater heater #8.

6Close HP feedwater #8 inlet isolation MOV and thenclose external desuperheater outlet MOV

7Open heater bypass MOV for HP feedwater heater #7and HP feedwater heater #6.

8Close heating steam supply MOV for HP feedwaterheater #7 and HP feedwater heater #6.

9Close HP feedwater #6 inlet isolation MOV and thenclose HP feedwater heater #7 outlet MOV.

10Check if the steam turbine load can be maintained atTMCR

- Steam Turbine TMCR

11The top heater out of service demonstration will bedeemed successful if the steam turbine can maintainits load at TMCR in this situation





Seq. no. RemarksDesired levelRunning

Time (min)Test RecordCheck ItemsUnit Operation Mode


Heater Out-of-Service Demonstration Sheets (OPT-008) - Top Heater Out-of-service

Unit No :

Comments:


Heater Out-of-Service Demonstration Sheets (OPT-008) - One (1) HP & One (1) LP Heaters Out-of-service

Unit No :


2 Loading up ST at TMCR


4Open heater bypass MOV for external desuperheaterand HP feedwater heater #8

5Close heating steam supply MOV for externaldesuperheater and HP feedwater heater #8.

6Close HP feedwater #8 inlet isolation MOV and thenclose external desuperheater outlet MOV

7 Open heater bypass MOV for LP feedwater heater #4.

8Close heating steam supply MOV for LP feedwaterheater #4.

9Close HP feedwater #4 inlet isolation MOV and thenclose HP feedwater #4 outlet isolation MOV.

10

The one (1) HP & one (1) LP feedwater heaters out ofservice demonstration will be deemed successful if thesteam turbine does not trip and can maintain its loadas stable as possible. The actual steam turbine loadwill be noted.

- Steam Turbine Load not specified.





RemarksSeq. no. Unit Operation ModeRunning



Heater Out-of-Service Demonstration Sheets (OPT-008) - One (1) HP & One (1) LP Heaters Out-of-service

Unit No :

Comments:


00-TA_-S-41-002-001

Documents

Transcript of 00-TA_-S-41-002-001