Beruflich Dokumente
Kultur Dokumente
C
B
A
Rev
Owner
08-NOV-14
03-NOV-14
20-JAN-14
Date
D.H Han
D.H Han
D.H Han
Prepared
K.H Jung
K.H Jung
K.H Jung
Checked
J. Kim
J. Kim
J. Kim
Approved
For Comment
For Comment
For Comment
Details of Revision
Project :
T10206
UAS
DN02
UNIT
P1
KKS
Title
COMMISSIONING PROCEDURE
FOR
GENERATOR H2 & CO2 CONTROL SYSTEM
MKG
Reg. No.
810001
Rev.
C
Pages No.
Document No.
T10206-DN02-P1MKG-810001
19
Rev. C
TABLE OF CONTENTS
1.0
1.1
Objective ........................................................................................................ 4
1.2
Scope ............................................................................................................ 4
1.3
1.4
1.5
1.5.1
1.5.2
2.0
PRE-COMMISSIONING................................................................................. 6
2.1
3.0
3.1
3.2
3.3
3.4
3.5
4.0
4.1
Start-up ........................................................................................................ 16
4.2
Shutdown ..................................................................................................... 17
5.0
ATTACHMENTS.......................................................................................... 19
Attachment 5.1 Checklist for Commissioning of Valves
Attachment 5.2 P&ID
Attachment 5.3 Measurement, Alarm and Trip List
Attachment 5.4 Valve Position Status for Commissioning
Attachment 5.5 Job Safety Analysis
Attachment 5.6 Risk Assessment
Page 2 of 19
Rev. C
LIST OF ABBREVIATIONS
CCR
DCS
H2
Hydrogen
CO2
Carbon Dioxide
TCS
TE
Turbine End
CE
Collector End
PRV
Page 3 of 19
Rev. C
1.0
GENERAL INFORMATION
1.1
Objective
The purpose of this document is to provide a systematic guideline to commission Generator
H2 & CO2 Control System.
1.2
Scope
The scope of commissioning of Generator H2 & CO2 Control System covers the following
activities and associated equipment list.
1.2.1
1.2.2
SL. No.
Equipment List
Tag No.
H2 Manifold
CO2 Manifold
MKG20GH001
MKG16AZ001
Liquid Detector
MKG10AZ001
Checking the integrity & readiness of all associated piping, valves and other fittings,
instrumentation and control system.
1.2.3
1.2.4
1.2.5
1.2.6
Checking the protection and functional interlocks of electrical / mechanical equipment in the
system.
1.2.7
Checking cleanliness of the system and ensuring that it is free of any foreign material or dirt,
which may damage the equipment or impair the system functionality.
1.2.8
Trial operation of the entire system and confirming the design parameters of the system such
as flow, temperature and pressure.
1.3
Page 4 of 19
Rev. C
1.4
1.4.1
P&ID
SL. No.
Title
T10206-XG11-P1MKG-210001
1.5
System Description
1.5.1
1.5.2
H2 Gas Dryer
Hydrogen Gas Dryer Package regenerates moisture by heating with the heater in the Tower.
After regenerating, the regenerated gas joins the gate gas. The heating process in the
regeneration process heats the absorbent using the hot gas from the heater in the tower, and
the cooling process cools down the absorbent by ramifying some of the gate humid gas.
After heating or cooling the absorbent, the regenerated gas joins the gate humid gas at the
orifice and enters the operation tower through the regeneration cooler and moisture separator.
The main components are Drying Tower, Piston Control Valve, Electric Heater, Fin Cooler
and Separator, and which are operated automatically every 16 hour on the TIMER (HMI)
attached on the CONTROL PANEL.
Operation Chart
Time
1
2
(hour)
Tower A
Tower B
Operation
Regeneration (Heating)
10
11
12
13
Regeneration (Heating)
Regeneration
(Cooling)
14
15
16
Regeneration
(Cooling)
Operation
Page 5 of 19
Rev. C
2.0
PRE-COMMISSIONING
2.1
Pre-Commissioning Requirements
2.1.1
The entire system has been thoroughly checked after erection. All leaks that were
detected have been rectified.
All Valves listed in Attachment 4.5 have been functionally checked and their trial
operation is found to be satisfactory in accordance with Attachment 4.2, Commissioning
of Valves.
Electric power system has been tested, energized and available for required equipment.
All instrumentation required for control, supervision & monitoring through DCS are
available. (All instruments have been commissioned after their respective impulse lines
are properly flushed with the working fluid.)
2.1.2
Proper communication facilities like walkie-talkies, telephone, system, etc. between various
control stations and Central Control Room have been installed and checked.
2.1.3
All necessary safety precautions and measures must be followed for safe commissioning
activities.
Manual Call Points are installed at critical locations to inform the CCR in case of any fire
hazard.
Page 6 of 19
Rev. C
3.0
3.1
Commissioning Requirement
SL
No.
3.2
Description
Checked
( / X)
Remarks
Checked
( / X)
Remarks
Description
Page 7 of 19
Rev. C
SL
No.
3.3
Description
Checked
( / X)
Remarks
Checked
( / X)
Remarks
Description
Page 8 of 19
Rev. C
SL
No.
Description
Checked
( / X)
Remarks
Supply CO2 gas until the purity of CO2 in vent gas is above
90%.
Close the CO2 manifold outlet valve (MKG04AA101 (HV2946) and casing vent valve (MKG02AA110 (HV-2954)).
10
11
Page 9 of 19
Rev. C
SL
No.
Description
Checked
( / X)
Remarks
12
NOTE:
2
If the pressure of generator is below 0.35 kg/cm , the
float trap in the seal oil system is by-pass operated.
(The pressure change is monitored by the oil level of
float trap.)
- Monitor the oil level of float trap until normal operation.
(The oil level of level gauge (MKW13CL502) shall be
monitored at medium level and if oil level falls below
medium level, close bypass valve (MKW13AA104)
immediately to prevent CO2 gas from escaping.)
- Please refer to the Float Trap Operating &
Maintenance Manual. .
Supply H2 gas until the purity of H2 gas in Vent Gas is
above 90%.
13
NOTE:
- H2 Purity in generator > H2 Purity in vent gas
14
15
NOTE:
- If the pressure of generator is below approx. 0.35
2
kg/cm , the float trap in the seal oil system is by-pass
operated. (The pressure is to change by monitor the
oil level of float trap.)
Page 10 of 19
Rev. C
SL
No.
Description
Checked
( / X)
Remarks
17
18
19
20
21
22
23
Page 11 of 19
Rev. C
SL
No.
Description
Checked
( / X)
Remarks
24
25
26
27
NOTE:
- If the pressure of generator is below approx. 0.35
2
kg/cm , the float trap in the seal oil system is by-pass
operated.
(The pressure change is monitored by the oil level of
float trap.)
- Please refer to the Float Trap Operating &
Maintenance Manual. .
28
29
30
31
33
Page 12 of 19
Rev. C
SL
No.
Description
34
35
36
Purge CO2 until the purity of air in Vent Gas is above 95%.
37
38
39
Please open cover plate at both side and blowing the Inside
of generator with the air for minimum 1 hour before
assembly process of generator.
40
Checked
( / X)
Remarks
Page 13 of 19
Rev. C
3.4
Air to
CO2
CO2 to
H2
H2 Fill
Normal
Degas
H2 to
CO2
CO2 to
Air
Purge
N/A
Normal
N/A
Purge
Purge
H2 in
CO2
H2 in
Air
H2 in
Air
H2 in
Air
H2 in
CO2
90%
H2
N/A
N/A
N/A
5%
H2
Down
Right
Right
Right
Down
Down
Down
Down
Right
Right
Right
Right
Down
Down
Partially
Open
Partially
Open
Closed
Closed
Full
Open
Partially
Open
Partially
Open
Closed
Open
Open
Open
Closed
Closed
Closed
Closed
Closed
Closed
Closed
Closed
Closed
Closed
Open
Closed
Closed
Closed
Closed
Open
Closed
Closed
Closed
Closed
Closed
Closed
Closed
Open
Stop %
Purge
CO2 in
Air
(Air in
CO2)
90%
CO2
(10% Air)
CO2 in
Air
(Air in
CO2)
5%
CO2
(95% Air)
Page 14 of 19
Rev. C
3.5
FLOW CHART
H2 CO2 AIR
Yes
Supply H2 Gas (CO2H2)
Yes
Purge CO2 from Gen. (CO2 Air)
Yes
Operation automatically during the
H2 Gas Pressurization
Page 15 of 19
Rev. C
4.0
4.1
Start-up
SL
No.
Description
Checked
( / X)
Remarks
10
11
12
Page 16 of 19
Rev. C
4.2
Shutdown
SL
No.
Description
Checked
( / X)
Remarks
Page 17 of 19
Rev. C
Page 18 of 19
Rev. C
5.0
ATTACHMENTS
Attachment 5.1 Checklist for Commissioning of Valves
Attachment 5.2 P&ID
Attachment 5.3 Measurement, Alarm and Trip List
Attachment 5.4 Valve Position Status for Commissioning
Attachment 5.5 Job Safety Analysis
Attachment 5.6 Risk Assessment
Page 19 of 19
1.0
1.2
Valve has been installed with correct orientation to match the correct pipe
flange.
1.3
1.4
1.5
1.6
1.7
1.8
Confirm setting of OPEN/CLOSE limit switches (if provided) have been done
(for Indication/check backs).
1.9
1.10
2.0
1 of 2
3.0
2.2
Confirm that the actuator limit switches have been adjusted and set on
LIMIT/TORQUE and have been checked manually on both CLOSE and
OPEN sides for cutting IN/OUT of the actuator motor through limit/torque
switches.
2.3
Confirm whether IR checks for the actuator motor, associated cables and
switchboard panels have been carried out.
2.4
Check motor overload protection healthiness and set as per OEM advice.
2.5
Confirm that the actuator motor electrical protections have been checked and
the breaker is ready for energizing.
2.6
Switch on power to the actuator and check for proper movement of the valve
as per CLOSE/OPEN command. Check also for inching operation of the
valve.
2.7
2.8
3.2
Confirm that all air pipelines have been purged before connecting them.
3.3
3.4
3.5
3.6
If airlock device is provided, initiate simulation of air failure and check the
valve stays in same condition.
3.7
Check also for inching operation of the valve by simulation (for CV).
2 of 2
[ATTACHMENT 4.3]
MEASUREMENT, ALARM AND TRIP LIST
TAG NO.
SIGNAL
CODE
P1MKG20CP001
XQ01
PT
0~7.1
Kg/Cm2
P1MKG10CL082
XB01
LS
P1MKG20CP082
XB01
PS
P1MKG10CL081
XB01
P1MKG20GH001
XB02
P1MKG16GH001
SERVICE DESCRIPTION
STATUS
RANGE
SETPOINT
UNIT
FUNCTION
SOE
P&ID NO
T10206- XG02-
AI
XG11-P1MKG-210001(1/2)
DI
XG11-P1MKG-210001(1/2)
DI
XG11-P1MKG-210001(1/2)
DI
XG11-P1MKG-210001(1/2)
NO
DI
XG11-P1MKG-210001(1/2)
125VDC
NO
DI
XG11-P1MKG-210001(1/2)
95
125VDC
NO
DI
XG11-P1MKG-210001(1/2)
125VDC
NO
DI
XG11-P1MKG-210001(1/2)
5.55
125VDC
NO
DI
XG11-P1MKG-210001(1/2)
90
125VDC
NO
DI
XG11-P1MKG-210001(1/2)
HH
Liter
Kg/Cm2
LS
Liter
IND
XB01
IND
P1MKG20CQ002
XB01
P1MKG20GH001
XB01
P1MKG20CP081
10
P1MKG20CQ001
SIGNAL
TYPE
CONT
TYPE
PWR
I/O TYPE
SRC
LL
4-20mA
125VDC
NO
5.12
125VDC
NO
1.8
125VDC
NO
125VDC
IND
85~100
IND
XB01
PS
Kg/Cm2
XB01
IND
85~100
Page 1 of 1
REMARKS
System
Description
Service
Tag No.
Status
MKG01
AA101
Closed
MKG01
AA102
Closed
MKG01
AA103
Closed
MKG01
AA104
Closed
MKG01
AA105
Closed
MKG01
AA106
Closed
MKG01
AA107
Closed
MKG01
AA108
Closed
H2 bottle header
isolation valve
MKG01
AA109
Closed
10
H2 PRV - A
MKG01
AA081
Closed
11
H2 PRV A isolation
valve
MKG01
AA110
Closed
12
H2 PRV A isolation
valve
MKG01
AA111
Closed
13
H2 PRV B
MKG01
AA082
Closed
14
H2 PRV B isolation
valve
MKG01
AA112
Closed
15
H2 PRV B isolation
valve
MKG01
AA113
Closed
16
MKG03
AA101
Open
MKG03
AA102
Open
H2 manifold
Checked
(/ X)
Remarks
CO2 manifold
17
Page 1 of 6
SL.
No.
System
Description
Service
Tag No.
Status
18
MKG03
AA103
Open
19
MKG03
AA104
Open
20
MKG03
AA105
Open
21
MKG03
AA106
Open
22
MKG03
AA107
Open
MKG03
AA108
Open
24
CO2 PRV
MKG03
AA081
Open
25
MKG03
AA110
Open
26
MKG03
AA111
Open
27
MKG03
AA109
Closed
28
PI isolation valve
MKG03
AA301
Closed
29
H2 PSV-2923 isolation
valve
MKG02
AA101
Open
30
H2 Vent
MKG02
AA102
Closed
31
PI isolation valve
MKG02
AA301
Open
H2 PRV
MKG02
AA081
Closed
33
MKG02
AA105
Closed
34
MKG02
AA106
Closed
35
MKG02
AA103
Open
23
32
CO2 manifold
Gas
Control
Valves
Checked
(/ X)
Remarks
Page 2 of 6
SL.
No.
System
Description
Service
Tag No.
Status
36
H2 isolation valve
MKG02
AA104
Open
37
3 Way valve 1
MKG02
AA107
Down
38
3 Way valve 2
MKG02
AA108
Down
39
PSV-2950 isolation
valve
MKG02
AA109
Open
40
MKG02
AA110
Partial
open
41
MKG15
AA401
Closed
42
MKG04
AA102
Open
PI isolation valve
MKG04
AA301
Open
44
MKG04
AA301
Open
45
MKG04
AA101
Open
46
MKG05
AA101
Closed
47
MKG13
AA101
Open
48
MKG13
AA102
Open
49
MKG13
AA103
Closed
50
PI isolation valve
MKG13
AA301
Open
51
MKG07
AA101
Open
MKG07
AA401
Open
MKG07
AA402
Closed
43
52
53
Gas
Control
Valves
Generator
Checked
(/ X)
Remarks
Page 3 of 6
SL.
No.
System
Description
Service
Tag No.
Status
54
MKG06
AA101
Closed
55
MKG06
AA401
Closed
56
MKG06
AA402
Closed
57
MKG11
AA101
Open
58
Outlet to Hydrogen
control cabinet line
drain valve
MKG11
AA401
Open
59
Outlet to Hydrogen
control cabinet line
drain valve
MKG11
AA402
Closed
60
MKG12
AA101
Open
Outlet to Hydrogen
control cabinet line
drain valve
MKG12
AA401
Open
62
Outlet to Hydrogen
control cabinet line
drain valve
MKG12
AA402
Closed
63
MKG10
AA105
Open
64
MKG10
AA104
Open
65
MKG10
AA401
Open
66
MKG10
AA402
Closed
67
MKG10
AA103
Open
68
MKG09
AA101
Open
69
MKG09
AA401
Open
61
Generator
Checked
(/ X)
Remarks
Page 4 of 6
SL.
No.
System
Description
Service
Tag No.
Status
70
MKG09
AA402
Closed
71
MKG08
AA101
Open
72
MKG08
AA401
Open
73
MKG08
AA402
Closed
MKG10
AA107
Open
75
MKG10
AA404
Open
76
MKG10
AA405
Closed
77
MKG10
AA102
Open
78
MKG10
AA101
Open
79
MKG10
AA106
Open
80
Drain valve
MKG10
AA403
Closed
81
MKG20
AA110
Open
82
Drain valve
MKG20
AA401
Closed
83
Drain valve
MKG20
AA402
Closed
MKG20
AA104
Open
85
MKG20
AA105
Open
86
MKG20
AA106
Closed
87
MKG20
AA108
Open
74
Generator
Liquid level
detector
84
Hydrogen
control cabinet
Checked
(/ X)
Remarks
Page 5 of 6
SL.
No.
System
Description
Service
Tag No.
Status
88
MKG20
AA109
Open
89
PI isolation valve
MKG20
AA111
Open
90
PT isolation valve
MKG20
AA303
Open
91
PS isolation valve
MKG20
AA302
Open
92
PS isolation valve
MKG20
AA301
Open
93
MKG20
AA113
Open
94
PRV
MKG20
AA081
Open
95
MKG20
AA114
Open
96
MKG20
AA115
Open
97
MKG20
AA116
Open
Hydrogen
control cabinet
Checked
(/ X)
Remarks
Page 6 of 6
AES-VCM
Rev Date:
Barricade Needed : No
Safety Harness:
No
Other Safety Equipment Required: Gas analyser
Remarks:
List of All Job Steps
Lockout:
Yes
Tag out:
Yes
Ground Fault Interrupter.
No
Revision : A
Dust Mask: Yes
Others:
Generator purging
H2 gas filling
Communication problem
In sufficient instructions
AES-VCM
RISK ASSESSMENT
Country Office/Project: Mong Duong II Coal Fired Power Project,
Vietnam
Ref No: 107
Date: 16/01/2014
Activity : Commissioning of Generator
H2 and CO2
control system
JOB/TASK
People at
risk
Connecting gas
cylinders or
manifold into line
Operators
Engineers
workers
Operators
Engineers
workers
Generator
purging
Operators
Engineers
workers
H2 gas filling
Operators
Engineers
workers
Purging H2 from
generator
Generator
Internal
inspection
Operators
Engineers
workers
Operators
Engineers
workers
Cause of
Adverse
effect
Adverse
effect
L1
S1
RF
N*
*
MITIGATING CONTROLS
L2
S2
RRN
*
Assessment
Gas leak
Pressurized
gas jet.
Eye injury
Creating
explosive
media
Trivial/
acceptable
CO2 leak
Dust and eye
injury
Asphyxiation
Eye injury
Trivial/
acceptable
Creating
explosive
media
Dust and eye
injury
Confined
space
Creating
explosive
media and
fire/
explosion
Line rupture
Asphyxiation
Eye injury
Trivial/
acceptable
Fire and
explosion
12
Tolerable
Creating
explosive
media
Explosion/
fire
CO2 and
confined
space.
Fire and
explosion
12
Tolerable
Asphyxiation
Trivial/
acceptable
Field operation
and CCR control/
communication
Operators
Engineers
workers
Communicati
on problem
In correct
operation
In sufficient
instructions
Likelihood (L)
1.Unlikely/Improbable
2. Remote
3. Quite possible/ Occasional
Severity(S)
1.Negligible
2.Slight
3.Moderate
4. Likely/Probable
4.Critical/High
5. Very likely/Frequent
5.Catastrophic/Ve
ry High
Bi-lingual operators
Competent CCR operators with clear
communication skills. Dedicated radio
channel for operation.
10-15 Substantial
Trivial/
acceptable
L1-Like as it is
L2-Likelihood with mitigating measures
S1-Severity as it is
S2-Severity with mitigating controls in
place
* Prepare job safety analysis and safety
verification check list when RFN is >= 6
** Prepare safety verification check list
when RFN is >= 6