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FOR COMMENT

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

AES-VCM MONG DUONG


POWER COMPANY LIMITED
Consultant

POWER ENGINEERING CONSULTING


JOINT STOCK COMPANY 2
Contractor

Doosan Heavy Industries & Construction Co., Ltd


PC

Project :

T10206

MONG DUONG II 2 x 560MW(NET)


THERMAL POWER PLANT

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

GENERAL INFORMATION ........................................................................... 4

1.1

Objective ........................................................................................................ 4

1.2

Scope ............................................................................................................ 4

1.3

Job Safety Analysis and Risk Assessment ..................................................... 4

1.4

Reference Documents / Drawings .................................................................. 5

1.5

System Description ........................................................................................ 5

1.5.1

H2 & CO2 Control System ............................................................................. 5

1.5.2

H2 Gas Dryer ................................................................................................. 5

2.0

PRE-COMMISSIONING................................................................................. 6

2.1

Pre-Commissioning Requirements ................................................................. 6

3.0

H2 & CO2 SYSTEM COMMISSIONING ........................................................ 7

3.1

Commissioning Requirement ......................................................................... 7

3.2

Line Flushing of Generator H2 & CO2 Control System .................................. 7

3.3

Purge Procedure of Generator ....................................................................... 8

3.4

Generator Hydrogen System Valve List ....................................................... 14

3.5

Generator Hydrogen System Flow Chart ..................................................... 15

4.0

H2 GAS DRYER COMMISSIONING............................................................ 16

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

Central Control Room

DCS

Distributed Control System

H2

Hydrogen

CO2

Carbon Dioxide

TCS

Turbine Control System

TE

Turbine End

CE

Collector End

PRV

Pressure Regulating Valve

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

Checking the completeness of all Equipment / Sub-systems required for commissioning of


Generator H2 & CO2 Control System. Equipment list includes the followings:

1.2.2

SL. No.

Equipment List

Tag No.

H2 Manifold

CO2 Manifold

Gas Control Valve Station

Hydrogen Control Cabinet

MKG20GH001

Hydrogen Gas Dryer

MKG16AZ001

Liquid Detector

MKG10AZ001

Checking the integrity & readiness of all associated piping, valves and other fittings,
instrumentation and control system.

1.2.3

Checking completeness of all the electrical connections and associated protections.

1.2.4

Checking the operation of individual valves and instruments.

1.2.5

Checking various control loops and their response.

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

Job Safety Analysis and Risk Assessment


Job Safety Analysis and Risk Assessment have been checked before commissioning.
Refer to Attachment 4.5 & 4.6.

Page 4 of 19

Rev. C

1.4

Reference Documents / Drawings

1.4.1

P&ID
SL. No.

Doc. / Drawing No.

Title

T10206-XG11-P1MKG-210001

H2 & CO2 Control Piping Diagram

1.5

System Description

1.5.1

H2 & CO2 Control System


The gas control system has the dual function of supplying hydrogen (H2) to the generator as
required to maintain selected pressure and to supply carbon dioxide (CO2) and H2 to the
generator for purging and filling operations.
The CO2 gas is used as intermediate median in order to prevent hydrogen gas from mixing
air. Therefore there will be not hydrogen gas and air mixture
If air is filled inside of generator, CO2 gas will be supplied to purge air and the generator will
be filled with CO2 gas. After then the hydrogen gas will be supplied to purge CO2 gas and the
generator will be filled with hydrogen gas. H2 will be filled up from generator top and purge
CO2 at the bottom, CO2 will be filled up for generator bottom and purge H2 at the top.

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

Pre-requisites for the commissioning

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.

Personal Protective Equipment is available for commissioning personnel.

Warning signs are placed in all concerned operating areas.

Portable Fire extinguishers or permanent fire-fighting systems are available at critical


location.

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

H2 & CO2 SYSTEM COMMISSIONING

3.1

Commissioning Requirement
SL
No.

3.2

Description

Ensure that the Instrument air system is available for line


flushing.

Ensure that sufficient CO2 is available to purge all H2 in


event of emergency.

Ensure that the seal oil system is in operation.

Please check to the Float Trap Operating & Maintenance


Manual.

Checked
( / X)

Remarks

Checked
( / X)

Remarks

Line Flushing of Generator H2 & CO2 Control System


SL
No.

Description

Ready to the flushing


Close all valves of generator and Hydrogen control
cabinet for the air not to flow into the system.

CO2 Gas line flushing


Connect the air supply line.
After selecting the CO2 side of MKG02AA108 (HV2955B) valve, Remove the MKG07AA101 (IV-2928)
valve and flush these piping lines.

CO2 Manifold line flushing


Separate CO2 pig tail and open MKG04AA101 (HV2946) valve. Open 8 valves above pig tail step by step,
flush these lines.(MKG03AA101~108)

H2 gas line flushing


Remove the SP-H2 and Connect the air supply line.
After selecting the H2 side of MKG02AA107 (HV2955A), Remove the MKG06AA101 (IV-2927) valve
and flush these piping lines.

H2 Manifold line flushing


Separate H2 pig tail and open MKG01AA110, 111,
112, 113 (HV-2920A/B, 2921A/B), MKG01AA081, 082
(PCV-2920A/B) valves.
Open 8 valves above pig tail step by step, flush these
lines. (MKG01AA101~108)

Page 7 of 19

Rev. C

SL
No.

3.3

Description

Liquid Detector line flushing


Connect the air supply line.
After selecting the CO2 side of MKG02AA108 (HV2955B) valve,
Open MKG07AA101(IV-2928) valve and pressurize
2
the inside of generator as 2 kg/cm
Open MKG10AA105 (IV-2920), MKG10AA104 (IV2923), MKG10AA103 (IV-2924), MKG10AA107 (IV2950), MKG10AA101 (IV-2932), and MKG10AA106
(HV-2990), MKG10AA403 (HV-2991) valves.
And then flush these lines.

Gas Dryer line flushing


Open MKG09AA101 (IV-2925), MKG08AA101 (IV2926) and pressurize the piping.
Open MKG09AA401/402 (IV-2935/2936),
MKG08AA401/402 (IV-2937/2938) and flush these
lines.

Vent pipe line flushing


Select the vent side of MKG02AA107 (HV-2955A)
valve.
Open MKG02AA110 (HV-2954) valve, MKG15AA101
(HV-2963) for upper pipe flushing and MKG15AA401
(HV-2952) for lower pipe flushing.

Checked
( / X)

Remarks

Checked
( / X)

Remarks

Purge Procedure of Generator


SL
No.

Description

Purge Procedure of Generator


(Replace the Air with CO2, Air CO2)

Refer to Air to CO2 in Section 3.4 Generator Hydrogen


system Valve List.
- During operation of turning gear and Seal oil system.

Operate valves to purge the air as bellow.


- MKG04AA101 (HV-2946) : Throttle Open
- MKG02AA107 (HV-2955A) : Down (Valve Handle)
- MKG02AA108 (HV-2955B) : Down (Valve Handle)
- MKG02AA110 (HV-2954) : Open (Vent Valve)

Page 8 of 19

Rev. C

SL
No.

Description

Checked
( / X)

Remarks

Connect CO2 bottles to CO2 manifold.


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.)
3
- 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.

Check the differential pressure (MKW10CP501 (PDI-3402))


between seal oil and CO2 as generator gas pressure
increase.
2
- P: 0.56 kg/cm

Adjust the flow control valve (MKG20AA115/116) for flow


meter (FI-2971A/B)

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)).

The Hydrogen supply of generator


(Replace CO2 with H2, CO2 H2)
8

Refer to 'CO2H2 and H2 Fill in Section 3.4 Generator


Hydrogen system Valve List.

Connect H2 bottles to H2 gas manifold. (or From H2


Generation)

10

Set the H2 gas manifold pressure regulator (MKG01AA081


2
(PCV-2920A)) to 8 kg/cm .

11

Set the function switch of gas analyzer to H2 in CO2.

Page 9 of 19

Rev. C

SL
No.

Description

Checked
( / X)

Remarks

Adjust the inside of generator pressure and H2 supply


quantity by using MKG01AA081 (PCV-2920A) and,
MKG02AA081 (PCV-2935) valves.

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

Close the vent valve (MKG02AA110, (HV-2954)) slowly to


2
keep the pressure such as 0.14 ~ 0.35 kg/cm if H2 purity
grows up steadily.
Close the vent valve (MKG02AA110, (HV-2954)), if H2
purity is to above 90%.

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

Pressurize in the inside of generator by controlling the


Hydrogen Machine Gas Pressure Regulator (MKG02AA081
(PCV-2935)) properly not to reach at the operation value.
2
(Generator Gas Pressure: 5.27 kg/cm )
NOTE:
- When rotor shaft rotates, the pressure will increase
according to the temperature increasing.
16
- 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. .

17

Check the differential pressure between seal oil and H2


(MKW10CP501 (PDI-3402)) as H2 gas pressure increases.
2
-P: 0.56 kg/cm

18

Close H2 manifold gas pressure regulator outlet valve


MKG01AA111 (HV-2920B), MKG01AA113 (HV-2921B) to
stop supplying H2, if the pressure will satisfy the required
value.

Operation automatically under H2 filling

19

20

Refer to Normal in Section 3.4 Generator Hydrogen


system Valve List.
For gas analyzer, refer to Hydrogen Control Cabinet
Controls in Section 3.4 Generator Hydrogen system Valve
List.

21

Connect H2 bottles to H2 manifold. (or From H2


Generation)

22

Set the H2 Gas Manifold Pressure Regulator


2
(MKG01AA081 (PCV-2920A)) to 8 kg/cm .

23

Maintain the required H2 operating pressure to control the


machine gas pressure regulator
(MKG02AA081 (PCV-2935)).
2
- Generator Gas Pressure: 5.27 kg/cm

Page 11 of 19

Rev. C

SL
No.

Description

Checked
( / X)

Remarks

Purge hydrogen from Generator


(replace H2 with CO2, H2 CO2)

24

Refer to H2 to CO2 in Section 3.4 Generator Hydrogen


system Valve List.
- During operation of turning gear and Seal oil system.

25

For gas analyzer, refer to Hydrogen Control Cabinet


Controls in Section 3.4 Generator Hydrogen system Valve
List.

26

Check the H2 gas supply stop.


Open the vent valve (MKG02AA110, (HV-2954) slowly and
depressurize the generator gas pressure.

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

Keep the pressure of Inside of generator such as 0.14 ~


2
0.35 kg/cm .

29

Connect CO2 bottles to CO2 manifold.

30

Adjust CO2 supply properly by control MKG04AA101 (HV2946) valve.

31

Purge H2 until the purity of CO2 in Vent Gas is above 95%


and CO2 purging quantity of 2 times of generator volume.
- CO2 purity > 95%
- Check that the used CO2 Gas bottle.
- CO2 quantity of purge is 2 times of generator volume
that is approximately 16~18 bottle

Purge CO2 from Generator with air


(replace CO2 with air, CO2 Air)
32

Check the valve position as per CO2 to air in Section 3.4


Generator Hydrogen system Valve List.

33

Close the CO2 supply valve (MKG04AA101 (HV-2946)).

Page 12 of 19

Rev. C

SL
No.

Description

34

For gas analyzer, refer to Hydrogen Control Cabinet


Controls in Section 3.4 Generator Hydrogen system Valve
List.

35

Open the air supply valve (MKG05AA101 (HV-2947)) and


throttle open the vent valve (MKG02AA110, (HV-2954) to
purge CO2 gas.

36

Purge CO2 until the purity of air in Vent Gas is above 95%.

37

Manually check H2 Gas Concentration at vent line by


portable H2 meter.

38

Full open the vent valve (MKG02AA110 (HV-2954)) to keep


the pressure of Inside of generator as the atmospheric
pressure.

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

Before welding or any other hot work inside and outside of


generator, perform purge by instrument air over 2 hours
and manually check H2 gas concentration at vent line by
portable H2 meter.

Checked
( / X)

Remarks

Page 13 of 19

Rev. C

3.4

Generator Hydrogen System Valve List


The gas control system has the dual function of supplying hydrogen (H2) to the generator as
required to maintain selected pressure and to supply carbon dioxide (CO2) and H2 to the
generator for purging and filling operations.
Operating
Condition

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

Hydrogen Control Cabinet Controls


Mode Selection
For H2 Analyzer
(P1MGK20AA113)
Function
Selection

Stop %

Purge
CO2 in
Air
(Air in
CO2)
90%
CO2
(10% Air)

CO2 in
Air
(Air in
CO2)
5%
CO2
(95% Air)

Gas Valve Station Valve Position


3-Way Valve
(MKG02AA107)
3-Way Valve
(MKG02AA108)
Main Vent Valves
(MKG02AA110)
Generator PRV
Isolation Valve
(MKG02AA105,
MKG02AA106)
Generator PRV
Bypass Valve
(MKG02AA103)
CO2 Shut-Off
Valve
(MKG04AA101)
Air Shut-Off Valve
(MKG05AA101)

Page 14 of 19

Rev. C

3.5

Generator Hydrogen System Flow Chart


FLOW CHART
Air CO2 H2

Air Purge of Inside of Gen.


(AirCO2)

Check the valve position


according to Air to CO2 in the
Appendix. B Valve List.

Supply CO2 Gas

Purity of CO2 in Vent Gas


is above 90%.

FLOW CHART
H2 CO2 AIR

Purge hydrogen from Gen.


(H2CO2)

Select Purge Mode By


Gas Analyzer Sampling 3 Way
Valve (MKG20AA113)

Check whether H2 Gas is shut off.


Open slowly the Gen Casing Vent
valve to reduce the H2 pressure.

Connect CO2 bottles to CO2 Manif


old
Purge until the purity of CO2 in Ve
nt Gas is above 95%.

Yes
Supply H2 Gas (CO2H2)

Select the Gas Analyzer in Cabinet

Purity of CO2 in Vent Gas


is above 95%.

Yes
Purge CO2 from Gen. (CO2 Air)

Connect H2 bottles to H2 Gas


Manifold
Select the Gas Analyzer

Purity of H2 in Vent Gas is


above 90%.

Yes
Operation automatically during the
H2 Gas Pressurization

Connect the Air Supply

Purge until the purity of air in Vent


Gas is above 95%.
Manually check H2 gas
concentration in vent line by
portable meter.

Page 15 of 19

Rev. C

4.0

H2 GAS DRYER COMMISSIONING

4.1

Start-up
SL
No.

Description

H2 Gas Dryer inlet and outlet valve should be open when


CO2 & H2 charging, during operation and CO2 & H2 purge.

Ensure that the drain valve of H2 Gas Dryer is closed.

H2 Gas Dryer vent valve shall be open during H2 & CO2


purge and maintain vent valve open after purge is
completed.

Before H2 gas charging, close the H2 Gas Dryer vent valve.

After synchronization, start the H2 Gas Dryer as following


sequence.

Turn the power select to ON on the control panel.


POWER ON lamp on / HMI Power on

Checked
( / X)

Remarks

After touching HMI setting button,


1) Time setting

Cycle Time : 480min.

Heating Time : 300 min.


2) Temperature setting

Heater over temperature High High : 420C

Heater Control Temperature : 350C

Turn the select switch to "AUTO" one the control panel.


( Dryer Cycle Timer Automatic Operation Status By )

Operation Step 1 (For 5 hours)


A-Tower : Operation
B-Tower : Regeneration (Heating)

10

Operation Step 2 (For 3 hours)


A-Tower : Operation
B-Tower : Regeneration (Cooling)

11

Operation Step 3 (For 5 hours)


A-Tower : Regeneration (Heating)
B-Tower : Operation

12

Operation Step 4 (For 3 hours)


A-Tower : Regeneration (Cooling)
B-Tower : Operation

Page 16 of 19

Rev. C

4.2

Shutdown
SL
No.

Description

When the Generator is desynchronized, H2 Gas Dryers


tower inlet/outlet solenoid valves will be closed
automatically.

Turn the power switch to "OFF" on the control panel.

During Generator purge, open the vent valve of H2 Gas


Dryer.

After purge is completed, if stopping for a long time, open


the drain valve and remove the pressure inside the tower.

Checked
( / X)

Remarks

CAUTION: when SHUTDOWN


It is best to shut down the machine at the cooling time after desorption, but in the case that it
needs to be shut down at the heating time, please be careful because the regenerated air is hot.
Also, a sudden interruption of the air flow can cause a momentary overheating of the heater, but
this momentary overheating does not affect the performance of the heater.

CAUTION: when RE-OPERATING


If you re-operate the machine in the heating status after shut down, when the tower has been
changed, the dew point can increase due to the incomplete regeneration of the absorbent.
Therefore, it is best to extend the heating time, even though the current dew point is not preferable.
Also, in the case that there is no pressure on the absorption tower, if you suddenly open
INLET/OUTLET V/V, it can damage the absorbent by the pressure hunting. Therefore, please
open the valve slowly with care.

Page 17 of 19

Rev. C

[Fig. 1] H2 Gas Dryer P&ID

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

[Attachment 4.1] Common Checklist for Valves

1.0

COMMON CHECKS FOR ALL VALVES


1.1

Valve installed matches with design drawing specifications.

1.2

Valve has been installed with correct orientation to match the correct pipe
flange.

1.3

Test certificate for the valve is available.

1.4

Confirm no process is affected due to valve trial.

1.5

Confirm no energy is present upstream or downstream of the valve.

1.6

Confirm no maintenance or commissioning activity is being carried out on the


valve.

1.7

Confirm proper greasing as per the Manufacturers recommendation has


been done on the valve.

1.8

Confirm setting of OPEN/CLOSE limit switches (if provided) have been done
(for Indication/check backs).

1.9

CLOSE the valve manually and check:

1.10

2.0

Valve is easy and free to operate towards CLOSE direction.

Valve closes fully.

The limit switch (if provided) operates on the CLOSE side.

OPEN the valve manually and check:

Valve is easy and free to operate towards OPEN direction.

Valve opens fully.

The limit switch (if provided) operates on the OPEN side.

SPECIAL CHECKS FOR MOTOR OPERATED VALVES


2.1

Lubricant of correct grade (as per actuator manufacturers recommendation)


is filled in the gearbox to required level.

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

Check for remote/DCS operation of the valve.

2.8

Check for abnormal sound or other problems in proper movement of the


valve by operation from local and remote positions.

SPECIAL CHECKS FOR PNEUMATIC VALVES


3.1

Confirm for proper erection of pneumatic tubing as per drawing.

3.2

Confirm that all air pipelines have been purged before connecting them.

3.3

Set the correct air pressure in the pressure regulator as recommended.

3.4

Check full opening and closing of the valve by local operation.

3.5

Check full opening and closing of the valve by remote operation.

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 4.2] P&ID

[ATTACHMENT 4.3]
MEASUREMENT, ALARM AND TRIP LIST

Mong Duong II 2 x 560MW(NET)


COAL FIRED POWER PROJECT
No.

TAG NO.

SIGNAL
CODE

P1MKG20CP001

XQ01

Generator Gas Pressure

PT

0~7.1

Kg/Cm2

P1MKG10CL082

XB01

High High Liquid Level in Generator Open to Alarm

LS

P1MKG20CP082

XB01

Generator Gas Pressure Low Open to Alarm

PS

P1MKG10CL081

XB01

High Liquid Level in Generator Open to Alarm

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

H2 Gas AC Power Failure Alarm

IND

XB01

Hydrogen Gas Dryer Fault

IND

P1MKG20CQ002

XB01

TGA Gas Purity low low

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

H2 Gas DC Power Failure Alarm

IND

XB01

Generator Gas Pressure High

PS

Kg/Cm2

XB01

TGA Gas Purity Low

IND

85~100

Page 1 of 1

REMARKS

[Attachment 4.4] Valve Position Status for Commissioning


SL.
No.

System
Description

Service

Tag No.

Status

H2 bottle isolation valve

MKG01
AA101

Closed

H2 bottle isolation valve

MKG01
AA102

Closed

H2 bottle isolation valve

MKG01
AA103

Closed

H2 bottle isolation valve

MKG01
AA104

Closed

H2 bottle isolation valve

MKG01
AA105

Closed

H2 bottle isolation valve

MKG01
AA106

Closed

H2 bottle isolation valve

MKG01
AA107

Closed

H2 bottle isolation valve

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

CO2 bottle isolation


valve

MKG03
AA101

Open

CO2 bottle isolation


valve

MKG03
AA102

Open

H2 manifold

Checked
(/ X)

Remarks

CO2 manifold
17

Page 1 of 6

SL.
No.

System
Description

Service

Tag No.

Status

18

CO2 bottle isolation


valve

MKG03
AA103

Open

19

CO2 bottle isolation


valve

MKG03
AA104

Open

20

CO2 bottle isolation


valve

MKG03
AA105

Open

21

CO2 bottle isolation


valve

MKG03
AA106

Open

22

CO2 bottle isolation


valve

MKG03
AA107

Open

CO2 bottle isolation


valve

MKG03
AA108

Open

24

CO2 PRV

MKG03
AA081

Open

25

CO2 PRV isolation


valve

MKG03
AA110

Open

26

CO2 PRV isolation


valve

MKG03
AA111

Open

27

CO2 PRV bypass valve

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

H2 PRV isolation valve

MKG02
AA105

Closed

34

H2 PRV isolation valve

MKG02
AA106

Closed

35

H2 PRV bypass valve

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

Main vent valve

MKG02
AA110

Partial
open

41

Vent line drain valve

MKG15
AA401

Closed

42

CO2 line PSV isolation


valve

MKG04
AA102

Open

PI isolation valve

MKG04
AA301

Open

44

CO2 line PI isolation


valve

MKG04
AA301

Open

45

CO2 line isolation valve

MKG04
AA101

Open

46

Purge Air supply


isolation valve

MKG05
AA101

Closed

47

Purge line isolation


valve

MKG13
AA101

Open

48

Purge line isolation


valve

MKG13
AA102

Open

49

Purge line isolation


valve

MKG13
AA103

Closed

50

PI isolation valve

MKG13
AA301

Open

51

CO2 inlet line isolation


valve

MKG07
AA101

Open

CO2 inlet line drain


valve

MKG07
AA401

Open

CO2 inlet line drain


valve

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

H2 inlet line isolation


valve

MKG06
AA101

Closed

55

H2 inlet line drain valve

MKG06
AA401

Closed

56

H2 inlet line drain valve

MKG06
AA402

Closed

57

Outlet isolation valve to


Hydrogen control
cabinet

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

Outlet isolation valve to


Hydrogen control
cabinet

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

Outlet isolation valve to


Liquid level detector

MKG10
AA105

Open

64

Outlet isolation valve to


Liquid level detector

MKG10
AA104

Open

65

Outlet to Liquid level


detector line drain valve

MKG10
AA401

Open

66

Outlet to Liquid level


detector line drain valve

MKG10
AA402

Closed

67

Outlet isolation valve to


Liquid level detector

MKG10
AA103

Open

68

Outlet isolation valve to


Gas dryer

MKG09
AA101

Open

69

Outlet to Gas dryer


Drain valve

MKG09
AA401

Open

61

Generator

Checked
(/ X)

Remarks

Page 4 of 6

SL.
No.

System
Description

Service

Tag No.

Status

70

Outlet to Gas dryer


Drain valve

MKG09
AA402

Closed

71

Outlet isolation valve to


Gas dryer

MKG08
AA101

Open

72

Outlet to Gas dryer


Drain valve

MKG08
AA401

Open

73

Outlet to Gas dryer


Drain valve

MKG08
AA402

Closed

Outlet isolation valve to


Liquid level detector

MKG10
AA107

Open

75

Outlet isolation valve to


Liquid level detector

MKG10
AA404

Open

76

Outlet isolation valve to


Liquid level detector

MKG10
AA405

Closed

77

Outlet isolation valve to


Liquid level detector

MKG10
AA102

Open

78

Outlet isolation valve to


Liquid level detector

MKG10
AA101

Open

79

Inlet isolation valve

MKG10
AA106

Open

80

Drain valve

MKG10
AA403

Closed

81

Inlet isolation valve


(GFP)

MKG20
AA110

Open

82

Drain valve

MKG20
AA401

Closed

83

Drain valve

MKG20
AA402

Closed

Inlet isolation valve


(Purge)

MKG20
AA104

Open

85

Inlet isolation valve


(GFS)

MKG20
AA105

Open

86

Vent line isolation valve

MKG20
AA106

Closed

87

PDI isolation valve

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

PDI isolation valve

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

Isolation valve to PRV

MKG20
AA113

Open

94

PRV

MKG20
AA081

Open

95

Isolation valve to PRV

MKG20
AA114

Open

96

TGA-A isolation valve

MKG20
AA115

Open

97

TGA-B isolation valve

MKG20
AA116

Open

Hydrogen
control cabinet

Checked
(/ X)

Remarks

Page 6 of 6

[Attachment 4.5] Job Safety Analysis

JOB SAFETY ANALYSIS

AES-VCM

MONG DUONG II 2x 560 MW (NET) COAL FIRED POWER PROJECT


(Developing a habit of analyzing methods to identify hazards & unsafe practices than developing solution that control, minimize or eliminating hazard.)

Task : Generator H2 and CO2 control system commissioning


Prepared by : Suresh nair
Original Date : 16/01/2014
Goggles : Yes
Gloves: Yes

Reviewed by: K Lee


Revised by:
Face Shield : No

Rev Date:
Barricade Needed : No

Safety Harness:

Hearing Protection: Yes

MSDS Need/Review (Y)

Long Sleeves: Yes

No
Other Safety Equipment Required: Gas analyser
Remarks:
List of All Job Steps

Approved by: YM Cho

List of All Known Hazard

Lockout:
Yes
Tag out:
Yes
Ground Fault Interrupter.
No

Revision : A
Dust Mask: Yes
Others:

How to Eliminate Hazards

H2 & CO2 line flushing

Creating explosive media


Dust and eye injury

Line shall be flushed with CO2, not with H2.


Wear goggles.

Generator purging

Creating explosive media


Dust and eye injury
Confined space
Creating explosive media and fire/ explosion
Line rupture

Purging with CO2 until venting gets purity 95% or


above.
Nobody shall be inside the generator enclosure.
Line leak checks shall have been done.
Check and confirm CO2 pressure inside before filling
H2.
Fill slowly by regulating the flow from top side until
desired purity is achieved.
Use only non-sparking tools. No hot works in the area.
Pressurize as per design criteria (4.48 bar)
Purge using CO2 only. Never use air.
CO2 shall be filled from bottom.
Pressure shall be regulated as per procedure.
Non sparking tools and no hot work policy to be
followed.
Purge with air and follow confined space entry permit
procedure.
Bi-lingual operators
Competent CCR operators with clear communication
skills. Dedicated radio channel for operation.

H2 gas filling

Purging H2 from generator for any work or


inspection.

Creating explosive media


Explosion/ fire

Generator Internal inspection

CO2 and confined space.

Field operation and CCR control/


communication

Communication problem
In sufficient instructions

[Attachment 4.6] Risk Assessment

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

Assessment Purpose : Identification of hazards and implementation of


mitigation measures

H2 and CO2

control system
JOB/TASK

People at
risk

Connecting gas
cylinders or
manifold into line

Operators
Engineers
workers

H2 & CO2 line


flushing using
CO2.

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

Assessors : Suresh Nair

L1

S1

RF
N*
*

MITIGATING CONTROLS

L2

S2

RRN
*

Assessment

Gas leak
Pressurized
gas jet.

Eye injury
Creating
explosive
media

Open the regulator only after tightening


connections.
Use non sparking tools. Ensure no hot works
or open flames in the area.

Trivial/
acceptable

CO2 leak
Dust and eye
injury

Asphyxiation
Eye injury

Line shall be flushed with CO2, not with H2.


Wear goggles. Do not enter inside generator
enclosure. LOTO of valve connecting Gen.
to be done.

Trivial/
acceptable

Creating
explosive
media
Dust and eye
injury
Confined
space
Creating
explosive
media and
fire/
explosion
Line rupture

Asphyxiation
Eye injury

Purging with CO2 until venting gets purity


95% or above.
Nobody shall be inside the generator
enclosure.

Trivial/
acceptable

Fire and
explosion

12

Tolerable

Creating
explosive
media
Explosion/
fire
CO2 and
confined
space.

Fire and
explosion

12

Tolerable

Asphyxiation

Line leak checks shall have been done.


Check and confirm CO2 pressure inside
before filling H2.
Fill slowly by regulating the flow from top
side until desired purity is achieved.
Use only non-sparking tools. No hot works in
the area.
Pressurize as per design criteria (4.48 bar)
Purge using CO2 only. Never use air.
CO2 shall be filled from bottom.
Pressure shall be regulated as per procedure.
Non sparking tools and no hot work policy to
be followed.
Purge with air and follow confined space
entry permit procedure.

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.

Risk Factor Number (RFN)


1-2 Trivial/Acceptable
3-5 Tolerable
6-9 Moderate/Acceptable with
review
10-15 Substantial

Residual Risk Number (RRN)


1-2 Trivial/Acceptable
3-5 Tolerable
6-9 Moderate/Acceptable with review

16-25 Intolerable/ Unacceptable

16-25 Intolerable/ Unacceptable

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

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