a4 - Chapter 4 - Complete

- Formalizes the final sign-off and system transition of the equipment and all the operating systems to the operations and maintenance crews. - Ensures that all equipment files and formal documentation is completed and integrated in the various electronic and hardcopy equipment managing and tracking programs.

What does step 13 of commissioning step sequencing involve?

- Involves factory acceptance testing of all equipment, instrumentation and control systems, electrical systems, and all off-site fabricated items to ensure that they achieve their performance acceptance benchmarks

What does step 5 of commissioning step sequencing involve?

- to ensure that the equipment that is installed conforms to all the original design standards for mechanical and fabrication integrity. - A non-energized test used to ensure that the quality of the equipment, fabrication, installation and construction of the gas turbine and its components and subsystems meet approved design criteria.

What are post-installation tests designed for?

1.) Building monitoring, safety, and fire suppression systems 2.) Turbine sound-proof compartment and HVAC systems 3.) Fuel oil system 4.) Natural gas system 5.) Lubrication oil system 6.) Air intake system 7.) Air compressor 8.) Combustion system 9.) Gas turbine blade and combustor or cooling system 10.) Gas/power turbine 11.) Gear reducing unit 12.) Hot air ducting from the exhaust of the turbine to the HRSG

1st Step - Equipment Identification: - List 12 key pieces of equipment that are included in the gas turbine system

- Involves cleaning out the equipment and pipelines and preparing major equipment. - Many times, a temporary steam boiler is set up on-site to assist in the line clean-out, chemical cleaning, and preparing main steam lines/headers and the main boilers. - Once the main boilers are ready to be fired, they are used to complete the rest of the commissioning process

What does step 10 of commissioning step sequencing involve?

- Verifies all functions and interconnections between the various pieces of equipment and ensures that all controls, commands, interlocks, monitoring and measurement systems, and fault and alarm systems perform according to design.

What does step 11 of commissioning step sequencing involve?

- Final facility testing demonstrates the quality and ability of the equipment and the various units and processes within the power plant to perform to clearly defined performance standards or deliverables under permanent operating conditions.

What does step 12 of commissioning step sequencing involve?

1.) Timing 2.) Objectives 3.) Specific tests

Although each piping system has its own unique components and design characteristics, there are number of commissioning steps and procedures that are common to each system, as per the following: (3)

1.) Full range of travel 2.) Speed of closure 3.) Limit switch positioning and contact 4.) Positioner functionality 5.) Trip operation and alarm activation 6.) Governor action and range of movement

(Valve steam chests/steam delivery systems) - When manually testing the HP stop and governor valves using either a temporary loading device or by initiating an open and closed signal from the main control panel. Valves are tested for: (6)

1.) Individual Testing (IT) 2.) Functionality Testing (FT) 3.) Final Testing

(Actual Commissioning Actions) - The following tests are included as part of the boiler commissioning process: (3)

1.) Material and equipment design specs. and relevant drawings and engineering specs. 2.) Persons involved in the test and test dates 3.) Purpose/objective of the test 4.) Conditions required for execution of the test and the methods to be used 5.) Expected, required, or desired result 6.) Actual results and all follow-ups required 7.) Transition requirements for functional testing

(Development of Commissioning Procedures) - The individual Test procedures include the following components: (7)

1.) Equipment identification 2.) Commissioning procedure development 3.) Factory acceptance testing (FATs) 4.) Post installation tests 5.) Individual testing (ITs) 6.) Turbine/components function testing 7.) Final quality/performance testing 8.) Transition of gas turbine to operations team

(Gas Turbine Commissioning) - The following steps are carried out to ensure compliance with the overall facility commissioning strategy and to meet the required expectations of the project management team: (7)

1.) Fan lubrication system 2.) Fan housing and ductwork from intake to discharge vanes 3.) Air flow control systems 4.) Variable speed coupling 5.) Fan motor 6.) 7.) Electrical system from MCC to starter and to motor 8.) Fan instrumentation and control systems

(Large boiler fan commissioning) - List 8 components that are included in individual equipment testing procedure development documents.

1.) Fan lubrication system 2.) Fan housing and ductwork from intake to discharge vanes 3.) Air flow control systems (dampers vanes) 4.) Variable speed coupling 5.) Fan motor 6.) Fan 7.) Electrical system from MCC to motor 8.) Instrumentation and control system

(Large boiler fan commissioning) - List 8 individual components that are tested under the commissioning protocol document.

1.) Date and timeline for commissioning 2.) Objective 3.) Individual components that are tested 4.) Everything has been function tested

(Large boiler fan commissioning) - What is covered in the commissioning protocol document? (4)

1.) Sufficient lighting is available 2.) Access and egress is sufficient and installed properly 3.) All construction equipment and debris are removed from the area 4.) The equipment is properly isolated and locked out from any other systems 5.) All lines, piping, and equipment are properly labelled 6.) All ancillary support and safety systems are in place and functional (i.e. fuel, air, water, electricity, hydraulics, lubrication, and fire and gas monitoring and mitigation).

(Post-Installation Testing) - A safety inspection is carried out to ensure that: (6)

1.) Fuel system from the main supply header isolation valve to the burner nozzle. 2.) Feedwater system from the main header isolation valves to the boiler 3.) Boiler chemical systems 4.) Lubrication and hydraulic systems 5.) Electrical system from the central MCC to the boiler and the auxiliary systems 6.) Instrument and utility air systems from the main headers to all the instruments 7.) All local instrumentation and communication systems to and from the main HMI's that operate and control the boiler 8.) Combustion air system from the intake of the forced draft fan to the boiler furnace 9.) Boiler flue gas handling and scrubbing systems 10.) Boiler pressure parts such as; economizers, superheaters, reheaters, steam air heaters, drums, tubes, and all drum internals and all connections to and from the boiler 11.) Boiler non-pressure parts such as; baffles, ducting, and internal dampers, brickwork refractory and linings, and boiler framework and support steel 12.) Ancillary equipment such as; blowdowns, safety valves, vent systems, silencers and exhaust piping 13.) All safety systems associated with the boiler

(Pre-Commissioning) - List 13 items with regards to "Identification of Equipment".

1.) Proper metallurgy 2.) Correct fabrication techniques 3.) Correct testing protocol 4.) Integrity of all coating and liners 5.) Initial function testing if the equipment is totally assembled off-site

Before the equipment is delivered to the site, a number of the components and control systems are inspected and factory tested to ensure compliance to design specs. The mechanical equipment is inspected for: (5)

- It is used to identify any visual non-conformances with the design data and/or any major issues in fabrication, construction, and installation. - This step verifies that all internal turbine clearances are correct, alignments are completed and matched to design criteria, and all external structural steel and support systems are in place and functional.

Briefly describe Post-Installation Testing

- This ensures that the equipment identified as belonging to the boiler meets all the design and engineering criteria approved by the project team. - All equipment is inspected for manufacturing, fabrication, construction, installation, and mechanical integrity

Briefly describe post-installation testing with regards to individual testing.

- The first step is to develop the overall project commissioning protocol document

Commissioning Step Sequencing - Step 1

- This step develops the detailed QA/QC protocol for factory acceptance tests (FATS) which are used to ensure that the equipment, instrumentation, and control systems fabricated and configured off-site meet all the design. standards set by the project team. The protocol is used to test performance, functionality, and operability of the supplied equipment and associated systems.

Commissioning Step Sequencing - Step 2

- This step develops the detailed QA/QC protocol for site acceptance tests (SATS). This process ensures that all the installed equipment, instrumentation, and control systems meet the engineering, design, safety, performance, regulatory control, and government certification standards approved by the design teams for the facility.

Commissioning Step Sequencing - Step 3

- This step develops the Individual Test Procedures (ITs), which include the detailed procedures required for all: 1.) Piece of equipment 2.) Control Systems 3.) Sections of pipe 4.) Auxiliary systems 5.) Utilities and all electrical feed 6.) Protection, control systems, and distribution lines to be commissioned

Commissioning Step Sequencing - Step 4 b.) List 6 types of Individual Test Procedures

- This system needs to be fully functional to allow testing of the other turbine equipment.

During the individual test procedures, what is the purpose of testing the Hydraulic/Governor Oil Systems?

a) The end device is tested for proper location, installation, equipment type, and function. b) The transmitter for the end device is properly installed, receiving the signal from the end device, and transmitting a corresponding signal to the controller. c) Thecontrollerisreceivingthereal-timeoractualprocesssignalfrom the transmitter, comparing it to an internal or HMI generated set point, and then sending a corresponding correction signal to an actuator of some type. d) The controller sends an alarm condition signal to the HMI. e) The operator can change the controller set point by making changes in the HMI.

Describe an individual test procedure to loop test an instrument on a turbine.

1.) Fuel delivery capable of firing the boiler at sustained maximum steam outputs. 2.) Feedwater supply capable of delivering sufficient water to sustain required water levels at or above sustained maximum steam outputs. 3.) Boiler circulation testing to ensure that the flow of water and water and steam mixtures through the various sections of the boiler are sufficient to maintain external tube surface cooling while firing at maximum steaming rates. 3.) Ability of the FD fan to sustain the designed excess O2 at maximum boiler firing rate using various fuels and factoring into the equation atmospheric conditions and boiler pluggage conditions. 4.) Ability of the ID fan to sustain the boiler draft profiles while under full-firing rates, taking into consideration partial boiler pluggage due to tube fouling. 5.) Ability of the boiler to deliver a sustained heat release rate while supplying superheated steam at the desired pressures, temperatures, and flow rates. 6.) Ability of the flue gas treatment systems to deliver below permit flue gas to the atmosphere under full-load conditions, taking into consideration a wide variety of fuel types and the impact of sootblowing during operation. 7.) Ability of the ash handling systems to capture and remove the ash from the boiler under full-load conditions using the lowest acceptable grade of fuel. 8.) Ability of the boiler to deliver steam to the turbine at the design parameters of steam temperature, flow rates, pressures, and steam purity to ensure maximum power output from the turbine through to the generator. 9.) Ability of the instrument and control systems, HMI systems, and supervisory control systems to ensure safe and efficient operation under all firing conditions and allow safe and effective equipment shutdown without sustaining unacceptable risks to people, equipment, or the surrounding environment.

Describe the 10 key items covered by the final quality commissioning tests for a large power plant boiler.

a) Factory acceptance testing of the main control programs to ensure functionality, stability of operation, and conformance to the approved control strategies and cause and effect diagrams. b) Testing all local monitoring and indicating devices ensuring that the devices installed conform to the approved design criteria including: orifice plates, differential pressure cells, RTDs, pressure gauges and pressure indicating devices with correct ranges, correct draft indication devices, pitot tubes, level indication, and measurement devices. c) Testing all transmitters and recorders d) Testing all local and remote controllers (including communication, control, alarm, response, and logic functions) e) Testing all HMI and DCS systems, including all tags, alarms, commands, interlocks, face plate layouts, and correct indication and control ranges f) Testingalldatahighwaycommunicationtoproveintegrityofsignal and control transmission. g) Dynamic testing of each device from the DCS/HMI to the field instrument and back including all alarms. h) Once each boiler system is put in service, the instrumentation and control systems are loop tested and functionality tested. All alarms are proven active and accurate to the parameters required by the design team. Each instrument is tested to ensure that the remote readings match the actual readings. Control signals are matched to valve travel and to damper positioning, and limit switches are checked for correct positioning and functionality. All safety systems, trip devices, ESD systems, and safety interlocks are tested for functionality and correct activation parameters.

Describe the steps in the commissioning process for the instrumentation and control systems for a large boiler.

- Valve steam chests and steam delivery systems to the turbine are inspected for mechanical and fabrication integrity.

During the individual test procedures, what is the purpose of testing the valve steam chests/steam delivery systems?

- Procedures are developed for individual equipment tests (ITs), function tests (FTs), and the final quality and sustainability of operation testing. The objectives for each step of the commissioning process must be identified, and the desired outcome for each step clearly detailed. The acceptance criteria and benchmark criteria are defined for each component. A final sign-off document is developed that identifies the individual(s) performing the tests, the date the tests were completed, the test steps that were taken, the standards to which the tests were performed, the final results that were achieved, and any recommendations or follow-up requirements that must be completed. - The engineering and design documentation, the FAT documentation, all relevant P&IDs, construction drawings, and erection data need to be compiled for each piece of equipment and included with the commissioning procedure. Any safety-specific, site-specific, company- specific, or regulatory-specific recommendations or requirements need to be evaluated and included with the commissioning protocol. All completed instrumentation and controls FATs need to be identified and included in the commissioning procedures protocol for review by the commissioning team.

Describe what is involved in the procedure development step for a large steam turbine.

1.) Equipment component types 2.) Equipment metallurgy 3.) Rules, regulations, codes, and standards of the province in which the facility operates 4.) Company specific standards, policies, and accepted practices 5.) International standards to which the company conforms (ISO, OSHA) 6.) Once the commissioning protocol has been established, the FATS completed, and the boiler equipment installed, the team uses a strategy with the following steps : (pre-commissioning and Actual commissioning actions)

Each facility has to develop site - and equipment - specific procedures for use by the boiler commissioning team. The content of these procedures depends on a number of specific items including: (8)

Dust collection and ash handling systems testing is carried out to ensure that the entire flue gas treatment and control system up to the inlet of the stack will: a) Manage the flow of flue gases supplied from the boiler under maximum flow rates without vibration, flow restriction, surging, or major velocity/impingement issues. This includes completing velocity profiles across various sections of the precipitators and flue gas ductwork. Ensure that no air leaks in to or out of the precipitators, including all points where the precipitator equipment passes through the casing walls. b) Dynamically test all rappers and dust collection equipment to prove functionality. c) Test all heating devices used to maintain hopper and penthouse temperatures. d) Ensure the penthouse and insulating compartments pressurization and drying systems function and deliver air at the proper temperature and flow rates during full ID fan flows. e) Checkallinsulation,cladding,andcoldsinkisolationforproper installation. f) Check the isolation damper operation and ensure that all interlocks function properly when the isolation dampers are activated. g) Prove the operation of all ash dumping, handling, and transmission systems. h) Withallpersonnelremovedfromtheinternalsoftheprecipitator and the access doors secured and locked, live tests are conducted on all electrical systems. Each section of the precipitator is energized and the transformer/rectifier units are manually and automatically operated to prove functionality of the system and test for the proper discharge voltages and current leakage. The rapper systems are then turned on and the system is rechecked to ensure proper operating sequencing, timer functionality, and discharge electrode current and voltages under simulated load conditions. i) If any gas conditioning systems are used to reduce NOx, SOx, or other flue gas constituents, these are function tested and proven fully operational at this time.

Explain the steps taken to function test the dust collection systems on a large power boiler.

1.) Overall project schedule identifying: - Fabrication schedules and FAT timelines - Construction schedules and SAT timelines - Process/unit specific commissioning completion dates - Process/unit transition or rollover dates - Facility fully operational dates 2.) QA/QC protocol for FATs 3.) QA/QC protocol for SATs 4.) Process/unit owners for the commissioning processes 5.) Report generation and document management protocol 6.) Non-conformance response protocol 7.) Overall equipment benchmark and acceptance protocol 8.) Process/unit transition protocol.

Identify the items contained in the overall commissioning protocol document for a power plant or large industrial facility.

1.) Hydraulic/governor oil 2.) Valve steam chests/steam delivery 3.) Lubrication 4.) Gland steam 5.) Steam condenser 6.) Ancillary equipment 7.) Turbine controls/protection

Individual test procedures are developed and used for testing the following turbine systems: (7)

1.) Complete inspection of turbine base, cylinder support steel, and structural framework 2.) Keyways and expansion control devices are lubricated and free to allow for movement 3.) Internal and external drains and vents are clear and valves are fully functional 4.) Casing bolt down tension is tested and bolt extensions are recorded 5.) Bearing placement and surfaces are checked and lubrication pathways are visually inspected

List 5 items that are checked by the commissioning team in the post-installation test step.

1.) Combustion air flow testing 2.) ID fan(s) testing 3.) Feedwater system testing 4.) Coal delivery system testing 5.) Dust collection and ash handling systems testing 6.) Fuel gas system testing

List 6 different Functionality Tests. (This is done after the individual tests on all pieces of equipment and ancillary systems are complete)

1.) Fuel oil system 2.) Natural gas system 3.) Lubrication system 4.) Air intake system 5.) Air compressor turbine 6.) Combustion system 7.) Gas/Power turbine 8.) Hot air ducting

List 8 individual tests that take place on the gas turbine and its ancillary equipment.

1. Minimum start, ramp up, and full-load times on the gas turbine and generator 2.) Base load capabilities 3.) Peak load capabilities 4.) Maximum turbine power output 5.) Maximum electrical power generated at rated conditions of phase, voltage, current, and power factor 6.) Temperature profiles across the unit at base loads and peak loads 7.) Maximum steam output from the HRSG at full gas turbine loads and full auxiliary firing rates (under design conditions of steam pressure, temperature, and steam quality 8.) Ability of the combustion controls to maintain permitted exhaust gas conditions at maximum firing rates. 9.) Ability of the building's noise suppression system to maintain required sound readings under all firing conditions.

List the 9 items defined by the final quality and performance tests done on a gas turbine.

1.) Land owner 2.) Equipment, processes, chemicals, and products that have been on the 3.) land during the time of operation 4.) Steps taken to de-commission the facility and reclaim the land 5.) Procedures used to dispose of all site equipment 6.) Documented list of companies who purchased any of the used equipment 7.) Final disposition of any hazardous wastes 8.) Auditing and testing completed to ensure full compliance with all regulations. 9.) Documented list of companies who performed the de- commissioning and land reclamation. 10.) New buyer of the land and what specific use the new owner has planned for the site

List the items found in a site profile document.

1.) Ensure off-site and installed equipment conforms to the design specifications that were approved by the project team. 2.) Ensure approved equipment is installed as per the final revision of the approved-for-construction drawings. 3.) Ensure approved and installed equipment meets the performance standards and requirements approved by the project team including all standards and regulations set by the provincial safety authorities acts and regulations and meets the criteria set by CSA and relevant engineering codes and standards. 4.) Ensure pipes, fittings, connections, couplings, and stationary equipment conform to the specifications approved by the project team. 5.) Ensure approved pipes, fittings, connections, couplings, and stationary equipment is installed as per the latest revision of the approved-for-construction drawings.

List the key objectives met by the power plant commissioning process. (Just name 5)

1.) Max. start, ramp up, and full-load times on the gas turbine and generator 2.) Base and peak load capabilities 3.) Maximum turbine power output 4.) Max. electrical power generated at rated conditions of phase, voltage, Current, and power factor 5.) Temperature profiles across the unit at base and peak loads 6.) Max. steam output from the HRSG at full gas turbine loads and aux. firing rates (under design conditions of steam pressure, temperature, and steam quality) 7.) Ability of the combustion controls to maintain permitted exhaust gas conditions at maximum firing rates 8.) Ability of the buildings noise suppression system to maintain required sound readings under all firing conditions

Once the function testing has been completed, the gas turbine is tested to prove sustainable operation at normal and full-load, or peak load, conditions. These final tests are carried out to define: (6)

1.) Identification of equipment 2.) Development of commissioning procedures

Pre-commissioning involves developing processes and setting up the documentation that guides the commissioning team through the entire commissioning process. It includes the following components: (2)

1.) Ensure that the quality and temperature of the water to be used for the testing are within the approved parameters 2.) Ensure that all boiler connections are properly blinded off using rated spectacle blinds for all lines. Since this is a new installation, the hydrostatic test should be done BEFORE the safety valves are installed. - If the PSVs are already installed, then they need to be blanked, plugged, or gagged during the hydrostatic test. 3.) Ensure that all instrumentation connects are blanked except the temporary temperature and pressure devices specifically calibrated and tested for monitoring and recording/documenting the hydrostatic test 4.) Flush to clean out all fill and feedwater lines before the boiler is filled 5.) Use demineralized water to fill the boiler and ensure that a compatible corrosion inhibitor is added to mitigate the potential for corrosion. 6.) Superheaters are normally designed with temporary connections so that they can be flushed backwards into the boiler to remove any fabrication and construction contaminants. 7.) Fill the boiler through the economizer with the steam drums doors open. When the drum begins filling, allow the water to fill the downcomers and then the waterfalls of the boiler. Periodically, blowdown all the water wall headers as the boiler fills and open the mud drum blowdowns and clean all the lines out as many times as necessary to prove the lines are blowing clear. Continue to monitor the water level in the steam drum until the water walls are full and water begins to return to the drum. Check the water in the drum for any contaminants or construction materials. Once the water is clean, all the wall tubes are full, and the water level reaches the drum door openings, stop the feed pump and install the doors. 8.) Continue to fill the boiler with the steam drum and superheater vents fully open until water begins to flow out of the boiler drum vents 9.) Close the steam drum vents and fill the superheaters with water until the water begins to flow out the superheater vents. Shut off the feedwater pump and close the superheater vents. 10.) Using the feedwater or fill pump, slowly raise the pressure within the pressure parts to the MAWP of the boiler. Fix leaks during this time. 11.) Once all the leaks have been repaired, the pressure on the boiler is raised slowly until it reaches 1.5 times the MAWP. - The pressure must be held for a minimum of 30 minutes and make sure the pressure doesn't decrease by 10%.

The basic steps required for performing a hydrostatic test are as follows: (11)

1.) Type of system installed 2.) Ancillary systems supporting the gas turbine 3.) Drive equipment powered off the gas turbine 4.) Use of the turbine waste heat

The commissioning process for a gas turbine depends directly upon the following: (4)

1.) Factory Acceptance Tests 2.) Site Acceptance Tests

The commissioning process has 2 clearly distinct components. Name them.

1.) Commissioning protocol document 2.) Individual equipment testing procedure development 3.) Functionality procedure development and implementation 4.) Final Equipment testing and performance certification

The detailed commissioning strategy for a large boiler fan covers the following topics: (4)

1.) Ensure that all documentation is completed, signed, and dated from all tests 2.) Ensure that all equipment files have been updated 3.) Any variances to the design must be documented and recommendations and action items put in place to address all variances 4.) All changes to the P&IDS or constructions drawings must be noted and as built drawings made up

The final step of the commissioning process is to turn the gas turbine over to the operations crew for everyday operation. This involves the following steps: (4)

1.) Post-installation testing 2.) Boiler pressure parts hydrostatic testing 3.) Boiler flushing/chemical cleaning/passivation/neutralization 4.) Installing steam/mud drum internals 5.) Instrumentation connections 6.) Fuel gas lines 7.) Coal delivery system 8.) Boiler valves 9.) Boiler burners 10.) Sootblowers 11.) Steam air heaters 12.) Boiler fans 13.) Steam and water sampling/boiler chemical systems 14.) Flue gas passage 15.) Flue gas stack 16.) Ash collection systems 17.) Electrostatic precipitatators 18.) Power supply 19.) Positive air flow systems 20.) Instrumentation and controls

The following IT steps are carried out simultaneously across the boiler unit: (20)

1.) Hydraulic and governor oil systems 2.) Steam valves, steam chest, and steam delivery system to the turbine 3.) Lubrication systems 4.) Gland seal systems 5.) Steam condenser system 6.) Turbine governor and controls system 7.) Turbine protection and supervisory instrumentation and control equipment 8.) Ancillary equipment (barring gear, jacking oil system, flange heating systems, auxiliary cooling systems)

The following are the main components of a large multi-stage turbine used to drive a medium-sized electrical generator: (8)

1.) Vacuum or sub-atmospheric pressures coming from the seals and glands at low pressure and exhaust end of the turbine and the very outside rings of the LP and IP glands 2.) Atmospheric pressure which receives steam from the IP and LP gland rings next to the outside or vacuum rings 3.) HP system which takes the steam from the inner rings and from the HP cylinder glands and re-injects it into the steam out of the HP cylinder before the reheater

The gland steam system is designed to handle steam at various pressures including: (3)

1.) Speed sensing equipment and instrumentation 2.) Generator load sensing equipment and instrumentation 3.) Steam pressure sensing equipment and instrumentation 4.) Protection equipment and instrumentation 5.) Central control systems, and control logic programs 6.) Data highway system and electrical signal systems 7.) Hydraulic signal system from the relays to the pilot valves 8.) Hydraulic drive or power systems to the HP and IP governor valve actuators and the stop valve actuators

The governor itself includes the following main components: (8)

1.) Identification of equipment 2.) Commissioning procedure development 3.) Post-installation testing 4.) Individual Tests (ITS) 5.) Functionality Tests (EFTs)

The overall steam turbine commissioning protocol follows the same steps as detailed for boiler commissioning. List the 5 steps.

1.) Condenser vessel 2.) Cooling water system 3.) Condensate collection, recirculation, and removal system 4.) Vacuum generating system

The steam condenser system is comprised of 4 basic units, name them.

1.) Detailed list of the equipment to be tested 2.) Testing protocol for each piece of equipment 3.) Benchmarks for each piece of equipment 4.) Process or system functionality tests (proves proper functioning of the equipment within the process or system) 5.) Acceptance criteria

What are 5 common components of a QA/QC protocol for SATS?

- Involves site acceptance testing of all the auxiliary systems to ensure their performance, functionality, and operability. This includes individual functionality and final operability tests on the following equipment and process: 1.) Fire and Safety systems 2.) Utility air systems 3.) Instrument air systems 4.) Utility water systems 5.) Lubrication systems 6.) Hydraulic systems 7.) Fuel storage, handling, and delivery systems 8.) Waste treatment and handling systems 9.) Utility power systems 10.) Instrumentation and control systems associated with the utility systems

What does step 6 of commissioning step sequencing involve? And list 10 equipments and process that its used on.

- Inspection and clean out of all utility systems from step 6, together with all the ancillary equipment. - This includes washing and flushing line; air and steam blowing of all pipe sections to atmosphere under controlled conditions of pressure, velocity, and flow rate; and final connecting of equipment, supply, and delivery lines and control systems

What does step 7 of commissioning step sequencing involve?

- Site acceptance testing (SAT) for all major piece of equipment: The SAT. strategy involves completing acceptance testing for the equipment in order of need. Once. the utility system SATs are. complete, clean out the processes and begin final functionality testing to be ready to support the main equipment items as they move through the commissioning steps.

What does step 8 of commissioning step sequencing involve?

- Involves site acceptance testing of instrumentation, controls, HMI devices, and all supervisory systems - Process begins with the inspection and proving of the end devices, transmitters, and local recorders and controllers. - The communication systems, data highways, and I/O termination panels are tested by integrity - All remote controllers and HMIs are function tested - Control loops are proven and all supervisory systems are checked for functionality, operability, and response time. - When this process is complete, begin equipment functionality testing (FT) to ensure that all equipment operates within the approved cause and effect strategies of each process

What does step 9 of commissioning step sequencing involve?

1.) The overall facility 2.) Each process within the facility 3.) Each piece of equipment and pipe and connection within the individual processes

With regards to plant commissioning - No matter how experienced the commissioning team, they must have developed a formalized commissioning strategy with clearly identified objectives for: (3)

1.) Steam Turbines 2.) Condensate return systems 3.) Forced draft and induced draft fans 4.) Feedwater systems including water treatment, deaerators, and storage tanks 5.) Boiler, including all combustion systems 6.) Flue gas cleaning systems 7.) Switchgear and main transformers 8.) High voltage distribution systems

With regards to step 8 of commissioning step sequencing, list 8 individual testing of equipment that it involves.