31.05/ Unit-1

Transcription

1 Semi-Annual Inspection FS Report 31.05/ Unit-1 Customer Representative: GE Field Service Representative: All technical recommendations and information contained in this report are based on GE manuals that have been developed and approved for use with GE engines and parts that have been operated and maintained in accordance with GE technical documentation and recommendations. GE has no technical knowledge of, nor obligation for, non GE-approved parts and repairs. Accordingly, this report is not intended to apply to non GE-approved parts and repairs, nor to any parts that may be directly or indirectly affected by non GE-approved parts and repairs.

2 DETAILS AND DATA Purpose of visit: The purpose of this visit was to perform the Semi-Annual Inspections. Work performed: Control system part of Semi-Annual Inspections was performed. SAI Summary: ; - We arrived to the site at 19:30. But the unit was found in working condition. We had a small meeting with the customer about stop time of the unit and offline water wash period. Customer informed that, the unit will run until 21:00 due to commercial reason. We had to leave the site. Offline water wash has been started by customer ; - We arrived to the site at 01:00 - Offline water wash was completed by customer. (03:45) - LOTO was applied by customer. - All engine thermocouples and RTDs were simulated. T48 and T3 thermocouples were measured and found within limits except T48 A and F thermocouples. T48 A and F were replaced with new ones ; - All pressure transmitters were calibrated according to actual ambient pressure. Ambient pressure was measured as during the Semi-Annual Inspection. All pressure transmitter lines have been checked for leakage. - Turbine and Generator Lube Oil systems pressure transmitter and switch calibrations were checked. Switch setting values have been set according to site P & ID. - Over-speed alarm, trip points and external over-speed detection system have been checked. Alarm and trip signals were appeared on the HMI Screen. - Magnetic Chip Detectors were checked. Chip Detector A was found damaged. It was replaced with a new one. - 24VDC Control, FPP and 125 VDC Battery Charger Systems have been checked as visually. Electrolyte levels have been checked and found as normal level. Battery measurements were performed. 24 VDC battery system ground leakage was found on the (-) polarity. It needs to be investigated next available outage. - Gap voltage of generator vibration proxy sensors were measured and found as within tolerances. - Off-engine and on-engine cables have been inspected as visually. Observed no anomalies. All off-engine cable plugs have been checked for tightness. - Unit was started by customer due to commercial reasons. Unit was reached up 42 MW without any problem Gas Fuel system pressure transmitter calibrations were checked. Fuel gas metering valve calibration and shut-off valves have been checked. - Generator vent fan (A) air flow switch function checks were performed. Observed no anomalies. - Fire protection system faulty strobe was replaced with new one. All cables have been connected to their terminals. - FPP Combustible Gas Detectors have been calibrated. Two gas sensor sensitivities were measured out of limit. Only one gas sensor was provided by the customer and then it was replaced. Other gas sensor needs to be replaced with new one. Two combustible gas sensor needs to be ordered. Optical flame detectors have been checked for their functionality. Fire alarm was received and SOVs have been activated by FPP. Horns, strobes have been activated by FPP.CO2 release stations have been checked and received the alarm from the FPP and HMI. Report completed by 2

3 - Remote emergency stop buttons were not working. Necessary investigations were performed on the Emergency system. Cabling and their connections were checked. Incorrect connections were found. Faulty connections were corrected. All Emergency Stop buttons have been checked for their functionality. Observed no anomalies. - Hydraulic Start System solenoid valve (SOV 1619) was replaced with new one. Demand value has been adjusted back. Replaced solenoid valve is working without any problem. - Generator Jacking Oil HP pressure gauge calibrations were checked. Pressure gauges were found normal condition. Troubleshooting need to be performed on the jacking oil system. - For HMI counter corrections, new control software (Rev: H) which is provided by engineering, has been uploaded to the controller. However, Linknet N212 fault signal and connected signals were received. Old control software (Rev: F) has been uploaded to the controller again. However, Linknet N212 fault signal and connected signals were received again. Faulty Linknet was replaced with new one. New control software which is provided by engineering has not been uploaded to controller due to lack of enough time. The new software (Rev: H) needs to be installed at the first available outage. - Unit has been started by customer due to commercial reasons and reached up 42 MW without any problem. - Customer ADSL modem configurations were checked for OSM connection issue. ADSL modem was configured as bridge mode. However internet connection was not established between ADSL modem and Cisco modem. Latest customer ISP account details have been shared with engineering to check Cisco configuration. Report completed by 3

4 CONCLUSIONS & RECOMMENDATIONS Open Items: - New control software which is provided by engineering has not been uploaded to controller due to lack of enough time. The new software (Rev: H) needs to be installed at the first available outage. - (-) Polarity ground leakage was measured on the 24VDC system. It needs to be investigated as soon as possible. - Water Injection flow meter could not be replaced with new one due to lack of the spare part on site. It needs to be replaced when the new flow meter delivered to the site. - Customer ADSL modem configurations were checked for OSM connection issue. ADSL modem was configured as bridge mode. However internet connection was not established between ADSL modem and Cisco modem. Latest customer ISP account details have been shared with engineering to check Cisco configuration. - Generator Jacking Oil HP pressure gauge calibrations were checked. Pressure gauges were found normal condition. Troubleshooting need to be performed on the jacking oil system. Follow Up Action Items Engineering: Follow Up Action Items SM/CPM/PM: Outage Data: Engine Data: ESN xxx-xxx Engine Fired Hours - Package Hours Model Engine Fired Starts - Package Fired Starts 2513 Maintenance Data: WP, SB, SL, PB, PL Performed Revision/manual reference Date completed WP T48 Thermocouple Inspection WP Vibration Monitoring System Check WP Chip Detector Check Comments Parts Data: Description PN Removed SN Removed Qty Disposition PN Installed SN Installed STROBE 382A5419P Replaced 382A5419P T M86P02-2 Replaced 1962M86P02 - CHIP DETECTOR L43563P01-1 Replaced L43563P01 - LINKNET Replaced GAS SENSOR 334A3940P Replaced 334A3940P IGNITER 9392M95P04-1 Replaced 9392M95P04 - SOV A5502P Replaced 382A5502P Report completed by 4

5 UDETAILS AND DATA Work performed T48 Thermocouple Inspection T48 Thermocouple Measurement T48 Probe Insulation Resistance KP-KN Insulation Resistance KN-KP Average KP-KN(Ohm) T48A T48B T48C T48D T48E T48F T48G T48H As per the GEK Volume II WP ; KP to KN circuit resistance should be between 2,4 ohm and 4,1 ohm. Insulation resistance between plug and case should be > 5Mohm. Tag As Found As Left -70 ºF 0 ºF 900 ºF 1600 ºF 1900 ºF -70 ºF 0 ºF 900 ºF 1600ºF 1900 ºF T48 A T48 B T48 C T48 D T48 E T48 F T48 G T48 H Turbine Control system simulated and re- tuned according to T48 low and high set points. Observed no big differences. - Between KP/KN and case ohm was > 5Mohm for all the probes. Report completed by 5

6 UDETAILS AND DATA T3A TE-6838A T3 Calibration Data T3B TE-6838B Range -70 to 1200 ºF Range -70 to 1200 ºF KP-KN KN-KP KP-KN KN-KP Resistance Resistance Sim. Temperature As Found As Left Sim. Temperature As Found As Left As per the GEK , Volume I, between A and B and between C and D pins Resistance should be between 4,3 ohm and 6 Ohms. - Turbine Control system simulated and re- tuned according to T3 low and high set points. Observed small differences (max. 4-5 Fahrenheit) before the simulation. - On- engine and off-engine cable sockets were cleaned with Contact Cleaner before the re-installation. T2 Calibration Data T2A T2B Range -70 to 500 ºF Range -70 to 500 ºF Sim. Sim. Temp. As Found As Left Temp. As Found As Left Report completed by 6

7 DETAILS AND DATA Work performed: T25A T25 Calibration Data T25B Range -70 to 500 ºF Range -70 to 500 ºF Sim. Sim. Temp. As Found As Left Temp. As Found As Left Calibration Data of Pressure Transmitters Ambient pressure was measured as PSI. Tag Range PSIG As Found P As Left P25 Calibration Data Tag P25A Tag P25B Range Range PSIG As Found As Left PSIG As Found As Left Report completed by 7

8 DETAILS AND DATA Work performed: PS3 Calibration Data Tag PS3 A Tag PS3 B Range Range % PSIG As Found As Left % PSIG As Found As Left Vacuum Vacuum % % % % % % % % PTB Calibration Data Tag PTB A Tag PTB B Range Range PSIG As Found As Left PSIG As Found As Left P48 Calibration Data Tag P48 Range PSIG As Found As Left Report completed by 8

9 Redundant Over-speed System Check U Speed signals are simulated from the off-engine cable via signal generator. Speed signals have been monitored as shown below tables. The alarm and trip points have been appeared on the Alarm Page when we send; Redundant over speed system check was carried out according to the following set points. XN25A XN25B (Hz) (rpm) HMI (rpm) (Hz) (rpm) HMI (rpm) (alarm) 8090 (trip) (alarm) (trip) 1 Rpm = Hz Alarm Point: > Rpm = 8015 Hz Trip Point: > Rpm = Hz NSDA NSDB (Hz) (rpm) HMI (RPM) (Hz) (rpm) HMI (RPM) (trip) (trip) For NSD Speed Sensors; 1Rpm = 0.8 Hz Trip Point > 4050 Rpm = 3240 Hz Report completed by 9

10 VIBRATION MONITORING SYSTEM - Vibration Monitoring System was checked according to WP Vibration signals were appeared on the HMI Screen. According to manual Check accelerometers by tapping it lightly with a small object (screwdriver handle). Accelerometer is good if control panel shows an indication of tapping, - During the taping test, indication was observed on HMI from the both accelerometers. GENERATOR GAP VOLTAGE ID NUMBER DESCRIPTION SET POINT UNIT AS FOUND AS LEFT XE-6807 DE_X GEN DRIVE END VIB PROBE VDC XE GEN DRIVE END VIB PROBE DE_Y VDC XE NON-GEN DRIVE END NDE_X VDC XE NON-GEN DRIVE END NDE_Y VDC GENERATOR LUBE OIL SYSTEM Tag Name Description Setpoint INC DE C FOUND LEFT PSL GLO Supply Press Low 20 PSIG DEC PSLL-6019 GLO Supply Press LowLow 12 PSIG DEC PSL-6073A GLO AC Pump A Press Low 40 PSIG DEC PSL-6073B GLO AC Pump B Press Low 40 PSIG DEC PSL-6074 GLO DC Pump Press Low 20 PSIG DEC PSL-6050 Jacking Oil Pump Inlet Press Low 10 PSIG DEC PSL-6051 Jacking Oil Pump Inlet Press Low Low 5 PSIG DEC PDSH-6015 GLO Filter Hi Difference 20 PSIG INC PT-6026 GEN. Lube Oil Pressure PSG , ,100 TURBINE LUBE OIL SYSTEM Tag Name PT-6122 PT-6121 Description TURBINE LUBE OIL SCAVENGE PRESSURE TURBINE LUBE OIL SUPPLY PRESSURE Setpoint PSIG PSIG Low As Found High As Found Low As Left Low As Left Report completed by 10

11 Tag Name Description SP Unit INC NO/ DEC NC Found Left PDSH-6120 TURB L/O SUPPLY FILTER HI DP 20 PSID INC NC PDSHH-6144 TURB L/O SUPPLY FILTER HI HI DP 25 PSID INC NC PDSH-6118 TURB SCAVENGE FILTER HI DP 20 PSID INC NC PDSHH-6119 TURB SCAVENGE FILTER HI HI DP 25 PSID INC NC PSLL-6115 TURBINE LUBE LO LO PRESS 15 PSIG DEC NO PSLL-6116 TURBINE LUBE LO LO PRESS 6 PSIG DEC NO PSH-6117 TURB SCAV OIL PUMP PRESS HI 100 PSIG INC NC PSLL-1605 HYD STARTER SKID PRESSURE LO LO 250 PSIG DEC NO PDSH-6146 TURBINE VG LUBE OIL FILTER DP 20 PSIG INC NC Pressure switches were calibrated within +- 1 PSIG of set-point. FIRE PROTECTION SYSTEM Report completed by 11

12 Tag Name Description Setpoint Unit AE-6304A AE-6304B AE-6304C AE-6304D AE-6304E AE-6313 TURBINE GAS DETECTOR TURBINE GAS DETECTOR TURBINE GAS DETECTOR TURBINE GAS DETECTOR TURBINE GAS DETECTOR GENERATOR GAS DETECTOR Found ( ma ) Left %0 LEL ( ma ) Left %50 LEL ( ma ) 50% LEL % LEL % LEL % LEL % LEL % LEL CHIP DETECTORS Tag Name Resistance As Found Test Results As Left MCD 6865 Open Circ. 161 Ohms 2 Ohms 161 Ohms MCD 6866 Open Circ. 161 Ohms 3 Ohms 161 Ohms MCD 6870 Open Circ. 161 Ohms 2 Ohms 161 Ohms BATTERY SYSTEMS 24 VDC CONTROL SYSTEM BATTERY VOLTAGES POSITIVE TO NEGATIVE POSITIVE TO GROUND NEGATIVE TO GROUND BATTERY WATER LEVELS VDC VDC VDC NORMAL 24 VDC FIRE SYSTEM BATTERY VOLTAGES POSITIVE TO NEGATIVE POSITIVE TO GROUND NEGATIVE TO GROUND BATTERY WATER LEVELS VDC VDC VDC NORMAL 125 VDC SYSTEM BATTERY VOLTAGES POSITIVE TO NEGATIVE VDC POSITIVE TO GROUND VDC NEGATIVE TO GROUND VDC BATTERY WATER LEVELS - Report completed by 12

13 Ambient Pressure Replaced Combustible Gas Sensor Replaced T48 Thermocouples Replaced Chip Detector Replaced Igniter Replaced RTD 6 Channel Linknet Report completed by 13

14 Replaced Hydraulic System SOV1619 Replaced Fire Protection System Strobe Fire Protection System Function Checks DC Battery System Report completed by 14

15 HMI SCREENS Report completed by 15

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