001 Gas Turbine Generator Commissioning Procedure

Procedure
Title Gas Turbine Generator Commissioning Procedure
TC2000PLUSSM Control System

Commissioning Procedure
Application: This Commissioning Procedure provides overall instruction for site testing of the
customer‟s equipment listed in the following table. The Outline beginning on page 2 lists all of the
commissioning tests that are required for this project.
Customer
Site
ICS Project Number
Customer Unit No.
GT OEM.
GT Model No.
Fuel Type
Doc ID: TIS-CS-GT-G-01 REV: 5 Date 18 JUN 08 Page 1 of 62

Procedure
DO NOT PROCEED WITHOUT THESE DOCUMENTS

References: Obtain a copy of the as-built drawings.
Document Number Rev Title
Control Schematic
Turbine Controller Technical Specification
IO List
Voltage Regulator
Piping &
Instrumentation
Other
NOTE: During commissioning there may be changes to the settings in the PLC. Each
change should be noted, initialed and dated on this form.
This test procedure is to be used in conjunction with a Gas Turbine

Operating Data sheet. Record the form number of the applicable data
sheet here:
Form Number Rev.

FM-OD-GT-G-FR-001
FM-OD-GT-G-GG-001

Procedure
Table of Contents
1.0. Safety Review ..................................................................................... 4
2.0. Panel Power-up Checks ....................................................................... 5
2.1. Visual Inspection ........................................................................................................ 5
2.2. Control Panel Power-Up Checks................................................................................... 5
2.3. DC Power Circuits ....................................................................................................... 6
2.4. AC Power Circuits ....................................................................................................... 7
2.5. HMI Interface and Controller Checks ........................................................................... 7
3.0. I/O Checks........................................................................................... 9
3.1 Verify the Master Protective Circuits ............................................................................. 9
3.2. Discrete Input Checks ............................................................................................... 13
3.3. Thermocouple Inputs ............................................................................................... 14
3.4 RTD Inputs .............................................................................................................. 14
3.5 Analog Inputs .......................................................................................................... 15
3.6. Discrete Output Checks ............................................................................................ 16
3.7. Analog Output Checks .............................................................................................. 17
3.8. Vibration Protection System I/O Checks ..................................................................... 18
3.9. Motor Control Center Checks ..................................................................................... 18
4.0 System Checks .................................................................................... 20
4.1 Electro-hydraulic actuator Tests ............................................................................. 20
4.2. Off-line Running Checks .......................................................................................... 28
4.3. Synchronization Checks ........................................................................................... 41
4.4. Turbine On-Line / Load Checks ................................................................................ 48
4.5. Shutdown Checks .................................................................................................... 59
NOTES ....................................................................................................... 62

Procedure
1.0. Safety Review

Check Completed
Record data
Completed by / date
Identify customer representative responsible
for site safety.
Verify with Customer that all site specific

safety practices and issues are identified
Establish lock-out and tag-out procedure with

Customer safety representative
Identify subcontractor reps responsible for

„crew‟ safety
Ensure that installation personnel are fully

aware of site safety issues and of proposed
testing.
Completely inspect turbine for any work that

may not have been finished and may impact
safety.
Completely inspect generator for any work

that may not have been finished and may
impact safety.
Completely inspect area for any work that may

not have been finished and may impact safety.
Before proceeding with the following checks

ensure that a device not controlled by the ICS
system isolates the fuel supply(s). Ensure that
the starting device is locked out.

Procedure
2.0. Panel Power-up Checks

2.1. Visual Inspection
Check Completed
Record data
Completed by / date
Visually check that the control panel has not been
physically damaged during transit to site.
Ensure that the relays and other auxiliary equipment

have not been disturbed and that the internal wiring
is secured.
Check that all removable modules are correctly

aligned and fully inserted.
Inspect field wiring. Check for loose connections,

frayed wires.
2.2. Control Panel Power-Up Checks

Consult the Turbine Controller drawing for panel power distribution circuit wiring details.
Check Completed
Record data
Completed by / date
Verify TCP (Turbine Control Panel) main ground
connection is terminated and connected to plant
ground grid. Ground conductor should be same size
(or larger) as biggest power feed conductor.
Verify that turbine systems are tagged-out and

isolated including ac and dc oil pumps, turning gear,
starting motor, etc.
Ensure that all panel circuit breakers are off and all
fuse holders are open.
Verify that the power supply for each control rack is

OFF.

Procedure
2.3. DC Power Circuits

Main DC Power Circuits
Refer to the DC Panel Power Distribution of the Turbine Controller drawing.

Check Completed
Record data
Completed by / date
Verify polarity of DC source input power at the main
fuse.
Verify that DC input power is not grounded. If so

determine its source and correct. Record DC
voltage.
Check that there are no grounds on the positive and

negative legs on the panel side of main DC fuse.
Check that no short-circuit exists between the positive
and negative legs. Record insulation resistance.
Insert the main DC fuse and apply DC power to the

panel.
Successively power-up each control rack, verifying

rack initialization.
Successively power-up any Remote I/O (RIO)

modules, verifying initialization.

Procedure
DC Power Sub-Circuits (24Vdc)

Refer to the DC Panel Power Distribution sheets of the Turbine Controller drawing.
Check Completed
Record data
Completed by / date
Energize all control panel 24Vdc circuits. Do not
install fuses for field circuits. Record panel
24Vdc power supply Voltage.
2.4. AC Power Circuits

Refer to the AC Panel Power Distribution sheets of the Turbine Controller drawing.
Check Completed
Record data
Completed by / date
Verify all AC power circuit breakers are open.
Verify value of AC source input power at the

isolating circuit breaker. Record the AC
voltage.
Turn AC power on. Successively close the other ac

circuit breakers in the panel and verify all circuits
are energized.
2.5. HMI Interface and Controller Checks

Load Software to HMI
Check Completed
Record data
Completed by / date
Ping the PLC
If the request times out, check the IP and subnet

addresses again and also verify that the link LED
is solid green at both the system and the hub
end.
Transfer of necessary files to the HMI PC at site
The latest PLC folder should be transferred from

the service laptop to HMI PC under
E:\???\Unlocked\Current\

Procedure
Check Completed
Record data
Completed by / date
The latest HMI folder should be transferred from
the laptop to the HMI PC under
E:\WW Projects\Current\
The latest LTI application should be downloaded

to the HMI PC under
E:\???\Current\
Establish Ethernet Communication to PLC from HMI
Check Completed
Record data
Completed by / date
Download the latest PLC logic and the reference

tables to the CPU.
Enable PLC
Check Completed
Record data
Completed by / date
Open PLC Programming Software (RSLogix, Proficy,
etc.) and confirm that the software is connected to
the PLC CPU and that PLC status indications are
correct.
Confirm that each of the modules is healthy. Resolve

any discrepancies.
Review the Diagnostic Alarm display of the HMI and

confirm that the system is healthy with the exception
of I/O Faults.

Procedure
3.0. I/O Checks
3.1 Verify the Master Protective Circuits

The Master Protective Circuits provide a means of tripping the gas turbine by shutting off fuel
flow. These circuits use relays in various combinations to cause the fuel stop valves to close in
the event of an emergency. The Master Protective Circuits are shown in the Turbine Controller
drawings.
Energize the Field Master Protective Circuit

Check Completed
Record data
Completed by / date
Reference Turbine controller drawing. Verify that all
the conditions required to energize the field Master
protective relay are properly wired.
Energize the Master Protective Circuit

Check Completed
Record data
Completed by / date
Force the software master protect logic(s) to
energize the software master protect relay(s). Verify
that the Master Protective relays energize.
Press the emergency stops pushbutton on the front

of the ICS system and verify that the solenoid drops
out. Reset the emergency stop pushbutton and
verify the solenoid is energized.
Drop out one part of the master protective circuit by

removing the force on the software master protect
logic and verify that the solenoid drops out.
Pick up the master protective circuit by restoring the

force on the software master protect logic and verify
that the solenoid picks up.
Drop out the other part of the master protective

circuit by dropping out the field master protective
relay and verify that the solenoid drops out.

Procedure
Test the „Fail-Safe Solenoids‟

The term „fail-safe solenoid‟ describes any solenoid that is required to be independently de-
energized in the event the unit is to be tripped. A fail-safe solenoid can be identified by the
presence of master protective relay contacts in its circuit. Because these solenoids are hardwired
to master protective relay normally open contacts it will ensure that the fail-safe solenoid will be
de-energized when a trip signal is received. During normal unit operation, a fail-safe solenoid is
normally energized and de-energized by an interposing relay that is operated by a PLC output.
Check Completed
Record data
Completed by / date
Reference the „Solenoid sheets‟ of the Turbine
Controller drawing. Force the logic to energize the
solenoids listed below. Verify the solenoid is
energized.
Complete chart below:

Procedure
Solenoid Check Completed

Completed by / date

Procedure
Solenoid Check Completed

Completed by / date

Procedure
3.2. Discrete Input Checks

Discrete or Digital Inputs: Discrete inputs are listed in the IO list.
The preferred method to check the integrity of discrete inputs is to simulate the process condition
operating the field device, for example, by applying process pressure to a pressure switch.
Toggling the actual device is the next best method. Jumpering or removing wires is also
acceptable where simulation or toggling is not possible. When jumpering, always jumper at the
field device.
Each input should be verified to the PLC, HMI screen and/or alarm per the IO list.
Verify that the field device is in its proper state per the IO list. If not, set device to proper state
and correct the software, I/O list or drawing as required. Verify description is correct.
Check Completed
Record data
Completed by / date
Verify that all discrete inputs are connected at the
panel per the Turbine Controller drawing.
Check for grounds on field wiring. If a ground is

found, isolate field circuits to locate ground.
Apply power to the discrete input circuits by

closing the appropriate circuit breaker or inserting
the required fuse (refer to Turbine Controller
drawing).
NOTE ANY DEVICE STATE CHANGES:

Procedure
3.3. Thermocouple Inputs

Use the following procedure as a guide and verify each thermocouple listed in the IO list.
Lift individual thermocouple wire at the field device and verify that the Thermocouple Fault
diagnostic alarm occurs.
Verify type of thermocouple. Note wire colors or any markings in the IO list.
At the HMI, verify the signal failure for the particular thermocouple. The failed thermocouple
temperature should be shown in red.
Reconnect the wire at the field end. Reset the diagnostic alarm from the Diagnostic Alarm display
and verify the alarm reset.
For thermocouples that are accessible heat each thermocouple and verify the change in
temperature on the Temperature Summary screen. Otherwise verify thermocouple is reading
ambient.
Check Completed
Record data
Completed by / date
Verify that all thermocouple inputs are connected at
the panel per the Turbine Controller drawing.
NOTE ANY T/C TYPE CHANGES:
3.4 RTD Inputs

Use the following procedure as a guide and verify each RTD input to the IO list.
Check Completed
Record data
Completed by / date
Lift all wires on one side of RTD element at the field
device junction box and verify the RTD Fault
diagnostic alarm occurs.
At the HMI Temperature Summary screen, verify the

signal failure for the particular RTD. The failed RTD
temperature should be shown in red.
Reconnect the wire at the field end. Reset the

diagnostic alarm from the Diagnostic Alarm display
and verify the alarm reset.
Verify RTD is reading ambient.

Procedure
3.5 Analog Inputs

Use the following procedures as a guide and verify each current analog input in the IO list.
Check Completed
Record data
Completed by / date
Reset the PLC Fault Tables.
Reset diagnostic alarms from the Diagnostic Alarm

display.
Disconnect the device wire at the field end and verify

the „signal fail‟ diagnostic alarm for the device.
Verify signal failure for the device on the applicable

HMI screen. The failed signal should be displayed in
red.
Reconnect the wire at the field end. Reset the

diagnostic alarm from the Diagnostic Alarm display and
verify the alarm reset.
Verify that with the field device connected, the

displayed value for the device corresponds to the value
of the signal, +/- 5.0% of span. For instance, a 4-
20mA signal which is expected to display a value of 0 -
200 psig, must be within 10 psi of expected value (200
x .05 = 10).
Verify sections in the IO list. If not correct, make

revision to software, I/O list and drawing as required.

Procedure
3.6. Discrete Output Checks

Verify that all discrete outputs and any field devices driven by these outputs are connected at the
control panel per the Turbine Controller drawing. Contacts being driven by discrete outputs may
be „wet‟ with power supplied by the ICS system or may be „dry‟ with power being supplied from
another source. Refer to the Turbine Controller drawing.
Some discrete outputs may drive Motor Control Center devices. Verify that all Motor Control
Center circuits are locked out or safe to operate. MCC function checks are done in section 3.9.
Use the following procedures as a guide and verify each discrete output in the IO list.
Check Completed
Record data
Completed by / date
Using the IO list and the Turbine Controller
drawing as a guide, toggle each PLC discrete
output. Verify that the field device controlled by
the relay changes state as the PLC output is
toggled. For certain solenoids, the Master
Protective Circuit must be energized; see the
Master Protective Circuit checks.
If it is not possible to verify a change in the field

device, use a multimeter at the field device
interface point to verify a change in the circuit.
Verify that the relay contacts are in the proper de-

energized state, e.g., the NC contacts are closed
when the relay is de-energized.

Procedure
3.7. Analog Output Checks

Use the following procedures as a guide and verify each procedure to the IO list for each analog
output. Cross check the IO list against the Turbine Controller drawings.
Check Completed
Record data
Completed by / date
Disconnect the device wire at the field end.
Connect a multimeter to the circuit to monitor

current or voltage as applicable.
Clear the PLC Fault Table. (FOR GE FANUC ONLY)
From the appropriate analog output test screen on

the HMI enable the analog output test. Simulate
values for the entire range of the variable and verify
the output of the multimeter.
Disable the analog output test.
Disconnect the multimeter and reconnect the device

in the circuit; verify at the display.
Clear the PLC Fault Table. (FOR GE FANUC ONLY)

Procedure
3.8. Vibration Protection System I/O Checks

All the vibration signals have been configured and the circuits checked at ICS. Voltages were
injected to the connection points for the various transducers and the alarm and trip functionality
for each of those channels verified.
Check Completed
Record data
Complete by / date
After the transducers have been wired in the field,
use the IO list to verify that each is correctly
connected to the proper channel by “stimulating” the
transducer in the field verifying a change in the
display.
*NOTE: Record method of “stimulating” transducer:
3.9. Motor Control Center Checks

Check Completed
Record data
Completed by / date
Confirm that it is safe to operate all of the
Motor Control Center devices.
Verify that all oil and other fluid lines are

connected.
Use the following procedures as a guide and verify each procedure to the IO list for each MCC
device.
Check Completed
Record data
Completed by / date
Verify that the device runs when Manual mode is
selected at the MCC.
Select Auto.

Procedure
Check Completed
Record data
Completed by / date
Verify that the device runs when Automatic mode is
selected at the MCC and its driving logic is true.
a. For any devices requiring an additional

permissive from a hardware device, e.g.,
pressure switch, toggle the hardware device
and logic to verify correct operation of the
device.
b. For any group of devices using a lead/lag

arrangement, e.g., dual lube oil pumps, verify
the lead/lag configuration functions correctly,
as well as any hardware device permissives.
c. For any devices triggering another MCC

device to start, e.g., lube oil heater triggering
a lube oil pump, verify the complete
sequence.
Verify that the dc motor driven lube oil pump starts if

the PLC is stopped or turned off.
Be sure to remove all logic forces/overrides at

the completion of the checks.

Procedure
4.0 System Checks

4.1 Electro-hydraulic actuator Tests
Application: This section provides instructions for calibration of an electro-hydraulic actuator
with servo valve and LVDT/RVDT position feedback.
(Check box if this section is not applicable for this commissioning)
Feedback Calibration
For each device listed on the Electro-hydraulic Actuator Calibration Table below, perform the
following steps:
 Position feedback (LVDT/RVDT) calibration
 Actuator Stroke Test
Ensure that the fuel supply is mechanically isolated from the turbine fuel system by
something other than the gas turbine controller.
A Signal conditioner is used to convert the LVDT feedback from the actuator to a 4-20 mA signal
for the turbine controller. The purpose of these checks is to calibrate the signal conditioner so
that the LVDT feedback accurately represents actuator position. This requires driving the actuator
against its „closed end‟ mechanical stop and adjusting the signal conditioner, then driving the
actuator against its „open end‟ mechanical stop and adjusting the signal conditioner and repeating
the procedure until fully closed and fully open consistently yields values as close to 20 and 4 mA
as possible.
This procedure requires an HMI access level of maintenance or higher.

Procedure
Actuator LVDT/RVDT Calibration
Check Completed by
Record data
Completed / date
Reference the relevant sheet of the controller
drawing. Install an ammeter in series between the
actuator LVDT signal conditioner and the controller
analog input card.
Install a mechanical indication device (dial indicator,

protractor, etc) to show the actual mechanical travel
of the actuator.
Ensure that hydraulic oil pressure is available. If

required, the hydraulic trip circuit will be enabled
when the test is enabled.
From the Maintenance Menu of the HMI, access the

relevant Test display for the valve / actuator; this
requires at least a maintenance level password.
Enable the actuator Servo Test.
Select „Enter Output To actuator Servo Coils‟ and

enter a value (+ or – Vdc) that will move the
actuator to the open position.
With the actuator fully open, adjust the „zero‟ on the

signal conditioner to yield a 4.00 mA feedback
output signal to the turbine controller.
Select „Toggle Voltage Sign‟. This should change

the output to the servo coil move the actuator to
the closed end stop.
With the actuator fully closed, adjust the „span‟ on

the signal conditioner to yield a 20.00 mA feedback
output signal to the turbine controller.
Continue back and forth from fully closed to fully

open, adjusting the span and zero to get as close to
20.00 mA and 4.00 mA as possible.
Record the data in the LVDT calibration section of

the table below.

Procedure
Check Completed by
Record data
Completed / date
Leave the ammeter and mechanical feedback
measurement in place and disable the Servo Test.
Actuator Stroke Test

This test will verify that the actuator follows the position reference.
Check Completed
Record data
Completed by / date
Enable the actuator Position Test.
Select „Enter actuator Position Reference‟ and enter

values from 0% to 100.00% per the table below.
Record the data in the table below.
Disable the actuator Test
Review the position data for linearity. Position errors

of greater than +/- 2% are to be resolved. Contact
ICS Engineering Dept. if this accuracy cannot be
obtained over the full actuator range.
Remove ammeter and mechanical position sensor.
NOTE: Data tables for electronic valves follow these for electro hydraulic actuators

Procedure
ACTUATOR NAME:
DEVICE Position Position Mechanical Meter mA Servo LVDT LVDT
Reference Feedback Position Volts Primary Scdy.
TAG on HMI Volts Volts
Vdc
Vrms Vrms
Position feedback (LVDT/RVDT) calibration

CLOSED
OPEN
ACTUATOR STROKE TEST
100%
75%
50%
25%
0%
ACTUATOR NAME :
Vdc
Vrms Vrms

CLOSED
OPEN
100%
75%
50%
25%
0%

Procedure
ACTUATOR NAME:
Vdc
Vrms Vrms

CLOSED
OPEN
100%
75%
50%
25%
0%
ACTUATOR NAME:
Vdc
Vrms Vrms

CLOSED
OPEN
100%
75%
50%
25%
0%

Procedure
ACTUATOR NAME:
Vdc
Vrms Vrms

CLOSED
OPEN
100%
75%
50%
25%
0%

Procedure
For use with electric valves

VALVE NAME:
DEVICE Position Position Feedback Mechanical Position
Reference on HMI
TAG
LIMIT SWITCH TEST
CLOSED
OPEN
STROKE TEST
100%
75%
50%
25%
0%
VALVE NAME:
Reference on HMI
TAG
LIMIT SWITCH TEST
CLOSED
OPEN
STROKE TEST
100%
75%
50%
25%
0%

Procedure
VALVE NAME:
Reference on HMI
TAG
LIMIT SWITCH TEST
CLOSED
OPEN
STROKE TEST
100%
75%
50%
25%
0%
VALVE NAME:
Reference on HMI
TAG
LIMIT SWITCH TEST
CLOSED
OPEN
STROKE TEST
100%
75%
50%
25%
0%

Procedure
4.2. Off-line Running Checks

Full Speed No Load Operation HD & AD
Application: This section provides instructions for commissioning a Heavy Duty Gas Turbine
or a Multi Shaft (Aero Derivative) Gas Turbine to Full Speed No Load.
Check Completed
Record data
Completed by / date
Verify turning gear operation
Turbine Crank / Spin Checks

These checks are to verify the integrity of the gas turbine and the speed signals from the gas
turbine.
Check Completed
Record data
Completed by / date
Verify starting motor operation
Verify that all MCC starters are On and in Auto.
Verify that all panel board DC and AC breakers are
On
Verify that all DC and AC fuses are installed.
Disable the ignition system by removing the
ignition relay(s).
Disable generator breaker closing.
Verify Ready To Start condition. If not ready to
start, check the start permissives and trips to
obtain a ready to start.
Select Spin or Crank mode on the Turbine Control
Panel display of the HMI. This mode will engage
starter, but not allow fuel into combustors.
Issue START. The unit start sequence should
commence.
After unit has reached ignition speed, observe that
the individual speed sensors read properly in the
PLC and on the HMI. Verify (using DVM) that
speed frequency as measured at the panel
terminal blocks compares with speed rpm in PLC
and on HMI.

Procedure
Check Completed
Record data
Completed by / date
No. 1 Magnetic Pickup Speed (Hz):
No. 1 Magnetic Pickup Voltage (Vac):


No. 5 Magnetic Pickup Voltage (Hz):
Shaft HMI Speed (%):

Shaft HMI Speed (Rpm):
Stop unit using the Emergency Stop push button
on the panel.
Record unit coast down time.
Shaft
Shaft
Shaft
Confirm that all Hz to % scaling are correct

Procedure
COMPLETE TABLE BELOW ONLY FOR “B” ENGINE OF A P&W TWINPAC UNIT
Check Completed
Record data
Completed by / date
Stop unit using the Emergency Stop push button on the panel.
Record unit coast down time.
Shaft
Shaft
Shaft
Confirm that all Hz to % scaling are correct

Procedure
GAS FUEL CHECKS
Fuel System - No Ignition Check

The purpose of these checks is to verify that the gas fuel flow during the ignition phase of start-
up is at the right level. Gas manifold pressure must be independently checked with a pressure
gage; the measured pressure may be compared to the pressure recorded on the HMI.
Check Completed
Record data
Completed by / date
Verify that the unit is Ready To Start.
Disable the ignition system by removing the ignition
relay(s).
At the Turbine Control Panel display of the HMI,
select FIRE (IDLE, or other mode indicating OK to
start fuel), and then START.
Verify that all gas valve positions match the
command setpoint from control system.
Monitor gas pressures at the unit gauge panel during
the start attempt.
Check fuel flow stability (no oscillation in fuel flow).
When the ignition timer has timed out – verify the
“Failure to Fire” / “No Flame After Ignition” alarm.
Using the Historical Trend, verify correct system
operation. Record applicable data in the table
below. Printout the HMI trend.

Procedure
GAS FUEL IGNITION CHECKS

Check Completed
Record data
Completed by / date
Main Line Gas Fuel Supply Pressure
(If regulator or upstream pressure control is

installed).
Gas Pressure to GT Gas Fuel System:
Pressure downstream of stop valve
(Inter-valve Pressure on GE units):
Pressure upstream of control valve
Gas Fuel Manifold Pressure:

Ignition Gas Pressure:
Gas Control Valve Position
SRV position (GE units only)
Pressure Regulating Valve Position
Turbine Speed
_____________ Temperature (hot gas)
The purpose of these checks is to verify that the amount of light-off fuel is correct. If any
independent means of verifying flow is used then record this:

Procedure
Gas Fuel Firing Test

Do not continue with firing checks if fuel flow exceeds the requirements in the
previous No Ignition check. This test will admit fuel to the combustion chambers and then
ignite it.
Expected Gas Manifold
Unit Type
Pressure
GE Frame type 5 to 10 Psig
Pratt & Whitney FT4
Check Completed
Record data
Completed by / date
Reinstall the ignition relay(s).
Verify that the unit is Ready To Start. Select FIRE

as the operating mode and start the unit.
With the unit firing, check that fuel control valve

position matches control valve reference. Unit
should indicate flame detection within 15 seconds
of applying fuel to the combustors.
Once flame has been detected, verify the start-up

fuel flow reference decreases to the warm-up
value. Record the warm-up FCR.
If flame is detected normally then STOP the unit

and use the Historical Trend of the HMI to review
the data and verify correct system operation.
Record applicable data in the table below.
Printout the HMI trend.

Procedure
GAS FUEL FIRING CHECKS

Check Completed
Record data
Completed by / date
Main Line Gas Fuel Supply Pressure
(If regulator or upstream pressure control is

installed).
Gas Pressure to GT Gas Fuel System:
Pressure downstream of stop valve
(Inter-valve Pressure on GE units):
Pressure upstream of control valve
Gas Fuel Manifold Pressure:

Ignition Gas Pressure:
Gas Control Valve Position
SRV position (GE units only)
Pressure Regulating Valve Position
Turbine Speed

Procedure
FULL SPEED NO LOAD CHECKS

This test will bring the unit to full speed and is used to verify the start-up, acceleration and
turbine speed control loops. This may be done as a continuation of the Ignition Test above or the
unit may be started from zero speed in the AUTO mode with the synchronizer OFF.
Check Completed
Record data
Completed by / date
Verify that the unit is Ready To Start. Select AUTO
as the operating mode and start the unit.
Verify that at 100% speed, the unit is on

„Speed/Load Governor‟ control.
Verify that all system (lube oil, cooling water, etc.)

pressure and temperatures are as expected. Verify
the HMI display with any gauge readings. Record
FSNL data in the appropriate Unit Data Sheet.
Use the Historical Trend of the HMI to review speed,

fuel flow, and temperature curves from the startup.
Turbine speed should smoothly come to the full
speed setpoint without overshooting and stay there
without „hunting‟.
Print out the „start-up curve‟ and attach to this report
At the Turbine Control Panel display of the HMI enter

a Speed Setpoint Target of 102%. Verify that the
Speed Setpoint ramps to the Setpoint Target at the
normal loading rate and that turbine speed tracks the
setpoint and settles at 102%.

Speed Setpoint ramps to the Setpoint Target and
that turbine speed tracks the setpoint and settles at
105%.

Speed Setpoint ramps to the Setpoint Target and
that turbine speed tracks the setpoint and settles at
100%.

Procedure
Check Completed
Record data
Completed by / date
Use the Historical Trend of the HMI to review Speed
Setpoint Target, Speed Setpoint and turbine speed
from the previous checks. Verify the speed control
regulation and adjust the integral and lead gains if
necessary.
NOTE: Contact ICS Engineering Dept. before making

any adjustments
If overspeed testing is required then allow the unit to

run at full speed no load for sufficient time in
advance of testing. Record this FSNL “warm-up‟
time.

Procedure
Metering Valve Liquid Fuel Check
Liquid Fuel No Ignition Check

The purpose of these checks is to verify the amount of fuel used to „fire‟ the unit. This may be
done by checking the fuel flow with a separate metering device. The measured fuel flow may be
compared to the fuel flow recorded on the HMI (if any).
Check Completed
Record data
Completed by / date
Verify that the turbine is Ready To Start.
Disable the ignition system by removing the ignition
relay(s) and fuses.
At the Turbine Control Panel select a Control Mode
that will admit fuel to the turbine, and then START.
Verify the fuel metering valve moves to the firing
position and that fuel control valve position matches
the control valve reference. See table below for
Required „firing‟ fuel flow. Verify that the actual
fuel flow matches the desired fuel flow with the
control valve at the firing position. Do not continue
with firing checks if actual fuel flow does not
match the required fuel flow.
Check fuel flow stability (no oscillation in fuel flow)
and adjust associated gains accordingly.
When the ignition timer has timed out the sequence
should shut the fuel stop valve. Allow the unit to
coast down to zero speed.

Procedure
Liquid Fuel Fire Check

Do not continue with firing checks if fuel flow exceeds the requirements in the
previous No Ignition check. This test will admit fuel to the combustion chambers and then
ignite it. This is used to examine various operating parameters to verify the starting fuel flow.
Check Completed
Record data
Completed by / date
Ensure that the unit is Ready to Start.
Reinstall the ignition relay(s).

select FIRE, and then START.
With the unit firing, check that fuel control valve

position matches control valve reference. Unit should
indicate flame detection within 45 seconds of applying
liquid fuel to the combustors.
Once flame has been detected, verify the fuel flow

follows expected governor schedule.
Fuel Flow Reference Table
Start-up Fuel
Gas Liquid
Manufacturer Model
Nozzle Nozzle
Flow Flow
Pressure Pressure
GE Frame 5 2.5 gpm
GE Frame 7

Procedure
Turbine Overspeed Trip Checks

Once the unit is at full speed no load, allow the unit to run for 20 - 30 minutes before performing
the overspeed trip checks.
Electronic (Software) Overspeed Trip Test
Check Completed
Record data
Completed by / date
Start the unit and bring it to full speed no load.

Do not enable the overspeed test.
Change the value of the electronic overspeed
control constant to a value higher than the
running speed. Record value:
Raise the speed of the unit until it trips on
„Electronic Overspeed Trip‟ and record the speed
at which the unit trips:
Change the value of the electronic overspeed
control constant back to its original value.

Procedure
Mechanical Overspeed Trip Test
Check Completed
Record data
Completed by / date
From the Maintenance Menu, select Overspeed Test.

Enable the overspeed test. This will raise the
electronic (software) overspeed trip setting above
the mechanical setting.
Enter in a speed setpoint approximately 1% above
the mechanical trip setpoint. Record Speed setpoint
entered:
Observe operation and record the speed at which %
the unit trips:
Rpm
When the unit goes into the cooldown cycle, reset
the mechanical overspeed trip mechanism and clear
the overspeed trip.

Procedure
4.3. Synchronization Checks

Application: This document provides instructions for performing Manual Synchronization, and
applies units regardless of the Exciter/Voltage Regulator applied.
PHASE ROTATION CHECKS

Required Tools: Voltmeter rated for generator terminal voltage, high voltage gloves, face shield
and ground mat.
A full voltage test with “hot sticks” across like phases is highly recommended.
A full voltage rotation test consists of utilizing a voltmeter rated for the voltage of the generator.
The following is a short procedure that should be carried out by qualified personnel
only.
Ensure that the breaker is racked out and in the test position before performing
checks.
Locate a high voltage test stick for checking the voltage difference (hence phase angle) between
the Bus and Generator Phase A, then B and then C. Only persons with proper training should
attempt this procedure.
Check Completed
Record data
Completed by / date
Verify that field wiring between the generator
control panel and the switchgear is complete and
correct.
Turn the voltage regulator off.
Tape off area for testing personnel only. Rack out

generator breaker and expose bus bars.
Verify the breaker close circuit is disabled and that

synchronizing is OFF.
Verify bus voltage and frequency readings on

control panel meters. Record readings.
Start the unit and bring it to synchronous speed.
Start the voltage regulator. At the generator

control panel, verify that the synchronizing lights
and the synchroscope are functioning.

Procedure
Check Completed
Record data
Completed by / date
At the generator control panel, verify that Voltage
Raise and Lower Switch is working.
Verify that the raise and lower voltage buttons are

working on the HMI.
At the generator control panel, verify that

Governor Raise and Lower Switch is working.
Verify that the raise and lower speed/load buttons

are working on the HMI.
Adjust generator voltage and speed until the

generator and bus voltage and frequency as
indicated on the meters are the same, with the
synchroscope is rotating slowly in the fast
direction.
When the sync lights are extinguished and the

sync needle at 12 o‟clock position, verify that
Phase A Generator-to-Bus voltage difference is
zero using the high voltage test sticks. At 6
o‟clock verify that Phase A Generator-to-Bus
voltage difference is at the maximum voltage.
This proves that the synch scope indicates in-
phase when the buses are actually in phase.

Phase B Generator-to-Bus voltage difference is
o‟clock verify that Phase B Generator-to-Bus

Procedure
Check Completed
Record data
Completed by / date
Phase C Generator-to-Bus voltage difference is
o‟clock verify that Phase C Generator-to-Bus
Remove the high voltage test sticks.

Procedure
Manual Synchronizing Circuit

Before performing this check, ensure the phase rotation is correct. Perform any required off-line
checks for the voltage regulator.
Check Completed
Record data
Completed by / date
Verify that the generator breaker is in the test
position. If the breaker does not have a test
position, rack the breaker out, remove the wire to
the breaker-close coil and monitor voltage to the
coil with a voltmeter.
Set synchronizing to MANUAL.
Bring the unit to synchronous speed and meet the

conditions required for manual breaker closing
(e.g., frequency, voltage, etc.).
Watch the synchroscope, synchronizing lights and

indications on the synch-check relay. Verify the
synch-check relay gives a breaker close permissive
when the synchroscope is at 12 o‟clock and the
synch lights are out.
Give a manual breaker close command when the

synchroscope is at 12 o‟clock. Verify that the
breaker closes in the test position or that voltage is
indicated at the breaker close coil. If the breaker
closes in the test position, verify proper indication
of breaker close signal back to the controller.
Trip the generator breaker open.
Give a manual breaker close command when the

synchroscope is at 6 o‟clock. Verify the breaker
does not close or that voltage is not indicated at
the breaker close coil.
Consult the turbine controller drawings and repeat

the above steps for any variations on manual
breaker closing, e.g., local, remote, etc.

Procedure
Generator Breaker Trip Circuit Checks

These checks are to verify the integrity of the applicable generator breaker trip commands. If
possible, these checks should be done with the breaker racked out and in the test position. If the
breaker does not have a test position, rack the breaker out, remove the wire to the breaker-trip
coil and monitor voltage to the coil with a voltmeter.
Check Completed
Record data
Completed by / date
With the unit still running and the breaker in the
test position, close the breaker manually.
Consult the turbine controller drawings and test

all possible combinations of the breaker trip
circuit.

Procedure
Automatic Synchronizing Circuit
Before performing this check, ensure the phase rotation is correct and complete the manual synch
checks.
Check Completed
Record data
Completed by / date
Verify that the generator breaker is in the test
position. If the breaker does not have a test
position, rack the breaker out, remove the wire to
the breaker-close coil and monitor voltage to the
coil with a voltmeter.
Set synchronizing to MANUAL.
Bring the unit to synchronous speed and meet the

conditions required for manual breaker closing (e.g.,
frequency, voltage, etc.).
Watch the synchroscope, synchronizing lights and

indications on the synch-check relay. Verify the
synch-check relay gives a breaker close permissive
when the synchroscope is at 12 o‟clock and the
synch lights are out.
Set synchronizing to AUTO. Verify the auto

synchronizer gives a breaker close command and
the synch-check relay gives a breaker close
permissive when the synchroscope is at 12 o‟clock
and the synch lights are out.
Trip the generator breaker open.
Set synchronizing to OFF. Manually lower the

generator terminal voltage to 95% of rated.
Manually lower generator speed to 99.5% of rated.
Set synchronizing to AUTO. Give the unit a start

signal to reset the auto-synch permissive.
Verify autosynchronizer speed matching and voltage

matching.

Procedure
Check Completed
Record data
Completed by / date
Trip the generator breaker by utilizing logic in the
turbine controller. Verify the breaker opens and
speed setpoint goes to 100%. The breaker should
not re-close.
Set generator synchronizing selector switch to OFF.
Consult the turbine controller drawings and repeat

the above steps for any variations on automatic
breaker closing, e.g., local, remote, etc.

Procedure
4.4. Turbine On-Line / Load Checks

Turbine Online Commissioning Procedure
Application: This section provides instructions for commissioning a Gas Turbine Generator up
to Full Load.
Use appropriate corresponding operating data sheet to record data in this section:
Unit Type Form Number
GE Frame type FM-OD-GT-G-FR-001
Pratt & Whitney FT4 FM-OD-GT-G-GG-001
Check Completed
Completed by / date
Synchronize the generator to the electric grid
Meter Display Checks

Check Completed
Record data
Completed by / date
Verify that all customer-supplied and ICS-supplied
meters, HMI, LTI, panel-mounted meters and any
other displays the correct values.
Turbine Speed
Generator Frequency
Generator Phase Currents
Generator Phase Voltages
Generator MW/kW
Generator MVar/kvar
Generator Power Factor
Generator Field Voltage / Current

Procedure
Load Control and Base Load Checks
Check Completed
Completed by / date
At the Turbine Control Panel display of the HMI, enable Speed/Load
Control and the Normal load rate. At the Turbine Control Panel
display of the HMI, enter a speed setpoint target of 101.0%. Verify
that the load increases at the set ramp rate value.
Verify that all systems (lube oil, cooling water, etc.) pressure and
temperatures are as expected. Record Operating Data in the
appropriate Unit Data Sheet.
At the Turbine Control Panel display of the HMI, enter a speed

setpoint target of 102.0%. Verify that the load increases at the set
ramp rate value.
At the Turbine Control Panel display of the HMI, enter a speed

setpoint target of 103.0%. Verify that the load increases at the set
ramp rate value.
At the Turbine Control Panel display of the HMI, select BASE load.
Verify the machine goes on temperature control.

Procedure
Peak Load Operation

These checks are to verify the peak load function of the controller. Record and investigate any
alarms that occur during testing.
Unit should be running with the generator breaker closed.
Check Completed
Record data
Completed by / date
At the Turbine Control Panel display of the HMI, select
Peak Load.
Verify that the speed setpoint target goes to 107.0%
and the setpoint ramps to that value.
Verify the unit goes on exhaust temperature control at
a higher exhaust temperature than the base load value.
Verify that all systems (lube oil, cooling water, etc.)

pressure and temperatures are as expected. Record
Operating Data in the appropriate Unit Data Sheet.

Procedure
Load Rejection Test (optional)

With the unit on-line select a load level to test the load rejection capability and proceed with the
test.
Check Completed
Record data
Completed by / date
With the unit on-line, select a load at which the test is
to be done. Record below.
Open the generator breaker and verify the speed

setpoint goes to 100.0%, the speed governor takes
over and the unit does not trip on overspeed.
Record turbine max speed after breaker open.

Procedure
Megawatt Control Checks

These checks are to verify the megawatt control function of the controller. Record and
investigate any alarms that occur during testing.
Check Completed
Record data
Completed by / date
select MEGAWATT CONTROL ENABLE. The megawatt
setpoint target and setpoint should be equal to the
present megawatt value.
Enter a megawatt setpoint target equal to 25% of
rated load. Verify the megawatt setpoint tracks to
the setpoint target at the normal rate and that the
unit output follows the setpoint. Record Megawatt
Setpoint here.
Record MW output here.
Enter a megawatt setpoint target equal to 75% of
rated load. Verify the megawatt setpoint tracks to
the setpoint target at the normal rate and that the
unit output follows the setpoint. Record Megawatt
Setpoint here.
Record MW output here.

Procedure
VAR Control Checks

These checks are to verify the VAR control function of the controller. Record and investigate any
Check Completed
Record data
Completed by / date
At the Generator Control Panel display of the HMI,
select VAR CONTROL ENABLE. The VAR setpoint
target and setpoint should be equal to the present
VAR value.
Enter a VAR setpoint target. Verify the VAR
setpoint tracks to the setpoint target at the normal
rate and that the unit output follows the setpoint.
When the generated VARs, the VAR setpoint target
and the VAR setpoint are all equal, change the
megawatt load on the unit. Verify the VARs do not
change as the megawatts change.

Procedure
Power Factor Control Checks

These checks are to verify the power factor control function of the controller. Record and
Check Completed
Record data
Completed by / date
select PF CONTROL ENABLE. The power factor setpoint
target and setpoint should be equal to the present
power factor.
Enter a PF setpoint target of 0.80. Verify the PF
setpoint tracks to the setpoint target at the normal
rate as the control system automatically adjusts the
Reactive power of the generator.
NOTE: Generator MW should NOT change
With Power factor control enabled, change the
megawatt load on the unit. Verify the power factor
does not change as the megawatts change.

Procedure
Automatic Synchronizing to Base Load
These checks are to verify the automatic synchronizing and loading functions of the controller.
Record and investigate any alarms that occur during testing.
Unit may be running, or shutdown, generator breaker should be open.

Check Completed
Record data
Completed by / date
select Base Load.
select automatic synchronizing.
If the unit is not running, give a START command to
start the unit. If unit is running, give a START
command to initiate the auto synch mode.
Verify that the breaker closes, the speed setpoint
target goes to 107.0% and the setpoint ramps to
that value. Record Exhaust Temperature
Setpoint here.
Record Time from breaker close to base load
Record Megawatts
Verify the unit goes on exhaust temperature control;
record Exhaust Temperature here.
In the applicable OPERATING DATA FORM record the
key turbine data.

Procedure
Fast Load Control Checks

These checks are to verify the fast loading functions of the controller. Record and investigate any
Unit may be running or shutdown, generator breaker should be open.
Check Completed
Record data
Completed by / date
select Base Load and Fast Load.
target goes to 107.0% and the setpoint ramps to that
value.
Verify the unit loads at the fast rate and goes on
exhaust temperature control; record Time from
breaker close to base load here.

Procedure
Emergency Load Control Checks

These checks are to verify the emergency loading functions of the controller. Record and
Unit may be running or shutdown, generator breaker should be open.
Check Completed
Record data
Completed by / date
select Base Load and Fast Load.
target goes to 107.0% and the setpoint ramps to
that value.
Verify the unit loads at the emergency rate and goes
on exhaust temperature control; record the Time
from breaker close to base load here.

Procedure
Isochronous Operation Checks
Isochronous Testing typically involves different configurations based on each customer

application. If isochronous testing is performed, describe below the preparation for the testing,
test results.

Procedure
4.5. Shutdown Checks

These checks are to verify the shutdown sequencing of the controller. Record and investigate any
Automatic Shutdown
Check Completed
Record data
Completed by / date
select MEGAWATT CONTROL ENABLE. Enter a
megawatt setpoint equivalent to 75% of machine‟s
capability.
select STOP.
Verify the unit unloads at the normal rate.
Record the megawatt level when the generator
breaker trips.
Verify that when the rotor reaches zero speed, the
rotor cooldown mechanism starts.
Verify that the rotor cooldown mechanism runs for
the correct amount of time.
Scheduled Unit Cooldown

Check Completed
Record data
Completed by / date
Adjust the scheduled cooldown time to start shortly.
Verify that the rotor cooldown mechanism starts and
runs for the scheduled amount of time.

Procedure
Final Operating Data
Obtain a copy of the Historical Log for this run to archive the operating conditions.

Procedure
Software Backup and Handover
Check Completed
Record data
Completed by / date
Configurations and Reference Tables of all units must
be backed up to the specific unit configuration files.
(Number of files = Number of units at site).
Back up Locked and Unlocked PLC folders.
Back up latest HMI application.
Export latest LTI software to the PRJ file under

E:\TCP\ and backup.
Ensure that all the software is stored in the

appropriate folders on the E drive of the HMI PC
The following is a list of software that must be

returned from the site by the Start up engineer at the
completion of the project:
1. Current Locked copy of PLC folder

2. Current Unlocked copy of the PLC folder
3. Current copy of the HMI folder
4. Current copy of individual unit
configuration / Reference tables
5. Current LTI Application
6. Current Basler / Decs software if applicable
7. Current Ultraware software if applicable

8. Current IO configuration - for panel/field
devices

Procedure
NOTES
Use this space to record any notes on this procedure.
Be sure to indicate the paragraph reference number before each comment.

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Procedure

Title Gas Turbine Generator Commissioning Procedure

TC2000PLUSSM Control System

Doc ID: TIS-CS-GT-G-01 REV: 5 Date 18 JUN 08 Page 1 of 62

Title Gas Turbine Generator Commissioning Procedure

DO NOT PROCEED WITHOUT THESE DOCUMENTS

This test procedure is to be used in conjunction with a Gas Turbine

Form Number Rev.

Doc ID: TIS-CS-GT-G-01 REV: 5 Date 18 JUN 08 Page 2 of 62

Title Gas Turbine Generator Commissioning Procedure

Doc ID: TIS-CS-GT-G-01 REV: 5 Date 18 JUN 08 Page 3 of 62

Title Gas Turbine Generator Commissioning Procedure

1.0. Safety Review

Verify with Customer that all site specific

Establish lock-out and tag-out procedure with

Identify subcontractor reps responsible for

Ensure that installation personnel are fully

Completely inspect turbine for any work that

Completely inspect generator for any work

Completely inspect area for any work that may

Before proceeding with the following checks

Doc ID: TIS-CS-GT-G-01 REV: 5 Date 18 JUN 08 Page 4 of 62

Title Gas Turbine Generator Commissioning Procedure

2.0. Panel Power-up Checks

Ensure that the relays and other auxiliary equipment

Check that all removable modules are correctly

Inspect field wiring. Check for loose connections,

2.2. Control Panel Power-Up Checks

Verify that turbine systems are tagged-out and

Verify that the power supply for each control rack is

Doc ID: TIS-CS-GT-G-01 REV: 5 Date 18 JUN 08 Page 5 of 62

Title Gas Turbine Generator Commissioning Procedure

2.3. DC Power Circuits

Refer to the DC Panel Power Distribution of the Turbine Controller drawing.

Verify that DC input power is not grounded. If so

Check that there are no grounds on the positive and

Insert the main DC fuse and apply DC power to the

Successively power-up each control rack, verifying

Successively power-up any Remote I/O (RIO)

Doc ID: TIS-CS-GT-G-01 REV: 5 Date 18 JUN 08 Page 6 of 62

Title Gas Turbine Generator Commissioning Procedure

DC Power Sub-Circuits (24Vdc)

2.4. AC Power Circuits

Verify value of AC source input power at the

Turn AC power on. Successively close the other ac

2.5. HMI Interface and Controller Checks

If the request times out, check the IP and subnet

Transfer of necessary files to the HMI PC at site

The latest PLC folder should be transferred from

Doc ID: TIS-CS-GT-G-01 REV: 5 Date 18 JUN 08 Page 7 of 62

Title Gas Turbine Generator Commissioning Procedure

The latest LTI application should be downloaded

Establish Ethernet Communication to PLC from HMI

Download the latest PLC logic and the reference

Confirm that each of the modules is healthy. Resolve

Review the Diagnostic Alarm display of the HMI and

Doc ID: TIS-CS-GT-G-01 REV: 5 Date 18 JUN 08 Page 8 of 62

Title Gas Turbine Generator Commissioning Procedure

3.0. I/O Checks

3.1 Verify the Master Protective Circuits

Energize the Field Master Protective Circuit

Energize the Master Protective Circuit

Press the emergency stops pushbutton on the front