Turbomachinery Package Installation Guidline 1000 Rev - B

TURBOMACHINERY PACKAGE INSTALLATION GUIDELINE
Generator Sets
Data Control Level
INSTALLATION GUIDELINE NO. TPIM 1000 REVISION: B

(Letter, Date and PRD/CR No.)
ISSUED: 11/07/2007, CR 18967

(Date and CR No.)
Release Stamp
A; 12/30/2007; CR 18967 B; 5/27/09: CR 22987
Rev. Ltr.
CR #
Author(s) / Approver(s)
Prepared By: Maria
Date
Pages Affected
22987
Naranjo Customer Service Interface Prepared By: Patrick Dugan Manager, Commissioning, PG Prepared By: Raul Duron Manager, Commissioning, O&G
Approved By: Jonathan Windt Manager, Package Development & Integration
5/26/09 4/29/09 ALL 5/26/09 5/06/09
ATTENTION This copyrighted work and the information herein is proprietary to Caterpillar Inc., Solar Turbines Incorporated, and/or subsidiaries of either. Without express, written prior permission, any copying, disclosure, or use except that for which it is loaned, is prohibited.
Caterpillar: Confidential Green
2007 Caterpillar
Installation Guideline No. TPIM 1000B
CONTENTS Paragraph 1.0 2.0 3.0 . 4.0 5.0 6.0 7.0 8.0 9.0 10.0 DOCUMENTING AND DELIVERY...1 CHECKLIST.........2 NOMENCLATURE......5 LIST OF REFERENCE MATERIALS ......7 OTHER DOCUMENTS..........7 INSTALLATION GUIDELINES......8 MISCELLANEOUS ...62 Page SCOPE.....1 GENERAL WARNINGS ....1 EXCEPTIONS TO GUIDELINES.........1
Caterpillar: Confidential Green 2007 Caterpillar
ii
Installation Guideline No. TPIM 1000B
FIGURES Figures Page
Figure 1: Two-Piece Bolted Skid.................................................................................................17 Figure 2: Dial Indicator Setup .....................................................................................................22 Figure 3: Typical T. I. R. Reference ............................................................................................22 Figure 4: Alignment Setup ..........................................................................................................24 Figure 5: Typical coupling cover .................................................................................................26 Figure 6: Insulation Screen Mounting Hardware.........................................................................28 Figure 7: Insulation Screen Location ..........................................................................................29 Figure 8: Schematic of Voltage Connection Insulation ...............................................................29 Figure 9: Typical Airflow Directions for Cylindical and Box Fans ................................................38 Figure 10: Typical Fire Damper Connection ...............................................................................40 Figure 11: Flange Caulking Method............................................................................................44 Figure 12: Optional Mist Eliminator Installation...........................................................................50
TABLES Tables Page
Table 1: Mechanical Installation Checklist ....................................................................................2 Table 2: Recommended Tape Layers.........................................................................................29 Table 3: Recommended Additional Electrical Run from Skid Edge to End Device.....................46 Table 4: Expansion Joint Allowable Displacement .....................................................................51
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INSTALLATION GUIDELINES Installation Guideline No. TPIM 1000B
1.0 SCOPE The intent of this document is to provide the Customer, as well as Solars FSRs, a general understanding of the lines of responsibility between Solar and the Customer, as it pertains to the package installation. Therefore, this document outlines the installation guidelines only for Solars pre-engineered standard package interface with a turbine-driven generator unit. This manual is applicable from the Saturn to the Titan 130 generator set.
2.0
GENERAL WARNINGS
WARNING - This general guideline is intended to facilitate communication between the owner, installer and Solar. Because these are guidelines and only intended to address common issues associated with pre-engineered "standard" package interface with a turbine-driven generator unit, it cannot replace the necessary dialog between the owner, installer and Solar; nor is it intended to replace the owner or installer's best practices. Failure to consider whether these general guidelines are applicable to the unique features of a project, or additions and/or modifications that are not reviewed and approved by Solar, may cause serious malfunction, may allow unsafe operation, or other unsafe condition, any of which could result in significant property damage, personnel injury, and/or loss of life. Solar's inspection, or failure to inspect, the performance of obligations of customer or its contractors shall not make Solar liable for such obligations of customer or its contractors. WELDING WARNING High currents flow between welding ground and the arc during arc welding. Precautions must be taken to ensure that this current does not pass through close tolerance moving surfaces, or electronic systems. Welding ground should be placed as close to the weld location as possible or on the component to be welded. Failure to observe this warning could void warranty claims. Prior to any welding procedures, ensure that the turbine package is not in operation and is grounded. Power must be removed from all PECC high force valves and actuators by opening the 120volt DC circuit breakers prior to welding on or in the vicinity of a turbine package. Weld grounding must be in proximity to weld activities. Power to the control system must be shut off. At no time is the skid to be used as a ground for welding or other facility purposes.
3.0
EXCEPTIONS TO GUIDELINES
This document does not cover any of the system commissioning activities, compressor sets or mechanical drive equipment, or site evaluation of the customer facilities to determine suitability for operation of Solars scope of supply. Proper integration with customer facilities should be discussed well upfront during the design phase of the project. This document is not applicable to mobile power unit (MPU). Refer to the MPU assembly/disassembly manual.
4.0
DOCUMENTATION AND DELIVERY
This document should be maintained along with the as-installed drawing set and updated as appropriate and made available to Solars Commissioning Personnel for the purpose of maintaining an accurate record of the package installation. The customer/contractor is responsible for maintaining an accurate and up-to-date record of the installation activities. As installation activities are completed, the Customer/Contractor must initial and date next to each completed activity on the checklist. Upon the completion of the package installation, Solars Commissioning Personnel are responsible for submitting a copy of the completed checklist to the corresponding District Service Manager along with all as-installed drawings.
5.0
CHECKLIST -
Below is the list of installation guidelines outlining the detail as provided by the individual operations found in section 9.0 of this document. Table 1: Mechanical Installation Checklist "THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR SOLAR TURBINES INCORPORATED, ANY COPYING, DISCLOSURE, OR USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
F12
INSTALLATION GUIDELINES GENERATOR SET
PROJECT NAME: PACKAGE S/N: GEAR BOX S/N: GENERATOR S/N: OPERATION Responsible Party
Customer
PACKAGE MODEL: PROJ. DEF. #: ENGINE S/N: GEAR BOX P/N: GENERATOR P/N: BRIEF DESCRIPTION Completion
Customer/Solar Initials (as applicable) Date
SITE PREPARATION OPERATIONS

1-0010 SECURITY AND STORAGE PACKING LIST Ensure all equipment is properly secured and stored. Audit the packing list to each shipping bill and document any discrepancies and damage found to any parts. Coordinate and plan on-site installation and commissioning activities.
1-0015
Customer & Solars FSR
1-0020
START-UP MEETING AND INSTALLATION & COMMISSIONING PLAN LIFTING 1-0030 GUIDELINES
Customer & Solars Project Manager Representative Customer
Ensure proper lifting guidelines are followed.
SITE PREPARATION OPERATIONS COMPLETED INSTALLATION OPERATIONS

2-1010 VERIFY PACKAGE FOUNDATION AND TIE-DOWN Customer Describe foundation criteria and discuss acceptable methods of attaching turbine package to a foundation.
OPERATION
2-1020 PACKAGE MOUNTING AND LEVELING DRIVE TRAIN ALIGNMENT
Responsible Party
Customer
BRIEF DESCRIPTION
Place Solar packages on their foundation, establish vertical elevation, level package, and prepare for drive train alignment. Provide an overview to complete the drive train alignment.
Completion
2-1030
2-1035
GENERATOR TERMINAL BOX INSTALLATION
Customer
Ensure proper installation of the generator terminal box per the manufacturers technical documentation. Provide a best-practice guide for the construction and verification of installation integrity of external pipe runs. Ensure installation integrity of the air/oil separator.
2-1040 EXTERNAL PIPING
Customer
2-1042
OIL TANK VENT AIR/OIL SEPARATOR
Customer
2-1044 LUBE OIL COOLER
Customer
Ensure installation integrity of the lube oil cooler.
2-1046 EXTERNAL LUBE OIL FLUSHING
Customer
Ensure the oil system flushing is performed per Solars suggested procedures.
2-1047
ENCLOSURE VENTILATION FANS CO2 FIRE SUPPRESSION SYSTEM
Customer
Ensure the proper orientation of the enclosure ventilation fan(s).
2-1048
Ensure installation integrity of the CO2 fire suppression system.
2-1049 WATER MIST FIRE SUPPRESSION SYSTEM
Customer
Ensure installation integrity of the Water Mist fire suppression system.
OPERATION
2-1050 ANCILLARY SUPPORT STRUCTURE AUDIT OF ELECTRICAL AND INSTRUMENT CONNECTIONS
Responsible Party
Customer
BRIEF DESCRIPTION
Inspect structure supports for package and auxiliary devices.
Completion
2-1052
Customer
Verify all electrical and instrument connections are routed to the proper location on the gas turbine package prior to installing cable tray or conduit. Verify electrical and instrument cable runs for package and auxiliary devices.
2-1054 ELECTRICAL AND INSTRUMENT RUNS 2-1056 SKID GROUNDING CHECKS
Customer
Verify the integrity of the frame ground in order to reduce the possibility of electrical hazard to personnel.
INSTALLATION OPERATIONS COMPLETED BALANCE OF PLANT RUNNING CHECKS

4-2010 INLET SYSTEMS Customer Verify the proper installation of the turbine inlet filter system.
4-2020
EXHAUST SYSTEMS
Ensure installation integrity and aid in commissioning of the turbine exhaust system. Verify the proper and complete installation of the evaporative cooler.
4-2030
EVAPORATIVE COOLER
Customer
4-2035
INLET CHILLER SYSTEMS
Customer
Verify the proper and complete installation of the inlet chiller.
4-2040
SWITCHGEAR
Customer
Understand the basic requirements Contractors/Customers have when connecting the switchgear with the Solar package. Understand the basic requirements Contractors/Customers have when connecting the heat recovery equipment to the Solar package.
4-2050
BOILER/WASTE HEAT RECOVERY EQUIPMENT
Customer
OPERATION
4-2060 FUEL TREATMENT EQUIPMENT
Responsible Party
Customer
BRIEF DESCRIPTION
Provide instruction for personnel connecting fuel treatment equipment to the Solar package. Provide instruction for personnel connecting the water purge module to Solar package. Provide instruction for personnel connecting a gas fuel system to the Solar package. Understand the basic requirements Contractors/Customers have when connecting the motor control center with the Solar package. Provide instruction for personnel connecting an air compressor to Solar package.
Completion
4-2070
WATER PURGE (SOLONOX ONLY)
Customer
4-2080 GAS FUEL SYSTEM INTERFACE CHECKLIST 4-2090 MOTOR CONTROL CENTER
Customer
Customer
4-2100 COMPRESSED AIR INTERFACE
Customer
BALANCE OF PLANT OPERATIONS COMPLETED

6.0
NOMENCLATURE The following is a list of Solar specific/unique terminology. 1. 2. 3. 4. 5. 6. 7. 8. 9. ACS Application Check Sheet DSM District Service Manager EPC Engineering Procurement Contract ER Engineering Report ES Engineering Specification FSR Field Service Representative MCC Motor Control Center MID Mechanical Interface Drawing PCV Pressure Control Valve
10. PIL Product Information Letter 11. PM Project Manager

12. PRV Pressure Relief Valve 13. SB Service Bulletin 14. VFD Variable Frequency Drive
7.0
LIST OF REFERENCE MATERIALS
The reference material listed below shall be provided to the customer, along with this Engineering Specification, as supporting documentation required for proper installation of the Solar package. 7.1 Engineering Specifications ES9-54 Fastener Installation and Torque Values ES9-62 Ingestive Cleaning Solar Turbine Engines ES9-98 Fuel, Air, and Water or Steam for Solar Gas Turbine ES9-224 Specification for Lubricating Oils for use in Solar Gas Turbine Engines ES9-414 Leveling and Installing of Package Bases ES1745 Installation Instructions for Lube Oil Tank Vent With Separator With and Without a Flame Arrestor for All of Solar Turbines ES2069 Installation, Set-up, & Operating Instructions for Evaporative Coolers ES2184 Cleaning and Flushing of Hydraulic Systems/Components ES2492 Installation, Set-up, & Operating Instructions for Air Inlet Chillers on Solar Turbines Engines Product Information Letters (PILs) PIL097 Package Preservation and Preparation for Shipment PIL149 Direct-drive AC Start System PIL181 Package Tie-Down Options PIL183 Package Lifting Guidelines Engineering Report ER 9298 Assessment of Package Deck Twist & Deflection Limits for Solar Packages Service Bulletin (SB) SB 5.0/111 Turbine Package Electrical Noise Reduction/Grounding Practices
7.2
7.3 7.4
8.0
OTHER DOCUMENTS -
The following documents serve as supporting information describing key customer documents and their standard delivery schedule: PIL 012-PG PIL 184 Customer Drawings Power Generation Customer Documentation Description Oil & Gas
9.0
INSTALLATION GUIDELINES
The following are the detailed installation guidelines as outlined by the checklist found in section 5.0 of this installation manual. 9.1 OP: 1-0010 PURPOSE:
Site Preparation
SECURITY AND STORAGE THE PURPOSE OF THIS OPERATION IS TO ENSURE THAT ALL EQUIPMENT IS PROPERLY SECURED AND STORED. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
NOTES: 1. Packages stored at site must be protected from the weather. 2. Do not use duct tape on painted surfaces; the adhesive will damage the paint. 3. Special care should be taken to protect the paint during opening of shipping crates. A protective tarp should cover the entire package on construction site to prevent potential paint damage from sand blasting, welding and grinding. Pre-Installation and Fabrication procedures: These procedures are to be performed prior to the arrival of Solars Commissioning Personnel, and are the responsibility of the customer and their contractor. 1. 2. Ensure that shipping crates are placed in weatherproof shelter. Place shipping crates on level ground elevated off grade before construction activities. Necessary preservatives for storage were applied on packages and all external openings were properly sealed in the factory. Refer to PIL097 for the preservation information. Store open shipping crates in a controlled environment, such as a warehouse or better, with reasonable temperature and humidity levels. If factory preserved equipment has been opened for inspection, these items should follow preservation procedures as outlined in PIL097 if these items are not intended to be in use within three months.
3.
4.
OP: 1-0015 PURPOSE:
PACKING LIST THE PURPOSE OF THIS OPERATION IS TO PERFORM AN INVENTORY CHECK BY COMPARING THE PACKING LIST TO THE SHIPPING BILL ATTACHED TO EACH SHIPPING CRATE. DOCUMENT ANY DISCREPANCIES OR DAMAGE FOUND TO ANY PART. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
NOTES: 1. Shipping crates with hazardous material will be labeled per local or national regulation and are usually shipped separately. 2. It is strongly recommended that Solars FSR be on site upon arrival of shipping crates to assist the customer in verifying the integrity and condition of delivered equipment. Customer and Solars FSR should perform complete inventory check of all equipment, loose ship components, and associated parts together. 3. If crates have been opened prior to arrival of Solars FSR, any missing items are not the responsibility of Solar unless listed as backordered on shipping list. 4. For projects that require disassembly for shipping, coordinate with Solars Project Manager. 5. Ensure parts are stored in a reasonable logical manner. Keep dry if at all possible. If they cannot be kept dry and secure, inform DSM. PROCEDURE: 1. 2. The customer can receive a copy of the packing list by contacting Solars Project Manager. The shipping bill attached to each shipping crate contains a list of all items in those crates under the same bill. There could be two or more bills in one shipment. Always separate and sort those shipping crates for multiple packages against packing list and/or color code on crates. Perform an inventory check; any discrepancies or damage found should be photographed and documented. If possible, all boxes should be opened to allow for inspection of all components. This should only be accomplished if the materials can be repacked and properly stored. Replacement or repairing efforts should be addressed at an early stage. The following criteria should be used when conducting the inventory inspection: A. Check for damage to package/enclosure internals during shipment (equipment-removal beams, vibration, etc.). Check for water damage and/or corrosion to packing and components. Open and inspect all electrical panels. Ensure all panels are tightly closed after inspection. Check for impact damage. Components such as battery chargers and VFDs can have internal damage while showing no external damage. Remove access panels for internal inspection.
3.
B. C.
D.
E. F. G.
Confirm that all vessels and tanks are closed and/or sealed. Check that the couplings and shaft ends are protected from dirt and corrosion. Confirm that the support structures, inlet and exhaust systems, and other large, dropshipped components include hardware installation kits.
4.
For items listed on packing list but not found, or items found but not listed, contact the DSM for resolution. Inspect for shipping/installation damage and missing items, and make note on carriers Bill of Lading, if possible. Report any findings to DSM. Complete the punch list, found in Section 8, for any missing and/or damaged items. Customer and Solar FSR should both sign off punch list. Forward completed copy of punch list to the DSM.
5.
6.
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OP: 1-0020 START-UP MEETING AND INSTALLATION & COMMISSIONING PLAN PURPOSE: THE PURPOSE OF THIS OPERATION IS TO COORDINATE AND PLAN SOLARS ONSITE INSTALLATION AND COMMISSIONING ACTIVITIES, END USER, AND ENGINEERING CONTRACTORS. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS. The Installation and Commissioning meeting has three primary objectives:
SAFETY:
NOTES:
1. Transition of day-to-day contact from Solars Project Manager to the Solars District Office (District Service Manager and Field Service Representative(s)). 2. Review of the customers installation and commissioning schedule and associated constraints/risks to be managed. 3. Review and establish installation and commissioning activities and associated responsibilities.
PROCEDURE: 1. Solars Project Manager establishes the requirement and schedules this meeting during the Customer Kick-Off Meeting. The preferred location is at the Customer site or fabrication yard to enable the commissioning team to meet the personnel with whom they will interface, and to become familiar with the facilities. Solars Project Manager will develop the required meeting participation based upon commissioning complexity and availability based upon the list of Key Personnel below: Solars Key personnel may include: Project Manager Project Engineer District Service Manager and/or District Project Engineer Field Service Representative San Diego Commissioning Specialist
2.
Key Customer/Supplier personnel include: Customer (End User) project representative(s): Project Manager/Project Engineer Commissioning Representative Operations Representative Maintenance Representative Fabrication Yard/EPC representative (s): Project Manager/Project Engineer Mechanical Contractor Lead/Supervisor Electrical Contractor Lead/Supervisor
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Installation Supervisor Commissioning Representative Safety Representative Transportation/Logistics Representative Driven Equipment representatives (if applicable): Project Manager/Project Engineer Commissioning Representatives 3. Solars Project Management representative chairs the Installation and Commissioning Meeting.
4.
The Pre-commissioning Meeting Agenda and Checklist are filled out during the meeting (Agenda and Checklist are included in Section 10 of this manual). The completed Checklist form the minutes of the meeting.
5.
The meeting Minutes are distributed to the meeting attendees and will include as a minimum the following: Customers, Project Manager Solars District Service Manger Solars Field Service Representative Solars Field Service Regional Manager Solars Commissioning Specialist
12
OP: 1-0030 PURPOSE: SAFETY:
LIFTING GUIDELINES THE PURPOSE OF THIS OPERATION IS TO PROVIDE LIFTING GUIDELINES. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
WARNINGS: 1. Qualified (licensed) riggers must follow standard rigging procedures in making any lift. 2. A spreader bar must be used for all package lifts and boxed crates. 3. Never stand under or near an object being lifted or around the path it will travel. 4. Never stand near an operating crane. If the crane operator does not plan the lift appropriately, the crane can tip over. These procedures are to be performed prior to the arrival of Solars Commissioning Personnel, and are the responsibility of the customer and their contractor. PROCEDURE: 1. When lifting the package with or without an export crate, refer to the Package Lifting Guidelines found in PIL183. All lifts must have adequate rigging gear that is designed to support the lift weight with a sufficient factor of safety. When lifting loose ship items, be aware of any specific unpacking or uncrating instructions to avoid damage to equipment and injury to personnel. Unpacking equipment out of sequence or improper orientation may not expose lifting features and could lead to equipment damage and/or personnel injury. Riggers must use lifting provisions on the equipment, where provided. Unless instructions state otherwise, riggers must be cautioned to not lift ancillary equipment as assemblies. Lifting in such a way may impose stresses that may damage equipment.
2.
3.
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9.2
OP: 2-1010 PURPOSE:
Installation Activities
VERIFY PACKAGE FOUNDATION & TIE-DOWN PURPOSE OF THIS DOCUMENT IS TO SUMMARIZE FOUNDATION CRITERIA, AND ACCEPTABLE METHODS OF ATTACHING TURBINE PACKAGES TO A FOUNDATION. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS. An improperly designed and constructed foundation can result in serious harm to personnel and significant damage to equipment.
SAFETY:
WARNING:
NOTES: 1. The procedures outlined in this section are a summary of the referenced material listed below. For details on the various methods to properly construct the package foundation and bolting Solar turbine packages to the foundation, the customer, or the customers contractor, should consult the reference material for further detail. 2. In some cases, the mounting hardware is supplied by Solar, but in most cases is supplied by the end-user. Prior to the start of any foundation construction, verify that the correct parts are present to properly mount package to foundation per the design intent shown on the MID. Be aware that some foundation hardware must be encased in foundation concrete, so timely hardware supply can be critical to site schedule. 3. A qualified Civil Engineer must be contracted by the end-user to design all aspects of the site foundations. Solar Turbines Incorporated takes no responsibility for any foundation design below Datum C. REFERENCES:For further details on any data listed within this procedure, please refer to PIL181, ES9414, and ER9298. Pre-Installation and Fabrication Procedures: These procedures are to be performed prior to the arrival of Solars Commissioning Personnel, and are the responsibility of the customer and their contractor. 1. Foundation fundamentals A. For on-shore applications, ensure that concrete with the proper compressive strength is chosen based on the Pad Loads listed on Solars MID. Note the pad loads can include dynamic and short circuit loads, which can be significant in relation to static loads. The foundation designer must ensure the equipment and foundation mass ratio is appropriate to industry standards, and is responsible for the vibration frequencies of the foundation outside of the operating speed range of the Turbomachinery. For offshore applications, it is assumed that the supporting structure will be designed with sufficient strength to support the Turbomachinery static and dynamic loads. The supporting structure should be designed to prevent excessive twist and vertical deflection of the package. If there is a question on deck deflection limits, please request a copy of ER9298 from Solar Turbines Incorporated.
B.
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2.
Turbomachinery is high precision equipment, and Solar Turbines Incorporated requires strict tolerances on foundation levelness and flatness. By following Solars foundation recommendations, the package can be mounted using commercially available shims. Failure to follow recommended foundation tolerances can often result in rework efforts such as the fabrication of tapered shims at the end-users, or installation contractors expense. A. Sole plates cast into foundation concrete must be coplanar to each other within 0.120 (0.30 cm). Sole plates cast into foundation concrete must be flat and level within 0.005/ft. (0.050 mm/cm). if mounting pad limits cannot be obtained, contact the DSM for appropriate action.
B.
Note: 3.
There are several methods suggested by Solar for bolting packages down to foundations, and two methods for leveling. While there may be other acceptable methods, it is suggested that the end-user consult with Solar if the proposed method differs from those outlined below. A full description, and diagrams of the below-listed methods are available from Solars PIL181. Tie Down Methods: A. Captive Anchor-Stud Assembly - Pullout strength must be specified based on the foundation materials, and the potential upward dynamic loads for each package. Solar has deemed a 40,000 lb. pullout strength as being sufficient for all packages. Nut and Bolt Arrangement A 1-1/2 diameter, Grade B7 (or equivalent) nut and bolt can be used to tie all Solar packages to foundation. The bolt must be sized sufficiently to pass through the customers foundation, and to allow a minimum of two threads to protrude through the retaining nut, when package tie-down is torqued. Bolt and Threaded Bearing Plate A 1-1/2 diameter, Grade B7 (or equivalent) bolt can be used in conjunction with a threaded bearing plate. The bearing plate should be constructed of A-572 steel (or equivalent) and has a recommended thickness of 2-1/2 in order to achieve the minimum 2 thread engagement.
B.
C.
Leveling Methods: A. Stainless steel shims Industrial stainless steel shims are a very effective way of leveling Solar machinery. Shims must be at least 50 inches-square, and should encompass the package tie-down bolt as closely as possible. Epoxy Grout Non-shrinking, epoxy grout has been a successful method of leveling many Solar packages. The type of grout, and the required strength should be specified by a qualified grout contractor based on the loads and site conditions. Note: Many customers choose to do a full-perimeter grout pour for noise-attenuation, sanitation purposes, and to prevent the collection of explosive gases. This is acceptable, but the grout contractor should specify a non-structural grout for these purposes.
B.
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OP: 2-1020 PURPOSE:
PACKAGE MOUNTING & LEVELING THE PURPOSE OF THIS OPERATION IS TO SUMMARIZE THE PROCEDURE TO PLACE SOLAR PACKAGES ON THEIR FOUNDATION, ESTABLISH VERTICAL ELEVATION, LEVEL PACKAGE, AND PREPARE FOR DRIVE TRAIN ALIGNMENT. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
WARNINGS: 1. Improper mounting can result in serious harm to personnel and significant damage to equipment. 2. Rigging and lifting packaged equipment can be extremely dangerous. Properly trained personnel must conduct all lifts to prevent serious injury to personnel, and possible damage to the equipment. NOTES: 1. The procedures outlined in this section are a summary of the reference material listed below. For details on the various methods for mounting and leveling of Solar turbine packages to the foundation, the customer, or the customers contractor, should consult the reference material for further detail. 2. This procedure is intended as a guideline for skid leveling activities. Because there are multiple configurations to Solars equipment, reference to ES9-414 may be necessary in order to successfully elevate and level the equipment. 3. Leveling of a package with a sub-base, anti-vibration mounts (AVM), or gimbals is beyond the scope of this operation. If the package is equipped with any of these features, please refer directly to ES9-414. 4. Verify all measurement instruments and tools are calibrated and meet required accuracy. 5. Be advised that Datum C shown on Solars MID is the lower surface of the skid mounting pads, and not the upper surface of the foundation. Provisions for leveling (shimming or grouting) must be allowed in the foundation, and establishment of a consistent site water mark to which the skid elevation will be referenced to will greatly aid in the positioning of all site equipment. 6. A machined surface exists on the top of all skid-lifting points. These machined surfaces form a plane referred to as Datum D, and are used as a reference during the elevation portion of installation. 7. Note that a two-piece skid that is shipped bolted together should not be considered as a single unit once on site, and the interface bolts should be loosened regardless of whether there has been any apparent shift in the interface joint.
16
Figure 1: Two-Piece Bolted Skid
REFERENCE: ES9-414 Installation and Fabrication Procedures: These procedures may be performed by the installation contractor prior to the arrival of Solars Commissioning Personnel. If Solars personnel are present on site, they should participate in an advisory role only. 1. Confirm that the foundation pads on which the package will rest are within the guidelines requested in Operation 2-1010. Measure the distances between tie-down locations in the foundation, and ensure that the pattern matches what is shown on Solars MID. Measure the tie-down points on the skid, and ensure that they will mate properly to the foundation before lifting the unit. Ensure that there are no high spots between the frame tie-down location that might interfere with the underside of the skid. It can be extremely difficult to raise some of the Solars larger packages using the jacking bolts due to their weight. While the package is being lifted, it is advisable to extend the jacking bolts downward by threading them through the frame foundation pads as far as possible. By doing this, the package can be lowered into the correct elevation with less effort. Lift the package into position, and rest it on the extended jacking bolts. If the package has a two-piece skid, the interface joint should be loosened at this point to allow independent movement of both the driver, and driven package. Lower the skids to the correct elevation using the machined surfaces of Datum D, and a predetermined Site Elevation Point. Setting the elevation of the skid is best done with a Surveyors transit, or equivalent measuring device. Ensure that the surfaces of Datum D are level and coplanar within 1/16 of one another. Special Note: On most multi-piece skids, machined match-marks are provided at the interface joint. Use the match marks at the package interface pads to ensure the elevation of the bases are equivalent. The elevation between the two sections of the package should have been set very closely during the prior elevation of Datum D, but elevation should be confirmed. If one of
2.
3.
4.
5. 6.
7.
17
the sections of the package is higher than the other, then it must be determined which one should be moved. That package section should be elevated or lowered until the match marks are aligned. This must be done evenly and carefully to retain the preliminary level established using Datum D. If the factory match marks are not provided, then the interface bolt holes must be used as the guide to elevating the skids. 8. Begin leveling the skid(s) by measuring the level of the machined surfaces used to mount the drive train equipment. Measurements should be taken using a machinists level, or equivalent measuring device. All measurements should be taken immediately adjacent to the location where the drive train equipment bolts to the skid. In the case of a multi-piece skid, the driver package should be leveled first, and then the driven skid. The machined equipment pads must be leveled in both the forward-to-aft, and the side-to-side orientation to the required level criteria of 0.005/ft on each pad. Special Note: Some Solar packages mount to their foundations using only 3 or 4 mounting points, and packages of this type will experience some deflection under their own weight. It may not be possible to get all pads within the level criteria in the forward to aft direction, and in these cases, the central gearbox pad will become the governing surface. For packages of this configuration, only this pad is required to meet the forward-to-aft level criteria. In all cases, all machined pads must meet the side-to-side level criteria of 0.005/ft. 10. At this point, multi-piece skids should be bolted together once again. Prior to torquing the interface bolts, the interface match-marks should be checked to ensure they are still aligned with one another. Note: Ultimately, the match-marks are only intended for guidance, and if a package is properly elevated and leveled, then those criteria override the match marks being aligned. Be aware that the match-marks are used during factory construction, and that a substantial misalignment could lead to issues with interconnect piping between the two halves of the package. Final Leveling and Pre-Alignment Checks: It is advisable to enlist Solars Commissioning Personnel for the remainder of this procedure. The following steps are critical to the performance of the Turbomachinery, and Solars personnel can work in an advisory role to ensure proper installation of the unit. 1. At this point, a preliminary alignment check should be performed (see OP 2-1030). The purpose of this check is to assure that the drive train equipment is capable of being aligned, and not to perform detailed alignment measurements. Make sure the equipment is not bolt-bound, and that there is sufficient room for movement in any direction. Prepare the leveling materials (shims or grout) for the final package tie-down. If the package is being leveled using shims, the gap between Datum C and the foundation should be carefully measured, and filled as completely as possible with shim. If the package is being leveled using epoxy grout, the manufacturers recommendations should be followed to ensure proper application. Special Note: When using shims, a maximum shim stack-up of no more than 1 is suggested, and a maximum shim count of six shims. There are cases where more shim thickness may be necessary, and these will require extra care to ensure that a soft-foot condition is not created. Grout chock thickness should be specified in accordance with manufacturers recommendations, but Solars recommendation is a minimum thickness of 1.5 in order to ease the physical constraints of constructing the damming material.
9.
2.
18
3.
Fill the gap between the skid and the foundation with the appropriate leveling material, and allow for proper cure time in the case of epoxy grout. Arrange a dial indicator with the dial indicator tip on the upper surface of the frame foundation pads, and zero the dial. Back the jacking bolts off to where there is at least 0.25 of clearance, and torque the skid tie-down hardware and observe the movement measured by the dial indicator. The measured movement should not exceed 0.002 in order to maintain the level of the equipment pads. If the movement exceeds the maximum allowable, then some re-shimming efforts may have to be performed. In some cases, the skid tie down pads will need to be elevated slightly in order to install sufficient shim. It is a good practice to leave the dial indicator in place during this operation so as not to lose the level reference point.
4.
Once all tie-down locations have been shimmed and torqued, a final level check should be performed on all machined equipment mounting pads. If any of the pads are outside of the level criteria, then some re-shimming efforts must be performed to bring those pads back within the criteria.
19
OP: 2-1030 PURPOSE:
DRIVE TRAIN ALIGNMENT THE PURPOSE OF THIS OPERATION IS TO PROVIDE AN OVERVIEW TO COMPLETE THE DRIVE TRAIN ALIGNMENT. OBSERVE STANDARD SAFETY PRACTICES. WHEN APPLICABLE, MAKE SURE PERSONNEL NOT DIRECTLY INVOLVED DURING INSTALLATON ARE CLEARED FROM AREA. Rotation of some equipment can be difficult, and can require large forces to overcome the equipment inertia. Do not, under any circumstances, use any technique or workaround that may put any site personnel in danger. Rotating shafts can also be extremely difficult to stop, so ensure that no personnel can be trapped or caught by moving equipment.
SAFETY:
WARNING:
CAUTIONS: 1. Pre-lube the machinery prior to rotation to prevent possible bearing or gear damage. 2. Rotate the machinery in the direction of normal operation. 3. If misalignment has been caused by attachment of header pipes or ducting, make corrections to the offending item(s). Do not reposition the driver or driven machines as a method of correcting the misaligned condition. NOTES: 1. Thermal growth targets are based on full load operating conditions and a 70F (21C) ambient temperature. Alignment measurements must be done with the machinery at ambient temperature, so be aware that a thermally soaked package can require 12-24 hours to cool from operating temperature. 2. All package heaters should be turned off during drive train alignment. In cold weather, efforts should be made to bring the drive train up to the appropriate temperature. If the unit is housed in a building, the buildings heating should be run at 70F (21C) for 8 hours prior to alignment measurements. If the unit is not housed in a building, then temporary space heaters inside the enclosure will be sufficient. 3. When aligning outdoors or in other unstable temperature environments, be aware of thermal growth effects on the package and alignment tooling. Alignment must take place during the most stable temperature conditions. 4. For Mars products, the air inlet must be loosened and the weight of the duct supported by the engine. The top flange of the exhaust bellows must be loosened to allow movement between the bellows and the ducting. 5. Alignment must be accomplished prior to initial starting and whenever any change has been made in the relative position of the driving to driven equipment. PROCEDURE: Pre-Alignment Set-up These procedures should be performed by Solars commissioning personnel, or by the installation contractor under advisement of Solars personnel. 1. Remove shipping braces before beginning alignment procedures.
20
Note: This alignment procedure assumes that no soft foot or short foot conditions exist on any of the machinery (i.e. skid to foundation, or driven equipment to skid), and it is assumed at this point that the base(s) have been properly elevated and leveled. 2. 3. Verify that all tie-down bolts are lubricated with anti-seize lubricant. Ensure the skid is still within the level criteria after being torqued down to the foundation; proceed with rotating equipment alignment and fitting of the coupling(s). Fill oil tank to the normal operating level prior to starting alignment. On Mars packages, remove the top half of the gearbox input casing to expose the machined bore and face surfaces for indicator access. Loosen the air inlet/exhaust duct engine interfaces to allow free movement between the bellows and ducting. Verify that manifolds (i.e. lube oil supply) are loosened to allow for free movement of the machines during alignment. Verify that the equipment mounting pad areas where shims are placed are clean and free of oil, grease, and debris. Use clean shims. Do not use shims that are rusted, oily, or deformed. Set components in their normal running positions. The purpose of running position thrusts" is to place the rotors of all the machines in their operational positions, prior to alignment. Set the generator shaft (if applicable) at the magnetic center. Note: This step is not required for generators with a thrust bearing. 11. For Mars turbine units, pull the power turbine output shaft out until it is biased against its thrust bearing, mark, and clamp. If an axial probe is provided, its gap voltage can be used to verify that the turbine shaft is contacting the thrust collar. Power Turbine Shaft Leveling Tool for Mars packages (FT30635): Note: The purpose of this tool is to push the shaft-end downward into the level position to simulate the operating condition. The level shaft condition is best found by using a dial indicator on the shaft end, and by determining the point where the shaft end face is perpendicular to the axis of the drive train. A. Install the power turbine shaft leveling tool (FT30635) to the power turbine housing using the top three (3) bolt holes of the power turbine housing. B. Verify tool is free to move up and down in its guides without binding. Install dial indicator base on turbine housing bearing face, with the dial indicator tip on outer perimeter of the shaft-end face. C. Turn hand knob on leveling tool until roller comes into contact with the power turbine shaft. D. Push the shaft down by rotating the hand knob until a 180 sweep of the shaft end face produces zero (+/-.001in) indicator movement. E. The shaft is now perpendicular to the bearing face and ready for alignment.
4. 5.
6.
7.
8.
9.
10.
12.
21
ALIGNMENT TERMINOLOGY 1. Dial Indicator A. B. C. D. BT is Bore Top and FT is Face Top BL is Bore Left and FL is Face Left BR is Bore Right and FR is Face Right BB is Bore Bottom and FB is Face Bottom
Figure 2: Dial Indicator Setup View is looking from sight to target. Accurately locate the 90 clocking positions.
E.
Dial indicator readings are Total Indicator Readings (T. I. R.).
Figure 3: Typical T. I. R. Reference F. G. Positive reading is implied when the dial indicator tip is compressing from a known origin. Negative reading is implied when the dial indicator tip is extending from a known origin.
22
2.
Laser Alignment A. B. C. VO is Vertical Offset and HO is Horizontal Offset. VA is Vertical Angularity and HA is Horizontal Angularity. The convention assumes that the stationary machine is always on your left and the moveable machine is always on your right. Therefore, the following signs apply: +VO = Moveable machine is higher than the stationary machine. VO = Moveable machine is lower than the stationary machine. +VA = Coupling open at the top. VA = Coupling open at the bottom. +HO = Movable machine is away from you relative to the stationary machine. HO = Movable machine is toward you relative to the stationary machine. +HA = Coupling open away from you. HA = Coupling open towards you.
Preliminary Alignment set-up 1. Once all the machinery is in running position, use the axially oriented jacking bolts to set the faceto-face (calculated flange to flange) distance between machines as shown on the MID. Verify axial position of the machinery. Use an inside micrometer to measure axial distance between faces at top, bottom and sides and average the readings. This average must be within the calculated flange-to-flange distance on Solars MID. Note: Hubs must be in their neutral positions during this verification. The dry hubs are in the neutral position when all lock down (yellow and red) screws are loose. 3. Ensure that none of the equipment is bolt-bound, and that if necessary, there is allowable movement in all directions. Equipment tie-down bolts can only be fully torqued approximately six times. In order to prevent exceeding this limit, equipment tie-down bolts should only be torqued to 70% of values given in ES9-54 while performing shim changes. Dial Indicator Notes: A. The face diameter is defined as that diameter on the specific housing face for which the face offset is given. This sweep diameter must be an uninterrupted surface. Bore Left (BL) readings and Face Left (FL) readings are recorded from equipment during a 360 sweep. All readings must be within specified tolerance.
2.
4.
5.
B.
C.
2007 Caterpillar
Caterpillar: Confidential Green
23
D.
Sweep with the BT and FT reading at 0.0 in the 12 oclock position. Slowly rotate the alignment tool one complete rotation in the direction of normal rotation and record the following dial indicator readings: FL, FR, FB, BL, BR, and BB. Face and bore may be swept independently. If lateral alignment adjustment is necessary, do not move the fixed reference point. From the FL, FR, BL, and BR readings adjust the other machine laterally using the near and far feet jacking bolts until the face and bore values are obtained. Reconfirm axial distance when satisfied. Fully retract jacking bolts. Recheck lateral alignment. Repeat the sweep alignment to verify repeatability of the dial indicators. The alignment drawings indicate the need to perform ALIGNMENT tooling sag verification for the purpose of checking for excessive tooling sag. For example: i) Set the dial indicator at 0.0 at the 12 oclock position. Sweep the bore and record the BL, BR, and BB readings. Verify BL + BR = BB +/- 0.005-inch (0.13mm). If BL + BR BB > 0.005-inch (0.13mm), locate and correct the problem of excessive sag. If sag > 0.005-inch (0.13mm) cannot be corrected, note the sag value and use it in determining vertical shim correction.
E.
F. G.
ii)
6.
Laser Alignment notes: A. Laser targets during cold alignment are given with the convention of shooting from the stationary equipment, to the movable equipment. Refer to the laser alignment equipment manual for detailed user instructions. Note: Alignment setup must have the Stationary Machine on the left and Movable Machine on the right.
B.
Figure 4: Alignment Setup
7.
The fixed piece of equipment is not to be shimmed or moved, and is to be doweled in place after alignment has been achieved. See the final alignment procedures for more on doweling. For each alignment, the near foot is the foot or pad closest to the machines face while the far foot is the foot or pad farthest away from machines face end. The sight machine is the machine with the laser-sending unit attached to it.
8.
9.
24
10. 11.
The target machine is the machine with the laser receiver attached. Adjustments must be made with clean shims. Do not use shims that are rusted, oily, or deformed. Make lateral adjustments before shimming.
Final Alignment Verification These procedures should be performed by Solars commissioning personnel to verify that the alignment readings have not been disturbed during the following installation and commissioning activities. 1. 2. 3. All manifolds are tightened in place. Oil tank is filled to its operating level. In cold weather, the oil tank heaters are turned on, and the oil temperature has stabilized at 70F (21C) for 8 hours prior to alignment. Jacking Bolts are retracted after use. The inlet and exhaust ducts are tightened in place. Doweling (If not completed at the factory): Typically, the fixed equipment is not shimmed but doweled. Once all alignment is acceptable, dowel the fixed equipment in place. Verify alignment after doweling. If any of the above listed activities has put the alignment readings outside of the allowable limits, make the necessary adjustments through re-shimming the movable equipment. Re-sweep, reshim, and re-check until there is confidence that all equipment loads are imposed on the drive train, and the equipment is within the allowable limits. Remove the alignment tool(s).
4. 5. 6.
7.
8.
COUPLINGS 1. Mars Wet/Gear type coupling installation: A. B. C. D. E. Install the wet/gear type coupling. Verify that the nuts and bolts are in good condition and in the correct holes. In a star pattern, incrementally tighten all bolts and nuts. Verify end float. Rotate both shafts until the dual keys are 90 to one another or the single keys are 180 to one another. Use KSG grease (Solars P/N 1013623) and gravity fill the coupling halves until grease comes out of the couplings grease fitting at the 12 oclock position. Note: Any older grease that is hard or dry should be removed prior to filling the coupling. G. Assemble coupling cover with rubber centered around shaft approximately one inch (2.5 cm) from generator housing. Rubber may rest on shaft and trimming is not required.
F.
25
Figure 5: Typical coupling cover
2.
Dry coupling installation (Kopflex coupling): A. Verify that the serial number electro-etched on the spacer is the same as the serial number on the hubs. Loosen the flanges yellow screws. Remove the flanges red screws. Retighten the flanges yellow screws to collapse the disk just enough to provide room for spacer installation. Do not completely tighten yellow screws one at a time. Tighten each one incrementally until each one is fully tightened. Do not use substitute nuts and bolts at anytime. Note: The spacer is originally sent with two shim packs. These shim packs are to be used as necessary to compensate for actual flange separation and the calculated flange separation. Never install both shim packs on the same side of the spacer. C. Install the spacer with its match-marked lines lined up with the match marks on the flanges. Rotate the machinery as necessary to line up the match marks. Remove the yellow screws from each flange. Do not remove each individually. Loosen and remove each incrementally. Once the spacer is installed, lightly tighten each spacer bolt around the flange. Do not tighten each bolt down individually. Once all of the bolts are equally tightened, torque each bolt in a star pattern to the values etched on the spacer. Remove the couplings red and yellow screws and spare shims and store them safely. Assemble coupling cover with rubber centered around the shaft approximately 1.0 inch (2.5 cm) from the generator housing. Rubber may rest on shaft and trimming is not required.
B.
D.
E.
F.
G. H.
26
OP: 2-1035 PURPOSE:
GENERATOR TERMINAL BOX INSTALLATION THE PURPOSE OF THIS OPERATION IS TO PROPERLY INSTALL THE GENERATOR TERMINAL BOX (STINGER BOX) PER THE MANUFACTURERS TECHNICAL DOCUMENTATION. OBSERVE STANDARD SAFETY PRACTICES. WHEN APPLICABLE, MAKE SURE PERSONNEL NOT DIRECTLY INVOLVED IN THE TEST ARE CLEARED FROM AREA. FOR ADDITIONAL INFORMATION, CONTACT SOLARS COMMISSIONING PERSONNEL. For personnel and equipment safety, verify that the generator terminal box is solidly grounded and all instrumentation is properly connected per Solars and manufacturer technical documentation. This operation only applies for turbine package units requiring the terminal box removed for shipping.
SAFETY:
WARNING:
NOTE:
These procedures are to be performed prior to the arrival of Solars Commissioning Personnel, and are the responsibility of the customer and their contractor. Section 1 Equipment Verification 1. Ensure that all hardware (mounting bolts, current transformers, lightning arrestors, terminal strips, buss bars, etc.) is provided and verified against drawings and packing lists. Visually inspect all generator connections and hardware for damage. Document any discrepancies and contact Solars Commissioning personnel. For turbine package units with an ABB generator capacity of over 12kV, a phase-neutral insulation screen is supplied with the terminal box (see Figure 5). The phase-neutral insulation on ABB generator terminal boxes can be removed in order to facilitate the installation of the terminal box, but must be replaced upon completion of lead terminal connections.
2.
3.
4.
Section 2 Terminal Box Installation Note: Ensure that lifting hardware is capable of supporting the weight of the assembled terminal box. 1. Remove all covering from the terminal box mounting area. Ensure that all bolt holes are clean and free of damage. Lift terminal box into place with suitable lifting device. While terminal box is suspended close to the mounting area, route the generator output cables through current transformers and cable supports per manufacturers drawings. This is not necessary on ABB generators because they use bus bars. Mount terminal box to generator housing using provided bolts and gaskets. NOTE: A. B. Bolts must be torqued to the generator manufacturers requirements. All connections must be properly insulated per manufacturers technical requirements.
2.
3.
27
4.
If the generator is equipped with a neutral terminal box, repeat steps 1, 2 & 3 for neutral terminal box. For enclosed generators, do not install flashing plate until final alignment of generator is complete.
5.
Section 3 - Phase- Neutral Insulation Screen Note: these procedures apply only if the insulation screen is removed for ease of terminal box installation. 1. Remove the 4-plastic screws
Figure 6: Insulation Screen Mounting Hardware 2. 3. Remove the insulation screen Install and fasten the main terminal box to the generator. Note: For generators over 12kV voltage, the generator/terminal bus bar connection must be insulated with a silicon tape per Section 4 below. 4. Re-insert the insulation screen between the neutral and phase side. If pushed into place from the back of the box (in the directions of the arrows in figure below), no other screens or components should have to be removed.
28
Figure 7: Insulation Screen Location 5. Install and tighten the 4 plastic screws.
Section 4 Insulation of High Voltage Connections 1. 2. Insulate the high voltage cable/bus bar connections at the stator terminals. Wind silicon tape with half overlap to a homogenous insulation with the proper number of tape layers as stated in the table below. Table 2: Recommended Tape Layers Supply voltage (kv) Number of tape layers 2 2 6 3 11 4 14 6 15 7
3.
Wind one layer of glass fibre tape with half overlap.
Figure 8: Schematic of Voltage Connection Insulation
29
OP: 2-1040 PURPOSE:
EXTERNAL PIPING THE PURPOSE OF THIS OPERATION IS TO PROVIDE A BEST-PRACTICE GUIDE FOR THE CONSTRUCTION AND VERIFICATION OF INSTALLATION INTEGRITY OF EXTERNAL PIPE RUNS. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
WARNINGS: 1. Failure to follow the best practices outlined within this operation can result in piping that is unfit for operation, and will be considered a serious safety concern. 2. Exhaust collector and combustor drains must drain to a safe location. Drains may go to a common location, but must never have shutoff valves installed. 3. Drain lines may contain preservation oil or flammable gas. Do not drain until downstream system is ready or temporary drain system has been put in place. 4. Exhaust collector drains should not be connected to any common drain that is also used to drain or vent flammable gasses or fluids. 5. Pipes may be pressurized even if the turbomachinery is not running. Ensure the pressure is released before performing any work. 6. Over-pressurizing of piping can cause serious personal injury, or even death. Ensure that the pressure limits of the piping, flanges, gasket and bolts are fully understood if the piping is to be pressurized to any value other than the design pressure. 7. Not all power-generating units use flame arresters; however, if one is used, flame arrester for lube oil tank vent must be installed to prevent fire flashback. 8. Pilot gas vent line shall not contain any valves or restricting devices. Excessive backpressure to this vent can result in system or component malfunction and can cause personal injury or death to personnel, and significant site damage. 9. Ensure that piping remains properly isolated from other pipe system, instrument, electrical runs, live devices and civil construction at all times during construction. This will prevent intrusion of oil, water, or other contamination. CAUTIONS: 1. Improper welding on Solar equipment or piping structures may damage sensitive components, and can void any warranty coverage on those components. Piping runs on which welding is being performed must be disconnected from the package. 2. Consider the use of temporary supports while constructing external piping systems. This can prevent improper loading on equipment, accumulation of stresses in the piping, and can prevent potential distortion to the systems. 3. Ensure the piping and its structure does not impose any pre-loads on the turbomachinery, as this can have detrimental effects on the longevity and performance of some components.
30
4. Ensure temporary blind plates in pipe loops have been removed prior to any commissioning activity. NOTES: 1. Structure for piping should be self-supporting unless otherwise noted. 2. If pressure test will be performed with a liquid media, the pressure test must be done before purging/cleaning of all external pipes. Installation Procedures: These procedures are typical steps to be performed by the Customer or their installation contractor prior to the arrival of Solars commissioning personnel. 1. Gas fuel piping: A. Check the nameplate on the equipment to confirm the correct components are present, and inspect the components for any visible damage. Install a shutoff valve downstream of the fuel-flow meter for zeroing operations. Ensure components are oriented with the correct flow direction.
B. C. 2.
Gas fuel filter coalescer: A. Check the nameplate on the equipment to confirm the correct components are present, and inspect the components for any visible damage. Check all transmitter tags for the correct calibration range. During installation, ensure there is sufficient space left around the fuel coalescer for the equipment maintenance. Inspect the filter housing and element for cleanliness, and then preserve the filter by closing all isolating valves.
B. C.
D.
3.
Lube oil system interconnect pipe: A. B. C. Confirm that all piping being used during construction conforms to Solars MID. Install drains at all of the system low-points where applicable. Ensure that the system routing does not create a pressure loss greater than that called out on the MID. Note: Leave provisions for the oil cooler interconnect piping to be flushed prior to operation. D. E. Construct all oil tank vent pipes with a 0.25-in/foot slope downward toward the tank. Purge and clean vent pipe to lube oil separator prior to installation. Note: All pipes and their supports are to be constructed such that they are self-supporting and do not impose a load on the lube oil separator.
31
4.
Verify installation of shutoff valves at the skid edge for all of the following systems, per appropriate Solar project drawings: Lube oil tank drain Lube oil filter drain Oil drain from drain pan Fuel gas inlet If required, engine air inlet duct drain Package air supply
5.
Ensure the following pipes do not have shutoff valves installed: Pilot valve gas vent Primary and secondary seal vents Liquid Fuel Purge
6.
Ensure gas vents are vented to a safe location where there is no source of ignition, and nonshrouded areas that could allow for the accumulation of gases. Check piping runs for pressure loss limitation. Undersized lube oil pipes or number of elbows and reducers for lube oil cooler connection may limit lube oil flow to the engine. Ensure installation of valves, instruments, gaskets, flange bolts and pipe supports have been completed to a satisfactory level of workmanship. A comprehensive list of Mechanical, Electrical, and Remote Mechanical connections can be found in Table 1 on Solars MID. All connections listed on Table 1 should be verified during pre-commissioning activities. Trace all fuel pipe-runs (on-skid and off-skid) to verify that they are constructed according to fuel system schematic. Ensure all instruments, orifice plates, valves, and other devices on drawing have been installed properly. Verify that all pneumatic start pipe-runs (if applicable) are constructed according to start system schematic. Ensure all instruments, orifice plates, valves, and other devices on drawing have been installed properly. Note: No gooseneck vents or rain caps are allowed on pneumatic start piping.
7.
8.
9.
10.
11.
Verify that pipe-runs related to the engine drains, air assist, and water wash pipes are constructed according to appropriate system drawings. Ensure all instruments, orifice plates, valves, and other devices on drawing have been installed properly. Check that the lube oil tank vent pipe has the proper slope denoted on Solars MID, and that it contains no traps or restrictions.
12.
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OP: 2-1042 PURPOSE:
OIL TANK VENT AIR/OIL SEPARATOR THE PURPOSE OF THIS OPERATION IS TO ENSURE INSTALLATION INTEGRITY OF THE AIR/OIL SEPARATOR. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS. Do not allow smoking, open flames, or spark-producing devices in the vicinity of the lube oil separator.
SAFETY:
WARNING:
NOTES: 1. Ensure engineering specification ES1745 is followed during installation. 2. Procedure is for a typical air/oil separator. Obtain vendor installation instruction for the project specific separator. Pre-Installation and Fabrication Procedures: These procedures are to be performed prior to the arrival of Solars Commissioning Personnel, and are the responsibility of the customer and their contractor. 1. Prior to any installation efforts, check the equipment nameplate for specifications, and verify component identity against those indicated on the MID. Proper planning for separator location should be considered prior to installation. Oil vapor must be vented to a safe location, and under no circumstances should it be vented to turbine air inlet, turbine exhaust, or another source of ignition. Any mounting structures or piping runs must be self-supporting, and must allow for passage of maintenance personnel. Piping must have a minimum downward slope of 0.25-in/ft (2.1-cm/m) toward the package. Separator must be mounted off-skid, in a vertical orientation. Separator vent pipe must be fitted with adequate protection to prevent the entry of rainwater, snow, or any large foreign object. Customer must ensure interconnect pipe cleanliness by flushing interconnect piping in accordance with ES2184-Appendix A before making connection to air/oil separator.
2.
3.
4.
5.
Oil Tank Vent Installation Verification Procedures: These procedures are to be performed by the customer or customers contractor prior to equipment start-up. 1. 2. 3. Ensure correct installation of gaskets, flange bolts and pipe supports have been completed. Fill overflow sump to the appropriate level as specified on the equipment drawings. The operation is now complete, and the lube oil separator is ready for operation.
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OP: 2-1044 PURPOSE:
LUBE OIL COOLER THE PURPOSE OF THIS OPERATION IS TO ENSURE INSTALLATION INTEGRITY OF THE LUBE OIL COOLER. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
WARNINGS: 1. During operation, moderate pressure may exist in pipe loop. Ensure the pressure is released before performing any operations.
2.
Cooling fan can cause serious personal injury. Isolate electricity to the lube oil cooler motor before opening the cooler housing for any operation.
NOTES: 1. The top of the cooler must not exceed the specified distance above Datum C as indicated on the MID. Cooler should be located in a suitable area where temperatures remain within the contractual design criteria. There must be no heat source in the vicinity of the oil cooler that could affect cooler performance. Downward slope of interconnect piping from cooler to skid is required to facilitate draining.
2.
3. 4. 5. 6. 7.
No airflow backpressure is allowed at the cooler face. Cooler exhaust air must not vent to the turbine air intake.
Cooler fan must not draw air from the turbine exhaust system.
Pre-Installation and Fabrication procedures: These procedures are to be performed prior to the arrival of Solars Commissioning Personnel, and are the responsibility of the customer and their contractor. 1. Prior to any installation efforts, check the equipment nameplate for specifications, and verify component identity against those indicated on MID. The lube oil cooler must be mounted on a surface designed to provide adequate support for the weight of the equipment. Lube oil coolers may contain rotating equipment, and must be mounted in a level manner to ensure smooth operation. The foundation on which the cooler resides must be designed to ensure long-term support.
2.
Applies to air-to-oil coolers only.
34
Note: Cooler weights, support layout, and all other details related to supporting the cooler can be found on the Solar mechanical drawing. 3. Check valves, strainers or other restrictive devices in external pipe loop for lube oil cooler are not allowed. Ensure all guards and covers are installed prior to operation. For water-to-oil coolers, ensure adequate space is allowed for cooler maintenance.
4. 5.
Lube Oil Cooler Installation Verification Procedures: These procedures are to be performed by the customer or customers contractor prior to equipment start-up. 1. Verify that all lube oil pipe-runs (on-skid and off-skid) are constructed according to lube oil system schematic drawing. Ensure all instruments, orifice plates, valves, and other devices defined on drawing have been installed properly. Ensure the installation of instruments, gaskets, flange bolts, and pipe supports have been completed to a satisfactory level of workmanship. Identify lube oil cooler inlet and outlet heads, and verify the correct orientation of the inlet and outlet pipe runs to the package. Check that the orifice is installed at lube oil vent port, if optional vent line is installed.
2.
3.
4.
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OP: 2-1046 PURPOSE:
EXTERNAL LUBE OIL FLUSHING THE PURPOSE OF THIS OPERATION IS TO ENSURE THAT THE LUBE OIL SYSTEM FLUSHING IS PERFORMED PER SOLARS SUGGESTED PROCEDURES. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS. Flushing procedures can involve pressurized fluids at high temperatures. For personnel safety reasons, and for the benefit of the equipment, only qualified personnel should be involved in the flushing of piping and coolers. Failure to follow the procedure outlined in this operation can result in unsatisfactory system cleanliness, and package contamination. Equipment failures caused by external contamination may not be covered by Solars warranty.
SAFETY:
WARNING:
CAUTION:
NOTES: 1. The Solar package is flushed and sealed at the factory. The package is certified clean, up to the skid-edge connections and as long as the skid edge and tank lid seals are not compromised during construction, there is no need to flush the unit any further. It is the customers responsibility to ensure that all lube oil connections remain sealed at all times prior to connection of the interconnect piping. Leaving lube oil connections open on site will result in the requirement of a package flush at the customer/contractor expense. Disturbing the factory installed seals without the supervision of Solars commissioning personnel can result in the requirement of a package flush at the customer/contractor expense.
2. To ensure the cleanliness of the lube oil cooler, the customer must arrange for all coolers to be flushed on site in accordance with ES2184 prior to making any piping connections. Ensure that the lube oil interconnect lines are flushed in an isolated loop prior to connecting to the cooler, as this will prevent the introduction of contaminants. The cooler itself can be flushed in isolation, or be connected in with the post-flushed interconnect piping depending on which method is most convenient. All vent lines shall be flushed in accordance with Appendix A of ES2184. Note: While lube oil coolers are flushed and sealed at the point of manufacture, Solar acknowledges that debris can become dislodged during transportation. It is the customers responsibilities to flush all lube oil coolers at site, regardless of the results of a visual inspection. All flushing must be performed using a flushing rig, and never with the package lube oil pumps as this will result in insufficient flow and contamination of the package. Caution: Flushing contractors equipment, if not clean, can cause the contamination to piping and equipment. 3. An external filtering rig must be used to perform all lube oil pipe flushing activities. Under no circumstances should the package lube oil pumps be used for flushing, as they are not capable of providing the required flow. The package filters also must not be used as they are not sufficient for these purposes, and this drastically increases the chances of package contamination. The flushing rig should utilize a 3-5 micron filter during pipe flushing.
36
4. Due to the cost of synthetic oils, the use of mineral oils can be an attractive option for flushing purposes. Care must be taken to ensure that the flushing oil is compatible with the service oil because any residual flushing oil left in the system will dilute and degrade the service oil. The oil supplier should be able to address any oil compatibility issues. 5. In many cases, the flushing oil is serviceable for package operation. The reusability of the oil can depend on several factors such as the steps taken to clean the site-erected piping, preservation practices, removal of any water used for hydro testing, etc. Additives such as the anti-foam additive may coat new metal surfaces, or may retain water due to its polar bond. The oil supplier should be queried about how to determine if the oil is still suitable for use. REFERENCES: ES9-224, ES2184 Pre-Installation and Fabrication Procedures: These procedures are to be performed prior to the arrival of Solars Commissioning Personnel, and are the responsibility of the customer and their installation contractor. 1. 2. Ensure that the oil-flushing rig is flushed Per ES2184. Add the off-skid cooler piping to the flush loop (without cooler or package connection) and flush/filter to ES2184 and number 100 mesh captured particles. Add the oil cooler to the flush loop and flush/filter to ES2184. Each flush shall be flushed at a flow rate and temperature so that a minimum Reynolds number of 4000 is achieved through each section, or 150% of design flow, whichever is greater. Connect the cooler lines to the package, and ensure that no blank flanges are left in the system. Refer to ES9-224 and ES2184 if any further background information is required. Once flushing activities are complete, and the lube oil cooler interconnect pipes are attached to the package, the oil tank should be filled with oil poured through a 3-micron filter.
3. 4.
5. 6. 7.
37
OP: 2-1047 PURPOSE:
ENCLOSURE VENTILATION FANS THE PURPOSE OF THIS OPERATION IS TO ENSURE THE PROPER ORIENTATION OF ENCLOSURE VENTILATION FANS. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
Ventilation Fan Installation Verification Procedure: These procedures are to be performed by the customer or customers contractor prior to equipment start-up. 1. 2. Locate the fan rotation and airflow direction indications on the side of the fan assembly. Ensure that the fan is installed in the correct direction, and that the blades rotate in the correct direction. Do not reverse blade rotation to attempt to compensate for reverse-mounting of a fan, because this generally reduces blade efficiency and thus reduced airflow.
Figure 9: Typical Airflow Directions for Cylindical and Box Fans 3. Field installation of tubing required for the vent fan fail switch. Tubing should be installed across the fan in a convenient area on either side of fan blades.
38
OP: 2-1048 PURPOSE:
CO2 FIRE SUPPRESSION SYSTEM THE PURPOSE OF THIS OPERATION IS TO ENSURE INSTALLATION INTEGRITY OF THE CO2 FIRE SUPPRESSION SYSTEM. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
WARNING: 1. Cylinders are shipped with extinguishant stored at high pressure. Caution must be taken when removing the cylinders from the shipping crates to avoid any damage to equipment or injury to personnel. 2. Do not connect the discharge heads to the CO2 bottles until required for complete system installation. 3. Observe, local onshore and offshore, regulations of the Authority Having Jurisdiction (AHJ) if there is a conflict between NFPA-12 rules and the AHJ requirements. 4. The gas turbine enclosure must be unmanned during any operation of the gas turbine.
NOTES: 1. The enclosure can be equipped with fire detection and suppression system. Therefore, this operation applies to Solar packages where a CO2 fire suppression system is supplied 2. Solars scope of supply contains fire and gas detection and suppression components that comply with NFPA-12 (2008). Solar does not, however, provide the manual lockout valves, pressure switches or interconnecting piping required by NFPA-12. If the customer has purchased them from Solar, they are provided as loose ship hardware and not installed. It is the end users responsibility that the design, installation and testing of the completed system is in compliance with NFPA-12 and satisfies the requirements of the local AHJ. 3. NFPA-12 requires a total flooding test of the system at site. This is not provided by Solar. Solar can provide technical support through the local service office. 4. The extinguishant discharge pressure activates pneumatically released fire dampers located in the package enclosure ventilation ducting (if supplied by Solar). 5. Fire system manual release must be easily accessible in an emergency per NFPA-12 and AHJ requirements. 6. Cylinders ship loose for field installation by others. 7. Interconnect tubing shall be of the size stated per appropriate Solar drawing, Interconnect tubing shall be made from ASTM-A312 TP316. Fittings shall be made from ASTM A 182-3000#, 316L or 316 stainless steel. 8. Interconnect wiring to the turbine package console must be complete. 9. When the AHJ requires manual only activation of CO2 and 20 second time delay is required, the installer is to place the fire panel activation switch in disable position.
39
PROCEDURE: These procedures are to be performed prior to the arrival of Solars Commissioning Personnel, and are the responsibility of the customer and their contractor. 1. 2. Reference NFPA-12. Cylinders must be located within 50 equivalent pipe feet (7.6 m) but no higher than 20-feet (6.1 m) elevation of the enclosure connection. Note: If the cylinders cannot be located within the indicated distance due to unique site conditions, the District Service Manager and Commissioning Personnel must be notified. The Commissioning Personnel will consult with Solars Engineering. 3. Trace all CO2 pipe-runs from cabinet to nozzles, and enclosure fire dampers to verify that they are installed correctly. Ensure all instruments, flexible hoses, and other devices on the loop have been installed properly.
Figure 10: Typical Fire Damper Connection Note: Orient the fire damper such that the flex house will reach the solenoid, and the solenoid is accessible from the edge of the enclosure. 4. Pipe runs must be routed to minimize pressure losses. After the interconnect piping is complete, remove discharge nozzles and blow out all piping. Customer supplied interconnect piping shall meet NFPA 12 requirements. The fire suppression system design requires minimal extinguishant leakage through package
5.
40
openings. To prevent leakage, ensure all enclosure and frame openings are sealed. Package drip pan drains must not be open to atmosphere. 6. Extinguishant cylinders must be installed in weather - and direct sunlight - protected environment. Maximum ambient temperature not to exceed +130oF (54 oC) or fall bellow 0 oF (-18 oC).
41
OP: 2-1049 PURPOSE:
WATER MIST FIRE SUPPRESSION SYSTEM THE PURPOSE OF THIS OPERATION IS TO ENSURE PROPER INSTALLATION INTEGRITY OF THE WATER MIST FIRE SUPPRESSION SYSTEM. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THRERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
NOTE: 1. Enclosure can be equipped with fire detection and suppression system. Therefore, this operation applies to Solar gas turbine packages where a water mist fire suppression system is supplied. 2. Solar Turbines package if equipped with a pre-engineered water mist fire suppression system, is in compliance with NFPA -750 land based and marine based requirements and associated referenced maritime rules and regulations. 3. Fire system manual release stations must be easily accessible as described by NFPA-750 or requirements set by the Authority Having Jurisdiction (AHJ). The AHJ could be the local Fire Chief, State or Government. 4. Interconnect tubing shall be of the size stated per the appropriate Solar drawing. Interconnect tubing shall be made from ASTM-A312 TP316. Fittings shall be made from ASTM A 182-3000#, 316L or 316 stainless steel. 5. Water Quality Requirements: Water used for the filling of water mist storage cylinders shall be potable water or as described by the system manufactures instruction. Seawater is not a suitable water supply for Solars gas turbine packages! Distilled water will be used in the H2O cylinders. 6. In all cases the fill line must be routed through a filter of micron size described by the system manufacturers instructions. Under no circumstances should additives be used with the stored water supply. 7. If the quantity of water and nitrogen containers supplied do not comply with the AHJ requirements; the installer is to provide and install additional water containers or provide an alternate potable water supply equal to the required amount, flow rate and required pressure. PROCEDURE: These procedures are to be performed prior to the arrival of Solars commissioning Personnel and are the responsibility of the customer and their contractor. 1. Reference NFPA-750. 2. Water mist cabinet and interconnect tubing shall be installed per manufacturer's installation, operating and maintenance manual. 3. Water mist fire suppression cabinet must be installed within the distance described by NFPA-750 or AHJ regulations and requirements from the turbine enclosure connection. 4. Water mist fire suppression cabinet should be installed in an adequately protected location where minimum ambient temperature does not fall below 40 deg F (4 deg C). If the location is below 40 deg F (4 deg C), the installer is to furnish bottle heaters. 5. The nominal nitrogen cylinder volume is 50 L each. Nominal nitrogen cylinder filled pressure is 2,900 psig (200 barg) at 60 deg F (15 deg C) ambient air supply, minimum pressure 50 psig (3.5 barg) is required for automatic closure of fire dampers.
42
OP: 2-1050 PURPOSE:
ANCILLARY SUPPORT STRUCTURE THE PURPOSE OF THIS OPERATION IS TO INSPECT STRUCTURE SUPPORT FOR PACKAGE ANCILLARY EQUIPMENT. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
WARNINGS: 1. Exceeding the design limits on equipment supports can cause serious personal injury and severe damage to the equipment. 2. Always construct support structures per the design. Do not substitute materials or hardware as this can cause serious safety concerns. CAUTIONS: 1. Improper welding procedure on Solar equipment or structures may damage sensitive components, and may void any warranty coverage on those components. 2. Consider the use of temporary supports while installing ancillary equipment. This can prevent improper loading on equipment and ducting, and can prevent potential distortion. NOTES: 1. Structure for ducts and auxiliary devices should be self-supporting unless otherwise noted. 2. During the sail-out of an offshore platform, the structure can be subjected to high loads. In some rare cases, these loads can be greater than the predicted loads, and can exceed the design intent of the equipment. If there is any chance of this occurrence, then unsupported vertical ducting should be temporarily removed during shipment, and temporary supports should be fabricated for other at-risk equipment. 3. Ensure the ancillary mounting structure does not impose any pre-loads on the turbomachinery, as this can restrain the equipment, and can, in some cases, drive increased vibration levels. 4. The predicted relative motion of duct supporting structure should be within the specified limitations of flexible joints. Ancillary Support Structure Installation and Verification Procedures: These procedures are to be performed prior to the arrival of Solars Commissioning Personnel, and are the responsibility of the customer and their contractor. 1. Ensure that the enclosure structure is not supporting any equipment weight beyond what is called for on the MID. Verify that the ancillary support structure is supporting the equipment as shown on the MID. Ensure that any facility-related equipment is either self-supporting, or that provisions are made on the MID for the supporting of that equipment by the Solar ancillary structure.
2.
43
3.
Ensure the layout of ancillary structure and ducting is performed according to the MID. Confirm that the installation has made provision for operation and maintenance access. Verify that support structure mounts are seated on appropriate foundation supports, or are tied to appropriate structure in the facility. Ensure pad loads on structure supports have been considered, and checked by end user. Check all flexible joints on installed ducting, and ensure that the appropriate amount of allowable movement is present in the static condition. No pre-load is allowed. Visually inspect all ducting joints to ensure they have been mated per Solars recommended methods. If an internal inspection is possible, ensure that no sealant is protruding into the ducting. If any excess sealant is present, it shall be cleaned out prior to equipment operation. All flanges, except turbine exhaust ducting, must be caulked per figure below to prevent leakage.
4.
5.
6.
Figure 11: Flange Caulking Method
44
OP: 2-1052 PURPOSE:
AUDIT ELECTRICAL AND INSTRUMENT CONNECTIONS THE PURPOSE OF THIS OPERATION IS TO VERIFY ALL ELECTRICAL AND INSTRUMENT CONNECTIONS ARE ROUTED TO THE PROPER LOCATION ON THE GAS TURBINE PACKAGE PRIOR TO INSTALLING CABLE TRAY OR CONDUIT. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
NOTE: 1. Circuits must be installed in separate cable trays or conduits. DO NOT mix AC, DC, and/or intrinsically safe circuits unless approved by Solars Engineering. 2. All materials, such as cable tray and conduit, referenced in this operation that is external to the package are customer provided. Pre-Installation and Fabrication Procedures: These procedures are to be performed prior to the arrival of Solars Commissioning Personnel, and are the responsibility of the customer and their contractor. 1. Referring to the MID, ensure that package electrical and instrument connections are accounted for in facility electrical utility schedule. This includes AC, DC, and intrinsically safe circuits. Referring to MID, ensure that the cable tray or conduit is adequately sized for service and length of wire run. Interconnect wire sizes listed in Solars MID are typically sized for 200ft (61 m) runs. Wire sizes should be increased appropriately depending on the actual length of run at customer site and is limited by conduit or terminal sizes of devices. Note: For Balance of Plant and Ancillary equipment, refer to manufacturers technical documentation for location and sizing of electrical and instrumentation connections. 3. Once adequate size and location of cable tray or conduit is determined, placement of cable tray or conduit may begin.
2.
45
OP: 2-1054 PURPOSE:
ELECTRICAL AND INSTRUMENT RUNS THE PURPOSE OF THIS OPERATION IS TO ENSURE THE INTEGRITY OF ELECTRICAL AND INSTRUMENT CABLE RUNS FOR PACKAGE AND ANCILLARY DEVICES. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
WARNING: 1. Do not touch energized electrical circuits. Energized electrical circuits can cause serious personal injury or death. NOTES: 1. If a remote console is part of the scope of supply, verify speed pickup interconnect cable where applicable for specification to total capacitance to be less than 0.01F. 2. If a remote console is part of the scope of supply, verify vibration system interconnect cable distances are limited to 1,000-ft (305 m). 3. Do not connect battery lead cables before completing all steps within this operation Pre-Installation and Fabrication Procedures: These procedures are to be performed prior to the arrival of Solars Commissioning Personnel, and are the responsibility of the customer and their contractor. 1. Verify the required space between control cable runs and AC power cables or devices per national specification or local design requirements. Note that wire sizes listed in Solars electrical interconnect drawing and field wire list are typically sized for a maximum run of 200ft (61 m). If runs will exceed 200 ft (61 m), customer shall notify Solar to allow a review of the alternatives and additional costs associated with longer runs. Refer to PIL 149 for information on AC start motor terminal block sizes. An additional wiring length allowance should be made from skid edge to termination at electrical connection. See Table x below for approximate extra length requirements to reach from skid edge to end device.
2.
3.
Table 3: Recommended Additional Electrical Run from Skid Edge to End Device O&G C40T60 AC Start Motor 24 ft (7m) T70 Mars T130 C40T60 24 ft (7 m) M50 PG T70 T130
25 ft (8m)
17 ft (5m)
15 ft (5 m)
9 ft (2.5 m) 10 ft
7 ft (2 m)
9 ft (2.5 m)
Lube Oil Tank

22 ft
29 ft
10 ft
15 ft
22 ft
8 ft
6 ft
46
Heater Pre-Post Lube Oil Pump DC Backup Lube Oil Pump AC Scavenging Pump DC Scavenging Pump Liquid Fuel Pump
(6.5 m) 7 ft (2 m) 9 ft (2.5 m) 23 ft (7 m) 23 ft (7 m) 15 ft (4.5 m) N/A
(9 m) 7 ft (2 m) 7 ft (2 m) 24 ft (7 m) 24 ft (7 m) 10 ft (3 m) N/A
(3 m) 14 ft (4 m) 14 ft (4 m) 7 ft (2 m) 7 ft (2 m) 8 ft (2.5 m) N/A
(4.5 m) 14 ft (4 m) 13 ft (4 m) 9 ft (3 m) 8 ft (2.5 m) 5 ft (1.5 m) 31 ft (9.5 m)
(6.5 m) 16 ft (5 m) 16 ft (5 m) N/A
(3 m) 17 ft (5 m) 16 ft (5 m) N/A
(2.5 m) 6 ft (2 m) 6 ft (2 m) N/A
(2 m) 6 ft (2 m) 6 ft (2 m) N/A
N/A
N/A
N/A
N/A
9 ft (2.5 m) N/A
N/A
10 ft (3 m) N/A
6 ft (2 m) 15 ft (4.5 m)
Generator Jacking Oil Motor 4.
N/A
Wire package in accordance with Solars appropriate system drawing.
Wiring Installation Verification Procedure: These procedures are to be performed by the customer or customers contractor prior to equipment start-up. 1. Only Solars electrical drawings should be used when verifying cable runs. Do not use third party generated terminal drawings for verification purposes. Review cable schedule to ensure cable sizes, specifications, and distances on site are in accordance with Solars appropriate system drawing. Inspect all control panels and junction boxes. Check the integrity and workmanship of wiring, and make sure all wiring is in accordance with Solars appropriate system drawing. Correct, and note any discrepancies. Check the integrity of interconnect cables by conducting a point-to-point check external to the package in accordance with appropriate system drawings. Check integrity of interconnect cables and shielding external to package in accordance with appropriate system drawings.
2.
3.
4.
5.
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OP: 2-1056 PURPOSE:
SKID GROUNDING CHECKS THE PURPOSE OF THIS OPERATION IS TO VERIFY THE INTEGRITY OF THE FRAME GROUND (FG). THE PURPOSE OF THE FRAME GROUND IS TO REDUCE THE POSSIBILITY OF ELECTRICAL HAZARD TO PERSONNEL. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS. High currents flow between welding ground and the arc during arc welding. Precautions must be taken to ensure that this current does not pass through close tolerance moving surfaces, or electronic systems. Welding ground should be placed as close to the weld location as possible or on the component to be welded. Failure to observe this warning could void warranty claims. Prior to any welding procedures, ensure that the turbine package is not in operation and is grounded. Power must be removed from all PECC high force valves and actuators by opening the 120volt DC circuit breakers prior to welding on or in the vicinity of a turbine package. Weld grounding must be in proximity to weld activities. Power to the control system must be shut off. At no time is the skid to be used as a ground for welding or other facility purposes.
SAFETY:
WARNING:
REFERENCE:
SB 5.0/111
These procedures are to be performed prior to the arrival of Solars Commissioning Personnel, and are the responsibility of the customer and their contractor. 1. 2. Ensure all skid grounds are tied to facility frame ground system per SB 5.0/111. Ensure all skid-to-skid, skid-to-structure, and device-to-skid ground cables are connected. These ground cables are supplied with the package.
48
9.3
OP: 4-2010 PURPOSE:
Balance of Plant
INLET SYSTEMS THE PURPOSE OF THIS OPERATION IS TO VERIFY THE CORRECT AND COMPLETE INSTALLATION OF THE TURBINE INLET FILTER SYSTEM. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
WARNINGS: 1. Filtration media within the air filtration system are combustible. Use every precaution to ensure filter media is kept away from heat sources. 2. Do not smoke or weld near the air filter system. NOTES: 1. Insect screens are only provided as a custom feature; therefore, the need for such equipment must be identified in the contract agreement. 2. Air supply for the self-cleaning system is to be from a clean, dry source regulated between 80 and 100 psig (552 and 689 kPag). Pre-Installation Procedure: These procedures are to be performed by the customer, or the customers contractor. 1. Prior to any installation efforts, check the equipment nameplate for, and verify component identity against those indicated on the MID. The air inlet assembly must be mounted on a surface designed to provide adequate support for the weight of the equipment. The foundation on which the inlet resides must be designed to ensure long-term support and service accessibility. Note: Inlet housing weights, support layout, and all other details related to supporting the cooler can be found on the project MID. Installation Procedure 1. Verify that the inlet housing drains are properly connected to a drain line, or if not connected to a drain, do not drain on equipment located under filter housing. Drains in the clean air section of the filter housing must be connected to prevent air backflow into the filter housing Filter elements vary from manufacturer to manufacturer; reference manufactures installation documentation for correct element installation. If required, verify drain traps are installed correctly. Note: Depending on site installation, it may be best to install filter elements, mist eliminators and insect screens prior to lifting the filter housing into place.
2.
2.
49
3.
If mist eliminators are supplied, verify that they are installed per manufacturers instruction. Airflow through the mist eliminator is in an upward S direction. See Figure 12 Optional Mist Eliminator Installation for correct orientation.
Figure 12: Optional Mist Eliminator Installation Self Cleaning Inlet System: 1. 2. Ensure an isolation valve in the air supply line to the self-cleaning system has been installed. Air supply is to be regulated, typically between 80-100 psig (552 - 689 kPag), from a clean, dry source. Instrument air is not required. Refer to the electrical schematic and verify electrical supply requirements for the system control panel. Ensure an electrical isolation (AC circuit breaker) to the system control panel has been installed. System set-up and functionality test will be conducted during commissioning.
3.
4. 5.
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OP: 4-2020 PURPOSE:
EXHAUST SYSTEMS THE PURPOSE OF THIS OPERATION IS TO ENSURE INSTALLATION INTEGRITY, AND AID IN COMMISSIONING OF THE TURBINE EXHAUST SYSTEM. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
These procedures are to be performed by the customer, or the customers contractor. WARNINGS: 1. Bare metal exhaust surfaces typically operate around 9000F (4820C). Personnel protection is recommended and care must be taken in the location of hot exhaust surfaces. 2. Do not locate exhaust components on or near flammable surfaces. NOTES: 1. General exhaust system design guidelines: A. Support of the exhaust system should prevent damage to components supplied by Solar Turbines due to thermal expansion. See package installation section of the MID notes for applicable package limits and criteria. B. Mounting Brackets i) For Centaur 40/50 and Taurus 60/65/70: Mounting brackets may be welded to the shell of the ducting. The typical metal thickness and type is 3/16 in. (5 mm) thick and ASTM A515 unless otherwise stated. For Titan 130 and Mars 90/100: Mounting brackets may be welded to the shell of the ducting. The typical metal thickness and type is 1/4 in. (6.35 mm) thick nominal, ASTM A516 unless otherwise stated.
ii)
C. Expansion Joint the expansion joint (if supplied) will not support the weight of ducting or components. Reference the table below for the allowable displacements of the expansion joint. In all cases the expansion joint has no appreciable spring rate. Table 4: Expansion Joint Allowable Displacement Axial Axial Compression Extension From From Installation Installation 2.0 in 0.625 in (5.1 cm) (1.588 cm) 2.0 in 0.625 in (5.1 cm) (1.588 cm) 1.0 in 1.0 in (2.54 cm) (2.54 cm) 3.0 in 0.625 in (7.6 cm) (1.588 cm) Radial Movement Allowable (degrees) 0.0 0.0 0.0 0.0
MODEL LINE
Centaur 40/50 - Taurus 60/65/70 Taurus 60E/65 Mercury 50 Titan 130 (Round) Axial
Lateral Movement Allowable (+/-) 0.50 in (1.27 cm) 0.38 in (0.965 cm) 1.0 in (2.54 cm) 0.25 in (0.635 cm)
51
Titan 130 - Mars 90/100 (Rectangular) Radial
1.50in (3.81 cm)
0.50 in (1.27 cm)
1.25in (3.18 cm)
NA
2. When assembling or disassembling the system, use the lifting lugs provided to handle each component individually. Employ industry accepted lifting techniques when lifting lugs are not provided. Refer to component weights and assume a geometric center of gravity. Do not use the lifting lugs for permanent mounting (see note 1, paragraph B above). 3. The drain connections shown on the ancillary components are designed to remove excessive amounts of rain or moisture from the system during extended shutdown periods. Connection to these drains is optional for the customer. Rain and moisture are also removed via the exhaust collector drain on the package. 4. Attaching hardware kits are included for all flanges in Solar Turbines scope or the turbine exhaust interface flange (as applicable). Hardware is not supplied for any other downstream connections. Hardware is not supplied for foundation or support steel interfaces, unless included in Solar Turbines scope of supply. 5. Individual components of the Solar Turbines exhaust system are designed to withstand a wind load of 120 mi/hr (193 km/hr) or 0.5g lateral acceleration. Assemblies of individual components cannot be considered to be structurally adequate to the same loads without additional engineering (non-standard systems require additional analysis).
52
OP: 4-2030 PURPOSE:
EVAPORATIVE COOLER THE PURPOSE OF THIS OPERATION IS TO VERIFY THE CORRECT AND COMPLETE INSTALLATION OF THE EVAPORATIVE COOLER. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
WARNINGS: 1. Do not weld on evaporative coolers. Welding on these devices may result in fire or damage to the device. Evaporative cooler media is extremely flammable. 2. Do not smoke or weld near the evaporative cooler.
CAUTIONS:
1. Evaporative cooler water quality must meet requirements listed in ES9-98. 2. Severe engine damage can result from improper installation, setup, water quality and operation of the evaporative cooler. Before operating the evaporative cooler, read and comply with Solars Engineering Specification ES2069 and the suppliers operation and instruction manual. NOTES: 1. Evaporative coolers require a drain system with shutoff valves and a P-Trap, refer to Solars Engineering Specification ES2069 for cooler drain schematics. 2. Winterization procedures must be followed for systems exposed to ambient temperatures below 40oF (4oC), refer to Solars Engineering Specification ES2069 for procedure. Pre-Installation Procedure: These procedures are to be performed by the customer, or the customers contractor. 1. Prior to any installation efforts, check the equipment nameplate and verify component identity against those called out on the MID. Complete all required assembly before installing in inlet system. Verify the evaporative cooler assembly is mounted on a surface designed to provide adequate support for the weight of the equipment. The foundation on which the cooler resides must be designed to ensure long-term support and service accessibility. Note: Evaporative Cooler weights, support layout, and all other details related to supporting the cooler, can be found on the project MID and in Solars Engineering Specification ES2069. Installation Procedure: 1. Refer to Solars Engineering Specification ES2069 and the suppliers operation and instruction manual.
2.
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OP: 4-2035 PURPOSE:
INLET CHILLER SYSTEMS THE PURPOSE OF THIS OPERATION IS TO VERIFY THE CORRECT AND COMPLETE INSTALLATION OF THE TURBINE INLET CHILLER SYSTEM. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
WARNINGS: 1. Do not weld on chillers. Welding on these devices may result in fire or damage. 2. Chiller inlet/outlet flanges are not designed to handle any piping structural loads. Adequate design provisions must be made to protect these flanges from structural and thermal loads. 3. Do not smoke or weld near the chiller system. CAUTIONS: 1. Chiller water quality must meet requirements listed in suppliers operation and instruction manual. 2. Severe engine damage can result from improper installation, water quality, setup and operation of the air inlet chiller. Before operating the chiller, read and comply with Solars Engineering Specification ES2492 and the suppliers operation and instruction manual. NOTES: 1. Inlet chillers require a drain system with shutoff valves and a P-Trap, reference Solars Engineering Specification ES2492 for chiller drain schematics. Each set of chiller coils will have an external vent and drain valve to remove liquids from each coil section. 2. Winterization procedures must be followed for systems exposed to ambient temperatures below 40oF (4oC), reference Solars Engineering Specification ES2492 for procedure.
Pre Installation Procedures:
These procedures are to be performed by the customer, or the customers contractor.

1. Prior to any installation efforts, check the equipment nameplate and verify component identity against those called out on the MID. Complete all required assembly before installing in inlet system. Ensure chiller coil drain is the lowest point in the coils. If not at the lowest point, contact DSM for appropriate action. Verify the chiller assembly is mounted on a surface designed to provide adequate support for the weight of the equipment. The foundation on which the chiller resides must be designed to ensure long-term support and service accessibility. Note: Chiller weights, support layout, and all other details related to supporting the cooler, can be found on the project MID and in Solars Engineering Specification ES2492.
2.
3.
54
OP: 4-2040 PURPOSE:
SWITCHGEAR THE PURPOSE OF THIS OPERATION IS TO PROVIDE AN UNDERSTANDING OF THE BASIC REQUIREMENTS CONTRACTORS HAVE WHEN INSTALLING SWITCHGEAR- SPECIFICALLY, SWITCHGEAR FOR INTERCONNECTION WITH THE SOLAR PACKAGE. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS. Ensure all Up Stream power feeders have been racked out and locked out prior to any switchgear checkouts. Understand how the system is supposed to operate prior to energizing. This can usually be accomplished by consulting with the site Electrical Contractor. Switchgear is equipment designed to switch power. This can include closing the generator circuit breaker to provide power from Solars generator to a full switchgear lineup that feeds loads, parallels with the Utility, and sharing loads with other generating units.
SAFETY:
WARNING:
NOTE:
Pre-Installation: These procedures are to be performed by the customer, or the customers contractor. 1. The customer or customers contractor should install the switchgear per the manufacturers installation instructions.
55
OP: 4-2050 PURPOSE:
BOILER/WASTE HEAT RECOVERY EQUIPMENT THE PURPOSE OF THIS OPERATION IS TO ASSIST SOLARS CUSTOMERS IN UNDERSTANDING THE BASIC REQUIREMENTS CONTRACTORS HAVE WHEN CONNECTING HEAT RECOVERY EQUIPMENT TO THE SOLAR PACKAGE. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
NOTES: 1. Heat recovery equipment recovers heat usually lost to the atmosphere from the turbine exhaust. This can include water heaters, steam generating equipment, hot oil heaters, and also simply diverting the exhaust stream through dryers of different sorts. 2. Solars personnel need to know when this equipment is available to be operated in conjunction with the Solar package. To assist with this task, the attached procedures have been created. These procedures are to be used as a general guideline by the customer, or the customers contractor, to verify correct interconnection to the turbine skid. 3. This Pre-commissioning Procedures is not a replacement for the heat recovery manufacturers installation procedure, which must be followed by the customer.
Pre-commissioning Procedures: These procedures are to be performed by the customer, or the customers contractor. 1. Review all of the appropriate Project Drawings and proceed through the attached check list in order.
Section 1: Civil/Structural Checks 1. 2. Verify grounding cables have been connected to the grounding grid. Confirm the grounding grid has been megger tested.
Section 2: Mechanical Checks 1. 2. Verify the turbine exhaust expansion joint has been properly installed. Verify all skid equipment is properly grounded.
Section 3: Instrumentation, Electrical & Controls Checks 1. 2. Verify all equipment components have been properly grounded. Verify all grounding has been tested.
56
OP: 4-2060 PURPOSE:
FUEL TREATMENT EQUIPMENT THE PURPOSE OF THIS OPERATION IS TO ASSIST SOLARS CUSTOMERS IN UNDERSTANDING THE BASIC REQUIREMENTS CONTRACTORS HAVE WHEN CONNECTING FUEL TREATMENT EQUIPMENT TO THE SOLAR PACKAGE. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
NOTE: 1. Fuel treatment equipment treats the fuel prior to consumption by the turbine. This can include liquid knock out equipment, filtration equipment, fuel oil centrifuge equipment, siloxane treatment equipment, fuel gas compressors, and fuel gas heaters. 2. Solars personnel need to know when this equipment is available to be operated in conjunction with the Solar package. To assist with this task, a checklist has been created. This checklist is to be used as a general guideline by the customer, or the customers contractor, to verify interconnection to the turbine skid. 3. The Pre-commissioning check is not a replacement for the fuel treatment manufacturers installation procedures, which the customer must follow. 4. This instruction does not cover nitrogen or special type seal gas pumps. Pre-commissioning Procedures: These procedures are to be performed by the customer, or the customers contractor. 1. Review all of the appropriate Project Drawings and Project Equipment List, determine what equipment is included on this project, and proceed through the checks in order for each piece of equipment in the system. Once it has been verified that each piece of equipment has been installed correctly, along with all of its ancillary equipment and connections, follow the vendors operations manual for starting and running each individual piece. After running the equipment in conjunction with the turbine for a sufficient period at various loads to ensure that it is functioning properly, follow the agreed-to Project Test Procedures to confirm that the turbine and associated fuel treatment equipment are performing to guarantee.
2.
3.
Section 1: Mechanical Checks 1. 2. 3. 4. 5. 6. 7. 8. Verify that all turbine supply piping has been routed per applicable drawings. Verify that all piping systems to the turbine skid have been hydro tested and recorded. Verify that all turbine connection flange joints have been properly tightened. Verify the vent stack grounding cable has been installed and meggered. Verify all skid equipment has been grounded. Verify fuel filter housings have been cleaned per manufacturers recommendations. Verify fuel filter elements have been installed correctly. Verify fuel lines have been cleaned.
Section 2: Electrical, Instrumentation & Controls Checks 1. 2. 3. 4. Verify all equipment components have been properly grounded. Verify all grounding has been tested. Verify the fuel gas supply pressure has been verified and recorded for review. Verify all gas turbine skid fuel supply safeties (PCV, PRV, alarms, etc.) have been verified.
57
OP: 4-2070 PURPOSE: SAFETY:
WATER PURGE (SOLONOX ONLY) TO PROVIDE INSTRUCTION FOR PERSONNEL CONNECTING WATER PURGE MODULE TO THE SOLAR PACKAGE. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
CAUTIONS: 1. Failure of the water purge system will result in turbine component damage and/or failure. 2. Measures must be taken in cold weather application to prevent freezing of any part of the water system. 3. Water quality must meet Solars specification limits defined in ES9-98. NOTES: 1. Prior to any installation efforts, check the equipment nameplate, and verify component identity against those indicated on the MID. 2. Water purge module must be located within 50 feet (15.2 m) of the skid edge connection. 3. Supply pressure to the water purge module must be between 10 and 40 psig (69 276 kPag). 4. Water purge sequence will be checked during engine commissioning.
These procedures are to be performed by the customer, or the customers contractor. PROCEDURES: 1. Ensure installation of instruments, gaskets, and flange bolts and pipe supports have been completed to a satisfactory level of workmanship. Identify water pump inlet and outlet heads, and verify correct connection of pump supply and discharge piping. Ensure inline water strainers are installed per package fuel system drawing. Ensure correct turbine/water module electrical connections have been completed. The operation is now complete, and the water pump system is now ready for commissioning systems test.
2.
3. 4. 5.
58
OP: 4-2080 PURPOSE:
GAS FUEL SYSTEM INTERFACE CHECKLIST TO PROVIDE INSTRUCTION FOR PERSONNEL CONNECTING A GAS FUEL SYSTEM TO THE SOLAR PACKAGE. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
WARNINGS: 1. Pressurized natural gas can present severe safety hazards. It is mandatory to read and comply with all operating and installation instructions relative to this equipment. 2. All safety systems must be checked out and fully functional prior to proceeding. Gas Fuel Compressor Interface Verification Procedures: These procedures are to be performed by the customer, or the customers contractor. 1. 2. 3. 4. Verify piping is correctly installed between the Solar package and gas compressor. Verify piping records show correct rating and testing per code. Verify isolation valves are present and correctly installed. Verify piping has been correctly cleaned before or after assembly.
59
OP: 4-2090 PURPOSE:
MOTOR CONTROL CENTER THE PURPOSE OF THIS OPERATION IS TO PROVIDE AN UNDERSTANDING OF THE BASIC REQUIREMENTS CONTRACTORS HAVE WHEN INSTALLING MOTOR CONTROL CENTERS - SPECIFICALLY, MOTOR CONTROL CENTER FOR INTERCONNECTION WITH THE SOLAR PACKAGE. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS.
SAFETY:
WARNINGS: 1. The Motor Control Center (MCC) has a high center of gravity and may tip over. An MCC falling on an individual can cause serious injury or death. 2. Solar recommends against installing any means of manually energizing either lube oil tank heaters or start motors due to the potential development of hazardous situations, ranging from equipment damage to personnel injury, and/or loss of life. These devices should not be operated without the benefit of control system monitoring instruments, unless qualified maintenance personnel are performing system tests.
NOTE:
Motor Control Center is equipment designed to switch power. This can be as simple as closing the generator circuit breaker to provide power from the Solar generator or as complex as a full MCC line-up that feeds loads, parallels with the Utility, and shares loads with other generating units.
Pre-Installation: These procedures are to be performed by the customer, or the customers contractor. 1. The customer or customers contractor must install the MCC per the manufacturers installation instructions.
60
OP: 4-2100 PURPOSE:
COMPRESSED AIR INTERFACE THE PURPOSE OF THIS INSTRUCTION IS TO PROVIDE INSTRUCTION FOR PERSONNEL CONNECTING AN AIR COMPRESSOR TO THE SOLAR PACKAGE. OBSERVE STANDARD SAFETY PRACTICES. MAKE SURE ALL PERSONNEL WHO ARE NOT DIRECTLY INVOLVED WITH THE INSTALLATION ARE CLEARED FROM THE AREA. CONSULT WITH LEAD SITE PERSONNEL IF THERE ARE ANY ISSUES OR QUESTIONS. Pressurized air can present severe safety hazards. It is mandatory to read and comply with all operating and installation instructions relative to this equipment.
SAFETY:
WARNING:
Air Compressor Interface Verification Procedures: These procedures are to be performed by the customer, or the customers contractor. 1. 2. 3. 4. Verify piping is correctly installed between the Solar package and air compressor. Verify piping records show correct rating and testing per code. Verify isolation valves are present and correctly installed. Verify piping has been correctly cleaned before or after assembly.
61
10.0
MISCELLANEOUS
This section provides the forms associated with operation 1-0015 (Packing List) and operation 1-0020 (Start-Up Meeting and Installation & Commissioning Plan).
62
INVENTORY PUNCH LIST The following is a list of items and/or additional materials to be supplied and/or included by Solar in connection with the inventory of the equipment included in this sales order (per ACS). Clearly identify which items are being replaced due to damage. Storage conditions:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
______________________ __
__/__/___
__________________________
__/_ /___
SOLAR REPRESENTATIVE
DATE
CUSTOMER REPRESENTATIVE
DATE
63
PRE-INSTALLATION AND COMMISSIONING MEETING AGENDA AND CHECKLIST Project Name: Solars PD Number: Customer P.O. Number: Major Equipment Supplier Ref. Number: Meeting Date: Meeting Place: Purpose This meeting has two principle objectives: 1. To transition the day-to-day contact from Solars Business Management to the Solars Customer Services Lead Commissioning Team (District Service Manager, Field Service Representative and San Diego Commissioning Specialist) 2. To understand the Customers Installation and Commissioning schedule and constraints so that potential risks can be identified and managed. Note: This meeting is not intended to be a further technical review, but more a logistic and commercial assessment, where roles and responsibilities should be established and expectations set. Subject Items in the Check List: 1. Introduction 2. Lines of Communication/Contact Information 3. Site Schedule 4. Procedure for Ordering Field Service Support and Commissioning and Service Parts 5. Third Party Commissioning Support 6. Site Logistics 7. Site Safety Procedures 8. Critical Steps of the Installation Process 9. Documentation 10. Supply of Consumables 11. Site Fuel/Fuel Suitability 12. Supply of Hardware Requirements 13. Warranty 14. Procedure for Commissioning and Warranty Parts Support 15. Field Testing / Running Requirements 16. Punch Lists 17. Training 18. Action Items 19. Notes/Other Items/Open Issues
64
Item #
Description
Notes / Action Item
1.
Introduction of Solars Key Personnel, Major Equipment Supplier, Customer & Contractor Personnel. Commissioning Manager (Customer) Contractor (Civil, Mechanical, Electrical, Main Sub-contractors) Field Service Reps (FSRs) Field Service Managers Third Party Major Equipment Supplier Commissioning Team (Commissioning Engineer, Field Service Coordinator) Lines of Communications (see below)
Meeting Attendees: Name
Company
Phone
E-mail Address
65
Item #
Description
Notes / Action Item
2.
Establish Lines of Communication
Contact Information:
Identify the Customers Primary Contact at Site. Contact Name: Telephone: Cell Phone/Pager: Fax: E-Mail: Identify the Back Up Contact at site. Contact Name: Telephone: Cell Phone/Pager: Fax: E-Mail: Identify the Customers Site Manager or Other Key Personnel. Contact Name: Telephone: Cell Phone/Pager: Fax: E-mail: Identify the District Office and District Service Manager. District Office: District Manager Name: Telephone: Cell Phone/Pager: Fax: E-mail: Solar San Diego Commissioning Engineer: Identify Solars Primary Contact (FSR). Contact Name: Telephone: Cell Phone/Pager: Fax: E-mail:
66
Item #
Description
Notes / Action Item
Identify Solar San Diego Project Manager

Contact Name: Telephone: Fax: E-mail: Identify Solar San Diego Project Engineer. Contact Name: Telephone: Fax: E-mail: Identify Solar Construction Services / B.O.P. Project Manager (If Applicable) Contact Name: Telephone: Cell Phone/Pager: Fax: E-mail: Identify the Driven Equipment Supplier Contact. Contact Name: Telephone: Cell Phone/Pager: Fax: E-mail: Identify Other Key Third Party Supplier Contact. Contact Name: Telephone: Cell Phone/Pager: Fax: E-mail: Identify Other Key Third Party Supplier Contact. Contact Name: Telephone: Cell Phone/Pager: Fax: E-mail:
67
Item #
Description
Notes / Action Item
Identify Customer Contact for Solars Customer Survey (after the unit(s) has received beneficial use, Solar will contact the person(s) listed below to request that a brief survey be completed to obtain feedback on the commissioning process to assist Solar in continuous improvement). Contact Name: Telephone: E-Mail: 3. Site Schedule:
Review Installation, Commissioning Schedule, and Proposal

Equipment departs/departed from San Diego on: Expected Delivery Date: Discuss time/mode/arrival location
Has All the Equipment Arrived at Site? List Items Missing:
Expected Installation Period (start/end): Does the customer have an Installation Schedule? If the schedule is not available, define who is responsible for creating and maintaining the schedule. Review Schedule if available. When is the FSR required at site? Expected Commissioning Period (start/end): Does the customer have a Commissioning Schedule? If the schedule is not available, define who is responsible for creating and maintaining the schedule. Review Schedule if available.
When is the FSR required at site? Expected In-Service Date for this equipment: Review Solars typical Commissioning Schedule and explain the use of the commissioning checklist/manual. Time required for dispatching Solars FSR: Will there be a requirement for more than one (1) FSR?
68
Item #
Description Expected manpower needs: Will customer supply mechanical & electrical assistance? Any project constraints (season, country, others):
Notes / Action Item
4.
Review the Procedure for Ordering Field Service Support and Commissioning Parts. Service man-days purchased by Customer (commissioning days): If service has not been purchased, DSM to present the rates and the terms and conditions. What are payment terms for Field Service:
Identify/Establish the procedure for ordering installation and commissioning support (if none was purchased with the turbine):
Solars DSM to discuss the process for any non-chargeable work done during the course of installation and commissioning: Review Factory Punch List (if applicable).
Solars DSM/PM to discuss the process and procedure for back charges if this should occur: Review form provided. Solar will not accept any charges by others for any work unless the work, the contractor, and the cost has been expressly agreed by PM/DSM before such work commences Was a quotation for recommended Operational Spare Parts provided?
69
Item #
Description What Start-Up & Commissioning Spares/Tools were purchased? What is the status of their delivery?
Notes / Action Item
Identify / Explain the procedure for ordering spare parts or tools (if none were purchased with the turbine).
24-hour service no. 1-800-SOLAR-50 (or DSM)
5.
Identify Third Party Commissioning Support (i.e. Compressor Supplier, Surge Control Supplier, etc.) Driven Equipment Supplier: Identify Equipment Scope of Supply: Equipment departed from Supplier/Solar on: Expected arrival at site: Has all the equipment arrived at site? List items missing: Surge Control Supplier: Identify Equipment Scope of Supply: Expected Arrival at Site: Has the customer purchased Third Party Commissioning Support? If service has not been purchased, Supplier to provide the rates and the terms and conditions. Identify/Establish the procedure for ordering installation and commissioning support for Third Party equipment if none purchased. Commissioning days purchased and/or required: Estimated man-days by Supplier: Who is responsible for the installation? Identify/Establish the payment terms and invoicing structure:
70
Item #
Description Review typical installation and commissioning schedule if available: Review installation steps / procedures:
Notes / Action Item
If available, review typical installation and commissioning checklist and service manuals.
Was a quotation for recommended Operational Spare Parts provided? What Start-Up & Commissioning Spares/Tools were purchased?
6.
Identify / Explain the procedure for ordering spare parts or tools (if none were purchased with the main order): Review Site Organizational Structure, Logistics, and Facilities for FSRs. To whom will the FSR report to on site? Solars DSM to explain the use of Service Orders and the process of ordering Field Service Assistance: High speed network access? Phone line available to FSR? Office space available to FSR? Recommended Lodging: On-Shore: Off-Shore (if applicable):
Working Hours On-Shore: Review rate sheet Off-Shore: Shifts: Maximum no. Hours/day: Review overtime hours
71
Item #
Description If an international location, what are the VISA requirements?
Notes / Action Item
Site Shipping Address:

Include Company Name and Final Site Address Site Contact (e-mail and telephone no.)
Site Mailing Address (if different from above):
For International Projects: What are INCO terms? Forwarder: (Solars or Customers?) If this is an ex-works shipment, we need contact name, tel, email address of person who arranges pick up such as forwarder. If small inexpensive parts can be shipped via DHL, please ask for the companys DHL account number for third party billing. If we pay for any part of freight, we will use our forwarder(s) up to the chosen destination. When we transfer responsibility, it is critical that we can contact the responsible parties to find out the status on the shipments to the FSR. RESPONSIBLE PARTIES: If the customer takes over responsibility and costs of shipment in US or before customs, we need ship-to-address, contact name, tel, email address of people who take responsibility.
72
Item #
Description CONSIGNEE: Who is the Consignee that should be listed on documents? (Simply stated, the Consignee is the company who takes charge at customs, often paying duties, taxes, & VAT. This is called the Importer of Record which is recognized by in-country customs.) This is especially important in cases where there is one company that purchases and another that is end user and a fab yard in between. CUSTOMER/CONSIGNEE/BROKER Contact, tel, email address is needed for person who helps clear customs, understands the urgency level, and makes sure appropriate persons are notified for smooth delivery to the site.
Notes / Action Item
7.
Review Site Safety Procedures. Any special training/work permit/health certificate/insurance policy required before personnel start working at the site? Is a site safety manual available? Site Safety Inspector (name/phone):
Swimming Certificate Required (if off-shore): Drug Test Required? Smoking Allowed on site? Required Safety Equipment.
8.
Hard Hats: Safety Shoes: Eye Protection: Ear Plugs: Gas Monitor: Radios/Cell Phone: Life Vest (if off-shore): Fire Retardant Clothing: Safety Harness: Critical steps of the installation process that should be witnessed by Solars FSR and Supplier FSR (if applicable; to be indicated). Arrival of Equipment: (Please note: the equipment must be stored in a dry, protected area until ready for installation)
73
Item #
Description Inventory check of all material at site:
Notes / Action Item
(Please note: Solar recommends that a company representative be present when the boxes are opened at site to do a comprehensive inventory. If Solar is not present to verify the equipment when the boxes are opened, any items that are missing from site will be the customers responsibility.)
By Who: When: Package Leveling By Who: When: Preliminary alignment of the turbine train. By Who: When: Supply of Alignment Tool is by: Will alignment be done using laser alignment tool or dial indicator method?
(Alignment data is available in the MID.)
Flushing of the lube oil system Reference Solars Flushing Specification, ES 9-2184 for procedures. By Who: When: Prior to start-up, the inspection of air inlet and exhaust ducting: Prior to start-up, the inspection of the fuel gas line: Prior to filling, the lube oil tank will need to be inspected for cleanliness: Hot Loop Check of AC & DC connections By Who: When:
74
Item #
Description Connection of the process piping to the compressor. By Who: When: Blow down requirements for process piping understood? Compressor venting & loading limitations understood? Final alignment of turbine train. By Who: When: Test Crank & Start-Up. By Who: When: Other Start-Up Criteria?
Notes / Action Item
9.
Have the following As-Shipped Documents been released to the Customer? Operation & Maintenance Manuals: Mechanical Interface Drawings: Hydro-Mechanical Schematics: Electrical Schematic/Wiring Diagram & Surge Control Drawing (if applicable): Third Party Major Equipment Supplier As-Built Drawings (if applicable): Has software been released? Are there any special communication/interface software required/provided? Solars FSR to install software Has Solars FSR received the project dossier and reviewed the as-shipped drawings? Package Test Report: Service Bulletins Provide a copy of the Service Bulletin Request Form, which can also be sent electronically. Procedure for field return drawings & software (As-Installed):
75
Item #
Description
Notes / Action Item
10.
Supply of the following Consumables and Tools During Commissioning: Lube Oil (per Solars Spec. ES9-224): Check quality of lube oil prior to tank fill Supplied by: Oil Type (C32 or C46): Flushing Oil Supplied By:
De-ionized water, if required: (Quantity required per engine for three water wash cycles; the first cycle to wash off preservative per Solars Spec. ES9-62) Supplied by: Detergents, if required: (Detergent per Solars Spec. ES9-62) Supplied by: Special Tools required other than alignment tool. Supplied by: If split skids, customer must provide torque tool. Define the instrumentation and/or tools that are to be provided by the Customer. Smart Transmitter Calibrator with HART Communicator Fuel for running equipment at the fabrication yard or string test (if applicable) Supplied by:
76
Item #
Description
Notes / Action Item
10A
For International Projects only, the following tools/instruments are to be provided by the customer or their contractor:
Equipment Description
RTD Simulator Pressure Simulator 0 to 10 inch H2O 0 to 250 inch H2O 0 to 50 PSIG 0 to 100 PSIG 0 to 1000 PSIG 0 to 2000 PSIG Hand Pressure Pump Vibration Generator Frequency Gen. 0 to 20 Khz. Amplitude 0 to 10 VDC Offset 0 to 15 VDC Wobulator or Shaker Table Multimeter Ma. Meter and source 0 to 20 mA Current Meter 0 to 5 amps DC/AC Current Meter 0 to 50 Amps DC/AC Thermocouple Type K Meter Thermocouple Type K Simulator UV Lamp Heat Gun Calibration Gas LEL 50% or 2.5% methane Thermocouple wire type K 10 feet 24 DC Power Supply Borescope Torque Multiplier 0 to 1000 ft-lbs Torque Wrench 100 and 250 ft-lbs Distilled Water Kerosene Liquid Soap Smart Transmitter Calibrator with HART communicator Turbine Shims CSI Vibration Analyzer Alignment Tools and Comparators Oil Pump 60 to 80 GPM Inside calibrator, precision .001 Deep sockets and wrenches for alignment Required Required Required Required Required Required Required Required Required Required Required Required Required Required Required Required Required Required Required Required Optional Required Required Optional Optional Required Required Required Required Required Required Required Required Required Required Required Required
77
Item #
Description
Notes / Action Item
11.
Confirm/review site fuel availability and verify fuel suitability if different from project specific. Fuel analysis available if different from site specific? What type of storage is fuel coming from (if liquid)? Supplied By: Installed By:
12.
Supply of the following hardware requirements. Skid Anchor/Tie Down Bolts: (Split skids or single lift?) Skid Interface Bolts: Lube Oil and Gas Interconnect Piping off-skid: Termination of Interconnect Harness: Wiring to MCC: AC & DC Power Cables: Turbine Inlet & Exhaust Supports: Supports for Lube Oil Separator (if applicable): Supports for Lube Oil Cooler: Supports for Enclosure Ventilation System: Compressor Suction & Discharge Flange bolts/studs: Suction Strainers for Compressor: Type of Warranty and Term:
13.
Identify the Warranty Purchased and/or Applicable for this Project.
(i.e. Standard 12/18 (domestic) or 12/24 (international): 12 months from start-up or 18 (24) months from date of readiness to ship, whichever comes first).
Was an Extended and/or Expanded Warranty Purchased? Return of defective parts
(Under Solars standard warranty, the customer has an obligation to ship defective parts back to Solar, this includes during the commissioning phase as the warranty is active as soon as a notice of readiness to ship is issued. Please note it is important that Solar receive these parts back and Solar reserves the right to issue an invoice for the part if they are not returned in a timely manner.)
78
Item #
Description Equipment Ready to Ship Date: (Start of Non-Operational period; If equipment has been in storage, the period starts on the date of the notice of readiness to ship if this date is on or after contractual delivery date): Expected Beneficial-Use Date (or completion of acceptance criteria):
Notes / Action Item
Note: Start of Operational period 14. Review Procedure for Commissioning & Warranty Parts Support. Unidentified Ship Short Material: (PM to establish handling of these part(s)) Identified Ship Short Material: (Items are handled as per contract shipping trade terms) Commissioning parts: (Parts that fail during start-up are supplied by Solar at Solars cost. Transport of the part(s) is per the contract warranty terms.) Customer to provide shipping instructions if different than original equipment delivery. Warranty Parts (after start-up): (For standard terms, warranty parts will be supplied Ex-Works, Factory unless warranty language deviate from this standard policy. For standard warranty, freight and labor is by the Customer) Review Field Testing / Running Requirements Is a Field Performance Test Required? What is the Guarantee Point (if applicable)? Who is responsible for conducting the test? Is special instrumentation required for testing and who is responsible for supply, installation, and set-up of test? (Note: If Field Testing is not required, Solar will still perform a mechanical run test using package instrumentation. Also, Field Test must be done within the first 100 hours) Is a Field Emissions Test Required? What is the Guarantee Point (if applicable)? Who is responsible for conducting the test? Is special instrumentation required for testing and who is responsible for supply, installation, and set-up of test?
15.
79
Item #
Description Is a Field Noise Test Required? What is the Guarantee Point (if applicable)? Who is responsible for conducting the test? Is special instrumentation required for testing and who is responsible for supply, installation, and set-up of test? Will the Package have a string test prior to field installation? Who will be responsible for re-packing and preserving the package if required? Will the Package be run in the Fab Yard? Review Package Preservation Requirements after installation / running. Who will be responsible for re-packing and preservation for Long Term if required? What are the Field Acceptance Criteria?
Notes / Action Item
16.
Punch Lists
Factory:
Review if applicable for Equipment supplied by Solar and Sub-Suppliers. (Refer to item 4, non-chargeable time) After completion of commissioning and startup: Explain the use of a punch list which will be created jointly between Solar & Customer. Develop a strategy covering how remaining punch list items will be handled at the end of commissioning / start-up. To be handled through the district office, as appropriate. Who should receive a copy of the Punch List? 17.
Training
Is any Customer operator training/familiarization required? Has the Customer purchased training with the Turbomachinery scope?
80
Item #
Description Solars Contact for Training: te: 90-day lead time is required for reservations) Type of Course Purchased: Is any training required for Major/Driven Equipment supplied within scope? Is translation required for the Manuals? Has Customer purchased translation? Does the instructor need to be bi-lingual? On-site or Factory Training? Timing/Schedule:
Notes / Action Item Lisa Walford/Oscar Ortega, 858-715-2070
18.
Actions (Technical or Commercial) No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Action Item Action By (date): Who:
19.
Notes/Open Issues/Comments (Technical or Commercial)
81
Item #
Description
Notes / Action Item
82

Turbomachinery Package Installation Guidline 1000 Rev - B

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Turbomachinery Package Installation Guidline 1000 Rev - B

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TURBOMACHINERY PACKAGE INSTALLATION GUIDELINE

Data Control Level

INSTALLATION GUIDELINE NO. TPIM 1000 REVISION: B

ISSUED: 11/07/2007, CR 18967

A; 12/30/2007; CR 18967 B; 5/27/09: CR 22987

5/26/09 4/29/09 ALL 5/26/09 5/06/09

Caterpillar: Confidential Green

Installation Guideline No. TPIM 1000B

Caterpillar: Confidential Green 2007 Caterpillar

Installation Guideline No. TPIM 1000B

FIGURES Figures Page

TABLES Tables Page

Caterpillar: Confidential Green 2007 Caterpillar

INSTALLATION GUIDELINES Installation Guideline No. TPIM 1000B

DOCUMENTATION AND DELIVERY

Caterpillar: Confidential Green 2007 Caterpillar

INSTALLATION GUIDELINES Installation Guideline No. TPIM 1000B

INSTALLATION GUIDELINES GENERATOR SET

SITE PREPARATION OPERATIONS

Customer & Solars FSR

Customer & Solars Project Manager Representative Customer

Ensure proper lifting guidelines are followed.

SITE PREPARATION OPERATIONS COMPLETED INSTALLATION OPERATIONS

Caterpillar: Confidential Green 2007 Caterpillar

INSTALLATION GUIDELINES Installation Guideline No. TPIM 1000B

Customer & Solars FSR

GENERATOR TERMINAL BOX INSTALLATION

2-1040 EXTERNAL PIPING

OIL TANK VENT AIR/OIL SEPARATOR

2-1044 LUBE OIL COOLER

Ensure installation integrity of the lube oil cooler.

2-1046 EXTERNAL LUBE OIL FLUSHING

ENCLOSURE VENTILATION FANS CO2 FIRE SUPPRESSION SYSTEM

Ensure the proper orientation of the enclosure ventilation fan(s).

Customer & Solars FSR

Ensure installation integrity of the CO2 fire suppression system.

2-1049 WATER MIST FIRE SUPPRESSION SYSTEM

Ensure installation integrity of the Water Mist fire suppression system.

Caterpillar: Confidential Green 2007 Caterpillar

INSTALLATION GUIDELINES Installation Guideline No. TPIM 1000B

2-1054 ELECTRICAL AND INSTRUMENT RUNS 2-1056 SKID GROUNDING CHECKS

Customer & Solars FSR

INSTALLATION OPERATIONS COMPLETED BALANCE OF PLANT RUNNING CHECKS

Customer & Solars FSR

INLET CHILLER SYSTEMS

Verify the proper and complete installation of the inlet chiller.

BOILER/WASTE HEAT RECOVERY EQUIPMENT

Caterpillar: Confidential Green 2007 Caterpillar

INSTALLATION GUIDELINES Installation Guideline No. TPIM 1000B

WATER PURGE (SOLONOX ONLY)

4-2100 COMPRESSED AIR INTERFACE

BALANCE OF PLANT OPERATIONS COMPLETED

10. PIL Product Information Letter 11. PM Project Manager

INSTALLATION GUIDELINES Installation Guideline No. TPIM 1000B

Caterpillar: Confidential Green 2007 Caterpillar

INSTALLATION GUIDELINES Installation Guideline No. TPIM 1000B

LIST OF REFERENCE MATERIALS

Caterpillar: Confidential Green 2007 Caterpillar

INSTALLATION GUIDELINES Installation Guideline No. TPIM 1000B

Caterpillar: Confidential Green 2007 Caterpillar

INSTALLATION GUIDELINES Installation Guideline No. TPIM 1000B

OP: 1-0015 PURPOSE: