Control Number : 40368
Item Number : 85
Addendum StartPage : 0
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SOAH DOCKET NO. 473-12-6200
PUC DOCKET NO. 40368
NOTICE OF VIOLATION BY
LUMINANT ENERGY COMPANY, LLC,
AN AUTHORIZED QUALIFIED
SCHEDULING ENTITY (QSE), OF PURA
§§ 39.151(d) AND (j), P.U.C. SUBST. R.
§
§
§
§
§
25.503(f)(2), ERCOT PROTOCOL
§
§6.5.7.6.2.3(4) RELATING TO NONSPINNING RESERVE SERVICE (NSRS)
DEPLOYMENT, AND ERCOT
PROTOCOL §8.1.1.4.3(3)(b) RELATING
TO NSRS ENERGY DEPLOYMENT
CRITERIA
§
§
§
§
§
§
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BEFORE THE
PUBLIC UTILITY COMMISSION
OF TEXAS
COMMISSION STAFF'S FIFTH SET OF REQUESTS FOR INFORMATION
TO LUMINANT ENERGY COMPANY, LLC, QUESTION NOS 5-1 - 5-31
The Staff of the Public Utility Commission of Texas (Staff) requests that Luminant
Energy Company, LLC, ( Luminant) provide the following information and answer the following
question(s) under oath. The question(s) shall be answered in sufficient detail to fully present all
of the relevant facts, within the time limit provided by the Presiding Officer or within 20 days, if
the Presiding Officer has not provided a time limit. Please copy the question immediately above
the answer to each question. These question(s) are continuing in nature, and if there is a relevant
change in circumstances, submit an amended answer, under oath, as a supplement to your
original answer. State the name of the witness in this cause who will sponsor the answer to the
question and can vouch for the truth of the answer.
85
Provide an original and ten copies of your answers to the questions to the Filing Clerk,
Public Utility Commission of Texas, 1701 N. Congress Avenue, P.O. Box 13326, Austin, Texas
78711-3326.
2
DATE: March 15, 2013
Respectfully Submitted,
Robert M. Long
Division Director
Oversight and Enforcement Division
State Bar No. 12525500
Su
. Stith
Attorney-Oversight and Enforcement Division
State Bar No. 24014269
(512) 936-7307
(512) 936-7208 (facsimile)
Public Utility Commission of Texas
1701 N. Congress Avenue
P.O. Box 13326
Austin, Texas 78711-3326
DOCKET NO. 40368
CERTIFICATE OF SERVICE
I certify that a copy of this document will be served on all parties of record on this the
15th day of March, 2013 in accordance with P.U.C. Procedural Rule 22.74.
LLLj,,, ^AA
Sus
. Stith
PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
DEFINITIONS
A.
"Luminant Energy" "the Company", "Luminant" or "you" refers to Luminant Energy
Company, LLC, and any person acting or purporting to act on their behalf, including without
limitation, attorneys, agents, advisors, investigators, representatives, employees or other persons.
B.
"Morgan Creek Combustion Turbines," "Morgan Creek CT Units," and "Morgan Creek
CTs" refers to all of the Morgan Creek combustion turbines unless specifically limited to certain
units.
INSTRUCTIONS
1.
Pursuant to P.U.C. Proc. R. 22.144(c)(2), Staff requests that answers to the requests for
information be made under oath.
2.
Please copy the question immediately above the answer to each question. State the name
of the witness in this cause who will sponsor the answer to the question and can vouch for the
truth of the answer.
3.
These questions are continuing in nature, and if there is a relevant change in
circumstances, submit an amended answer, under oath, as a supplement to your original answer.
4.
Words used in the plural shall also be taken to mean and include the singular.
used in the singular shall also be taken to mean and include the plural.
Words
5.
The present tense shall be construed to include the past tense, and the past tense shall be
construed to include the present tense.
6.
If any document is withheld under any claim of privilege, please furnish a list identifying
each document for which a privilege is claimed, together with the following information: date,
sender, recipients or copies, subject matter of the document, and the basis upon which such
privilege is claimed.
7.
Pursuant to P.U.C. Proc. R. 22.144(g)(4), if the response to any request is voluminous,
please provide a detailed index of the voluminous material.
L+
PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
5-1
Provide the official results of the Quick Start Tests for each Morgan Creek CT conducted
on March 2, 2010. Be sure to include the High Sustained Limits (HSLs) as verified by the Quick
Start Test that day for each Morgan Creek CT.
5-2
Provide the date and time that the incorrect firing curves were loaded, entered into, or
configured within the Emerson Control Systems for Morgan Creek CTs 1, 2, 3, 4, 5, and 6 as
described to ERCOT on the morning of February 2, 2011.
5-3
Provide the name and job title of the employee(s) that loaded, entered into, or configured
the incorrect firing curves within the Emerson Control Systems for Morgan Creek CTs 1, 2, 3, 4,
5, and 6 as described to ERCOT on the morning of February 2, 2011.
5-4
Provide the name and job title of the employee(s) that discovered the incorrect firing
curves within the Emerson Control Systems for Morgan Creek CTs 1, 2, 3, 4, 5, and 6 as
described to ERCOT on the morning of February 2, 2011. Provide the date and time the
employee discovered the incorrect firing curves within the Emerson Control Systems for Morgan
Creek CTs 1, 2, 3, 4, 5, and 6 as described to ERCOT on the morning of February 2, 2011.
5-5
a.
Provide the date and the time that the Luminant QSE was first made aware
that incorrect firing curves were loaded, entered into, or configured within the Emerson
Control Systems for Morgan Creek CTs 1, 2, 3, 4, 5, and 6 as described to ERCOT on the
morning of February 2, 2011 (That is, the date and time that the Luminant QSE was made
aware that the Morgan Creek CTs were limited to 70 MWs).
b.
Provide the name and job title of the QSE employee initially notified by
the plant of the incorrect firing curves.
c.
If an audio recording of the firing curve notification by the Plant to the
QSE (and any related QSE to Plant communications) conversation exists, provide a copy
of the audio recording (or alternatively a certified transcript of the audio recording).
5-6
Provide an explanation of how the incorrect firing curves were loaded, entered into, or
configured within the Emerson Control Systems for Morgan Creek CTs 1, 2, 3, 4, 5, and 6 as
described to ERCOT on the morning of February 2, 2011.
5-7
Provide copies of the firing curves (or develop and provide a graphical representation of
the firing curves) that were installed (or otherwise present) in the control systems for CTs 1, 2, 3,
4, 5, and 6 on the morning of February 2, 2011.
5
PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
5-8
Provide copies of the firing curves (or develop and provide a graphical representation of
the firing curves) that were installed (or otherwise present) in the control systems for CTs 1, 2, 3,
4, 5, and 6 after new curves were loaded during the evening of February 2, 2011.
5-9
Admit or deny that the incorrect firing curves within the control systems for Morgan
Creek CT 1, 3, 4, 5, and 6 on the morning of February 2, 2011 would have prevented the CTs
from supplying more than 70 MWs of generation had the CTs successfully deployed in response
to the NSRS Dispatch at 4:26 am on February 2, 2011.
5-10 Admit or deny that Morgan Creek CTs 1, 3, 4, 5, and 6 were obligated to provide the
following MW amounts of NSRS for Hour Ending 5 on February 2, 2011:
CT1 - 89MW
CT3 - 92MW
CT4 - 88MW
CT5 - 89MW
CT6 - 90MW
5-11 Provide the dates that "Remote Start" testing was completed for each CT after changes
were made to the Emerson Control System on January 25, 2011 for each Morgan Creek CT. If
testing was not performed, please describe method of control system change validation utilized
including dates and times of such testing.
5-12 Was the automatic generation control (AGC) testing completed on all six CTs as part of
the Site Acceptance Testing (prior to the Commercial Operation Dates in Exhibit TAW-4, Page
29 of Mr. Warren's Direct Testimony)? If not, provide dates that AGC testing was completed for
each CT.
5-13 Confirm that on the morning of February 2, 2011, all six of the CT's were started up (or
attempted to start-up) using the new Emerson Control System from the central control room
(utilizing "remote start").
5-14 Confirm that on the morning of February 2, 2011, all six of the Morgan Creek CTs
utilized (or would have utilized if the CTs had successfully started) remote AGC control of the
units from the central plant control room using the newly installed Emerson Control System.
5.15
Has Luminant or Emerson engaged an independent, third party testing
a.
firm to examine and test the Morgan Creek CT Unit 1 relay (removed from Module 2.2.4
- annunciator horn relay)?
PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
b.
If so, please provide copies of such testing. If not, please explain if (and
when) such testing is planned.
c.
If such testing is not planned, please explain the reason(s).
5-16
a.
Does Luminant have records of the actual temperatures inside the Morgan
Creek CT electronics rooms (that house the new Emerson Control Cabinets) for each CT
for February 2, 2011? If so, provide copies.
b.
Does Luminant have records of the actual temperatures inside the Morgan
Creek CT new Emerson Control Cabinets for each CT for February 2, 2011? If so,
provide copies.
5-17
a.
Does Luminant have records, files (including electronic), or documents
that confirm that the electrical heaters inside the Morgan Creek CT electronics rooms
(that house the new Emerson Control Cabinets) performed as expected on February 2,
2011? If so, provide copies. If not, how did Luminant insure that the heaters were
properly configured and continuously operating on February 2, 2011 ?
b.
What was the temperature setting for each of the heater thermostats in the
electronics rooms that housed the new Emerson Control Cabinets on the morning of
February 2, 2011?
5-18 Provide a copy of the Luminant procedure(s),as they existed on February 2, 2011, for
installing and testing changes or modifications to the Emerson Control Systems at the Morgan
Creek plant.
5-19 Provide the maximum and minimum operating temperature (per the OEM - Original
Equipment Manufacturer) for the "failed" 700-HK Slim Line Relay installed in Module 2.2.4
that was originally installed in the Emerson Control Cabinets for the annunciator horn for
Morgan Creek CT 1 and CT 4. Does the OEM provide a maximum rate of change for
temperature? If so, provide that information.
5-20 Provide the maximum and minimum operating temperature (per the OEM) for the new
Emerson Control Cabinets and Emerson Control Modules at the Morgan Creek plant. Does the
OEM provide a maximum rate of change for temperature? If so, provide that information.
5-21 Is this same model of relay (700-HK Slim Line Relay) as the one pulled from CT1
Emerson control cabinet (currently replaced with a different model) still in use in any of the
Emerson Control Cabinets at the Morgan Creek plant? If so, provide the number of identical
relays installed and still in use at the Morgan Creek plant in the Emerson Control Cabinets for all
CTs.
-1
PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
5-22 Please refer to attached pdf file (Attachment 1) containing 1 drawing received from site
visit of February 28, 2014, titled "GOV_CORRECTED_SPEED" and dated December 18, 2010.
a.
Describe the impact to each unit on February 2, 2011 of the incorrect
"Correction Reference Temperature - VALU=540.0" and the handwritten notation that
the VALU "should be 410".
b.
Confirm that the notation is from Mr. Calloway and is apparently dated
February 2, 2011.
c.
Confirm which units had this "incorrect value" of 540.
d.
Confirm when the change was made to each unit and describe when and
how the change was tested for each unit.
e.
Confirm the source of the "incorrect value" of 540 and explain why it was
not discovered during previous FAT (Factory Acceptance Testing) and SAT (Site
Acceptance Testing) efforts.
5-23 Please refer to the attached pdf file (Attachment 2) containing 2 drawings received from
site visit of February 28, 2013, titled "GOV_EXH_TEMP_CONTROL" and both dated
December 18, 2010.
a.
Please provide an explanation of the handwritten notes that read "Old
Curves" and "Curves Need To Be Changed".
b.
Do these, handwritten notes, refer to the incorrect firing curves? If so,
confirm which units had the incorrect "curves". If not, describe the "curves" referenced
by the notes on the drawings and affected units.
Confirm when the change was made to each unit and describe when and
c.
how the change was tested for each unit.
Confirm the source of the "incorrect curves" and explain why it was not
d.
discovered during previous FAT and SAT efforts.
Confirm and describe any unit impacts or limitations caused by the
e.
"incorrect curves".
5-24 Please refer to the attached pdf file (Attachment 3) containing 2 drawings received from
site visit of February 28, 2013' titled "GOV_SPEED_SETPOINT_RATE" and both dated
December 18, 2010.
Please provide an explanation of the handwritten notes that read ".0062"
a.
and "changed 1-27-2011 SLC".
Do these refer to the modified ramp rates previously referenced in a log
b.
supplied in a previous RFI? If so, confirm the difference between the old ramp rate
(based on .0055) and the new ramp rate of .0062 expressed in MWs per minute.
fi
PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
c.
Confirm when the change was made to each unit and describe when and
how the change was tested for each unit.
d.
Confirm the source of the "incorrect values" and explain why it was not
discovered during previous FAT and SAT efforts.
5-25 Please refer to attached pdf file (Attachment 4) containing 2 drawings received from site
visit of February 28, 2013, titled "PROT_EXHAUST_OVERTEMP" and dated December 18,
2010.
a.
Confirm that these drawings and the manual notations are in reference to
the logic that required the units to achieve 150 degree exhaust temperatures within 15
seconds during start-up (or trip the unit if not achieved).
b.
Confirm when the change(s) was/were made to each unit and describe
when and how the change(s) was/were tested for each unit.
c.
Confirm that this logic and these values were documented and present in
all 6 units during the design of the Emerson Controls project and during the FAT and
SAT efforts (well before 2-2-2011).
d.
Confirm that Luminant approved the design of the Emerson Control
System Project that included this "150 degrees in 15 seconds" logic.
e.
Confirm that Luminant approved the FAT that included this "150 degrees
in 15 seconds" logic.
f.
Confirm that Luminant approved the SAT that included this "150 degrees
in 15 seconds" logic.
g.
Confirm that Luminant took commercial acceptance of the six Emerson
Control Systems with this "150 degrees in 15 seconds" logic installed.
5-26 Please refer to attached pdf file (Attachment 5) containing 3 drawings \received from site
visit of February 28, 2013, titled "SYS_CONTROLCONSTANTS" and dated December 18,
2010.
Please provide an explanation of the handwritten notes that read "changed
a.
from 17.0 on all units 1-27-22 SLC" and "Changed from 18 to 19 on Drop 3 Only
2/19/11 SLC as per Chambers".
Confirm when the change(s) was/were made to each unit and describe
b.
when and how the change(s) was/were tested for each unit.
Confirm that this logic and these values were utilized for all 6 Morgan
c.
Creek CTs during the design of the project and during the FAT and SAT efforts - all well
before 2-2-2011.
9
ti
PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
d.
Confirm the source of the "incorrect value" of "17" and how it was not
discovered during previous FAT and SAT efforts. Describe the impact of the "incorrect
value" to the operation of the CTs.
5-27 Please refer to the attached pdf file (Attachment 6) containing 1 drawing received from
site visit of February 28, 2013, titled "GCS AGC - PLANT STATUS TO RTU#3" and dated
December 18, 2010.
a.
Please provide an explanation of the handwritten notes that read "Added
1-25-11".
b.
Describe the functionality added with this change.
c.
Confirm when the change was made to each unit and describe when and
how the change was tested for each unit.
5-28 Please refer to the attached pdf file (Attachment 7), containing 112 documents provided
based on a request to view the voluminous documents maintained at the ENOCH KEVER
offices, and titled "SiteTestDOCSFromENOCHKEVER". Confirm that the documents contained
in this file are records of the site testing performed by Innovative Control Systems, Inc. as part of
the site acceptance testing and commissioning process for the new Emerson Controls Systems
for the six Morgan Creek CTs.
5-29 Please refer to the attached pdf file (Attachment 8) containing 15 pages of Emails,
received as a result of site visit of February 28, 2013, and titled
"LuminantEmails_ControlsChanges_03142013". On the first page of the documents, the text
reads: "Tim has said he is concerned about making changes without them being tested and I am
trying to do this. There are other changes coming down the pipe in the next couple of days and if
I don't coordinate it there is going to be confusion until we get to a baseline." Identify the sender
of the Email, the recipient(s) of the Email and the full name and title of the referenced "Tim".
5-30 Please refer to the attached pdf file (Attachment 8) containing 15 pages of Emails,
received as a result of site visit of February 28, 2013 titled
"LuminantEmails_ControlsChanges_03142013". On the 4th and 5th pages, there are Emails
directing changes to be made to the Morgan Creek CTs and the Permian Basin CTs (affecting
Gas Flow Ranges in the Emerson Ovation System). The changes directed are to the "High
Operating Range - Change from 1582 to 1145" and to the two conversion coefficients.
Given that the dates of these Emails are in early April of 2011, verify that
a.
the "incorrect values" were in the Morgan Creek CT's new Emerson Control Systems
during the design phase and continuing through the FAT, SAT and for the first several
months of commercial operation - including the morning of February 2, 2011.
10
PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
b.
Confirm that, as described on page 6 of the attachment ("If the Morgan
Creek scaling on these devices is not as calibrated above then the current measurements
may be erroneous."), there were questions and concerns expressed about this scaling on
January 27, 2011.
5-31 Please state each and every specific alarm that was received with respect to the initial
start-up attempts of the Morgan Creek CTs 1, 3, 4, 5 and 6 in response to ERCOT's Dispatch
Instruction on February 2, 2011.
ii
PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
Attachment 1
GOV_CORRECTED_SPEED
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PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
Attachment 2
GOV_EXH_TEMP_CONTROL
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PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
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PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
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PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
Attachment 5
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PUC DOCKET NO. 40368
SOAH DOCKET NO. 473-12-6200
COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
Attachment 6
GCS AGC - PLANT STATUS TO RTU#3
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COMMISSION STAFF'S FIFTH SET OF REQUESTS
FOR INFORMATION TO LUMINANT ENERGY LLC
Attachment 7
SiteTestDOCSFromENOCHKEVER
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CONTROL
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Electr0-Hydraulic Actuator Tests
Electro-Hydraulic Actuator Tests
CUSTOMER
0-^
SITE
ICS ]OB NUMBER
ICS UNIT NUMBER
10
-01
CUSTOMER UNIT' 1#0
APPLICATION: This Test Instruction is used for On-Site testing and calibration
ElcttroHydrauifc Actuator with servo valve and IVVT'/RVDT position feedback,
TEST' SOMPMENT!
TEST COMPLETED BY:
DATE COMPLETED:
'
'17S-GE-HD-EH-01
REV:
1
Date
14CKT 19
Page 1 of 22
3I
^^ {{^^{ovar{v`
t
^ - ^ C O N T N O L
8 Y6rEMS,{YC.
ON_S^T^ TEST IN^UCROlV
^
Eiecav-HydrauNc Actuator Tests
REFERENCES:
DOCUMENT NUMBER
TITLE
WIRING SCHEMATIC
P&ID
SYSTEM ASSEMBLY
INSTRUCTION
COMPONENT MANUAL
OTHER
77
TIS.GE-HD-EH-O1
REV:
I
Date:
14-OCf-09
Page 2 of 22
3^-
^ Ip>rovaTive
CONTR OL
EYfTfME,IMC.
O(WSI'fE
Twe
TEST INStRtKTtON
EfeCtno-Hydraulic Actuator Taft
Feedback Calibration
For each device listed on the Elearofiydraulfc Actuator Calibration Table below, perform the
following steps:
Position feedback (tVDT/RVDT) calibration
Ach+ata Stroke Test
Ensure that the fuel supply Is mechanically isolated from the turbine fue! system by
something other than the gas turbine oonbjper.
A Signal conditioner is used to convert the LVDT feedback from the actuator to a 4-20 mA signal for
the turbine controller. The purpose of these checks is to calibrate the s9na' conditioner so that be
LVDT feedback accurately represents actuator position.
This requires driving the actuator against it3
'dosed end' mechanical stop and adjusting the signal condltloner, then driving the actuator
against
its'open end' mechanical stop and adjusting the signal conditioner
and repeating the procedure wt;
MY dosed and fully open consistently yields values as dose to 20 and 4 mA as possible.
This procedure requires an HMI access level of maintenance or higher.
.ti
7^
TIS-GE-HD-EH-Oi
REV
1
Date
140CT-09
Page 3 of 22
39)
^ INNOVATIVE
a a N T a OL
sreTFwrs,i^re
ON-SITL TEST INSTRUCTION
T+^ :
Electro-Hydraulic Actuator Tests
For each actuator perform the following sequence of ctredcs. Record the
relevant data in the corresponding record sheet for the valve or actuator
Actuator Pre-calibration
Chedc
Completed
on aN
actuators
Disconnect the servovatve wires for the actuator and measure
the cog resistance
q
Adjust the LVDT signal conditioner osdNator amplitude to
7.OV ac rms. Record the o6dUator frequency also.
q
NOTE :- Oscillator frequency Is NOT adjustable
TtS-GE-HD-EH-01
REV;
Completed t^v ,
date
I
Date:
240C'T 09
Page 4 of 22
^^
Promdm
INNOVATIVE
ON TROL
nl^ Gas Turbine Generator Commissioning Procedure
rsrEMS,llrc.
toad Control and Base Load Checks
Check
Com I ed
At the Turbine Control Panel display of the HMI, enable Speed/Load
Control and the Normal load rate. At the Turbine Control Panel
display of the HMI, enter a speed setpoint target of 101.0%. Verify
that the load increases at the set ramp rate value.
Completed
date
^
Verify that all systems (lube oil, cooling water, etc.) pressure and
temperatures are as expected. Record Operating Data in the
appropriate Unit Data Sheet.
At the Turbine Control Panel display of the HMI, enter a speed
setpoint target of 102.0%. Verify that the load increases at the set
ramp rate value.
Verify that all systems (lube oil, cooling water, etc.) pressure and
temperatures are as expected. Record Operating Data in the
appropriate Unit Data Sheet.
At the Turbine Control Panel display of the HMI, enter a speed
setpoint target of 103.0%. Verify that the bad increases at the set
ramp rate value.
Verify that all systems ( lube oil, cooling water, etc.) pressure and
temperatures are as expected. Record Operating Data in the
appropriate Unit Data Sheet
At the Turbine Control Panel display of the HMI, select BASE load.
Verify the machine goes on temperature control.
Verify that all systems (lube oil, cooling water, etc.) pressure and
temperatures are as expected. Record Operating Data in the
appropriate Unit Data Sheet.
1-ts I^
uAe
SP
j
Doc ID: TIS-CS-GT-C,01
Lo
o\ to
WhO PA PVIL ^ 'I C --44--2-SPIKIK.
S'A
REV:
7
Date
13 APR 09
Page 42 of 55
hacean
INNOVATIVE
avsTEMiiNc.
T'^
Gas Turbine Generator Commissioning Procedure
Automatic Synchrontzing to Base Load
These checks are to verify the automatic synchronizing and loading functions of the controller.
Record and investigate any alarms that occur during testing.
Unit may be running, or shutdown, generator breaker should be open.
Record data
At the Turbine Control Panel display of the HMI,
select Base Load.
Check
Completed
M/
Completed
date
At the Generator Control Panel display of the HMI,
select automatic synchronizing.
to
If the unit is not running, give a START command to
start the unit. If unit is running, give a START
command to initiate the auto synch mode.
C7v^
Verify that the breaker doses, the speed setpoint
target goes to 107.0% and the setpoint ramps to
that value. Record Exhaust Temperature
Setpoint here.
Record Time from breaker dose to base load
Record Megawatts
Verify the unit goes on exhaust temperature control;
reaord Exhaust Temperature here.
In the applicable OPERATING DATA FORM record the
key turbine data.
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I Doc ID: TS-CS-GT-G-01
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REV:
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Dabe
13 APR 09
Page 48 of 55
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IRNOVATIV$
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SY6TlN18,INC.
.
^
Tide Gn Turbine Generator Commissionin g Procedure
2.3. DC Power Circuits
Main DC Power Circuits
Refer to the DC Panel Power Distribution of the Turbine Controller drawing.
Record data
Check
Co eted
Completed
by date
Verify polarity of DC source input power at the main
fuse.
Verify that DC input power is not grounded. If so
determine its source and correct. Record DC
vottage.
Check that there are no grounds on the positive and
negative legs on the panel side of main DC fuse.
Chedc that no short-circuit exists between the positive
and negative legs. Record insulation resislance.
Insert the main DC fuse and apply DC power to the
panel.
^. ^ . Successively power-up each control rack, verifying
rack initialization.
Successively poww-up any Remote I/O (RIO)
modules, verifying initialization.
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Doc ID: nS-CS-GT-G-Ol
REV:
^
Dabe
- ^^+s-
13 APR 09
Page 6 of SS
- -
-
-
^^
IMR OVA TIV III
COYTp0 L
srsTEMa, IN C.
ON-SITE TEST INSYRUCTION
E^."^utic Actuator TaSts
zi^
STANDARD ACTUATOR CONFICsURATIONS.
As Shipped from ICS factory, the stamdard efectro-hydraulic actuators are configured per the table
below. Any deviation from this configuration may have serious control system impHaatials. If
actuators cannot be set up per table below then consult ICS Engineering Dept.
ACiUATOR/
MINIMUM POSITION
MAXIMUM POSITION
VALVE
POSITION
INLET GUIDE
ItV's
VANES
CLOSED
mA
FULL 4.00
Pi'!S
POSICION
1 3070
IGVs
40
I MA
FULL 20.00
OPEN
P05
80 TO 90
Degrees
Degrees
LIQUID FUEL
VALVE
BYPASS
OPEN
FULL 4.00
100 %
VALVE
FULL 20.00
1 0%
CLOSED
(CONTROL) VALVE
LIQUID FUEL
PUMP AT MIN
VARIABLE
SMOKE
4.00
0%
PUMP AT MAX 20.00
100 %
SMOKE
DISPLACEMENT
PUMP
SPEED RATIO
VALVE
VALVE
CLOSED
GAS CONTROL
VALVE
VAt.VE
d-OSED
STEAM INjECTION
VALVE
CONTROL VALVE
CLOSED
WATER IN7ECt'ION
VALVE
CONTROL VALVE
CLOSED
TIS-GE-HD-EH-01
FULL 4.00
1 0%
VALVE
FULL 20.00
100 %
FULL 20.00
100 q,
FULL 2000
100 °4
FULL 20.00
100 %
OPEN
FULL 4.00
1 0%
VALVE
OPEN
FUL.. 4.00
0%
FULL 4.00
0%
VALVE
OPEN
VALVE
OPEN
ftEV:
1
Date: i 14-OCT 09
Page 5 of 22
3`t
INNOVATIVE
CONTR OL
ON-SITE TEST INSTRUCTION
QYBTEM9.tNC.
Electro-Hydraulic Actuator Tests
J
LVDT/ RVDT CALIBRATION
Completed
for at
Reference the relevant sheet of the controller drawing. Use a
mutimeter to measure the LVbT secondary voltage and the
DC Input voltage to analog input cards.
pcC
Completed by
date
r.3 q40;
Install a mechanical indication device (dlal indicator,
protractor, etc) to show the actual mechanical travel of the
actuator.
Ensure that hydraulic oil pressure is available. if required,
the hydraulic trip circuit will be enabled when the test is
enabled.
From the Maintenance Menu of the HMI, acess the relevant
Test display for the valve / actuator; this requires at least a
maintenance level password.
Enable the actuator Servo Test.
\o
Select 'Enter Output To actuator Servo Cok' and enter a
value (- Vdc) that will move the actuator to the maximum
end stop position.
NOTE: Positive ( +) voltage on servo coils moves the actuator
to the minimum position. Negative (-) voltage moves the
actuator towards the maximum position. The Iaroger the
voltage then the faster the actuator moves in the Intended
direction.
With the actuator at minimum end stop, adjust the'zero'on
t
' naI conditioner to yield
mA feedback output
slgna
the turbine controller.
Is a 1.00 Vdc input to
the ana
k^put module.
Select ToggVe'^ge Sign'. This shoukinge the output
to the servo vaf tdts and move the actu
to the
maximum end sboa
With the ad:ua
airmalknum end stop,
the signal
ner to yl
a 20.00 mA
signal to
turbine controtie .
DKW.
7IS-GE-HD-EH-01
' on
ck output
REV.
I
Date;
1732r-09
Page 6 of 22
L^ "
IQNOVATiVE
CONTROL
srsrsMS.INC.
^''`M ^IMM"^
Electro-Hydraulic Ackuatof Tests
j
Check
CDM*W
Completed by
for all
actuators
Continue back and forth from minimum end stop to maximum
end stop, adjusting the span and zero to get as close to
20.00 mA and 4.00 mA as possible.
q
Record the data In the LVDT calibration section of the table
below.
q
Leave the mechanical feedback measurement in place and
disable the Servo Test.
q
date
Actuator Stroke Test
This test will verity that the actuator follows the position reference.
Check
Completed
for all
actuators
Enable the actuator Position TesL
q
Select 'Enter actuator Position Reference' and enter values
from 0% to 100-00% per the table below.
q
Record the data in the table below.
q
q
Disable the actuator Test
Review the Position data for linearity. Position errors of
greater than +- 296 are to be resohved. Contact ICS
En9wmenng Dept. If this accuracy cannot be obtained over the
full actuator range.
q
Remove mechanical position sensor
q
^^.
77S-GE-HD-EH-01
REV: (
1
Date:
14-0Ci'-09
Completed
by / date
Page 7 of 22
L^\
INNOVATIVE
CONT ROL
81fRTEMS.INC.
aN-SM TEST t111srTRUmON
TM+^
Electro-Hydraulic Aduabar Teas
jACTUATOR NAME: INLET GUIDE VANES
L^__ _
DEVICE
TAG
SERVO VALVE
9aTV-^
COIL No.i
Ohms
90TV-2
COIL No.2
Ohms
90TV-3
COIL No.3
Ohms
O7C)
LVDT Oscillator
DEVICE
TAG
Position
Reference
a.osED
OPEN
Position
Feedback
on HMI
Vac
Mechanical
Position
HSA
Input
(Vdc)
Servo
Volts
Vdc
LVDT
Primary
Volts
LVDT
Sac
Volts
Vrnns
Vrms
Position f®®dlsadt (LVDT/RVDT) calibration
^
Sa
57
ACTUATOR STROKE TEST
967V•1
100%
75%
57
73,9
^ 't0 'obI L,
$
I-.-
73
50%
1=b
25%
0%
•(02 r'a^%
1 Gjp
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lYS-GE•HD-EHr01
M.
Date:
14-dCT 09
yrr f
rVV {
Page 8 of 22
^ ^.
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I
L7 -
yr,cvu LULL No.z DISCONNECTID- HMI voNage
ifld'ICaI7m
► ^r
Vdc
SERVO COIL No.3 DISCONNECTED- HMI wltage
indication
Vdc
TLS-GE-HD-EH-03
REV'
I
Datr
140CT-09
I
Page 9 of 22
43
^ 1MNOVATIVE
NTROL
l^J C O
S YETEMB .iNa.
1 Iwo
Op_SM TM I^^^nQN
EfeCtro-H"PBNiiGAGtt(aboPTests
ACTUATOR NAME: LIQUID FUEL BYPASS (CONTROL) VALVE
DEVICE
TAG
SERVO VALVE
65FP-1
COIL No.i
Ohms
65FP-2
COIL No.2
ohms
65FP-3
COIL No.3
Ohms
LVDT Osdllabr
DEVICE
TAG
Position
Reference
Position
Feedback
on HMI
Hz
Mechanical
Position
HSA
Input
(Vdc)
^9^ 7
^ps-7
/03
6
,
Vac
Servo
Volts
Vdc
LVDT
Primary
Volts
Vrms
LVDT
Sec
Volts
Vnus
Position feedback (LVDT/RVDT) calibration
CLOSED
OPEN
Oo
ro
3^N
A1W
--143
g.
^S
4
Y iy
L• a
s`
ACTUATOR STROKE TEST
96FP-1
100°.o
pL
3'
^
^. 3
ir •^"
3.
75%
50%
5'0.Al
25%
as ,
00/0
'fTS-GE-HD-EH-81
3ur
333
. 7-
q-14
hI
REV
1
Date:
14-OCT o9
I-
•
^ a.oYr
,
. 2 -F4
L
Page lo of 22
`^^
^ t111NDVAtIVE
s`,r° STEM i iNe.
Prooldue
'^^ Gas Turbine Generator Commissioning Pr+ocBdure
GAS FUEL CHECKS
Fuel Systern - No Ignition Cho*
The purpose of these checks is to verify that the gas fuel flow during the ignition phase of startup is at the right level. Gas manifold pressure must be Independently checked with a pressure
gage; the measured pressure may be compared to the pressure recorded on the HMI.
Check
Completed
eted
date
Record data
Verify that the unit is Ready To Start.
Disable the ignition system by removing the ignition
relay(s).
At the Turbine Control Panel display of the HMI,
select FIRE (IDLE, or other mode indicating OK to
start fuel), and then START.
6'1K
Verify that all gas valve positions match the
command setpoint from control system.
Monitor gas pressures at the unit gauge panel during
the start attempt.
Check fuel flow stability (no oscillation in fuel flow).
When the ignition timer has timed out - verify the
"Failure to Fire" /"No Flame After Ignition" alarm.
Using the Historical Trend, verify correct system
operation. Record applicable data in the table
below. PrintDut the HMI trend.
^ ^^ ^'^JV
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itlo
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el-
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=:>-IWNOYATtYE
OUTROL
RMM SYS TEMS .Inc .
Maceckim
117d
Gds Turbine Generator Commissioning Pro Oedure
M" Watt Control Checks
V (Check box if this section is not applicable for this commissioning)
These checks are to verify the megawatt control function of the controller.
investigate any alarms that occur during testing.
Record and
Unit should be running with the generator breaker closed.
Record data
At the Turbine Control Panel display of the HMI,
MEGAWATT CONTROL ENASLE. The megawatt
etpoint target and setpoint should be equal to the
,resent megawatt value.
Enter a megawatt setpoint target equal to 25% of
Fated load. Verify the megawatt setpoint tracks to
he setpoint target at the normal rate and that the
Z
nit output follows the setpoint Record Megawatt
tpoint here.
(K
W
11tecord MW output here.
^nber a megawatt setpoint target equal to 75% of
ted load. Verify the megawatt setpoint tracks to
he setpoint target at the normal rate and that the
nit output follows the setpoint. Record Megawatt
Wpoint her+e.
i
MW output here.
RW
e 1 ntzpJ
7 ^.^ P(a)
Doc M: TIS'Cs'GT'G'Ot
REV:
7
Date
13 APR 09
°W^
Page 45 of55
4^
^,^^ INNOVATIVE
lf^ CONTROL
Rooahire
srsreMs.11110.
Kft
'we
sTurbine Generafior Commissioning prooedure
Fast Load Control checks
These checks are to verify the fast
loading functions of the controller. Record and investigate any
alarms that occur during testing.
Unit may be running or shutdown, generator
breaker should be open.
Record data
At the Turbine Control Panel display of the HMI,
select Base Load and Fast Load.
Check
Completed
q
At the Generator Control Panel display of the HMI,
select automatic synchronizing.
q
If the unit is not running, give a START command to
start the unit. If unit is running, give a START
command to Initiate the auto synch mode.
q
Verify that the breaker doses, the speed setpoint
target goes to 107.0% and the setpoint ramps to that
value.
q
Verify the unit loads at the fast rate and goes on
exhaust temperature control; record Time from
breaker dose to base load here.
q
12.3
Doc ID: TIS-CS-GT-G-01
I
REV:.
7
Completed
b^ ate
Date
02 y
13 APR 09
Page 49 of 55
,^, ^ I NNOVATIVE
^J CONTRO L
srsreMS,,NC.
F
Qs Turbine Generator Commissioning Procedure
Automatic Synchronizing to Bass Load
These checks are to verify the automatic synchronizing and loading functions of the controller.
Record and investigate any alarms that occur during testing.
Unit may be running, or shutdown, generator breaker should be open.
Check
Com ieted
Record data
At the Turbine Control Panel display of the HMI,
select Base Load.
q
At the Generator Control Panel display of the HMI,
select automatic synchronizing.
q
If the unit is not running, give a START command to
start the unit If unit is running, give a START
command to initiate the auto synch mode.
q
Verify that the breaker closes, the speed setpoint
target goes to 107.0% and the setpoint ramps to
that value. Record Exhaust Temperature
Setpoint here.
q
Record rime from breaker dose to base load
q
Record Megawatts
q
Verify the unit goes on exhaust temperature control;
record Exhaust Temperature here.
q
Completed
by date
In the applicable OPERATING DATA FORM record the
key turbine data.
o
N
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i;;
^b
I Doc M. T3-CS-GT-G-01
REV:
7
Date
jo pt
)^^
13 APR 09
Page 48 of 55
14s
iNNavATivE
^ 1 1^
C O N T R O L
t^^
SYSTlMS.iNC.
ON-$M TEST rHSTRiG4
I Me
Eiectra-Hydraulic Actuator Tests
ACTUATOR NAME: GAS CONTROL VALVE
DEVICE
TAG
SERVO VALVE
65GC-1
COIL No.1
Ohms
65GC-2
COIL No.2
Ohms
65GC-3
COIL N0.3
Ohms
LVDT Oscillator
6
Hz
bto
DEVICE
TAG
Position
RMUM
Position
FNWbaft
on HMI
Vac
6,$
Mechanical
Position
HSA
Input
(Vdc)
Servo
Volts
Vdc
LVDT
Primary
Volts
Vrms
LVDT
Sec
Volts
Vnns
Position feedback (LVDT/RVDT) calibration
CLOSED
OPEN
ACTUATOR STROKE TEST
96GC-1
100%
7s96
®
50%
D o
}
's'! '
25%
0%
Ift-e
®
yp
:745
,71
f^,78
a
1.'
.3`'f
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0
W7
^;^e
SD
100 o
' 07
bV
L(,1L
..l 5-GE-HD-EH- 01
REV;
1
Dete: . 14-OCf-09
Page 14 of 22
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