Table of Contents

Section Page
I. Introduction........................................... 2
II. Safety.................................................... 3
III. Instrument Maintenance Phases........... 5
IV. Checks and Calibrations........................ 8
Setup Procedure................................... 9
Engine Temp Meter Calibration......... 9
Engine Speed Calibration..................... 11
110% Backup Overspeed Check........... 11
Fire Control Circuit Verification........... 12
Combustible Gas Monitor Check........... 13
Electrostatic Oil Mist Precipitator.......... 13
Boiler Tube Water Pressure Probes. 15
V. List of Illustrations.................................. 17
Instrument Location Illustrations........ 18
Alarm and switch set points table... 20
Pressure switch table 23
VI. Index...................................................... i-iv
COGEN\MAN.DOC Revised: 2/07/94
2

INTRODUCTION
The Betacomm Cogen facility plays an important part in the
overall mission of cost-effective operation of the refinery. The
three Cogen turbine packages, operating in parallel with each
other (and with the YadaYada Electric Company facilities), are
capable of generating a major portion of the refinery electrical
demand.
Cogen downtime, during which more power must be purchased
from YadaYada, seriously impacts this mission. Additionally, on
the occasions when YadaYada facilities are down, the refinery
must shed load based directly upon how much Cogen power is
available. It is obvious that the Cogen facility output must be
dependable and consistent.
Personnel familiar with the maintenance, calibration, and opera-
tion of the Cogen facility play a major role in keeping the refin-
ery operating efficiently. Since payroll costs dictate that the
number of persons working on and with the Cogen will always
be limited, cross-training is important.
A second factor of having only a few fully-trained Cogen techni-
cians is that the loss of just one or two key people can seriously
affect the maintenance (and refinery) mission. Maintenance
aids and instruction manuals must be not only available, but
should be of such a nature that personnel with less-than-normal
time working with the Cogen can adequately and efficiently per-
form the maintenance, checks, and calibrations when neces-
sary.
To that end, this manual is formatted to be of the highest assis-
tance possible to maintenance personnel still in the process of
familiarizing themselves with the Cogen maintenance mission.
3
NOTE: All information, suggestions, notes and statements in this section and in this
manual concerning safety or safety-related subjects are subordinate to BETACOMM
OPERATING STANDARD H-9900 and other Betacomm operation- and safety-
related documents, memos, rules, standards, and regulations in effect at the time of
a Cogen Shutdown for Maintenance. Betacomm employees and Contractor employ-
ees MUST be familiar with and COMPLY WITH current Betacomm working stan-
dards and rules.
FOR DETAILED OR SPECIFIC SAFETY INFORMATION, SEE OPERATING
STANDARD H-9900, REFINERY INSTRUCTION RI-71, THE GERMANE
MAINTENANCE SECTIONS OF THIS MANUAL, AND THE RFC MATERIAL
SAFETY DATA SHEET SECTION IN THE INDEX OF THIS MANUAL.
SAFETY
The Betacomm Cogen area has a full complement of hazards to be
aware of at all times. There are steam lines with both high pressures and
high temperatures. There are AC voltages over three hundred volts, and
DC voltages to fourteen thousand volts. The possibility of a hazardous
material leak is always present. During some instrument repairs or
checks workmen may be required to work in a confined space. Hazard-
ous materials exist on-site and others are brought into the area during
the maintenance cycle.
KNOW THE DANGER SIGNALS! The following signals are currently
used when a danger has been detected:
FIRE = Pulsed warble (10 sec. on, 5 sec. off, for two minutes)
CHEMICAL LEAK = Two tone / High low (10 on, 5 off, for two)
MEDIC NEEDED = Spaced beep (One minute)
ALL CLEAR = Siren for 20 seconds, accompanied by two beeps
WHEN A DANGER SIGNAL SOUNDS, LEAVE THE AREA AND GO TO THE
LOCKER ROOM OR OTHER SUPERVISOR-DESIGNATED ASSEMBLY AREA!
4
CHECK IT OUT! If there is any question of the hazards or effects of
working on a particular piece of equipment, or if the possibility exists that
the work can't be completed safely for any reason, ask a supervisor to
explain and okay the work.
GET THE BIG PICTURE! Others will be working in the area; work in
progress by one worker will often affect many others. The removal of /
maintenance on instruments, for example, will generally coincide with
work being done by mechanics and others on the same lines or in the
same areas. All workers must remain aware of the overall effects before
beginning work on a portion of the package, and take steps to ensure
the safety of themselves and others.
TAG IT OUT! Lockouts are used to ensure that no switch or valve can
be activated before work personnel are ready and clear of danger. The
use of approved lockout tags and locks is mandatory. These tags and
their proper use are described in full-color detail in BETACOMM
OPERATING STANDARD H-9900; all workers are responsible for famil-
iarizing themselves with proper lockout-and-tag procedure before begin-
ning work.
Generally, major valves will be chained in a safe position during main-
tenance; electricians, mechanics, and others will individually add their
own locks and tags to the chain, ensuring that no one can remove the
chain and operate the valve until cleared by every worker.
NOTE: Individuals with locks and tags on a multi-lockout valve or switch
must be available in case the locks must be removed for some reason.
If a worker must leave the area while his or her lock is in place, the key
should be left with someone remaining on-site who is familiar with the
work being performed.
DRESS FOR IT! NOMEX (fire retardant) clothing, long sleeves, hard
hat, safety glasses, and sturdy shoes that enclose the foot are manda-
tory while in the refinery. (Only Central Control Building, Admin Building,
Shop, and Storehouse areas are exempt from the dress regulations).
FOR DETAILED OR SPECIFIC SAFETY INFORMATION SEE OPERATING
STANDARD H-9900, REFINERY INSTRUCTION RI-71, THE GERMANE
MAINTENANCE SECTIONS OF THIS MANUAL, AND THE RFC MATERIAL
SAFETY DATA SHEET SECTION IN THE INDEX OF THIS MANUAL.
5
INSTRUMENT MAINTENANCE PHASES
Cogen maintenance is based on a 10-week cycle; approximately every 10 weeks
each package is shut down, maintained and started back up, with two packages op-
erating on-line while the third is being worked on.
The following is offered only as a general overview, adapted from Betacomm Cogen
"Maintenance Clarification" data; DETAILED INFORMATION AND STEP-BY-STEP
INSTRUCTIONS FOLLOW THIS SECTION.
A. STANDARD MAINTENANCE
1. Use stopwatch to time from Stop initiation to final rotation of generator
coupling.
2. Verify physical condition and P increase.
3. Use approved solvents to clean inside and outside of package (avoid
spraying solvent / water inside generator).
4. Verify Reservoir Tank level and refer to daily Run Logs for consumption.
5. Clean and service batteries, using proper safety procedures. Note voltage
and amperage output of charger.
6. Verify temperature switch settings and meter calibrations using Fluke
tester FT 50010
.
7. Verify that all meters and gauges are functional.
8. Verify the security of terminal board screws.
9. Visually check the package for leaks, loose items, and lines rubbing.
10. Verify the operation of fire and gas detection equipment, using proper test
equipment.
11. Verify normal operation of fire and gas detection equipment, using proper
test equipment.
12. Send lube oil sample to test lab for evaluation.
6
B. INTERMEDIATE MAINTENANCE
1. Perform all elements of standard maintenance outlined
above.
2. Verify operation and accuracy of temperature and pressure
gauges, using proper test equipment.
3. Verify Speed Switch and Meter calibration using Fluke FT 50010.
Magnetic pickup loop resistance should be around 100 .
Servo actuator loop resistance should be around 200 .
Output voltage depends on voltage.
4. Verify calibration of overspeed protection.
5. Calibrate M.F.A.C. to specifications.
6. Replace during intermediate maintenance and major maintenance unless
P indicates sooner.
7. Rebuild Versa valve (primary fuel valve).
8. Check for contamination and damage.
9. Verify fuel valves operate properly.
10. Remove poppet valve and check for bellows damage and contamination.
11. Verify smooth operation of bleed valve.
12. Observe operation of variable vane system.
13. Vibration readings taken and analyzed by Solar.
7
C. MAJOR MAINTENANCE
1. Perform all items on Standard and Intermediate maintenance as stated.
2. Verify operation; cleanliness; leaks.
3. Remove and check for damage.
4. Verify condition with ohmmeter. Individual harness should read 3.35 to 3.75
.
5. Remove and clean coupling, verify alignment, lubricate and install coupling.
6. Verify that all alarm and shutdown systems operate properly.
7. Clean orifice for fan purge system.
8. Clean high voltage insulators on generator end.
HRSG MAJOR MAINTENANCE
1. Check all shutdowns and alarms.
2. Check flow meters and controllers.
3. Check all TI's and controllers.
4. Replace springs in gas regulation valves.
5. Check conductivity analyzers.
6. Replace bad skin temperature points.
8
CO-GEN MAINTENANCE
CHECKS and CALIBRATIONS
PREPARATION
EQUIPMENT NEEDED:
Large standard screwdriver (for Kidde Electric Control head)
12" Crescent wrench (to remove Kidde Electric Control head)
Obtain Work Order requesting Turbine and Heat Recovery Steam Generator
package shutdown
Clear work with Head Operator, and obtain signature on Work Order
Get and save signed second page of Work Order from Operators
Operator will...
1. Display the completed Work Order
2. Decrease output of the unit to be shut down, then press the Stop button on
the Control Console;
3. Make a note of the Coastdown Time (in minutes and seconds);
4. Determine the two breakers associated with the unit just shut down;
5. Select Remote on each breaker's Local / Remote switch;
6. Move the Breaker switch on the Control Console door to the Trip position;
7. Rack out, lock out, and tag both associated breakers;
8. Give E & I / DES clearance to begin Cogen maintenance.
Using 12" Crescent wrench, remove Kidde Electric Control head from Halon tank
(left-hand side of turbine package)
Begin setup procedure in CIB Building
9
SETUP PROCEDURE:
EQUIPMENT NEEDED
FT 50010-1 Tester (alternately, a multimeter, audio frequency generator, and
thermocouple tester may be used)
Small table or support for FT 50010-1 Tester
Betacomm Co-Generation Maintenance Data Form
List of recommended/desired settings (from Page 2 of Drawing 01141-K149060,
or from Co-Gen E & I supervisor)
Small standard screwdriver (for terminal strip screws)
Two-foot jumper with alligator clips on each end
1. Reset all alarms by pressing Malfunction Reset button on front of Control
Console door;
2. Open Control Console door and log engine hours (and package hours if dif-
ferent from engine hours), and number of starts;
3. Connect FT 50010-1 Tester power leads to any Control Console points fur-
nishing 24-VDC (any points with wires labeled #13 [hot] and #2 [common]);
turn Tester POWER switch to ON;
ENGINE TEMP meter calibration
4. Disconnect (red and yellow) thermocouple input leads from right-hand side of
TB 213, points # 9 and # 10;
5. Using FT 50010-1 or multimeter, measure resistance of thermocouples across
the leads just disconnected, and log under Comments: ;
6. Plug the yellow FT 50010-1 Tester temperature output leads into either of the
two-prong female connectors on the FT 50010-1; select F setting (for Type-
K thermocouples);
7. Attach other ends of the temperature output leads to the left-hand side of TB
213, points # 9 and # 10; ensure that output is reading 000.0 on the FT
50010-1 display;
8. Locate ENGINE TEMP meter on Control Console door and short across the
output terminals for several seconds;
9. Zero ENGINE TEMP meter;
10. Adjust temperature output from FT 50010-1 to read 300 F and compare with
ENGINE TEMP meter reading;
11. Repeat the comparison with outputs for 600 F., 900 F., and 1200 F.;
10
NOTE: The ENGINE TEMP meter accuracy is the most vital around 1200 F.
(our operating temperature), so adjust the meter set screw to correspond with
the FT 50010-1 Tester at 1200 F.
1. Adjust temperature output from FT 50010-1 toward 1500 F. and watch for
DS-4 (High Engine Temp) indicator to illuminate; reset the DS-4 indicator by
pressing the Malfunction Reset button;
2. Set FT 50010-1 temperature output below 300 F., then adjust upward and lis-
ten for Ignition Relay Z-282 (on top row, inside of Control Console) to transfer
at around 350 F.; log setting on Data form under Ignition @:;
3. Locate purple jumper on Motherboard, TB-4, bottom-right edge, point # 33,
and disconnect from point # 33;
4. Adjust FT 50010-1 temperature output toward 1185 F. and listen for the T-5
relay to transfer contacts; DS-31 indicator should illuminate; log on Data form
under Impending High Warning;
5. Replace jumper onto point # 33; (DS-31 will go out);
6. Adjust FT 50010-1 temperature output toward 1200 F. and look for DS-31 to
illuminate; log setting on Data form under Impending High Warning Offset;
7. Remove jumper from point # 33; (DS-31 will stay lit);
8. Adjust FT 50010-1 temperature output toward 1235 F. and look for DS-4 to il-
luminate; log setting on Data form under High T-5 Shutdown;
9. Replace jumper onto point # 33; press Malfunction Reset button to clear DS-4;
10. Adjust FT 50010-1 temperature output toward 1265 F. and look for DS-4 to
illuminate; log setting on Data form under High T-5 Shutdown Offset; reset
DS-4 by pressing Malfunction Reset button;
11. Disconnect FT 50010-1 temperature output leads from TB 213;
12. Dress thermocouple input wire leads and reconnect to right-hand side of TB
213, points # 9 and # 10, ensuring a good electrical connection;
13. Double-check that the purple jumper is in place on the Motherboard,TB-4,
bottom-right edge, point # 33.
11
ENGINE SPEED calibration
1. Disconnect Mag Pickup input wires from the right-hand side of TB-214, points
# 8 and # 9 (wires # 22 and # 23);
2. Connect compatible cable to FT 50010-1 Tester AUDIO FREQ output connec-
tor, select steady (not square wave) audio frequency, and attach free ends to
left-hand side of TB-214, points # 8 and # 9;
3. Attach one end of a jumper wire from any Control Console 24-VDC point (wire
# 13) and the other end to the Motherboard, TB-1, top left, point # 24, wire #
60 (to bypass Low Lube Oil Pressure shutdown);
4. Adjust audio frequency output from the FT 50010-1 up to 9967 Hz and look
for 100% speed on Control Console ENGINE SPEED meter;
5. Adjust audio frequency output upward toward 10565 Hz and look for DS-3 in-
dicator to illuminate after 8 seconds; log setting on Data form under 106%
Overspeed + 8 seconds; reset DS-3 by pressing Malfunction Reset button;
6. Locate Z-183-1 on Control Console door (bottom right) and disconnect the
common wire (wire # 572);
7. Adjust audio frequency output of FT 50010-1 upward toward 10764 Hz and
look for DS-3 to illuminate; log setting on Data form under 108% Overspeed;
reset DS-3 by pressing Malfunction Reset button;
8. Reconnect common wire # 572 on Z-183-1;
9. Remove jumper and replace wires # 22 and # 23 to TB-214, points # 8 and #
9.
110% BACKUP OVERSPEED CHECK
1. Open Electrical Junction Box on left-hand side of Turbine enclosure;
2. Attach FT 50010-1 power leads to TB-301, positions # 1 and # 7 (or any other
available source of 24 VDC);
3. Disconnect the wires from the right-hand side of TB-302, points # 18 and # 19
(wire # 602 [- / black] and wire # 603 [+ / clear]);
4. Connect compatible cable to TB 50010-1 AUDIO FREQ connector (steady
audio frequency, not square wave), and attach negative to wire # 602 (TB-
302, left-hand side, point # 18) and positive to wire # 603 (point # 19);
12
5. Attach leads of a VOM across the coil of K-353 (SEE
PICTURE AT RIGHT) on relay block above Z-353);
VOM should read 24 VDC;
6. Adjust audio frequency output of FT 50010-1 upward
toward 9043 Hz and watch for VOM reading to drop to 0; log FT 50010-1
AUDIO FREQ setting on Data form under 110% Backup Overspeed;
7. DS-11 indicator light on Control Console should have illuminated when relay
contacts transferred; reset DS-11 at the Control Console by pressing Mal-
function Relay button , or at the Turbine package by touching a jumper wire
between TB-301, point # 7 and TB-306, point # 5, wire # 82);
8. The Backup Overspeed Switch transfer point can be adjusted by removing the
cover plate (four small Phillips screws) of the Z-353 Backup Overspeed unit
and adjusting with a small screwdriver through the bottom-most of the two ac-
cess holes;
NOTE: as necessary while adjusting, reset the DS-11 alarm with a jumper wire
from TB-301, point # 7, and TB-306, point # 5 (wire # 82) after each adjustment
that triggers the alarm;
9. When Z-353 setting is acceptable, replace cover plate and reconnect wires to
right-hand side of TB-302, points # 18 and # 19.
FIRE CONTROL CIRCUIT VERIFICATION
EQUIPMENT NEEDED:
UV-source flashlight
Large standard-blade screwdriver
1. With Kidde Electric Control head trigger mechanism from Halon tank (outside
Turbine, on left-hand side of package) disconnected;
2. Turn keyswitch on Detronics panel to Normal and FIRE SYSTEM switch on
Control Console to On;
3. Point UV-source test lamp at one of the three UV "fire-eyes" in the package,
and watch for the triggering pin in the Kidde head to extend;
4. Ensure that DS-22 on the Control Console has illuminated;
5. Turn keyswitch on Detronics panel to Reset, then back to Normal and press
the Malfunction Reset button;
13
6. You will now be able to reset the trigger pin in the Kidde head (with the large
screw-driver) to the Retracted position;
7. Repeat entire procedure for the other two "fire-eyes".
COMBUSTIBLE GAS MONITOR CHECK
EQUIPMENT NEEDED:
Bottle of methane test-gas mixture (2.5% methane / balance air)
% LFL transmitter calibrator test meter
Note: The gas sensors (identifiable by the clear plastic test hoses suspended
from them) are located inside the turbine package, overhead above the turbine
exhaust and above the transmission coupling. The transmitter test points are lo-
cated just inboard of the light switch. The transmitter closest to the light switch
corresponds to the sensor above the transmission coupling.
1. Remove covers to the two transmitter points and plug the % LFL
transmitter calibrator meter (right side up) into one of the points.
2. Inject methane test gas into test hose of one of the two gas sensors,
allowing sufficient time for the % LFL to be measured by Gas Monitor Z-199-1;
alarm (in the CIB) should occur at 30%, and shutdown should occur at 50%, il-
luminating DS-26; reset DS-26 by pressing Malfunction Reset;
3. The two transmitters in the turbine package should each read 50% with ample
gas input; adjust Zero and Span as necessary for calibration;
4. Repeat procedure for the other gas sensor, remove test meter, and replace
covers.
ELECTROSTATIC OIL MIST PRECIPITATOR
EQUIPMENT NEEDED:
10" Channel-locks
7/16" socket and ratchet, with 6" extension
7/16" box-end wrench
Rope to lower collector and ionizer from platform to ground.
1. Remove 120 Volt AC power by locking out the corresponding
breaker in Panel "C" in the CIB building;
2. Unscrew the power cord connector leading to the cover and power supply;
14
CAUTION: High voltage @ 14 kVDC is present at power supply,
so make sure that power is off and the connector removed !!!
3. Remove the collector and ionizer trays from the stack unit, lower to ground
and clean well with solvent, then water hose, ensuring that all ionizer wires are
in place and not broken (Note: updated units may have scalloped plates,
rather than wires);
NOTE: the ionizer wires are delicate; treat with extreme care!
4. Clean interior stack surfaces and replace collector and ionizer;
5. Replace power supply / cover, bolts, and reconnect cable;
6. If oil mist is still excessive after startup, OPEN CIRCUIT BREAKER in Panel
"C", CIB to remove 120 VAC power to unit;
7. Remove bolts and set the cover / power supply on a sturdy cardboard box or
other non-conducting support;
8. Remove cover to ES-527 supply / cover unit and then restore power;
CAUTION: High voltage @ 14 kVDC will be present; use protective rubber
gloves and maintain a safe arc distance at all times !!!
9. Using a high-voltage probe with a DC voltmeter, check for approximately 14.5
kVDC on the ionizer and approximately one-half the ionizer's voltage on the
collector;
10. Replace power supply if voltages are too low.
15
BOILER TUBE WATER-LEVEL PROBES
EQUIPMENT NEEDED:
7/8" deep socket and ratchet
5/16" nut driver
Large standard-tip screwdriver
Small standard-tip screwdriver
Jeweler's rouge, 600-grit sandpaper, or extra-fine steel wool
Wire labels
Electrician's tape
DDVM or Mini-Tick Tracer
Gloves (probe cover may not yet be cool enough to handle)
Replacement 1/2" high-temp aluminum compression washers (Qty. 5)
1. Open power panel on right-hand side of probe area, removing and taping AC hot
lead (connection # 1 on upper-left-hand relay) ;
CAUTION: Power on live probes is at 330 VAC, and high- pressure and high-
temperature steam may be present !
Check with operators to ensure that steam pressure has been removed from
probes, and that power is off !!
2. Remove two long screws holding round metal cover;
3. LABEL HIGH-TEMPERATURE LEADS AND CORRESPONDING PROBES !
4. Remove leads from probes and inspect for heat damage; trim leads and replace
connectors if indicated;
NOTE: Working space among the probes is limited if you are using a wrench
rather than ratchet and socket; assuming the leads to have been labeled on the
"clock method" (i.e., facing the boiler tube, the probes are labeled "1 [o'clock]",
"3", "6", and "9" to correspond to their positions on an imaginary clock face), then
probes are most easily loosened in the order: "9", "6", "3", "Center", and "1"; re-
placement / tightening order is: "1", "Center", "3", "6", and "9" .
5. Loosen all five probe rods, leaving rods in their respec-
tive holes (rods are of various lengths and must be
returned to the correct position);
6. Remove probes one at a time and gently burnish probe
rods, with extra fine steel wool, 600 grit sand paper, or
jeweler's rouge, being careful not to scratch or scour
rod surface;
16
7. Apply a light coat of HighTemperature / no-lead Anti-seize to the threads, replace
the flattened aluminum washers with new ones, and return each probe in turn to
its respective position;
8. Tighten probes in order (per boxed instructions above);
9. Replace high temperature wires and tighten;
10. Replace probe cover, using High Temp Anti-seize on the bolt threads.
11. Replace 330-volt wiring in junction box, lubricate junction box hinge and fasten-
ers, and close box tightly against weather.
17
List of Illustrations
Figure 1. Locations of:
PSH 3010
PSHH 3011
PT 3009
Figure 2. Locations of:
TE 3201 A
TE 3201 B
TIT 3201 A
TIT 3201 B
Figure 3. Locations of:
LAH 1521
PSLL 3116
PT 3116
TE 3212 A
TE 3212 B
TE 3212 C
TIT 3212 A
TIT 3212 B
TIT 3212 C
TIT 3300
Figure 4. Locations of:
FV 3100
PSHH 3110
18
19
20
ALARM TABLE
(Table of alarms, switches, set points, and switch illustration locations)
ALARM DESCRIPTION SWITCH SET POINT PAGE FIG.
BA 1213 SINGLE SCANNER
FAILURE
BS 1205
A, B ,C
N / A
BA 1214 HRSG FLAME FAILURE BS 1205
A, B, C, D
Loss of
Flame
EA 1118 PLC FAILURE N / A N / A
EA 1603 86-2 LOCK OUT
RELAY
EAL 1568 LOW DC VOLTAGE
ALARM
FAL 1550 WATER INJECT. LOW
FLOW
FAL 1606 LOW N2 PURGE
LAH 1015 HIGH STEAM DRUM
LEVEL
LSH 1015 4 In. Above
center
LAH 1521 HIGH LEVEL FUEL GAS
POT
LAH 1555 PURGE TANK HIGH
LEVEL
LAH 1563 HIGH LUBE LEVEL
ALARM
LAHH 1015 HIGH HIGH STEAM
DRUM LEVEL
LSHH
1015
6 In. above
center
LAL 1015 LOW STEAM DRUM
LEVEL
LSL 1015 4 In. below
center
LAL 1559 LOW LUBE LEVEL
ALARM
LALL 1015 LOW LOW STEAM
DRUM LEVEL
LSLL 1015 6 In. below
center
PADH 1558 LUBE FILTER DIFFER.
PRESSURE
PAH 1010 HIGH STEAM DRUM
PRESSURE
PSH 1010 650 Psig 1
PAH 1112 HIGH GAS PRESSURE PI 1112 A 11 Psig
PAH 1302 HIGH STEAM OUTLET
PRESSURE
PI 1302 A 640 Psig
PAH 1593 HIGH LSR FUEL
PRESSURE
PAHH 1011 HIGH HIGH STEAM
DRUM PRESSURE
PSHH
1011
660 Psig 1
21
PAHH 1110 HIGH HIGH GAS
PRESSURE
PSHH
1110
13 Psig
PAL 1002 LOW FEEDWATER
PRESSURE
PI 1002 A 500 Psig
PAL 1302 LOW STEAM OUTLET
PRESSURE
PI 1302 A 500 Psig
PAL 1554 LOW GAS FUEL
PRESSURE
PAL 1556 LOW LUBE PRESSURE
ALARM
PAL 1594 LOW LSR FUEL
PRESSURE
PAL 1595 FUEL LINE PURGE
SHUT DOWN
PALL 1017 LOW LOW
INSTRUMENT AIR
PRESSURE
PSLL 1017 25 Psig
PALL 1101 LOW LOW GAS
PRESSURE
PSLL 1101 15 Psig
PALL 1114 LOW LOW SCANNER
AIR PRESSURE
PSLL 1114 27 In. W.C.
PALL 1210 LOW LOW TURBINE
EXHAUST FLOW
PSLL 1210 2 In. W.C.
PDAH 1564 HIGH AIR FILTER
PRESSURE
DIFFERENT.
TAH 1201 HIGH BOILER TUBE
METAL TEMPERATURE
TSH 1201 600 F.
TAH 1202 HIGH FIRING
TEMPERATURE
TI 1202 A 1650 F.
TAH 1212 HIGH SH TUBE METAL
TEMPERATURE
TSH 1212 840 F.
TAH 1557 HIGH LUBE
TEMPERATURE ALARM
TAH 1567 ENCLOSURE
TEMPERATURE HIGH
TAH 1571 HIGH ENGINE
TEMPERATURE
ALARM
TAHH 1203 HIGH HIGH FIRING
TEMPERATURE
TSHH
1203
1700 F.
TAHH 1306 HIGH HIGH STEAM
TEMPERATURE
TSHH
1306 A , B
765 F.
TAHL 1304 HIGH LOW STEAM
TEMPERATURE
HIC 1304
A
590 -700
F.
UAL 1561 HIGH VIB / TEMP
COMM. ALARM
22
XA 1018 MANUAL EMERGENCY
SHUTDOWN
HS 1018 N / A
XA 1538 FIRE SYSTEM
XA 1553 GAS MONITOR FAULT
XA 1560 BATTERY CHARGE
FAIL (ENCLOSURE)
XA 1562 VIB SYSTEM FAIL
ALARM
XA 1591 AIR PURGE FAN # 1
FAILURE
XA 1592 AIR PURGE FAN # 2
FAILURE
XA 1596 A CGTL not Electrically
Loaded (Cooldown
Mode)
N / A N / A
XAH 1551 ENCLOSURE HIGH GAS
ALARM
XAHH 1552 ENCLOSURE HIGH
GAS SHUTDOWN
XAL 1569 FIRE MONITOR FAIL
23
CO-GEN TURBINE PACKAGE PRESSURE SWITCH TABLE
1
SWITCH NAME INC. XFER DEC. XFER
TYPE
TEST POINT WIRE
S-322
PRE/POST
LUBE
6 # INC. 4 # DEC. NC TB-303, # 7 # 67
S-380
LOW LUBE
SHUTDOWN
35 # INC. 25 # DEC. NC TB-303, # 1 # 28
S-380-2
LOW LUBE
ALARM
45 # INC. 42 # DEC. NC TB-304, # 5 # 431
S-398
GEN. BEARING
LOW
PRESSURE
6 # INC. 4 # DEC. NC TB-307, # 6 # 299
S-342
VALVE SEQ
CHECK
45 # INC. 42 # DEC. NO TB-304, # 14 # 529
S-386-2
HIGH GAS
PRESSURE
204 # INC. 174 # DEC. NO TB-303, # 11 # 103
S-389-1
LOW LSR
PRESSURE
850 # INC. 700 # DEC. NC TB-313, # 43 # 128
Switches should be measured at noted test locations. Record actual values. If not accept-
able, replace switch.
i
INDEX
% LFL, 13
10-week cycle, 5
106% Overspeed, 11
106% Overspeed + 8 seconds, 11
108% Overspeed, 11
110% Backup Overspeed, 11, 12
110% Backup Overspeed Check, 1
14 kVDC, 13
24-VDC, 9
A
AC voltages, 3
alarms, 7
alignment, 7
an purge system, 7
approved solvents, 5
arc distance, 14
audio frequency generator, 9
B
backup overspped, 11
Backup Overspeed Switch, 12
batteries, 5
bellows damage, 6
bleed valve, 6
breakers, 8
C
charger, 5
Checks and Calibrations, 1
Betacomm Co-Generation Maintenance Data Form, 9
BETACOMM OPERATING STANDARD H-9900, 3
CIB Building, 8
Coastdown Time, 8
collector, 14
collector and ionizer trays, 14
ii
collector voltage, 14
Combustible Gas Monitor Check, 1
conductivity analyzers, 7
confined space, 3
consumption, 5
contamination, 6
controllers, 7
coupling, 7
cross-training, 2
D
danger signals, 3
DC voltages, 3
Detronics, 13
downtime, 2
Drawing 01141-K149060, 9
DS-11, 12
DS-22, 12
DS-3, 11
DS-31, 10
DS-4, 10
E
Electrostatic Oil Mist Precipitator, 1
engine hours, 9
engine speed calibration, 1, 8
engine temp meter, 9
engine temp meter calibration, 1
ES-527, 14
F
fire, 3
fire and gas detection equipment, 5
Fire Control Circuit Verification, 1
Fire Control Verification, 8
fire system, 12
fire-eyes, 13
flow meters, 7
FT 50010, 5, 9
fuel valves, 6
G
gas detection equipment, 5
gas leak, 3
iii
gas regulation valves, 7
gas sensors, 13
H
H-9900, 3
Halon tank, 8
Hawaiian Electric, 2
hazardous material leak, 3
hazards, 3
Head Operator, 8
YADAYADA, 2
High Engine Temp, 10
high pressures, 3
High T-5 Shutdown, 10
High T-5 Shutdown Offset, 10
high temperatures, 3
high voltage insulators, 7
high-voltage probe, 14
hours, 9
HRSG Major Maintenance, 7
I
Ignition @, 10
Ignition Relay Z-282, 10
Impending High Warning, 10
Impending High Warning Offset, 10
Individual harness, 7
Instrument Location Illustrations, 1
Instrument Maintenance Phases, 1
Instrument Settings Charts, 1
insulators, 7
Intermediate Maintenance, 6
Introduction, 1
ionizer, 14
ionizer voltage, 14
ionizer wires, 14
J
K
K-353, 12
keys, 4
Kidde Electric Control head, 8
iv
L
leaks, 5
LFL, 13
LFL test gauge, 13
List of Illustrations, 1
load, 2
lock out, 8
lockout tags, 4
lockout-and-tag procedure, 4
Lockouts, 4
locks, 4
loose items, 5
Low Lube Oil Pressure, 11
Low Lube Oil Pressure shutdown, 11
Fluke tester FT 50010, 5
M
M.F.A.C., 6
Mag Pickup input, 11
Magnetic pickup loop resistance, 6
Maintenance Clarification, 5
Major Maintenance, 7
major valves, 4
Malfunction Reset, 9
material leak, 3
Material Safety Data Sheet, 3
methane test-gas, 13
MSDS, 13
multi-lockout valve or switch, 4
N
number of starts, 9
O
orifice, 7
Output voltage, 6
Overspeed, 11
v
P
P, 5
P increase, 5
package hours, 9
package shutdown, 8
percent LFL, 13
poppet valve, 6
potential hazards, 3
power supply, 14
preparation, 8
protective rubber gloves, 14
R
rack out, 8
refinery electrical demand, 2
REFINERY INSTRUCTION RI-71, 3
regulations, 3
Reservoir Tank, 5
RFC Material Safety Data Sheet, 3
RI-71, 3
Rules, 3
Run Log, 5
S
safe arc distance, 14
Safety, 1
safety information, 3
safety standards, 3
Servo actuator loop resistance, 6
Setup Procedure, 1
shutdowns, 7
shutdowns and alarms, 7
skin temperature points, 7
Solar Turbine, 6
solvents, 5
springs, 7
stack unit, 14
standard maintenance, 5
starts, 9
steam, 3
Stop button, 8
vi
T
T-5 relay, 10
T-5 Shutdown, 10
Table of Contents, 1
thermocouple tester, 9
TI's, 7
triggering pin, 12
Type-K thermocouples, 9
U
UV-source, 12
V
variable vane system, 6
Versa valve, 6
vibration readings, 6
W
Work Order, 8
X
Y
Z
Z-183-1, 11
Z-199-1, 13
Z-282, 10
Z-353, 12