1 Commissioning of Combined Cycle Power Plants Part 1

This is the first in a series of four articles on the commissioning of combined cycle plants. This article covers the
preparatory work, normally conducted in the office of the architect/engineering firm, before the startup team goes to
the job site.
1 Introduction
Phases of a New Plant The creation of a new power plant moves through the following phases:

Contract negotiation
Design
Procurement
Construction
Startup/commissioning
Operation
The startup phase is a crucial and final quality check of the previous phases. Any previous mistakes or omissions
which have been overlooked will be uncovered. Problems which are brought to light during commissioning can be
very expensive to correct. The procurement and delivery of new equipment during the startup phase can be costly.
To commission a plant, experienced startup personnel are necessary, since they have acquired the skills to
implement the various programs that are discussed in this article.

Types of Plants to Discuss

A typical combined cycle power plant has two dual-fuel combustion turbine generators, two heat recovery steam
generators (HRSGs), and one steam turbine, with a hydrogen-cooled generator. Duct burners may be specified to
compensate for megawatt production shortfall during non-isometric conditions. The total output of a typical
combined cycle plant is approximately 500 MW.

In this article, the term combustion turbine will be used, rather than gas turbine, because many facilities do not
use fuel gas, but rather a liquid fuel.

Many simple cycle combustion turbine generators are also being commissioned at the present time. In addition,
various chemical plants, refineries, and process plants are adding combined cycle power plant additions to their
facilities.

2 Work in the Office

Assignments
The nucleus of the commissioning crew should be brought onto the project in the early design stage. The startup
manager and the lead discipline engineers should be drafted to work in the office of the architect/engineering firm.
They can assist in design review, and, while in the office, they can prepare the startup deliverables.

Contract Review
The startup manager will review the project contract to identify the project deliverables in his scope of responsibility.
The schedule dates for the milestone activities should be ascertained.

Deliverables
The following are examples of typical contract deliverables that may be included in the commissioning scope:

Commissioning schedule
System turnover packages
Commissioning organization chart
 Manpower schedule
Commissioning procedures
Lockout and tag out program
List of chemicals
List of lubricants
Startup consumables list
Operating procedures
Training program for operators and maintenance personnel
Emission guarantee procedures (air permit)
Heat balance guarantee procedures
Plant acceptance testing procedures
(Note: On some projects, the last three items are prepared by the architect/engineering firm.)
Budget
The startup manager will review the budget for the commissioning effort, and will prepare the estimate that keeps
the commissioning effort within the budget and still meets the contractual obligations. Some of the costs that will be
considered are the manpower, vendor representatives, and equipment. The scope of subcontracts can be adjusted
by self-performing some of the activities, to keep the budget costs lower. The cost structure for field personnel
should be developed, as well as the various expenses (transportation to and from the jobsite, per diem, R&R
breaks, and living accommodations at the field location).

Project Review
While in the office, the commissioning personnel can utilize their unique perspective to review the design of the
project. They can critique the piping and instrumentation diagrams (P&IDs), electrical one-line diagrams, vendor
manuals, and other related documents. They can interact with the design personnel, and develop relationships
which will promote problem solving during the difficult startup phase ahead. They can review project drawings and
documents for commissioning feasibility, system operability, and maintainability.

The architect/engineering firm will also produce lists, such as equipment lists, valve lists, instrument lists, and line
(piping) lists, which should be collected by the commissioning crew for later use.

Commissioning Manual
The commissioning program is detailed in the Commissioning Manual, which should be distributed to all project
organizations.

Cleaning Procedures
The cleaning of systems should be conducted in accordance with approved procedures. The equipment and pipes
must be cleaned to the level required for their service. The procedures are included in the Commissioning Manual,
and become part of the respective system turnover package when the procedure is completed.

Commissioning Procedures
Each individual system should have a commissioning procedure which demonstrates that the system has been
placed into operation within design parameters. The procedures are included in the Commissioning Manual, and
become part of the respective system turnover package when the procedure is completed.

Schedule
The startup manager reviews the project schedule to identify activities and milestone dates. The milestone
schedule activities that are evaluated by the startup manager are:

Back feed power, or temporary power for startup testing

 HRSG chemical cleaning
Air blow or steam blow of the steam piping
DCS loop checks
First fire of the combustion turbines
Initial roll of the steam turbine
Synchronization of the generators
Full load testing
Commercial operation date
Each system turnover package is integrated into the project schedule. The commissioning schedule logic is tied to
the construction schedule logic through the turnover packages. When construction completes a system, the
turnover package is issued and the commissioning work begins.

The commissioning portion of the project schedule has the same outline as the commissioning work: the individual
components are inspected and tested, then the system is tested by itself, then the combustion turbine is started,
and finally the entire plant is operated and tested. Most projects use scheduling software to track the project
schedule. Commissioning personnel can nowadays easily build and modify their own startup schedules that can be
linked to the construction schedule. The predecessor and successor relationships, total float, constraints, and
resources are some of the schedule parameters that should be analyzed.

Matrix of Responsibilities
The startup manager must identify the specific responsibilities of each party in the project (the design organization,
the construction team, the commissioning team, the plant owner, the operators, etc.). The project management
should approve and implement the division of responsibilities.

The matrix of responsibilities is included in the commissioning manual. The plant owner is normally responsible for
reviewing and approving the commissioning data and results. The startup manager must identify the process for
the review and approval.

Vendor Representatives
Some equipment may require the assistance of vendor representatives during the commissioning phase, to bring
their expertise and also to protect product warranties. The startup manager will review the vendor representative
requirements and make arrangements for the vendors to arrive at the job at the correct time. The representatives
for the following equipment may be required:

Heat recovery steam generators

Duct burners
Soot blowers
Stack dampers
Auxiliary boiler
Emergency or black start diesel generator(s)
Fire pumps
Fire detection and suppression systems
Water treatment equipment
Chemical feed systems
Feed water pumps
Gas compressors
Steam and combustion turbine generator sets
Continuous emissions monitoring (CEM)
Distributed controls system (DCS)
 Programmable logic controllers
Power transformers
High voltage oil-filled cables
Switchgear
Switchyard equipment
Some projects may have special equipment requirements, which necessitate a vendor representative, but other
projects do not need the vendor. Experienced startup personnel can commission many pieces of equipment without
the vendor assistance.

Additional Items to Review

Some additional programs or activities which the startup manager should review while in the office:

Commissioning water program (based on the source of water, destination of waste water, recycling water
during commissioning, waste water limitations, and water permits.)
Fuel specifications
Fuel consumption (at some plants, the client needs to know the anticipated consumption during
commissioning, to make bids for fuel)
Craft support requirements
Maintenance program, in accordance with the vendors literature
Interface-points between the new plant, outside utilities, or an existing plant
Government or insurance company inspectors required for testing safety valves, fire detection/protection
systems, etc.
Equipment to Purchase or Rent
Before going to the job site, the startup manager should make the following requisitions or rentals (per the contract
requirements):

Chemicals
Lubricants
Test equipment
Chemical analysis equipment
Tools (mechanics tool set, electricians tool set, packing removal tools, rigging gear, air conditioning tool
set, valve wrenches of all sizes)
Storage container for tools
Storage container for equipment which has been temporarily removed from the plant
Temporary pumps, hoses, plastic tubing, and fittings
Spare parts (mechanical seals for pumps, DCS cards)
Consumables (gaskets, packing, light bulbs, fuses, panel lenses, etc.)
Solvents to dissolve grease or remove rust
Truck(s) for hauling equipment and personnel on jobsite
Office space, office equipment, furniture, supplies, telephones, fax machine
Computers, printers, and software for the commissioning office
Radios (and frequencies), antennas, base stations, and repeaters for onsite communication
Transportation requirements for personnel (automobiles, vans, and drivers for international locations)
The startup manager needs to determine who is responsible for supplying the various chemicals and lubricants. On
some projects, the commissioning team is responsible for supplying the first load of chemicals and/or lubricants,
and the plant owner is responsible after that.

If the architect/engineering firm does not produce their own lubrication list, the startup manager may be able to
have one of the well-known oil companies produce a lubrication list for the project, as part of their scope of supply.
It is more cost effective to rent the more unusual test equipment for a limited time, and to purchase the normal,
everyday type of test equipment. The schedule for the full-blown commissioning effort occurs at a time when the
construction team is winding down their manpower and equipment, so you cannot always rely on them for support
in areas like tools and consumables. The startup manager should therefore plan on purchasing or renting a full
repertoire of tools. Some tools, like welding machines, rigging equipment, and scaffolding, may be supplied by the
construction team, at least for the beginning of the commissioning effort.

On some projects, there has been considerable time lost because the right gasket was not available, or maybe the
pipefitters needed a 2 1/8 slugging wrench, or no more fuses were left for the DCS input circuits. The
commissioning team that prepares all the necessary consumables and tools will not have those costly delays.

Some seemingly insignificant tools can be very important during a startup. A fin comb, for example, can straighten
out the fins on an air conditioning condenser before a walk down, and therefore avoid unnecessary punch list
records.

Safety
Safety equipment, such as eye wash stations, safety showers, breathing apparatus, respirators, etc. should be
ready for use during the system commissioning, as conditions warrant. If the permanent safety equipment is not yet
available, temporary equipment can be purchased or rented. Safety signs and warning beacons must be in place,
and the workers in the area should be trained in the identification of safety hazards and the remedial actions in
case of an incident or accident. Permits should be used for confined space entry, in order to have the proper
equipment for monitoring the safety of the atmosphere in the vessel, and to have the required standby personnel to
monitor those in the vessel.

Material Safety and Data Sheets must be available onsite for all the hazardous chemicals used during the startup.

Work permits are used to allow construction personnel to work within the boundaries of a system that has been
turned over to startup. Special attention should be placed on hot work permits, where any welding, cutting, or
grinding will occur.

The safety tagging program (lock out and tag out) is the principle means of preventing injury to personnel or
equipment when the systems have been energized.

Figure 1
2 Commissioning of Combined Cycle Power Plants Part 2
This is the second in a series of four articles on the commissioning of combined cycle plants. This article covers the
beginning of the field work for the startup team, from the point of the system turnovers from construction to the
component testing.
1 System Turnover (from Construction to Commissioning)
Turnover Packages
The construction team builds the power plant by area (for example, the Fuel Storage Area).

Figure 1

The construction equipment, such as a welding machine, is most efficiently used by completing one area at a time
and concentrating on the bulk work. As work progresses, the construction team should change their focus to the
completion of systems (for example, the Fuel Oil Heating System, the Fuel Oil Unloading System, and the Fuel Oil
Forwarding System). When system construction is complete, the construction team prepares a turnover package
for each system.

Early in the project, the startup manager provides marked-up engineering drawings, P&IDs, and electrical one-line
diagrams, which depict the boundaries of each system and the equipment included. These drawings are the
system scoping drawings. The drawings identify all the equipment, pipes, cables, and instruments that are in each
system.

On some projects, where computerized databases of equipment are available, the lists can be coded for the
respective systems and may be included in the turnover package.

The system scoping drawings and completed test documents are assembled into a turnover package. The startup
manager also provides a schedule that specifies the target date for each system turnover. When the construction
team is satisfied that a system is ready for turnover, the system turnover package is submitted to the startup
manager for review. Any incomplete construction items are noted in the package documentation. Those work items
are completed later, under the commissioning work permit program.
System Walkdown
After the startup manager reviews the turnover package, a joint construction and commissioning walkdown of the
system is scheduled. The walkdown verifies that all work within the boundaries is complete. Any incomplete work is
noted in the punch list.

Punch List
The punch list contains individual records for each deficiency noted. It lists the respective system, the component
tag number and description, a definition of the discrepancy, the work group responsible for fixing the deficiency, the
dates that the item was generated and closed, etc. The punch list is sorted by the system designator, using the
same designators as the turnover packages.

On some projects, there is a tendency for each organization to keep their own punch list, but those projects that
combine the punch lists into one integrated list seem to complete the work faster. A single project punchlist allows
for better scheduling of equipment and manpower, which allows for the work to be completed faster or in a way that
better supports the overall schedule.

The punchlist should be kept in a database program. On many projects, the punchlist is kept in a word processor
file or a spreadsheet file. But those applications do not have the sorting and report capability of a database
program. It definitely takes more effort to establish a database format, but it allows much more flexibility. With the
database, you can quickly present to a work group a customized list of only those items that they are responsible
for fixing. You can also print customized lists of items belonging to one system, for inclusion in system turnover
packages. Although it seems tedious, it is not a good idea to put multiple items within one record, because it is
difficult sometimes to determine which ones are closed.

2 Component Testing
Responsibilities
On some projects, the construction team performs some or all of the component testing, and on other projects, the
commissioning team performs some or all of them.

Nameplate Data
Before testing any component, the nameplate data on the equipment should be verified against the design
documentation.

Test Specifications
Equipment should be tested to the applicable specifications of the project. The architect/engineering firm usually
lists the technical specifications for equipment and systems. In some cases, the project contract requires that
equipment be tested to various standards, such as the American National Standards Institute (ANSI), American
Petroleum Institute (API), National Electrical Manufacturers Association (NEMA), or other programs. In other cases,
the vendors specifications are the testing criteria.

Lubrication
Equipment must be properly lubricated before it can be commissioned. The field personnel follow the
manufacturer's instructions in the vendor manual. Equipment is sometimes received with a factory-installed
lubricant, which protects the equipment during shipping and storage. The field personnel must replace this lubricant
with a charge of the normal lubricant.

While the rotating equipment is in the warehouse, it is a good idea to follow the recommendation of the various
vendors, and rotate the equipment by hand periodically. This ensures the shafts dont become bowed, and keeps
lubricants in the bearings. All lubrication documents are inserted into the turnover package.
Flushing
Flushing is conducted on the following systems:

Lubricating oil (using oil as the flushing medium)

Fuel oil (using fuel oil as the flushing medium)
Hydraulic oil (using hydraulic oil as the flushing medium)
Cooling water (using water as the flushing medium, or at some projects the system is chemically cleaned)
Raw water and service water (using water as the flushing medium)
Fire protection (using water as the flushing medium)
Feed water and condensate (sometimes chemically cleaned)
When flushing a piping system, the startup engineer must be vigilant to spot potential flushing problems early. If
possible, the pipes should be inspected prior to fit up, to guarantee there are no foreign objects in the pipe.

Water and oil piping systems are usually flushed using the installed pumps. In some cases, temporary pumps of
high volume are used during the flushing.

Over the past few years, high-pressure water has been used, with special lances and nozzles, to blast debris and
rust from pipe interiors. This technique has been successfully employed as a prelude to steam blows or air blows
on steam piping.

Depending on the nature of the debris, flush water may be considered a hazardous waste. At some facilities, where
there is a shortage of water, the flushing water has been recycled by temporary filtration and ion exchange.

Some modifications may be required to prepare the system for flushing. Temporary piping jumpers are installed to
avoid pumping debris into heat exchangers or control valves, and to avoid putting flushing oil into bearings. Before
flushing, all orifice plates, control valves, or other restrictions must be removed. Sometimes, a check valve needs to
have its disc or plug removed to allow flow in the opposite direction. All modifications should be recorded, so that
the corresponding restoration can be verified.

The restorations following the flushing should be recorded. A bag and tag procedure can also be implemented so
that all equipment, which has been removed, gets installed again. When installing orifice plates, verify the correct
tag number, dimensions, type, and orientation. Make sure control valves are re-installed in the proper orientation.
As the system is restored following the flushing, verify the proper type and size of gaskets are installed at each
location.

Valves
Valves should be inspected prior to system flushing, and should be monitored during the period of initial operation.
The manual valves must be inspected, in addition to the air, motor, or hydraulically operated valves. Packing glands
should be adjusted, but tightened only as necessary to preclude leakage. Every check valve must be inspected to
insure the flow is in the correct direction. Some globe or plug valves also have a flow orientation, which must be
observed. Look for the arrow or marking that indicates the direction of flow.

Pumps
The correct direction of rotation of the pump and the driver should be verified. Usually there is an arrow on the
equipment, but sometimes you need to check the vendor drawing.

Review the vendor manual for any special operating characteristics or additional hardware requirements. Make
sure that the associated support equipment is installed properly before starting the pump (cooling water, seal water,
seal leak-off, vents, coupling area drain pipes, etc.).
Run the pump on the minimum flow recirculation line, if there is one, with the minimum flow valve open, or spool
through the minimum flow valve with a temporary spool piece, if the minimum flow valve is an automatic control
valve. After the minimum flow recirculation line is flushed, the line can be placed in service.

Run the pump as necessary to flush the system. During the flushing, after some time of regular operation is
achieved, the pump performance and vibration data can be collected.

Pumps should be tested in accordance with a standard test program (such as ASME Performance Test Code 7.1 or
8.2, or the Hydraulic Institute Standards). For centrifugal pumps, the capacity versus the head is compared to the
pump curve, which was developed during the factory shop test. Verify the pump meets or exceeds the design point.
Positive displacement pumps should be tested for the capacity measurement by volume rate of flow.

Lubricating Oil Flushing

The site personnel may flush the combustion turbine and steam turbine lubricating oil systems. The area around
the turbine should be free of dirt and construction debris (especially the reservoir and bearing areas). Temporary
power and lighting must be available. Several strategically located emergency lubricating oil pump shutoff switches
should be installed. Fire protection equipment must be available. Although it seems like it would be very unusual to
have a fire during a lubricating oil flush, it has indeed happened in the past. Also, make provisions for dealing with
oil spills and leaks (have sufficient adsorbent compound, rags, plastic bags, squeegees, and barrels on hand).
Personnel should be trained to handle oil spills.

At some plants, a subcontractor, using temporary flush skids with pumps, filters, and heat exchangers, performs the
lubricating oil flushing. Some bigger pumps, like feed water pumps, have an integral lubricating oil system. These
systems are generally cleaned in a manner similar to that used on the turbines.

Heat Exchangers
When flushing the system, it is preferable to bypass any heat exchanger, to prevent debris from entering the
exchanger. Because the flow rate drops in the heat exchanger, the debris might not ever come out, and it can affect
the heat transfer of the heat exchanger.

One end of the heat exchanger is bolted down, and the other end is free to travel, for thermal expansion. Check the
hold-down bolts during the initial inspection. This check must be performed even for huge heat exchangers, like air-
cooled condensers.

Chemical Cleaning
Chemical cleaning of the HRSGs takes place after hydrostatic testing. The boiler waterside surfaces, condensate,
and feed water piping will normally be chemically degreased. At some plants, the additional step of acid cleaning is
also employed. A chemical cleaning subcontractor, who will supply the necessary chemicals, equipment, and
manpower, customarily performs the chemical cleaning of the boiler and related piping. Equipment typically
supplied are the circulating pumps, portable boiler, heat exchangers, duplex filters, chemical mixing tanks, water
and chemical storage tanks (sized to store several hundred thousand gallons), and temporary piping for fabricating
flush path jumpers.

Water and chemicals are introduced into the boiler and related piping, heated in the temporary heat exchanger, and
then circulated by means of temporary jumper piping and the temporary pump. The chemistry of the cleaning
solution is closely monitored to ensure the proper chemical reactivity. The safe and economical disposal of
chemical cleaning effluent is an important consideration in planning this activity. The waste water amounts to
several hundred thousand gallons, including the rinse water.
Air Blow vs. Steam Blow
Steam and gas piping systems are cleaned using the normal medium (steam or gas) or by using a substitute
medium (for example, compressed air). In order to properly clean such piping, it is essential to develop a
momentum that exceeds the momentum encountered during normal operation. The measurement of this cleaning

is referred to as the Cleaning Force Ratio (CFR), or the Disturbance Factor (DF),
where:
Wb = Mass flow rate during the blow,
Wn = Normal mass flow rate,
Vb = Specific volume during the blow,
Vn = Normal specific volume.

Calculations determine the start and stop pressure for each blow. Pressure readings taken during the blows
ensure that the momentum will meet or exceed the CFR goals. Cleanness may be confirmed by placing a target in
the outlet of the piping, and evaluating any impacts, or hits. The target is made from polished mild steel or copper.
The steam turbine vendor specifies the number and size of allowable impacts.

Air blow and steam blow are generally considered equally effective in removing pipeline debris and mill scale
(although there still seems to be some debate over the issue). The pros and cons of the two processes are:
Air blows (pro):
Air blows can take place immediately after the HRSG and steam piping is hydrostatically tested. This takes the air
blow off the critical path of the schedule.

Air blows (pro):

Air blows do not use any water.

Air blows (con):

Air blows require expensive compressor rentals and extra manpower.

Steam blows (pro):

Steam blows do not require extra equipment rental. (Both air blows and steam blows require temporary piping,
silencers, and valves.)

Steam blows (con):

Steam blows can be done only after first fire, and only after the steam and condensate cycle is operational. This
puts the steam blow squarely on the critical path of the schedule. The steam blows also require piping insulation to
be installed.

Steam blows (con):

Steam blows use very large quantities of water. Where permanent demineralizer water production is not sufficient
to sustain the steam blow, expensive portable demineralizer rentals are required.

Temperature Cycling
This is the core of the debate on air blow vs. steam blow. The steam blow proponents argue that it is only by flexing
the pipe, through repeated heating and cooling, that the mill scale is removed. Air blow proponents argue that a
proper disturbance factor ensures the mill scale will be scoured.
As indicated previously, high-pressure water has been used, with special lances and nozzles, to blast mill scale,
debris, and rust from pipe interiors. This technique has been successfully employed as a prelude to steam line
cleaning.

On one project that had two identical units side-by-side, one plant was cleaned by air blow and the other by steam
blow. The cleanness results were identical. On both air blow and steam blow, the respective techniques must be
performed accurately for good results.

Depending on the plant configuration, it may be beneficial when conducting air blows to connect unrelated systems
together to form a larger reservoir of air. This produces longer air blows. For example, at one very large chemical
plant, the product line was combined with the main steam header to produce a reservoir of much larger size.

Motors
The internal heaters on large motors, generators, and motor-operated-valves should be energized with temporary
power. On projects which have a long duration, the heaters may be energized in the warehouse or laydown area.

Large motors and generators are megger-tested during the construction period to verify insulation integrity. A
megger test instrument introduces a moderately high voltage into the motor windings. Any winding insulation
breakdown that permits winding-to-winding shorts, or winding-to-ground shorts is detected by the megger
instrument.

Electric motors should be tested uncoupled from the driven component to verify proper motor rotation and
operation.

Cables, Switchgear, and Motor Control Centers

All cables and switchgear/MCC buses are tested prior to energization. Cables are tested for continuity and
insulation resistance. The megger test instrument introduces a moderately high voltage (500 or 1,000 Volts) to
detect any shorts to ground that may be caused by an insulation breakdown.

For switchgear and MCCs, hi-pot testing (using very high voltage) to test high voltage feeders and
switchgear/buses requires special test equipment. The design engineer typically provides hi-pot test acceptance
criteria. Breakers and switches should be tested in accordance with the vendor instructions.

Transformers and Switchyards

Transformer and switchyard tests are performed according to the manufacturers instructions. Transformers,
bushings, circuit breakers, and disconnect switches are commonly inspected and tested by a subcontractor.

Oil-filled transformers, HV bushings, and circuit breakers may require conditioning of the insulating oil to remove
vapors and water. Special equipment is required for this conditioning and testing process, and normally a
subcontractor is hired to process the oil.

Electrical Meters and Relays

Power transformers, switchyard equipment, generators, switchgear, and load centers are protected by
sophisticated relay systems. If the protective relays detect faults, they will re-route or trip the circuits in order to
protect personnel and equipment.

Meter and relay testing must be coordinated with the local utility, for those circuits that interact with the utility grid.
Plant power output and utility-supplied power input are metered for performance and billing data. Special
equipment and expertise is required for setting the meters and relays. The design engineer specifies the relay
settings, testing requirements, and acceptance criteria by means of a relay coordination study. A subcontractor
often tests the circuits.

Instrumentation
The field instrumentation devices must be calibrated and installed prior to commissioning. Instrumentation devices
are initially inspected and calibrated in the shop, but final calibration often takes place in the field, in the installed
configuration. Calibration set points are provided by the design engineer, or by the vendor. Calibration stickers are
affixed to the instrument after the field calibration is successfully completed.

Loop Checks
A sensing instrument is tested by simulating a specific parameter, which is then converted to an electrical signal
and displayed on the control system graphics.

Figure 2

The displayed parameter, scaling, and engineering units are confirmed at the panel display. The transmitter is then
tested through a range of settings and certified as accurately tuned. Many input signals to the plant control system
are used to control various system processes. For example, the input signal above may be used as an output
signal to control a valve. The architecture of this input and output (I/O) signal configuration is known as a loop.
There may be thousands of loops in a combined cycle plant, with the total number dependent upon the design
philosophy and degree of automation. Alarm, runback, and trip signals are all functionally tested during
commissioning.
3 Commissioning of Combined Cycle Power Plants Part 3
This is the third in a series of four articles on the commissioning of combined cycle plants. This article covers the
continuation of the field work for the startup team, with the system commissioning, which energizes each system in
the plant.
1 System Commissioning
DC Power and UPS System
The first electrical system to be energized during commissioning is the direct current (DC) power system.
Sometimes the project contract or specifications require the DC system to be load tested. The commissioning team
rents load banks for this testing.

The DC power system provides power to the switchgear circuit breakers, equipment protective relays, and
emergency pumps (such as the steam turbine emergency lubricating oil and seal oil pumps). DC voltage also
powers an uninterruptible power supply (UPS), which supports the plant control system. During commissioning, the
DC system battery chargers are temporarily powered using construction power.

The battery room must be ventilated to exhaust hydrogen gas developed during the charging process. An eyewash
station must be available for personnel safety. The battery room floors are coated with an acid-resistant sealer.

When the DC system distribution system is energized, testing of the AC switchgear and associated relays may
begin.

Initial Plant Energization

The initial energization of switchgear is an important commissioning milestone. Energization of large, high voltage
equipment such as the switchyard or the generator step-up transformer requires coordinated planning between the
plant and the public utility. A detailed procedure should be prepared, reviewed, and approved.

At some plants, due to the project schedule, back feed power cannot be achieved in time to support the
commissioning effort. Large diesel generators and transformers can be rented to provide temporary power.

Distributed Control System

Figure 1

Typical steps in the checkout of the distributed control system (DCS):

Inspect and inventory the hardware

Check the ground connection
Clear any grounds
Energize, but with no terminations made
Energize each processor and check status
Load software
Setup the human machine interface (HMI)
Perform component and functional checks
Verify data historian hardware and software
Establish communications between the DCS and the other control systems, such as the combustion
turbine controls, the steam turbine controls, the CEMS, etc.
As entire systems are placed in service, and the plant becomes operational, the DCS personnel will
perform loop tuning, where the control parameters (proportional, integral, and derivative gains, or PID) are
adjusted to achieve optimum control. Schedule time should be allotted for this loop tuning.
Instrument Air
The first mechanical system to be started during commissioning is the instrument air system. For complex air
compressor configurations, the vendor should be present to assist in the startup. The controls for the compressor
should be verified against the design.

Moisture traps on the discharge of the air compressor should be inspected very closely to make sure they are
installed correctly. Review the vendor literature.

The air dryers, if they are self-regenerating, may take some time to produce dry air. The system humidity indicator
should be closely monitored for proper indication during the initial operation. During the blowing of the systems
distribution piping, the air dryers should be monitored to prevent excessive flow rates.

The piping system must be blown out with dry air, and the drops to each instrument should be cleaned vigorously.

At add-on units where the existing unit will provide the instrument air, the new plant undergoing commissioning may
draw more air than normal, because of the commissioning activities. This can jeopardize the operation of the
existing facility. In these cases, rented compressors and driers may be necessary.

Water Treatment
Normally, the second mechanical system to start is the water treatment system. Modern water treatment systems
can be very large, with complicated control systems. The vendor representative should be expected to work with
the commissioning team until the system is running reliably in the automatic mode.

The chemical analysis equipment needed to monitor the systems should be made available, and a suitable
laboratory should be fabricated. At some projects, a rented cargo container suffices for a temporary chemistry
laboratory, with the various utilities connected. The following items should be completed prior to adding the resin to
a demineralizer vessel:

The interior portions of demineralizers should be inspected.

The regeneration control sequence (valve stroking, pumps starts and stops) should be thoroughly tested.
The rinse water flow rates and chemical dilution flow rates should be adjusted.
 An eductor should be purchased, since most vendors require that an eductor be used to sluice the resin
into the vessels.
Waste Water Treatment
When the water treatment system is started, there is a corresponding need to get rid of waste water.
Demineralizers and reverse osmosis units generate predictable quantities of waste water. So the waste water
treatment system is very important, and should receive a high priority in the commissioning planning. At some
projects, waste water and solid waste export must be subcontracted.

At some facilities, the waste water treatment system can be quite complex, such as at a zero discharge plant.
This consists of multiple trains of reverse osmosis units, filtration systems, evaporators, concentrators, and filter
presses. Sometimes the influent water to the plant is a gray water effluent from a nearby sewage treatment
facility. Then there are additional backwash filters, clarifiers, and filter presses. It is vital that the manpower required
to commission and maintain big systems like these not be underestimated.

Most plants incorporate some type of oily water separation. The separating device should be tested early in the
startup sequence, since invariably there will be some oil to process.

Fire Detection and Protection

The installation subcontractor normally tests the fire detection system, but the commissioning personnel must
monitor the testing closely, in order to become familiar with the system.

Fire protection systems, such as sprinklers, deluge valves, and gas discharge systems may be tested by a
subcontractor, or by the commissioning team. Depending on the job location, a government inspector or an
insurance company inspector may need to witness the testing.

Fire pumps should be one of the first pumps to be placed in service, after the water supply system makes water
available. (At some plants, the fire protection water supply comes from well water or raw water, while at other
plants, the source may be a water treatment system.) Monitor the jockey pump for frequent cycling, which may be
an indication that there is a leak in the fire main, perhaps underground. The motor-driven or diesel-driven fire pump
should be placed in the automatic mode as soon as possible.

If the cooling tower is fabricated from wood, the associated fire protection deluge valves should be placed in
service as soon as possible.

Make sure that post indicator valves have their indicators calibrated to show the correct position.

Cooling Water
Circulating water systems that use seawater need special care during the commissioning phase, due to the
corrosive nature of seawater and the marine life and debris associated with seawater. The rakes, traveling screens,
tube cleaning systems, and pump intake screens require meticulous care during the commissioning phase, to
prevent the introduction of debris into the condenser.

Large circulating water pumps must be aligned carefully and accurately. Depending on the system design, the
pumps may have a special valve that vents the air from the discharge column. Seal water for lubrication of the
pump packing may have to be provided by a backup system. The pump discharge valve is normally motor-
operated, and its operation should be verified prior to starting the pump.

The condenser water boxes may have vent valves which must be opened and closed manually when starting the
system. If there is a water box priming system, it should be commissioned and placed in service at the beginning of
the program. If not, air pockets will build up in the water boxes, and some tubes may not be filled with seawater.
Some plants require throttling of the outlet valves on the water boxes, to setup the proper flow or pressure
parameters. The water boxes may have sacrificial zinc anodes. These anodes must be checked after the initial
operation of the system. The commissioning personnel must research these features prior to starting the system.

During the walkdown of the condenser, all the fittings should be inspected closely, to make sure there are no
materials installed that are non-compatible with seawater.

Cooling towers require special monitoring prior to use. The spray nozzles, distribution headers, and fill should be
inspected before starting the system, and also sometime after the first use, to make sure there are no problems
created by the force of the water. Cooling tower fans should be checked for vibration, and their gearboxes should
be monitored for proper lubrication. If the cooling tower has a place to mount corrosion coupons, the coupons
should be installed prior to introducing water. A wooden cooling tower should have its fire protection system in
service as soon as possible. Once a wooden cooling tower is put in service, it should remain wet as much as
practicable, so that it does not dry out and become a fire hazard.

Steam, Feed Water, and Condensate

After these systems are cleaned, as discussed above, they are prepared for service.

The condensate pumps are tested, along with their various control valves. Special care is taken with the pump seal
or packing. Some pumps require an external source of seal water; the pump technical manual should be reviewed
for this feature. If possible, some spare seals or packing should be on the list of spare parts.

The condenser air removal system may consist of steam jet air ejectors, vacuum pumps, or a combination of the
two. The startup engineer must monitor the various steam traps very closely, making sure they have free drainage
to their destination. Some traps on air ejector packages require a vent line back to the after condenser. Some
plants have a vacuum breaker valve, which requires seal water to prevent air in-leakage. Make sure the seal water
is installed.

The condenser (or steam turbine) rupture disc should be inspected closely prior to vacuum operations. Some discs
have to be installed in one particular direction. The area around the disc should not be accessible for personnel.

The deaerator should be inspected before use, to make sure the trays are installed in the proper orientation, and
that they are secure. The spray nozzles should be left out, if not yet installed, or removed, if they have been
installed. The deaerator should be inspected after the initial round of flushing, to remove any debris that settled in
the storage vessel, and to install the spray nozzles. The deaerator should receive a final inspection after the period
of initial operation, to check the spray nozzles and trays.

The various types of feed water pumps need customized care to ensure smooth operation. The pump suction
strainer is very likely to plug when first running the pump. The minimum flow valve and any minimum flow orifice
should be inspected to make sure they dont cause too much flow restriction for the pump. If the pump has an
automatic recirculation valve in the discharge, the valve should either be removed for the initial operation, or (in
some cases) a special startup trim installed for initial operation.

Heat Recovery Steam Generator (HRSG)

A few plants, which burn crude oil or some other heavy oil, have soot blowers. The alignment of the soot blower is
critical to their smooth operation. Also important is proper lubrication.
Some plants can run the combustion turbine solo, by means of a stack damper and a simple cycle stack, then later
put the exhaust through the HRSG and out the main stack. The stack damper must be tested to ensure it operates
in simple cycle mode without allowing any leakage into the HRSG.

HRSGs with horizontal tube bundles have recirculation pumps. Because they must operate at all times, it is
important to the commissioning team that the pump suction strainers be easy to clean. The designers should avoid
any in-line spool piece strainers, since they require a longer time to clean.

Sample Panels
Modern plants have sample panels, where sample lines are routed to centrally located panels for analysis. The
sample panels may measure conductivity, cation conductivity, degassed cation conductivity, pH, sodium, hydrazine,
dissolved oxygen, silica, and other parameters.

Too often, there is a push to put the sample panels in service as soon as possible. But the steam and condensate
systems can be heavy with rust or debris during the initial startup, and the sample panel equipment, with its tight
tolerances, will get plugged with debris. At some plants, temporary sample coolers have been installed, by running
sample tubing through 55-gallon drums and using cooling water from a service water hose station, in order to delay
the use of the sample panels.

Another helpful feature is a sediment pot installed on the inlet of each sample connection. The pots large diameter
in relation to the sample tubing allows debris to settle to the bottom, where it can be blown down. Sediment pots
can be added to the sample panel design with minimal cost.

The maintenance of sample panels can be easily underestimated. They require constant monitoring, chemicals,
and calibrations.

Fuel Gas
The introduction of fuel gas necessitates safety precautions, such as testing the gas fuel piping flanges for leaks.
This is done by wrapping each piping flange or joint with masking tape, punching a small hole in the tape, and then
positioning a hand-held gas detector near the hole. (This leak testing is often preceded by leak testing with air
pressure, before the fuel gas comes into the battery limits.)

The installed gas monitor should be functionally tested using a calibrated gas.

Gas fuel temperature should be verified to be above the dew point temperature. If there is a pressure letdown
station, and there are liquid constituents in the gas, the expansion of the gas causes the temperature to plummet
precipitously, and freezing can occur.

Liquid Fuel
At some plants, a liquid fuel, such as distillate, is used as a backup fuel for the combustion turbine, the auxiliary
boiler, and the duct burners. The liquid fuel system must be cleaned well, to prevent plugging of equipment with
close tolerances.

Some liquid fuel tanks have floating suction devices. This hardware should be inspected prior to filling the tank. Any
special coatings in the tank interior should also be checked. Siphon breakers on the tank should be disassembled,
to make sure there are no shipping stops in the valves.

The liquid fuel unloading station should be checked for proper spill containment and fire safety.
Air Conditioning and Ventilation
At many plants, the air conditioning and ventilation systems are seemingly abandoned after their initial start,
because they are someone elses responsibility. Therefore, a good commissioning team will monitor these
systems, even if they are in fact some other organizations responsibility, because degradation of these systems
can have an adverse impact on plant performance.

Replace air filters regularly during startup. Use good quality pleated air filters, rather than the cheap fiberglass
types. The pleated air filters can take more abuse, and they keep your system cleaner. Due to the dust and dirt at
construction sites, air conditioning condenser coils may need frequent cleaning.

Condensate drains need to be directed to a suitable location. Most units have a p trap on the condensate, to allow
the water to drain, but not allow un-filtered air to be drawn into the unit. If there are troubles with the trap, it may
cause water to back up in the unit.

System Checkout
The remaining systems needed for running the combustion turbine and HRSG are tested on a system basis. The
equipment is energized, and the process fluid is put into the system. The various control circuits are checked, to
verify controls and interlocks work as designed. Where possible, the system parameters are adjusted to produce
the various set points which cause the controls and interlocks to function. For example, tank levels are raised and
lowered to trigger alarms or trips, or system valves are throttled to cause low flow or low pressure conditions.

If a system has heat tracing installed on its pipes or instrument lines, and the weather predictions are for freezing
temperatures, make sure the heating supply is ready and the insulation is installed. The heat may be applied from
steam or an electrical supply.

Combustion Turbine
In most plants, the commissioning of the combustion turbine itself is the responsibility of the turbine vendor. They
provide specialists in the various systems of the turbine: the controls, the electrical systems, and the mechanical
systems.

The lubricating oil flush is customarily one of the first activities, and has traditionally been a milestone benchmark.
Temporary power is used to power the lubricating oil pumps for the flush. The oil should be purified before filling the
reservoir, since brand new oil shipments have been received with debris in the oil.

The turbine control systems also receive a temporary power supply, in order to checkout the circuits early in the
commissioning program. The aim of the system commissioning period is to get the combustion turbine shaft
rotating and ready for firing.

Steam Turbine
The steam turbine is also commissioned by the vendors personnel, who are specialists in their area of
responsibility. The steam turbine commissioning occurs later in the schedule, so permanent power is usually
available for the steam turbine equipment. The lubricating oil flush of the steam turbine is conducted in a manner
similar to that of the combustion turbine.

The goal of the system commissioning period is to have the turbine shaft on turning gear, with gland sealing steam
applied and vacuum on the condenser. The steam turbine is then ready to admit steam.
 Thermal Expansion
Before the initial heat up of the plant, the steam headers and other hot pipes will be inspected. The spring hangers,
supports, guides, will be adjusted according to their design.

During the initial heat up, the pipes and support devices must be inspected very closely, to verify the proper
direction and amount of thermal growth. (Example: 100 feet of schedule 80 carbon steel pipe, when heated up
300F, will grow 2.5 inches!)

4Commissioning of Combined Cycle Power Plants

Part 4
1 Operational Testing

First Fire
The combustion turbine is ready for first fire after successfully completing control sequence checks, cranking
checks, emergency shutdown checks, false-fire checks, and has been on turning gear for twenty four hours.
Once the combustion turbine is fired, the hot exhaust gas will generate steam in the HRSG. The steam can be
vented from the HRSG drums and superheater vents during the initial first fire operation. But after reaching a
sustained full speed/no load condition (FSNL), these vents will not be adequate for removing the steam and the
HRSG pressure will rise. If the air blow process was used to clean the steam pipes, the steam can be routed to
an atmospheric dump valve or to the steam turbine bypass. If the steam piping will undergo steam blows, a
temporary valve and silencer arrangement will take the steam out of the system, until the necessary cleanness
is achieved. When the combustion turbine is fired and the HRSG heated up for the first time, blow down the
HRSG to remove any magnetite that has loosened from the tube walls.

Steam Turbine Bypass

The steam turbine bypass system dumps steam to the condenser through pressure-reducing control valves that
also have an associated attemperating water spray. The initial operation of the steam turbine bypass must be
monitored closely. The steam temperature should not be too high in the superheated region, as this may
overheat the condenser structure. Also, the steam should not enter the saturated range, as this heavier steam
may cause condenser tube aerodynamic problems (rattling and eventual cracking of the tubes, or damage to
the bypass valve itself). Steam is dumped to the condenser until steam purity is achieved (clean enough to be
admitted to the steam turbine). This can often take several days, or a week, of continuous dumping.

Figure 1
Generator Synchronization
After a combustion turbine or steam turbine starts, its generator is connected to the utility grid to export power.
The generator breaker is closed to the grid after synchronizing the voltage and frequency of the generator to
the system's voltage and frequency. The generator's field excitation and speed are adjusted until the voltage
and frequencies of both systems are closely matched. The generator breaker is then closed, and the power
output of the generator is increased by raising the combustion turbine firing (or by raising the steam turbine
steam admission rate). Failure to accurately synchronize the generator to the grid before closing the circuit
breaker may damage the generator. Protective relays detect any out-of-phase conditions and will not permit
breaker closure.
Water Use
During chemical cleaning and first fire operation, demineralized water demands can exceed the water
production rate and storage capacity. Chemical cleaning requires large quantities of demineralized water for
preparing the cleaning solutions and the subsequent filling, flushing, and rinsing of the piping and HRSG's. At
the time of combustion turbine first fire, frequent blowing down of the HRSG is required to remove loose
magnetite and achieve the steam purity necessary for steam admission to the steam turbine. During
commissioning, the water treatment system will become increasingly reliable and will attain the throughput
guarantees and chemical purity specifications. It may be necessary on a temporary basis to augment the water
production by mobile demineralizers.
Normal BOP Systems Operation
After a balance of plant (BOP) system checkout is complete, the system is placed in normal operation in a step-
by-step fashion. This activity may take several days, and may require frequent stops in order to perform
inspections, make equipment adjustments, or review data. The following example of the condensate and feed
water initial startup demonstrates this process.

Step #1: The condensate storage tank is filled with demineralized water. Tank level indicator signals are
verified at the DCS.

Step #2: The condensate make-up pump is started and placed in recirculation operation from the DCS.
Pump suction pressure, discharge pressure, and suction strainer differential pressure are monitored.

Step #3: The condenser hotwell is filled using the condensate make-up pump. Hotwell level indicator
signals are verified at the DCS. The control valve operation is checked, and then the controls can be

placed in the automatic mode.

Figure 2

Step #4: The condensate piping and the HRSG drums, economizers, and evaporators are filled via the
condensate make-up pump cold fill line.

Step #5: The condensate pump is started and placed in recirculation operation from the DCS. Pump
motor amperage, thermal rise, and vibration are monitored. Pump suction pressure, discharge
pressure, and suction strainer differential pressure are also monitored.

Step #6: The condenser hotwell level controls are verified in both manual and automatic operation.

Step #7: Condensate flows to the HRSG LP economizer and is recirculated to the condenser via the
economizer recirculation line (if such a recirculation line is included).

Step #8: Condensate flows through the LP economizer 3-way valve bypass and into the LP drum. The
condensate is then redirected via the 3-way valve into the economizer and into the LP drum. 3-way
bypass control is verified at the DCS. Thermocouple indications in the LP economizer are verified at the
DCS.
 Step #9: A feed water pump is started and placed in recirculation operation. LP drum level indicator
signals are monitored at the DCS. Level control valve operation is verified. Feed water pump lubricating
oil distribution, temperature and pressure is verified locally and at the DCS. Cooling water flow and
temperature is monitored locally and at the DCS. Pump motor amperage, thermal rise, and vibration
are checked. Pump suction pressure, discharge pressure, and suction strainer differential pressures are
monitored.

If the condenser has excessive leakage while under vacuum, and all the normal leakage sites have been
checked by site personnel, it is beneficial to subcontract a specialist in condenser air in-leakage testing. These
companies use helium detectors, installed at the air discharge of the condense air removal system, and they
spray helium around the joints, man ways, and flanges of the condenser and steam turbine. The helium
detector can even be "calibrated" to estimate the amount of leakage. The subcontractor can spot the source of
the leakage in a matter of hours. Shift Work
When the combustion turbines are fired for the first time, the commissioning team moves into shift work, with
two or three shifts assigned for round-the-clock coverage. On some projects, the most experienced personnel
are assigned to the night shift. Since there are fewer workers on night shift to coordinate, and fewer
distractions, the night shift can initiate new tests much easier than can be done on day shift. Test Data
In preparing for testing, the startup manager prepares test log sheets and may also use DCS software logs that
capture operational data. Software logs can be formatted to depict operating data graphically, displaying the
dynamics of the system operation. Steam Traps
Steam traps are deceptively simple components, which can cause big problems if they are not specified
properly, or if they are installed incorrectly. The commissioning team should check the design features of the
traps, to make sure they are installed with the correct range of pressures, temperatures, and back-pressures.
They should also check the various piping runs, and verify that traps are installed at all the necessary points in
the systems. During the system walkdown, the commissioning team should make sure the traps are installed in
the proper orientation, and that the associated piping is routed correctly. After some period of operation, the
traps which have internal strainers should be disassembled and cleaned. Plant Outages
During the operation of the plant, there will be a collection of punch list items which require the plant to be
shutdown in order to perform the work. Also, the startup schedule will include some known outage activities,
like removing the strainers from the steam turbine inlet valves, or pulling the strainers from the combustion
turbine fuel lines. The work should be scheduled just like a regular plant outage, with work permits arranged in
advance, materials staged in the warehouse, and personnel assigned to the tasks. When the predetermined
time arrives for the outage, the work can then proceed smoothly. There should also be an ongoing list of punch
list items that can be done during a short outage, so that if the plant is shutdown or trips without notice, some
of those short work items can be accomplished. Special Situations
Emergency leak repair is sometimes warranted if there is a bad leak but you don't want to shutdown the plant
to fix the leak. A leak repair subcontractor can be called to the site. They will make a temporary fitting which
can be applied around the leak, and then they will pump a system-friendly compound into the fitting to stop the
leak. These leak repairs have been successfully employed on high pressure steam systems, circulating water
systems, glycol cooling systems, and elsewhere. Another technique for making repairs on the run is to use a
"freeze seal" to isolate an otherwise un-isolable section of a system and allow a repair to be made. Kits are
available for "do it yourself" freeze seals, or subcontractors can be employed for the more difficult cases.
Repairs on flanges or valves can often be performed by an "in place machining" subcontractor. Housekeeping
It is a well-known fact that plants that have good housekeeping are easier to start. When the commissioning
team is not encumbered by construction dirt and debris, the equipment stays clean and more trouble-free. The
startup manager should insist on good housekeeping from all the organizations on the project. Performance
Testing
The heat rate test is based on the engineered heat balances supplied by the plant designer. The net plant heat
rate typically supercedes any individual combustion turbine and steam turbine guarantees and is calculated as
BTU/kWh.

Heat rate testing should be performed when the plant is in a new and clean condition with less than 300 hours
of operation. When this is not possible, the plant designer will supply heat rate degradation correction curves
for calculating the adjusted heat rate. Additional correction curves are supplied to adjust the heat rate
calculation to the guaranteed combustion turbine compressor inlet temperature, humidity, and barometric
pressure (commonly cited as 59o F, 60% relative humidity, 14.66 psia barometric pressure). The specified fuel
gas heating value (BTU/lb) and chemical composition (per cent methane, ethane, propane, etc.) is verified by
drawing samples during the test for subsequent analysis. Stable operating conditions within the emission limit
guarantees are required during the test period (usually four hours at base load). Other operating conditions and
limitations may include:
 HRSG blowdown = 0%

Generator power factor = 0.85 lagging

Generator frequency = 60 Hz

Electrical output = as measured on the high-voltage side of the step-up transformer(s).

Combined cycle heat rates of approximately 6,000 BTU/kWh, LHV are now common. The heat rate test
procedure will typically identify the temporary test instruments and permanent plant instruments that will be
used to collect data. These instruments require calibration certificates to validate their accuracy and tolerances.
Of special importance are the electrical power output meter, the auxiliary electrical load meter, and the fuel gas
flow meter. Whenever possible, the data should be read on the actual plant revenue or billing meters, since
these meters will be used to pay fuel costs and to calculate the plant's electrical sales revenues. Emissions
Testing
HRSG stack emissions testing validates the emission limit guarantees. In many plants, the combustion turbine
exhaust gas nitrous oxide (NOx) reduction equipment will not satisfy the local environmental permit
requirements, and it is therefore necessary to supplement the combustion turbine NOx reduction equipment
with an HRSG selective catalytic reduction (SCR) unit. The combustion turbine exhaust enters the HRSG and
passes through SCR modules located behind the high pressure evaporator modules. Ammonia is injected into
the flue gas, and it reduces the NOx while on the catalyst surface. The ammonia decomposes NOx into

harmless N2 and H2O, according to the reactions:

The stack NOx is tested as NO2 and measured in parts per million (PPM) by volume on a dry gas basis,
corrected to 15% oxygen. HRSG stack emissions testing may also include tests for:

Ammonia (excess ammonia admitted to the SCR)

Carbon monoxide

Particulate (sized in microns)

Volatile organic compounds (e.g. methane)

Sulfur

HRSG stack emissions testing is typically performed after the installed CEM has been certified. However, if the
permanent plant CEM is not certified at the time of emissions testing, a rented, portable CEM is used. The HRSG
stack emission testing may be performed in conjunction with the heat rate testing. However, the emissions test
may be conducted at several different load points (50%, 75%, 100% for example, with and without duct
burners) on a one-hour average basis, while the heat rate testing may be performed at only one load point.
Combustion turbine exhaust gas NOX emission guarantees of 9.0 ppmvd (@15% O2) are now common.
Combined cycle plant HRSG stack emission guarantees (with an SCR) can be as low as 3.5 ppmvd (@ 15%
O2). Contract Testing
The following tests may be required by the contract:
Steam Turbine and Combustion Turbine Overspeed Tests Modern overspeed controls are now redundant
electronic circuits (replacing the spring-loaded mechanical bolt-type overspeed device). At least two overspeed
tests are performed (one on each circuit), and then repeated if necessary. CO2 Concentration Tests
After the combustion turbine CO2 piping is cleaned and pressure tested with air, and the fire control and alarm
system is fully tested, the CO2 storage tank may be filled. The system is dynamically tested by initiating a fire
alarm (via any of the heat detection sensors). The CO2 concentration is measured. The concentration test
requires special equipment and is typically performed by the fire system vendor. Electrical Full-Load
Rejection Test
A full-load rejection test demonstrates the ability of each combustion turbine and the steam turbine to instantly
shed their full-load, without tripping on overspeed, and then run down to full-speed-no-load. Combustion
turbine full-load rejection tests are conducted individually, one combustion turbine at a time. In order to
achieve full-load on the steam turbine both combustion turbines must be in base load operation. When the
steam turbine generator breaker is opened, the combustion turbines must runback to a preset lower load and
begin dumping steam to the condenser via the steam turbine bypass. Control of this runback and bypass
operation is a function of the DCS control logic. A station trip test simulates a switchyard failure, wherein the
combustion turbine generators and steam turbine generator are separated from the grid. In this case, the
steam turbine is tripped and the combustion turbines run back to full-speed-no-load. In stations where there is
no backup power, one of the combustion turbine generators may be configured to runback and later implement
a safe shutdown. Duct Burner Testing
Duct burners may be functionally tested to full-fire capability only after the combustion turbine is at base load.
For this reason, the duct burners are frequently the last system to be fully commissioned, and are on the critical
path to performance testing and emissions testing. Partial Load Stability Test
A partial load stability test seeks to determine the plant's lowest megawatt output operating point. At this point
the megawatt output remains stable, and the stack emissions remain in compliance with the air
permit.Reliability Test
A reliability test may take the form of a continuous operations test, where the plant operates continuously, with
no emergency trips, for a period of perhaps 7 to 30 days. Other variations of this test include performing
repeated startup and shutdown operations, performing hot and cold re-starts with fast loading, unit
maneuvering (for example, steam turbine extraction steam tests), and peaking operation tests. 2 System
Turnover (from Commissioning to the Owner)
The turnover from commissioning to the plant owner follows the same principles as the turnover from
construction to commissioning. Turnover Packages
The commissioning team maintains the system turnover packages during the commissioning phase, and the
various records collected for each system are added to the packages during the commissioning. Sometimes an
entire train of one combustion turbine generator and associated HRSG are turned over to the owner as one
package. This type of turnover includes multiple system turnover packages being turned over
simultaneously.System Walkdown
The system walkdown is conducted in the same manner as the construction turnover walkdown. The walkdown
verifies the work within the boundaries is complete. Any incomplete work is noted on the punchlist. Those work
items are completed later, under the owner's work permit program. "Wish List"
The owner's personnel are not always conversant with the contract for designing and building the plant, and
sometimes they write into the punch list items which are beyond the scope of the contract (therefore known as
"wish list" items). The startup manager will differentiate between in-scope deficiencies and out-of-scope
requests. The plant owner may need to establish a separate contract to add these enhancements at a later
time, after the plant startup is completed. 3 Conclusions
Due to the popularity of the combined cycle power plant, many startups have occurred in the past few years,
and a system of commissioning has evolved. That system is based on the historical groundwork of the electrical
utility fossil and nuclear plant startups, and has been modified to match the needs of the modern combined
cycle power plant. Experienced startup personnel have been trained and are ready to meet the technical
demands and challenges of their industry.