PPCM Table of Contents

1.0 1.1 1.2 1.3 1.4 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 3.0 3.1 3.2 3.3 3.4 4.0 4.1 5.0 System Purpose/Description.......................................................................... System Purpose............................................................................................. System Description........................................................................................ System Precautions....................................................................................... System Prerequisites..................................................................................... System Commissioning Mechanical............................................................. Pumps Vessels Check Valves.............................................................................................. Control Valves............................................................................................. Safety Relief Valves.................................................................................... Manual Valves............................................................................................. Specialty Equipment................................................................................... Hangers and Supports................................................................................ Heat Exchangers......................................................................................... Expansion Joints............................................................................................ Flushing Valve Line-up System Commissioning Checklist.................................................................. ISLT Vendor Documents........................................................................................ Maintenance System Startup Electrical.............................................................................. High Voltage Equipment................................................................................ Median Voltage Equipment............................................................................ Low Voltage Equipment................................................................................. MCC Equipment............................................................................................. System Startup I&C...................................................................................... Instrument Calibration and Loop Check......................................................... Reference.......................................................................................................

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1.0

SYSTEM PURPOSE / DESCRIPTION

1.1 Purpose

The purpose of this work plan is to establish a sequence of events, instructions, and specific check offs necessary to prepare the Ammonia Injection System (AMS-1) for operational readiness. The Commissioning Engineer must review all of the General Test Plans and Vendor O&M manuals that may apply to this system before beginning any Commissioning procedure. 1.2 Description

The aqueous ammonia injection skid distributes ammonia into the HRSG exhaust gas through the ammonia injection grid to reduce NOx concentration in the flue gas. The ammonia injection skid is composed of the catalytic reactor, ammonia injection system and the air supply system. The SCR reactor is located in the flue gas duct downstream of the gas turbine/HRSG. The flue gas flows into the SCR reactor where the inherent NOx reacts with the injected ammonia and is converted into N2 and O2 gases. The ammonia/gas injection system consists of supply headers, a grid of injection pipes and nozzles. Each supply header is equipped with a manual throttling valve and flow orifice for obtaining a uniform distribution of the gas mixture to the injection pipe grid. 1.3 Precautions

WARNING: A THOROUGH CHECK WITH A GAS DETECTOR MUST BE ACCOMPLISHED PRIOR TO ISSUING A HOT WORK PERMIT IN THE AREA OF NATURAL GAS. WARNING: ISOLATE AND DEPRESSURIZE ANY EQUIPMENT OR SUPPLY LINE THAT REQUIRES MAINTENANCE. WARNING: BEFORE OPERATING THIS EQUIPMENT, THOROUGHLY FAMILIARIZE YOURSELF WITH THE CONTROLS AND OPERATING CHARACTERISTICS. A NATURAL GAS AND AIR MIXTURE UNDER PRESSURE CAN EXPLODE CAUSING SEVERE INJURY OR DEATH. CAUTION: BE SURE A SEQUENTIAL SHUTDOWN OF THE REST OF THE PLANT HAS BEEN ACCOMPLISHED PRIOR TO SHUTTING DOWN THE FUEL GAS SYSTEM.

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1.4 Prerequisites

1.4.1 The Commissioning Engineer must review all of the General Test Plans and Vendor O&M manuals that may apply to this system before beginning any Commissioning procedure. 1.4.2 REVIEW operations logbook for any condition prohibiting safe startup or need for resetting of controls or instrumentation. 1.4.3 VERIFY the system has been turned-over in accordance with PPCM Administrative Plan. 1.4.4 VERIFY that all personnel have reviewed the Job Hazard Awareness (JHA) for each job performed within the scope of this work plan. 1.4.5 VERIFY proper communications are established between Operators and the Control Room. 1.4.6 VERIFY personnel are rehearsed with the startup procedures and are prepared with emergency response actions. 1.4.7 VERIFY that all personnel involved with the operation of this system are familiar with the equipment manufacturers startup and operating procedures. 1.4.8 VERIFY safety tags and locking devices are installed in accordance with Commissioning Lockout/Tagout procedures. WARNING: VERIFY THAT STARTUP ACTIVITIES ARE COMPLETE BEFORE SAFETY TAGS AND LOCKING DEVICES ARE REMOVED. NEVER REMOVE A TAG OR LOCKING DEVICE UNLESS YOU ARE AUTHORIZED TO DO SO. 1.4.9 VERIFY all applicable safety practices and procedures are in place. 1.4.10 INSPECT safety relief devices for debris or paint that would prevent operation. 1.4.11 Safe Working Permit System and JHA completed. Safety is of paramount importance to Commissioning. The Commissioning Manager will gain a working knowledge of the clients Project Safety Plan, including the appropriate Environmental and Health policies and regulations. The health and safety policies and procedures as defined in the Commissioning Safety Manual shall be followed at all times during the Commissioning phase of the Project. The Commissioning Manager is responsible to insure the Commissioning Work Control Program developed for the project adheres to the requirements of the clients Project Safety Plan, as well as the Commissioning Safety Manual.

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During the Commissioning phase all work on systems under the care, custody, and control of Commissioning shall comply with the requirements of the Commissioning Work Control Program. The Commissioning Work Control Program shall adhere to (or include) the following portions of the Commissioning Safety Manual: 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 Personal Protective Equipment Lock and Tag Safeguards Confined Space Hot/Cold Work Elevated Work

SYSTEM COMMISSIONING MECHANICAL

Pumps Vessels Check Valves Control Valves Safety Relief Valves Manual Valves Specialty Equipment Hangers and Supports Heat Exchangers Expansion Joints Flushing Valve Line-up System Commissioning Checklist ISLT Vendor Documents Maintenance

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2.1 Pumps

Inspect and test the attached list of pumps in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: Mechanical Commissioning and Start-up Mechanical Inspection Rotating Equipment Pre-Operational Inspection Leak Testing Inspection Rotating Equipment Alignment Rotating Equipment Initial Start-up Vibration Testing Equipment Lubrication

Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. 2.2 Vessels

Inspect and test the attached list of vessels in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: Mechanical Commissioning and Start-up Vessel and Tank Inspection Flush Cleaning

Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. 2.3 Check Valves

Inspect and test the attached list of check valves in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: Mechanical Commissioning and Start-up Mechanical Inspection Flush Cleaning Leak Testing Inspection

Check all list check valves for correct direction of flow. Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. Control Valves Inspect and test the attached list of control valves in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: Mechanical Commissioning and Start-up Mechanical Inspection

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Flush Cleaning Leak Testing Inspection Calibration and Loop Checkout

Check all list control valves for following: Valve fully strokes 0 to 100% and back to 0. No binding of valve during stroke. Check packing for proper installation.

Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. Safety Relief Valves Inspect and test the attached list of safety relief valves in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: SU-300 Mechanical Commissioning and Start-up SU-301 Mechanical Inspection SU-307 Flush Cleaning SU-308 Leak Testing Inspection

Check all list safety relief valves for following: Lead seal is intact. Proper set point is set Discharge is to a safety place. SRV certification is attached.

Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. 2.4 Manual Valves

Inspect and test the attached list of manual valves in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: Mechanical Commissioning and Start-up Mechanical Inspection Flush Cleaning Leak Testing Inspection

Check all list valves for the following: Valve fully strokes 0 to 100% and back to 0. No binding of valve during stroke.

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Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. 2.5 Specialty Equipment

Inspect and test the attached list of specialty equipment in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: Mechanical Commissioning and Start-up Mechanical Inspection

Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. Hangers and Supports Inspect all hangers and supports associated with this system in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: Mechanical Commissioning and Start-up Mechanical Inspection Hanger and Support Inspection

All hangers and supports must be witness in accordance with the Commissioning Inspection and Test Program. All hangers and supports require witness by the Owner and Commissioning per P3.3. Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. Heat Exchangers Inspect and test the attached list of heat exchangers in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: Mechanical Commissioning and Start-up Mechanical Inspection Heat Exchangers Inspection

Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. Expansion Joints Inspect and measure the attached list of expansion joints in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply:

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Mechanical Commissioning and Start-up Mechanical Inspection

Record all required measurements of the expansion joint per the generic expansion joint layout. Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. 2.6 Flushing

Flush the system in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: Flush Cleaning

Highlight the P&ID in yellow for the primary system to be flushed. Highlight the P&ID in green for all secondary systems, drains, valves, and instruments. Insert a copy of the highlighted P&IDs into this manual. Acceptance Criteria for flushes not specified in the Vendor O&M manuals are as follow: Pull a sample from the flush stream with a clear and clean bottle/vessel. Verify that there are no suspended solids or sediment on the bottom of the sample bottle/vessel. All flushes must be witness in accordance with the Commissioning Inspection and Test Program. All flushes require witness by the Owner and the Commissioning Team. Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. . 2.7 Valve Line-up List Insert a valve line-up of all valves and their Commissioning position. Show valve Commissioning position as open, throttled, or closed. The valve may be highlighted and the valve position noted on P&I Ds. 2.8 System Commissioning Checklist

Insert a system Commissioning checklist into this manual. The checklist is to show all steps in sequences required to start the system. The system set points and start points should be defined. 2.9 Initial System Leak Test

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Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. Vendor Documents Insert a copy of the vendor documents into this manual. All Commissioning steps must be initialed as they are completed. Once all steps have been performed, sign vendor document at the bottom of the last page and mark as completed. 2.10 Maintenance

Insert a copy of vendor maintenance requirements and maintenance schedule from the vendor O&M manual. As maintenance is completed, insert a signed copy of the maintenance record into this manual. 2 SYSTEM STARTUP ELECTRIAL 2.4 High Voltage Equipment 2.5 Medium Voltage Equipment 2.6 Low Voltage Equipment 2.7 MCC Equipment 3.1 High Voltage Equipment

Inspect and test the attached list of equipment in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: High Voltage Motor Test High Voltage Switchgear Breaker Test

Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. Medium Voltage Equipment Inspect and test the attached list of equipment in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: Low/Medium Voltage Motor Test Low/medium Voltage Switchgear Breaker Test

Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. . 3.2 Low Voltage Equipment Inspect and test the attached list of equipment in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: Low/Medium Voltage Motor Test Low/medium Voltage Switchgear Breaker Test

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Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator. 3.3 MCC Equipment

Inspect and test the attached list of equipment in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: 480V MCC Inspection and Test

Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator.

SYSTEM COMMISSIONING INSTRUMENTATION

2.8 Instrument Calibration and Loop Check Instrument Calibration and Loop Check Inspect and test the attached list of equipment in accordance with the Vendor O&M manuals and any of the following General Test Plans that may apply: Calibration and Loop Checkout

Complete all test reports and forms that are required and insert a copy into this manual. The original is turned over to the Commissioning Coordinator.

5.0
5.1 5.2

References
P&I DS Manuals