COMMISSIONING

COMBINED CYCLE POWER PLANTS

Author: Daniel A. Parker

Company: Granite Services International
Country: USA

POWER-GEN Asia 5th – 7th September 2006, Asia World Expo, Hong Kong

© 2006, Granite Services International, Inc. All rights reserved.

1302 N 19th Street, 4th Floor, Tampa, FL 33605 USA
Certified to ISO 9001:2000
Phone (813) 242-7400, Fax (813) 248-7400, Web www.gsinc.com
COMMISSIONING COMBINED CYCLE POWER PLANTS

Preface
This paper outlines a program that will successfully commission a combined cycle power plant.
Commissioning personnel, plant owners, operators, and others will benefit from the lessons
learned and experiences discussed in this paper. Engineering and construction personnel who
interface with the commissioning team may also see how their work influences the commission-
ing effort.
There are several ways to commission a power plant, all of which will get the job done. Each
project is unique in its contract requirements, specifications, and commercial aspects, so com-
missioning personnel must have a flexible approach to their work. This paper does not espouse
any particular method of commissioning a plant, but instead highlights some of the varied ap-
proaches.

Company Background
Granite Services, Inc has been a valued supplier to the global power generation industry since
1990. Granite Services, Inc is certified to ISO 9001:2000 and employs over 3,000 engineers and
technicians, with services in commissioning, operations, maintenance, and training. Our safety
record is superlative.

Table of Contents
Introduction..................................................................................................................................... 1
1 Design and Procurement Phases ............................................................................................. 1
2 System Turnover (from Construction to Commissioning) ..................................................... 5
3 Component Testing................................................................................................................. 5
4 System Commissioning .......................................................................................................... 8
5 Operational Testing............................................................................................................... 13
6 System Turnover (from Commissioning to the Owner) ....................................................... 16
7 Conclusion ............................................................................................................................ 17
8 Bibliography ......................................................................................................................... 17

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Introduction
A combined cycle power plant (CCPP) has one or more combustion turbine generators (CTG’s),
corresponding heat recovery steam generators (HRSG’s), and one or more steam turbine genera-
tors (STG’s). A new CCPP has the following phases: contract negotiation, design, procurement,
construction, commissioning, and operation. The commissioning of the CCPP is the final quality
check of all the previous processes.

Table 1, Commissioning Steps The safety of site personnel is the highest priority for the
Turnover From Construction commissioning team. They ensure the safety equipment is
Component Testing
System Commissioning ready, such as eye wash stations, safety showers, and fire-
Operational Testing fighting equipment. They train the site personnel to per-
Turnover To The Client
form work in compliance with the safety program.
1 Design and Procurement Phases
The commissioning team works in the office of the architect/engineering (A/E) company during
the design and procurement phases of the project. We recommend one or two trips to the CCPP
during this phase, to assess construction status. The team performs the following steps while in
the office.

1.1 Contract Review

The commissioning team reviews the project contract. They identify the commissioning deliver-
ables, milestone activities, inspection and test requirements, safety requirements, budget allow-
ances, training requirements, craft support, and vendor representative requirements.

1.2 Schedule

The commissioning team reviews the project schedule and integrates the commissioning activi-
ties. The team merges each system turnover date within the project schedule. The high priority
schedule activities are temporary power or backfeed power, HRSG chemical cleaning, steam
blow of the steam piping, loop checks, first fire of the CTG’s, condenser vacuum and rolling the
STG, synchronizing the generators, scheduled outages, full load testing, and commercial opera-
tion. During the commissioning phase, the commissioning team constantly checks their progress
against the planned schedule, and makes improvements as necessary. (Note: The schedule in Fig-
ure 1 is for display only, and does not represent any particular plant.)

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Figure 1 - CCPP Commissioning Schedule (for display only)

1.3 Budget

The commissioning costs are: manpower and duration; personnel expenses, such as salaries,
transportation, per diem, and living accommodations; vendor representatives; craft support;
chemical cleaning; consumables; chemicals; lubricants; spare parts; tools; equipment; security;
and contingencies.

1.4 Project Review

The commissioning team reviews the project design using the piping and instrumentation dia-
grams, electrical one-line diagrams and schematics, logic diagrams, and vendor manuals. They
assess commissioning feasibility, operability, and maintainability. They collect lists for mechani-
cal and electrical equipment, instruments, and piping, in order to build the turnover packages.
The commissioning team also reviews the water sources; the disposition of waste water; tempo-

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rary equipment; fuel specifications and consumption; maintenance requirements; interface be-
tween the new project, the electrical transmission system, or an existing project. They also re-
view the schedule for inspectors from government agencies or insurance companies.

1.5 System Turnover Packages

The commissioning team marks engineering drawings with the boundaries of each system. They
identify all the equipment, pipes, cables, and instruments in each system. At the jobsite, the con-
struction team adds their inspection and test records to these packages. (See Figure 2.) After the
system turnover, the commissioning team will control the records in the packages.

P&ID’s
Electrical
one-line
diagrams
Loop
Electrical
diagrams
equipment list
Client accepts the
1 6
system
Mechanical
equipment list Commissioning team
creates the packages
Instrument list

System Turnover Package

5 Commissioning
Meter and relay punch list
tests
Instrument
Construction puts their Client/
Calibrations
data in the packages. commissioning
walk down
Hydrostatic tests Rotating
equipment 2
alignments

Cable continuity Commissioning puts their

checks data in the packages.
Instrument
Construction/ calibrations
commissioning walk
Megger checks 3 down 4 Performance data

Construction Lube oil flush

punch list inspections
Pump data

Electrical interlock
Loop checks
check lists

Figure 2 - System Turnover Package

1.6 Commissioning Manual

The commissioning team creates the commissioning manual and maintains document control.
The manual contains:
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COMMISSIONING COMBINED CYCLE POWER PLANTS

• Procedures for safety tagging, work permits, hot work permits, fire protection measures,
safety equipment, and confined space entry.
• The “Matrix of Responsibilities,” which determines the scope of work between construction
and commissioning. The commissioning team identifies the responsibilities of each project
team member (A/E, construction, commissioning, and plant owner).
• Administrative procedures. The system turnover interface needs to be very clear. The plant
owner reviews and may approve the commissioning data.
• Procedures to attain and verify the cleanness level required for each system piping and
equipment.
• Procedures to demonstrate that each system operates within design parameters.
• Procedures for electrical power to the switchyard or substation and to the plant distribution
system; also a procedure to track jumpers and lifted leads.
• Checklists for instrument calibrations and loop checks.
• Integrated tests of the entire facility (all systems in operation).
The A/E team specifies the test criteria: (1) calculated, (2) international or national standards, or
(3) the vendor’s specification. The A/E electrical engineer specifies the meter and relay settings
in the relay coordination study. The A/E instrument engineers provide instrument calibration set
points. The A/E mechanical engineer determines the systems’ cleanness criteria, material or flow
balances, and vibration criteria.

1.7 Purchasing and Subcontracts

The commissioning team reviews the vendor representative requirements and arranges for the
vendors to arrive at the job to meet the schedule. Some vendor representatives are included in the
original equipment purchase orders while others may be subcontracted by the commissioning
team.
The team prepares requisitions or rental agreements: craft support, chemicals, lubricants, test
equipment, chemical analysis equipment, water supply, fuel supply, tools, storage containers,
temporary pumps, spare parts, consumables, vehicles, office space, radios, and transportation for
personnel. They also setup subcontracts for electrical testing, HRSG chemical cleaning, instru-
ment calibration, and other services, as required. They will also need office space, communica-
tion equipment (phones, facsimile machines), equipment storage, and a laydown area.
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1.8 Training

Some clients purchase training for their operations and maintenance personnel. The commission-
ing team develops the schedule and format for the training, selects required vendors or training
agencies, and generates the training manuals.
2 System Turnover (from Construction to Commissioning)
2.1 System Turnover Packages

The construction team builds the power plant by area (e.g., the fuel storage area). As work pro-
gresses, the construction team changes their focus to systems (e.g., the fuel oil forwarding sys-
tem). When a system is “mechanically complete,” the construction team completes the system
turnover package and submits the package to the commissioning team.

2.2 System Walk Down

A joint construction and commissioning walk down of the system verifies all work within the
boundaries is complete. Any incomplete work items go into the punch list. The construction team
finishes those items later, under the commissioning work permit program.

2.3 Punch List Table 2, Comparing ISO 9001:2000 and Commissioning

ISO 9001:2000 Commissioning
The punch list records each non- Quality Management System Commissioning Plan
Document Control Commissioning Manual
conformity. It shows the system, Control of Records Turnover Packages
the component tag number and de- Management Responsibility Matrix of Responsibilities
Resource Management Schedule, Budget
scription, a definition of the dis- Service Realization Inspection and Test Reports
crepancy, the work group responsi-
Measurement, Analysis, Im- Schedule Review, Audits
ble for fixing the deficiency, and provement
Nonconformity Punch List
the dates that the item was gener-
ated and closed.
Project management integrates the punch lists from the various work entities into one master list,
to optimize the scheduling of equipment and manpower.
3 Component Testing
Depending on the contract, the construction team performs some of the component tests and the
commissioning team performs others. Some tasks may be subcontracted. The project manage-
ment reviews the “Matrix of Responsibilities” and each organization’s goals.
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3.1 Nameplate Data

Before testing any component, verify the nameplate data against the design documentation.

3.2 Alignment

Align rotating equipment to the manufacturer’s tolerances before operation.

3.3 Lubrication

Lubricate equipment before commissioning. Follow the manufacturer's instructions. Equipment

may have a factory-installed lubricant that protects the equipment during shipping and storage.
Replace factory lubricant with the normal lubricant.

3.4 Pumps

Review the vendor manual before operation. Verify the correct direction of rotation for the pump
and the driver. Test pumps in accordance with a standard test program. Compare centrifugal
pump capacity versus the head on the pump curve. Test positive displacement pumps for the ca-
pacity measurement by volume rate of flow.

3.5 Flushing

If possible, inspect the pipes prior to welding to guarantee there are no foreign objects in the
pipe. In cold climates check the freeze protection prior to filling any liquid systems. Before
flushing, bypass any heat exchangers to prevent debris from entering. Because the flow rate
drops in the heat exchangers, any debris will settle, and the heat transfer capability of the heat
exchangers is diminished. Remove instruments, orifice plates, and control valves prior to flush-
ing. If the installed pumps are not ready for flushing, use temporary pumps instead. Flush the
pipes, and inspect the system for cleanness verification. Restore the system and make prepara-
tions for system operation.
For some systems, chemical cleaning may be faster than flushing with the process fluid.

3.6 Heat Exchangers

Tighten the bolts on one end of a heat exchanger, and ensure the other end is free to travel for
thermal expansion, per the vendor instructions. Check the bolts during the initial inspection.
Even large heat exchangers, such as air-cooled condensers, must be checked for movement.

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3.7 Cleaning of HRSG’s and Steam Headers

After hydrostatic tests, clean the HRSG’s. The traditional cleaning cycle: degrease, perform cit-
ric acid cleaning; rinse; run CTG’s; clean the steam headers by steam blows; bypass the STG un-
til chemistry is satisfactory; and send steam to the STG. The drawback is high water usage.
An alternative: degrease, clean the HRSG’s and the steam system with hydrofluoric (HF) acid,
rinse, run CTG’s, bypass the STG until chemistry is satisfactory, and send steam to the STG.
This method has a shorter duration on the schedule. The drawback is the safety issues of HF.
Another alternative: rent air compressors, pressurize the HRSG’s with air, and use a quick-
opening valve to blast the pipes. Air blows can also shorten the overall schedule since the blows
are conducted off the critical path. The drawback is the cost of the air compressor rental.

3.8 Motors

Energize the internal heaters on large motors, generators, and motor-operated valves with tempo-
rary power, until permanent power is available. Verify insulation resistance of large motors and
generators. Uncouple electric motors, check lubrication, and verify proper motor rotation and
vibration. Couple the motors. Check motor parameters again during normal operation.

3.9 Cables, Switchgear, and Motor Control Centers (MCC’s)

Test cables for continuity and insulation resistance. Perform hi-pot testing on switchgear and
MCC’s. Test breakers and switches. Verify all alarms, interlocks, and trip circuits.

3.10 Transformers and Switchyards

A subcontractor or other third-party inspects and tests the transformers, bushings, circuit break-
ers, and disconnect switches. Condition the oil in oil-filled transformers, HV bushings, and cir-
cuit breakers to remove vapors and water. Test all disconnect switches.

3.11 Electrical Meters and Relays

A subcontractor or third party calibrates and tests the meters and relays. Lookup the set points
for trips and alarms in the design engineer’s coordination study.

3.12 Maintenance

The commissioning team performs maintenance, and they train the plant maintenance personnel.

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3.13 Instrumentation

Inspect and calibrate the instruments in the shop. The instruments may also be calibrated in–situ.

3 Verify valve travel

M
2
Verify indication Figure 3 - Loop Checks
Output
at DCS
Output 3.14 Loop Checks
Process
I/O
Fluid
Vessel Level Input DCS
Rack There are thousands of loops in a
Xmtr Input

CCPP, depending on the design and

1 Inject process
simulation here degree of automation. Provide the
correct number of experienced per-
sonnel to complete the loop checks on schedule. Perform loop checks from “end to end,” from
the instrument to the control system and then to the control device. Test all control, alarm, and
trip signals before operation.

3.15 Training

The commissioning team and vendor perform classroom training and on-the-job training for the
plant operators and maintenance personnel during the component testing.
4 System Commissioning
When starting systems, start them by “group.” The cooling water group might be circulating wa-
ter (CW), auxiliary cooling water (ACW), and closed circuit cooling water (CCCW). Another
group might be the condensate and feed water systems. This technique speeds up the schedule,
since the similar systems will work together quicker if handled as a group.

4.1 DC Power and UPS System

Direct current (DC) power is the first electrical system to energize. The specifications may re-
quire a load test on the DC system. The commissioning team rents load banks for this test. Apply
temporary power to the battery chargers. Ventilate the battery room to exhaust hydrogen gas
from the charging process. Verify an eyewash station is available for personnel safety. Now start
testing the electrical distribution switchgear controls and meters and relays.
Connect a temporary power supply to the uninterruptible power supply (UPS) backup, for emer-
gency power. Now begin the controls systems commissioning.
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4.2 Initial Electrical Power

Energizing the plant distribution system requires planning between the plant and the local trans-
mission system. Due to the schedule, backfeed power may not be available to support commis-
sioning. In that case, rent diesel generators and transformers to provide temporary power. Other
systems may also require temporary power (e.g., CTG lubricating oil pump).

4.3 Distributed Control System

Perform the checkout of the distributed control system (DCS). Check the DCS ground connec-
tion. Energize each processor and load software. Setup the human machine interface. Perform
component and functional checks. Establish communications with other control systems. Per-
form loop checks. Conduct loop tuning as systems become operational.

4.4 Instrument Air/Service Air

The first mechanical system in operation is the instrument air system. Inspect the moisture traps
on the discharge of the air compressor. Make sure they are installed correctly and operating.
Monitor the system humidity indicator. While blowing the air distribution piping, monitor the air
dryers for excessive flow rates. Blow the piping until clean, dry air is ready at each instrument.

4.5 Water Treatment

The second mechanical system in operation is the water treatment system. Prior to adding the
resin to a demineralizer vessel, inspect the vessel interior and the resin screens. Test the regen-
eration control sequence, adjust the rinse rates, and adjust the chemical dilution rates. Purchase
an eductor to sluice the resin into the vessels. Verify the safety eyewash and showers are avail-
able for use. Ensure all required chemicals are on hand.
Clean the chemical feed systems meticulously prior to operation. Any debris in the piping can
upset the diaphragm-type pumps. Provide the proper chemical analysis equipment. A rented
cargo container often suffices for a temporary chemistry laboratory, with the various utilities
connected.

4.6 Waste Water Treatment

At “zero discharge” projects, the waste water treatment system can be complex. Do not underes-
timate the manpower to commission and maintain the system. Test all sumps for proper alarm

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and pump control. Test the oily water separating device early in the commissioning sequence,
since there may be some oil in the sumps.

Exhaust

Aux
Steam Drum Steam Air & Gases
Stop/Control
STG
Air &
Air Gases ST Bypass G
Fuel
Air Ejectors
Aux Steam
Sea Water Out
G
Sea Water In
Deaerator
CTG
Condenser
Exhaust Duct HRSG
(Not all modules shown)
Boiler Feed Water Pump

Condensate Pump

Figure 4 - CCPP Prime Movers and Balance of Plant Systems

4.7 Fire Detection and Protection

The installation subcontractor tests the fire detection system. Inspect or test all sprinklers, deluge
valves, and gas discharge systems. A government inspector or an insurance company inspector
may witness the testing.
After the water supply system is running, start the fire pumps. Place the motor-driven and/or die-
sel-driven fire pump in the automatic mode. Monitor the jockey pump for frequent cycling; it
may mean there is a leak in the fire main. Calibrate the post indicator valves to show the correct
position.
Test the CTG’s fire suppression systems, such as CO2 or FM200, before initial operation. These
systems may be in the control cabinet or in the turbine housing.

4.8 Cooling Water

Verify the circulating water pump discharge valve sequence prior to starting the pump. Throttle
the outlet valves on the water boxes to set the proper flow. Circulating pump seal water, for lu-
brication of the pump packing, may need a temporary backup system. The water boxes may have
sacrificial zinc anodes. Check the anodes after initial operation for integrity. Inspect fittings on
the seawater side. Make sure materials are compatible with seawater. Install corrosion coupons.
Start any cathodic protection systems as soon as the system is filled with seawater.
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If there is a water box priming system, start it early in the program. Otherwise, air pockets pre-
vent the tubes from filling with seawater.
If the project has cooling towers, inspect the spray nozzles, distribution headers, and “fill” mate-
rial before starting. After the first use, check again to make sure there are no problems created by
the force of the water, such as loose fittings. Monitor pump strainers closely. Check cooling
tower fans for vibration and monitor gearboxes for proper lubrication. Place a wooden cooling
tower’s fire protection system in service as soon as possible. Once a wooden cooling tower is put
in service, keep it wet so that it does not dry out and become a fire hazard.

4.9 Steam, Feed Water, and Condensate

Test the condensate pumps and the control valves. Some pumps require an external source of
seal water, and may require installation of a temporary system.
Inspect the deaerator before use. Install the trays in the proper orientation. Remove the spray
nozzles. Flush the piping into and out of the deaerator. Inspect the deaerator again. Remove any
debris from the storage vessel. Install the spray nozzles. After initial operation, inspect the
deaerator one last time. Check the spray nozzles and trays.
Monitor the strainer feed water pump suction strainer carefully during initial operation. Inspect
the minimum flow valve and any minimum flow orifices to make sure the recirculation flow is
proper. If the pump has an automatic recirculation valve in the discharge, remove the valve for
the initial operation, or (in some cases) install a special “commissioning trim” for initial opera-
tion.
Inspect all steam traps for proper cycling. After initial operation, disassemble and clean steam
traps that have internal strainers. Traps that don’t operate properly can cause bigger problems.

4.10 Heat Recovery Steam Generators

Test all valves and pumps on the HRSG’s. Test the duct burner controls. Some plants run the
CTG in “simple cycle” mode by means of a stack damper and a bypass stack. Test the stack
damper for any leakage into the HRSG. Check all interlocks and alarms. Inspect all safety
valves, exhaust piping, silencers, and any associated drain piping.
If the CTG’s burn crude oil or some other heavy oil, the HRSG’s may have soot blowers. The
alignment and lubrication of the lances are critical to smooth operation.

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4.11 Sample Panels

Put the sample panels in service after the systems are clean. Until then, create temporary sample
coolers. Monitor the pressure regulating valves and other small passages for plugging.

4.12 Fuel Systems

Perform leak tests with air before the fuel gas comes inside the plant. Test the installed gas moni-
tor using a calibrated gas. Start the hot work permit program. Purge with nitrogen prior to admit-
ting gas. During operation, verify the fuel gas temperature is above the dew point. If there are
liquids in the gas then the expansion at the pressure letdown station causes the temperature to
drop. Freezing can occur.
Inspect the coatings and special hardware, such as floating suction apparatus or siphon breakers,
prior to filling the tank. Flush the pipes using a high velocity flow. Run the fuel forwarding
pumps to flush the oil supply lines to the CTG’s.

4.13 CTG’s

In most plants the commissioning of the CTG is the responsibility of the turbine vendor. The
vendor representatives test the electrical circuits, run the pumps and fans, flush and clean the sys-
tems, and calibrate the instruments. Completed test records go into the CTG turnover package.
For lubricating oil flushing, ensure the area is free of dirt and construction debris (especially the
reservoirs and bearings). Install temporary power, lighting, and fire protection. Prepare for oil
spills before they happen. Have sufficient adsorbent compound, rags, plastic bags, squeegees,
and barrels on hand. Purify the oil before filling the reservoir. Even brand new oil shipments
have debris in the oil. Perform the flush. Use temporary pumps and filters for better results. Re-
place the flushing oil with new oil. Restore the piping.
The turbine control systems need a temporary power supply to checkout the circuits early in the
commissioning program.

4.14 Steam Turbine Generator

The vendor’s personnel commission the STG. The effort occurs later in the schedule, so perma-
nent power is usually available for testing the STG equipment. Conduct the lubricating oil flush.
Test the control systems. Place the turbine on the turning gear for steam blows.

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4.15 Air Conditioning and Ventilation

Degradation of these systems can have an adverse impact on DCS equipment. Use good quality
air filters and replace them regularly. Condenser coils may need frequent cleaning.

4.16 Piping

Before the initial heat up, inspect the steam headers, other pipes, and supports. Unlock and adjust
all spring hangers. While preparing for CTG first fire, setup the temporary steam piping for the
steam blows. Install necessary pipe insulation.

4.17 Administration

Every day, the project leaders conduct a commissioning meeting and the commissioning team
reviews the “Plan of the Day.” They discuss safety topics, the events planned for the day, and the
support required. They determine the expected power output and fuel needs. They monitor the
schedule and budget. The commissioning team issues the “two week look-ahead” schedule. Once
a week, at the project punch list meeting, the various team leaders review the status of all the
punch list items.

4.18 Training

The commissioning team trains the operators and maintenance personnel in “hands-on” sessions.
5 Operational Testing
5.1 First Fire

The CTG is ready for first fire after successfully completing control sequence checks, cranking
checks, emergency shutdown checks, false-fire checks, fire detection and protection tests, and
turning gear checks. During the first fire operation, vent steam from the HRSG drums and super-
heater vents. Perform the various tests in Table 3 during the operational testing phase.

5.2 Steam Line Cleaning

After achieving stable operation on the CTG’s, perform steam line cleaning. Calculate the pres-
sure required for each blow. Make targets from polished mild steel or copper. Use jeweler’s
rouge to polish them. Place a target in the outlet of the piping. Compare the number and size of
impacts on the target to the criteria of the steam turbine vendor. Portable demineralizers may be
necessary to produce water for steam blows.
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5.3 STG Bypass

During operation the steam temperature should not be too high in the superheated region, as the
condenser structure may overheat. The steam should not enter the saturated range. This heavier
steam may cause aerodynamic problems, cracking of the tubes, or damage to the bypass valve.
Dump steam to the condenser until it is clean, and then roll the STG.

Table 3, CTG Initial Operation Check List (Typical)

1 Overspeed test 2 Zero speed to full-speed- 3 Manual trip functional test
no-load (FSNL) sequence
test
4 Exhaust temperature trip 5 Igniter checks 6 Air inlet checks
and sequence checks
7 Starting checks (listen for 8 Test emergency STOP 9 False start checks
rubs, unusual noises) pushbutton (purge/fire sequence with
ignition spark plugs pulled;
verify unit shutdown on
flame failure)
10 First fire on fuel gas 11 Manual trip test 12 Fuel gas pressure control
calibration
13 Ignition cross fire checks 14 FSNL 15 Off-line excitation checks
16 Phase sequence checks 17 Synchronization checks 18 Synchronization
19 On-line excitation checks 20 Commission fuel gas 21 Test evaporative cooler
heater system
22 Test inlet filter cleaning 23 Fuel strainer removal 24 Perform water wash
system
25 Base load tuning 26 Liquid fuel false start test- 27 Liquid fuel first fire
ing
28 Liquid fuel FSNL and syn- 29 Load to base load and 30 Fuel transfer tests
chronize conduct water or steam in-
jection tuning
Note: Some CTG’s may be configured differently.
5.4 Thermal Expansion

During the initial heat up verify the proper direction and amount of thermal growth.

5.5 Generators

Test the generator excitation, meters, and relays. Verify the trips and interlocks. Perform a pres-
sure test on the hydrogen cooling, purge with CO2, and pressurize with H2 to the prescribed con-
centration. Synchronize the voltage and frequency to the grid. Close the generator breaker.

5.6 Condenser Operation

If the condenser has excessive air in-leakage, subcontract a specialist to use a helium detector to
detect leakage. Install the detector at the air removal vent. Spray helium on all the joints.

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5.7 Special Situations

Sometimes it is undesirable to shutdown the plant to fix a leak. Special subcontractors use tem-
porary fittings to stop leaks. These repairs work on high pressure steam systems, circulating wa-
ter systems, or even cooling systems. Another technique is a “freeze seal.” Liquid nitrogen
freezes the process fluid to isolate a section of pipe. “In-place machining” subcontractors repair
flanges or valves by bringing their equipment to the plant and performing the repairs in place.

5.8 Plant Outages

Some work items require a long shutdown. The schedule includes some long activities, such as
removing the strainers from the STG inlet valves, or pulling the strainers from the CTG fuel
lines. Schedule the work like a regular plant outage: work permits, materials, and personnel. If
the plant trips without notice, perform any known short work items.

5.9 Performance Testing

Perform heat rate testing when the plant is new and clean. The protocol from the A/E identifies
the temporary and permanent plant instruments to collect data. Calibrate the instruments to vali-
date their accuracy and tolerances. Verify the fuel gas heating value and chemical composition
by analyzing actual samples. Calculate the net plant heat rate. If necessary, the A/E supplies cor-
rection curves to calculate the adjusted heat rate. Use the data to determine plant performance
losses during the life of the plant.

5.10 Emissions Testing

The HRSG stack emission testing protocol (prepared by the A/E) validates the emission limit
guarantees in terms of nitric oxide (NO) and nitrous oxide (NO2), or NOX; particulates; carbon
dioxide; carbon monoxide; excess ammonia slipping past the selective catalytic reduction mod-
ules; particulates, in microns; volatile organic compounds (e.g. methane); and sulfur. Local or
national agencies specify emissions testing parameters and criteria.

5.11 Contract Testing

The contract may require some of the following tests:

5.11.1 STG and CTG Overspeed Tests
Perform at least two overspeed tests (one on each circuit).

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5.11.2 CO2 Concentration Tests

Test the CTG fire suppression system by activating the heat detection sensors. Measure the
CO2 concentration in the turbine housing.
5.11.3 Electrical Full-Load Rejection Test
Demonstrate the ability of the CTG’s and the STG to shed load. The turbines should not trip
on overspeed and will run down to full-speed-no-load. One of the CTG’s may be configured
to runback and implement a safe shutdown.
5.11.4 Duct Burner Testing
Test duct burners at full-fire capability only after the CTG is at base load. For this reason, the
duct burners are frequently the last system to commission and are on the critical path to pro-
ject completion.
5.11.5 Partial Load Stability Test
This test measures the plant’s lowest megawatt output operation. The output should be stable
and the stack emissions should stay in compliance with the air permit.
5.11.6 Reliability Test
This test proves the plant can operate continuously, with no emergency trips, for a period of
perhaps 7 to 30 days. Other variations of this test: repeated starts and shutdowns, hot and cold
re-starts with fast loading, unit maneuvering, STG extraction steam tests, and peaking opera-
tion tests.

5.12 Training

The commissioning team trains the operators on steady-state operation, emergency response, and
startup and shutdown of the units. The operators should exhibit more self-reliance during this
phase, and the commissioning team acts in a more supervisory role.
6 System Turnover (from Commissioning to the Owner)
The turnover from commissioning to the plant owner follows the same methods as the turnover
from construction to commissioning.

6.1 System Turnover Packages

Add the commissioning records for each system to the construction packages. Include the com-
pleted system procedures, testing data, and the performance test reports.
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COMMISSIONING COMBINED CYCLE POWER PLANTS

6.2 System Walk Down

Conduct walk downs in the same manner as those done in the construction turnover. Note any
incomplete work on the punch list. Complete those work items later, under the owner’s work
permit program. Add the punch list to the package. Verify all work is correct as specified and is
ready for client approval.
7 Conclusion
Commissioning personnel started many CCPP’s during the past few years, and the various teams
around the world assembled a fairly standard method of commissioning. That method uses the
historical groundwork of the electrical utility fossil and nuclear plant commissioning, modified
to match the needs of the modern CCPP. Experienced commissioning personnel are ready to
meet the future technical demands and challenges.
8 Bibliography
Note: These documents are typical of those that may be used to develop the acceptance crite-
ria for commissioning. Check the individual plant contract to determine which documents
are required for the project.
1) Acceptance Testing Specifications for Electric Power Distribution Equipment and Sys-
tems: 2003. InterNational Electrical Testing Association.
2) ANSI/HI Pump Standards: 2005. Hydraulic Institute.
3) ISO 9001:2000, Quality Management Systems: 2000. International Organization for
Standardization
4) Performance Test Code Series: Various dates. American Society of Mechanical Engi-
neers.

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