t10206-dn02-p1mkg__810001 generator h2 & co2 control system_rev.c
DESCRIPTION
lTRANSCRIPT
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FOR COMMENT
C 08-NOV-14 D.H Han K.H Jung J. Kim For Comment
B 03-NOV-14 D.H Han K.H Jung J. Kim For Comment
A 20-JAN-14 D.H Han K.H Jung J. Kim For Comment
Rev Date Prepared Checked Approved Details of Revision
Owner
Consultant
Contractor
Project :
MONG DUONG II 2 x 560MW(NET)
THERMAL POWER PLANT
PC
T10206
UAS
DN02
UNIT
P1
Title
COMMISSIONING PROCEDURE
FOR
GENERATOR H2 & CO2 CONTROL SYSTEM
KKS
MKG
Reg. No.
810001
Rev.
C
Document No.
T10206-DN02-P1MKG-810001 Pages No.
19
AES-VCM MONG DUONG
POWER COMPANY LIMITED
Doosan Heavy Industries & Construction Co., Ltd
POWER ENGINEERING CONSULTING
JOINT STOCK COMPANY 2
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Rev. C
Page 2 of 19
TABLE OF CONTENTS
1.0 GENERAL INFORMATION ........................................................................... 4
1.1 Objective ........................................................................................................ 4
1.2 Scope ............................................................................................................ 4
1.3 Job Safety Analysis and Risk Assessment ..................................................... 4
1.4 Reference Documents / Drawings .................................................................. 5
1.5 System Description ........................................................................................ 5
1.5.1 H2 & CO2 Control System ............................................................................. 5
1.5.2 H2 Gas Dryer ................................................................................................. 5
2.0 PRE-COMMISSIONING ................................................................................. 6
2.1 Pre-Commissioning Requirements ................................................................. 6
3.0 H2 & CO2 SYSTEM COMMISSIONING ........................................................ 7
3.1 Commissioning Requirement ......................................................................... 7
3.2 Line Flushing of Generator H2 & CO2 Control System .................................. 7
3.3 Purge Procedure of Generator ....................................................................... 8
3.4 Generator Hydrogen System Valve List ....................................................... 14
3.5 Generator Hydrogen System Flow Chart ..................................................... 15
4.0 H2 GAS DRYER COMMISSIONING ............................................................ 16
4.1 Start-up ........................................................................................................ 16
4.2 Shutdown ..................................................................................................... 17
5.0 ATTACHMENTS.......................................................................................... 19
Attachment 5.1 Checklist for Commissioning of Valves
Attachment 5.2 P&ID
Attachment 5.3 Measurement, Alarm and Trip List
Attachment 5.4 Valve Position Status for Commissioning
Attachment 5.5 Job Safety Analysis
Attachment 5.6 Risk Assessment
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Rev. C
Page 3 of 19
LIST OF ABBREVIATIONS
CCR : Central Control Room
DCS : Distributed Control System
H2 : Hydrogen
CO2 : Carbon Dioxide
TCS : Turbine Control System
TE : Turbine End
CE : Collector End
PRV : Pressure Regulating Valve
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Rev. C
Page 4 of 19
1.0 GENERAL INFORMATION
1.1 Objective
The purpose of this document is to provide a systematic guideline to commission Generator
H2 & CO2 Control System.
1.2 Scope
The scope of commissioning of Generator H2 & CO2 Control System covers the following
activities and associated equipment list.
1.2.1 Checking the completeness of all Equipment / Sub-systems required for commissioning of
Generator H2 & CO2 Control System. Equipment list includes the followings:
SL. No. Equipment List Tag No.
1 H2 Manifold -
2 CO2 Manifold -
3 Gas Control Valve Station
4 Hydrogen Control Cabinet MKG20GH001
5 Hydrogen Gas Dryer MKG16AZ001
6 Liquid Detector MKG10AZ001
1.2.2 Checking the integrity & readiness of all associated piping, valves and other fittings,
instrumentation and control system.
1.2.3 Checking completeness of all the electrical connections and associated protections.
1.2.4 Checking the operation of individual valves and instruments.
1.2.5 Checking various control loops and their response.
1.2.6 Checking the protection and functional interlocks of electrical / mechanical equipment in the
system.
1.2.7 Checking cleanliness of the system and ensuring that it is free of any foreign material or dirt,
which may damage the equipment or impair the system functionality.
1.2.8 Trial operation of the entire system and confirming the design parameters of the system such
as flow, temperature and pressure.
1.3 Job Safety Analysis and Risk Assessment
Job Safety Analysis and Risk Assessment have been checked before commissioning.
Refer to Attachment 4.5 & 4.6.
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Rev. C
Page 5 of 19
1.4 Reference Documents / Drawings
1.4.1 P&ID
SL. No. Doc. / Drawing No. Title
1 T10206-XG11-P1MKG-210001 H2 & CO2 Control Piping Diagram
1.5 System Description
1.5.1 H2 & CO2 Control System
The gas control system has the dual function of supplying hydrogen (H2) to the generator as required to maintain selected pressure and to supply carbon dioxide (CO2) and H2 to the generator for purging and filling operations. The CO2 gas is used as intermediate median in order to prevent hydrogen gas from mixing air. Therefore there will be not hydrogen gas and air mixture If air is filled inside of generator, CO2 gas will be supplied to purge air and the generator will be filled with CO2 gas. After then the hydrogen gas will be supplied to purge CO2 gas and the generator will be filled with hydrogen gas. H2 will be filled up from generator top and purge CO2 at the bottom, CO2 will be filled up for generator bottom and purge H2 at the top.
1.5.2 H2 Gas Dryer
Hydrogen Gas Dryer Package regenerates moisture by heating with the heater in the Tower. After regenerating, the regenerated gas joins the gate gas. The heating process in the regeneration process heats the absorbent using the hot gas from the heater in the tower, and the cooling process cools down the absorbent by ramifying some of the gate humid gas. After heating or cooling the absorbent, the regenerated gas joins the gate humid gas at the orifice and enters the operation tower through the regeneration cooler and moisture separator. The main components are Drying Tower, Piston Control Valve, Electric Heater, Fin Cooler and Separator, and which are operated automatically every 16 hour on the TIMER (HMI) attached on the CONTROL PANEL. Operation Chart
Time (hour)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Tower A Operation Regeneration (Heating) Regeneration
(Cooling)
Tower B Regeneration (Heating) Regeneration
(Cooling) Operation
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Rev. C
Page 6 of 19
2.0 PRE-COMMISSIONING
2.1 Pre-Commissioning Requirements
2.1.1 Pre-requisites for the commissioning
The entire system has been thoroughly checked after erection. All leaks that were
detected have been rectified.
All Valves listed in Attachment 4.5 have been functionally checked and their trial
operation is found to be satisfactory in accordance with Attachment 4.2, Commissioning
of Valves.
Electric power system has been tested, energized and available for required equipment.
All instrumentation required for control, supervision & monitoring through DCS are
available. (All instruments have been commissioned after their respective impulse lines
are properly flushed with the working fluid.)
2.1.2 Proper communication facilities like walkie-talkies, telephone, system, etc. between various
control stations and Central Control Room have been installed and checked.
2.1.3 All necessary safety precautions and measures must be followed for safe commissioning
activities.
Personal Protective Equipment is available for commissioning personnel.
Warning signs are placed in all concerned operating areas.
Portable Fire extinguishers or permanent fire-fighting systems are available at critical
location.
Manual Call Points are installed at critical locations to inform the CCR in case of any fire
hazard.
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Rev. C
Page 7 of 19
3.0 H2 & CO2 SYSTEM COMMISSIONING
3.1 Commissioning Requirement
SL No.
Description Checked
( / X) Remarks
1 Ensure that the Instrument air system is available for line flushing.
2 Ensure that sufficient CO2 is available to purge all H2 in event of emergency.
3 Ensure that the seal oil system is in operation.
4 Please check to the Float Trap Operating & Maintenance Manual.
3.2 Line Flushing of Generator H2 & CO2 Control System
SL No.
Description Checked
( / X) Remarks
1
Ready to the flushing
Close all valves of generator and Hydrogen control cabinet for the air not to flow into the system.
2
CO2 Gas line flushing
Connect the air supply line.
After selecting the CO2 side of MKG02AA108 (HV-2955B) valve, Remove the MKG07AA101 (IV-2928) valve and flush these piping lines.
3
CO2 Manifold line flushing
Separate CO2 pig tail and open MKG04AA101 (HV-2946) valve. Open 8 valves above pig tail step by step, flush these lines.(MKG03AA101~108)
4
H2 gas line flushing
Remove the SP-H2 and Connect the air supply line.
After selecting the H2 side of MKG02AA107 (HV-2955A), Remove the MKG06AA101 (IV-2927) valve and flush these piping lines.
5
H2 Manifold line flushing
Separate H2 pig tail and open MKG01AA110, 111, 112, 113 (HV-2920A/B, 2921A/B), MKG01AA081, 082 (PCV-2920A/B) valves.
Open 8 valves above pig tail step by step, flush these lines. (MKG01AA101~108)
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Rev. C
Page 8 of 19
SL No.
Description Checked
( / X) Remarks
6
Liquid Detector line flushing
Connect the air supply line.
After selecting the CO2 side of MKG02AA108 (HV-2955B) valve,
Open MKG07AA101(IV-2928) valve and pressurize the inside of generator as 2 kg/cm
2
Open MKG10AA105 (IV-2920), MKG10AA104 (IV-2923), MKG10AA103 (IV-2924), MKG10AA107 (IV-2950), MKG10AA101 (IV-2932), and MKG10AA106 (HV-2990), MKG10AA403 (HV-2991) valves.
And then flush these lines.
7
Gas Dryer line flushing
Open MKG09AA101 (IV-2925), MKG08AA101 (IV-2926) and pressurize the piping.
Open MKG09AA401/402 (IV-2935/2936), MKG08AA401/402 (IV-2937/2938) and flush these lines.
8
Vent pipe line flushing
Select the vent side of MKG02AA107 (HV-2955A) valve.
Open MKG02AA110 (HV-2954) valve, MKG15AA101 (HV-2963) for upper pipe flushing and MKG15AA401 (HV-2952) for lower pipe flushing.
3.3 Purge Procedure of Generator
SL No.
Description Checked
( / X) Remarks
Purge Procedure of Generator
(Replace the Air with CO2, Air CO2)
1 Refer to Air to CO2 in Section 3.4 Generator Hydrogen system Valve List.
- During operation of turning gear and Seal oil system.
2
Operate valves to purge the air as bellow. - MKG04AA101 (HV-2946) : Throttle Open - MKG02AA107 (HV-2955A) : Down (Valve Handle) - MKG02AA108 (HV-2955B) : Down (Valve Handle) - MKG02AA110 (HV-2954) : Open (Vent Valve)
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Rev. C
Page 9 of 19
SL No.
Description Checked
( / X) Remarks
3
Connect CO2 bottles to CO2 manifold. NOTE: - If the pressure of generator is below approx. 0.35
kg/cm2, the float trap in the seal oil system is by-pass
operated. (The pressure change is monitored by the oil level of float trap.)
- Monitor the oil level of float trap until normal operation. (The oil level of level gauge (MKW13CL502) shall be monitored at medium level and if oil level falls below medium level, close bypass valve (MKW13AA104) immediately to prevent CO2 gas from escaping.)
- Please refer to the Float Trap Operating & Maintenance Manual.
4
Check the differential pressure (MKW10CP501 (PDI-3402)) between seal oil and CO2 as generator gas pressure increase.
- P: 0.56 kg/cm2
5 Adjust the flow control valve (MKG20AA115/116) for flow meter (FI-2971A/B)
6 Supply CO2 gas until the purity of CO2 in vent gas is above 90%.
7 Close the CO2 manifold outlet valve (MKG04AA101 (HV-2946) and casing vent valve (MKG02AA110 (HV-2954)).
The Hydrogen supply of generator (Replace CO2 with H2, CO2 H2)
8 Refer to 'CO2H2 and H2 Fill in Section 3.4 Generator Hydrogen system Valve List.
9 Connect H2 bottles to H2 gas manifold. (or From H2 Generation)
10 Set the H2 gas manifold pressure regulator (MKG01AA081 (PCV-2920A)) to 8 kg/cm
2.
11 Set the function switch of gas analyzer to H2 in CO2.
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Rev. C
Page 10 of 19
SL No.
Description Checked
( / X) Remarks
12
Adjust the inside of generator pressure and H2 supply quantity by using MKG01AA081 (PCV-2920A) and, MKG02AA081 (PCV-2935) valves.
NOTE: If the pressure of generator is below 0.35 kg/cm
2, the
float trap in the seal oil system is by-pass operated. (The pressure change is monitored by the oil level of float trap.)
- Monitor the oil level of float trap until normal operation. (The oil level of level gauge (MKW13CL502) shall be monitored at medium level and if oil level falls below medium level, close bypass valve (MKW13AA104) immediately to prevent CO2 gas from escaping.)
- Please refer to the Float Trap Operating & Maintenance Manual. .
13
Supply H2 gas until the purity of H2 gas in Vent Gas is above 90%.
NOTE: - H2 Purity in generator > H2 Purity in vent gas
14 Close the vent valve (MKG02AA110, (HV-2954)) slowly to keep the pressure such as 0.14 ~ 0.35 kg/cm
2 if H2 purity
grows up steadily.
15
Close the vent valve (MKG02AA110, (HV-2954)), if H2 purity is to above 90%.
NOTE: - If the pressure of generator is below approx. 0.35
kg/cm2, the float trap in the seal oil system is by-pass
operated. (The pressure is to change by monitor the oil level of float trap.)
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Rev. C
Page 11 of 19
SL No.
Description Checked
( / X) Remarks
16
Pressurize in the inside of generator by controlling the Hydrogen Machine Gas Pressure Regulator (MKG02AA081 (PCV-2935)) properly not to reach at the operation value. (Generator Gas Pressure: 5.27 kg/cm
2)
NOTE: - When rotor shaft rotates, the pressure will increase
according to the temperature increasing.
- Monitor the oil level of float trap until normal operation. (The oil level of level gauge (MKW13CL502) shall be monitored at medium level and if oil level falls below medium level, close bypass valve (MKW13AA104) immediately to prevent CO2 gas from escaping.)
- Please refer to the Float Trap Operating & Maintenance Manual. .
17 Check the differential pressure between seal oil and H2 (MKW10CP501 (PDI-3402)) as H2 gas pressure increases.
-P: 0.56 kg/cm2
18
Close H2 manifold gas pressure regulator outlet valve MKG01AA111 (HV-2920B), MKG01AA113 (HV-2921B) to stop supplying H2, if the pressure will satisfy the required value.
Operation automatically under H2 filling
19 Refer to Normal in Section 3.4 Generator Hydrogen system Valve List.
20
For gas analyzer, refer to Hydrogen Control Cabinet Controls in Section 3.4 Generator Hydrogen system Valve List.
21 Connect H2 bottles to H2 manifold. (or From H2 Generation)
22 Set the H2 Gas Manifold Pressure Regulator (MKG01AA081 (PCV-2920A)) to 8 kg/cm
2.
23
Maintain the required H2 operating pressure to control the machine gas pressure regulator
(MKG02AA081 (PCV-2935)). - Generator Gas Pressure: 5.27 kg/cm
2
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Rev. C
Page 12 of 19
SL No.
Description Checked
( / X) Remarks
Purge hydrogen from Generator
(replace H2 with CO2, H2 CO2)
24 Refer to H2 to CO2 in Section 3.4 Generator Hydrogen system Valve List.
- During operation of turning gear and Seal oil system.
25 For gas analyzer, refer to Hydrogen Control Cabinet Controls in Section 3.4 Generator Hydrogen system Valve List.
26 Check the H2 gas supply stop.
27
Open the vent valve (MKG02AA110, (HV-2954) slowly and depressurize the generator gas pressure.
NOTE: - If the pressure of generator is below approx. 0.35
kg/cm2, the float trap in the seal oil system is by-pass
operated. (The pressure change is monitored by the oil level of float trap.)
- Please refer to the Float Trap Operating & Maintenance Manual. .
28 Keep the pressure of Inside of generator such as 0.14 ~ 0.35 kg/cm
2.
29 Connect CO2 bottles to CO2 manifold.
30 Adjust CO2 supply properly by control MKG04AA101 (HV-2946) valve.
31
Purge H2 until the purity of CO2 in Vent Gas is above 95% and CO2 purging quantity of 2 times of generator volume.
- CO2 purity > 95% - Check that the used CO2 Gas bottle. - CO2 quantity of purge is 2 times of generator volume
that is approximately 16~18 bottle
Purge CO2 from Generator with air
(replace CO2 with air, CO2 Air)
32 Check the valve position as per CO2 to air in Section 3.4 Generator Hydrogen system Valve List.
33 Close the CO2 supply valve (MKG04AA101 (HV-2946)).
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Rev. C
Page 13 of 19
SL No.
Description Checked
( / X) Remarks
34 For gas analyzer, refer to Hydrogen Control Cabinet Controls in Section 3.4 Generator Hydrogen system Valve List.
35 Open the air supply valve (MKG05AA101 (HV-2947)) and throttle open the vent valve (MKG02AA110, (HV-2954) to purge CO2 gas.
36 Purge CO2 until the purity of air in Vent Gas is above 95%.
37 Manually check H2 Gas Concentration at vent line by portable H2 meter.
38 Full open the vent valve (MKG02AA110 (HV-2954)) to keep the pressure of Inside of generator as the atmospheric pressure.
39 Please open cover plate at both side and blowing the Inside of generator with the air for minimum 1 hour before assembly process of generator.
40
Before welding or any other hot work inside and outside of generator, perform purge by instrument air over 2 hours and manually check H2 gas concentration at vent line by portable H2 meter.
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Rev. C
Page 14 of 19
3.4 Generator Hydrogen System Valve List
The gas control system has the dual function of supplying hydrogen (H2) to the generator as required to maintain selected pressure and to supply carbon dioxide (CO2) and H2 to the generator for purging and filling operations.
Operating Condition
Air to CO2
CO2 to H2
H2 Fill Normal Degas H2 to CO2
CO2 to Air
Hydrogen Control Cabinet Controls
Mode Selection For H2 Analyzer
(P1MGK20AA113) Purge Purge N/A Normal N/A Purge Purge
Function Selection
CO2 in Air
(Air in CO2)
H2 in CO2
H2 in Air
H2 in Air
H2 in Air
H2 in CO2
CO2 in Air
(Air in CO2)
Stop % 90% CO2
(10% Air)
90% H2
N/A N/A N/A 5% H2
5% CO2
(95% Air)
Gas Valve Station Valve Position
3-Way Valve (MKG02AA107)
Down Right Right Right Down Down Down
3-Way Valve (MKG02AA108)
Down Right Right Right Right Down Down
Main Vent Valves (MKG02AA110)
Partially Open
Partially Open
Closed Closed Full
Open Partially
Open Partially Open
Generator PRV Isolation Valve (MKG02AA105, MKG02AA106)
Closed Open Open Open Closed Closed Closed
Generator PRV Bypass Valve
(MKG02AA103) Closed Closed Closed Closed Closed Closed Closed
CO2 Shut-Off Valve
(MKG04AA101) Open Closed Closed Closed Closed Open Closed
Air Shut-Off Valve (MKG05AA101)
Closed Closed Closed Closed Closed Closed Open
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Rev. C
Page 15 of 19
3.5 Generator Hydrogen System Flow Chart
Connect CO2 bottles to CO2 Manifold
Purge until the purity of CO2 in Vent Gas is above 95%.
Check the valve position
according to Air to CO2 in the Appendix. B Valve List.
Select Purge Mode By Gas Analyzer Sampling 3 Way
Valve (MKG20AA113)
Connect H2 bottles to H2 Gas Manifold
Check whether H2 Gas is shut off. Open slowly the Gen Casing Vent
valve to reduce the H2 pressure.
Purge until the purity of air in Vent
Gas is above 95%.
Manually check H2 gas
concentration in vent line by
portable meter.
FLOW CHART
Air CO2 H2 FLOW CHART
H2 CO2 AIR
Air Purge of Inside of Gen.
(AirCO2)
Supply CO2 Gas
Purity of CO2 in Vent Gas
is above 90%.
Yes
Supply H2 Gas (CO2H2)
Select the Gas Analyzer in Cabinet
Purity of H2 in Vent Gas is
above 90%.
Yes
Operation automatically during the
H2 Gas Pressurization
Purge hydrogen from Gen.
(H2CO2)
Purity of CO2 in Vent Gas
is above 95%.
Yes
Purge CO2 from Gen. (CO2 Air)
Select the Gas Analyzer
Connect the Air Supply
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Rev. C
Page 16 of 19
4.0 H2 GAS DRYER COMMISSIONING
4.1 Start-up
SL No.
Description Checked
( / X) Remarks
1 H2 Gas Dryer inlet and outlet valve should be open when CO2 & H2 charging, during operation and CO2 & H2 purge.
2 Ensure that the drain valve of H2 Gas Dryer is closed.
3 H2 Gas Dryer vent valve shall be open during H2 & CO2 purge and maintain vent valve open after purge is completed.
4 Before H2 gas charging, close the H2 Gas Dryer vent valve.
5 After synchronization, start the H2 Gas Dryer as following sequence.
6 Turn the power select to ON on the control panel.
POWER ON lamp on / HMI Power on
7
After touching HMI setting button, 1) Time setting
Cycle Time : 480min. Heating Time : 300 min.
2) Temperature setting
Heater over temperature High High : 420C Heater Control Temperature : 350C
8 Turn the select switch to "AUTO" one the control panel. ( Dryer Cycle Timer Automatic Operation Status By )
9 Operation Step 1 (For 5 hours)
A-Tower : Operation B-Tower : Regeneration (Heating)
10 Operation Step 2 (For 3 hours)
A-Tower : Operation B-Tower : Regeneration (Cooling)
11 Operation Step 3 (For 5 hours)
A-Tower : Regeneration (Heating) B-Tower : Operation
12 Operation Step 4 (For 3 hours)
A-Tower : Regeneration (Cooling) B-Tower : Operation
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Rev. C
Page 17 of 19
4.2 Shutdown
SL No.
Description Checked
( / X) Remarks
1 When the Generator is desynchronized, H2 Gas Dryers tower inlet/outlet solenoid valves will be closed automatically.
2 Turn the power switch to "OFF" on the control panel.
3 During Generator purge, open the vent valve of H2 Gas Dryer.
4 After purge is completed, if stopping for a long time, open the drain valve and remove the pressure inside the tower.
CAUTION: when SHUTDOWN
It is best to shut down the machine at the cooling time after desorption, but in the case that it
needs to be shut down at the heating time, please be careful because the regenerated air is hot.
Also, a sudden interruption of the air flow can cause a momentary overheating of the heater, but
this momentary overheating does not affect the performance of the heater.
CAUTION: when RE-OPERATING
If you re-operate the machine in the heating status after shut down, when the tower has been
changed, the dew point can increase due to the incomplete regeneration of the absorbent.
Therefore, it is best to extend the heating time, even though the current dew point is not preferable.
Also, in the case that there is no pressure on the absorption tower, if you suddenly open
INLET/OUTLET V/V, it can damage the absorbent by the pressure hunting. Therefore, please
open the valve slowly with care.
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Rev. C
Page 18 of 19
[Fig. 1] H2 Gas Dryer P&ID
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Rev. C
Page 19 of 19
5.0 ATTACHMENTS
Attachment 5.1 Checklist for Commissioning of Valves
Attachment 5.2 P&ID
Attachment 5.3 Measurement, Alarm and Trip List
Attachment 5.4 Valve Position Status for Commissioning
Attachment 5.5 Job Safety Analysis
Attachment 5.6 Risk Assessment
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1 of 2
[Attachment 4.1] Common Checklist for Valves
1.0 COMMON CHECKS FOR ALL VALVES
1.1 Valve installed matches with design drawing specifications.
1.2 Valve has been installed with correct orientation to match the correct pipe flange.
1.3 Test certificate for the valve is available.
1.4 Confirm no process is affected due to valve trial.
1.5 Confirm no energy is present upstream or downstream of the valve.
1.6 Confirm no maintenance or commissioning activity is being carried out on the valve.
1.7 Confirm proper greasing as per the Manufacturers recommendation has been done on the valve.
1.8 Confirm setting of OPEN/CLOSE limit switches (if provided) have been done (for Indication/check backs).
1.9 CLOSE the valve manually and check:
Valve is easy and free to operate towards CLOSE direction.
Valve closes fully.
The limit switch (if provided) operates on the CLOSE side.
1.10 OPEN the valve manually and check:
Valve is easy and free to operate towards OPEN direction.
Valve opens fully.
The limit switch (if provided) operates on the OPEN side.
2.0 SPECIAL CHECKS FOR MOTOR OPERATED VALVES
2.1 Lubricant of correct grade (as per actuator manufacturers recommendation) is filled in the gearbox to required level.
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2 of 2
2.2 Confirm that the actuator limit switches have been adjusted and set on LIMIT/TORQUE and have been checked manually on both CLOSE and OPEN sides for cutting IN/OUT of the actuator motor through limit/torque switches.
2.3 Confirm whether IR checks for the actuator motor, associated cables and switchboard panels have been carried out.
2.4 Check motor overload protection healthiness and set as per OEM advice.
2.5 Confirm that the actuator motor electrical protections have been checked and the breaker is ready for energizing.
2.6 Switch on power to the actuator and check for proper movement of the valve as per CLOSE/OPEN command. Check also for inching operation of the valve.
2.7 Check for remote/DCS operation of the valve.
2.8 Check for abnormal sound or other problems in proper movement of the valve by operation from local and remote positions.
3.0 SPECIAL CHECKS FOR PNEUMATIC VALVES
3.1 Confirm for proper erection of pneumatic tubing as per drawing.
3.2 Confirm that all air pipelines have been purged before connecting them.
3.3 Set the correct air pressure in the pressure regulator as recommended.
3.4 Check full opening and closing of the valve by local operation.
3.5 Check full opening and closing of the valve by remote operation.
3.6 If airlock device is provided, initiate simulation of air failure and check the valve stays in same condition.
3.7 Check also for inching operation of the valve by simulation (for CV).
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[Attachment 4.2] P&ID
-
HH H L LL
1 P1MKG20CP001 XQ01 Generator Gas Pressure PT 0~7.1 Kg/Cm2 - - 4-20mA - E AI A - XG11-P1MKG-210001(1/2)
2 P1MKG10CL082 XB01 High High Liquid Level in Generator Open to Alarm LS - Liter 2 - - - 125VDC NO I DI A - XG11-P1MKG-210001(1/2)
3 P1MKG20CP082 XB01 Generator Gas Pressure Low Open to Alarm PS - Kg/Cm2 - - 5.12 - 125VDC NO I DI A - XG11-P1MKG-210001(1/2)
4 P1MKG10CL081 XB01 High Liquid Level in Generator Open to Alarm LS - Liter 1.8 - - - 125VDC NO I DI A - XG11-P1MKG-210001(1/2)
5 P1MKG20GH001 XB02 H2 Gas AC Power Failure Alarm IND - - - - - - 125VDC NO I DI A - XG11-P1MKG-210001(1/2)
6 P1MKG16GH001 XB01 Hydrogen Gas Dryer Fault IND - - - - - - 125VDC NO I DI A - XG11-P1MKG-210001(1/2)
7 P1MKG20CQ002 XB01 TGA Gas Purity low low IND 85~100 % - - - 95 125VDC NO I DI A - XG11-P1MKG-210001(1/2)
8 P1MKG20GH001 XB01 H2 Gas DC Power Failure Alarm IND - - - - - - 125VDC NO I DI A - XG11-P1MKG-210001(1/2)
9 P1MKG20CP081 XB01 Generator Gas Pressure High PS - Kg/Cm2 - - 5.55 - 125VDC NO I DI A - XG11-P1MKG-210001(1/2)
10 P1MKG20CQ001 XB01 TGA Gas Purity Low IND 85~100 % - - 90 - 125VDC NO I DI A - XG11-P1MKG-210001(1/2)
REMARKSFUNCTION SOEP&ID NO
T10206- XG02-
SIGNAL
CODE
[ATTACHMENT 4.3]
MEASUREMENT, ALARM AND TRIP LIST
CONT
TYPE
PWR
SRCI/O TYPE
Mong Duong II 2 x 560MW(NET)
COAL FIRED POWER PROJECT
SETPOINT SIGNAL
TYPENo. TAG NO. SERVICE DESCRIPTION STATUS UNITRANGE
Page 1 of 1
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Page 1 of 6
[Attachment 4.4] Valve Position Status for Commissioning
SL. No.
System Description
Service Tag No. Status Checked
(/ X) Remarks
1
H2 manifold
H2 bottle isolation valve MKG01 AA101
Closed
2 H2 bottle isolation valve MKG01 AA102
Closed
3 H2 bottle isolation valve MKG01 AA103
Closed
4 H2 bottle isolation valve MKG01 AA104
Closed
5 H2 bottle isolation valve MKG01 AA105
Closed
6 H2 bottle isolation valve MKG01 AA106
Closed
7 H2 bottle isolation valve MKG01 AA107
Closed
8 H2 bottle isolation valve MKG01 AA108
Closed
9 H2 bottle header isolation valve
MKG01 AA109
Closed
10 H2 PRV - A MKG01 AA081
Closed
11 H2 PRV A isolation
valve MKG01 AA110
Closed
12 H2 PRV A isolation
valve MKG01 AA111
Closed
13 H2 PRV B MKG01 AA082
Closed
14 H2 PRV B isolation
valve MKG01 AA112
Closed
15 H2 PRV B isolation
valve MKG01 AA113
Closed
16
CO2 manifold
CO2 bottle isolation valve
MKG03 AA101
Open
17 CO2 bottle isolation
valve MKG03 AA102
Open
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Page 2 of 6
SL. No.
System Description
Service Tag No. Status Checked
(/ X) Remarks
18
CO2 manifold
CO2 bottle isolation valve
MKG03 AA103
Open
19 CO2 bottle isolation
valve MKG03 AA104
Open
20 CO2 bottle isolation
valve MKG03 AA105
Open
21 CO2 bottle isolation
valve MKG03 AA106
Open
22 CO2 bottle isolation
valve MKG03 AA107
Open
23 CO2 bottle isolation
valve MKG03 AA108
Open
24 CO2 PRV MKG03 AA081
Open
25 CO2 PRV isolation
valve MKG03 AA110
Open
26 CO2 PRV isolation
valve MKG03 AA111
Open
27 CO2 PRV bypass valve MKG03 AA109
Closed
28 PI isolation valve MKG03 AA301
Closed
29
Gas
Control
Valves
H2 PSV-2923 isolation valve
MKG02 AA101
Open
30 H2 Vent MKG02 AA102
Closed
31 PI isolation valve MKG02 AA301
Open
32 H2 PRV MKG02 AA081
Closed
33 H2 PRV isolation valve MKG02 AA105
Closed
34 H2 PRV isolation valve MKG02 AA106
Closed
35 H2 PRV bypass valve MKG02 AA103
Open
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Page 3 of 6
SL. No.
System Description
Service Tag No. Status Checked
(/ X) Remarks
36
Gas
Control
Valves
H2 isolation valve MKG02 AA104
Open
37 3 Way valve 1 MKG02 AA107
Down
38 3 Way valve 2 MKG02 AA108
Down
39 PSV-2950 isolation
valve MKG02 AA109
Open
40 Main vent valve MKG02 AA110
Partial open
41 Vent line drain valve MKG15 AA401
Closed
42 CO2 line PSV isolation
valve MKG04 AA102
Open
43 PI isolation valve MKG04 AA301
Open
44 CO2 line PI isolation
valve MKG04 AA301
Open
45 CO2 line isolation valve MKG04 AA101
Open
46 Purge Air supply isolation valve
MKG05 AA101
Closed
47 Purge line isolation
valve MKG13 AA101
Open
48 Purge line isolation
valve MKG13 AA102
Open
49 Purge line isolation
valve MKG13 AA103
Closed
50 PI isolation valve MKG13 AA301
Open
51
Generator
CO2 inlet line isolation valve
MKG07 AA101
Open
52 CO2 inlet line drain
valve MKG07 AA401
Open
53 CO2 inlet line drain
valve MKG07 AA402
Closed
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Page 4 of 6
SL. No.
System Description
Service Tag No. Status Checked
(/ X) Remarks
54
Generator
H2 inlet line isolation valve
MKG06 AA101
Closed
55 H2 inlet line drain valve MKG06 AA401
Closed
56 H2 inlet line drain valve MKG06 AA402
Closed
57 Outlet isolation valve to
Hydrogen control cabinet
MKG11 AA101
Open
58 Outlet to Hydrogen control cabinet line
drain valve
MKG11 AA401
Open
59 Outlet to Hydrogen control cabinet line
drain valve
MKG11 AA402
Closed
60 Outlet isolation valve to
Hydrogen control cabinet
MKG12 AA101
Open
61 Outlet to Hydrogen control cabinet line
drain valve
MKG12 AA401
Open
62 Outlet to Hydrogen control cabinet line
drain valve
MKG12 AA402
Closed
63 Outlet isolation valve to
Liquid level detector MKG10 AA105
Open
64 Outlet isolation valve to
Liquid level detector MKG10 AA104
Open
65 Outlet to Liquid level
detector line drain valve MKG10 AA401
Open
66 Outlet to Liquid level
detector line drain valve MKG10 AA402
Closed
67 Outlet isolation valve to
Liquid level detector MKG10 AA103
Open
68 Outlet isolation valve to
Gas dryer MKG09 AA101
Open
69 Outlet to Gas dryer
Drain valve MKG09 AA401
Open
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Page 5 of 6
SL. No.
System Description
Service Tag No. Status Checked
(/ X) Remarks
70
Generator
Outlet to Gas dryer
Drain valve MKG09 AA402
Closed
71 Outlet isolation valve to
Gas dryer MKG08 AA101
Open
72 Outlet to Gas dryer
Drain valve MKG08 AA401
Open
73 Outlet to Gas dryer
Drain valve MKG08 AA402
Closed
74 Outlet isolation valve to
Liquid level detector MKG10 AA107
Open
75 Outlet isolation valve to
Liquid level detector MKG10 AA404
Open
76 Outlet isolation valve to
Liquid level detector MKG10 AA405
Closed
77 Outlet isolation valve to
Liquid level detector MKG10 AA102
Open
78 Outlet isolation valve to
Liquid level detector MKG10 AA101
Open
79 Liquid level
detector
Inlet isolation valve MKG10 AA106
Open
80 Drain valve MKG10 AA403
Closed
81
Hydrogen control cabinet
Inlet isolation valve (GFP)
MKG20 AA110
Open
82 Drain valve MKG20 AA401
Closed
83 Drain valve MKG20 AA402
Closed
84 Inlet isolation valve
(Purge) MKG20 AA104
Open
85 Inlet isolation valve
(GFS) MKG20 AA105
Open
86 Vent line isolation valve MKG20 AA106
Closed
87 PDI isolation valve MKG20 AA108
Open
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Page 6 of 6
SL. No.
System Description
Service Tag No. Status Checked
(/ X) Remarks
88
Hydrogen control cabinet
PDI isolation valve MKG20 AA109
Open
89 PI isolation valve MKG20 AA111
Open
90 PT isolation valve MKG20 AA303
Open
91 PS isolation valve MKG20 AA302
Open
92 PS isolation valve MKG20 AA301
Open
93 Isolation valve to PRV MKG20 AA113
Open
94 PRV MKG20 AA081
Open
95 Isolation valve to PRV MKG20 AA114
Open
96 TGA-A isolation valve MKG20 AA115
Open
97 TGA-B isolation valve MKG20 AA116
Open
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JOB SAFETY ANALYSIS AES-VCMMONG DUONG II 2x 560 MW (NET) COAL FIRED POWER PROJECT
(Developing a habit of analyzing methods to identify hazards & unsafe practices than developing solution that control, minimize or eliminating hazard.)
Task : Generator H2 and CO2 control system commissioning
Prepared by : Suresh nair Reviewed by: K Lee Approved by: YM Cho
Original Date : 16/01/2014 Revised by: Rev Date: Revision : A
Goggles : Yes Gloves: Yes Face Shield : No Barricade Needed : No Lockout: Yes
Tag out: Yes
Dust Mask: Yes
Safety Harness:
No
Long Sleeves: Yes Hearing Protection: Yes MSDS Need/Review (Y) Ground Fault Interrupter.
No
Others:
Other Safety Equipment Required: Gas analyser
Remarks:
List of All Job Steps List of All Known Hazard How to Eliminate Hazards H2 & CO2 line flushing Creating explosive media
Dust and eye injury
Line shall be flushed with CO2, not with H2.
Wear goggles.
Generator purging Creating explosive media
Dust and eye injury
Confined space
Purging with CO2 until venting gets purity 95% or
above.
Nobody shall be inside the generator enclosure.
H2 gas filling Creating explosive media and fire/ explosion
Line rupture
Line leak checks shall have been done.
Check and confirm CO2 pressure inside before filling
H2.
Fill slowly by regulating the flow from top side until
desired purity is achieved.
Use only non-sparking tools. No hot works in the area.
Pressurize as per design criteria (4.48 bar)
Purging H2 from generator for any work or
inspection.
Creating explosive media
Explosion/ fire
Purge using CO2 only. Never use air.
CO2 shall be filled from bottom.
Pressure shall be regulated as per procedure.
Non sparking tools and no hot work policy to be
followed.
Generator Internal inspection CO2 and confined space. Purge with air and follow confined space entry permit
procedure.
Field operation and CCR control/
communication
Communication problem Bi-lingual operators
In sufficient instructions Competent CCR operators with clear communication
skills. Dedicated radio channel for operation.
[Attachment 4.5] Job Safety Analysis
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AES-VCM
RISK ASSESSMENT Country Office/Project: Mong Duong II Coal Fired Power Project,
Vietnam
Ref No: 107 Date: 16/01/2014
Assessors : Suresh Nair
Activity : Commissioning of Generator H2 and CO2
control system
Assessment Purpose : Identification of hazards and implementation of
mitigation measures
JOB/TASK People at
risk
Cause of
Adverse
effect
Adverse
effect
L1 S1 RF
N*
*
MITIGATING CONTROLS L2 S2 RRN
*
Assessment
Connecting gas
cylinders or
manifold into line
Operators
Engineers
workers
Gas leak
Pressurized
gas jet.
Eye injury
Creating
explosive
media
3 2 6 Open the regulator only after tightening
connections.
Use non sparking tools. Ensure no hot works
or open flames in the area.
1 2 2 Trivial/
acceptable
H2 & CO2 line
flushing using
CO2.
Operators
Engineers
workers
CO2 leak
Dust and eye
injury
Asphyxiation
Eye injury
3 3 9 Line shall be flushed with CO2, not with H2.
Wear goggles. Do not enter inside generator
enclosure. LOTO of valve connecting Gen.
to be done.
1 2 2 Trivial/
acceptable
Generator
purging
Operators
Engineers
workers
Creating
explosive
media
Dust and eye
injury
Confined
space
Asphyxiation
Eye injury
3 3 9 Purging with CO2 until venting gets purity
95% or above.
Nobody shall be inside the generator
enclosure.
1 2 2 Trivial/
acceptable
H2 gas filling
Operators
Engineers
workers
Creating
explosive
media and
fire/
explosion
Line rupture
Fire and
explosion
3 4 12 Line leak checks shall have been done.
Check and confirm CO2 pressure inside
before filling H2.
Fill slowly by regulating the flow from top
side until desired purity is achieved.
Use only non-sparking tools. No hot works in
the area.
Pressurize as per design criteria (4.48 bar)
2 2 4 Tolerable
Purging H2 from
generator Operators
Engineers
workers
Creating
explosive
media
Explosion/
fire
Fire and
explosion
3 4 12 Purge using CO2 only. Never use air.
CO2 shall be filled from bottom.
Pressure shall be regulated as per procedure.
Non sparking tools and no hot work policy to
be followed.
2 2 4 Tolerable
Generator
Internal
inspection
Operators
Engineers
workers
CO2 and
confined
space.
Asphyxiation 2 3 6 Purge with air and follow confined space
entry permit procedure.
1 2 2 Trivial/
acceptable
[Attachment 4.6] Risk Assessment
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Field operation
and CCR control/
communication
Operators
Engineers
workers
Communicati
on problem
In sufficient
instructions
In correct
operation
3 2 6 Bi-lingual operators
Competent CCR operators with clear
communication skills. Dedicated radio
channel for operation.
1 2 2 Trivial/
acceptable
Likelihood (L) Severity(S) Risk Factor Number (RFN) Residual Risk Number (RRN) L1-Like as it is
1.Unlikely/Improbable 1.Negligible 1-2 Trivial/Acceptable 1-2 Trivial/Acceptable L2-Likelihood with mitigating measures
2. Remote 2.Slight 3-5 Tolerable 3-5 Tolerable S1-Severity as it is
3. Quite possible/ Occasional 3.Moderate 6-9 Moderate/Acceptable with
review
6-9 Moderate/Acceptable with review S2-Severity with mitigating controls in
place
4. Likely/Probable 4.Critical/High 10-15 Substantial 10-15 Substantial * Prepare job safety analysis and safety
verification check list when RFN is >= 6
5. Very likely/Frequent 5.Catastrophic/Ve
ry High
16-25 Intolerable/ Unacceptable 16-25 Intolerable/ Unacceptable ** Prepare safety verification check list
when RFN is >= 6