T10206-DN02-P1MKG__810001 Generator H2 & CO2 Control System_Rev.C

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

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

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

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.

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

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.

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)

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)

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.

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.)


- 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


operated. (The pressure is to change by monitor the oil level of float trap.)

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.



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

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


operated. (The pressure change is monitored by the oil level of float trap.)


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)).

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.

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

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

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)


A-Tower : Operation B-Tower : Regeneration (Cooling)


A-Tower : Regeneration (Heating) B-Tower : Operation


A-Tower : Regeneration (Cooling) B-Tower : Operation

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.

Rev. C

Page 18 of 19

[Fig. 1] H2 Gas Dryer P&ID

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

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.

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).

[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

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


Closed


Closed


Closed


Closed


Closed


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

of 6

SL. No.

System Description


(/ X) Remarks

18

CO2 manifold

CO2 bottle isolation valve

MKG03 AA103

Open


valve MKG03 AA104

Open


valve MKG03 AA105

Open


valve MKG03 AA106

Open


valve MKG03 AA107

Open


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


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

of 6

SL. No.

System Description


(/ 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


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


valve MKG13 AA102

Open


valve MKG13 AA103

Closed


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

of 6

SL. No.

System Description


(/ 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


drain valve

MKG11 AA402

Closed



MKG12 AA101

Open


drain valve

MKG12 AA401

Open


drain valve

MKG12 AA402

Closed


Liquid level detector MKG10 AA105

Open



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



Open


Gas dryer MKG09 AA101

Open

69 Outlet to Gas dryer

Drain valve MKG09 AA401

Open

of 6

SL. No.

System Description


(/ X) Remarks

70

Generator

Outlet to Gas dryer


Closed


Gas dryer MKG08 AA101

Open



Open



Closed



Open



Open



Closed



Open



Open

79 Liquid level

detector

Inlet isolation valve MKG10 AA106

Open

80 Drain valve MKG10 AA403

Closed

81


Inlet isolation valve (GFP)

MKG20 AA110

Open


Closed


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

of 6

SL. No.

System Description


(/ X) Remarks

88


PDI isolation valve MKG20 AA109

Open


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

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

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

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

T10206-DN02-P1MKG__810001 Generator H2 & CO2 Control System_Rev.C

Documents

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h jung

commissioning requirements